Drones in industrial inspection
Drones such as the DJI M30T and the collision-tolerant Flyability Elios 3 are revolutionising industrial inspection: they make system maintenance safer, more efficient and more cost-effective. With advanced multi-sensor technology, AI and digital twin technology, they effortlessly master even hard-to-reach and high-risk areas. Find out why these technologies are taking industrial inspection to the next level - and will soon be indispensable.
Drones in industrial inspection: efficiency, safety and future potential
Industrial inspection using drones has become increasingly important in recent years. Drones offer a fast, safe and cost-effective solution for inspection tasks that used to be time-consuming and risky. With advancing technology and specific models such as the DJI Matrice 30T, the Drone inspection in the industry are becoming increasingly powerful and versatile.
1. areas of application and industries that benefit from drone inspections
Drone inspections today cover numerous sectors and offer specific advantages in each area that help to increase efficiency and optimise safety.
Here are the main industries and their use cases:
- Industrial plants and production facilities: Drones are ideal for inspecting chimneys, tanks, pipelines and production lines. They can get into confined or complex areas and carry out inspections that were previously time-consuming and dangerous.
- Energy and utility companies: In the energy sector, drone inspections of wind turbines, solar parks, high-voltage power lines and cooling towers are particularly useful. The drones can detect damage to rotor blades, solar panels and cables and thus contribute to preventive maintenance, which minimises outages and optimises energy production.
- Oil and gas industry: Refineries, pipelines and offshore platforms are demanding and safety-critical environments. Drones reduce the risk to employees by monitoring these facilities safely and cost-effectively. By using special sensors such as thermal imaging or gas sensors, they can detect leaks and overheating at an early stage.
- Infrastructure: Drones are often used to inspect roads, bridges and other public infrastructure. They offer an efficient solution for detecting structural damage and contribute to the safety and longevity of these important structures.
- Construction and architecture: In the construction industry, drones are used to create 3D maps, monitor construction progress and inspect buildings. Drones enable comprehensive inspections without the need for costly scaffolding and document construction defects or structural problems before they become serious issues.
- Agriculture and insurance: In agriculture, drones help to monitor plant health and crop yields. In the insurance industry, they enable accurate damage assessments and can be used for precise, documented insurance claims.
- Public safety: Drones support inspections in the area of public safety and facilitate the rapid inspection of sources of danger in emergencies.
The wide range of possible applications and the clear safety and efficiency benefits make drone technology an indispensable tool for many industries.
2. advantages of drone inspection in the industry
Drones bring with them a number of advantages that traditional Inspection methods and the Maintenance industrial plants more efficiently and safely.
Here are the most important advantages in detail:
- Security: The safety of the inspection personnel is paramount. Drone inspections make it possible to inspect dangerous or difficult-to-access areas without people having to take any risks. This is particularly important in high-risk areas such as high-voltage power lines, industrial chimneys, offshore facilities or chemical plants. Drones can be used to carry out potentially dangerous tasks from a safe distance.
- Time and cost savings: Drone inspections offer considerable savings in terms of time and costs. As they can be deployed quickly and have access to hard-to-reach areas, there is no need to erect scaffolding or use lifting platforms. In addition, inspections can often be carried out during ongoing operations, which minimises downtime. Efficient data collection reduces the workload, and the cost of drone technology is often amortised after just a few deployments.
- Accessibility and flexibility: One of the outstanding features of drones is their flexibility. They can be quickly adapted to different inspection requirements and can reach areas that are difficult to access, such as narrow tanks, high chimneys or rough terrain. This enables a more comprehensive and precise inspection than with conventional methods.
- Detailed data collection and analyses:Drones are equipped with high-resolution cameras and special sensors that provide precise data. Modern drone models such as the Flyability Elios 3 offer integrated cameras and sensors to capture HD images, thermal images and 3D scans. This data is invaluable for analysing and assessing damage, corrosion or structural defects. Inspection reports can be created faster and with more accuracy.
3. technology and equipment for drone inspections
The specific requirements of industrial inspections have led to the development of highly specialised drone technologies. Here are the most important components and technologies used in drone inspection:
Specialised industrial drones
There are specially developed drones for industrial applications that can also be used in difficult and complex environments. One example is the Flyability Elios 3, which is suitable for inspections in confined indoor spaces or hazardous environments thanks to a robust, collision-tolerant cage. It can fly in complex installations and even continue to work in the event of collisions.
Sensors and cameras
Drohneninspektionen nutzen eine Vielzahl spezialisierter Sensoren und Cameras, die auf die jeweilige Inspektionsaufgabe zugeschnitten sind:
- Optical RGB cameras for high-resolution colour images that visually document the general condition of a system. Thermal imaging cameras recognise temperature anomalies and enable the early detection of overheating or thermal leaks.
- LiDAR sensors enable detailed 3D models to be created and precise measurements to be carried out, which are particularly important when analysing building structures and complex systems.
- Ultrasonic sensors are specially designed for the non-destructive testing of wall thicknesses and the detection of corrosion damage in the oil and gas industry.
- Multispectral cameras and magnetometers: Detect material changes or corrosion damage that are not immediately recognisable in the visible spectrum.
- Gas sensors are particularly useful for detecting gas leaks and contribute to safety in industrial environments. Specialised lighting systems
To ensure clear images even in dark or difficult-to-access environments, many inspection drones are equipped with powerful LED lighting systems. These lighting systems are particularly useful for inspections of Tanksshafts or pipes that are difficult to see without a light source.
4. data acquisition and analysis
Die Qualität und Effizienz der industrial inspection hängt nicht nur von der Erfassung, sondern auch von der Analyse der gesammelten Daten ab. Drohneninspektionen bieten heute zahlreiche Möglichkeiten, um Daten effizient zu sammeln und zu verarbeiten.
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Real-time data transmission
Modern drones have the ability to transmit image and sensor data to ground stations in real time. This enables inspectors to react immediately to critical findings and make precise decisions during the inspection. Real-time transmission is particularly helpful when experts are assigned to inspect at a safe distance or for complex structures such as high-voltage power lines where immediate intervention may be required. -
AI and machine learning
Advanced software based on artificial intelligence (AI) is increasingly being integrated into the analysis of inspection data. AI-supported algorithms can automatically recognise and mark anomalies such as cracks, corrosion or material fatigue, which significantly increases the efficiency of data evaluation. These algorithms continuously learn from previous inspections and can therefore deliver increasingly precise results. -
3D modelling and digital twins
The combination of drones and 3D mapping technology enables the creation of detailed 3D models of the inspected objects. These models can be used as "digital twins" in real time to ensure continuous monitoring of the condition of facilities. This is particularly relevant for buildings or production facilities that need to be monitored regularly to ensure their structural integrity. The 3D models provide a precise basis for maintenance and servicing work, and any future condition can be compared with the model to immediately recognise changes or damage. -
Data archiving and documentation
The data collected by drones can be easily archived and stored for later comparison. This data history is crucial for recognising trends in the condition of a plant and planning preventive maintenance measures. In addition, detailed documentation helps to ensure compliance with legal regulations and industry standards
5 Special use cases and industry-specific advantages
Drone technology offers specific advantages in certain use cases and industries that contribute to the efficiency and accuracy of industrial inspections.
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Corrosion monitoring
Corrosion monitoring is a crucial aspect in the maintenance of metal structures such as tanks, pipelines or offshore platforms. Drones can collect detailed visual and thermal data to track the development of corrosion over time and take early action before the damage becomes severe. The oil and gas industry as well as the chemical industry particularly benefit here, as the costs and risks of uncontrolled corrosion are considerable. -
Construction defects and structural inspection
Inspecting buildings for structural defects is an important task in the construction industry and in infrastructure. Drones enable a quick and detailed inspection of facades, roofs, bridges and other building structures. High-resolution cameras can be used to detect cracks, spalling and discolouration that indicate structural weaknesses. This is particularly valuable during the construction phase or when maintaining old buildings. -
Inspections in poor lighting conditions
Industrial facilities such as tanks or pipelines are often located in dark or difficult to see environments. Drones with powerful LED lights can deliver high-quality images even in poor lighting conditions. This enables continuous and accurate inspection, even in areas that would not be visible without artificial light. -
Insurance-relevant inspections
Regular drone inspections help companies to recognise and document potential damage at an early stage. This is particularly important for insurance companies, as detailed inspection reports provide a transparent basis for damage assessments. Good documentation can also help to reduce insurance premiums as the risk of undetected damage is minimised.
6. challenges and security aspects
Although drones offer many benefits, there are certain challenges that need to be considered to ensure the safety and effectiveness of inspections.
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Weather conditions and battery life
Drones are susceptible to unfavourable weather conditions such as rain, snow or strong winds. Such conditions can limit their operational capabilities and affect the accuracy of data collection. In addition, battery life is often a challenge during extended or comprehensive inspections, as drones must regularly fly back to base to change their batteries. This can delay the process and require additional logistics. -
Signal interference and GPS dependency
Signal interference can occur indoors or in underground facilities as GPS signals are not available. In these cases, specialised industrial drones use technologies such as visual odometry and SLAM (Simultaneous Localisation and Mapping) to ensure reliable and precise navigation without GPS. This is particularly important in confined spaces such as tanks, shafts or underground pipes, where the drone needs to maintain its exact position. -
Legal requirements and compliance
The operation of drones is subject to legal requirements that must be strictly adhered to. Professional drone inspections require:- a drone licence or proof of knowledge for the pilots
- liability insurance
- authorisation from the competent aviation authorities for certain missions, if applicable.
In addition, safety measures such as a thorough site analysis, safety barriers and emergency plans must be put in place to prevent accidents. These measures contribute to the safety of personnel, equipment and the environment.
7. future prospects and new technologies
Industrial inspection using drones is developing rapidly, and various technologies are opening up new possibilities for the future.
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Autonomous inspections and multi-drone missions
The next generation of drones will be able to fly pre-programmed inspection routes autonomously, which will further increase efficiency. In the future, several drones could be used simultaneously to inspect large or complex structures from different perspectives at the same time. This autonomous technology is particularly advantageous for large facilities such as refineries or solar parks, as it significantly shortens the inspection time. -
Integration in Industry 4.0 and digital twins
Drone inspections are increasingly being integrated into the digital infrastructure of companies and contribute to the creation of digital twins. A digital twin is an exact virtual copy of a plant that is continuously updated with current data from drone inspections. This enables data-driven maintenance and optimisation of operating processes and offers real added value for industrial maintenance. -
5G and real-time transmission
The introduction of 5G technology will further improve the real-time transmission of high-resolution inspection data and enable remote inspections even in challenging environments. Inspectors can analyse the data immediately and make decisions when needed without being on site, further increasing efficiency. -
Improved AI and predictive maintenance
Artificial intelligence will continue to play a key role in data analysis in the future. Predictive maintenance allows drone anomalies to be recognised in advance so that potential failures can be rectified before they occur. This reduces maintenance costs, as preventive maintenance measures are cheaper and easier to plan than reactive repairs.
Conclusion
Drones have revolutionised industrial inspection and offer an efficient, cost-effective and safe alternative to traditional inspection methods. They improve occupational safety, reduce operating costs and provide precise data for maintenance. With the continuous technological development, especially in the field of autonomous control and data analysis, the importance of drones in industrial inspection will continue to grow. Companies that adopt drone technology at an early stage can optimise their maintenance strategy and gain a competitive advantage.
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Frequently asked questions
Drones offer a safer, faster and more cost-effective alternative to conventional inspections. They allow access to hard-to-reach or hazardous areas without the need for costly scaffolding or downtime, while providing accurate and comprehensive data.
Specialised models such as the DJI M30T and the Flyability Elios 3 are ideal for industrial applications. They have high-resolution cameras, thermal imaging sensors, obstacle avoidance and stable flight capabilities that have been specially developed for demanding inspection tasks.
Drones are used particularly in the energy, construction, oil and gas, infrastructure and public safety sectors. They are ideal for inspecting wind turbines, high-voltage power lines, refineries, bridges and buildings.
Yes, drones like the Flyability Elios 3 are specifically designed for use in confined and GPS-less environments. They utilise technologies such as visual odometry and SLAM for precise navigation and collision tolerance.
Drones reduce the need for inspectors to enter hazardous areas. They can safely perform complex tasks at height, in confined spaces or in hazardous environments, while providing detailed data.
Drones can provide high-resolution images, thermal images and even 3D models. They capture precise data on surface changes and material damage, Corrosion and structural weaknesses.
Yes, drone inspections save costs by reducing labour, safety measures and production downtime. They often pay for themselves after just a few missions.
Drone inspections are significantly faster than traditional methods. Thanks to modern technology, large areas and complex structures can be precisely inspected in a short time.
In den meisten Ländern benötigen professionelle Drohnenpiloten eine Zertifizierung, und der Einsatz von Drohnen muss den lokalen Vorschriften entsprechen, einschließlich Aufstiegsgenehmigungen und Versicherungsschutz.
Drones can carry out regular inspections and recognise signs of wear, cracks or corrosion at an early stage. This data is crucial for initiating preventive maintenance measures in good time and thus avoiding costly breakdowns.
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