WO2023209734A1

WO2023209734A1 - Method and system for visual inspection of surfaces and non-destructive testing of ferromagnetic structures

Info

Publication number: WO2023209734A1
Application number: PCT/IN2023/050408
Authority: WO
Inventors: Gulshan Kumar; Ishan Bhatnagar
Original assignee: Octobotics Tech Pvt. Ltd.
Priority date: 2022-04-27
Filing date: 2023-04-26
Publication date: 2023-11-02

Abstract

The present disclosure provides a motorized electromagnetic vehicle for inspection of surfaces and non-destructive testing of ferromagnetic structures. The motorized electromagnetic vehicle [100] comprises a magnetic wheel assembly [102], [104], a robotic arm manipulator [106], a tool assembly [108] connected to the robotic arm manipulator, an electromagnetic anchor arrangement [110], a chassis assembly comprising at least one front chassis [112] and at least one rear chassis [114], a segmentary joint [116], and a steering assembly [118]. The motorized electromagnetic vehicle [100] is designed to cross a pre-defined angle range of the convex bend.

Description

METHOD AND SYSTEM FOR VISUAL INSPECTION OF SURFACES AND NONDESTRUCTIVE TESTING OF FERROMAGNETIC STRUCTURES

TECHNICAL FIELD

The present disclosure generally relates to methods and systems for visual inspection of structural elements and, more particularly, relates to method and system for remote inspection of complex and uneven surfaces and non-destructive testing of ferromagnetic structures.

BACKGROUND

The following description of the related art is intended to provide background information pertaining to the field of the disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section is used only to enhance the understanding of the reader with respect to the present disclosure, and not as admissions of the prior art.

As is generally known, ferromagnetic materials are preferred for construction of complex structures in ships, bridges, oil rigs, refineries, wind turbines towers, power transmission towers, and the like. Ferromagnetic materials are known to have long operating life and additionally provide strength to the complex structures. At the same time, ferromagnetic materials are susceptible to corrosion, fatigue, overload, weathering, ageing thereby creating numerous defects in these structures such as the thinning of steel plates, cracks, buckling, welding failure, and the like. If any of these defects remain undetected, it may cause the sudden collapse of complete structure or failure of strengthening members resulting in catastrophic events like the sinking of ships, the collapse of bridges, failure of the wind turbine or power transmission towers. To prevent such sudden failures, the continuous inspection and maintenance of ferromagnetic structures and surfaces is required. The conventionally available solutions involve inspection and maintenance either manually or through remotely controlled vehicles with pre-installed cameras.

The conventionally available solutions include several limitations and problems. The manual inspection and maintenance methods are primitive, prone to hazards, and cannot be performed in inaccessible location like underwater conditions. The remotely controlled vehicles used in the existing solutions also suffer from several drawbacks. The vehicles used for inspection and monitoring suffers from several stability issues in operating on complex and uneven ferromagnetic structures that may include inability to operate on vertical surfaces and crossing 90-degree convex bend, stability issues due to sticking of fine ferromagnetic particles on the wheels of the vehicle, stability issues encountered while performing surface preparation and non-destructive testing of the surface. The vehicle additionally suffers from performance issues in underwater operation that may include issues with waterproofing of the electronic components of the vehicle and thermal management in the motor assembly used in the vehicle.

The currently known solutions are inefficient and include a plurality of limitations and therefore, there is a need for improvement in this area of technology. In the light of the aforementioned, there is a need for a method and a system for providing a motorized electromagnetic vehicle to conduct surface preparation and non-destructive testing of complex and uneven ferromagnetic structures.

SUMMARY

This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.

To overcome at least a few problems associated with the known solutions as provided in the background section, an object of the present disclosure is to provide a novel method and system for visual inspection and non-destructive testing of complex and uneven ferromagnetic structures. Another object of the present disclosure is to provide a motorized electromagnetic vehicle with a bi-wheel design consisting of a magnetic front wheel assembly and a magnetic rear wheel assembly. It is yet another object of the present disclosure to prevent sticking of metal particles to the magnetic wheel assembly of the motorized electromagnetic vehicle. It is yet another object of the present disclosure to ensure electromagnetic shielding of the electronic components of the motorized electromagnetic vehicle. It is yet another object of the present disclosure to provide a method for crossing convex 90-degree bend on electromagnetic surfaces by the motorized electromagnetic vehicle. It is yet another object of the present disclosure to conduct surface preparation and non-destructive testing of complex and uneven ferromagnetic structures for the removal of thick layers of rust and thin films of eroded paint by the robotic arm. It is yet another object of the present disclosure to provide electromagnetic anchor arrangement to provide stability to the motorized electromagnetic vehicle when conducting surface preparation and non-destructive testing of complex and uneven ferromagnetic structures.

To achieve the aforementioned objectives, the present disclosure provides a motorized electromagnetic vehicle for the visual inspection of defects, surface preparation, and nondestructive testing of ferromagnetic surfaces and structures.

A first aspect of the present invention relates to a motorized electromagnetic vehicle for inspection of complex surfaces and non-destructive testing of ferromagnetic structures. The motorized electromagnetic vehicle includes a magnetic wheel assembly, a robotic arm manipulator, a tool assembly connected to the robotic arm manipulator, an electromagnetic anchor arrangement, a chassis assembly comprising at least one front chassis and at least one rear chassis, a segmentary joint, and a steering assembly. Further, the motorized electromagnetic vehicle [100] designed to cross a pre-defined angle range of the convex bend.

Another aspect of the present disclosure relates to a method for inspection and non-destructive testing of complex and uneven ferromagnetic structures using a motorized electromagnetic vehicle. The method comprises steering the motorized electromagnetic vehicle for inspection and non-destructive testing of complex and uneven ferromagnetic structure using a magnetic wheel assembly. The method thereafter comprises holding the motorized electromagnetic vehicle on surface of the complex and uneven ferromagnetic structure using an electromagnetic anchor arrangement. The method thereafter comprises cleaning the surface of the complex and uneven ferromagnetic structure for the non-destructive testing using a robotic arm manipulator and a tool assembly. The method thereafter comprises performing the non-destructive testing and inspection of the surface of the complex and uneven ferromagnetic structure using the robotic arm manipulator, the tool assembly, and at least one image recording system of the motorized electronic vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein, and constitute a part of this disclosure, illustrate exemplary embodiments of the disclosed methods and systems in which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that disclosure of such drawings includes disclosure of electrical components, electronic components, or circuitry commonly used to implement such components.

FIG. 1 illustrates a schematic diagram of the motorized electromagnetic vehicle [100], in accordance with exemplary embodiment of the present disclosure.

FIG. 1A illustrates a schematic diagram of the motorized electromagnetic vehicle [100A], in accordance with exemplary embodiment of the present disclosure.

FIG. 2 illustrates a schematic diagram of the front and rear wheel assembly of the motorized electromagnetic vehicle [200], in accordance with exemplary embodiment of the present disclosure.

FIG. 2A illustrates a graphical representation of the variation in the magnetic field strength as a function of thickness of steel used and as a function of air gap between the components used in the motorized electromagnetic vehicle [200A], in accordance with exemplary embodiment of the present disclosure.

FIG. 3 illustrates a schematic diagram of the steering and segment rotary joint assembly of the motorized electromagnetic vehicle [300], in accordance with exemplary embodiment of the present disclosure.

FIG. 4 illustrates a schematic diagram of the electromagnetic anchor arrangement of the motorized electromagnetic vehicle [400], in accordance with exemplary embodiment of the present disclosure.

FIG. 5 illustrates a schematic diagram of the robotic manipulator and tool assembly of the motorized electromagnetic vehicle [500], in accordance with exemplary embodiment of the present disclosure.

FIG. 6 illustrates a line diagram of the method of crossing a 90-degree convex bend when moving upwards from horizontal direction to vertical direction using the motorized electromagnetic vehicle [600], in accordance with exemplary embodiment of the present disclosure.

FIG. 6A illustrates a schematic diagram of the method of crossing a 90-degree convex bend when moving upwards from horizontal direction to vertical direction using the motorized electromagnetic vehicle [600A], in accordance with exemplary embodiment of the present disclosure.

FIG. 7 illustrates a schematic diagram of the possible variations of the motorized electromagnetic vehicle [700], in accordance with exemplary embodiment of the present disclosure.

FIG. 8 illustrates a schematic diagram of the waterproof smart actuator for the underwater operation of the motorized electromagnetic vehicle [800], in accordance with exemplary embodiment of the present disclosure.

FIG. 9 illustrates an exemplary method flow diagram for inspection and non-destructive testing of complex and uneven ferromagnetic structures using a motorized electromagnetic vehicle, in accordance with an embodiment of the present disclosure.

The foregoing shall be more apparent from the following more detailed description of the disclosure.

DETAILED DESCRIPTION In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address any of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.

Exemplary embodiments now will be described with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this invention will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements.

The specification may refer to "an", "one" or "some" embodiment(s) in several locations. This does not necessarily imply that each such reference is to the same embodiment(s), or that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.

As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms "include", "comprises", "including" and/or "comprising" when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, "connected" or "coupled" as used herein may include wirelessly connected or coupled. As used herein, the term "and/or" includes any and all combinations and arrangements of one or more of the associated listed items.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

The figures depict a simplified structure only showing some elements and functional entities, all being logical units whose implementation may differ from what is shown. The connections shown are logical connections; the actual physical connections may be different.

In addition, all logical units described and depicted in the figures include the software and/or hardware components required for the unit to function. Further, each unit may comprise within itself one or more components, which are implicitly understood. These components may be operatively coupled to each other and be configured to communicate with each other to perform the function of the said unit. In the following description, for the purposes of explanation, numerous specific details have been set forth in order to provide a description of the invention. It will be apparent, however, that the invention may be practiced without these specific details and features.

As discussed in the background section, the known solutions fail to conduct the visual inspection, surface preparation, and non-destructive testing of complex and uneven ferromagnetic structures. The present disclosure provides a solution relating to a motorized electromagnetic vehicle for the visual inspection and non-destructive testing of complex and uneven ferromagnetic structures. More specifically, the present disclosure provides a motorized electromagnetic vehicle with a magnetic wheel assembly, electromagnetic anchor arrangement and robotic arm manipulator connected to the tool assembly for the surface preparation and Non-Destructive testing of complex and uneven ferromagnetic structures.

The present disclosure provides a motorized electromagnetic vehicle with a rubber-lined magnetic wheel assembly to prevent the sticking of fine ferromagnetic particles to the magnetic wheel assembly of motorized electromagnetic vehicle. Further, the present disclosure provides a motorized electromagnetic vehicle with a tool assembly that is provided with an electric impact needle descaler, a grinding wheel, and a Non-destructive Testing (NDT) Tool for enabling the removal of thick scales of rust and thin layers of eroded paint from the surface of complex and uneven ferromagnetic structures for the surface preparation.

FIG. 1 illustrates a schematic diagram of the motorized electromagnetic vehicle [100], in accordance with exemplary embodiment of the present disclosure. FIG. 1A illustrates a schematic diagram of the motorized electromagnetic vehicle [100A], in accordance with exemplary embodiment of the present disclosure. In order to avoid the duplicity of the information, the description of the FIG.l and FIG.1A has been explained in conjunction with each other. As shown in FIG. 1, the motorized electromagnetic vehicle comprises at least one front wheel assembly [102], at least one rear wheel assembly [104], at least one robotic manipulator [106], at least one tool assembly [108], at least one electromagnetic anchor arrangement [110], at least one front chassis [112], at least one rear chassis [114], at least one segment rotary joint [116], and at least one steering assembly [118] that are operatively connected to enable the visual inspection of complex and uneven ferromagnetic structures by the motorized electromagnetic vehicle, wherein all the components are assumed to be connected to each other unless otherwise indicated below. Also, in FIG. 1 only one front wheel assembly, only one rear wheel assembly, only one robotic manipulator, only one tool assembly, only one electromagnetic anchor arrangement, only one front chassis, only one rear chassis, and only one segment rotary joint is shown, however, the motorized electromagnetic vehicle may comprise multiple such units and modules or the system may comprise any such numbers of said units and modules, as may be required to implement the features of the present disclosure. Also, there may be one or more sub-units of said units and modules of the motorized electromagnetic vehicle and the same is not shown in the FIG. 1 and the FIG. 1A for the purpose of clarity.

In an example, the irregularities inspected and detected by the motorized electromagnetic vehicle includes corrosion, fatigue, overload, weathering, ageing, thinning of steel plates, cracks, buckling, welding failure, and the like on the complex and uneven ferromagnetic structure. In an exemplary embodiment, the segmentary joint connected to the at least one front chassis and the at least one rear chassis provides flexibility to the motorized electromagnetic vehicle to adapt to the uneven and complex surfaces. The at least one front chassis and the at least one rear chassis of the motorized electromagnetic vehicle are connected through the segmentary joint, where the angle between the front chassis and the rear chassis may vary up to 180 degrees. The angle between the front chassis and the rear chassis facilitates balance movement of the motorized electromagnetic vehicle on the uneven and complex surfaces.

It should be noted that the motorized electromagnetic vehicle [100] is provided with magnetic shielding to protect the electronic components in the motorized electromagnetic vehicle from electromagnetic interference. The source of electromagnetic interference is usually the electromagnetic field produced by the magnetic wheel assembly [102], [104] along with other electromagnetic field inducing components of the motorized electromagnetic vehicle. In an exemplary embodiment, the motorized electromagnetic vehicle is provided with a plurality of Mu-metal sheets as the lower covering to the front chassis [112] and the rear chassis [114], Mumetal is a nickel-iron alloy and provides a path of least magnetic reluctance to the electromagnetic field in the vicinity. The high relative permeability of the Mu-metal is responsible for the ability to channelise electromagnetic field in the vicinity and providing a path of least magnetic reluctance. The electromagnetic field interacts with the Mu-metal sheets thereby protecting the electronic components of the motorized electromagnetic vehicle. In an exemplary embodiment, the plurality of components of the motorized electromagnetic vehicle protected from electromagnetic interference include, but are not limited to, encoders, relays, communication sensors, and the like. In another non-limiting embodiment, the actuators in the robotic arm manipulator [106] are enclosed in a plurality of Mu-metal sheets to protect the actuators from electromagnetic interference. In an example, the plurality of Mu-metal sheets disclosed herein may be implemented as three (3) layers of Mu-metal sheets.

FIG. 2 illustrates a schematic diagram of the front and rear wheel assembly of the motorized electromagnetic vehicle [200], in accordance with exemplary embodiment of the present disclosure. As shown in FIG. 2, the motorized electromagnetic vehicle [200] comprises at least one magnetic front wheel assembly and at least one magnetic rear wheel assembly provided with a smart actuator [242] and a plurality of ball bearings [210], The smart actuator [242] is attached to the aluminium shaft [208] with the help of the plurality of bolts [202], The plurality of ball bearings [210] is positioned inside the bearing housing [212] with a plurality of circlips [214], The magnetic wheel assembly is provided with at least three ring magnets of neodymium [216, 218, 220] placed in conjunction with a plurality of steel washers [222, 224], Further, a thick rubber lining [204, 206] is fitted inside the grooves of the steel washer [222, 224], The magnetic wheel assembly is positioned on an aluminium shaft [208] and located in a place with a plurality of circlips [230, 232], The bearing housing [212] that houses the plurality of ball bearings [210] is positioned on the aluminium shaft [208] and fitted in with a plurality of circlips [226, 228, 230, 232], The smart actuator [242] of the magnetic wheel assembly is positioned with a motor side frame hold [244] with a plurality of bolts [236] and the bearing housing is positioned with a housing side frame hold [234] for enabling the motion of the motorized electromagnetic vehicle on the surface of complex and uneven ferromagnetic structures. The cross tie [238] is positioned firmly with the frame hold [244, 234] with at least two bolts [240] to enable the steering movement of the motorized electromagnetic vehicle.

In an exemplary embodiment of the present disclosure, the at least one smart actuator [242] is connected with at least one processing unit (not shown in the FIG. for the clarity purpose) to enable crossing of the pre-defined angle range of the convex bend. The at least one processing unit is configured to deactivate the at least one smart actuator [242] associated with the at least one rear wheel assembly [104] in an event the at least one front wheel assembly [102] reaches to an edge of the convex bend. The deactivation of the at least one smart actuator [242] starts a crawling movement of the at least one rear wheel assembly [104] based on a forward movement of the at least one front wheel assembly [102], Next, the processing unit is configured to enable crossing of the convex bend by the at least one front wheel assembly [102] using the forward movement of the at least one front wheel assembly [102], Next, the processing unit is configured to re-activate the at least one smart actuator [242] associated with the at least one rear wheel assembly [104], Thereafter, the processing unit is configured to enable crossing of the convex bend by the at least one rear wheel assembly [104] to enable a complete crossing of the predefined angle range of the convex bend by the motorized electromagnetic vehicle.

As used herein, a "processing unit" or "processor" includes one or more processors, wherein processor refers to any logic circuitry for processing instructions. A processor may be a general- purpose processor, a special-purpose processor, a conventional processor, a digital signal processor, a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits, Field Programmable Gate Array circuits, any other type of integrated circuits, etc. The processor may perform signal coding data processing, input/output processing, and/or any other functionality that enables the working of the system according to the present disclosure. More specifically, the processor or processing unit is a hardware processor. In an embodiment of the present disclosure, the at least one processing unit is present inside the at least one smart actuator. In another embodiment of the present disclosure, the at least one processing unit may be present outside the at least one smart actuator and is connected with the at least one smart actuator. In yet another embodiment, the at least one processing unit may be present at any suitable position associated with the motorized electromagnetic vehicle. In an embodiment, the at least one processing unit includes a first processing unit connected with at least one first smart actuator associated with at least one front wheel assembly. The at least one second processing unit includes a second processing unit connected with at least one second smart actuator associated with at least one rear wheel assembly. The at least one processing unit is configured to enable and control the operations associated with the at least one smart actuator.

It should be noted that the smart actuator [242] is a brushless DC motor that functions in combination with a 36:1 planetary gearbox and is provided with a multiturn absolute encoder and integrated control electronics. It has the capability to produce the peak torque of 70 NM at 60 RPM and is fitted in with an aluminium shaft [208] by a plurality of bolts. In an example, the smart actuator includes a first actuator connected with the front magnetic wheel assembly and a second actuator connected with the rear wheel assembly. As illustrated in the figure, the magnetic front wheel assembly and the magnetic rear wheel assembly are a combination of a steel washer and three neodymium ring magnets [216, 218, 220], In an example, the steel washer of the magnetic wheel assembly is made with Material SS410. The reason for using SS410 material in the steel washer is its ferromagnetic and corrosion-resistant nature. In an exemplary embodiment, the magnetic wheel assembly is provided with rubber lining on the outer circumference of the magnetic wheel assembly to prevent the sticking of the fine ferromagnetic particles on the outer circumference of the magnetic wheel assembly where it makes contact with the complex and uneven ferromagnetic structures. If the fine ferromagnetic particles come directly in between the magnetic wheel assembly wheel and the complex and uneven ferromagnetic structures, the stability of the motorized electromagnetic vehicle on the complex and uneven ferromagnetic structures is compromised which may additionally lead to slipping of the motorized electromagnetic vehicle.

FIG. 2A illustrates a graphical representation of the variation in the magnetic field strength as a function of thickness of steel used and as a function of air gap between the components used in the motorized electromagnetic vehicle [200A], in accordance with exemplary embodiment of the present disclosure. As shown in the figure, the magnetic field strength emanating from a magnet varies approximately square of the inverse of the distance from the magnets. In an exemplary embodiment, the thickness of the washer on the magnetic wheel assembly is 27.02 mm. A 12.01 mm wide and 7.77 mm deep groove is cut around the periphery of the steel washer and a rubber lining is 9.02 mm thick and 12.01 mm wide is inserted in the groove so that 1.25 mm of rubber lining protrudes outside the washer. When the exemplary magnetic wheel assembly is placed on a steel plate that has a thickness of more than 8 mm, the rubber lining compresses due to magnetic force between the steel washer and the steel plate. The thickness of the rubber lining is reduced to around 0.6 mm due to the compression. The nature of the magnetic field as illustrated in the graphical representation as shown in FIG. 2A ensures that the magnetic field strength on top of the rubber lining is negligible when compared to the magnetic field strength at the top of steel washer of the magnetic wheel assembly. The difference in the magnetic field strength at the top of rubber lining in comparison with the magnetic field strength at the steel washer causes the sides of the steel washer to attract the fine ferromagnetic particles. The present arrangement prevents slipping of the motorized electromagnetic vehicle and provides stability in the operation on complex and uneven ferromagnetic structures. Further, FIG. 200A-1 illustrates the fine ferromagnetic particles sticking on the periphery of the magnetic wheel assembly making it slippery, in the absence rubber lining on the magnetic wheel assembly. Also, the FIG. 200A-2 depicts the situation when the motorized electromagnetic vehicle is provided with a plurality of rubber lining on the magnetic wheel assembly. The figure shows the fine ferromagnetic particles sticking on the side of the steel washer and not over the plurality of rubber lining embedded in the grooves on the steel washer of the magnetized wheel assembly.

FIG. 3 illustrates a schematic diagram of the Steering & Segment Rotary Joint assembly of the motorized electromagnetic vehicle [300], in accordance with exemplary embodiment of the present disclosure. As illustrated in the figure, the steering shaft [302] is positioned with the cross tie [238] with at least two bolts and is located inside the steering housing [314], supported by the upper steering housing bearing [316] and the bottom steering housing bearing [318], It is evident from the figure that the plurality of ball bearings and the steering shaft are positioned with a plurality of circlips [320, 322, 324, 326], The pinion gear [304] of the steering and segment rotary joint assembly of the motorized electromagnetic vehicle is fitted in with the steering shaft [302] through the key slot that is provided on the steering shaft and the pinion gear. The worm gear [306] of the steering and segment rotary Joint assembly is supported at one end with a plurality of bearings positioned inside the bearing housing [308], while the other end of the worm gear is operatively connected to a smart actuator [310] that is positioned with the frame and with the actuator mounting block [312], It should be noted that the steering is driven by the worm gear arrangement thereby enabling the movement of the motorized electromagnetic vehicle. Further, as illustrated in the figure, the Segment rotary joint is made of segment housing [328], a segment rotor [330], and a segment stopper [332], The segment housing [328] is attached to the rear frame [338] and the segment rotor [330] is attached to the forward frame [336], The segment stopper [332] is attached to the segment housing [328] with a plurality of bolts [334], The segment stopper prevents the segment rotor from coming out of the segment housing. Further, the fine clearance and the lubrication between the segment housing and the segment rotor allow flexibility between the forward and the Aft frame.

As illustrated in the figure, the rotation of the steering shaft and the consequent rotation of the magnetic wheel assembly is enabled by operating the smart actuator with a remote control to turn the worm gear and pinion gear positioned with the steering shaft to rotate the steering shaft. The worm gear mechanism keeps the steering shaft locked in position while the smart actuator detects the position of the steering shaft through its absolute multiturn encoder and displays the steering angle in the control station down below. Also, the segment rotary joint is provided for flexibility between the forward and rear frame. Due to unevenness on the surfaces where the crawler works, both the magnetic wheels are not always present in the same plane. Therefore, the segment rotary joint provides flexibility to adapt each magnetic wheel and their respective plane as per terrain down below on which the motorized electromagnetic vehicle functions. FIG. 4 illustrates a schematic diagram of the electromagnetic anchor arrangement of the motorized electromagnetic vehicle [400], in accordance with exemplary embodiment of the present disclosure. As illustrated in the figure, the electromagnetic anchor assembly includes at least two electromagnets [402, 404], a plurality of chrome rods [406, 408], a plurality of linear bearings [410, 412], a lead screw [414], positioned with a lead screw nut [416], a small pulley [420] working in conjunction with a big pulley [422], at least one timing belt [426], at least one actuator [428], and a plurality of bearings [430] fitted inside the bearing housing [432], The at least two electromagnets [402, 404] are positioned at the base of the bottom fix plate [434] with the help of a plurality of bolts [436, 438], The lower section of the plurality of chrome rods [406, 408] is operatively connected to the base of the bottom fix plate with a plurality of bolts [436, 438] while the upper section of the plurality of chrome rods is welded to the top fix plate [440], The plurality of ball bearings [430] is positioned inside the ball bearing housing [432] with the help of a circlip [442], The ball bearing housing [432] as well as the linear Bearing [410, 412] are fitted inside the linear Bearing housing [444, 446] with the help of a plurality of circlips [448, 450, 452, 454] and are bolted to the top carriage plate [456], The lead screw nut [416] is bolted with an actuator shaft [460] and the combination of pulleys [420, 422] is positioned inside the ball bearing housing [432] with the help of a plurality of circlips. The actuator [428] is positioned with the aluminium shaft hub [458] and the combination of a big pulley [422] and small pulley [420], The system further includes the forward frame [418] and the Aft frame [424],

The smart actuator is enabled to move the lead screw nut through the combination of pulleys which is operatively connected by the timing belt. The lead screw and the lead screw nut work in association to convert rotary motion into linear motion to be transferred to the plurality of chrome rods through the top fix plate [446], The linear motion of the plurality of chrome rods enables the bottom fix plate [434] to move in a linear motion with respect to the at least two electromagnets [402, 404] that are positioned at the top to prevent obstruction when the motorized electromagnetic vehicle moves across convex bends of 90 degrees. The motorized electromagnetic vehicle is designed to enable the use of the robotic arm while it moves across convex bends of 90 degrees on complex and uneven ferromagnetic structures, by lowering electromagnets to enable it to come in contact with the steel plates to enable the robotic arm to grip the steel plate firmly for the visual inspection and non-destructive testing of ferromagnetic surfaces and structures. Further, the smart actuator is enabled by its multiturn absolute encoder to store information related to the top stowing position and bottom anchor position of the at least two electromagnets to display the information in the control station of the motorized electromagnetic vehicle.

FIG. 5 illustrates a schematic diagram of the robotic manipulator and tool assembly of the motorized electromagnetic vehicle [500], in accordance with exemplary embodiment of the present disclosure. As illustrated in the figure, the robotic manipulator, is provided with joints and actuators to enable movement in different directions to the allow the tool assembly connected to the robotic manipulator to prepare and inspect the complex ferromagnetic surface, is mounted on an arm mounting plate [502] and is ergonomically engineered to be lightweight and stiff at the same time. This is mainly due to the extensive use of carbon filter composites and 3D printed parts. The robotic manipulator is connected to the tool assembly that may include a plurality of surface preparation tools and a plurality of inspection tools. In an example, the tool assembly includes surface preparation tools such as an electric impact needle descaler [536], grinding tool [538], and the like. The tool assembly further includes inspection tool that may include Ultrasonic Thickness (UT) gauge [540], ultrasonic scanner, eddy current tester for crack detection, and the like.

As shown in the figure, the robotic manipulator consists of at least two high torque actuators designed that may include a base actuator [506] and a shoulder actuator [524] enabled to work in association with at least three low torque actuators that may include an elbow actuator [516], an elbow joint [514], a wrist actuator [522] and a tool positioning actuator [530], The base actuator [506] of the robotic manipulator & tool assembly is positioned inside the base stator housing [504] that is connected with the arm mounting plate [502] with at least six studs [542], The shoulder actuator [524] of the robotic manipulator and tool assembly is positioned inside the shoulder stator housing [508] that is connected to the rotor of the base actuator [506] by a plurality of bolts. The shoulder actuator [524] is connected to the shoulder rotor connector [510], The twin fork-type design of the shoulder actuator connector is enabled to stay connected to carbon fiber tubes [512, 526] that are operatively positioned in connection with the elbow stator housing [518], with the wrist rotor connecter [528], and with the tool positioning actuator housing [544], The wrist actuator Housing [520] of the robotic manipulator and tool assembly is connected to the elbow actuator rotor. The robotic manipulator and tool assembly further consists of a lower base plate [532] and an upper cover plate [534] composed of carbon fiber composites and at least three tools that may include the electric needle descaler [536], the grinding wheel [538] and the Ultrasonic Thickness (UT) gauge [540] that are operatively connected to enable the surface preparation and non-destructive testing.

The robotic arm manipulator and tool assembly is supported by a front and rear Chassis that provides a framework of support to the robotic manipulator and tool assembly of the motorized electromagnetic vehicle and is composed of non-magnetic stainless-steel sheets of 6 mm in thickness that are welded together to provide the framework of support to the robotic manipulator and tool assembly. The steel sheets are cut in shape with high power laser cutting machine. Now, it is bent in shape with a CNC bending machine. After all individual parts are ready, it is welded together to build the complete frame in one piece.

For the surface preparation and non-destructive testing of complex and uneven ferromagnetic structures, the motorized electromagnetic vehicle is enabled to move to the specific location by positioning the electromagnetic anchor and switching on the motorized electromagnetic vehicle for conducting the surface preparation and non-destructive testing of that location of the surface of the complex and uneven ferromagnetic structures. During the motion of the motorized electromagnetic vehicle, the robotic manipulator and tool assembly is enabled to move in any direction away from the starting position for conducting the surface preparation and nondestructive testing of that location using the different tools.

After the execution of the surface preparation and non-destructive testing of that location, the robotic manipulator and tool assembly is reinstated in the starting position by disabling the electromagnets and dismounting the electromagnetic anchor from its position. The motorized electromagnetic vehicle is now ready to move in various locations. The motorized electromagnetic vehicle is equipped with an image recording system. In an example, the image recording system may include at least three monocular image recording systems and at least one stereo image recording system enabled to conduct the visual inspection of defects in complex and uneven ferromagnetic structures. The image recording system provides video feed in realtime and video feed is recorded for the preparation of visual inspection reports in the form of still images. If any defect like buckling, bend, or crack is found on the structure, it can be saved in an image format and the details of the defect are described. The stereo image recording system provides depth to the image and is used for measuring the size of the defect that is recorded for future reference as well.

Further, the robotic manipulator and tool assembly of the motorized electromagnetic vehicle is provided with a Light Detection and Ranging (LIDAR) tool to enable the creation of a three- dimensional (3D) map of the area of operation for the efficient detection of obstacles and to avoid the obstacles. With the help of the LIDAR, the robotic manipulator and tool assembly can move in semi-autonomous or autonomous mode. The motion of the motorized electromagnetic vehicle can be controlled remotely by a long-range mesh router. For underwater application, it is connected with a tether cable for communication while the steering & robotic manipulator operation is controlled by a joystick that operates in connection with the long-range mesh router to enable the remote-controlled movement of the motorized electromagnetic vehicle across the surface of complex and uneven ferromagnetic structures.

FIG. 6 illustrates a line diagram of the method of crossing a 90-degree convex bend when moving upwards from horizontal direction to vertical direction using the motorized electromagnetic vehicle [600], in accordance with exemplary embodiment of the present disclosure. FIG. 6A illustrates a schematic diagram of the method of crossing a 90-degree convex bend when moving upwards from horizontal direction to vertical direction using the motorized electromagnetic vehicle [600A], in accordance with exemplary embodiment of the present disclosure. In order to avoid the duplicity of the information, the description of the FIG. 6 and FIG. 6A has been explained in conjunction with each other.

In an exemplary embodiment, the method of crossing the 90-degree convex bend from the lower plane [608] to the upper plane [604] by the motorized electromagnetic vehicle is disclosed. The motorized electromagnetic vehicle on reaching the edge [606] of the complex and uneven ferromagnetic structure disables the smart actuator of the rear wheel [610] and the motorized electromagnetic vehicle is propelled by the smart actuator of the front wheel [602] only. After crossing the edge [606] by the front wheel, the smart actuator of the rear wheel [610] is enabled again and the motorized electromagnetic vehicle is propelled by the combined use of smart actuators associated with the front wheel [602] and rear wheel [610],

In another exemplary embodiment, the method of crossing the 90-degree convex bend from the upper plane [604] to the lower plane [608] by the motorized electromagnetic vehicle is disclosed. The motorized electromagnetic vehicle on reaching the edge [606] of the complex and uneven ferromagnetic structure disables the smart actuator in the front wheel [602] and the motorized electromagnetic vehicle is propelled by the smart actuator of the rear wheel [602] only. After crossing the edge [606], the smart actuator of the front wheel [602] is enabled again and the motorized electromagnetic vehicle is propelled by the combined use of smart actuators situated in the front wheel [602] and rear wheel [610],

FIG. 7 illustrates a schematic diagram of the possible variations of the motorized electromagnetic vehicle [700], in accordance with exemplary embodiment of the present disclosure. As illustrated in the figure, the framework of this version of the motorized electromagnetic vehicle is supported with at least four castor wheels [702, 704] at the four corner positions. The four castor wheels at the corners with hard suspension as illustrated in the present embodiment of the disclosure provides stability to the motorized electromagnetic vehicle to use the robotic arm and to move across convex bends of angles up to 90 degrees.

In an exemplary embodiment, the motorized electromagnetic vehicle is enabled for underwater inspection. The motorized electromagnetic vehicle, the motor is made waterproof by a mechanical seal and thermal management and is done by immersion cooling of the motors and other electronic components. Further, 3M Novec 7300 or Opteon SF10 is used for the elimination of excessive heat from the motor and processors of the motorized electromagnetic vehicle, which then passes through the radiator.

In another exemplary embodiment, the motorized electromagnetic vehicle, instead of using only one steering gear, both the forward and the rear wheel assembly is operatively coupled with twin steering gear [706,708] to enable greater manoeuvrability and better lateral movement. Further, the several types of payloads can be mounted on it like Electromagnetic Acoustic Transducer (EMAT) sensors, welding holders, and the like. FIG. 8 illustrates a schematic diagram of the waterproof smart actuator for the underwater operation of the motorized electromagnetic vehicle [800], in accordance with exemplary embodiment of the present disclosure. The figure shows the underwater operation of the motorized electromagnetic vehicle for the underwater inspection of the ships and the maritime structures. The smart actuators with integrated electronics have been made waterproof for the underwater operation of the motorized electromagnetic vehicle. These actuators have been tested at a pressure of at least 10 bar which makes them suitable for operation up to 100 meters deep in water for the visual inspection, surface preparation, and surface testing of ferromagnetic structures underwater.

In an exemplary embodiment, as illustrated in the figure, the smart actuator is housed in a steel casing [851], and the cable side of the smart actuator is sealed with a cover plate [852] with an O-Ring [860] and a plurality of bolts [855], The cover plate is connected with a 9-pin male waterproof connector [853] for power and communication as well as with a 9-pin female connector [854], The sealing between the rotary shaft [808] and the smart actuator [842] is done by using a mechanical seal for which both the rotary and stationary faces are made of tungsten carbide (WC). The use of tungsten carbide for both the faces ensures the durability of operation in the marine environment. The mechanical seal is made of a stationary face [857] which is sealed against the casing [851] using the O-Ring [858], The rotary face [861] is compressed against the stationary face [857] with a spring [856], that provides a positive sealing.

In another exemplary embodiment, the motorized electromagnetic vehicle is capable of underwater operation, where the smart actuator may be enclosed using at least one of a plurality of sealing assembly. The sealing assembly protects the smart actuator of the motorized electromagnetic vehicle from getting in contact with water and thereby enabling underwater operation. In an example, the plurality of sealing assembly includes but is not limited to mechanical sealing assembly like the one illustrated in FIG. 8, oil-based sealing assembly, rubberbased sealing assembly, and the like.

In an exemplary embodiment, for the thermal management of the motors and electronics of the motorized electromagnetic vehicle, the casing [851] is filled with the immersion cooling fluid Opteon SF10. Opteon SF10 has a boiling point of 110-degree Celsius, liquid thermal conductivity of 0.077 W/m-K, and dielectric constant of 5.48 at 1 kHz. These properties make it suitable for the immersion cooling as it can safely be in contact with the electronics and the motor windings without triggering a short circuit. In another exemplary embodiment, the at least one immersion cooling fluid may be used for the thermal management in the motorized electromagnetic vehicle. In an example, the at least one immersion fluid include but is not limited to Opteon SF10, 3M Novec 7300, and the like.

By employing this arrangement, the successful waterproofing and thermal management can be achieved for the underwater operation of the motorized electromagnetic vehicle.

FIG. 9 illustrates an exemplary method flow diagram for inspection and non-destructive testing of complex and uneven ferromagnetic structures using a motorized electromagnetic vehicle, in accordance with an embodiment of the present disclosure. The method begins at step 902 with the need for inspection and non-destructive testing of complex and uneven ferromagnetic structures.

At step 904, the method includes steering the motorized electromagnetic vehicle for visual inspection and non-destructive testing of complex and uneven ferromagnetic structure using a magnetic wheel assembly. In an example, the motorized electromagnetic vehicle is controlled remotely using a remote-control station. The remote-control station is connected to motorized electromagnetic vehicle using a long-range mesh router for controlling in terrestrial operations. The remote-control station is connected to motorized electromagnetic vehicle using a tether cable for controlling underwater operations. The steering movement corresponds to the translational movement of the motorized electromagnetic vehicle enabled using smart actuators present in the magnetic wheel assembly.

At step 906, the method includes holding the motorized electromagnetic vehicle on surface of the complex and uneven ferromagnetic structure using an electromagnetic anchor arrangement. In an example, the motorized electromagnetic vehicle is firmly secured to the complex and uneven ferromagnetic structure using an electromagnetic anchor arrangement. The motorized electromagnetic vehicle is thereby capable of performing inspection and non-destructive testing using tool assembly without slipping or falling. At step 908, the method includes cleaning the surface of the complex and uneven ferromagnetic structure for the non-destructive testing using a robotic arm manipulator and a tool assembly. In an example, the tool assembly includes surface preparation tools such as an electric impact needle descaler, grinding tool, and the like. The tool assembly further includes inspection tool that may include Ultrasonic Thickness (UT) gauge, ultrasonic scanner, eddy current tester for crack detection, and the like.

At step 910, the method includes performing the non-destructive testing and inspection of the surface of the complex and uneven ferromagnetic structure using the robotic arm manipulator, the tool assembly, and at least one image recording system of the motorized electronic vehicle. In an example, the image recording system includes at least three monocular image recording systems, at least one stereo image recording system to record data associated with the inspection.

In accordance with an exemplary embodiment, the method further includes enabling a movement of the motorized electromagnetic vehicle to cross a pre-defined angle range of a convex bend. The method includes deactivating a smart actuator associated with the at least one rear wheel assembly in an event the at least one front wheel assembly reaches to an edge of the convex bend, wherein deactivation of the smart actuator starts a crawling movement of the at least one rear wheel assembly based on a forward movement of the at least one front wheel assembly. Next, the method includes crossing the convex bend by the at least one front wheel assembly using a forward movement of the at least one front wheel assembly. In an example, the smart actuator associated with the front wheel assembly is used to enable the movement of the motorized electromagnetic vehicle and to cross the convex bend. Next, the method includes re-activating the smart actuator associated with the at least one rear wheel assembly. Thereafter, the method includes crossing the convex bend by the at least one rear wheel assembly to enable the crossing of the pre-defined angle range of the convex bend by the motorized electromagnetic vehicle.

In accordance with an exemplary embodiment, the pre-defined angle range of the convex bend corresponds to a range of at most 90 degrees. In an embodiment, the pre-defined angle range of the convex bend may vary.

In accordance with an exemplary embodiment, the method further includes embedding at least one layer of rubber lining on at least one magnetic front wheel assembly and at least one magnetic rear wheel assembly of the magnetic wheel assembly to prevent slippery movement of the motorized electromagnetic vehicle, wherein the at least one layer of rubber lining prevents sticking of metal particles on the magnetic wheel assembly.

The method terminates at step 912 after inspection and non-destructive testing of complex and uneven ferromagnetic structures using a motorized electromagnetic vehicle.

As is evident from the above disclosure, the present solution provides significant technical advancement over the existing solutions by providing a method and system for the visual inspection of complex and uneven ferromagnetic structures. The factors providing the technical advancements in the present disclosure overthe existing solutions include but are not limited to:

• The motorized electromagnetic vehicle, as disclosed herein, is provided with magnetic wheel assembly with a bi-wheel design implemented through a front wheel assembly and a rear wheel assembly. The segmentary joint connected to the at least one front chassis and the at least one rear chassis provide flexibility to the motorized electromagnetic vehicle to adapt to the uneven and complex surfaces. Further, the method related to crossing the convex bend of at most 90 degrees through the alternate activation and deactivation of the smart actuator associated with the at least one rear wheel assembly enables the movement and crossing of the convex bends by the motorized electromagnetic vehicle.

• The motorized electromagnetic vehicle, as disclosed herein, is provided with a robotic arm manipulator and tool assembly to perform surface preparation and non-destructive testing of the complex and uneven ferromagnetic structures. The plurality of actuators provided in the robotic arm manipulator allow the installation of multiple tools on the tool assembly at the same time.

• The motorized electromagnetic vehicle, as disclosed herein, is provided with rubber lining embedded in the grooves provided on the washer of the magnetic wheel assembly. The rubber lining prevents sticking of fine ferromagnetic particles to the magnetic wheel assembly thereby enhancing the stability of the motorized electromagnetic vehicle.

• The motorized electromagnetic vehicle, as disclosed herein, has underwater operating capabilities and performs inspection to a depth of about 100 m in water. Underwater operation capability is achieved by providing waterproof mechanical sealing of electronic components. Additionally, smart actuator is filled with the immersion cooling fluid like Opteon SF-10 for heat management and elimination of excess heat from the smart actuators of the motorized electromagnetic vehicle.

• The stability of the motorized electromagnetic vehicle, as disclosed herein, is enhanced by providing electromagnetic anchor arrangement. The electromagnetic anchor arrangement is used to provide grip to the motorized electromagnetic vehicle on complex and uneven ferromagnetic structures. The enhanced stability facilitates the movement of the robotic arm manipulator and tool assembly without encountering the motorized electromagnetic vehicle falling over.

• The present disclosure relies upon plurality of Mu-metal sheets as the covering material for housing electronic components of the motorized electromagnetic vehicle. The material is preferred herein due to the capability to provide protection to the electronic components of the motorized electromagnetic vehicle from electromagnetic interference. The application of a plurality of Mu-metal sheets enhances the performance and the durability of electronic components used in motorized electromagnetic vehicles.

Therefore, as disclosed in the present disclosure, the present invention is helpful to the user and hence an overall improved user experience is realized.

While considerable emphasis has been placed herein on the disclosed embodiments, it will be appreciated that many embodiments can be made and that many changes can be made to the embodiments without departing from the principles of the present disclosure. These and other changes in the embodiments of the present disclosure will be apparent to those skilled in the art, whereby it is to be understood that the foregoing descriptive matter to be implemented is illustrative and non-limiting.

Claims

We Claim:

1. A motorized electromagnetic vehicle [100] for inspection of complex surfaces and nondestructive testing of ferromagnetic structures comprising: a magnetic wheel assembly [102], [104]; a robotic arm manipulator [106]; a tool assembly [108] connected to the robotic arm manipulator; an electromagnetic anchor arrangement [110]; a chassis assembly comprising at least one front chassis [112] and at least one rear chassis [114]; a segmentary joint [116]; and a steering assembly [118], wherein the motorized electromagnetic vehicle [100] is designed to cross a pre-defined angle range of a convex bend.

2. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the magnetic wheel assembly comprises: at least one magnetic front wheel assembly [102]; at least one magnetic rear wheel assembly [104]; at least one smart actuator [242]; and a plurality of ball bearings [210], wherein the at least one smart actuator [242] is connected with at least one processing unit to enable the crossing of the pre-defined angle range of the convex bend, wherein the at least one processing unit is configured to: deactivate the at least one smart actuator [242] associated with the at least one rear wheel assembly [104] in an event the at least one front wheel assembly [102] reaches to an edge of the convex bend, wherein deactivation of the at least one smart actuator [242] starts a crawling movement of the at least one rear wheel assembly [104] based on a forward movement of the at least one front wheel assembly [102]; enable crossing of the convex bend by the at least one front wheel assembly [102] using the forward movement of the at least one front wheel assembly [102]; re-activate the at least one smart actuator [242] associated with the at least one rear wheel assembly [104]; and enable crossing of the convex bend by the at least one rear wheel assembly [104] for a complete crossing of the pre-defined angle range of the convex bend by the motorized electromagnetic vehicle.

3. The motorized electromagnetic vehicle [100] as claimed in claim 2, wherein the at least one magnetic front wheel assembly [102] and the at least one magnetic rear wheel assembly [104] are embedded with at least one layer of rubber lining to prevent slippery movement of the motorized electromagnetic vehicle, wherein the at least one layer of rubber lining prevent sticking of metal particles on the magnetic wheel assembly.

4. The motorized electronic vehicle [100] as claimed in claim 1, wherein the segmentary joint [116] connected to the at least one front chassis [112] and the at least one rear chassis [114] provide flexibility to the motorized electromagnetic vehicle to adapt to the uneven and the complex surfaces.

5. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the predefined angle range of the convex bend corresponds to a range of at most 90 degrees.

6. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the robotic arm manipulator [106] is connected to a plurality of surface preparation tools and a plurality of inspection tools to conduct inspection and non-destructive testing of the complex and uneven ferromagnetic structure.

7. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the motorized electromagnetic vehicle comprises a plurality of Mu metal sheets positioned around the front chassis [112] and the rear chassis [114] to prevent a plurality of components associated with the motorized electromagnetic vehicle from magnetic interference.

8. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the robotic arm manipulator [106] comprises at least two high torque actuator and at least three low torque actuator, wherein the high torque actuator comprises a Base Actuator [506], a Shoulder Actuator [524], and the low torque actuator comprises an Elbow Actuator [516], a Wrist Actuator [522] and a Tool Positioning Actuator [530],

9. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the segment rotary joint [116] comprises: a segment housing [328] connected to a rear frame [338]; a segment rotor [330] connected to a forward frame [336]; and a segment stopper [332] connected to the segment housing [328] with a plurality of bolts [334],

10. The motorized electromagnetic vehicle [100] as claimed in claim 2, wherein the at least one smart actuator [242] is enclosed using at least one of a plurality of sealing assembly and at least one immersion cooling fluid to enable underwater operation of the motorized electromagnetic vehicle. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the electromagnetic anchor arrangement [110] comprises: at least two electromagnets [402, 404]; a plurality of chrome rods [406, 408]; a plurality of linear bearings [410, 412]; a lead screw [414] positioned with a lead screw nut [416]; a small pulley [420] coupled with a big pulley [422]; at least one timing belt [426]; at least one actuator [428]; and a plurality of bearings [430] fitted inside the bearing housing [432], wherein the electromagnetic anchor arrangement [110] of the motorized electromagnetic vehicle [100] facilitates holding the motorized electromagnetic vehicle to the surface of the complex and uneven ferromagnetic structure. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein the motorized electromagnetic vehicle is controlled remotely using a remote-control station, wherein the remote-control station is connected with: a long-range mesh router for controlling the operation of the motorized electromagnetic vehicle on terrestrial, and a tether cable for controlling underwater operations of the motorized electromagnetic vehicle. A method for inspection and non-destructive testing of complex and uneven ferromagnetic structures using a motorized electromagnetic vehicle [100], the method comprising: steering the motorized electromagnetic vehicle [100] for inspection and nondestructive testing of complex and uneven ferromagnetic structure using a magnetic wheel assembly [102], [104]; holding the motorized electromagnetic vehicle on surface of the complex and uneven ferromagnetic structure using an electromagnetic anchor arrangement [110]; cleaning the surface of the complex and uneven ferromagnetic structure for the nondestructive testing using a robotic arm manipulator [106] and a tool assembly [108]; and performing the non-destructive testing and inspection of the surface of the complex and uneven ferromagnetic structure using the robotic arm manipulator [106], the tool assembly [108], and at least one image recording system of the motorized electronic vehicle. The method as claimed in claim 13 further comprises enabling a movement of the motorized electromagnetic vehicle [100] to cross a pre-defined angle range of a convex bend, wherein the enabling the movement of the motorized electromagnetic vehicle comprises: deactivating a smart actuator associated with the at least one rear wheel assembly in an event the at least one front wheel assembly reaches to an edge of the convex bend, wherein deactivation of the smart actuator starts a crawling movement of the at least one rear wheel assembly based on a forward movement of the at least one front wheel assembly; crossing the convex bend by the at least one front wheel assembly using the forward movement of the at least one front wheel assembly; and re-activating the smart actuator associated with the at least one rear wheel assembly; and crossing the convex bend by the at least one rear wheel assembly to enable the crossing of the pre-defined angle range of the convex bend by the motorized electromagnetic vehicle. The method as claimed in claim 14, wherein the pre-defined angle range of the convex bend corresponds to a range of at most 90 degrees. The method as claimed in claim 13, wherein the method comprises embedding at least one layer of rubber lining on at least one magnetic front wheel assembly [102] and at least one magnetic rear wheel assembly [104] of the magnetic wheel assembly, wherein the at least one layer of rubber lining prevents slippery movement of the motorized electromagnetic vehicle by preventing a sticking of metal particles on the magnetic wheel assembly.