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Drones & robotics

Thermal inspection drone

A survey aircraft that flies a programmed grid over your assets, measures a real temperature in every pixel, locates each hot spot to the panel, and lands you a graded defect map instead of a memory card of images.

The problem

Heat is the first symptom.

Industrial assets announce a fault as heat long before it shows in a way you can see. A cracked solar cell, a bolted busbar working loose, a wet patch of insulation under a flat roof: each runs hotter than its neighbours for weeks or months first. The trouble is that heat is invisible from the ground, and a walking inspection with a handheld camera covers a fraction of a site in a day, reads each panel at a different angle and hour, and leaves you a folder of loose images nobody can hold to a standard. By the time a fault shows as lost output or a shutdown, the cheap window to fix it has closed. What an operator needs is the whole site measured the same way on the same morning, every hot spot located to the panel, and a report that says what is wrong and where. That is a scheduled flight, not a clipboard.

Design targets
640 x 512 Radiometric pixels per frame
< 40 mK Thermal sensitivity, NETD
+/- 2 C Measured temperature accuracy
1 cm Geotag precision, RTK
The system

One flight, three jobs.

Measure it, cover it, report it. Each part earns its place by turning a walking inspection's weakness into a fixed method. Open a part for what it does and how far it goes.

Every pixel a value
Imagery in production

Radiometric sensing

It measures, not just sees.

640 x 512 uncooled LWIR, 7.5 to 13.5 um < 40 mK NETD, +/- 2 C accuracy Paired 20 MP visual for context
Every pixel a value
Imagery in production

Radiometric sensing

It measures, not just sees.

640 x 512 uncooled LWIR, 7.5 to 13.5 um < 40 mK NETD, +/- 2 C accuracy Paired 20 MP visual for context

The payload is a radiometric long-wave infrared camera, not a colour-mapped thermal viewer. Every one of its 327,680 pixels carries a calibrated temperature, stored in the saved frame, so an anomaly is a number in Celsius you can threshold and defend, not a warm-looking blob. The uncooled vanadium oxide microbolometer runs under 40 mK sensitivity, enough to separate a cell 3 C above its string from a reflection, and holds +/- 2 C absolute against a traceable blackbody reference. A 20 MP visual camera is bore-sighted alongside so every thermal hit has a matching photo of the actual part. The same head flies on every airframe in the range.

Repeatable to the pixel
Imagery in production

Automated grid flight

The whole site, the same way.

Programmed serpentine grid, terrain follow RTK geotag to 1 cm Same path, altitude and sun angle each visit
Repeatable to the pixel
Imagery in production

Automated grid flight

The whole site, the same way.

Programmed serpentine grid, terrain follow RTK geotag to 1 cm Same path, altitude and sun angle each visit

You draw the boundary once. The flight stack plans a serpentine grid at a fixed altitude and overlap, follows the terrain so ground sample distance stays constant, and flies it the same way on every visit, so month-on-month scans line up and a growing fault is obvious. RTK positioning tags every frame to within a centimetre, which is what lets the software place an anomaly on the right panel out of tens of thousands rather than somewhere in a row. Flights are scheduled for the sun angle and time of day that give a clean thermal signal, typically clear sky with a load on the asset. No two operators, no two walking routes, no drift between inspections.

Located, graded, exported
Imagery in production

Analysis and reporting

A defect map, not a photo dump.

Thermal orthomosaic of the whole site Every anomaly geo-located and classified PDF report plus GIS and CSV export
Located, graded, exported
Imagery in production

Analysis and reporting

A defect map, not a photo dump.

Thermal orthomosaic of the whole site Every anomaly geo-located and classified PDF report plus GIS and CSV export

On the ground the frames are stitched into a single thermal orthomosaic of the site, and analysis runs anomaly detection against the standard fault signatures: a single hot cell, a hot diode or substring, a hot junction box, an offline string, a wet roof bay, a hot electrical joint. Each detection is placed on the map by its RTK position, graded by temperature rise above its neighbours and by pattern, and dropped into a report that names the fault, the delta-T, the GPS location and the matching visual photo. You get a PDF for the file, a CSV for the work-order system and a GIS layer for the asset map. The output is a repair list, not a folder of images.

Solution optimized products

Configured for inspection.

Every line item selected for scheduled radiometric survey.

Imagery in production
Airframe

Weather-rated inspection multirotor

35 min class

Sealed carbon airframe, IP4x, rated to 12 m/s wind and light rain, hot-swap smart battery, low-noise props for flight near occupied buildings and live sites.

Imagery in production
Payload

Radiometric thermal and visual head

640 x 512 LWIR

Uncooled long-wave infrared array bore-sighted to a 20 MP visual camera, +/- 2 C radiometric accuracy, on-board R-JPEG recording with a temperature in every pixel.

Imagery in production
Payload

RTK positioning module

1 cm geotag

Real-time kinematic GNSS tags every frame to centimetre accuracy, so anomalies land on the correct panel and repeat scans align between visits.

Imagery in production
Ground

Ruggedised planning controller

Field ready

Bright-screen controller running the mission planner, terrain-follow grid, geofencing and a live radiometric preview, so a soft or reflective frame is caught before you land.

Imagery in production
Software

CalyOS Embedded inspection stack

Onboard + desk

Flight planning, thermal orthomosaic stitching, anomaly detection against IEC 62446-3 and EN 13187 signatures, and one-click defect-map and report export.

What you get

A morning's flight, a day's repairs.

The deliverable

Report

You do not get a drone and a memory card. You get a scheduled survey turned into a graded defect list: every anomaly located to the panel or the metre, ranked by severity, with the thermal image, the matching photo and the temperature rise, ready to hand to whoever holds the spanner.

Imagery in production

Every fault graded

Anomalies ranked by temperature rise and pattern, so you fix the string outage before the single warm cell.

Located to the panel

RTK geotag drops each hit onto the right module or the right metre of roof, not just the right field.

Baselined over time

Same grid every visit, so a fault that is growing shows as a trend, not a surprise.

Radiometric data kept

Every pixel holds a real temperature in the exported file, so a finding can be re-checked and defended later.

“The first flight found four dead strings and a junction box running at 70 C that our annual walk-round had missed twice. It paid for the programme before lunch.”
Asset manager, a utility solar portfolio
The payload

How it measures.

Imagery in production
Radiometric core

A temperature in every pixel

The sensor is a 640 by 512 uncooled vanadium oxide microbolometer sensitive from 7.5 to 13.5 um, the long-wave band where objects near ambient emit most strongly. Sensitivity is under 40 mK, so a cell a few degrees above its string stands clear of noise, and absolute accuracy holds to +/- 2 C or +/- 2 percent against a factory blackbody calibration. Each frame is saved as radiometric R-JPEG, so the temperature of any point is recoverable on the desk, not baked into a colour map.

Imagery in production
Visual pairing

The photo that proves the hot spot

A 20 MP visual camera sits on the same gimbal, bore-sighted to the thermal frame, so every anomaly comes with an ordinary photo of the exact part. That is what turns a warm blob into a work order: the roofer sees the wet bay, the electrician sees the scorched junction box, and nobody argues about which panel. Both channels ride a three-axis gimbal, so ground sample distance stays honest at survey altitude.

Imagery in production
Emissivity and calibration

Set for the surface, not the guess

A reading is only as good as the emissivity you tell it, so the software carries per-surface presets for glass, painted metal, bare metal, felt and membrane, with reflected-temperature compensation for a clear sky. The camera is calibrated across its range against a traceable blackbody source and re-verified on a schedule, so the numbers in the report survive scrutiny from an insurer or a warranty claim.

The measurement, at a glance

< 40 mK Thermal sensitivity, NETD
+/- 2 C Radiometric accuracy
16-bit Radiometric data per frame
30 Hz Thermal frame rate
Read across

One camera, many faults.

The same radiometric head reads a different fault signature on each asset class.

Solar

Cells, diodes, strings

Hot cells, hot bypass diodes, PID and whole offline strings show as distinct thermal patterns, scored against IEC 62446-3 delta-T bands.

Electrical

Joints and connections

Loose or corroded bolted joints, overloaded conductors and failing connections on lines and in substations run hot long before they fail.

Envelope

Moisture and heat loss

Trapped moisture under a flat roof and missing insulation in a facade read as thermal anomalies, assessed against EN 13187 building thermography.

Engineering questions

About the sensor.

Is it radiometric or just a thermal picture?

Radiometric. Every pixel stores a calibrated temperature in the saved file, so you can re-measure any point, change the emissivity and re-threshold on the desk. A colour thermal picture cannot do any of that.

How accurate are the temperatures?

Plus or minus 2 C or 2 percent against a traceable blackbody calibration, provided emissivity and reflected temperature are set correctly, which the software presets handle per surface. For fault-finding the delta between a part and its neighbours matters more than the absolute, and that resolves well inside a tenth of a degree.

Does weather stop the survey?

Thermography needs a thermal load and a clean sky, so solar is flown under good irradiance and roofs at the right hour. The airframe is rated to 12 m/s wind and light rain, but the physics, not the aircraft, sets the window.

“We stopped arguing with the maintenance contractor about where a fault was. The report has the panel ID, the photo and the temperature. They just go and fix it.”
Reliability engineer, a renewables operator
Flight & autonomy

It flies the grid for you.

You set the boundary and the schedule. The aircraft plans the coverage, holds the altitude and overlap, and flies the same path every time, so the data lines up between visits.

A single survey

From boundary to map.

  1. Draw the site

    Mark the asset boundary once on the planner and set altitude, overlap and the fault types you care about. The stack generates a serpentine grid and a geofence.

  2. Fly the grid

    The aircraft flies the route on RTK guidance, following terrain to keep ground sample distance constant, tagging every frame with a centimetre-accurate position.

  3. Capture both channels

    Thermal and visual frames are recorded together at each waypoint, with a live radiometric preview on the controller so a soft or reflective frame is caught before landing.

  4. Stitch and detect

    On the ground the frames become a thermal orthomosaic and anomaly detection runs against the fault signatures for the asset class.

  5. Export the report

    Graded defects drop onto the map with location, delta-T and photo, and export as PDF, CSV and a GIS layer for the asset system.

Autonomy

Repeatable beats heroic.

The value of an aerial inspection is not a spectacular one-off flight; it is the same flight, flown identically, every quarter for years, so that a fault which grows two degrees a month is caught while it is cheap. That only works if the aircraft removes the operator's variability. Grid altitude, overlap, speed and the sun window are fixed in the plan, not left to the person on the sticks. Terrain follow holds ground sample distance constant over a sloped array or a stepped roof. Geofences and no-fly volumes live in the flight stack and are enforced, not advisory. Link loss triggers a return-to-home, and a low battery ends the current lane cleanly and resumes after a hot-swap. The pilot supervises and keeps the site safe; the aircraft flies the survey the same way it did last time.

Per flight day
50 MW Solar capacity scanned per day
35 min Endurance per battery
12 m/s Rated wind tolerance
1 cm RTK frame position
Specify it with us

Map your assets.

Send us the site boundary and the asset class and we will scope the survey, the flight schedule and the report format. You keep the aircraft, the data and the licence outright.

Reporting & data

The point is the report.

The drone is the cheap part. What you buy is a graded, located, defensible defect list that goes straight to the crew who fix it and the file that proves you inspected.

The pipeline

From frame to fix.

Imagery in production
Stitch

One map of the whole site

Thousands of geotagged frames are mosaicked into a single thermal orthomosaic, so instead of scrolling images you see the whole solar field, roof or line run as one map with real coordinates. Overlap and RTK position let the software place every pixel correctly, which is what makes the next step trustworthy.

Imagery in production
Detect and grade

Faults found and ranked

Detection runs against the known signatures for the asset: a single hot cell, a hot diode, a hot junction box, an offline string, a wet roof bay, a hot electrical joint. Each is graded by its temperature rise above the local baseline and by pattern, so a whole dead string outranks one warm cell and the crew works the list in the order that protects output.

Imagery in production
Deliver

In the format the work uses

Every anomaly carries a GPS location, a delta-T, a severity, the thermal crop and the matching visual photo. It exports as a PDF report for the record, a CSV that drops into a maintenance or work-order system, and a GIS layer for the asset map. Nothing has to be retyped for a job card.

What lands

Three outputs, one flight.

The same survey serves the crew, the system and the auditor.

For the crew

A located repair list

Ranked anomalies with panel ID or grid reference, photo and temperature, so a technician walks to the fault, not the field.

For the system

A CSV and GIS layer

Structured records that import into the maintenance system and drop onto the asset map without re-keying.

For the record

A defensible PDF

A dated report with radiometric evidence and method, the kind an insurer, an auditor or a warranty claim will accept.

The difference

Walk versus flight.

Scheduled drone surveyHandheld walk-round
Coverage Whole site in a morning, every panel measured A sample, whatever fits the day on foot
Consistency Same grid, altitude and sun angle each visit Different route, angle and operator each time
Location Every fault geotagged to 1 cm A note and a memory of roughly where
Output Graded defect map, CSV and GIS export A folder of loose images to sort by hand
Trend Visits line up, growth is visible Hard to compare one year to the next
Evidence Radiometric data kept per pixel Colour snapshots, the values not recoverable
Data questions

Who owns the data.

Where does the analysis run?

On your own desk or server. The stitching and detection run locally in the CalyOS inspection stack, so footage and asset data do not have to leave your network, and there is no per-report cloud meter.

Can we get the raw radiometric data?

Yes. You keep the radiometric R-JPEG frames, the orthomosaic and the exports. Every pixel's temperature is recoverable, so a third party can re-check a finding independently.

Does it fit our existing systems?

Exports are standard PDF, CSV and GIS layers, so anomalies drop into a maintenance or work-order system and onto the asset map without a proprietary viewer.

See a sample

Read a real report.

We will send a sample defect map and report from an anonymised survey so you can see the output before you commit. Then we scope it to your assets.

The library

Briefs and cases.

The documents and worked examples behind the solution.

Brief
Imagery in production

Solution brief

The one-page case.

2 pages For decision makers
Brief
Imagery in production

Solution brief

The one-page case.

2 pages For decision makers

A two-page summary: the inspection problem, the design targets, the assets it covers and the deliverable, with the headline specification and the price model. Written for the person who signs the survey programme off, not the person who integrates it.

White paper
Imagery in production

Radiometric inspection white paper

Method and accuracy.

16 pages For technical evaluators
White paper
Imagery in production

Radiometric inspection white paper

Method and accuracy.

16 pages For technical evaluators

The sensing rationale, the emissivity and calibration method, the fault signatures for solar, electrical and building envelope, and how delta-T grading maps to IEC 62446-3 and EN 13187, with a worked accuracy budget.

White paper
Imagery in production

Data and integration guide

For your engineers.

18 pages For integrators
White paper
Imagery in production

Data and integration guide

For your engineers.

18 pages For integrators

The export formats, the radiometric R-JPEG structure, the CSV schema and the GIS layer, plus how the reports import into a maintenance or work-order system, so integration is scoped before purchase.

Use case
Imagery in production

Solar farm survey

50 MW, one morning.

AssetPV portfolio Outputdefect map
Use case
Imagery in production

Solar farm survey

50 MW, one morning.

AssetPV portfolio Outputdefect map

A 50 MW site flown on a single clear morning under load. The survey found four offline strings, eleven hot bypass diodes and a junction box at 70 C, all located to the panel and graded, and the report went to the maintenance contractor as a work list the same day.

Use case
Imagery in production

Flat-roof moisture survey

Before the re-roof.

Assetwarehouse roofs Outputwet-area map
Use case
Imagery in production

Flat-roof moisture survey

Before the re-roof.

Assetwarehouse roofs Outputwet-area map

A portfolio of warehouse roofs flown at dusk to catch trapped moisture holding heat. The wet bays mapped as clear thermal anomalies under EN 13187 practice, so the repair was targeted to the failed sections instead of stripping the whole roof.

Use case
Imagery in production

Substation and line survey

Hot joints, live asset.

Assetdistribution network Outputgraded joint list
Use case
Imagery in production

Substation and line survey

Hot joints, live asset.

Assetdistribution network Outputgraded joint list

A run of overhead line and a substation flown under load, reading bolted joints and connections. Several joints ran 30 to 50 C above their neighbours and were scheduled for maintenance before they failed, without taking the asset offline to inspect.

Request the files

Get the documents.

The datasheet, the integration guide and the white paper, sent on request.

How the pack is supplied

6 Documents and cases
3 yr Warranty standard
10 yr Spares and images held
0 Per-report cloud fees
Specify it with us

Start a survey.

Tell us the asset class and the site and we will scope the aircraft, the schedule and the report. You own the drone, the data and the software outright.