Autonomous Aerial Non-Destructive Testing: Ultrasound Inspection with a Commercial Quadrotor in an Unstructured Environment

This paper presents a non-contact approach for vibration-based structural damage detection using an autonomous and customized cost-effective unmanned aerial vehicle (UAV). Vibration signals are extracted from video recordings through vision-based motion tracking to identify shifts in natural frequencies indicative of structural degradation. A laboratory-scale frame structure is evaluated under healthy and simulated-damage conditions. The proposed system is validated through an experimental study involving two smartphones, a USB camera, and a custom-built low-cost UAV equipped with an onboard camera and an autonomous alignment system for operation in GPS-denied environments. The displacement time is extracted and analyzed in the frequency domain and compared to reference measurements from contact accelerometers and a finite element model. Experimental results show that all platforms successfully capture the fundamental frequency and its shift due to damage. Although the UAV exhibits slightly higher errors (up to 5.7%) due to platform-induced disturbances and sensing limitations, it reliably detects damage-induced frequency changes. Compared to commercial UAV systems, the proposed platform achieves comparable inspection performance at significantly lower cost. These results demonstrate that low-cost autonomous UAVs provide a practical, flexible, and scalable solution for structural health monitoring, particularly in scenarios where contact-based sensing is impractical. The findings also support the potential for the deployment of multiple cooperative UAVs to further enhance inspection coverage and robustness.

Reliable pipeline inspection is critical to safe energy transportation, but is constrained by long distances, complex terrain, and risks to human inspectors. Unmanned aerial vehicles provide a flexible sensing platform, yet reliable autonomous inspection remains challenging. This paper presents an autonomous quadrotor near-proximity pipeline inspection framework for three-dimensional scenarios based on image-based visual servoing model predictive control (VMPC). A unified predictive model couples quadrotor dynamics with image feature kinematics, enabling direct image-space prediction within the control loop. To address low-rate visual updates, measurement noise, and environmental uncertainties, an extended-state Kalman filtering scheme with image feature prediction (ESKF-PRE) is developed, and the estimated lumped disturbances are incorporated into the VMPC prediction model, yielding the ESKF-PRE-VMPC framework. A terrain-adaptive velocity design is introduced to maintain the desired cruising speed while generating vertical velocity references over unknown terrain slopes without prior terrain information. The framework is validated in high-fidelity Gazebo simulations and real-world experiments. In real-world tests, the proposed method reduces RMSE by 52.63% and 75.04% in pipeline orientation and lateral deviation in the image, respectively, for straight-pipeline inspection without wind, and successfully completes both wind-disturbance and bend-pipeline tasks where baseline method fails. An open-source nano quadrotor is modified for indoor experimentation.

Infrastructure maintenance, contact-based inspection, and emergency response can benefit from aerial vehicles that act as a flying human hand with extreme maneuverability, manipulation, and resiliency (MMR): maneuverability to fly in arbitrary orientations to reach remote and tight locations; manipulation to point sensors, turn valves, and press tools at arbitrary orientations; resiliency to maintain accurate motion and force control despite disturbances from arbitrary directions, such as wind, ground effects, and friction. Realizing MMR on aerial vehicles requires not only omnidirectional flight; it also requires (I) vectoring of maximum thrust in any direction, to maximize capacity for contact-force application and disturbance rejection, (II) global stability, to enable control over any orientation/position, and (III) compact, standard designs that build upon platforms such as quadrotors to inherit technological know-how. No current aerial vehicle simultaneously enables I--III, due to structural and control limitations that constrain actuation. We present MorphQuad: a morphable quadrotor that enjoys MMR. Key to our approach is a hardware and control co-design: on hardware, we independently articulate each of the four rotor systems via two-axis gimbals; on control, we introduce globally-stable control, and energy-optimal thrust allocation that permits inter-rotor thrust cancellations only to avoid downwash interference and gimbal lock. With fully-onboard autonomy, MorphQuad demonstrates multi-revolution rotation while translating or hovering, for pipe inspection and target tracking (maneuverability); valve turning, perching, and object pressing and pushing with human-level strengths (manipulation); and wind rejection from any direction, even directed to a single rotor, and push-pull recovery (resiliency).