The technology offers a smart and effective solution for inspecting HVAC systems, with key strengths in its design, modularity, and wireless data streaming all helping to improve safety and deliver better results. The robot’s circular shape allows it to move smoothly through tight spaces without getting stuck or flipping over, making it ideal for navigating complex ductwork. Its modular structure means different tools or sensors can be easily added or changed, so the robot can be customised for different inspection tasks or special applications. The system also features wireless data streaming, which sends inspection results in real time. This lets users spot issues immediately and take action on the spot, reducing downtime and improving the speed of repairs.

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The current state of HVAC inspections presents significant challenges that compromise both safety and efficiency within the industry. Human inspectors are exposed to substantial safety risks as they navigate confined spaces, leading to a heightened potential for injury and workplace accidents. Moreover, the limited visualization provided by flat images hinders the ability to acquire a comprehensive 3D view of the systems, impeding the accurate identification of potential issues. This, in turn, contributes to inefficiencies in the inspection process, as manual inspections are not only time-consuming but also incur significant costs, thereby impacting the overall operational efficiency of HVAC inspections. These challenges underscore the critical need for an improved solution that enhances safety, provides comprehensive visualization, and streamlines the inspection process to ensure the safety and efficiency of HVAC inspections.

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Our earlier research developed a rolling and bouncing spherical robot, showing it could move stably and effectively in various environments. This prototype reached Technology Readiness Level (TRL) 4/5 and demonstrated strong potential for use in disaster response, search and rescue, and surveillance. Building on that success, we are now adapting the robot for the HVAC industry to carry out duct inspections more safely and efficiently. The new version of the robot is designed to inspect standard HVAC trunk ducts, typically measuring 2 feet by 1 foot. Current inspection methods rely on human technicians or expensive, tethered robots, both of which have limited access and high costs. Our improved robot offers a wireless, flexible alternative that can navigate tight duct spaces easily. HVAC systems often suffer from problems like leaks, blockages, moisture buildup, and poor air quality. These issues can reduce energy efficiency, increase costs, and even pose health risks. Our robot can help identify these problems early by detecting air leaks, structural damage, moisture, mould, and contamination inside the ducts. By making inspections faster, safer, and more affordable, our spherical robot can help the HVAC industry improve system performance, reduce operational costs, and maintain a healthier indoor environment.

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The innovation of this project is SphereGuard, a smart, rolling robot designed to inspect HVAC systems safely and efficiently. Unlike traditional inspections that require people to enter small, dangerous spaces or use expensive wired robots, SphereGuard can move through ducts wirelessly and with ease. It uses high-definition video and multispectral cameras (infrared, visible, and UV) to spot problems like leaks, blockages, temperature changes, and damage. It can also carry extra sensors to check air quality, humidity, and other important factors. SphereGuard makes inspections faster, safer, and cheaper, while helping HVAC systems run better and avoid breakdowns. It’s a smart, flexible solution that meets the growing need for modern, reliable inspection tools in the HVAC industry.

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