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After 2 years of R&D,  (Troy, Mich., U.S.) a global player in engineering and innovation, has announced the completion of its Topone prototype, an autonomous composite drone designed to inspect power lines in underground tunnels and other confined spaces. This high-level project, led by the group’s Research and Innovation department, aims at protecting technicians exposed to high-risk environments

Topone specializes in the visual inspection of power lines in tunnels and underground galleries. This project stems from the need to reduce the number of work-related accidents among technical staff, one of the jobs where the risk is highest.

The drone’s main structure rests on four tubes of carbon fiber-reinforced polymer (CFRP), surrounded by a sheet of CFRP to protect it from impact. Its six circular propeller protection frames are also made entirely of a CFRP sandwich. The joints between the tubes and the top covers are made of 3D printed plastic.

The system is distinguished by several technical capabilities, which Segula says guarantee smooth navigation and accurate diagnostics, improving the efficiency of inspections in hard-to-reach areas.

High-precision sensors and cameras. The drone is equipped with a camera that provides RGB and thermographic images of the cables, mounted on a gimbal for stability and mobility. Its sensors measure temperature, oxygen percentage and harmful gas levels to identify anomalies, often due to cable breaks or cracks caused by overheating. At the same time, it has a control station (Ground Control Station) that displays all the information needed to inspect the power lines and visualize the route taken by the drone.

Autonomous navigation. The prototype is equipped with two high-precision cameras and altimeters. The data collected is processed by an on-board computer, enabling the drone to create a 3D model of the environment from a cloud of points and to move around the underground gallery without a constant connection to a control station.

Software architecture. Topone required the development of a complex and innovative software architecture that integrates several modules for localization and perception, a control and guidance system and a data collection system specific to each mission.

The drone prototype has already been tested in real-life conditions in the Málaga Convention Centre (FYCMA) galleries in Spain. Segular says these conclusive tests pave the way for commercial use in various sectors include:

• Inspection of rail and industrial infrastructure: tunnels, power cables and caisson bridges
• Applications in caving and rescue: exploration and intervention in difficult-to-access areas.
• Mining and construction: supervision of installations in complex environments.

Following the success of the initial test phases, Topone is now entering its second prototyping phase prior to future commercialization. For Segula Technologies, this innovation is part of a wider strategy to offer global solutions for key industrial sectors. 

The prototype drone was developed with the Topone project framework, funded by the Spanish Centre for Technological Development and Innovation (CDTI).