Inner Side of Metal Tube Inspection Using AI and Boroscopic Imaging

Published on: Jul 21, 2025

Introduction

Inspecting the inner surface of metal tubes is one of the most critical quality assurance tasks in industries such as oil & gas, aerospace, medical devices, chemical processing, and power generation. Traditional manual inspection methods using boroscopic cameras are time-consuming, error-prone, and often inconsistent due to human limitations in detecting subtle or hidden defects. Intelgic addresses these challenges through an advanced, AI-driven boroscopic inspection system designed for automation, accuracy, and scalability.

Intelgic’s Complete Inspection Solution for Metal Tube Interiors

Intelgic offers a comprehensive and modular solution for inspecting the inner walls of metal tubes, regardless of their length or diameter. The system combines:

• Boroscopic Camera Systems
• Automated Mechanical Insertion Units
• AI-Powered Defect Detection Software
• Data Processing & Reporting Module

High-Resolution Boroscopic Imaging

 

The solution begins with a high-resolution boroscopic camera equipped with advanced lighting to illuminate the tube’s interior. This type of camera is capable of navigating through narrow and deep cavities, capturing clear and distortion-free images of the internal surface.

Intelgic’s cameras are tailored for various tube dimensions and materials. They are capable of detecting:

• Micro cracks
• Corrosion spots
• Pitting
• Welding defects
• Scratches and deposits
• Irregular internal surfaces
• Other anomalies

Mechanical System for Camera Insertion

To support a wide range of tube diameters and lengths, Intelgic custom-builds mechanical systems that precisely guide and insert the boroscopic camera into the tube. These mechanisms can range from:

• Robotic rails
• Motorized push-pull actuators
• Flexible guiding systems for curved or coiled tubes

This automation ensures a systematic and repeatable scanning motion, allowing full coverage of the internal surface from entry to exit without missing any sections.

Real-Time AI Image Processing & Defect Detection

Captured images are continuously streamed to a CPU-based industrial controller, where Intelgic’s proprietary Live Vision AI software processes the data. This robust software:

• Analyzes each frame individually
• Stitches frames together to create a complete visual map
• Identifies, highlights, and categorizes defects
• Generates precise coordinates for defect locations
• Counts the number of defective pixels per issue

Intelgic’s AI is trained to differentiate between acceptable material inconsistencies and actual defects—dramatically reducing false positives and ensuring reliable results.

Detailed Inspection Reporting

Upon completion of the inspection cycle, the system automatically generates a comprehensive inspection report, which includes:

• Images of detected defects
• Location and severity of each defect
• Tube identification and metadata
• Pixel count of defect-affected areas
• Pass/Fail status based on configured thresholds

Reports can be exported in PDF, CSV, or integrated into MES/ERP systems via API.

Key Benefits of Intelgic’s Tube Interior Inspection System

• Non-Destructive Testing (NDT) – No structural compromise during inspection
• Coverage Guarantee – Ensures complete 360° scanning of tube walls
• Defect detection Consistency - No defects will be ignored or missed.
• Detect all kinds of defect: The automated system detects every possible defects.
• Scalable Architecture – Works for small pipes and large industrial tubes
• Consistent Quality Control – Minimizes human errors and subjectivity
• Fast Turnaround – Reduces inspection time with automation and AI

Customizable Thresholds – Flexible settings for various defect tolerance levels

Applications

• Heat exchanger tube inspection
• Gas and hydraulic pipe quality checks
• Boiler tube and steam pipe analysis
• Aircraft and automotive fuel line QA
• Stainless steel tubing for food and pharma

 

With Intelgic’s inner metal tube inspection solution, industries can now automate a complex and traditionally manual process. Whether you are inspecting kilometers-long pipelines or high-precision stainless tubes for medical use, Intelgic ensures your internal surface QA is accurate, fast, and intelligent. The combination of boroscopic cameras, mechanical automation, and AI-driven software sets a new standard in internal defect detection and digital inspection reporting.