Robot Dogs for Industrial Inspections: How Maintenance in Factories Is Changing

Industrial automation continues to advance rapidly, and one of the technologies garnering significant attention is the use of robot dogs for inspections in complex and potentially hazardous environments.

More and more companies are incorporating quadruped robots capable of autonomously navigating facilities, gathering real-time information, and detecting anomalies before they escalate into serious breakdowns. This evolution not only improves the efficiency of industrial processes but also reduces workers' exposure to risky situations.

The recent case of a European cement company that has incorporated a robot dog to replace manual inspections in certain areas of the plant reflects a trend already spreading across sectors such as energy, mining, construction, and the chemical industry.

What happened?

A cement plant has decided to automate part of its periodic inspections using an autonomous quadruped robot capable of traversing the facilities overnight without constant supervision.

Until now, operators had to access different areas daily to check the condition of motors, pumps, pipes, electrical panels, and other critical equipment. Many of these inspections involved navigating spaces with dust, high temperatures, continuous noise, or heavy machinery in operation.

The incorporation of the robot allows these tasks to be performed automatically, collecting precise information through various sensors and sending all data to the maintenance team for subsequent analysis.

The goal is not to replace workers but to free them from repetitive and potentially dangerous tasks so they can focus on higher value-added work.

How an industrial inspection robot dog works

Although they externally resemble a dog, these robots are highly advanced mobility platforms designed to move across terrains where a wheeled robot would face many difficulties.

Thanks to their four legs, they can:

• Climb stairs.

• Overcome uneven terrain.

• Walk on gravel or uneven surfaces.

• Avoid obstacles.

• Maintain balance even in complex spaces.

Their true potential lies in the combination of mobility and artificial intelligence.

State-of-the-art sensors

Depending on the manufacturer and configuration, these robots can incorporate different data capture systems:

• High-resolution RGB cameras.

• Thermal cameras.

• LiDAR sensors for creating 3D maps.

• Gas detectors.

• Industrial microphones.

• Acoustic cameras.

• Environmental sensors.

• Autonomous navigation systems.

All this information allows incidents to be detected even before they are visible to an operator.

Artificial intelligence applied to predictive maintenance

One of the greatest advancements is not just the robot, but the software that interprets all the collected information.

Artificial intelligence algorithms can automatically compare thousands of data points obtained in each inspection to identify small variations that could indicate a future problem.

For example:

• A motor that starts to heat up more than usual.

• A valve with a small leak.

• Anomalous vibrations.

• Temperature increases.

• Appearance of corrosion.

• Changes in pressure.

Instead of reacting when a breakdown has already occurred, companies can act before the failure causes a production stoppage.

This approach is called predictive maintenance and is becoming one of the pillars of Industry 4.0.

Why is this a game changer for the industry?

For decades, industrial inspections have relied almost exclusively on manual rounds carried out by specialized technicians.

While still essential, they present several limitations:

• They are time-consuming.

• They expose workers to risks.

• Results can vary between different individuals.

• Some incidents go unnoticed.

Autonomous robots can always follow the same route, adhering to the exact same procedure.

This offers significant advantages:

Increased safety

They reduce the need for workers to access dangerous areas.

More frequent inspections

They can operate 24 hours a day, even overnight or on weekends.

Greater precision

Sensors detect variations impossible to see with the naked eye.

Historical record

Each inspection is stored to compare equipment evolution.

Cost reduction

Detecting a breakdown before it causes a stoppage can save thousands of euros.

Sectors where robot dogs are already in use

Although these solutions were initially reserved for large technology companies, today they are being implemented in numerous sectors.

Manufacturing industry

• Production lines.

• Logistics centers.

• Automated warehouses.

Energy

• Solar plants.

• Power plants.

• Substations.

Oil and gas

• Refineries.

• Pipelines.

• Offshore facilities.

Mining

Robots can move through tunnels where human presence poses a high risk.

Construction

They allow monitoring of construction sites, generation of 3D models, and periodic inspections of project progress.

Chemical industry

They help control facilities where dangerous gases or extreme temperatures may exist.

Unitree Robots: An alternative for industrial inspection and automation

Within the XRShop catalog are the Unitree quadruped robots, designed for research, education, development, and inspection.

Thanks to their mobility and ability to integrate different sensors, these devices can adapt to multiple industrial scenarios and serve as a basis for customized automation projects.

Furthermore, they can be combined with industrial augmented reality solutions, remote maintenance, and process digitalization to create safer and more efficient work environments.

What we can expect in the coming years

All indications are that quadruped robots will cease to be an exclusive technology for large companies and will become common tools in industrial maintenance.

Key trends include:

• Increased autonomy through artificial intelligence.

• Integration with digital twins.

• Collaboration between robots and operators.

• Completely automated inspections.

• Combined use with drones and autonomous vehicles.

• Continuous monitoring using IoT sensors.

Automation no longer seeks to replace people but to provide higher quality information so that technical teams can make better decisions.