HVAC Duct Cleaning & Inspection Robotic System

A full-stack mechatronic system for automated cleaning and inspection of HVAC duct networks, integrating active brush mechanisms, embedded sensing, tethered power delivery, and real-time vision.

Overview

This project develops a deployable robotic system for automated cleaning and inspection of HVAC duct networks, targeting real-world industrial adoption. The system integrates confined-space navigation, active cleaning, environmental sensing, and real-time vision into a single field-deployable platform.

The project comprises four interconnected subsystems developed and validated as an integrated whole:

Subsystem 1: Autonomous HVAC Duct Navigation Robot

The core mobile platform is designed to navigate confined duct geometries and carry the cleaning and sensing payload.

Core Capabilities

  • Confined-space mobile navigation inside duct systems
  • Onboard air quality sensing (particulate and contamination monitoring)
  • Real-time inspection via embedded vision system
  • Full-stack mechatronic system integration
  • Sensor fusion and environmental data acquisition

The platform is designed from the outset for harsh, constrained environments, with a clear engineering trajectory from prototype to field-deployable system.

Subsystem 2: Active Brush Mechanism with Dynamic Stability Optimization

A dedicated cleaning subsystem focused on maximising cleaning efficiency while maintaining mechanical stability under load.

System Features

  • Linear actuator-driven, height-adjustable brush assembly
  • Crane-like linkage for controlled brush positioning
  • Tunable contact force with duct surfaces

Key Engineering Insights

Early prototyping identified instability arising from a single-hinge architecture. Design iteration involved a structured trade-off analysis between compliance and structural rigidity, leading to a migration toward multi-point constraint mechanisms with reduced oscillation under operational load.

Subsystem 3: Tethered Monitoring & Power Delivery Robot

A robust robotic system designed for high-reliability operation in constrained or hazardous environments, providing stable power and communication over extended cable runs.

System Architecture

  • 24V tethered power delivery over cables up to 15 m in length
  • Custom-built controller interface
  • Embedded camera system with real-time video streaming and recording capability
  • Noise-resistant signal handling for reliable communication

Key Design Challenges

  • Voltage drop and power stability management across cable length
  • EMI and noise mitigation to preserve signal integrity
  • Compact integration of the vision system within the robot chassis

Subsystem 4: Wired Control & Power Distribution System

A supporting power and control infrastructure subsystem bridging laboratory prototypes to field-deployable robotic systems.

Key Features

  • Mains-powered input with regulated 24V output
  • Aluminium enclosure for heat dissipation and mechanical durability
  • Integrated safety considerations including isolation and protection circuitry

This subsystem standardises the power and control interface across the robotic ecosystem, enabling reliable and repeatable tethered deployment.

Engineering Significance

The HVAC robotic system represents a full-stack mechatronic integration challenge — combining mechanism design, embedded sensing, power electronics, and field robotics into a single coherent system. The project emphasises engineering rigour across the full development lifecycle, from concept and prototyping through to validation and deployment readiness.