Completed Prototype of Autonomous Drone for Underground Tunnel Inspections

A prototype of an autonomous drone designed to inspect power lines in tunnels and confined spaces, has been completed, called the TOPONE.

TOPONE from SEGULA Technologies is an autonomous drone specialising in the visual inspection of power lines in tunnels and underground galleries that can be visited. 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.

Every year, almost 200 people lose their lives in confined spaces due to extreme conditions such as lack of oxygen, high concentrations of noxious gases, extreme temperatures and the risk of collapse. The TOPONE drone offers a safe and effective alternative for technical inspections, eliminating the need for human intervention in these high-risk areas.

The TOPONE drone is distinguished by its advanced technical capabilities, which guarantee smooth navigation and accurate diagnostics, improving the efficiency of inspections in hard-to-reach areas, including:

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 (GCS – Ground Control Station) that displays all the information needed to inspect the power lines and visualise 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.

Innovative Software Architecture

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

A Multi-Sector Tool in the Making

The TOPONE prototype has been tested in real-life conditions in the galleries of the Málaga Convention Centre (FYCMA) in Spain. These conclusive tests pave the way for commercial use in various sectors:

• 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.

This prototype drone was developed in the framework of the TOPONE project, funded by the Spanish Centre for Technological Development and Innovation (CDTI).

Following the success of the initial test phases, TOPONE is now entering its second prototyping phase prior to future commercialisation.

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