Inspections in critical industrial environments like silos, tunnels, chimneys, crushers, and pipelines have always posed logistical, technical, and above all human challenges. Gaining access to confined or elevated spaces required rappelling, scaffolding, or extended production shutdowns, making the process slow, dangerous, and costly.
With the introduction of Flyability’s Elios 3, a new era of smart inspections has arrived in Brazilian industries. This drone is designed specifically for indoor environments, capable of capturing high-resolution visual and structural data with full safety, speed, and no need for direct human contact with the assets.
Elios 3: Designed for Extreme Environments
Developed by Swiss company Flyability, the Elios 3 is the world’s most advanced drone for internal visual inspections and 3D modeling of confined spaces. It can access areas that were once only reachable with high human risk.
Key technical specifications:
- LiDAR Sensor: Captures 600,000 points per second for generating point clouds and highly accurate 3D models.
- 4K Camera with Digital Zoom: Enables the detection of cracks, corrosion, and wear with millimetric clarity.
- Thermal Camera: Detects thermal variations indicating insulation failures, overheating, or infiltration.
- Spherical Cage: Anti-collision protection, ideal for tight or obstacle-filled environments.
- 3-Axis Image Stabilization: Smooth footage even in turbulent air conditions.
- Integrated Lighting: Powerful LEDs to fully illuminate internal spaces.
Real-World Cases: The Impact of Elios 3 in the Field
1. Refractory Silo Inspection – Pulp & Paper Industry
Refractory silos over 70 meters tall are usually only inspected during plant shutdowns. Traditionally, this involved a rope-access team using flashlights and handheld cameras a slow, expensive, and dangerous process.
With the Elios 3, everything changed:
- The drone navigated the entire interior of the silo, identifying cracks, deformations, and wear points.
- Simultaneous capture of 4K images and thermal video.
- 3D model generation via point cloud.
- No need for scaffolding, rope access, or human risk.
Video Demonstration – Internal Silo Inspection
The video captured during the silo inspection demonstrates the Elios 3’s capabilities in narrow vertical spaces. It flies from top to bottom, capturing ultra-high-quality imagery for detailed analysis by engineers and maintenance teams.
Key findings:
- Cracks in the internal lining.
- Refractory wear near the base.
- Residue accumulation in critical areas.
- Possibility of future comparison with other flights (predictive maintenance).
2. Crusher Inspection – Mining
In mining, the crusher is a vital part of the production chain, but inspecting it involves considerable risk. In a real case, the Elios 3 was used to inspect a crusher’s interior without human entry.
- The drone navigated easily through metallic structures.
- Captured internal 4K and thermal images, even in dark environments.
- Generated a complete point cloud and 3D model of the crusher, allowing detailed wear mapping.
- The inspection was performed while the equipment was in semi-operational state no disassembly required.
3D Model Visualization
The vídeo shows a frame from the 3D model of the crusher captured by the Elios 3. Photogrammetry software enabled detailed asset reconstruction, structural segmentation, and evidence-based maintenance planning.
Benefits of Using Elios 3 for Industrial Inspections
Safety
- Zero exposure of workers to hazardous environments.
- Fewer accidents in confined or high places.
Agility
- Inspections completed in minutes, with no major production downtime.
- Simultaneous capture of visual, thermal, and spatial data.
Cost Reduction
- Savings on access structures (scaffolding, rope access, PPE).
- Fewer shutdowns and unexpected failures.
Rich and Comparable Data
- High-precision 3D modeling for future comparisons.
- Technical reports with videos, thermal images, and structural maps.
Industry 4.0 Inspections: Intelligence, Automation, and Digitalization
The Elios 3 is a key enabler of industrial digital transformation. It supports predictive inspection models based on concrete data, capable of reducing corrective maintenance costs and increasing the operational reliability of assets.
With its LiDAR and 3D reconstruction software, companies can create digital twins of their inspected assets, monitor degradation over time, and make data-driven decisions with precision.
Elios 3 as a Strategic Ally in Modern Maintenance
Industries investing in technologies like the Elios 3 are not only improving inspection processes—they’re shaping the future of maintenance, safety, and asset analysis. The drone offers more than just visibility; it provides operational intelligence, turning hostile environments into accessible, actionable data.
