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Custom Robotic Crawler WHRU (Waste Heat Recovery Unit)

Custom WHRU

The key design requirements are for a system to travel up to 20m through a 24’’ header pipe and deploy a camera inspection system into the 12 adjacent 6’’ exchanger tubes.

Key design requirements:

• Primary robotic platform required to fit within a 24’’ OD straight pipe and travel up to 20m
• Each header row will consist of 12 adjacent exchanger tubes
• The secondary robotic system required to be deployed from the header pipe into the adjacent heat exchanger pipes
• The secondary robotic system is required to fit within a 6’’ OD straight pipe and travel up to 10m
• The secondary robotic system is required to visually inspect the 6’’ exchanger pipes

Key Considerations:

• Primary robotic platform required to provide a stable platform for the secondary robotic system to be deployed from and recovered to.
• The design needed to provide protection to the secondary system’s tether from the 90° transitions
• The solution needs to provide a safe and functional method for recovery in the event of power loss or drive system failure
• The primary system is required to be able to adjust the height of the platform


Contact us to find out more about the Custom Robotic Crawler WHRU (Waste Heat Recovery Unit) or any of our custom robotic solutions.

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The Process

To solve complex assignments, a strategy that considers both purpose and potential is required. Our hybrid approach maximises the opportunity to solve virtually any design challenge, no matter the industry.  A cross-section of our development process reveals an agile method, which blends science, technology and business. The physical output of our process results in products that meet end-user goals, business objectives and utilise next-generation manufacturing.

Discovery & Opportunity Identification

We actively seek to uncover the most potent opportunity for your immediate position, while considering the most optimal finance, acquisition and support model to complement asset life-span.


With all planning and specifications defined, a complete electrical, mechanical and software prototype is produced and rigorously tested by our dedicated engineering team.

Recommendation & Validation

We collect high-level data from testing, to provide you with the best solution for your inspection, independent of hidden agendas. This ensures that the right technology is applied to the relevant project.

Deliver, Deploy & Support

Your system is delivered ready for deployment, complete with structured training and documentation to assist with immediate usage, backed by our 24/7 support team.

Need a custom solution?

Nexxis focuses on future outcomes, to try and achieve the best possible outcome for clients.