Kopterflug deploys the ELIOS 3 as its primary system for interior inspections – in tanks, boilers, silos, chimneys and confined spaces. No scaffolding, no rope access, no human entry: the drone flies in, your team stays outside.
The ELIOS 3 with its collision-safe carbon cage – designed for confined industrial environments.
GPS-independent, collision-safe, LiDAR-supported. The ELIOS 3 inspects confined interior spaces where no human can work safely – delivering 4K video, thermography and 3D point clouds in one flight.
The ELIOS 3 is Kopterflug's primary system for all interior and confined space inspections. The advantages are clear: safety through zero human entry, data quality through 4K + thermography + LiDAR, and efficiency through eliminating scaffolding and access equipment.
Practical check – will it fit? The ELIOS 3 measures approx. 50 × 45 cm and fits through a standard DN 600 manhole in many installations – depending on entry angle and clearance.
What matters for data: 4K video for visual findings, thermography for thermal indications, and LiDAR for 3D positional reference – so findings are locatable and repeatable.
Before every deployment, we coordinate three areas with you:
We check opening dimensions and entry feasibility (DN 600 as guideline), potential bottlenecks, airflow, dust and moisture conditions. We also clarify start/landing zones and communication between pilot and plant operator.
You decide what data you need: 4K video and photos for visual findings, thermography for thermal anomalies, LiDAR/3D for surveying and volume calculation. The result is a structured findings list with positional reference – not raw, uncontextualized video.
Zero human entry is our target – whether this is fully achievable depends on the scope. We work according to your operator standards for gas-free measurements and work permits, and clarify roles and responsibilities (pilot, spotter, plant supervisors) in advance.
Storage and process tanks in chemical, petrochemical and water supply industries. Wall corrosion, deposits, coating damage – inspectable without human entry.
Steam boilers, water-tube boilers, pressure vessels per BetrSichV (German Industrial Safety Regulation). Findings list for certified inspectors – without confined space entry per DGUV (German statutory accident insurance regulations).
Cement, chemical and agricultural silos. LiDAR volume measurement, buildup detection, outlet inspection – without entry.
Tall vertical interior structures such as industrial chimneys, flue gas ducts and liner pipes. Interior inspection without climbing teams.
Sewers, large-diameter pipes, galleries – anywhere humans cannot safely access.
Refractory linings, furnace interiors, combustion chambers in cooled-down state. Thermography for residual hotspots and early damage detection.
| Aspect | Conventional (scaffolding / climbers / entry) | Flyability ELIOS 3 |
|---|---|---|
| Human entry | Required – respiratory protection, rescue chain, DGUV confined space entry | No entry – drone flies in, team stays outside |
| Navigation | Technician navigates manually – limited by body size and safety overhead | GPS-free SLAM navigation – stable in tanks, boilers, shafts |
| Collision protection | None – damage from tools or falls possible | Collision-safe carbon cage – wall contact without crash |
| Sensors | Handheld camera, flashlight – spot checks only | 4K + thermography + LiDAR 3D in one flight |
| Preparation | Scaffolding, safety posts, permits – days | Gas-free measurement, access point – deployment in hours |
| Result | Subjective technician report, not reproducible | Structured findings report, position-referenced, repeatable |
LiDAR 3D point cloud generated by the ELIOS 3 – centimeter-accurate geometry data for documentation and digital twins.
The ELIOS 3 is not an all-purpose system. It is specialized for confined, dark, GPS-denied interior spaces. For exterior inspections of facades, bridges or chimney outer walls, other platforms are more suitable.
Own vs. service: With fewer than 10 deployments per year, owning the drone rarely pays off. We advise honestly – even if the recommendation is: commission rather than purchase.
Which assets, what frequency, what data? We help you assess whether owning or commissioning the service makes more sense for your situation.
DN dimensions, access routes, sensor requirements (4K / thermal / LiDAR), safety concept – we create a practical technology profile for your installations.
On request, we fly a reference installation as proof of concept. This way you see data quality and workflows before any procurement decision.
Depending on the outcome: referral to supply sources, or direct commissioning as inspection service – straightforward, no detours.
Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for ELIOS 3 projects.
Christian Engelke and Dipl.-Ing. Karsten Lehrke are your direct contacts for technical questions about the ELIOS 3 – deployment, configuration, safety concepts. Since 2017, we have been operating the drone in industrial installations: blast furnaces, tanks, silos, chimneys.
We advise without sales pressure – even if the recommendation is: commission the service rather than purchasing.
Kopterflug is primarily an inspection service provider. For procurement, we advise on the right configuration and can refer you to suitable supply sources and partners.
As a rough guide: the ELIOS 3 typically ranges between €80,000 and €120,000 depending on configuration, payloads and software packages. Add training costs, maintenance and ongoing operating costs (replacement batteries, service contracts, software licenses). We don't quote fixed prices – we're happy to clarify your scope and connect you with suitable suppliers.
Practical check: The ELIOS 3 measures approx. 50 × 45 cm and fits through a DN 600 manhole in many installations – the key factors are entry angle, edges, internals and the specific clearances on site.
For most integrity and maintenance processes, three sensors are the standard: 4K video (see the findings), thermography (hotspots and moisture), LiDAR/3D (volumetry and positional reference) – individually or combined depending on the asset.
The ELIOS 3 is not an all-purpose drone. Exterior inspections (facades, bridges, chimney outer walls) require different platforms. It is not ATEX-certified and may only be deployed in potentially explosive areas after gas-free measurement. Maximum ambient temperature is 50°C – installations must be fully cooled before inspection.
With fewer than 10 deployments per year, varying assets or high internal training effort, commissioning the service is often more economical than owning. At higher deployment frequency with standardized assets, ownership can make sense. We advise openly on both options.
The ELIOS 3 is one of the few drones purpose-built for confined spaces – not retrofitted. Key differentiators: collision-robust carbon cage, GPS-free SLAM+LiDAR navigation, and the combination of 4K, thermography and 3D data in a single deployment. Standard FPV or industrial drones cannot reliably operate in tight interior spaces and have no collision tolerance.
In many cases: yes. Concretely: no respiratory protection, no rescue chain, no work in hazardous spaces. The drone flies in – your team stays outside. Whether zero entry is fully achievable depends on the installation type, clearance situation and specific findings requirements. We clarify this with you in advance.
Accuracy is in the centimeter range – typically ±2–5 cm depending on distance, flight speed and surface properties. Sufficient for geometry capture, deformation analysis and digital twins – not sufficient for precision surveying under 1 cm. For higher requirements, we recommend terrestrial reference points as supplements.
The ELIOS 3 can automatically overlay point clouds with 4K color information – you see not just geometry but also surfaces, corrosion spots, coating damage and deposits directly in the 3D view. This makes findings significantly easier to interpret – especially for engineers and assessors who weren't present during the flight.
Typically 10–12 minutes per battery depending on payload, flight style and ambient temperature. Multiple flights with battery changes are planned for a complete installation. We work with a battery pool to minimize downtime. Large tanks or chimneys are fully documented in 2–4 flights. Total time on site: usually 1–4 hours.
Three things are relevant for professional operation: a suitable drone qualification (the exact category depends on deployment location and context), Flyability-specific training for ELIOS control and firmware, and – often underestimated – practical confined space experience: safety concepts, gas-free measurement, communication with plant operators.
The carbon protective cage is engineered to tolerate light collisions – the drone bounces off and remains stable. With light contacts, relevant damage to typical industrial surfaces is not expected – the drone's mass and energy are too low for significant impact on steel walls or concrete surfaces.
With restrictions: The ELIOS 3 is not ATEX-certified. Deployment in Ex zones is only possible when the area has been gas-free measured and a corresponding operating permit (hot work permit or similar) is in place. With the optional gas sensor, the ELIOS 3 can monitor gas levels during flight and withdraw if thresholds are exceeded.
Typically 1–4 hours on site depending on installation size, complexity and sensor setup. Multiple assets per day are possible for compact installations. Post-processing (data processing, findings list and report) is typically delivered within a few working days.
A structured findings report typically contains: 4K images and video excerpts with localized findings, thermography evaluation with anomalies, 3D LiDAR data with positional reference, and a commented findings list (severity, action recommendation, comparison to previous inspection). No uncontextualized video – every finding is traceably located.
Yes – with the optional UT payload (ultrasonic wall thickness measurement). This is additional sensor equipment mounted on the drone that makes contact with the inner wall to measure wall thickness. LiDAR only measures geometry – wall thickness is a separate measurement process. Combining LiDAR scan and UT measurement in one deployment is possible.
Yes – this is one of the most practically valuable aspects. Flight paths and finding positions are documented so that follow-up inspections can take place at exactly the same locations. Corrosion progress, material fatigue and damage development become traceable over months and years – as a basis for maintenance planning and RBI decisions.
Significantly faster than conventional access equipment. No scaffolding, no long lead times for safety measures. If your installation is accessible and gas-free measured, we are typically on site within a few working days. For planned revisions, we recommend early scheduling to optimally use the revision window.
Key improvements: LiDAR payload for 3D point clouds and precise positional reference (ELIOS 2 had no true LiDAR), significantly better 4K camera quality and lighting (16,000 vs. ~10,000 lumens), improved SLAM navigation for more stable flights in tight and feature-poor spaces, and a new cockpit interface with real-time 3D live map. The protective cage is lighter and more robust.
The effort on your side is typically minimal: access to the installation (manhole, inspection opening – at least DN 600 as guideline), information about atmospheric conditions (we perform gas-free measurement ourselves), brief safety briefing by your on-site safety officer, and – for vessel inspections – a depressurized, cooled-down installation. No scaffolding, no separate confined space entry preparation.
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