Control system and method of steel wire traction type overhead rail inspection robot with sliding contact line

Abstract

The invention discloses a control system and method for a steel wire traction type overhead rail inspection robot with a sliding contact line, and relates to the technical field of modern industry and infrastructure construction.The system comprises a steel wire traction control module and traction devices connected with the two ends of a rail through steel wires, the traction devices are provided with servo motors, and the servo motors are used for driving traction wheels to rotate; the movement control of the inspection robot along the track is realized; the sliding contact line power supply control module comprises a sliding contact line laid along the track and a power taking device carried by the inspection robot, and the sliding contact line is matched with the power taking device and used for providing continuous and stable power supply control for the inspection robot; the steel wire traction control module is further integrated with a steel wire tension real-time monitoring control unit, and the steel wire tension real-time monitoring control unit is electrically connected with the servo motor and used for dynamically adjusting the output power of the servo motor according to the tension data of the steel wire, so that the tension of the steel wire is kept within the preset optimal range. According to the invention, intelligent control of the inspection robot can be realized.

Description

Technical Field

[0001] This application relates to the field of modern industrial and infrastructure construction technology, and in particular to a control system and method for a wire-traction suspended rail contact line inspection robot. Background Technology

[0002] With the continuous expansion of industrial production scale and the continuous improvement of automation, the stable operation of various industrial equipment is becoming increasingly crucial for production efficiency, product quality, and safe production. Against this backdrop, the importance of industrial equipment inspection is becoming increasingly prominent. Traditional manual inspection methods have many drawbacks. They are not only inefficient and unable to meet the high-frequency inspection needs of large-scale equipment, but also highly susceptible to human factors, resulting in missed inspections and false inspections. For example, in large substations, a single manual inspection of equipment often takes several hours or even days. Moreover, due to the large number and wide distribution of equipment, it is difficult for humans to ensure accurate inspection of every detail. At the same time, in some harsh or dangerous environments such as high temperature, high pressure, and high radiation, manual inspection also faces great safety risks. In areas such as around chemical reactors and inside nuclear power plants, personnel may suffer serious physical harm if they stay for a long time.

[0003] To overcome the shortcomings of manual inspection, track-based inspection robots have emerged and been widely used. In the field of suspended track robots, early products mostly relied on motors to drive rollers to move on tracks to monitor equipment. However, this driving method has revealed many problems in practical applications. When running on long tracks, the rollers are prone to slippage due to insufficient friction. Especially in humid or dusty environments, the moisture or dust adhering to the track surface will further reduce the friction between the rollers and the track, resulting in a significant reduction in the robot's operational stability, making it unable to accurately reach the designated inspection position, and seriously affecting the inspection effect.

[0004] Some inspection robots use cable traction to move, which solves the power problem for long-distance operation to some extent. However, existing cable traction systems generally lack effective real-time tension monitoring methods. When the cable tension becomes uneven due to changes in the robot's motion state or track undulations during traction, it can easily cause the robot to stall. In some cases, excessive tension may even cause the cable to break, resulting in the robot losing power and hanging on the track. This not only interrupts the inspection task but may also pose safety hazards to the equipment and the surrounding environment.

[0005] In terms of power supply, sliding contact line power supply technology is widely used in inspection robots. This technology frees robots from the limitation of battery life and theoretically enables them to work continuously for a long time. However, in actual industrial environments, when the robot is running at high speed, the power receiving device and the sliding contact line may not be able to maintain stable contact due to the excessive relative speed, which can easily lead to brief power outages. In environments with strong vibration sources, such as the vibration generated by the operation of large mechanical equipment in factory workshops, the power receiving device and the sliding contact line may collide and separate frequently, resulting in frequent interruptions in power transmission. This seriously affects the normal operation of the robot and prevents it from continuously and stably obtaining power to perform inspection tasks.

[0006] In summary, existing inspection robot technologies have significant shortcomings in terms of drive and power supply, failing to meet the requirements of modern industry for efficient, accurate, intelligent, and reliable equipment inspection. There is an urgent need for a new technological solution to address these issues. Summary of the Invention

[0007] In view of this, this application provides a control system and method for a wire-traction type suspended rail with sliding contact line inspection robot, which can realize intelligent control of the inspection robot and meet the requirements of modern industry for efficient, accurate, intelligent and reliable equipment inspection.

[0008] According to a first aspect of this application, a control system for a wire-driven suspended rail with a sliding contact line inspection robot is provided, comprising: a collaborative drive control module, wherein the collaborative drive control module is composed of a wire-driven control module and a sliding contact line power supply control module;

[0009] The steel wire traction control module connects the traction devices at both ends of the track via steel wire. The traction device is equipped with a servo motor, which drives the traction wheel to rotate, thereby realizing the movement control of the inspection robot along the track.

[0010] The sliding contact line power supply control module includes a sliding contact line laid along the track and a power-collecting device mounted on the inspection robot. The sliding contact line and the power-collecting device work together to provide continuous and stable power supply control for the inspection robot.

[0011] The wire traction control module also integrates a real-time wire tension monitoring and control unit. The real-time wire tension monitoring and control unit is electrically connected to the servo motor and is used to collect wire tension data in real time and dynamically adjust the output power of the servo motor according to the tension data so that the wire tension is maintained within a preset optimal range.

[0012] According to a second aspect of this application, a control method for a wire-traction suspended rail with sliding contact line inspection robot is provided, comprising:

[0013] The inspection robot is controlled to move along the track via a collaborative drive control module;

[0014] During the robot's movement, the data transmission and processing control module receives the equipment operation data collected by the inspection robot's detection equipment for the tested equipment, and based on the equipment operation data, uses a pre-trained fault prediction model to determine the remaining service life prediction value, fault probability distribution, and health status score of the tested equipment.

[0015] The environmental monitoring module collects real-time data on temperature, humidity, dust concentration, and air pressure in the working environment, generates an environmental status data package, and dynamically adjusts the operating parameters of the detection equipment and the operating parameters of the wire traction control module based on the environmental status data package.

[0016] By utilizing the above technical solution, this application provides a control system and method for a wire-traction suspended rail inspection robot with a sliding contact line. By constructing a collaborative drive control module containing a wire traction control module and a sliding contact line power supply control module, wire traction replaces the earlier motor-driven roller movement method. Through the wire connecting the traction devices at both ends of the track and the traction wheels being driven by servo motors, the dependence of roller movement on track surface friction can be eliminated. Even in conditions that easily reduce friction, such as dampness or dust, slippage can be avoided, ensuring stable operation of the inspection robot and accurate arrival at the designated inspection position, thus solving the problem of long-distance operation. The problem of poor stability of the roller drive and the impact on inspection results can be addressed by integrating a real-time monitoring and control unit for wire tension into the wire traction control module. This unit collects wire tension data in real time and dynamically adjusts the output power of the servo motor, ensuring that the wire tension is always maintained within the preset optimal range. This effectively avoids the problem of uneven tension caused by the lack of real-time tension monitoring in cable traction systems, prevents robot jamming and wire breakage, avoids inspection task interruption and safety hazards in the surrounding environment, and ultimately comprehensively solves the core technical pain points of existing track-type inspection robots in terms of drive stability and traction safety.

[0017] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0018] Figure 1 This illustration shows a schematic diagram of the system structure of a wire-traction suspended rail with sliding contact line inspection robot according to an embodiment of this application;

[0019] Figure 2 A flowchart illustrating a control method for a wire-traction suspended rail with sliding contact line inspection robot provided in an embodiment of this application is shown.

[0020] In the picture:

[0021] 10-Cooperative drive control module, 101-Wire traction control module, 1011-Wire tension real-time monitoring and control unit, 102-Sliding contact line power supply control module, 1021-Sliding contact line, 1022-Power supply device;

[0022] 20-Data transmission and processing control module; 201-Intelligent analysis and control unit;

[0023] 30-Environmental Adaptive Control Module, 301-Environmental Monitoring Submodule, 302-Parameter Adjustment Submodule, 303-Motion Attitude Optimization Submodule;

[0024] 40 - Multi-robot collaborative control module; 401 - Task allocation submodule; 402 - Data fusion submodule;

[0025] 50-Multi-level emergency response module. Detailed Implementation

[0026] The present application will be described in detail below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present application can be combined with each other.

[0027] To overcome the shortcomings of manual inspection, track-based inspection robots have emerged and been widely used. In the field of suspended track robots, early products mostly relied on motors to drive rollers to move on tracks to monitor equipment. However, this driving method has revealed many problems in practical applications. When running on long tracks, the rollers are prone to slippage due to insufficient friction. Especially in humid or dusty environments, the moisture or dust adhering to the track surface will further reduce the friction between the rollers and the track, resulting in a significant reduction in the robot's operational stability, making it unable to accurately reach the designated inspection position, and seriously affecting the inspection effect.

[0028] Some inspection robots use cable traction to move, which solves the power problem for long-distance operation to some extent. However, existing cable traction systems generally lack effective real-time tension monitoring methods. When the cable tension becomes uneven due to changes in the robot's motion state or track undulations during traction, it can easily cause the robot to stall. In some cases, excessive tension may even cause the cable to break, resulting in the robot losing power and hanging on the track. This not only interrupts the inspection task but may also pose safety hazards to the equipment and the surrounding environment.

[0029] In terms of power supply, sliding contact line power supply technology is widely used in inspection robots. This technology frees robots from the limitation of battery life and theoretically enables them to work continuously for a long time. However, in actual industrial environments, when the robot is running at high speed, the power receiving device and the sliding contact line may not be able to maintain stable contact due to the excessive relative speed, which can easily lead to brief power outages. In environments with strong vibration sources, such as the vibration generated by the operation of large mechanical equipment in factory workshops, the power receiving device and the sliding contact line may collide and separate frequently, resulting in frequent interruptions in power transmission. This seriously affects the normal operation of the robot and prevents it from continuously and stably obtaining power to perform inspection tasks.

[0030] In summary, existing inspection robot technologies have significant shortcomings in terms of drive and power supply, failing to meet the requirements of modern industry for efficient, accurate, intelligent, and reliable equipment inspection. There is an urgent need for a new technological solution to address these issues.

[0031] To address the aforementioned issues, this invention provides a control system for a wire-driven overhead rail-guided contact line inspection robot. This system can be deployed in a steel plant workshop, where the environment is complex, the equipment operation generates significant vibrations, and there is a certain degree of dust pollution.

[0032] like Figure 1 As shown, the control system of the wire-traction type suspended rail with sliding contact line inspection robot includes: a collaborative drive control module 10, which consists of a wire traction control module 101 and a sliding contact line power supply control module 102; the wire traction control module 101 is connected to the traction devices at both ends of the track via a wire, and the traction devices are equipped with servo motors, which are used to drive the traction wheels to rotate, so as to realize the movement control of the inspection robot along the track. Specifically, the traction devices at both ends of the track can be connected by high-strength steel wires. The servo motors equipped with the traction devices can drive the traction wheels to rotate, thereby moving the inspection robot along the suspended track. The sliding contact line power supply control module 102 includes a sliding contact line 1021 laid along the track and a power-taking device 1022 mounted on the inspection robot. The sliding contact line 1021 and the power-taking device 1022 work together to provide continuous and stable power supply control for the inspection robot. The steel wire traction control module 101 also integrates a steel wire tension real-time monitoring and control unit 1011. The steel wire tension real-time monitoring and control unit 1011 is electrically connected to the servo motor to collect the tension data of the steel wire in real time and dynamically adjust the output power of the servo motor according to the tension data to keep the steel wire tension within the preset optimal range.

[0033] In this application, steel wire traction and servo motor drive are used instead of traditional roller drive, which eliminates the dependence of rollers on the friction of the track surface. Even in working conditions such as dampness and dust that reduce friction, the robot can avoid slipping and ensure that it accurately reaches the designated inspection position. At the same time, the steel wire tension monitoring and control unit can dynamically adjust the tension in real time, eliminating the running jam or steel wire breakage caused by uneven tension, avoiding the interruption of inspection tasks and safety hazards. On the other hand, the cooperation between the sliding contact line and the power supply device can provide the robot with uninterrupted and stable power supply, eliminating the need for frequent charging and meeting the needs of long-distance and long-term inspection. Ultimately, this enables the robot to move stably, be safely tractioned, and have continuous power supply in complex industrial scenarios, thereby significantly improving the reliability and efficiency of inspection.

[0034] In specific application scenarios, the power supply device 1022 of the inspection robot consists of two core components: carbon brushes and an elastic pressure mechanism. The carbon brushes are made of copper-based graphite composite material, which combines excellent conductivity and wear resistance, maintaining stable power transmission performance even under long-term contact friction. The elastic pressure mechanism is a spring-loaded structure whose core function is to apply constant pressure to the carbon brushes, ensuring that the brushes maintain close contact with the sliding contact line laid along the track as the robot moves along the track, regardless of slight track undulations, robot vibrations, or environmental dust. This prevents power transmission interruptions due to contact gaps, providing a fundamental guarantee for the robot's continuous power supply. Even when the robot is running at high speeds (up to 1.2 m / s) or affected by equipment vibrations, the carbon brushes maintain close contact with the sliding contact line. During testing, the peak vibration acceleration generated by the operation of large steel rolling equipment in the workshop reached 0.5g; even under such harsh conditions, the power transmission of the inspection robot remained uninterrupted. Statistics on robot operation data show that there were zero power transmission interruptions during the one-month operation cycle, ensuring that the robot could operate continuously and stably and complete the inspection tasks of the equipment in the workshop.

[0035] Through the coordinated optimization of material selection and structural design, the power acquisition device can effectively solve the problem of power supply stability under complex working conditions in traditional power acquisition structures. Specifically, the copper-based graphite composite carbon brushes avoid the defects of pure metal materials that are prone to wear and require frequent replacement, and overcome the problem of insufficient conductivity of ordinary graphite materials, extending the service life of components while ensuring power transmission efficiency. The constant pressure provided by the spring pressure mechanism can offset the influence of water vapor on the track surface in humid environments and foreign matter adhesion in dusty environments on the contact state between the carbon brushes and the sliding contact line, completely eliminating instantaneous power outages or power supply fluctuations caused by poor contact. This ensures that the robot always obtains continuous and stable power during long-distance inspections and operation under complex working conditions, providing reliable power support for the normal operation of core modules such as testing equipment and drive systems, and further improving the continuity and stability of inspection tasks.

[0036] In specific application scenarios, the real-time monitoring and control unit 1011 for steel wire tension consists of a pressure sensor and a control chip. The two work together to achieve dynamic monitoring and adjustment of steel wire tension. The pressure sensor is precisely installed at the connection between the steel wire and the traction wheel. This location can directly and accurately capture the tension changes of the steel wire during traction. The sensor continuously collects the tension data of the steel wire at a preset frequency (e.g., multiple times per second), providing real-time data support for subsequent adjustments. The control chip, as the decision-making core of this unit, receives the tension data transmitted by the pressure sensor in real time and compares it with a preset tension threshold range. Once it is found that the collected tension data exceeds the threshold range (e.g., excessive tension may cause the steel wire to break, while insufficient tension may cause the robot to slip), the control chip immediately generates and outputs an adjustment signal to the servo motor. By dynamically adjusting the output power of the servo motor (reducing power when the tension is too high and increasing power when the tension is too low), the steel wire tension is ultimately maintained within the preset optimal range, ensuring the stability of the traction process.

[0037] The installation of pressure sensors at key locations and high-frequency data acquisition can avoid the defect of not being able to detect tension changes in time, ensuring timely detection of abnormal wire tension. The control chip's fast response based on thresholds and the dynamic adjustment of servo motor output power can correct the tension instantly when it exceeds the safe range, completely eliminating robot operation jams caused by uneven tension. At the same time, it prevents the risk of wire breakage caused by excessive tension and avoids the situation where the robot loses power to suspend the track. This not only ensures the continuous operation of inspection tasks, but also eliminates equipment damage and safety hazards in the surrounding environment, significantly improving the reliability and safety of wire-traction inspection robots in long-distance and complex working conditions.

[0038] From the perspective of data transmission and analysis, existing inspection robots rely heavily on traditional wireless technologies such as Wi-Fi or ZigBee for data transmission. However, these technologies face severe challenges in complex industrial environments. The numerous metal structures and electrical equipment in factories can cause strong interference and attenuation of wireless signals, resulting in a significant reduction in signal transmission distance, a marked increase in data transmission latency, and a significant rise in packet loss rate. For example, in a metal processing workshop, the effective transmission distance of a Wi-Fi signal may be less than 50 meters, and the bit error rate may exceed 5%. This makes it impossible for the data collected by the inspection robot to be transmitted to the control center in a timely and accurate manner, seriously affecting the real-time monitoring and judgment of equipment operating status. Furthermore, traditional inspection systems only focus on simple data collection and intuitive display, lacking in-depth data mining and analysis capabilities. Faced with massive amounts of equipment operating data, they cannot utilize big data and artificial intelligence technologies for in-depth analysis, making it difficult to accurately predict potential equipment failures in advance. They can only rely on manual judgment based on experience, which is not only inefficient but also has limited ability to identify early and latent faults, failing to achieve the transformation from "post-event maintenance" to "pre-event prevention" intelligent operation and maintenance model.

[0039] In view of this, such as Figure 1 As shown, the control system of the wire-traction suspended rail with sliding contact line inspection robot provided in this application also includes a data transmission and processing control module 20, which integrates an intelligent analysis and control unit 201. The data transmission and processing control module 20 is electrically connected to the inspection robot's detection equipment and is used to receive equipment operation data collected by the detection equipment for the tested equipment. The data transmission and processing control module 20 uses a 5G network and an industrial-grade wireless local area network to form a dual transmission link. The dual transmission link is used to establish a connection between the data transmission and processing control module 20 and the control center, ensuring that data can be transmitted synchronously to the control center. At the same time, the data transmission and processing control module 20 transmits the received equipment operation data to its integrated intelligent analysis and control unit 201. The intelligent analysis and control unit 201 is used to determine the remaining service life prediction value, fault probability distribution, and key component health status score of the tested equipment based on the equipment operation data and using a pre-trained fault prediction model.

[0040] The data transmission and processing control module, through a collaborative design of dual transmission links and integrated intelligent analysis, effectively solves the problems of insufficient data transmission stability and ambiguous assessment of the status of the tested equipment in traditional inspection systems. Specifically, the dual transmission links can automatically switch to an industrial-grade wireless LAN when a single network (such as 5G) signal is weak, interrupted, or interfered with, ensuring uninterrupted data transmission during equipment operation and avoiding data loss affecting inspection judgments. The intelligent analysis and control unit, relying on the quantitative results output by the fault prediction model, replaces the qualitative judgments based on experience in traditional manual inspections. It can not only predict potential fault risks of the tested equipment in advance, providing support for planned maintenance to reduce losses from sudden downtime, but also accurately assess the health status of key components, avoiding over-maintenance or under-maintenance.

[0041] Among them, the fault prediction model is the core algorithm tool of the intelligent analysis and control unit in the inspection robot control system. It is built upon historical operation and maintenance data of the tested equipment (such as industrial production equipment and power facilities), covering normal operating parameters, past fault records, and wear patterns of key components, and is trained using machine learning and other algorithms to form a model system. In actual inspections, the model takes real-time operating data of the tested equipment (such as temperature, current, vibration frequency, and appearance characteristics) collected by the detection equipment as input. After data preprocessing and feature extraction, the model analyzes the current health status of the tested equipment through calculations, and finally outputs the predicted remaining service life (the predicted duration of normal operation), fault probability distribution (the likelihood of different types of faults occurring), and health status score of key components (quantitatively assessing the degree of wear of core components). This provides data support for maintenance personnel to identify potential faults in advance, formulate accurate maintenance plans, and avoid sudden downtime.

[0042] In specific application scenarios, industrial environments are complex and ever-changing, with harsh conditions such as high temperatures, low temperatures, humidity, and dust being commonplace. This poses a significant challenge to the stability and reliability of inspection robots. In high-temperature environments, such as near blast furnaces in steel plants, temperatures often exceed 80°C. The robot's sensors are highly susceptible to drift due to excessive heat, leading to a severe decrease in detection accuracy. Existing heat dissipation measures are insufficient to meet the requirements for long-term stable operation. In locations with extremely high dust concentrations, such as underground coal mines, the dust content may exceed 1000 mg / m³. 3 The inspection lens is quickly contaminated by dust, causing the visual inspection function to fail. The current cleaning mechanism has low reliability and cannot remove dust from the lens surface in a timely and effective manner. In humid environments, electrical components are prone to moisture and short circuits, which greatly affects the overall performance of the robot. According to relevant industry reports, the failure rate of inspection robots caused by harsh environments exceeds 35%. This not only increases the maintenance cost of the equipment, but also seriously affects the continuity and stability of production.

[0043] In view of this, such as Figure 1 As shown, the control system of the wire-traction suspended rail sliding contact line inspection robot provided in this application also includes an environment adaptive control module 30. The environment adaptive control module 30 includes an environment monitoring submodule 301 and a parameter adjustment submodule 302. The environment monitoring submodule 301 integrates temperature and humidity sensors, dust concentration sensors, and air pressure sensors to collect temperature, humidity, dust content, and air pressure fluctuation parameters of the working environment in real time, and integrates these scattered environmental data into a unified environmental status data package to provide a data basis for subsequent adjustment. The parameter adjustment submodule 302 is connected to the inspection robot's detection equipment and the wire traction control module 101, respectively, and is used to automatically adjust the working parameters of the detection equipment (such as sensor sensitivity, image acquisition parameters, etc.) and the operating parameters of the wire traction control module 101 (such as wire tension, drive wheel speed, etc.) according to the environmental status data package to ensure that both can work stably in different environments.

[0044] Through real-time sensing by the environmental monitoring submodule, changes in temperature, humidity, dust, and air pressure in the working environment can be captured in a timely manner, avoiding equipment malfunctions caused by unknown environmental parameters. The automatic adjustment function of the parameter adjustment submodule can specifically optimize the parameters of the detection equipment and the wire traction control module, so that the inspection robot can maintain a stable operating state and accurate detection capabilities even under harsh working conditions such as high temperature, high humidity, and high dust. This significantly improves the system's adaptability to different working environments and reduces the interference of environmental factors on the inspection effect.

[0045] In specific application scenarios, when the parameter adjustment submodule 302 automatically adjusts the operating parameters of the detection equipment according to the environmental status data packet, it is configured as follows: when the ambient temperature is greater than the first temperature threshold or less than the second temperature threshold, the constant temperature compensation mechanism of the detection equipment is activated, and the temperature of the core components of the sensor is maintained within the preset rated range through the built-in heating or cooling module; when the dust concentration is greater than the preset concentration value, the automatic cleaning program of the corresponding detection lens of the detection equipment is triggered, and the image acquisition exposure parameters are adjusted simultaneously; when the relative humidity of the environment is greater than the preset humidity value, the electrical component moisture protection circuit is activated, and the sampling frequency of the infrared detection equipment is increased. The electrical component moisture protection circuit is used to provide moisture protection for the electrical components in the detection equipment.

[0046] Adjustments to abnormal temperature and humidity can prevent detection errors caused by sensor temperature drift and electrical component short circuits due to moisture, ensuring the stability of the sensor's core performance. Adjustments to excessive dust can not only remove dust from the lens that obstructs image acquisition, but also compensate for the influence of the dusty environment on light through exposure parameter optimization, ensuring clear and usable visual inspection data. Adjustments to excessive humidity can protect the safety and lifespan of the electrical components of the detection equipment, improve the accuracy of thermal imaging detection, and ultimately enable the detection equipment to output stable and accurate detection data under complex conditions such as high temperature, low temperature, high dust, and high humidity, providing a reliable data foundation for subsequent fault diagnosis by the intelligent analysis and control unit.

[0047] like Figure 1 As shown, the environment adaptive control module also includes a motion posture optimization submodule 303, which is electrically connected to the environment monitoring submodule 301 and the wire traction control module 101. The motion posture optimization submodule 303 is used to dynamically adjust the wire tension and drive wheel speed of the wire traction control module according to the environmental status data packet and the real-time motion status of the robot through a PID adaptive control algorithm.

[0048] For scenarios where strong winds or slippery tracks can easily cause the robot to lose balance or slip, the motion posture optimization submodule 303 can adjust the wire tension (e.g., increasing tension to enhance traction stability in strong winds) and the drive wheel speed (e.g., reducing speed to reduce the risk of slippage in slippery conditions) to correct the robot's motion posture in real time, avoiding operational stuttering or positional deviation due to environmental interference. At the same time, the application of the PID adaptive control algorithm ensures the timeliness and accuracy of the adjustment response, enabling the robot to quickly adapt to environmental changes and maintain a stable operating state at all times. This ensures that the relative position of the detection equipment and the tested parts remains constant, further improving the accuracy of inspection data collection and the continuity of inspection tasks.

[0049] In specific application scenarios, for large-area or structurally complex inspection areas, a single inspection robot often cannot complete the inspection task comprehensively and efficiently. Although there are ideas for multi-robot collaborative operations, existing multi-robot collaborative systems have obvious defects in task allocation algorithms and lack an efficient and reasonable task allocation mechanism. This leads to situations where multiple robots repeatedly inspect the same area during the inspection process, while some areas are left unchecked for a long time. For example, in the inspection of a large warehouse, multiple robots may be concentrated in a small area at the same time, resulting in wasted resources, while other areas remain unmonitored for a long time. This causes the overall inspection efficiency to decrease by about 40% compared to when tasks are reasonably allocated. At the same time, the data fusion and collaborative decision-making technology between multiple robots is not yet mature, making it impossible to efficiently integrate and comprehensively analyze the data collected by each robot, and making it difficult to fully leverage the advantages of multi-robot collaborative operations.

[0050] In view of this, such as Figure 1 As shown, the control system of the wire-traction suspended rail sliding contact line inspection robot provided in this application also includes a multi-robot collaborative control module 40. The multi-robot collaborative control module 40 includes a task allocation submodule 401 and a data fusion submodule 402. The task allocation submodule 401 is preset with a regional partitioning algorithm and priority rules. When the inspection task is started, it will dynamically divide the overall inspection area into multiple non-overlapping sub-regions according to the scale, complexity and importance of the equipment in the inspection area. Then, according to the priority rules (such as prioritizing the inspection of the sub-region where the key equipment is located), the inspection tasks of each sub-region will be allocated to different inspection robots, which logically avoids the problem of multiple robots repeatedly inspecting the same area or missing a certain area. The data fusion submodule 402 is used to receive the data collected by multiple inspection robots. When multiple robots collect multi-source data (such as image data from different angles and temperature data from different sensors) for the same inspection object (such as the same transformer or the same group of switch cabinets), they will integrate and analyze these data through a weighted fusion algorithm to reduce the error interference of data collected by a single robot.

[0051] The dynamic partitioning and priority allocation mechanism of the task allocation submodule can not only improve the overall inspection efficiency (multiple robots can work in parallel, shortening the inspection cycle), but also eliminate the waste of resources caused by repeated inspections and the risks and hidden dangers caused by missed inspections in certain areas. It is especially suitable for complex inspection scenarios with large areas and multiple devices. The weighted fusion algorithm of the data fusion submodule can integrate multi-source data of the same inspection object. Through data complementarity and error cancellation, it can improve the accuracy and reliability of inspection data, avoid misjudgments caused by single robot sensor failure or limited acquisition angle, and provide better data support for the subsequent intelligent analysis and control unit to generate accurate fault diagnosis results, further ensuring the comprehensiveness and effectiveness of the inspection task.

[0052] In specific application scenarios, such as Figure 1 As shown, the control system of the wire-traction suspended rail sliding contact line inspection robot provided in this application may further include a multi-level emergency response module 50, which is electrically connected to the detection equipment and the data transmission and processing control module 20. When the detection equipment collects abnormal operating signals (such as excessive current, sudden temperature rise, abnormal vibration, etc.), it will synchronously transmit the abnormal signal to the multi-level emergency response module 50. The multi-level emergency response module 50 will then activate the multi-level emergency response mechanism, which includes: calling a preset equipment abnormality knowledge base to determine the type of abnormal signal; and generating a preliminary handling plan including the fault location, impact range, and risk level through a decision tree algorithm.

[0053] The multi-level emergency response module 50 is directly linked to the detection equipment, enabling it to initiate a response immediately after an abnormal signal is generated, avoiding the escalation of the fault due to delays caused by manual intervention. On the other hand, the preset equipment anomaly knowledge base ensures the accuracy of anomaly type determination, avoiding ineffective handling due to misjudgment. The decision tree algorithm generates handling plans that include fault location, scope of impact, and risk level, which can replace the reliance on the experience of maintenance personnel and the ambiguity of handling measures in traditional emergency response. This reduces the decision-making difficulty for maintenance personnel and guides them to prioritize handling high-risk and wide-ranging faults, reducing the safety threat of faults to the tested equipment and the surrounding environment. At the same time, it ensures the continuity of inspection tasks, avoiding inspection interruptions or escalation of accidents due to untimely handling of anomalies.

[0054] In summary, the control system of the wire-traction suspended rail-mounted sliding contact line inspection robot provided by this invention, by constructing a collaborative drive control module including a wire traction control module and a sliding contact line power supply control module, replaces the early motor-driven roller movement method with wire traction. By connecting the traction devices at both ends of the track with wire and driving the traction wheels with servo motors, the dependence of roller movement on track surface friction can be eliminated. Even in conditions that easily reduce friction, such as dampness or dust, slippage can be avoided, ensuring stable operation of the inspection robot and accurate arrival at the designated inspection position. This solves the problem of poor stability of roller drive and the impact on inspection results during long-distance operation. Furthermore, by integrating a real-time wire tension monitoring and control unit into the wire traction control module, this unit collects wire tension data in real time and dynamically adjusts the servo motor output power, ensuring that the wire tension is always maintained within a preset optimal range. This effectively avoids the problem of uneven tension caused by the lack of real-time tension monitoring in cable traction systems, preventing robot stalling and wire breakage, avoiding inspection task interruptions and safety hazards in the surrounding environment. Ultimately, it comprehensively solves the core technical pain points of existing track-mounted inspection robots in terms of drive stability and traction safety.

[0055] Furthermore, to fully illustrate the implementation of this embodiment, this embodiment also provides a control method for a wire-driven suspended rail with sliding contact line inspection robot. This method is applied to the control system of the aforementioned wire-driven suspended rail with sliding contact line inspection robot, such as... Figure 2 As shown, the method includes:

[0056] Step 210: Control the inspection robot to move along the track through the collaborative drive control module.

[0057] In this embodiment, stable robot movement can be achieved using a collaborative drive control module, which consists of a wire traction control module and a sliding contact line power supply control module. The wire traction control module connects traction devices at both ends of the track via a wire. The servo motors in these traction devices drive the traction wheels, providing power for the inspection robot to move along the track. Simultaneously, the integrated wire tension real-time monitoring and control unit collects wire tension data in real time. If the tension deviates from a preset range, the servo motor output power is dynamically adjusted to ensure the tension remains within the optimal range. Furthermore, the sliding contact line power supply control module, through the sliding contact line laid along the track and in conjunction with the robot's power supply device, provides continuous and stable power support for the inspection robot's movement, avoiding battery life limitations and ensuring smooth robot movement along the track.

[0058] Compared to the early motor-driven rollers that were prone to slippage due to insufficient friction (in humid or dusty conditions), or the ordinary cable traction that lacked tension monitoring and caused jamming or breakage, the collaborative drive control module, through steel wire traction and real-time tension adjustment, can ensure that the robot moves accurately and without deviation. Combined with the continuous power supply of the sliding contact line, it can prevent the inspection from being interrupted due to power failure or insufficient power during the movement.

[0059] Step 220: During the robot's movement, the data transmission and processing control module receives the equipment operation data collected by the inspection robot's detection equipment for the tested equipment. Based on the equipment operation data, the pre-trained fault prediction model is used to determine the predicted remaining service life, fault probability distribution, and health status score of key components of the tested equipment.

[0060] In this embodiment of the disclosure, firstly, the data transmission and processing control module is electrically connected to the inspection equipment of the inspection robot, and can receive the equipment operation data collected by the inspection equipment for the tested equipment in real time; secondly, the data transmission and processing control module adopts a dual transmission link composed of a 5G network and an industrial-grade wireless local area network, on the one hand establishing a stable connection with the control center, and on the other hand synchronously transmitting the received equipment operation data to the intelligent analysis and control unit integrated in the data transmission and processing control module; finally, the intelligent analysis and control unit calls the pre-trained fault prediction model to perform calculation and analysis on the operation data, and finally outputs the predicted value of the remaining service life of the tested equipment, the fault probability distribution, and the health status score of key components.

[0061] Dual transmission links ensure that equipment operation data is not lost or interrupted in complex industrial environments, avoiding the impact of data loss on judgment. The quantitative health status parameters output by the fault prediction model can replace the qualitative assessment of manual inspection. It can not only identify potential fault risks of the tested equipment in advance, providing a basis for planned maintenance and reducing losses from sudden downtime, but also accurately assess the wear and tear of key components, avoiding over-maintenance or under-maintenance, and significantly improving the intelligence and accuracy of inspection.

[0062] Step 230: Use the environmental monitoring module to collect the temperature, humidity, dust concentration, and air pressure parameters of the working environment in real time, generate an environmental status data package, and dynamically adjust the working parameters of the detection equipment and the operating parameters of the wire traction control module based on the environmental status data package.

[0063] In this embodiment of the disclosure, the robot can adaptively adjust to the working environment through an environmental monitoring module, which includes an environmental monitoring submodule and a parameter adjustment submodule. The environmental monitoring submodule integrates temperature and humidity sensors, dust concentration sensors, and air pressure sensors, enabling real-time collection of temperature, humidity, dust content, and air pressure fluctuation parameters of the working environment, and integrating these dispersed parameters into a unified environmental status data package. The parameter adjustment submodule is electrically connected to the inspection robot's detection equipment and wire rope traction control module, respectively. After receiving the environmental status data package, it adjusts the parameters accordingly. For example, when the temperature exceeds the threshold, the constant temperature compensation mechanism of the detection equipment is activated; when the dust exceeds the limit, the lens is automatically cleaned and the image exposure parameters are adjusted; when the humidity exceeds the standard, the moisture-proof circuit of the electrical components is activated and the infrared detection sampling frequency is increased. Simultaneously, the operating parameters of the wire rope traction control module, such as tension and drive wheel speed, are adjusted to adapt to environmental changes.

[0064] By collecting environmental parameters in real time, the performance degradation of the equipment due to unknown environments can be avoided (such as sensor drift caused by high temperature or lens obstruction by high dust). The dynamic adjustment of the parameter adjustment submodule can ensure that the detection equipment can still output accurate data under conditions such as high temperature, high humidity, and high dust, while ensuring the movement stability of the wire traction control module (such as increasing tension to prevent deviation in strong winds).

[0065] In summary, the technical solution in this application, by replacing traditional roller drive with wire traction and adjusting servo motor power through real-time tension monitoring, effectively avoids the problems of roller slippage and jamming or breakage caused by uneven cable tension during long-distance operation. This provides the inspection robot with stable and continuous mobility, ensuring that the robot can accurately reach the designated inspection position and laying the foundation for inspection. Furthermore, the dual transmission links of the data transmission and processing control modules ensure uninterrupted and lossless data transmission of the tested equipment's operational data. Simultaneously, through a pre-trained fault prediction model, the dispersed operational data is transformed into the remaining service life, fault probability distribution, and health scores of key components of the tested equipment. Quantifying results, replacing traditional manual experience-based judgment, enables early identification of potential faults in the tested equipment, reducing losses from sudden downtime. By capturing operational environment parameters in real time and generating data packets through the environmental monitoring module, the operating parameters of the testing equipment and the operating parameters of the wire traction control module are dynamically adjusted. This avoids interference from harsh environments such as high temperature, high dust, and high humidity on testing accuracy and robot operational stability. Consequently, it enables continuity of the inspection process, validity of data, and forward-looking maintenance decisions, significantly improving the reliability, efficiency, and intelligence of the wire-traction suspended rail sliding contact line inspection robot in complex industrial scenarios, providing full-process technical support for predictive maintenance of the tested equipment.

[0066] Through the above description of the embodiments, those skilled in the art can clearly understand that this application can be implemented by means of software plus necessary general-purpose hardware platform, or it can be implemented by hardware.

[0067] This solution can achieve the following overall technical effects:

[0068] 1. The collaborative drive control module combines wire traction with sliding contact line power supply, which can avoid the slippage of traditional wheel drive and the loss of control of cable traction tension. The wire tension real-time monitoring and control unit can dynamically adjust the motor output to prevent operation failure due to abnormal tension. The optimized sliding contact line contact design can ensure stable power transmission of the robot under complex working conditions and ensure continuous operation capability.

[0069] 2. By adopting 5G networks or industrial-grade wireless LANs, combined with data compression, encryption and redundant transmission technologies, the real-time performance and stability of data transmission can be greatly enhanced. The intelligent analysis and control unit based on big data and artificial intelligence can build a fault prediction model through machine learning, which can realize the forward-looking judgment of equipment status and promote the transformation of operation and maintenance mode from passive maintenance to proactive prevention.

[0070] 3. The environmental adaptive control mechanism can automatically adjust the working parameters of the detection equipment according to environmental parameters such as temperature, humidity, dust, and air pressure, ensuring constant detection accuracy in harsh environments such as high temperature, low temperature, humidity, and dust. Combined with the PID adaptive control algorithm to optimize the robot's motion posture, it can effectively resist interference factors such as wind and slippery tracks, and improve the stability of operation in complex environments.

[0071] 4. The multi-level emergency response mechanism enables rapid acquisition and accurate diagnosis of fault signals, which can significantly shorten the fault handling cycle. The multi-robot collaborative operation mechanism avoids repeated inspections and missed inspections in areas through intelligent task allocation and data collaborative processing, significantly improving inspection efficiency and data reliability, and meeting the high-efficiency operation and maintenance needs of large-scale complex scenarios.

[0072] Those skilled in the art will understand that the accompanying drawings are merely schematic diagrams of a preferred embodiment, and the modules or processes shown in the drawings are not necessarily essential for implementing this application. Those skilled in the art will understand that the modules in the apparatus of the embodiment can be distributed within the apparatus of the embodiment as described, or can be modified to be located in one or more apparatuses different from this embodiment. The modules of the above-described embodiment can be combined into one module, or further divided into multiple sub-modules.

[0073] The serial numbers in this application are for descriptive purposes only and do not represent the superiority or inferiority of any particular implementation scenario. The above disclosures are merely a few specific implementation scenarios of this application; however, this application is not limited thereto, and any variations conceived by those skilled in the art should fall within the protection scope of this application.

Claims

1. A control system of a steel wire traction overhead monorail belt trolley line inspection robot, characterized in that, The system comprises: a cooperative driving control module composed of a steel wire traction control module and a trolley wire power supply control module; the steel wire traction control module connects traction devices at both ends of the track through a steel wire, the traction devices are provided with servo motors for driving traction wheels to rotate to realize movement control of the inspection robot along the track; the trolley wire power supply control module comprises a trolley wire laid along the track and a power taking device carried by the inspection robot, the trolley wire cooperates with the power taking device to provide continuous and stable power supply control for the inspection robot; the steel wire traction control module further integrates a steel wire tension real-time monitoring control unit electrically connected with the servo motor, which is used to collect tension data of the steel wire in real time and dynamically adjust the output power of the servo motor according to the tension data so as to maintain the steel wire tension in a preset optimal range.

2. The control system of the steel wire traction overhead monorail belt trolley line inspection robot according to claim 1, characterized in that: the power taking device comprises a carbon brush and an elastic pressure mechanism; the carbon brush is made of copper-based graphite composite material, and the elastic pressure mechanism is a spring pressure structure for applying constant pressure to keep the carbon brush in close contact with the trolley wire at all times and ensure the continuity of power supply.

3. The control system of the steel wire traction overhead monorail belt trolley line inspection robot according to claim 1, characterized in that, the steel wire tension real-time monitoring control unit comprises a pressure sensor and a control chip; the pressure sensor is installed at the connection between the steel wire and the traction wheel and is used to collect tension data at a preset frequency; the control chip is used to output an adjustment signal to the servo motor to dynamically adjust the output power of the servo motor when the collected tension data exceeds a preset tension threshold range, so as to maintain the steel wire tension in a preset optimal range.

4. The control system of the steel wire traction overhead monorail belt trolley line inspection robot according to claim 1, characterized in that, the system further comprises a data transmission and processing control module integrated with an intelligent analysis control unit; the data transmission and processing control module is electrically connected with detection equipment of the inspection robot and is used to receive device operation data collected by the detection equipment for a measured device; the data transmission and processing control module adopts 5G network and industrial-grade wireless local area network to form a double transmission link, which is used to establish a connection between the data transmission and processing control module and a control center, and at the same time, the data transmission and processing control module transmits the received device operation data to the intelligent analysis control unit integrated therein; the intelligent analysis control unit is used to determine a remaining service life prediction value, a fault probability distribution and a key component health state score of the measured device based on the device operation data and a pre-trained fault prediction model.

5. The control system of the steel wire traction overhead monorail belt trolley line inspection robot according to claim 1, characterized in that, the system further comprises an environment adaptive control module comprising an environment monitoring submodule and a parameter adjustment submodule; the environment monitoring submodule integrates a temperature and humidity sensor, a dust concentration sensor and a barometric pressure sensor, which are used to collect temperature and humidity, dust content and barometric pressure fluctuation parameters of the working environment in real time to generate an environment state data packet; The parameter adjustment submodule is electrically connected with the detection device of the inspection robot and the steel wire traction control module, and is configured to automatically adjust the working parameters of the detection device and the operation parameters of the steel wire traction control module according to the environment state data packet.

6. The control system of the steel wire traction overhead monorail belt sliding contact line inspection robot according to claim 5, characterized in that, When the environmental temperature is greater than a first temperature threshold or less than a second temperature threshold, a constant temperature compensation mechanism of the detection device is started, and the temperature of a sensor core component is maintained within a preset rated range by a built-in heating or refrigeration module. When the dust concentration is greater than a preset concentration value, an automatic cleaning program of a corresponding detection lens of the detection device is triggered, and the image acquisition exposure parameters are adjusted synchronously. When the environmental relative humidity is greater than a preset humidity value, a moisture-proof protection circuit for electrical components is started, and the sampling frequency of the infrared detection device is increased, and the moisture-proof protection circuit is configured to provide moisture-proof protection for the electrical components in the detection device. The environment adaptive control module further comprises a motion posture optimization submodule electrically connected with the environment monitoring submodule and the steel wire traction control module.

7. The control system of the steel wire traction overhead monorail belt sliding contact line inspection robot according to claim 5, characterized in that, The motion posture optimization submodule is configured to dynamically adjust the steel wire tension and the driving wheel rotation speed of the steel wire traction control module according to the environment state data packet and the real-time motion state of the robot by a PID adaptive control algorithm. The system further comprises a multi-robot cooperative control module, which comprises a task allocation submodule and a data fusion submodule.

8. The control system of the steel wire traction overhead monorail belt trolley line inspection robot according to claim 1, characterized in that, The task allocation submodule is provided with a region partition algorithm and a priority rule, and is configured to dynamically divide the inspection region into a plurality of sub-regions, and allocate the sub-region tasks to different inspection robots to avoid repeated inspection and region omission. The data fusion submodule is configured to receive the collected data of a plurality of inspection robots, and integrate and analyze the multi-source data of the same inspection object by a weighted fusion algorithm. The system further comprises a multi-level emergency response module electrically connected with the detection device and the data transmission and processing control module.

9. The control system of the steel wire traction overhead monorail belt sliding contact line inspection robot according to claim 1, characterized in that, When the detection device collects an equipment operation abnormal signal, the multi-level emergency response module starts a multi-level emergency response mechanism, which comprises calling a preset equipment abnormal knowledge base to determine the type of the abnormal signal, and generating a preliminary treatment scheme including the fault position, the influence range and the risk level by a decision tree algorithm. The method comprises:

10. A control method of a steel wire traction overhead monorail belt trolley line inspection robot, characterized in that, controlling the inspection robot to move along the track by the cooperative driving control module; during the movement of the robot, receiving the equipment operation data collected by the detection device of the inspection robot for the measured equipment by the data transmission and processing control module, and determining the remaining service life prediction value, the fault probability distribution and the key component health state score of the measured equipment by using a pre-trained fault prediction model based on the equipment operation data; and ​ The environmental monitoring module is used to collect the temperature and humidity, dust concentration and air pressure parameters of the working environment in real time, generate an environmental state data packet, and dynamically adjust the working parameters of the detection device and the running parameters of the steel wire traction control module based on the environmental state data packet.

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