A device and method for inspecting and repairing anti-fall guide rails for iron towers

Abstract

This invention discloses a device and method for inspecting and repairing iron tower fall arrestor rails. The device includes a motion platform, a repair mechanism, and an image inspection module. The motion platform is movably connected to the fall arrestor rail to enable the device to move on the rail. The image inspection module is located on the forward side of the motion platform and is used to identify defective parts of the fall arrestor rail. The repair mechanism is located between the motion platform and the image inspection module. The repair mechanism includes a rust removal component, a cleaning component, and a spraying component. The cleaning component is located between the rust removal component and the motion platform. The rust removal component is used to remove rust and grind the defective parts. The cleaning component is used to clean the waste generated during rust removal on the surface of the fall arrestor rail. The spraying component is used to spray and repair the defective parts after rust removal. This embodiment achieves efficient and reliable repair operations, shortens the repair cycle, eliminates the need for manual repair, and reduces the repair costs of large-scale high-altitude operations.

Description

Technical Field

[0001] This invention relates to the field of anti-fall guide rail inspection technology, and in particular to a device and method for inspecting and repairing anti-fall guide rails for iron towers. Background Technology

[0002] Repairing defects in the fall arrestor rails of iron towers is a typical high-altitude, high-risk special operation. After problems are discovered during inspections, repair work must be planned and organized separately, resulting in a long cycle during which rust continues to develop, turning minor problems into major ones, increasing the difficulty and cost of repair. Secondly, repairs require specialized work teams, the use of large aerial work platforms or complex scaffolding, and the construction window is subject to weather constraints, leading to extremely high costs in manpower, equipment, time, and management, and low efficiency. Repair personnel must spend long periods suspended in the air, using angle grinders and sandpaper to remove rust, followed by manual brushing or simple spraying, resulting in low safety and high labor intensity. Summary of the Invention

[0003] This invention provides a device and method for inspecting and repairing anti-fall guide rails of iron towers, which solves the problems of high repair difficulty, high cost, low efficiency, low safety and high labor intensity in the existing repair work of defective parts of anti-fall guide rails of iron towers.

[0004] The present invention provides an inspection and repair device for a tower fall arrestor rail, comprising: a motion platform, a repair mechanism, and an image inspection module; the motion platform is used to be movably connected to the fall arrestor rail to enable the device to move on the fall arrestor rail;

[0005] The image inspection module is located on the forward side of the motion platform and is used to identify defective parts of the fall-prevention guide rail. The repair mechanism is located between the motion platform and the image inspection module.

[0006] The repair mechanism includes a rust removal component, a cleaning component, and a spraying component. The cleaning component is disposed between the rust removal component and the motion platform. The rust removal component is used to remove rust and grind the defective area. The cleaning component is used to clean the waste generated during rust removal on the surface of the anti-fall guide rail. The spraying component is used to spray and repair the defective area after rust removal.

[0007] Furthermore, the rust removal assembly is connected to the motion platform via a connecting rod;

[0008] The rust removal assembly includes a wire roller brush and a U-shaped component. The closed end of the U-shaped component is connected to the connecting rod, and the open end of the U-shaped component is rotatably connected to the center of both ends of the wire roller brush.

[0009] The connecting rod is telescopically connected to the motion platform, which is used to move the wire brush closer to or away from the anti-fall guide rail.

[0010] Furthermore, the closed end of the U-shaped component is connected to the connecting rod via a gas spring.

[0011] Furthermore, the cleaning assembly includes a blower, which is used to promptly blow away the waste generated by the friction between the wire roller brush and the defective area from the surface of the anti-fall guide rail.

[0012] Furthermore, the cleaning assembly includes a soft-bristled roller brush, which is used to contact the surface of the anti-fall guide rail after the rust removal assembly stops operating to sweep off the waste material attached to the surface of the anti-fall guide rail.

[0013] Furthermore, the spraying assembly includes an annular spray pipe and multiple nozzles, with the multiple nozzles evenly distributed on the annular spray pipe to achieve multiple nozzles surrounding the surface of the fall arrestor rail, so that a repair coating with uniform thickness and sufficient coverage of defective areas is formed on the surface of the fall arrestor rail after spraying.

[0014] Furthermore, the spraying assembly includes a pressure controller and a flow controller. The input end of the annular nozzle is connected to the pressure controller, and the input end of the annular nozzle is equipped with the flow controller for realizing atomized spraying.

[0015] Furthermore, it includes a control module, which is connected to the motion platform, the image inspection module, the rust removal component, the cleaning component, and the spraying component, respectively;

[0016] The image inspection module is used to identify the defective parts of the fall-prevention guide rail and then send the defect information to the control module. The control module records the defect location based on the defect information.

[0017] The control module is used to control the movement of the motion platform based on the defect location record, so that the rust removal component, spraying component or cleaning component can be aligned with the defect location and the corresponding component can be controlled to start operation.

[0018] This invention also provides a method for inspecting and repairing anti-fall guide rails of iron towers based on the aforementioned device, comprising the following steps:

[0019] The motion platform of the device is installed on the bottom end of the anti-fall guide rail, ensuring that the image inspection module is ahead of the motion platform in the forward direction;

[0020] The motion platform is activated to move the device upwards toward the top of the fall arresting rail. The image inspection module is activated to continuously collect images of the surface of the fall arresting rail, and the image inspection module automatically identifies defective parts.

[0021] When the image inspection module detects that the area of ​​the defect is greater than or equal to a preset area value, the motion platform drives the rust removal component to align with the defect and then stops moving.

[0022] The rust removal component contacts the surface of the anti-fall guide rail to remove rust and polish the defective area.

[0023] The cleaning component is started synchronously with the rust removal component, or the cleaning component is started after the rust removal and grinding are completed, to clean up the waste generated after the rust removal and grinding, and to ensure that the surface of the defective part to be sprayed on the anti-fall guide rail is clean and dry;

[0024] After the device reaches the top of the fall arresting guide rail, it moves downwards towards the bottom of the fall arresting guide rail and activates the spraying assembly to spray and repair the defective parts to be sprayed.

[0025] Furthermore, the process of spraying repair on the defective areas to be sprayed includes:

[0026] The pressure of the coating is adjusted to the preset pressure value by a pressure controller and then delivered to the annular nozzle.

[0027] The control module adjusts the flow rate of the nozzle and the moving speed of the motion platform according to the defect area through the flow controller, thereby adjusting the moving speed of the annular nozzle so that the atomized coating accurately and evenly covers the defect area to be sprayed, forming a repair coating of a preset thickness.

[0028] As can be seen from the above technical solutions, the present invention has the following advantages:

[0029] In this embodiment, during the upward movement of the device, after the image inspection module located at the front of the motion platform detects the defect, the rust removal and cleaning components located between the motion platform and the image inspection module perform rust removal, grinding, and cleaning operations. Before the motion platform moves to the defective area, any protrusions that may exist at the defective area are removed, reducing the risk that the protrusions at the defective area will affect the moving accuracy and stability of the motion platform. During the downward movement, the spraying component located at the front of the motion platform performs spraying operations. The coating formed after spraying repair will not be crushed by the motion platform, making the repair operation both efficient and reliable, shortening the repair cycle, eliminating the need for manual repair, and reducing the repair costs of large-scale high-altitude operations.

[0030] In addition, when the rust removal component removes and grinds the defective parts, the waste generated during the rust removal and grinding will tend to spread in the direction of gravity. The cleaning mechanism located between the rust removal component and the motion platform can promptly clean the waste off the surface of the anti-fall guide rail, so as to avoid contaminating the anti-rust material when the subsequent spraying component sprays the anti-rust material, thus ensuring the spraying quality. At the same time, the waste can reduce the impact on the movement accuracy and stability of the motion platform after it leaves the track surface. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 A three-dimensional schematic diagram of a device for inspecting and spraying repairing anti-fall guide rails for iron towers;

[0033] Figure 2 A front view schematic diagram of a device for inspecting and spraying repairing anti-fall guide rails for iron towers;

[0034] Figure 3 This is a three-dimensional schematic diagram of the moving platform in a device for inspecting and spraying repairing anti-fall guide rails of iron towers;

[0035] Figure 4 This is a bottom view schematic diagram of the moving platform in a tower anti-fall guide rail inspection and spraying repair device;

[0036] Figure 5 This is a flowchart illustrating a method for inspecting and spraying repairs on anti-fall guide rails of iron towers.

[0037] Explanation of reference numerals in the attached diagram: 1. Anti-fall guide rail; 2. Motion platform; 21. Mounting base; 22. Guide seat; 23. Guide wheel; 24. Clamping wheel; 25. Traveling wheel; 26. Adaptive clamping mechanism; 3. Image inspection module; 4. Rust removal component; 41. Steel wire roller brush; 42. Gas spring; 43. U-shaped component; 5. Cleaning component; 6. Spraying component; 61. Annular spray pipe; 62. Nozzle; 7. Connecting rod; 8. Control module. Detailed Implementation

[0038] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0039] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the present application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0040] Please see Figure 1 , Figure 1 This invention provides a device for inspecting and repairing anti-fall guide rails for iron towers.

[0041] The present invention provides an inspection and repair device for a tower anti-fall guide rail, comprising: a motion platform 2, a repair mechanism and an image inspection module 3; the motion platform 2 is used to be movably connected to the anti-fall guide rail 1 to enable the device to move on the anti-fall guide rail 1;

[0042] The image inspection module 3 is located on the forward side of the motion platform 2 and is used to identify the defective parts of the fall-prevention guide rail 1. The repair mechanism is located between the motion platform 2 and the image inspection module 3.

[0043] The repair mechanism includes a rust removal component 4, a cleaning component 5, and a spraying component 6. The cleaning component 5 is located between the rust removal component 4 and the motion platform 2. The rust removal component 4 is used to remove rust and grind the defective parts. The cleaning component 5 is used to clean the waste generated during rust removal on the surface of the anti-fall guide rail 1. The spraying component 6 is used to spray and repair the defective parts after rust removal.

[0044] It is understandable that, in specific implementation, the inspection and repair work in this embodiment targets the vertically distributed fall arrestor rails 1 at high altitudes. The motion platform 2 of the inspection and repair device needs to move along the fall arrestor rails 1 to be inspected and repaired. The operational stability and movement accuracy of the motion platform 2 directly determine the positioning accuracy of the repair mechanism. Therefore, how to make the motion platform 2 move stably and accurately on the defective fall arrestor rails 1, while ensuring that the inspection and repair work and the operation of the motion platform 2 do not interfere with each other, and ensuring high-efficiency inspection and repair work, is the core technical problem that needs to be solved in this embodiment.

[0045] In this embodiment, during the upward movement of the device, after the image inspection module 3 located at the front of the motion platform 2 detects the defect, the rust removal component 4 and the cleaning component 5 located between the motion platform 2 and the image inspection module 3 perform rust removal, grinding, and cleaning operations. Before the motion platform 2 moves to the defect, any protrusions that may exist at the defect are removed, reducing the risk that the protrusions at the defect will affect the movement accuracy and stability of the motion platform 2. During the downward movement, the spraying component 6 located at the front of the motion platform 2 performs a spraying operation. The coating formed after the spraying repair will not be crushed by the motion platform 2, making the repair operation both efficient and reliable, shortening the repair cycle, eliminating the need for manual repair, and reducing the repair cost of large-scale high-altitude operations.

[0046] In addition, when the rust removal component 4 removes rust and grinds the defective parts, the waste generated by the rust removal and grinding will be scattered in the direction of gravity. The cleaning mechanism located between the rust removal component 4 and the motion platform 2 will clean the waste away from the surface of the anti-fall guide rail 1 in a timely manner, so as to avoid contamination of the anti-rust material when the subsequent spraying component 6 sprays the anti-rust material, and ensure the spraying quality. At the same time, the waste can reduce the impact on the movement accuracy and stability of the motion platform 2 after leaving the track surface.

[0047] In a more specific embodiment, the spraying component 6 is disposed between the image inspection module 3 and the rust removal component 4.

[0048] Understandably, in practice, the spraying component 6 is used to spray anti-rust materials, such as paint. Paint has irregular volatility. When the spraying operation is carried out in the downward direction of the device, the spraying component 6 is set between the image inspection module 3 and the rust removal component 4 to reduce the risk of insulating paint contaminating the cleaning component 5 and the motion platform 2.

[0049] In a more specific embodiment, the rust removal assembly 4 is connected to the motion platform 2 via a connecting rod 7;

[0050] The rust removal component 4 includes a wire roller brush 41 and a U-shaped component 43. The closed end of the U-shaped component 43 is connected to the connecting rod 7, and the open end of the U-shaped component 43 is rotatably connected to the center of both ends of the wire roller brush 41.

[0051] Link 7 is telescopically connected to motion platform 2 to enable the steel wire brush 41 to move closer to or away from the anti-fall guide rail 1.

[0052] Understandably, in practical implementation, when the image inspection module 3 identifies a defect on the surface of the fall arresting guide rail 1, the motion platform 2 moves, causing the wire brush 41 to move to one side of the defect. The connecting rod 7 moves closer to the motion platform 2, causing the wire brush 41 to move closer to the defect until it contacts it. The wire brush 41 rotates at high speed, grinding away the oxide scale and rust on the surface of the fall arresting guide rail 1 until the rust pits are polished to reveal a metallic luster. The wire brush 41 is durable, easy to replace, and removes rust quickly and cleanly. It can conform to the shape of the fall arresting guide rail 1, replacing the sandpaper used manually in existing technologies and overcoming the defect of sandpaper being easily damaged.

[0053] In a more specific embodiment, the connecting rod 7 is arranged parallel to the fall arrestor rail 1, and the connecting rod 7 is connected to the top of the motion platform 2 through a telescopic member, the telescopic direction of which is perpendicular to the connecting rod 7.

[0054] In a more specific embodiment, both the image inspection module 3 and the spraying assembly 6 are connected to the connecting rod 7.

[0055] In a more specific embodiment, such as Figure 2 As shown, the closed end of the U-shaped part 43 is connected to the connecting rod 7 via a gas spring 42.

[0056] Understandably, during implementation, when the connecting rod 7 drives the wire brush 41 to contact the anti-fall guide rail 1, the gas spring 42 is compressed. The gas spring 42 can ensure a constant and stable force output, guaranteeing the stability of the force applied to the wire brush 41 when it contacts the anti-fall guide rail 1, ensuring stable contact between the wire brush 41 and the anti-fall guide rail 1, and ensuring that the oxide scale and rust on the surface of the anti-fall guide rail 1 are thoroughly removed. Furthermore, when there are protruding defective parts, it can cooperate with the wire brush 41 to achieve floating grinding. Under the buffering effect of the gas spring 42, the wire brush 41 will not exert a large reaction force on the overall equipment and damage it when floating grinding on protruding defective parts.

[0057] It should be noted that the advantages of using gas spring 42 include: small thrust fluctuation within the compression stroke of gas spring 42, which is different from the linear increase characteristic of coil spring where the elastic force increases with the shorter compression stroke. It can provide stable support force throughout the entire compression stroke. The compression process generates damping through oil and throttle orifice, avoiding the hard impact of rapid compression of traditional springs, reducing noise and protecting the mechanism. After the gas spring 42 is compressed and stored, it can automatically and smoothly extend and return to its original position without the need for an additional drive mechanism.

[0058] In a more specific embodiment, the central shaft portion of the wire brush 41 is connected to a drive assembly, which includes a motor, the output shaft of which is connected to the central shaft portion of the wire brush.

[0059] Understandably, in practice, the wire brush 41 is driven by a motor, and the motor speed can be controlled to regulate the efficiency and quality of rust removal. The motor drives the wire brush 41 to rotate at high speed, performing targeted grinding on the defective areas until the metallic luster is revealed.

[0060] In a more specific embodiment, the cleaning component 5 includes a blower for timely blowing away waste generated by the friction between the wire brush 41 and the defective area from the surface of the anti-fall guide rail 1.

[0061] Understandably, when the wire brush 41 is performing rust removal, the waste material will fall in the direction of gravity. By simultaneously turning on the blower, the waste material can be blown away from the track surface in time, reducing the amount of waste material that falls directly along the track surface into the gap between the motion platform 2 and the anti-fall guide rail 1. This reduces the subsequent movement resistance of the motion platform 2, improves the movement accuracy of the motion platform 2, and helps to achieve accurate positioning of the subsequent spraying component 6.

[0062] In a more specific embodiment, the hair dryer uses a blower.

[0063] Understandably, in practice, the high-pressure airflow blown out by the blower ensures that the waste material is removed from the surface of the anti-fall guide rail 1, thoroughly removing the floating dust, abrasive residue and metal shavings from the surface of the treatment area, ensuring that the surface of the anti-fall guide rail 1 is clean before spraying, and ensuring the cleaning effect.

[0064] In some more specific embodiments, the cleaning assembly 5 includes a soft-bristled roller brush, which is used to sweep off the waste adhering to the surface of the anti-fall guide rail 1 after the rust removal assembly 4 has stopped operating.

[0065] Understandably, in practice, the soft-bristled roller brush can conform to the curved / flat / shallow gaps of the anti-fall guide rail 1 as it rolls, with the bristles penetrating deep into the dust-attached areas. Through physical friction, it directly sweeps away floating dust and loose accumulated ash, further enhancing the cleaning effect. The soft-bristled roller brush is positioned between the rust removal component 4 and the moving platform 2. When the rust removal component 4 is grinding and removing rust, the soft-bristled roller brush can press against the surface of the anti-fall guide rail 1, preventing waste from falling into the gap between the moving platform 2 and the anti-fall guide rail 1.

[0066] In a more specific embodiment, the spraying assembly 6 includes an annular nozzle 61 and a plurality of nozzles 62, which are equally spaced on the annular nozzle 61 to achieve the distribution of the plurality of nozzles 62 around the surface of the fall arrest guide rail 1, so that a repair coating with uniform thickness and sufficient coverage of the defective parts is formed after spraying on the surface of the fall arrest guide rail 1.

[0067] Understandably, in high-altitude environments, the quality of existing processes is difficult to guarantee: key quality indicators such as surface treatment grade (e.g., St2 / St3), coating thickness, and uniformity rely entirely on worker skill, making it difficult to meet standards and resulting in a short lifespan for the repair layer, which is prone to failure again in a short period. This embodiment, by setting multiple annular nozzles 62 with equal spacing, helps to ensure the uniformity of the repair coating thickness, ensuring full coverage of the defective areas, and achieving or exceeding the quality of manual repair.

[0068] In a more specific embodiment, the spraying assembly includes a pressure controller and a flow controller. The input end of the annular nozzle 61 is connected to the pressure controller, and the input end of the annular nozzle 61 is provided with a flow controller for realizing atomized spraying.

[0069] Understandably, in practice, the flow rate of nozzle 62 is controlled by a flow controller, the air pressure for spraying is controlled by a pressure controller, and the moving speed of nozzle 62 is controlled by a motion platform 2 to achieve atomized spraying. Atomized spraying enables directional, controllable, and precise spraying in vertical working environments, effectively avoiding material dripping and accumulation caused by gravity, ensuring a uniform and dense coating on vertical surfaces, free from defects such as sagging and missed spraying, and further ensuring coating adhesion and material utilization.

[0070] In a more specific embodiment, the spraying assembly further includes a high-pressure diaphragm airless sprayer connected to the annular nozzle 61, which provides high-pressure power to the annular nozzle 61.

[0071] Understandably, the high-pressure diaphragm airless sprayer uses a gasoline-powered high-pressure diaphragm pump with a rated working pressure of up to 20MPa. The equipment includes a detachable handle (for easy transport), a fuel tank (power source; if electric, a battery pack), an air filter (to ensure the cleanliness of the power system), a pressure gauge (to monitor spraying pressure in real time), a pressure regulating valve (to precisely control output pressure), and a return valve and return pipe (to regulate paint circulation and prevent sedimentation). Through the reciprocating motion of the diaphragm pump, the paint in the material container is pressurized to a high-pressure state, giving the paint the kinetic energy to atomize without compressed air assistance, providing a foundation for uniform film formation.

[0072] In a more specific embodiment, the annular nozzle 61 is connected to a high-pressure diaphragm airless sprayer via a flexible high-pressure hose. The annular nozzle 61 covers the outside of the fall arrestor rail 1, and multiple fine nozzles with a diameter of 0.3 mm are evenly arranged on its inner side. When the high-pressure paint flows through the nozzles 62, a pressure drop occurs due to the sudden contraction of the flow channel cross-section, causing the paint volume to expand rapidly and achieve efficient atomization. Multiple nozzles 62 simultaneously spray around the front and both sides of the fall arrestor rail 1, ensuring coverage of all working surfaces and forming a uniform and well-adhered coating.

[0073] In a more specific embodiment, the annular nozzle 61 is connected to the material container via a high-pressure diaphragm airless sprayer.

[0074] Understandably, the material container is a high-pressure material tank (10-20L capacity), which has sealing and pressure-resistant characteristics and can store insulating coatings such as fluorosilicone PI, preventing the coating from leaking or deteriorating under high pressure.

[0075] In a more specific embodiment, the material hose is made of high-pressure resistant insulating rubber with a pressure resistance of ≥30MPa, ensuring that the high-pressure coating does not crack or leak electricity during transmission.

[0076] The basic principle of spraying component 6 for spraying operations is as follows:

[0077] 1) High-pressure atomization stage: The high-pressure diaphragm airless sprayer pressurizes the paint in the material tank to 20MPa. The high-pressure paint is transported to the annular nozzle 61 through the material hose. When it passes through the 0.3mm diameter nozzle, the pressure drops suddenly and "volume expansion-liquid column tearing" occurs, forming uniform atomized particles.

[0078] 2) Walking and spraying stage: The motion platform 2 carries the spraying component 6 and walks on the fall arrest guide rail 1. By adjusting the spraying flow rate and moving speed, the atomized paint is accurately attached to the surface of the fall arrest guide rail 1 to complete the construction of the anti-rust coating.

[0079] In a more specific embodiment, a control module 8 is included, which is connected to the motion platform 2, the image inspection module 3, the rust removal component 4, the cleaning component 5, and the spraying component 6, respectively.

[0080] The image inspection module 3 is used to identify the defective parts of the fall-prevention guide rail 1 and then send the defect information to the control module 8. The control module 8 records the defect location based on the defect information.

[0081] The control module 8 is used to control the movement of the motion platform 2 based on the defect location record, so that the rust removal component 4, the spraying component 6 or the cleaning component 5 can be aligned with the defect location and the corresponding component can be started to operate.

[0082] Understandably, in practice, the image inspection module 3 and the control module 8 work together to record the location of defects, so that the rust removal component 4, the spraying component 6, and the cleaning component 5 can be aligned with the defective area for operation.

[0083] In a more specific embodiment, the control module 8 includes an encoder.

[0084] Understandably, the encoder is coupled to the image inspection module 3 on the motion platform 2, which collects motion parameters such as displacement and running speed of the motion platform 2 along the fall arrest guide rail 1 in real time, and converts these physical motion signals into electrical pulse digital signals and transmits them to the control module 8. When the image inspection module 3 identifies a defect in the fall arrest guide rail 1 and sends defect information, the control module 8 receives the motion parameter signal synchronously transmitted by the encoder, matches and converts the parameter with the preset spatial coordinates of the fall arrest guide rail 1, and accurately records the actual physical position of the fall arrest guide rail 1 corresponding to the defect, forming a defect position record. Subsequently, when the control module 8 issues a movement command to the motion platform 2 based on the defect position record, the encoder continuously provides real-time feedback on the dynamic displacement data of the motion platform 2, providing the control module 8 with a closed-loop position detection and feedback adjustment basis, ensuring that the control module 8 can accurately control the motion platform 2 to move along the fall arrest guide rail 1 to the target defect position, and achieve precise positioning of the defect position and precise position control for subsequent operations.

[0085] In a more specific embodiment, the image inspection module 3 integrates a high-definition visible light camera to identify the appearance of the rusted and peeling anti-fall guide rail 1. The image inspection module 3 consists of a high-definition visible light camera and an edge computing module located at the front end. Utilizing the YOLOv8 target detection algorithm, it runs a deep learning-based defect recognition algorithm to analyze images in real time, automatically select rusted areas, calculate the percentage of rusted area, assess the defect level, and trigger the repair process immediately based on a preset threshold (e.g., rusted area > 5%).

[0086] In a more specific embodiment, such as Figure 3 and Figure 4 As shown, the motion platform 2 is the foundation for the robot's attachment and movement on the anti-fall guide rail 1. It provides continuous and adjustable positive pressure to generate sufficient friction, enabling the robot to adapt to the anti-fall guide rail 1 for walking and obstacle crossing.

[0087] The motion platform 2 includes a mounting base 21, a guide seat 22, an adaptive clamping mechanism 26, and a traveling mechanism. The guide seat 22 is fixed to the bottom of the mounting base 21 and is equipped with guide wheels 23 for limiting the fall arrestor rail 1 from the left and right sides, and clamping wheels 24 for pre-tightening the fall arrestor rail 1 from below. The adaptive clamping mechanism 26 is mounted on the mounting base. The traveling mechanism includes traveling wheels 25. The adaptive clamping mechanism 26 applies a constant clamping force to the traveling wheels 25, enabling the traveling wheels 25 to adapt to the curved fall arrestor rail 1 and the obstacle crossing requirements of misaligned joints. The traveling wheels 25 cooperate with the clamping wheels 24 below to clamp the fall arrestor rail 1 and provide the driving force for climbing along the fall arrestor rail 1. The control module 8 is mounted on the mounting base 21 and is used to collect sensor data and convert upper computer instructions into action codes to control the actuators, thereby enabling the motion platform 2 to move forward, backward, stop, and adjust its speed.

[0088] This invention provides a method for inspecting and repairing tower fall-prevention guide rails based on the above-mentioned tower fall-prevention guide rail inspection and repair device, comprising the following steps:

[0089] The motion platform 2 of the device is installed on the bottom end of the anti-fall guide rail 1 to ensure that the image inspection module 3 is ahead of the motion platform 2 in the forward direction;

[0090] The motion platform 2 is started to drive the device to move upward toward the top of the fall arrest guide rail 1. The image inspection module 3 is started to continuously collect images of the surface of the fall arrest guide rail 1. The image inspection module 3 automatically identifies the defective parts.

[0091] When the image inspection module 3 detects that the area of ​​the defect is greater than or equal to the preset area value, the motion platform 2 drives the rust removal component 4 to align with the defect and then stops moving.

[0092] Rust removal component 4 contacts the surface of anti-fall guide rail 1 to remove rust and polish defective areas;

[0093] The cleaning component 5 is started simultaneously with the rust removal component 4, or the cleaning component 5 is started after the rust removal and grinding are completed to clean up the waste generated by the rust removal and grinding, ensuring that the surface of the defective part to be sprayed on the anti-fall guide rail 1 is clean and dry.

[0094] After the device reaches the top of the fall arrest guide rail 1, it moves downwards towards the bottom of the fall arrest guide rail 1 and activates the spraying component 6 to spray and repair the defective parts to be sprayed.

[0095] It is understandable that, in specific implementation, the inspection and repair work in this embodiment targets the vertically distributed fall arrestor rails 1 at high altitudes. The motion platform 2 of the inspection and repair device needs to move along the fall arrestor rails 1 to be inspected and repaired. The operational stability and movement accuracy of the motion platform 2 directly determine the positioning accuracy of the repair mechanism. Therefore, how to make the motion platform 2 move stably and accurately on the defective fall arrestor rails 1, while ensuring that the inspection and repair work and the operation of the motion platform 2 do not interfere with each other, and ensuring high-efficiency inspection and repair work, is the core technical problem that needs to be solved in this embodiment.

[0096] In this embodiment, during the upward movement of the device, after the image inspection module 3 located at the front of the motion platform 2 detects the defect, the rust removal component 4 and the cleaning component 5 located between the motion platform 2 and the image inspection module 3 perform rust removal, grinding, and cleaning operations. Before the motion platform 2 moves to the defect, any protrusions that may exist at the defect are removed, reducing the risk that the protrusions at the defect will affect the moving accuracy and stability of the motion platform 2. During the downward movement, the spraying component 6 located at the front of the motion platform 2 performs a spraying operation. The coating formed after the spraying repair will not be crushed by the motion platform 2, making the repair operation both efficient and reliable, shortening the repair cycle, eliminating the need for manual repair, and reducing the repair cost of large-scale high-altitude operations.

[0097] In addition, when the rust removal component 4 removes rust and grinds the defective parts, the waste generated by the rust removal and grinding will be scattered in the direction of gravity. The cleaning mechanism located between the rust removal component 4 and the motion platform 2 will clean the waste away from the surface of the anti-fall guide rail 1 in a timely manner, so as to avoid contamination of the anti-rust material when the subsequent spraying component 6 sprays the anti-rust material, and ensure the spraying quality. At the same time, the waste can reduce the impact on the movement accuracy and stability of the motion platform 2 after leaving the track surface.

[0098] This embodiment completes defect identification, rust removal, grinding, and cleaning during the upward movement of the device, and completes the spraying operation during the downward movement, eliminating the need for the device to move back and forth, thus improving work efficiency.

[0099] In a more specific embodiment, spraying repair of the defective areas to be sprayed includes:

[0100] The pressure of the coating is adjusted to the preset pressure value by the pressure controller and delivered to the annular nozzle 61;

[0101] The control module 8 adjusts the flow rate of the nozzle and the moving speed of the motion platform 2 according to the defect area through the flow controller, thereby adjusting the moving speed of the annular nozzle 61 so that the atomized coating accurately and evenly covers the defect area to be sprayed, forming a repair coating of preset thickness.

[0102] Understandably, in practice, the flow rate and moving speed of nozzle 62 are controlled according to the size of the defect area to ensure that the atomized coating accurately and evenly covers the defect area to be sprayed. The specific control method is as follows:

[0103] The defect area (S) is a variable, ranging from pinpoint blemishes to large sheet-like damage. Differences in area directly affect the total paint demand (Qtotal = Q0 × S). The nozzle 62 flow rate (F, unit: mL / s, i.e., the amount of paint sprayed per unit time) and moving speed (V, unit: m / s, i.e., the speed at which the nozzle 62 moves along the defect surface) are two controllable execution parameters. These parameters are linked to the defect area through the "paint output per unit length," and are primarily implemented in two scenarios:

[0104] 1) For small-area defects:

[0105] The total demand for coatings, Q, is too low, requiring adjustments to the dual control mechanism:

[0106] Reduce the flow rate of nozzle 62: Reduce the paint output per unit time to avoid paint accumulation and sagging in small areas;

[0107] Slow down the moving speed: Ensure that the nozzle 62 has enough time to stay in the small defect area, so that the atomized paint can cover evenly and prevent missed spraying and insufficient film thickness caused by excessive speed.

[0108] 2) For large-area defects

[0109] The total demand for coatings, Q, is large, requiring reverse dual-control adjustments:

[0110] Increase the flow rate of nozzle 62: Increase the paint output per unit time to meet the total material requirements of large areas;

[0111] Increase the moving speed: Avoid the nozzle 62 from staying in the same position for too long, prevent the paint from being too thick and dripping in large areas, while ensuring spraying efficiency and maintaining the paint adhesion per unit area at Q0.

[0112] This invention also provides a method for inspecting and repairing tower fall-prevention guide rails based on the above-mentioned tower fall-prevention guide rail inspection and repair device, such as... Figure 5 As shown, it includes the following steps:

[0113] Phase 1: Work Preparation and Equipment Installation

[0114] S01. Device Installation and System Self-Check: Reliably install the device at the starting end of the fall arrestor rail 1 (usually at the bottom of the fall arrestor rail 1). Start the equipment, and the control module 8 will automatically perform a system self-check to confirm that the motion platform 2, image inspection module 3, rust removal component 4, spraying component 6, cleaning component 5, etc. are in normal condition.

[0115] S02. Parameter setting and task assignment: Set the parameters for this operation, such as the travel speed and the defect location judgment threshold (e.g., area > 5%), through the host computer or handheld terminal, and assign the operation task to the control module 8 of the device.

[0116] Phase Two: Upward Inspection and Pre-processing

[0117] S03, Image Acquisition and Intelligent Recognition: The device moves autonomously upwards along the fall arrestor rail 1. The image inspection module 3 continuously acquires high-definition images of the surface of the fall arrestor rail 1 and uses the YOLOv8 algorithm for real-time analysis to automatically identify and frame defects such as rust and coating peeling.

[0118] S04, Defect Location and Data Recording: The control module 8 combines encoder data to record the precise longitudinal position coordinates of each identified defect and generates a preliminary inspection report containing the defect image, size, and location.

[0119] S05 Automatic Rust Removal: When a defect requiring treatment is detected, the device pauses. The telescopic component connecting the link 7 and the motion platform 2 retracts, controlling the link 7 to move closer to the fall arrest guide rail 1, causing the wire brush 41 to descend and contact the surface of the fall arrest guide rail 1. The gas spring 42 is compressed to apply constant pressure to the wire brush, and the drive assembly drives the wire brush 41 to rotate at high speed, performing targeted grinding on the defective area until a metallic luster is revealed (meeting St2 / St3 standards).

[0120] S06. Cleaning and Surface Preparation: After rust removal is completed, the cleaning mechanism (blower or soft brush) is immediately started to thoroughly blow away the oxide scale, rust dust, residue and other waste generated during grinding, ensuring that the surface to be sprayed is clean and dry and meets the coating requirements.

[0121] Phase 3: Downward Spraying Repair

[0122] S05, Spraying Path Planning: After the device reaches the top of the fall arrestor rail 1, it automatically plans the downward path. The control module 8 retrieves the defect location coordinates recorded during the upward movement and converts them into a precise spraying operation point sequence for the downward movement.

[0123] S06. Precision spraying of anti-rust coating: When the device descends to the first work point, spraying component 6 performs spraying repair work, specifically including:

[0124] S061, High-pressure atomization: The high-pressure diaphragm airless sprayer pressurizes the paint to 20MPa and delivers it to the ring spray gun.

[0125] S062, Precise Coverage: The control module 8 adjusts the moving speed and on / off state of the nozzle 62 according to the size of the defect, so that the atomized coating accurately and evenly covers the treated rusted area, forming a repair coating of the specified thickness.

[0126] S07. Online inspection of coating quality: After the coating is completed, the image inspection module 3 can take a second photo of the repaired area and compare it with the original defect image as a preliminary visual record of the coating coverage.

[0127] Phase 4: Assignment Completion and Report Generation

[0128] S08. Data Upload and Report Generation: After the device returns to the starting point, the control module 8 integrates the data from the entire process (inspection images, defect coordinates, rust removal records, and spraying parameters), automatically generates a structured maintenance operation report, and uploads it to the cloud asset management platform via wireless network.

[0129] In a more specific embodiment, machines are used to replace humans in the inspection and rust removal repair of the fall arrestor rail 1, keeping personnel away from high-risk working environments. Through programmed control, it is ensured that every rust removal reaches the standard level, and that the thickness, path, and overlap rate of each spray are precisely consistent, fundamentally solving the safety risks and quality fluctuations associated with manual operations.

[0130] In summary, the embodiments of the present invention have the following advantages:

[0131] (1) This invention is the first to integrate "high-definition visual inspection, positioning rust removal, and automatic spraying" into a single device continuous operation mode, changing "regular general inspection and post-event repair" into "instant inspection and treatment" for precise repair.

[0132] (2) Personnel do not need to climb the tower to carry out high-risk rust removal and spraying operations, which fundamentally eliminates the safety risk of falling from heights. At the same time, mechanized operations ensure that the repair quality is highly consistent and traceable, overcoming the randomness of manual operations.

[0133] (3) Inspection and repair can be completed simultaneously in a single operation, saving the high costs of repeatedly building platforms and entering the site multiple times. In the long run, preventive maintenance avoids the huge cost of replacing the anti-fall guide rail 1 due to rust deterioration, resulting in significant economic benefits.

[0134] (4) The image, rust removal, cleaning, and spraying modules are linearly integrated into the same motion platform according to the work process, resulting in a compact structure. The central control module automatically schedules the sequential start and stop of each mechanism during the upward and downward phases based on encoder positioning, ensuring seamless connection. This enables the completion of all work in a single climb, compressing the discrete operations that require multiple tower climbs and coordination among different trades in the traditional mode into a continuous automated process, increasing efficiency several times over and significantly reducing labor intensity and organizational complexity.

[0135] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A device for inspecting and repairing anti-fall guide rails for iron towers, characterized in that, include: Motion platform, repair mechanism, and image inspection module; The motion platform is used to be movably connected to the fall arrest rail to enable the device to move on the fall arrest rail; The image inspection module is located on the forward side of the motion platform and is used to identify defective parts of the fall-prevention guide rail. The repair mechanism is located between the motion platform and the image inspection module. The repair mechanism includes a rust removal component, a cleaning component, and a spraying component. The cleaning component is disposed between the rust removal component and the motion platform. The rust removal component is used to remove rust and grind the defective area. The cleaning component is used to clean the waste generated during rust removal on the surface of the anti-fall guide rail. The spraying component is used to spray and repair the defective area after rust removal.

2. The tower anti-fall guide rail inspection and repair device according to claim 1, characterized in that, The rust removal assembly is connected to the motion platform via a connecting rod; The rust removal assembly includes a wire roller brush and a U-shaped component. The closed end of the U-shaped component is connected to the connecting rod, and the open end of the U-shaped component is rotatably connected to the center of both ends of the wire roller brush. The connecting rod is telescopically connected to the motion platform, which is used to move the wire brush closer to or away from the anti-fall guide rail.

3. The tower anti-fall guide rail inspection and repair device according to claim 2, characterized in that, The closed end of the U-shaped component is connected to the connecting rod via a gas spring.

4. The tower anti-fall guide rail inspection and repair device according to claim 3, characterized in that, The cleaning assembly includes a blower, which is used to promptly blow away the waste generated by the friction between the wire brush and the defective area from the surface of the anti-fall guide rail.

5. The tower anti-fall guide rail inspection and repair device according to claim 3 or 4, characterized in that, The cleaning assembly includes a soft-bristled roller brush, which is used to sweep off the waste material adhering to the surface of the anti-fall guide rail after the rust removal assembly stops operating.

6. The tower anti-fall guide rail inspection and repair device according to claim 1, characterized in that, The spraying assembly includes an annular spray pipe and multiple nozzles. The multiple nozzles are evenly distributed on the annular spray pipe to achieve multiple nozzles surrounding the surface of the fall arresting guide rail, so that a repair coating with uniform thickness and sufficient coverage of defective areas is formed on the surface of the fall arresting guide rail after spraying.

7. The tower anti-fall guide rail inspection and repair device according to claim 6, characterized in that, The spraying assembly includes a pressure controller and a flow controller. The input end of the annular nozzle is connected to the pressure controller, and the input end of the annular nozzle is equipped with the flow controller for atomizing spraying.

8. The tower anti-fall guide rail inspection and repair device according to claim 1, characterized in that, The system includes a control module, which is connected to the motion platform, the image inspection module, the rust removal component, the cleaning component, and the spraying component. The image inspection module is used to identify the defective parts of the fall-prevention guide rail and then send the defect information to the control module. The control module records the defect location based on the defect information. The control module is used to control the movement of the motion platform based on the defect location record, so that the rust removal component, spraying component or cleaning component can be aligned with the defect location and the corresponding component can be controlled to start operation.

9. A method for inspecting and repairing anti-fall guide rails of iron towers based on the device described in any one of claims 1-8, characterized in that, Includes the following steps: The motion platform of the device is installed on the bottom end of the anti-fall guide rail, ensuring that the image inspection module is ahead of the motion platform in the forward direction; The motion platform is activated to move the device upwards toward the top of the fall arresting rail. The image inspection module is activated to continuously collect images of the surface of the fall arresting rail, and the image inspection module automatically identifies defective parts. When the image inspection module detects that the area of ​​the defect is greater than or equal to a preset area value, the motion platform drives the rust removal component to align with the defect and then stops moving. The rust removal component contacts the surface of the anti-fall guide rail to remove rust and polish the defective area. The cleaning component is started synchronously with the rust removal component, or the cleaning component is started after the rust removal and grinding are completed, to clean up the waste generated by the rust removal and grinding, and to ensure that the surface of the defective part to be sprayed on the anti-fall guide rail is clean and dry. After the device reaches the top of the fall arresting guide rail, it moves downwards towards the bottom of the fall arresting guide rail and activates the spraying assembly to spray and repair the defective parts to be sprayed.

10. The method for inspecting and repairing anti-fall guide rails of iron towers according to claim 9, characterized in that, The process of spraying and repairing the defective areas to be sprayed includes: The pressure of the coating is adjusted to the preset pressure value by a pressure controller and then delivered to the annular nozzle. The control module adjusts the flow rate of the nozzle and the moving speed of the motion platform according to the defect area through the flow controller, thereby adjusting the moving speed of the annular nozzle so that the atomized coating accurately and evenly covers the defect area to be sprayed, forming a repair coating of a preset thickness.

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