A wall-climbing robot for weld seam detection

Abstract

The present invention discloses a wall-climbing robot for weld detection, which includes a top plate, a flaw detection mechanism, a magnetic wheel mechanism, a sensor assembly, a liquid supply mechanism, a gravity feedback mechanism, and a controller. An industrial camera in the sensor assembly detects the weld. The controller drives the rotation of four groups of magnetic wheel mechanisms for weld tracking according to the weld detection result. The gravity feedback mechanism drives the water pump in the liquid supply mechanism to continuously spray magnetic suspension liquid on the weld to be detected according to the gravity detection result. The first servo motor in the flaw detection mechanism drives the magnetic particle flaw detector to move downwards to continuously detect the weld to be detected. The device has a simple structure. Through four independent groups of magnetic wheel mechanisms, it can adapt to different container wall surfaces. At the same time, through gravity detection, continuous liquid supply of the liquid supply mechanism is realized, improving the efficiency, accuracy and reliability of weld detection.

Description

Technical Field

[0001] The present invention relates to a mechanical device, and more particularly to a wall-climbing robot for weld detection. Background Art

[0002] With the continuous development and progress of technology, robots are more commonly used in the industrial field, enabling robots to replace humans in industrial production for some labor-intensive and dangerous tasks. For various large pressure vessels operating under corrosive, low-temperature, high-temperature or high-pressure conditions for a long time, in order to ensure their safe and effective normal operation, it is necessary to regularly conduct safety inspections on the container welds. Traditional inspection methods often require a large number of scaffolds to be erected on the inner and outer walls of the container, and then manual inspection equipment is carried by humans to detect the welds. Traditional inspection methods have a long construction period, low inspection efficiency, certain dangers, and high requirements for the professional level of workers. Using a wall-climbing robot to replace humans to detect welds can greatly improve the inspection efficiency of weld flaw detection. In view of the above defects, it is necessary to design a wall-climbing robot for weld detection. Summary of the Invention

[0003] The purpose of the present invention is to provide a wall-climbing robot for weld detection. The wall-climbing robot for weld detection is driven by four independent magnetic wheels, can adapt to different container wall surfaces, and at the same time, through gravity detection, realizes the continuous liquid supply of the liquid supply mechanism, improving the efficiency, accuracy and reliability of weld detection.

[0004] To solve the above technical problems, the technical solution of the present invention is: a wall-climbing robot for weld detection, including a top plate, a flaw detection mechanism, a magnetic wheel mechanism, a sensor assembly, a liquid supply mechanism, a gravity feedback mechanism, and a controller. The flaw detection mechanism is located at the center of the top plate and is connected to the top plate by bolts. The magnetic wheel mechanism is located at the lower end of the top plate and is connected to the top plate by bolts. The number of the magnetic wheel mechanisms is 4, and they are symmetrically arranged along the front-back direction and the left-right direction of the top plate. The sensor assembly is located at the lower end of the flaw detection mechanism and is connected to the flaw detection mechanism by bolts. The liquid supply mechanism is located outside the top plate and is connected to the top plate by bolts. The gravity feedback mechanism is located at the lower end of the top plate and is connected to the top plate by bolts. The controller is fixed to the upper end of the top plate.

[0005] The further improvement of the present invention is as follows:

[0006] Further, the flaw detection mechanism further includes two first servo motors, a ball screw, a feed nut, a floating clamping plate mechanism, and a magnetic particle flaw detector. The two first servo motors are symmetrically arranged at the upper end of the top plate. The ball screw is located below the first servo motors and penetrates through the top plate. The ball screw is connected to the first servo motors by bolts. The feed nut is penetrated by the ball screw and is threadedly connected to the ball screw. The floating clamping plate mechanism is located below the feed nut and is threadedly connected to the feed nut. The magnetic particle flaw detector penetrates through the floating clamping plate mechanism.

[0007] Further, the floating clamping plate mechanism further includes a floating plate, fixed pins, an upper clamping plate, a lower clamping plate, an upper spring, and a lower spring. The floating plate is located below the feed nut and is connected to the feed nut by bolts. There are four fixed pins, which are symmetrically arranged along the floating plate. The floating plate slides up and down along the fixed pins. The upper clamping plate is located at the upper end of the fixed pins and is connected to the fixed pins by interference fit. The lower clamping plate is located at the lower end of the fixed pins and is connected to the fixed pins by clearance fit. The lower clamping plate is connected to the upper clamping plate by bolts. The upper spring is located outside the fixed pins and between the floating plate and the upper clamping plate. The lower spring is located outside the fixed pins and between the floating plate and the lower clamping plate. The two symmetrically arranged first servo motors drive the ball screw to rotate, thereby driving the floating clamping plate mechanism fixed to the feed nut to move downward. The magnetic particle flaw detector clamped by the upper clamping plate and the lower clamping plate then moves downward. After the magnetic particle flaw detector contacts the container wall surface, the first servo motors continue to work, causing the floating plate to move downward along the fixed pins, the upper spring to reset and the lower spring to be compressed, thereby pressing the magnetic particle flaw detector against the container wall surface to achieve flexible fixation. When there are pits or foreign object protrusions on the container surface, the lower spring and the upper spring work together to enable the floating clamping plate mechanism to elastically float up and down, thereby ensuring the stability of weld detection.

[0008] Further, the magnetic wheel mechanism further includes a deflection mechanism, a second servo motor, a flange, a first annular yoke, a permanent magnet, a second annular yoke, a magnetic wheel restraint, connecting bolts, auxiliary support columns, and an elastic mechanism. The deflection mechanism is located at the lower end of the top plate, and the deflection mechanism is connected to the top plate by bolts. The second servo motor is located on the right side of the deflection mechanism, and the second servo motor is connected to the deflection mechanism by bolts. The flange is located on the left side of the deflection mechanism and on the left side of the second servo motor, and the flange is connected to the second servo motor by bolts. The first annular yoke, the permanent magnet, the second annular yoke, and the magnetic wheel restraint are arranged in sequence from right to left along the axis of the flange. The connecting bolts sequentially penetrate through the magnetic wheel restraint, the second annular yoke, the permanent magnet, the first annular yoke, and the flange from left to right, and the connecting bolts are threadedly connected to the flange. The auxiliary support columns are located at the lower end of the top plate, and the auxiliary support columns are connected to the top plate by bolts. The elastic mechanism is located at the lower end of the auxiliary support columns, and the elastic mechanism is connected to the auxiliary support columns and the second servo motor by bolts respectively. The permanent magnet is magnetized along the thickness direction. The materials of the first annular yoke and the second annular yoke are pure electrical iron, and the material of the permanent magnet is neodymium iron boron permanent magnet. When the permanent magnet is magnetized along the thickness direction, the first annular yoke, the permanent magnet, and the second annular yoke form a complete magnetic circuit unit. Most of the magnetic force lines constrained by the first annular yoke and the second annular yoke pass through the wall of the container and return to the permanent magnet, and only a few magnetic force lines escape. The magnetic induction intensity of the container wall directly below the permanent magnet is significantly higher than the magnetic induction intensity inside the first annular yoke, the permanent magnet, and the second annular yoke, thus ensuring the maximum utilization rate of magnetic energy. When the adsorption force generated by a single magnetic circuit unit cannot meet the load requirements, an array structure is formed by expanding the magnetic circuit unit to increase the adsorption force, so as to cope with different working conditions. Both the magnetic wheel restraint and the flange are made of aluminum alloy material and have a magnetic isolation effect. On the one hand, it can prevent ferromagnetic objects from being directly adsorbed to the side of the magnetic wheel and being difficult to remove. On the other hand, it can further reduce the escape of magnetic force lines and improve the adsorption force. The shapes of the magnetic wheel restraint and the flange are frustum-shaped, and the bottom diameter is not greater than the diameters of the first annular yoke and the second annular yoke, which can ensure to the greatest extent that the magnetic circuit unit composed of the first annular yoke, the permanent magnet, and the second annular yoke avoids contact with the container and improves the adsorption force.

[0009] Further, the deflection mechanism further includes a U-shaped bracket, rotating screws, and a motor front cover. The U-shaped bracket is located at the lower end of the top plate, and the U-shaped bracket is connected to the top plate by bolts. The number of rotating screws is 2, which are symmetrically arranged at the lower end of the U-shaped bracket. The rotating screws are connected to the U-shaped bracket with a clearance fit. The motor front cover is located inside the U-shaped bracket and on the left side of the second servo motor. The motor front cover is threadedly connected to the rotating screws and is connected to the second servo motor by bolts.

[0010] Furthermore, the elastic mechanism further includes a left fixing block, a right fixing block, a guide rod, a guide sleeve, and a first spring. The left fixing block is located at the lower end of the auxiliary support column, and the left fixing block is connected to the auxiliary support column by bolts. The right fixing block is located at the lower end of the second servo motor, and the right fixing block is connected to the second servo motor by bolts. The guide rod is located on the right side of the left fixing block, and the guide rod is threadedly connected to the left fixing block. The guide sleeve is located on the left side of the right fixing block and outside the guide rod. The guide sleeve is integrally connected to the right fixing block and is in clearance fit with the guide rod. The first spring is sleeved outside the guide sleeve and the guide rod. When the magnetic wheel mechanism walks on the arc-shaped container wall surface, the permanent magnet generates a magnetic force with the container wall surface. The permanent magnet is deflected along the rotating screw under the force, and the first spring resets. The guide rod slides along the guide sleeve to compensate for the small displacement when the permanent magnet is deflected along the rotating screw, so that the permanent magnet is fully attached to the container wall surface. The second servo motor drives the flange to rotate, thereby driving the magnetic circuit unit composed of the first annular yoke, the permanent magnet, and the second annular yoke to rotate, realizing reliable and stable walking. When the permanent magnet encounters unevenness such as protrusions and welding slag, the first spring can play a damping role to achieve shock absorption and buffering, and improve the stability of walking.

[0011] Furthermore, the sensor assembly further includes a cross plate, a spray head, and an industrial camera. The cross plate is located at the lower end of the lower clamping plate, and the cross plate is connected to the lower clamping plate by bolts. The number of spray heads is 2, which are installed on the right side of the cross plate. The spray heads are fan-shaped spray heads. The spray heads are connected to the liquid supply mechanism through hoses. The industrial camera is installed in the middle of the cross plate. The industrial camera collects weld data and transmits the data to the controller through a local area network or. The controller processes the extracted weld data to generate path correction data. The controller controls the rotation speeds of the four second servo motors according to the obtained control data, so as to achieve the effect of weld tracking and realize the automation of the detection work. Subsequently, the cross plate moves down with the lower clamping plate, driving the spray heads to move down. The two fan-shaped spray heads are aligned with the weld. The front fan-shaped spray head is used for pre-spraying, and the rear fan-shaped spray head is used for inspection. By reducing the distance between the spray heads and the weld and adopting the design of fan-shaped spray heads, it is ensured that the weld can be attached with magnetic suspension liquid, thereby improving the accuracy of inspection.

[0012] Furthermore, the liquid supply mechanism further includes a connecting plate, a water tank, a liquid supply head, a liquid inlet head, and a water pump. The connecting plate is located outside the top plate, and the connecting plate is connected to the top plate by bolts. The water tank is located at the lower end of the connecting plate, and the water tank is connected to the connecting plate by bolts. The number of the liquid supply heads is 2, which are symmetrically arranged along the left-right direction of the water tank. The liquid inlet head is located at the center of the top of the water tank, and the liquid inlet head is threadedly connected to the water tank. The number of the water pumps is 2, which are symmetrically arranged along the left-right direction of the connecting plate. The water inlet of the water pump is connected to the liquid supply head by a hose, and the water outlets of the water pump are respectively connected to the liquid inlet head and the nozzle by hoses.

[0013] Furthermore, the liquid supply head further includes a straight-through head, a silica gel tube, and a spherical countersunk head. The straight-through head is located outside the water tank, and the straight-through head is threadedly connected to the water tank and connected to the water inlet of the water pump by a hose. The silica gel tube is sleeved on the lower end of the straight-through head and extends into the inner side of the water tank. The spherical countersunk head is sleeved on the lower end of the silica gel tube and extends into the inner side of the water tank. A liquid inlet hole is opened at the lower end of the spherical countersunk head, and the liquid inlet hole communicates with the cavity of the silica gel tube.

[0014] Furthermore, the gravity feedback mechanism further includes an L-shaped bracket, a ranging sensor, a sliding rod, a slider, and a second spring. The number of the L-shaped brackets is 2, which are symmetrically arranged along the left-right direction at the lower end of the top plate. The ranging sensor is installed at the upper end of the L-shaped bracket, and the ranging sensor is connected to the L-shaped bracket by bolts. The sliding rod is located between the two symmetrically arranged L-shaped brackets, and the sliding rod is connected to the L-shaped bracket by bolts. The slider is penetrated by the sliding rod, and the slider slides along the left-right direction of the sliding rod. The number of the second springs is 2, which are symmetrically arranged along the left-right direction outside the sliding rod. The two ends of the second spring are respectively in contact with the slider and the L-shaped bracket. When the gravity feedback mechanism is not triggered, the two water pumps are in a one-use-one-backup form. After one of the water pumps is powered on, the magnetic suspension liquid is extracted from the liquid supply head. After being split by a tee, a part of the magnetic suspension liquid enters the liquid inlet head and flows into the water tank for turbulent flow stirring and circulation, and the other part of the magnetic suspension liquid enters the two sector nozzles for spraying the weld. The spherical countersunk head can roll along the wall of the water tank, so as to ensure that the magnetic suspension liquid can enter the water pump through the liquid inlet hole, the silica gel tube, and the straight-through head in sequence, realizing reliable and uniform liquid supply. When the water tank is in a vertical state, the slider slides along the sliding rod under the action of gravity. When the ranging sensor detects that the slider is at the trigger distance, the water pump on the same side as the triggered ranging sensor works, and the other water pump stops working, so as to avoid the air suction of the water pump, ensure the continuous spraying of the magnetic suspension liquid, and improve the detection accuracy.

[0015] Compared with the prior art, when the weld detection wall-climbing robot works, the industrial camera in the sensor assembly detects the weld. According to the weld detection result, the controller drives the four groups of magnetic wheel mechanisms to rotate for weld tracking. The gravity feedback mechanism drives the water pump in the liquid supply mechanism to continuously spray the magnetic suspension liquid on the weld to be detected according to the gravity detection result. The first servo motor in the flaw detection mechanism drives the magnetic particle flaw detector to move down to continuously detect the weld to be detected. The device has a simple structure. Through the independent four groups of magnetic wheel mechanisms, it can adapt to different container wall surfaces. At the same time, through gravity detection, the continuous liquid supply of the liquid supply mechanism is realized, improving the efficiency, accuracy and reliability of weld detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Showing the three-dimensional view of the present invention

[0017] Figure 2 Showing the three-dimensional view of the flaw detection mechanism of the present invention

[0018] Figure 3 Showing the three-dimensional view of the floating splint mechanism of the present invention

[0019] Figure 4 Showing the three-dimensional view of the magnetic wheel mechanism of the present invention

[0020] Figure 5 Showing the three-dimensional view of the deflection mechanism of the present invention

[0021] Figure 6 Showing the three-dimensional view of the elastic mechanism of the present invention

[0022] Figure 7 Showing the three-dimensional view of the sensor assembly of the present invention

[0023] Figure 8 Showing the three-dimensional view of the liquid supply mechanism of the present invention

[0024] Figure 9 Showing the schematic structural diagram of the liquid supply head of the present invention

[0025] Figure 10 Showing the schematic structural diagram of the gravity feedback mechanism of the present invention

[0026] In the figure: top plate 1, flaw detection mechanism 2, magnetic wheel mechanism 3, sensor assembly 4, liquid supply mechanism 5, gravity feedback mechanism 6, controller 7, first servo motor 201, ball screw 202, feed nut 203, floating clamping plate mechanism 204, magnetic particle flaw detector 205, floating plate 206, fixing pin 207, upper clamping plate 208, lower clamping plate 209, upper spring 210, lower spring 211, deflection mechanism 301, second servo motor 302, flange 303, first annular yoke 304, permanent magnet 305, second annular yoke 306, magnetic wheel restraint 307, connecting bolt 308, auxiliary support column 309, elastic mechanism 310, U-shaped bracket 311, rotating screw 312, motor front cover 313, left fixing block 314, right fixing block 315, guide rod 316, guide sleeve 317, first spring 318, cross plate 401, nozzle 402, industrial camera 403, connecting plate 501, water tank 502, liquid supply head 503, liquid inlet head 504, water pump 505, straight-through head 506, silicone tube 507, spherical countersunk head 508, liquid inlet hole 509, L-shaped bracket 601, distance measuring sensor 602, slide rod 603, slider 604, second spring 605. Detailed implementation manner

[0027] As Figure 1 shown, a weld detection wall-climbing robot includes a top plate 1, a flaw detection mechanism 2, a magnetic wheel mechanism 3, a sensor assembly 4, a liquid supply mechanism 5, a gravity feedback mechanism 6, and a controller 7. The flaw detection mechanism 2 is located at the center of the top plate 1 and is connected to the top plate 1 by bolts. The magnetic wheel mechanism 3 is located at the lower end of the top plate 1 and is connected to the top plate 1 by bolts. The number of the magnetic wheel mechanisms 3 is 4, and they are symmetrically arranged along the front-back direction and the left-right direction of the top plate 1. The sensor assembly 4 is located at the lower end of the flaw detection mechanism 2 and is connected to the flaw detection mechanism 2 by bolts. The liquid supply mechanism 5 is located outside the top plate 1 and is connected to the top plate 1 by bolts. The gravity feedback mechanism 6 is located at the lower end of the top plate 1 and is connected to the top plate 1 by bolts. The controller 7 is fixed to the upper end of the top plate 1.

[0028] As Figure 2 、 Figure 3As shown in the figure, the flaw detection mechanism further includes a first servo motor 201, a ball screw 202, a feed nut 203, a floating clamping plate mechanism 204, and a magnetic particle flaw detector 205. There are 2 first servo motors 201, which are symmetrically arranged at the upper end of the top plate 1. The ball screw 202 is located at the lower end of the first servo motor 201 and penetrates the top plate. The ball screw 202 is connected to the first servo motor 201 by bolts. The feed nut 203 is penetrated by the ball screw 202, and the feed nut 203 is threadedly connected to the ball screw 202. The floating clamping plate mechanism 204 is located at the lower end of the feed nut 203, and the floating clamping plate mechanism 204 is threadedly connected to the feed nut 203. The magnetic particle flaw detector 205 penetrates the floating clamping plate mechanism 204. The floating clamping plate mechanism 205 further includes a floating plate 206, a fixing pin 207, an upper clamping plate 208, a lower clamping plate 209, an upper spring 210, and a lower spring 211. The floating plate 206 is located at the lower end of the feed nut 203, and the floating plate 206 is connected to the feed nut 203 by bolts. There are 4 fixing pins 207, which are symmetrically arranged along the floating plate 206. The floating plate 206 slides up and down along the fixing pins 207. The upper clamping plate 208 is located at the upper end of the fixing pins 207, and the upper clamping plate 208 is connected to the fixing pins 207 by interference fit. The lower clamping plate 209 is located at the lower end of the fixing pins 207, and the lower clamping plate 209 is connected to the fixing pins 207 by clearance fit. The lower clamping plate 209 is connected to the upper clamping plate 208 by bolts. The upper clamping plate 208 is fixedly connected to the fixing pins 207, while the lower clamping plate 209 is connected to the fixing pins 207 by clearance fit, which facilitates the rapid installation of the magnetic particle flaw detector 205. The upper spring 210 is located outside the fixing pins 207 and between the floating plate 206 and the upper clamping plate 208. The lower spring 211 is located outside the fixing pins 207 and between the floating plate 206 and the lower clamping plate 209. The two symmetrically arranged first servo motors 201 drive the ball screw 202 to rotate, thereby driving the floating clamping plate mechanism 204 connected to the feed nut 203 to move downward. The magnetic particle flaw detector 205 clamped by the upper clamping plate 208 and the lower clamping plate 209 then moves downward. After the magnetic particle flaw detector 205 contacts the container wall surface, the first servo motor 201 continues to work, causing the floating plate 206 to move downward along the fixing pins 207. The upper spring 210 is reset and the lower spring 211 is compressed, thereby pressing the magnetic particle flaw detector 205 against the container wall surface to achieve flexible fixation. When there are pits or foreign object protrusions on the container surface, the lower spring 211 and the upper spring 210 work together, enabling the floating clamping plate mechanism 204 to elastically float up and down, thereby ensuring the stability of weld detection.

[0029] As Figure 4 , Figure 5 , Figure 6As shown, the magnetic wheel mechanism 3 further includes a deflection mechanism 301, a second servo motor 302, a flange 303, a first annular yoke 304, a permanent magnet 305, a second annular yoke 306, a magnetic wheel restraint 307, a connecting bolt 308, an auxiliary support column 309, and an elastic mechanism 310. The deflection mechanism 301 is located at the lower end of the top plate 1, and the deflection mechanism 301 is connected to the top plate 1 by bolts. The second servo motor 302 is located on the right side of the deflection mechanism 301, and the second servo motor 302 is connected to the deflection mechanism 301 by bolts. The flange 303 is located on the left side of the deflection mechanism 301 and on the left side of the second servo motor 302. The flange 303 is connected to the second servo motor 302 by bolts. The first annular yoke 304, the permanent magnet 305, the second annular yoke 306, and the magnetic wheel restraint 307 are arranged in sequence from right to left along the axis of the flange 303. The connecting bolt 308 sequentially passes through the magnetic wheel restraint 307, the second annular yoke 306, the permanent magnet 305, the first annular yoke 304, and the flange 303 from left to right. The connecting bolt 308 is threadedly connected to the flange 303. The auxiliary support column 309 is located at the lower end of the top plate 1, and the auxiliary support column 309 is connected to the top plate 1 by bolts. The elastic mechanism 310 is located at the lower end of the auxiliary support column 309, and the elastic mechanism 310 is respectively connected to the auxiliary support column 309 and the second servo motor 302 by bolts. The permanent magnet 305 is magnetized along the thickness direction. The materials of the first annular yoke 304 and the second annular yoke 306 are electrolytic iron. The material of the permanent magnet 305 is neodymium iron boron permanent magnet. The materials of the first annular yoke 304 and the second annular yoke 306 are electrolytic iron. After the permanent magnet 305 is magnetized along the thickness direction, the first annular yoke 304, the permanent magnet 305, and the second annular yoke 306 form a complete magnetic circuit unit. Most of the magnetic force lines constrained by the first annular yoke 304 and the second annular yoke 306 pass through the wall of the container and return to the permanent magnet 305, and only a few magnetic force lines escape. The magnetic induction intensity of the container wall surface directly below the permanent magnet 305 is significantly higher than the magnetic induction intensity inside the first annular yoke 304, the permanent magnet 305, and the second annular yoke 306, thereby ensuring the maximum utilization rate of magnetic energy. When the adsorption force generated by a single magnetic circuit unit cannot meet the load requirements, an array structure is formed by expanding the magnetic circuit unit to increase the adsorption force, so as to cope with different working conditions. Both the magnetic wheel restraint 307 and the flange 303 are made of aluminum alloy material,It has a magnetic isolation effect. On the one hand, it can prevent ferromagnetic objects from being directly adsorbed to the side of the magnetic wheel and being difficult to remove. On the other hand, it can further reduce the escape of magnetic force lines and improve the adsorption force. The shapes of the magnetic wheel restraint 307 and the flange 303 are frustum-shaped, and the bottom diameter is not greater than the diameters of the first annular yoke 304 and the second annular yoke 306, which can ensure to the greatest extent that the magnetic circuit unit composed of the first annular yoke 304, the permanent magnet 305, and the second annular yoke 306 avoids contact with the container and improves the adsorption force. The deflection mechanism 301 further includes a U-shaped bracket 311, a rotating screw 312, and a motor front cover 313. The U-shaped bracket 311 is located at the lower end of the top plate 1, and the U-shaped bracket 311 is connected to the top plate by bolts. The number of the rotating screws 312 is 2, which are symmetrically arranged at the lower end of the U-shaped bracket 311. The rotating screw 312 is connected to the U-shaped bracket 311 with a clearance fit. The motor front cover 313 is located inside the U-shaped bracket 311 and on the left side of the second servo motor 302. The motor front cover 313 is threadedly connected to the rotating screw 312 and is connected to the second servo motor 302 by bolts. The elastic mechanism 310 further includes a left fixing block 314, a right fixing block 315, a guide rod 316, a guide sleeve 317, and a first spring 318. The left fixing block 314 is located at the lower end of the auxiliary support column 309, and the left fixing block 314 is connected to the auxiliary support column 309 by bolts. The right fixing block 315 is located at the lower end of the second servo motor 302, and the right fixing block 315 is connected to the second servo motor 302 by bolts. The guide rod 316 is located on the right side of the left fixing block 314, and the guide rod 316 is threadedly connected to the left fixing block 314. The guide sleeve 317 is located on the left side of the right fixing block 315 and outside the guide rod 316. The guide sleeve 317 is integrally connected to the right fixing block 315 and is connected to the guide rod 316 with a clearance fit. The first spring 318 is sleeved outside the guide sleeve 317 and the guide rod 316. When the magnetic wheel mechanism 3 walks on the arc-shaped container wall surface, the permanent magnet 305 generates a magnetic force with the container wall surface. The permanent magnet 305 is deflected along the rotating screw 312 under the force, the first spring 318 resets, and the guide rod 316 slides along the guide sleeve 317 to compensate for the small displacement when the permanent magnet 305 is deflected along the rotating screw 312, so that the permanent magnet 305 is fully attached to the container wall surface. The second servo motor 302 drives the flange 303 to rotate, thereby driving the magnetic circuit unit composed of the first annular yoke 304, the permanent magnet 305, and the second annular yoke 306 to rotate, realizing reliable and stable walking. When the permanent magnet 305 encounters unevenness such as protrusions and welding slag, the first spring 318 can play a damping role to achieve shock absorption and buffering and improve the stability of walking.,

[0030] Such as Figure 7As shown, the sensor assembly further includes a horizontal plate 401, a spray head 402, and an industrial camera 403. The horizontal plate 401 is located at the lower end of the lower clamping plate 209, and the horizontal plate 401 is connected to the lower clamping plate 209 by bolts. The number of the spray heads 402 is two, and they are installed on the right side of the horizontal plate 401. The spray heads 402 are fan-shaped spray heads. The spray heads 402 are connected to the liquid supply mechanism 5 through hoses. The industrial camera 403 is installed in the middle of the horizontal plate 401. The industrial camera 403 collects weld data and transmits the data to the controller 7 through a local area network. The controller 7 processes the extracted weld data to generate path correction data. The controller controls the rotation speeds of the four second servo motors 302 according to the obtained control data, so as to achieve the effect of weld tracking and realize the automation of the detection work. Subsequently, as the lower clamping plate 208 moves downward, the horizontal plate 401 drives the spray head 402 to move downward. The two fan-shaped spray heads 402 are aligned with the weld. The front fan-shaped spray head 402 is used for pre-spraying, and the rear fan-shaped spray head 402 is used for inspection. By reducing the distance between the spray head 402 and the weld and adopting the design of two fan-shaped spray heads, it is ensured that the weld can adhere to the magnetic suspension liquid, thereby improving the accuracy of inspection.

[0031] As Figure 8 , Figure 9 , Figure 10As shown in the figure, the liquid supply mechanism further includes a connecting plate 501, a water tank 502, a liquid supply head 503, a liquid inlet head 504, and a water pump 505. The connecting plate 501 is located outside the top plate 1, and the connecting plate 501 is connected to the top plate 1 by bolts. The water tank 502 is located at the lower end of the connecting plate 501, and the water tank 502 is connected to the connecting plate 501 by bolts. The number of the liquid supply heads 503 is two, which are symmetrically arranged along the left-right direction of the water tank 502. The liquid inlet head 504 is located at the center of the top of the water tank 502, and the liquid inlet head 504 is threadedly connected to the water tank 502. The number of the water pumps 505 is two, which are symmetrically arranged along the left-right direction of the connecting plate 501. The water inlet of the water pump 505 is connected to the liquid supply head 503 by a hose. The water outlets of the water pump 505 are respectively connected to the liquid inlet head 504 and the spray head 402 by hoses. The liquid supply head 503 further includes a straight-through head 506, a silica gel tube 507, and a spherical countersunk head 508. The straight-through head 506 is located outside the water tank 502, and the straight-through head 506 is threadedly connected to the water tank 502 and is connected to the water inlet of the water pump 505 by a hose. The silica gel tube 507 is sleeved at the lower end of the straight-through head 506 and extends into the inner side of the water tank 502. The spherical countersunk head 508 is sleeved at the lower end of the silica gel tube 507 and extends into the inner side of the water tank 502. A liquid inlet hole 509 is opened at the lower end of the spherical countersunk head 508, and the liquid inlet hole 509 communicates with the cavity of the silica gel tube 507. The gravity feedback mechanism 6 further includes an L-shaped bracket 601, a ranging sensor 602, a sliding rod 603, a slider 604, and a second spring 605. The number of the L-shaped brackets 601 is two, which are symmetrically arranged along the left-right direction at the lower end of the top plate 1. The ranging sensor 602 is installed at the upper end of the L-shaped bracket 601, and the ranging sensor 602 is connected to the L-shaped bracket 601 by bolts. The sliding rod 603 is located between the two symmetrically arranged L-shaped brackets 601, and the sliding rod 603 is connected to the L-shaped bracket 601 by bolts. The slider 604 is penetrated by the sliding rod 603, and the slider 604 slides along the left-right direction of the sliding rod 603. The number of the second springs 605 is two, which are symmetrically arranged along the left-right direction outside the sliding rod 603. The two ends of the second spring 605 are respectively in contact with the slider 604 and the L-shaped bracket 601. When the gravity feedback mechanism 6 is not triggered, the two water pumps 502 are in a one-use-one-spare form. After one of the water pumps 502 is powered on, the magnetic suspension liquid is extracted from the liquid supply head 503. After being split by a tee, a part of the magnetic suspension liquid enters the liquid inlet head 504 and flows into the water tank 502 for turbulent flow stirring and circulation, and the other part of the magnetic suspension liquid enters the two sector-shaped spray heads 402 for spraying the weld. The spherical countersunk head 508 can roll along the wall surface of the water tank 502, so as to ensure that the magnetic suspension liquid can enter the water pump 505 through the liquid inlet hole 509, the silica gel tube 507, and the straight-through head 506 in sequence, realizing reliable and uniform liquid supply. When the water tank 502 is in a vertical state, the slider 604 slides along the sliding rod 603 under the action of gravity,When the distance measuring sensor 602 detects that the slider 604 is at the trigger distance, the water pump 502 on the same side as the triggered distance measuring sensor 602 operates, while the other water pump 502 stops operating, thereby avoiding the air suction of the water pump 502, ensuring the continuous spraying of the magnetic suspension liquid, and improving the detection accuracy.

[0032] During the operation of the weld detection wall-climbing robot, the industrial camera 402 in the sensor assembly 4 detects the weld. The controller 7 drives the four groups of magnetic wheel mechanisms 3 to rotate according to the weld detection result, so that the industrial camera 403 is aligned with the weld. The gravity feedback mechanism 6 drives the water pump 502 in the liquid supply mechanism 5 to continuously spray the magnetic suspension liquid on the weld to be detected according to the gravity detection result. The first servo motor 201 in the flaw detection mechanism 2 drives the magnetic particle flaw detector 205 to move down to continuously detect the weld to be detected. The device has a simple structure. Through the independent four groups of magnetic wheel mechanisms, it can adapt to different container wall surfaces. At the same time, through gravity detection, the continuous liquid supply of the liquid supply mechanism is realized, improving the efficiency, accuracy and reliability of weld detection.

[0033] The present invention is not limited to the above specific embodiments. Various changes made by those of ordinary skill in the art starting from the above concepts without creative labor fall within the protection scope of the present invention.

Claims

1. A wall-climbing robot for weld inspection, characterized in that It includes a top plate, a flaw detection mechanism, a magnetic wheel mechanism, a sensor assembly, a liquid supply mechanism, a gravity feedback mechanism, and a controller. The flaw detection mechanism is fixed to the center of the top plate by bolts. The magnetic wheel mechanism is fixed to the lower end of the top plate by bolts. The number of magnetic wheel mechanisms is 4, and they are symmetrically arranged along the front-back and left-right directions of the top plate. The sensor assembly is fixed to the lower end of the flaw detection mechanism by bolts. The liquid supply mechanism is fixed to the outside of the top plate by bolts. The gravity feedback mechanism is fixed to the lower end of the top plate by bolts. The controller is fixed to the upper end of the top plate. The magnetic wheel mechanism includes a deflection mechanism, a second servo motor, a flange, a first annular yoke, a permanent magnet, a second annular yoke, a magnetic wheel restraint, a connecting bolt, an auxiliary support column, and an elastic mechanism. The deflection mechanism is fixed to the lower end of the top plate by bolts. The second servo motor is fixed to the right side of the deflection mechanism by bolts. The flange is located on the left side of the deflection mechanism and on the left side of the second servo motor. The flange is connected to the second servo motor by bolts. The first annular yoke, the permanent magnet, the second annular yoke, and the magnetic wheel restraint are arranged in sequence from right to left along the axis of the flange. The connecting bolt sequentially penetrates the magnetic wheel restraint, the second annular yoke, the permanent magnet, the first annular yoke, and the flange from left to right, and the connecting bolt is threadedly connected to the flange. The auxiliary support column is fixed to the lower end of the top plate by bolts. The elastic mechanism is located at the lower end of the auxiliary support column. The elastic mechanism is connected to the auxiliary support column and the second servo motor by bolts respectively. The permanent magnet is magnetized along the thickness direction. The materials of the first annular yoke and the second annular yoke are pure electrical iron. The deflection mechanism further includes a U-shaped bracket, a rotating screw, and a motor front cover. The U-shaped bracket is fixed to the lower end of the top plate by bolts. The number of rotating screws is 2, and they are symmetrically arranged at the lower end of the U-shaped bracket. The rotating screws are connected to the U-shaped bracket with a clearance fit. The motor front cover is located inside the U-shaped bracket and on the left side of the second servo motor. The motor front cover is threadedly connected to the rotating screws and connected to the second servo motor by bolts. The elastic mechanism includes a left fixing block, a right fixing block, a guide rod, a guide sleeve, and a first spring. The left fixing block is fixed to the lower end of the auxiliary support column by bolts. The right fixing block is fixed to the lower end of the second servo motor by bolts. The guide rod is located on the right side of the left fixing block and is threadedly connected to the left fixing block. The guide sleeve is located on the left side of the right fixing block and outside the guide rod. The guide sleeve is integrally connected to the right fixing block and is connected to the guide rod with a clearance fit. The first spring is sleeved outside the guide sleeve and the guide rod.

2. The weld seam detection wall-climbing robot according to claim 1, characterized in that The described flaw detection mechanism further includes a first servo motor, a ball screw, a feed nut, a floating clamping plate mechanism, and a magnetic particle flaw detector. The number of the first servo motors is 2, and they are symmetrically arranged on the upper end of the top plate. The ball screw is located at the lower end of the first servo motor and penetrates the top plate. The ball screw is connected to the first servo motor by bolts. The feed nut is penetrated by the ball screw, and the feed nut is threadedly connected to the ball screw. The floating clamping plate mechanism is located at the lower end of the feed nut, and the floating clamping plate mechanism is threadedly connected to the feed nut. The magnetic particle flaw detector penetrates the floating clamping plate mechanism.

3. The weld detection wall-climbing robot according to claim 2, wherein The floating splint mechanism further includes a floating plate, fixing pins, an upper splint, a lower splint, an upper spring, and a lower spring. The floating plate is located at the lower end of the feed nut, and the floating plate is connected to the feed nut by bolts. The number of fixing pins is 4, and they are symmetrically arranged along the floating plate. The floating plate slides up and down along the fixing pins. The upper splint is located at the upper end of the fixing pins and is connected to the fixing pins by interference fit. The lower splint is located at the lower end of the fixing pins and is connected to the fixing pins by clearance fit. The lower splint is connected to the upper splint by bolts. The upper spring is located outside the fixing pins and between the floating plate and the upper splint. The lower spring is located outside the fixing pins and between the floating plate and the lower splint.

4. The weld detection wall-climbing robot according to claim 3, characterized in that The sensor assembly further includes a cross plate, spray nozzles, and an industrial camera. The cross plate is located at the lower end of the lower splint and is connected to the lower splint by bolts. The number of spray nozzles is 2, and they are installed on the right side of the cross plate. The spray nozzles are fan-shaped spray nozzles, and the spray nozzles are connected to the liquid supply mechanism by hoses. The industrial camera is installed in the middle of the cross plate.

5. The weld detection wall-climbing robot according to claim 4, wherein The liquid supply mechanism further includes a connecting plate, a water tank, liquid supply heads, a liquid inlet head, and water pumps. The connecting plate is located outside the top plate, and the connecting plate is connected to the top plate by bolts. The water tank is located at the lower end of the connecting plate, and the water tank is connected to the connecting plate by bolts. The number of liquid supply heads is 2, and they are symmetrically arranged along the left and right directions of the water tank. The liquid inlet head is located at the center of the top of the water tank, and the liquid inlet head is threadedly connected to the water tank. The number of water pumps is 2, and they are symmetrically arranged along the left and right directions of the connecting plate. The water inlet of the water pump is connected to the liquid supply head by a hose, and the water outlets of the water pumps are respectively connected to the liquid inlet head and the spray nozzles by hoses.

6. The weld detection wall-climbing robot according to claim 5, wherein The liquid supply head further includes a straight-through head, a silicone tube, and a spherical countersunk head. The straight-through head is located outside the water tank, and the straight-through head is threadedly connected to the water tank and is connected to the water inlet of the water pump by a hose. The silicone tube is sleeved on the lower end of the straight-through head and extends into the inner side of the water tank. The spherical countersunk head is sleeved on the lower end of the silicone tube and extends into the inner side of the water tank. An inlet hole is opened at the lower end of the spherical countersunk head, and the inlet hole communicates with the cavity of the silicone tube.

7. The wall-climbing robot for weld seam detection according to claim 6, characterized in that The gravity feedback mechanism further includes L-shaped brackets, distance sensors, sliding rods, sliders, and second springs. The number of L-shaped brackets is 2, and they are symmetrically arranged along the left and right directions at the lower end of the top plate. A distance sensor is installed at the upper end of the L-shaped bracket, and the distance sensor is connected to the L-shaped bracket by bolts. The sliding rod is located between two symmetrically arranged L-shaped brackets, and the sliding rod is connected to the L-shaped bracket by bolts. The slider is penetrated by the sliding rod, and the slider slides along the left and right directions of the sliding rod. The number of second springs is 2, and they are symmetrically arranged along the left and right directions outside the sliding rod. The two ends of the second spring are respectively in contact with the slider and the L-shaped bracket.

Images