Method and device for ultrasonic detection of welding defects in large components

Abstract

The application discloses a large component welding defect ultrasonic detection method and device, a flexible robot chassis system is built to perform autonomous crawling movement on the wall surface of a large steel welding component, a high-precision surface profile laser three-dimensional scanning and point cloud reconstruction technology is used to construct the spatial position coordinates of the outer contour of the large equipment under a large field of view, a spatial position coordinate solution module is loaded on the motion control system of the robot chassis to guide the robot spatial motion path, a high-definition image visual system capable of remote data transmission is used to assist the operator in online monitoring the walking route of the robot chassis system, after the robot advances to a predetermined detection point, four high-rigidity air cylinders installed on both sides of the robot chassis system are extended to attach the powerful adsorption electromagnet connected with the air cylinder rods to the component wall surface, the application can realize rapid detection of the internal damage welding defects of the large component, can improve the detection point positioning precision, and is simple, easy, feasible, and good in universality.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic detection technology for welding defects in large equipment such as ships constructed in sections, specifically to a method and apparatus for ultrasonic detection of welding defects in large components. Background Technology

[0002] Large warships and major equipment such as submarines and aircraft carriers are developing towards integrated structures, larger component structures, and more precise manufacturing processes. The segmented assembly of large components using integral welding is a common method in modern shipbuilding, placing extremely high demands on the multi-layered, multi-pass welding process of thick, ultra-high-strength steel plates. Large equipment often faces complex stress-strain scenarios such as intense fluid-structure interaction and massive transient impacts in operational or combat environments. Under these conditions, welded large structural components may experience deformation of their outer wall profile, potentially leading to internal structural damage or even fatigue fracture failure, posing a significant risk to the normal operation of the equipment. Because it is difficult to quickly detect external contour deformation and internal structural damage of such large equipment under laboratory conditions, traditional manual flaw detection methods have disadvantages such as low detection efficiency, the need for preparation work such as building complex scaffolding before operation, high labor intensity and operational safety risks during the detection process. It is also difficult to track the detection point position in real time during manual flaw detection operations. For large-area, complex structural workpieces, it is impossible to quickly and accurately achieve risk assessment of external contour deformation and global splicing and online intelligent identification of internal structural damage detection surfaces. This has become a technical problem that urgently needs to be solved to restrict the speed and accuracy of maintenance and support of large equipment.

[0003] During the construction or maintenance of large equipment, on-site inspection requires instruments to work in conjunction with the target for online inspection. However, this process is subject to adverse effects such as measurement offset, numerous environmental interference factors, and missing reference points, ultimately leading to a loss of measurement accuracy. High-precision 3D scanning measurement of complex surface contours can rapidly reconstruct the 3D point cloud of the outer contour of large ships. This allows for rapid assessment of surface deformation of the hull's outer contour, improving the speed of hull structural integrity inspection. Furthermore, it can construct a 3D position coordinate model for large-scale scenes, providing on-site navigation for online inspection instruments. This reduces the impact of measurement offset, missing reference points, and other adverse factors, improving the positional consistency accuracy of the instrument's inspection.

[0004] Because 3D contour scanning technology is still under development, it is difficult to identify micro-deformations in the outer contours of large equipment and potential micro-cracks within them. Typically, ultrasonic non-destructive testing is used during the segmented manufacturing of large components and during post-service maintenance to identify and assess damage such as micro-cracks within weld seams. However, current techniques generally involve manual operation with the flaw detector, heavily relying on the operator's expertise. This can easily lead to misjudgments or missed detections of welding defects due to operator fatigue, blind spots, and other factors. Global detection is physically demanding, and manual detection also struggles to achieve real-time tracking of detection points and global splicing of the detection surface. Therefore, there is an urgent need to develop an autonomous, multi-sensor fusion robot testing platform to address the technical requirements for detecting internal damage in weld seams of large components; to develop adaptive ultrasonic damage testing processes for multiple spatial positions and spatial position navigation analysis methods for detection surfaces in large field-of-view environments; and to combine this with laser dynamic navigation technology to achieve global splicing of the ultrasonic damage detection surface. Finally, a portable online ultrasonic testing platform and an intelligent internal damage identification solution for large components were established to automate and intelligentize the on-site support process for large equipment, thereby enhancing my country's overall technical level in the comprehensive maintenance of large equipment. In summary, improving the ability to perceive large-field-of-view environments, rapid detection capabilities, and the accuracy of detection surface integrity and structural damage assessment during the maintenance of large equipment, and enabling rapid and accurate online testing and risk assessment of large components, has significant scientific value and practical engineering implications for improving the manufacturing and maintenance support capabilities of large equipment in my country. Summary of the Invention

[0005] To address the technical challenge of achieving rapid and accurate global digital damage detection of large-sized components during welding construction and maintenance of large equipment, this invention provides a fast, convenient, and low-cost ultrasonic detection method for welding defects in large components, along with a wall-climbing robot device.

[0006] The technical solution adopted by this invention to solve its technical problem is as follows:

[0007] An ultrasonic detection method for welding defects in large components, based on an ultrasonic detection device for welding defects in large components, includes the following steps:

[0008] 1) Construct a flexible robot chassis system to enable autonomous crawling motion on the wall of a steel welded component;

[0009] 2) Construct the spatial coordinates of the equipment's outer contour in a large field of view environment based on high-precision surface contour laser 3D scanning and point cloud reconstruction technology;

[0010] 3) The robot chassis system is equipped with a spatial position coordinate calculation module for robot spatial motion path navigation;

[0011] 4) After the robot moves to the predetermined detection point, it adheres to the wall surface of the steel welded component;

[0012] 5) The robot chassis system is equipped with a disc-type surface grinding mechanism to clean and grind the surface to be inspected;

[0013] 6) The robot chassis system is equipped with an adaptive ultrasonic detection system to perform adaptive internal damage detection in multiple spatial positions on the polished surface;

[0014] 7) By integrating laser dynamic navigation technology, ultrasonic detection data inside large-sized components (such as hull components that need to be assembled and welded during the segmented construction of submarines or aircraft carriers) are globally stitched together, thereby realizing full-process digital damage detection of the surface structure inside large equipment (such as submarines or aircraft carriers).

[0015] An ultrasonic detection device for welding defects in large components includes a robot chassis system, a protective cover, an industrial camera, a disc-type surface grinding mechanism, a spatial position laser tracking module, an adaptive ultrasonic detection system, a power supply module, a servo motor controller, and an information processing module. The disc-type surface grinding mechanism, the adaptive ultrasonic detection system, the power supply module, the servo motor controller, and the information processing module are respectively mounted on the robot chassis system. The protective cover is mounted on top of the robot chassis system. The industrial camera is mounted at one end of the protective cover, and the spatial position laser tracking module is mounted at the other end of the protective cover.

[0016] Furthermore, the robot chassis system includes a robot chassis, a nitrogen spring, an active wheel assembly, a driven wheel assembly, a walking function drive servo motor, and a steering function drive servo motor. The active wheel assembly is mounted on a drive wheel connecting plate, and the drive wheel connecting plate is provided with a floating wheel assembly mounting plate. The floating wheel assembly mounting plate is mounted on a floating wheel assembly hinge connecting block at the bottom of the robot chassis. One end of the nitrogen spring is mounted on a nitrogen spring fixed end mounting block on the robot chassis, and the other end is mounted on a floating wheel assembly hinge connecting block via a nitrogen spring floating end mounting block. The driven wheel assembly is mounted on a driven wheel mounting frame. Above, the driven wheel mounting bracket is provided with a driven wheel floating hinge connecting block. One end of the nitrogen spring is mounted on the robot chassis via a nitrogen spring fixed end mounting block, and the other end is mounted on the driven wheel floating hinge connecting block via a nitrogen spring floating end mounting block. The walking function drive servo motor is mounted on the drive wheel connecting plate. The active wheel set is connected to the walking function drive servo motor via a planetary gear reducer flange to realize the walking function. The active wheel set is connected to the drive wheel connecting plate via an axial support bearing, and is connected to the drive wheel connecting plate via a steering function drive servo motor to realize the steering function.

[0017] The robot chassis system consists of four independent suspension wheel sets composed of high-rigidity, retractable nitrogen springs. Each independent suspension wheel set is a multi-link mechanism, with the high-precision servo-driven magnetic adsorption wheel set mounted on the floating end mounting block of the nitrogen spring. The high-rigidity, retractable nitrogen springs are initially in a neutral, balanced state, at which point the magnetic adsorption wheel sets connected to the multi-link mechanism are horizontal, meaning all independent suspension wheel sets are horizontal. When the magnetic adsorption wheel sets encounter a raised obstacle, the adsorption wheel rises, and the nitrogen spring extends a corresponding distance, while maintaining the overall balance of the robot chassis system. When the magnetic adsorption wheel sets encounter a sunken surface, the adsorption wheel sets sink, and the nitrogen spring retracts a corresponding distance, allowing the robot chassis system to maintain its overall balance. Furthermore, the extension force of the nitrogen springs can be selected based on the load required by the flexible robot chassis system, thereby enabling the flexible robot chassis system to maintain a certain level of obstacle avoidance and passage performance under certain load conditions.

[0018] The high-precision servo-driven magnetic adsorption wheel set consists of a pair of active wheel sets driven by high-precision servo motors and a pair of passive wheel sets without driving force. The active wheel sets are driven by four high-precision servo motors, each driving one of the two active wheel sets to achieve walking and steering functions. The walking function is driven by a planetary gear reducer flange connected to the two high-precision servo drive motors, which are directly connected to the pair of active wheel sets. The walking function drive servo motor is mounted on the drive wheel connecting plate. The steering function drive servo motor is connected to the drive wheel connecting plate via an axial support bearing to achieve the steering function. The walking and steering function drive servo motors are each controlled by an independent servo controller, allowing for independent control according to the motion control system, thereby improving the motion flexibility of the flexible robot chassis system. Furthermore, the power supply and control signals of the flexible robot chassis system are transmitted via remote cables, enabling remote control over a relatively long distance.

[0019] Furthermore, the robot chassis system also includes a high-rigidity support mechanism, which comprises a high-rigidity double-guide rod support cylinder, a cylinder connecting block, a high-rigidity double-guide rod support cylinder mounting plate, and an electromagnet. The high-rigidity double-guide rod support cylinder is connected to the robot chassis system via the mounting plate, and the electromagnet is mounted on the end of the cylinder guide rod. When energized, the electromagnet can tightly engage with the wall surface of a large component through electromagnetic force, thus forming a high-rigidity support mechanism for the wall-climbing robot's detection operation. This prevents relative displacement between the robot's body and the wall surface due to external forces during subsequent detection operations, ensuring the overall system stability and detection accuracy during the detection process.

[0020] Furthermore, the disc-type surface polishing mechanism includes a rotating disc, a rotating disc drive mechanism, a visual sensor for measuring the height and surface finish of the detection surface, a surface cleaning mechanism, a fine surface polishing mechanism, and a high-speed air blowing head. The visual sensor for measuring the height and surface finish of the detection surface, the surface cleaning mechanism, the fine surface polishing mechanism, and the high-speed air blowing head are distributed along the circumference of the rotating disc, and the rotating disc drive mechanism is drively connected to the rotating disc. The visual sensor for measuring the height and surface finish of the detection surface includes a detection surface height measurement sensor and a detection surface finish detection visual sensor. The detection surface height measurement sensor is a laser reflection distance sensor based on the high-precision triangulation principle, which can be used to measure the height distance of the surface to be ultrasonically inspected, thereby providing control parameter data such as the working distance of the polishing mechanism for the disc-type surface polishing mechanism. The height measurement of the detection surface is the first step in data collection when the wall-climbing robot moves to the surface to be tested. The measured data will be transmitted to the control system of the wall-climbing robot. The visual sensor for detecting the surface smoothness is a visual sensor system with LED lighting. After the height measurement sensor of the detection surface measures the height of the surface to be tested, it performs a visual judgment on the surface cleanliness of the surface to be tested, and then transmits the data to the control system for analysis to determine the subsequent polishing process. Furthermore, after the fine polishing operation is completed, the visual sensor for detecting the surface smoothness will perform a second judgment on the surface smoothness to determine whether it can meet the requirements of ultrasonic detection. If it can, the next step of ultrasonic detection will be carried out. If it cannot, a second polishing plan needs to be formulated and polishing will be carried out until the surface to be tested meets the smoothness requirements.

[0021] Furthermore, the rotating disk drive mechanism includes a disk rotation drive motor, a synchronous belt mechanism, and a high-rigidity cantilever support bearing seat mechanism. The disk rotation drive motor is fixed to the robot chassis system via a disk rotation motor mounting plate. The high-rigidity cantilever support bearing seat mechanism is fixed to the robot chassis system. The rotating disk is mounted on the high-rigidity cantilever support bearing seat mechanism, and the high-rigidity cantilever support bearing seat mechanism is connected to the disk rotation drive motor via a synchronous belt mechanism. The high-rigidity cantilever support bearing seat mechanism includes a support body, an angular contact ball bearing, a deep groove ball bearing, a high-rigidity rotating shaft, an end cap, a bushing, and a locking nut. The high-rigidity rotating shaft is located inside the support body. The bushing is located between the support body and the high-rigidity rotating shaft. The angular contact ball bearing is mounted on the rotating shaft near one end of the rotating disk. The deep groove ball bearing is mounted on the shaft end near the synchronous belt pulley. The end cap is located at both ends of the support body.

[0022] Furthermore, the surface cleaning mechanism includes a wire brush linear motion guide rail, a servo drive cylinder, a drive motor A, and a customized wire brush for surface cleaning. The customized wire brush is connected to the drive motor A and installed on the wire brush linear motion guide rail. The servo drive cylinder is connected to the slider of the wire brush linear motion guide rail and drives the customized wire brush to perform rotational brushing and coarse cleaning on the ultrasonic surface to be inspected.

[0023] Furthermore, the fine grinding mechanism includes a pneumatic grinding wheel head linear motion guide rail, a servo drive cylinder, a drive motor B, and a surface fine grinding airbag grinding wheel. The surface fine grinding airbag grinding wheel is connected to the drive motor B and installed on the linear motion guide rail. The servo drive cylinder is connected to the slider of the linear motion guide rail and drives the surface fine grinding airbag grinding wheel to perform rotary grinding and fine grinding treatment on the ultrasonic surface to be tested.

[0024] Furthermore, the high-speed blowing head is mounted on a high-rigidity slide cylinder, which is installed on a rotating disk. The high-pressure blowing head is connected to an air storage tank and receives air from the tank. The high-speed blowing head is a linear high-pressure blowing head composed of a row of micro-holes. It is a mechanism for blowing away impurities from the surface to be inspected after the roughing and fine treatment operations are completed.

[0025] Furthermore, the adaptive ultrasonic detection system includes a couplant injection valve, an automatic couplant filling tank, a servo cylinder with displacement detection, an adhesion force sensor, and an ultrasonic probe. The couplant injection valve is mounted on the robot chassis system via an injection valve mounting plate, and the servo cylinder with displacement detection is mounted on the robot chassis system via an electric actuator mounting plate. The couplant injection valve and the automatic couplant filling tank are connected via a supply hose. The couplant injection valve is installed on one side of the servo cylinder with displacement detection, and the ultrasonic probe is connected to the extension rod of the servo cylinder with displacement detection via the adhesion force sensor. The couplant injection valve is a programmable high-precision point injection valve that can automatically and accurately inject the couplant required for ultrasonic detection onto the surface to be tested. After the wall-climbing robot completes the surface polishing of the surface to be tested, the robot needs to move to bring the adaptive ultrasonic detection system to the area of ​​the surface to be tested. The coupling agent injection valve automatically sprays a certain amount of gel-like coupling agent onto the surface to be tested. The gel-like coupling agent is automatically supplied by the coupling agent automatic filling tank. A rubber piston is provided in the automatic filling tank. Compressed air at a certain pressure is filled between the piston and the end cap of the automatic filling tank, so that the gel can be continuously dispensed, ensuring that the gel-like coupling agent is continuously replenished in the coupling agent injection valve tube. The automatic coupling agent filling tank is installed inside the wall-climbing robot and connected to the coupling agent injection valve via a supply hose. The coupling agent injection valve is installed on one side of the servo cylinder with displacement detection and automatically sprays the gel-like coupling agent onto the surface to be detected at a certain tilt angle. The ultrasonic probe is connected to the extension rod of the servo cylinder with displacement detection via the adhesion force sensor. After the coupling agent injection valve completes the coupling agent spraying operation, the servo cylinder extends to attach the ultrasonic probe to the surface to be detected. The displacement detection function of the servo cylinder converts the data output by the detection surface height measurement sensor in the disc-type surface grinding mechanism and automatically calculates the extension stroke required by the ultrasonic probe. Furthermore, the adhesion force sensor automatically measures the adhesion force between the ultrasonic probe and the wall surface to ensure that the adhesion force between the ultrasonic probe and the wall surface is within the design threshold, thereby ensuring detection accuracy and equipment safety during automatic detection.

[0026] The technical concept of this invention is as follows: A flexible robot chassis system is built using a high-precision servo-driven magnetic adsorption wheel assembly to perform autonomous climbing motion on the wall surface of a large steel welded component. This develops a wall-climbing robot device with autonomous execution function. Based on high-precision surface contour laser 3D scanning and point cloud reconstruction technology, high-definition image vision-assisted control technology, and laser dynamic navigation technology, ultrasonic detection data inside the large-size component structure is globally stitched together, thereby realizing full-process digital damage detection of the surface structure inside large equipment. This avoids the disadvantages of traditional manual flaw detection methods, such as low detection efficiency, the need for complex scaffolding and other preparatory work before operation, high labor intensity during the detection process, and operational safety risks.

[0027] This process has the following characteristics: 1) The high-precision servo-driven magnetic adsorption wheel set consists of a pair of active wheel sets driven by high-precision servo motors and a pair of passive wheel sets without driving force. The active wheel sets are driven by four high-precision servo motors, each driving two drive wheels to achieve walking and steering functions. The walking and steering servo motors are controlled by independent servo controllers, allowing for independent control according to the motion control system, thereby improving the movement flexibility of the flexible robot chassis system. 2) The flexible robot chassis system consists of four independent suspension wheel sets composed of high-rigidity, retractable nitrogen springs. Each independent suspension wheel set is a multi-link mechanism, with the high-precision servo-driven magnetic adsorption wheel mounted on one of the swing arms. The high-rigidity, retractable nitrogen springs are initially in a neutral equilibrium state, at which point the magnetic adsorption wheels connected to the multi-link mechanism are horizontal, meaning all independent suspension wheel sets are horizontal. When the magnetic adsorption wheel encounters a protruding obstacle, the adsorption wheel rises, and the nitrogen spring extends a corresponding distance, while maintaining the overall balance of the chassis system. When the magnetic adsorption wheel encounters a concave road surface, the adsorption wheel assembly sinks, the nitrogen spring retracts a corresponding stroke, and the chassis system can maintain its overall balance. The flexible robot chassis system also has a certain obstacle avoidance and passage performance under certain load conditions; 3) High-precision surface contour laser three-dimensional scanning and point cloud reconstruction technology is a comprehensive technology that uses high-precision line laser to perform three-dimensional contour scanning of the surface structure of large-sized components, and then performs digital point cloud reconstruction of complex outer contour structures, thereby realizing the rapid construction of the spatial position coordinate system of large equipment surface, and finally using the constructed coordinate system to navigate the wall-climbing robot to detect point positions; 4) Laser dynamic navigation technology is a comprehensive technology that uses laser positioning base station and positioning target ball installed at the tail of the wall-climbing robot to work in coordination to solve the spatial coordinate position of the wall-climbing robot and navigate; wherein the solution of the spatial coordinate position of the wall-climbing robot requires the spatial position coordinate system data of the large equipment surface constructed by the high-precision surface contour laser three-dimensional scanning and point cloud reconstruction technology, which is solved by the spatial position coordinate calculation module of the motion control system of the wall-climbing robot chassis, and then the robot is crawling motion controlled, thereby achieving real-time tracking and adjustment of motion control and actual position, ensuring that the wall-climbing robot can accurately reach the surface to be detected.

[0028] This technology can provide a fully digital portable ultrasonic detection solution for the manufacturing and maintenance of large-sized components of large equipment. It eliminates the cumbersome process of setting up complex scaffolding or deploying large lifting equipment required for manual detection. It also avoids the risks of inaccurate detection location and inaccurate judgment of detection results caused by physical and spatial limitations during manual detection. It provides a new method and equipment that is simple to operate and cost-effective for implementing digital rapid detection in the development and use of large equipment in China.

[0029] The beneficial effects of this invention are as follows:

[0030] 1) The flexible robot chassis system consists of four independent suspension wheel sets composed of high-rigidity, stretchable nitrogen springs. Each independent suspension wheel set is a multi-link mechanism, with a high-precision servo-driven magnetic adsorption wheel mounted on one of the swing arms. The high-precision servo-driven magnetic adsorption wheel set comprises a pair of active wheel sets driven by high-precision servo motors and a pair of passive wheel sets without driving force. The active wheel sets are driven by four high-precision servo motors, each driving two drive wheels to achieve walking and steering functions. The walking and steering servo motors are controlled by independent servo controllers, allowing for independent control according to the motion control system, thereby improving the movement flexibility of the flexible robot chassis system.

[0031] 2) When the wall-climbing robot reaches the surface to be detected, the cylinder guide rod extends to attach the electromagnet to the wall of the large component. After the electromagnet is energized, it can be tightly attracted to the wall of the large component through electromagnetic force, thereby forming a high-rigidity support mechanism for the wall-climbing robot during the detection operation. This avoids the relative displacement between the robot body and the wall surface caused by external forces during the subsequent detection operation, thus ensuring the overall system stability and detection accuracy of the detection operation.

[0032] 3) The "shield-like" disc-type surface grinding mechanism, consisting of a disc rotation mechanism, a detection surface height measurement sensor, a detection surface smoothness detection vision sensor, a surface cleaning mechanism, a surface fine grinding mechanism, and a high-speed air blowing head, is a special mechanism used to clean and finely grind the surface to be tested by ultrasonic waves, thus ensuring the accuracy of ultrasonic detection.

[0033] 4) This invention can provide a fully digital portable ultrasonic detection solution for the manufacturing and maintenance of large-sized components of large equipment. It eliminates the cumbersome process of setting up complex scaffolding or deploying large lifting equipment required for manual detection. It also avoids the risks of inaccurate detection position and inaccurate judgment of detection results caused by physical and spatial limitations during manual detection. It provides a new method and equipment that is simple to operate and cost-effective for implementing digital rapid detection in the development and use of large equipment in my country, and has a wide range of application prospects. Attached Figure Description

[0034] Figure 1 This is a flowchart of the method of the present invention;

[0035] Figure 2 This is a schematic diagram of the overall device structure of the present invention. Figure 1 ;

[0036] Figure 3 This is a schematic diagram of the overall device structure of the present invention. Figure 2 ;

[0037] Figure 4 This is a schematic diagram of the overall device structure of the present invention. Figure 3 ;

[0038] Figure 5 This is a schematic diagram of the overall device structure of the present invention. Figure 4 ;

[0039] Figure 6 This is a schematic diagram of the overall device structure of the present invention. Figure 5 ;

[0040] Figure 7 This is a schematic diagram of the chassis structure of the device of the present invention. Figure 1 ;

[0041] Figure 8 This is a schematic diagram of the chassis structure of the device of the present invention. Figure 2 ;

[0042] Figure 9 This is a schematic diagram of the chassis structure of the device of the present invention. Figure 3 ;

[0043] Figure 10 This is a schematic diagram of the chassis structure of the device of the present invention. Figure 4 ;

[0044] Figure 11 This is a schematic diagram of the disc-type surface polishing mechanism of the present invention. Figure 1 ;

[0045] Figure 12 This is a schematic diagram of the disc-type surface polishing mechanism of the present invention. Figure 2 ;

[0046] Figure 13 This is a schematic diagram of the disc-type surface polishing mechanism of the present invention. Figure 3 ;

[0047] Figure 14 This is a schematic diagram of the ultrasonic detection system.

[0048] In the diagram: 1. Robot chassis system; 2. Protective cover; 3. Industrial camera; 4. Disc-type surface polishing mechanism; 5. Spatial position laser tracking module; 6. Adaptive ultrasonic detection system; 7. Power supply module; 8. Servo motor controller; 9. Information processing module; 10. Coupling agent automatic filling tank; 11. Gas storage tank; 12. Electromagnetic control valve; 1-1. Magnetic adsorption wheel assembly; 1-2. Walking function drive servo motor; 1-3. Drive wheel connecting plate; 1-4. Floating wheel assembly mounting plate; 1-5. Steering function drive servo motor; 1-6. Robot chassis mounting plate; 1-7. Floating wheel assembly hinge connecting block; -8. Nitrogen spring fixed end mounting block; 1-9. Nitrogen spring floating end mounting block; 1-10. Nitrogen spring hinge pin; 1-11. Nitrogen spring; 1-12. Floating wheel assembly connecting hinge pin; 1-13. Driven wheel mounting bracket; 1-14. Driven wheel floating connecting block; 1-15. Electromagnet; 1-16. Cylinder connecting block; 1-17. Electromagnet; 1-18. Cylinder mounting plate; 1-19. High-rigidity double guide rod support cylinder; 1-20. High-rigidity double guide rod support cylinder mounting plate; 1-21. Bearing; 1-22. Axial support bearing; 4-1. Rotating disk; 4-2. Servo drive electric cylinder; 4-3. Linear motion guide rail for wire brush; 4-4. Customized wire brush for surface cleaning; 4-5. Drive motor clamping mechanism; 4-6. Drive motor A; 4-7. Locking nut on the end face of the mounting shaft; 4-8. Electric push cylinder for pneumatic grinding wheel head; 4-9. Visual sensor for surface finish detection; 4-10. Camera mounting plate; 4-11. Linear motion guide rail for pneumatic grinding wheel head; 4-12. Drive motor B; 4-13. Airbag grinding wheel for fine surface polishing; 4-14. Mounting seat for pneumatic grinding wheel head; 4-15. High-rigidity slide cylinder; 4-16. High-speed air blowing head; 4-17. Mounting plate for rotary disc motor; 4-18. Rotary disc drive motor; 4-19. Detection surface Height measurement sensor; 4-20, High-rigidity cantilever support bearing seat mechanism; 4-21, Driven side synchronous drive wheel; 4-22, Synchronous belt; 4-23, Driven side synchronous drive wheel; 4-24, Deep groove ball bearing; 4-25, Angular contact ball bearing; 4-26, Support seat body; 4-27, High-rigidity rotating shaft; 4-28, End cover; 4-29, Bushing; 4-30, Locking nut; 6-1, Ultrasonic probe; 6-2, Adhesion force sensor; 6-3, Servo electric cylinder with displacement detection; 6-4, Coupling agent injection valve; 6-5, Injection valve mounting plate; 6-6, Electric push cylinder mounting plate; 6-7, Force sensor connecting plate; 6-8, Ultrasonic probe connecting plate. Detailed Implementation

[0049] The present invention will now be described in detail with reference to the accompanying drawings.

[0050] See attached document Figure 1 ~Attached Figure 14 An ultrasonic detection method for welding defects in large components is described in the attached figure. Figures 1-14 As shown, the specific implementation steps can be described as follows: A flexible robot chassis system 1 is constructed using a high-precision servo-driven magnetic adsorption wheel assembly 1-1 to perform autonomous crawling motion on the wall of a large steel welded component. Based on high-precision surface contour laser 3D scanning and point cloud reconstruction technology, the spatial position coordinates of the outer contour of the large equipment in a large field of view environment are constructed. The motion control system of the robot chassis 1 is equipped with a spatial position coordinate calculation module to navigate the robot's spatial motion path. A high-definition image vision system capable of remote data transmission assists the operator in monitoring the walking route of the robot chassis system 1 online. After the robot moves to the predetermined detection point, four high-rigidity double guide rod support cylinders 1-19 installed on both sides of the robot chassis system 1 are activated. A powerful electromagnet 1-17, which connects to the cylinder rod, extends and attaches to the wall of the component. The electromagnet 1-17 connects the robot body to the wall of the component to form a high-rigidity support mechanism. Furthermore, the robot chassis system 1 is equipped with a "shield-like" disc-type surface grinding mechanism 4 to clean and grind the surface to be inspected. Then, the adaptive ultrasonic detection system 6 performs multi-spatial adaptive internal damage detection on the ground surface. Finally, the laser dynamic navigation technology is integrated to globally stitch together the ultrasonic detection data inside the large-size component structure, thereby realizing full-process digital damage detection of the surface structure of large equipment, improving the efficiency of internal damage detection of large-size welded structural components and the accuracy of detection point positioning.

[0051] The high-precision surface contour laser 3D scanning and point cloud reconstruction technology involved in the above solution is a comprehensive technology that uses high-precision line laser to perform 3D contour scanning of the surface structure of large-sized components, then performs digital point cloud reconstruction of the complex outer contour structure, thereby realizing the rapid construction of the spatial position coordinate system of large equipment surface, and finally performs detection point position navigation of the wall-climbing robot based on the constructed coordinate system.

[0052] Laser dynamic navigation technology is a comprehensive technology that utilizes a laser positioning base station and a positioning target ball installed at the tail of the wall-climbing robot to coordinate and solve for the spatial coordinate position and navigate the wall-climbing robot. The solution for the spatial coordinate position of the wall-climbing robot requires the use of the spatial position coordinate system data of the surface of large equipment constructed by the high-precision surface contour laser three-dimensional scanning and point cloud reconstruction technology. After the spatial position coordinate calculation module is installed in the motion control system of the wall-climbing robot chassis system 1, the robot's crawling motion is controlled, thereby achieving real-time tracking and adjustment of motion control and actual position, ensuring that the wall-climbing robot can accurately reach the surface to be detected.

[0053] Global stitching of ultrasonic detection data refers to the transmission of ultrasonic detection data and the detection position of the wall-climbing robot to the control system via laser dynamic navigation technology for comparison and storage. This enables the construction of a global spatial digital detection scheme for large components in a virtual environment, and further allows for the development of intelligent evaluation methods and intelligent judgment systems for ultrasonic detection results. This method can provide a fully digital portable ultrasonic detection solution for large-sized components of large equipment during manufacturing and maintenance, eliminating the cumbersome process of setting up complex scaffolding or deploying large lifting equipment required for manual detection. It also avoids the risks of inaccurate detection positions and inaccurate judgments due to physical limitations and space constraints during manual detection. This provides a simple, cost-effective new method and equipment for implementing rapid digital detection in the development and use of large equipment in my country.

[0054] A wall-climbing robot device for ultrasonic detection of welding defects in large components, the composition of which is shown in the attached figure. Figures 2-14 As shown, the system comprises components including a robot chassis system 1, a protective cover 2, an industrial camera 3, a disc-type surface polishing mechanism 4, a spatial position laser tracking module 5, an adaptive ultrasonic detection system 6, a power supply module 7, a servo motor controller 8, an information processing module 9, an automatic coupling agent filling tank 10, an air storage tank 11, and an electromagnetic control valve 12.

[0055] The flexible robot chassis system 1 consists of four independent suspension wheel sets composed of four high-rigidity, retractable nitrogen springs 1-11. Each independent suspension wheel set is a multi-link mechanism, with the high-precision servo-driven magnetic adsorption wheel set 1-1 mounted on the floating end mounting block 1-9 of the nitrogen spring. The high-rigidity, retractable nitrogen spring 1-11 is initially in a neutral balanced state, at which point the magnetic adsorption wheel set 1-1 connected to the multi-link mechanism is horizontal, meaning all independent suspension wheel sets are horizontal. When the magnetic adsorption wheel set 1-1 encounters a raised obstacle, the adsorption wheel rises, and the nitrogen spring 1-11 extends a corresponding distance, while maintaining the overall balance of the robot chassis system 1. When the magnetic adsorption wheel set 1-1 encounters a sunken surface, the adsorption wheel set 1-1 sinks, and the nitrogen spring 1-11 retracts a corresponding distance, allowing the robot chassis system 1 to maintain its overall balance. Furthermore, the extension force of the nitrogen springs 1-11 can be selected according to the load that the flexible robot chassis system 1 needs to carry, so that the flexible robot chassis system 1 can also have a certain obstacle avoidance and passage performance under a certain load.

[0056] The magnetic adsorption wheel assembly 1-1 consists of a pair of active wheel assemblies 1-15 driven by a walking function drive servo motor 1-2 and a pair of passive wheel assemblies 1-16 without driving force. The active wheel assemblies 1-15 are driven by four high-precision walking function drive servo motors 1-2, each driving two active wheel assemblies 1-15 to achieve walking and steering functions. The walking function is driven by a planetary gear reducer flange connected to the two walking function drive servo motors 1-2, which is directly connected to the pair of active wheel assemblies 1-15. The walking function drive servo motors 1-2 are mounted on the drive wheel connecting plate 1-3. The steering function drive servo motor 1-5 is connected to the drive wheel connecting plate 1-3 via the axial support bearing 1-22, thereby realizing the steering function (direct motor drive); the walking function drive servo motor 1-2 and the steering function drive servo motor 1-5 are controlled by independent servo controllers, which can be independently controlled according to the motion control system, thereby improving the motion flexibility of the flexible robot chassis system 1; furthermore, the power supply and control signals of the flexible robot chassis system 1 are transmitted via remote cables, thereby enabling remote control over a relatively long distance;

[0057] The high-rigidity support mechanism includes components such as a high-rigidity double-guide rod support cylinder 1-19, a cylinder connecting block 1-16, a high-rigidity double-guide rod support cylinder mounting plate 1-20, and an electromagnet 1-17. The high-rigidity double-guide rod support cylinder 1-19 is connected to the wall-climbing robot chassis system 1 via the high-rigidity double-guide rod support cylinder mounting plate 1-20. The electromagnet 1-17 is mounted on the end of the guide rod of the cylinder 1-19. When the wall-climbing robot reaches the surface to be detected, the guide rod of the cylinder 1-19 extends, attaching the electromagnet 1-17 to the wall surface of the large component. When energized, the electromagnet 1-17 can be tightly attracted to the wall surface of the large component through electromagnetic force, thus forming a high-rigidity support mechanism during the wall-climbing robot's detection operation. This prevents relative displacement between the robot's body and the wall surface caused by external forces during subsequent detection operations, ensuring the overall system stability and detection accuracy during the detection process.

[0058] The "shield-like" disc-type surface grinding mechanism 4 is a specialized mechanism for cleaning and fine grinding the surface to be tested by ultrasonic testing. It includes a rotating disc 4-1, a surface height measuring sensor 4-19, a surface smoothness detection vision sensor 4-9, a custom-made steel wire brush for surface cleaning 4-4, a custom-made airbag grinding wheel for fine surface grinding 4-13, and a high-speed air blowing head 4-16. The rotating disc 4-1 is driven by a high-precision servo motor 4-18 connected to a synchronous belt mechanism 4-22, and is mounted on the rotating shaft of a high-rigidity cantilever support bearing seat mechanism 4-20. The high-rigidity cantilever support bearing housing mechanism 4-20 includes a support housing body 4-26, a set of face-to-face mounted angular contact ball bearings 4-25 and a deep groove ball bearing 4-24, a high-rigidity rotating shaft 4-27, an end cover 4-28, a bushing 4-29, and a locking nut 4-30, among other components. The face-to-face mounted angular contact ball bearings 4-25 are installed on the rotating shaft 4-27 near one end of the rotating disk 4-1. The angular contact ball bearing set 4-25 provides axial and radial dual support for the disc-type surface grinding mechanism 4. Furthermore, the deep groove ball bearing 4-24 is installed on the shaft end near the synchronous pulley 4-21, approximately 200mm from the end face of the disk 4-1, which further improves the radial support rigidity of the disc-type grinding mechanism 4. The high-rigidity cantilever support bearing housing 4-20 is easy to install and has high rigidity, thus ensuring the overall structural rigidity during the grinding process and consequently guaranteeing the grinding quality.

[0059] The detection surface height measurement sensor 4-19 is a laser reflection distance sensor based on the high-precision triangulation principle. It can be used to measure the height of the surface to be ultrasonically tested, thereby providing control parameter data such as the working distance of the disc-type surface grinding mechanism 4. The detection surface height measurement is the first data collection operation performed by the wall-climbing robot when it moves to the surface to be tested, and the measured data will be transmitted to the wall-climbing robot control system.

[0060] The surface finish detection visual sensor 4-9 is a visual sensor system with an LED light. After the surface height measurement sensor 4-9 measures the height of the surface to be measured, it visually determines the surface cleanliness of the surface to be measured and then transmits the data to the control system for analysis to determine the subsequent polishing process. Furthermore, after the fine polishing operation is completed, the surface finish detection visual sensor 4-9 performs a second surface finish determination to determine whether it meets the requirements for ultrasonic detection. If it does, the next step of ultrasonic detection is performed; if it does not, a second polishing plan is formulated and polishing is carried out until the surface finish of the surface to be measured meets the requirements.

[0061] The surface cleaning mechanism includes a wire brush linear motion guide rail 4-3, a servo drive cylinder 4-2, a drive motor A4-6, and a custom-made wire brush 4-4 for surface cleaning. The custom-made wire brush 4-4 is connected to the drive motor A4-6 and mounted on the wire brush linear motion guide rail 4-3. The servo drive cylinder 4-2 is connected to the slider of the wire brush linear motion guide rail 4-3, driving the custom-made wire brush 4-4 to perform a rotating brushing coarse cleaning of the ultrasonic surface to be inspected, ensuring that there are no large debris on the surface to be inspected, and preparing for the next step of fine surface polishing.

[0062] The fine grinding mechanism includes a pneumatic grinding wheel head linear motion guide rail 4-11, a pneumatic grinding wheel head electric pusher cylinder 4-8, a drive motor B4-12, and a custom-designed airbag grinding wheel 4-13 for fine surface grinding. The custom-designed airbag grinding wheel 4-13 is connected to the drive motor B4-12 and is mounted on the linear motion guide rail 4-11. The pneumatic grinding wheel head electric pusher cylinder 4-8 is connected to the slider of the linear motion guide rail 4-11, driving the custom-designed airbag grinding wheel 4-13 to perform rotary grinding and fine grinding on the ultrasonic surface to be tested.

[0063] The high-speed air blowing head 4-16 is a line-scanning high-pressure air blowing head composed of a row of micro-sized air holes. The high-speed air blowing head 4-16 is a mechanism for blowing away impurities from the surface to be inspected after the rough surface treatment and the fine surface treatment are completed. The high-pressure air blowing head 4-16 is supplied with air by an air storage tank 11 installed in the body of the wall-climbing robot.

[0064] The adaptive ultrasonic detection system 6 is a flexible multi-spatial detection system with automatic control of the contact force and displacement of the ultrasonic probe head, featuring automatic couplant spraying. It includes a couplant injection valve 6-4, an automatic couplant filling tank 10, a servo electric cylinder 6-3 with displacement detection, a contact force sensor 6-2, and an ultrasonic probe head 6-1. The couplant injection valve 6-4 is a programmable, high-precision point-spray valve that can automatically and accurately spray the couplant required for ultrasonic detection onto the surface to be tested. After the wall-climbing robot completes the surface polishing of the surface to be tested, the robot needs to move to bring the adaptive ultrasonic detection system 6 to the area of ​​the surface to be tested. The coupling agent injection valve 6-4 automatically sprays a certain amount of gel-like coupling agent onto the surface to be tested. The gel-like coupling agent is automatically supplied by the automatic coupling agent filling tank 10. The automatic filling tank 10 is equipped with a rubber piston. Compressed air at a certain pressure is filled between the piston and the end cap of the automatic filling tank 10, so that the gel can be continuously dispensed, ensuring that the gel-like coupling agent is continuously replenished in the tube of the coupling agent injection valve 6-4. The automatic coupling agent filling tank 10 is installed inside the body of the wall-climbing robot and is connected to the coupling agent injection valve 6-4 by a glue supply tube. The coupling agent injection valve 6-4 is installed on one side of the servo cylinder 6-3 with displacement detection and automatically sprays the gel-like coupling agent onto the surface to be tested at a certain tilt angle.

[0065] The ultrasonic probe 6-1 is connected to the extension rod of the servo cylinder 6-3 with displacement detection via the adhesion force sensor 6-2. After the coupling agent spraying valve 6-4 completes the coupling agent spraying operation, the servo cylinder 6-3 extends to attach the ultrasonic probe 6-1 to the surface to be tested. The displacement detection function of the servo cylinder 6-3 automatically calculates the extension stroke of the ultrasonic probe 6-1 after converting the data output by the detection surface height measuring sensor 4-19 in the disc-type surface grinding mechanism 4. Furthermore, the adhesion force sensor 6-2 automatically measures the adhesion force between the ultrasonic probe 6-1 and the wall surface to ensure that the adhesion force between the ultrasonic probe 6-1 and the wall surface is within the design threshold, thereby ensuring the detection accuracy and the safety of the equipment during the automatic detection process.

[0066] During operation, high-precision surface contour laser 3D scanning and point cloud reconstruction technology are used to construct the spatial coordinates of the outer contour of large equipment in a large field of view environment. Then, a flexible robot chassis system 1 is built using a high-precision servo-driven magnetic adsorption wheel set 1-1 to perform autonomous crawling motion on the wall of a large steel welded component. The motion control system of the robot chassis 1 is equipped with a spatial position coordinate calculation module to navigate the robot's spatial motion path. The wall-climbing robot can automatically find the position point to be detected according to the specified spatial position coordinates. A high-definition image vision system with remote data transmission assists the operator in monitoring the walking route of the robot chassis system 1 online. After the robot moves to the predetermined detection point, four high-rigidity cylinders 1-19 installed on both sides of the robot chassis system 1 extend and attach the powerful adsorption electromagnets 1-17 connected to the cylinder rods to the component wall to form a high-rigidity support mechanism.

[0067] The robot chassis system 1 is equipped with a "shield-like" disc-type surface grinding mechanism 4 to clean and grind the surface to be inspected. First, the detection surface height measuring sensor 4-19 detects the height of the surface to be inspected. The measured data is transmitted to the wall-climbing robot control system as the basis for subsequent operations. This data will determine the control parameters such as surface cleaning, grinding, and the stroke of the ultrasonic probe head. Further, the disc-type surface grinding mechanism 4 rotates 90° to perform surface cleaning, typically taking 10 seconds per cleaning cycle, followed by disc-type surface grinding. Mechanism 4 rotates 90° to perform impurity blowing; further, disc-type surface polishing mechanism 4 rotates 90° to perform surface polishing, generally each polishing operation takes 15 seconds, followed by impurity blowing; even further, disc-type surface polishing mechanism 4 rotates the detection surface smoothness detection vision sensor 4-9 to the working surface to determine the surface cleanliness. If it meets the ultrasonic detection requirements, ultrasonic detection is performed; if it does not meet the requirements, the above surface cleaning and polishing operations are repeated until the surface to be tested meets the ultrasonic detection requirements.

[0068] After completing the cleaning and polishing work, the wall-climbing robot moves forward a certain distance and then performs ultrasonic detection. The coupling agent injection valve 6-4 automatically sprays a certain amount of gel-like coupling agent onto the surface to be tested. The servo cylinder 6-3 extends to attach the ultrasonic probe head 6-1 to the surface to be tested. The displacement detection function of the servo cylinder 6-3 converts the data output by the detection surface height measurement sensor 4-19 in the disc-type surface polishing mechanism 4 and automatically calculates the extension stroke required of the ultrasonic probe head 6-1, thereby completing the ultrasonic detection operation.

[0069] Finally, the ultrasonic detection data and the detection position of the wall-climbing robot are transmitted to the control system through laser dynamic navigation technology for comparison and storage, thereby constructing a global spatial digital detection process for large components in a virtual environment, and then globally stitching the ultrasonic detection data. Furthermore, intelligent evaluation methods and intelligent judgment systems for ultrasonic detection results can also be developed.

[0070] Finally, it should be noted that the above-described embodiments are merely one specific example of the present invention. Obviously, the present invention is not limited to the above embodiments and many variations are possible. All variations that can be directly derived or conceived by those skilled in the art from the disclosure of the present invention should be considered within the scope of protection of the present invention.

Claims

1. An ultrasonic detection device for welding defects in large components, characterized in that, The system includes a robot chassis system (1), a protective cover (2), an industrial camera (3), a disc-type surface polishing mechanism (4), a spatial position laser tracking module (5), an adaptive ultrasonic detection system (6), a power supply module (7), a servo motor controller (8), and an information processing module (9). The disc-type surface polishing mechanism (4), the adaptive ultrasonic detection system (6), the power supply module (7), the servo motor controller (8), and the information processing module (9) are respectively installed on the robot chassis system (1). The protective cover (2) is installed above the robot chassis system (1). The industrial camera (3) is installed at one end of the protective cover (2), and the spatial position laser tracking module (5) is installed at the other end of the protective cover (2). The disc-type surface polishing mechanism (4) includes a rotating disc (4-1), a rotating disc drive mechanism, a visual sensor for measuring the height of the detection surface and detecting the smoothness, a surface cleaning mechanism, a surface fine polishing mechanism, and a high-speed air blowing head (4-16). The visual sensor for measuring the height of the detection surface and detecting the smoothness, the surface cleaning mechanism, the surface fine polishing mechanism, and the high-speed air blowing head (4-16) are distributed around the circumference of the rotating disc (4-1). The rotating disc drive mechanism is connected to the rotating disc (4-1) in a transmission manner. The rotating disk drive mechanism includes a disk rotation drive motor (4-18), a synchronous belt mechanism, and a high-rigidity cantilever support bearing seat mechanism. The disk rotation drive motor (4-18) is fixed to the robot chassis system (1) via a disk rotation motor mounting plate (4-17). The high-rigidity cantilever support bearing seat mechanism (4-20) is fixed to the robot chassis system (1). The rotating disk (4-1) is mounted on the high-rigidity cantilever support bearing seat mechanism, and the high-rigidity cantilever support bearing seat mechanism (4-20) is connected to the disk rotation drive motor (4-18) via a synchronous belt mechanism. The high-rigidity cantilever support bearing seat mechanism (4-20) includes a support seat body (4-26), an angle... The components include a contact ball bearing (4-25), a deep groove ball bearing (4-24), a high-rigidity rotating shaft (4-27), an end cap (4-28), a bushing (4-29), and a locking nut (4-30). The high-rigidity rotating shaft (4-27) is located inside the support body (4-26), and the bushing (4-29) is located between the support body (4-26) and the high-rigidity rotating shaft (4-27). The angular contact ball bearing (4-25) is mounted on the rotating shaft (4-27) near one end of the rotating disk (4-1). The deep groove ball bearing (4-24) is mounted on the shaft end near the synchronous pulley (4-21), and the end cap (4-28) is located at both ends of the support body (4-26).

2. The ultrasonic detection device for welding defects in large components according to claim 1, characterized in that, The robot chassis system (1) includes a robot chassis, a nitrogen spring (1-11), a magnetic adsorption wheel assembly (1-1), a walking function drive servo motor (1-2), and a steering function drive servo motor (1-5). The magnetic adsorption wheel assembly (1-1) includes a pair of active wheel assemblies and a pair of passive wheel assemblies. The active wheel assembly is mounted on a drive wheel connecting plate (1-3). A floating wheel assembly mounting plate (1-4) is provided on the drive wheel connecting plate (1-3). The floating wheel assembly mounting plate (1-4) is mounted on a floating wheel assembly hinge connecting block (1-7) at the bottom of the robot chassis. One end of the nitrogen spring (1-11) is mounted on a nitrogen spring fixed end mounting block (1-8) on the robot chassis, and the other end is mounted on the floating wheel assembly hinge connecting block (1-7) via a nitrogen spring floating end mounting block (1-9). The passive wheel assembly is... On the driven wheel mounting bracket (1-13), a driven wheel floating hinge connecting block (1-14) is provided. One end of the nitrogen spring (1-11) is mounted on the robot chassis via a nitrogen spring fixed end mounting block (1-8), and the other end is mounted on the driven wheel floating hinge connecting block (1-14) via a nitrogen spring floating end mounting block (1-9). The walking function drive servo motor (1-2) is mounted on the drive wheel connecting plate (1-3). The active wheel set is connected to the walking function drive servo motor (1-2) via a planetary gear reducer flange to realize the walking function. The active wheel set is connected to the drive wheel connecting plate (1-3) via an axial support bearing (1-22), and is connected to the drive wheel connecting plate (1-3) via a steering function drive servo motor (1-5) to realize the steering function.

3. The ultrasonic detection device for welding defects in large components according to claim 1, characterized in that, The robot chassis system (1) further includes a high-rigidity support mechanism, which includes a high-rigidity double guide rod support cylinder (1-19), a cylinder connecting block (1-16), a high-rigidity double guide rod support cylinder mounting plate (1-20), and an electromagnet (1-17). The high-rigidity double guide rod support cylinder (1-19) is connected to the robot chassis system (1) through the high-rigidity double guide rod support cylinder mounting plate (1-20), and the electromagnet (1-17) is installed at the end of the guide rod of the high-rigidity double guide rod support cylinder (1-19).

4. The ultrasonic detection device for welding defects in large components according to claim 1, characterized in that, The surface cleaning mechanism includes a wire brush linear motion guide rail (4-3), a servo drive cylinder (4-2), a drive motor A (4-6), and a custom-made wire brush (4-4) for surface cleaning. The custom-made wire brush (4-4) is connected to the drive motor A (4-6) and is mounted on the wire brush linear motion guide rail (4-3). The servo drive cylinder (4-2) is connected to the slider of the wire brush linear motion guide rail (4-3) and drives the custom-made wire brush (4-4) to perform rotational brushing and coarse cleaning on the ultrasonic surface to be inspected.

5. The ultrasonic detection device for welding defects in large components according to claim 1, characterized in that, The fine grinding mechanism includes a pneumatic grinding wheel head linear motion guide rail (4-11), a pneumatic grinding wheel head electric push cylinder (4-8), a drive motor B (4-12), and a surface fine grinding airbag grinding wheel (4-13). The surface fine grinding airbag grinding wheel (4-13) is connected to the drive motor B (4-12) and installed on the linear motion guide rail (4-11). The pneumatic grinding wheel head electric push cylinder (4-8) is connected to the slider of the linear motion guide rail (4-11) and drives the surface fine grinding airbag grinding wheel (4-13) to perform rotary grinding fine grinding on the ultrasonic surface to be tested.

6. The ultrasonic detection device for welding defects in large components according to claim 1, characterized in that, The high-speed air blowing head (4-16) is mounted on a high-rigidity slide cylinder (4-15), which is installed on a rotating disk (4-1). The high-speed air blowing head (4-16) is connected to an air storage tank (11) and provides an air source through the air storage tank (11).

7. The ultrasonic detection device for welding defects in large components according to claim 1, characterized in that, The adaptive ultrasonic detection system (6) includes a coupling agent injection valve (6-4), an automatic coupling agent filling tank (10), a servo cylinder with displacement detection (6-3), a bonding force sensor (6-2), and an ultrasonic probe (6-1). The coupling agent injection valve (6-4) is mounted on the robot chassis system (1) via an injection valve mounting plate (6-5). The servo cylinder with displacement detection (6-3) is mounted on the robot chassis system (1) via an electric push cylinder mounting plate (6-6). The coupling agent injection valve (6-4) and the automatic coupling agent filling tank (10) are connected via a glue supply pipe. The coupling agent injection valve (6-4) is installed on one side of the servo cylinder with displacement detection (6-3). The ultrasonic probe (6-1) is connected to the extension rod of the servo cylinder with displacement detection (6-3) via the bonding force sensor (6-2).

8. The detection method of the ultrasonic detection device for welding defects in large components according to any one of claims 1-7, characterized in that: Includes the following steps: 1) Construct a flexible robot chassis system (1) to realize autonomous crawling motion on the wall of steel welded components; 2) Construct the spatial coordinates of the equipment's outer contour in a large field of view environment based on high-precision surface contour laser 3D scanning and point cloud reconstruction technology; 3) The robot chassis system (1) is equipped with a spatial position coordinate calculation module to navigate the robot's spatial motion path; 4) After the robot moves to the predetermined detection point, it adheres to the wall surface of the steel welded component; 5) Robot chassis system (1) equipped with a disc-type surface polishing mechanism (4) to clean and polish the surface to be inspected; 6) The robot chassis system (1) is equipped with an adaptive ultrasonic detection system (6) to perform multi-spatial adaptive internal damage detection on the polished surface; 7) By integrating laser dynamic navigation technology, ultrasonic detection data inside the component structure are globally stitched together, thereby realizing full-process digital damage detection of the equipment surface structure.

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