A small-diameter pipeline robot intelligent control system

Abstract

The present application belongs to the technical field of pipeline robots, and particularly relates to a small-diameter pipeline robot intelligent control system, which comprises a pipeline robot, an in-pipe robot end for controlling the pipeline robot, and an out-of-pipe control operation end; the out-of-pipe control operation end comprises a first power carrier module, an industrial PC, and a two-degree-of-freedom force feedback operation frame; the in-pipe robot end collects control signals of the out-of-pipe control operation end through a network port and the first power carrier module and a second power carrier module, and sends collected image information, sensor information, and current feedback values to the out-of-pipe control operation end, so that each driver of the pipeline robot is provided with a force feedback function, operation body sensation is improved, operation is more intuitive and convenient, the condition of the pipeline robot has one more layer of tactile perception, operation is more accurate in cooperation with the force feedback function, and operation efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the field of pipeline robot technology, and specifically relates to an intelligent control system for a small-diameter pipeline robot. Background Technology

[0002] Pipelines are a widely used means of material transportation in industries such as industry, energy, military equipment, and urban construction. Ensuring the safety and effectiveness of these pipeline systems is crucial. However, with increasing service life, pipelines inevitably experience aging, cracks, corrosion, or damage from external construction. If not addressed promptly, accidents can lead to significant economic losses. Therefore, regular pipeline inspection and maintenance are essential. To extend pipeline lifespan, limited inspection and maintenance are necessary. Pipeline inspection robots have emerged to meet this need, thus emphasizing the importance of regular pipeline inspection and maintenance.

[0003] Although pipeline robots have a long history of development, the control method of ordinary buttons or levers is inconvenient to operate, lacks a force feedback mechanism, and cannot provide real-time feedback to the operator on the various reaction forces that the pipeline robot receives during operation, resulting in poor operating feel.

[0004] Once a pipeline robot enters a pipeline, apart from the image information transmitted back from the front or back end cameras, it is impossible to have a detailed understanding of the robot's own posture, especially its posture inside the pipeline. This is very important when the pipeline robot passes through bends in the pipeline, as it can prevent the robot from getting stuck inside.

[0005] Intra-pipe communication has always been a major challenge in the field of pipeline robots, especially for small-diameter pipeline robots. Because small-diameter pipeline robots do not have enough space to build voltage conversion circuits, communication protocol conversion circuits, etc., pipeline robots generally need to drag multiple cables at the tail, including power supply cables, video cables, and control signal cables. The numerous cables severely hinder the movement of the pipeline robot inside the pipe. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the present invention aims to provide an intelligent control system for small-diameter pipeline robots. By utilizing a helical wheel-type force feedback control system for pipeline robots, the operation of the robot becomes more intuitive and tactile. This system also solves problems such as excessive cable usage in pipeline robots, thereby improving the efficiency of pipeline robot operation.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A small-diameter pipeline robot intelligent control system includes a pipeline robot, an in-pipe robot end for controlling the pipeline robot, and an external control operation end. The external control operation end includes a first power line carrier module, an industrial PC, and a two-degree-of-freedom force feedback operating frame. The industrial PC communicates with the first power line carrier module via a network port, and the industrial PC and the two-degree-of-freedom force feedback operating frame are electrically connected to collect image information, sensor information, and current feedback values ​​from the pipeline robot end, and send control signals to the pipeline robot end. The in-pipe robot end includes a second power line carrier module, a controller, and a pipeline robot execution and sensing system. The controller communicates with the second power line carrier module via a network port and supplies power to the pipeline robot execution and sensing system through the second power line carrier module. The in-pipe robot end and the external control operation end are connected via power lines, and the in-pipe robot end collects control signals from the external control operation end through the network port and the first and second power line carrier modules, and sends the collected image information, sensor information, and current feedback values ​​to the external control operation end.

[0009] As a further improvement to the above technical solution, the two-degree-of-freedom force feedback operating frame includes a display screen, a bottom controller, a brushless DC motor, a control handle, and a frame. The display screen is installed on the top of the frame, and there are two brushless DC motors, which are respectively connected to the frame and the control handle.

[0010] As a further improvement to the above technical solution, the control handle has degrees of freedom to rotate around the z-axis and x-axis. The control handle is provided with a forward and backward knob for controlling the pipe robot to move forward or backward. The front end of the control handle is also provided with a first button and a second button for controlling the movement of the pipe robot's electric cylinders to drive and control the pipe robot to work close to the inner wall of the pipe.

[0011] As a further improvement to the above technical solution, a potentiometer and a servo motor are provided between the control handle and the underlying controller. A slider is connected between the operation button and the potentiometer. A spring is sleeved on the slider. One end of the spring is connected to the operation button, and the other end is fixedly connected to the servo motor.

[0012] As a further improvement to the above technical solution, the pipeline robot execution and sensing system includes a drive motor, a steering motor, an electric cylinder, a camera, and an angle sensor. At least two of each of the drive motor, steering motor, and electric cylinder are provided, and a current acquisition module is provided in both the electric cylinder and the steering motor. Multiple angle sensors are provided, and the angle sensors are installed on each joint of the pipeline robot to collect the angle information of each joint.

[0013] As a further improvement to the above technical solution, both the drive motor and the steering motor adopt a force feedback control system.

[0014] In summary, the beneficial effects of this invention are as follows: First, the intelligent control system for the small-diameter pipeline robot of this invention uses a two-degree-of-freedom force feedback operating frame with a force feedback system to operate the robot, enabling each actuator of the pipeline robot to have force feedback function, improving the tactile experience of operation, making operation more intuitive and convenient, adding a layer of tactile perception to the status of the pipeline robot, and making operation more precise and improving operational efficiency in conjunction with the force feedback function; Second, the intelligent control system for the small-diameter pipeline robot of this invention uses a visual operating interface, which can monitor the posture of the pipeline robot in the pipeline in real time; combined with the images transmitted back from the robot's camera, the working status of the pipeline robot can be understood more intuitively; Third, the intelligent control system for the small-diameter pipeline robot of this invention uses power line carrier communication technology to solve the problem of the pipeline robot's movement being hindered by too many cables; More specifically, the two-degree-of-freedom force feedback operating frame of the force feedback system in this invention operates the robot, enabling each actuator of the pipeline robot to have force feedback function, improving the tactile experience of operation, making operation more intuitive and convenient, adding a layer of tactile perception to the status of the pipeline robot, and making operation more precise and improving operational efficiency in conjunction with the force feedback function. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0016] Figure 1 This is a schematic diagram of the structure of the pipeline robot control system provided in an embodiment of the present invention;

[0017] Figure 2 This is a control block flowchart of the pipeline robot control system provided in an embodiment of the present invention;

[0018] Figure 3 This is a schematic diagram of the working principle of the force feedback control system provided in the embodiment of the present invention;

[0019] Figure 4 This is another working principle diagram of the force feedback control system provided in the embodiment of the present invention;

[0020] Figure 5 This is a schematic diagram of the structure of the external control operation terminal of the present invention;

[0021] Figure 6 This is a schematic diagram of the control handle in the external control operation terminal of the present invention;

[0022] Figure 7 This is a schematic diagram of the force feedback control system of the present invention.

[0023] Explanation of the reference numerals in the figure:

[0024] 1. Pipeline robot; 2. External control terminal; 21. Industrial PC; 22. Two-DOF force feedback control frame; 221. DC brushless motor; 222. Bottom controller; 223. Control handle; 224. Forward / backward knob; 225. First button; 226. Second button; 227. Display screen; 228. Frame; 23. First power line carrier module; 24. Potentiometer; 25. Slider; 26. Spring; 3. Internal robot terminal; 31. Second power line carrier module; 32. Controller; 33. Pipeline robot execution and sensing system; 331. Drive motor; 332. Steering motor; 333. Electric cylinder; 334. Camera; 335. Angle sensor; 336. Current collector. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0026] Those skilled in the art should understand that, in the disclosure of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the above terms should not be construed as limiting this invention.

[0027] In the description of this invention, the use of terms such as "a number" means one or more, with "more than" meaning two or more. Terms like "greater than," "less than," and "exceeding" are understood to exclude the stated number, while terms like "above," "below," and "within" are understood to include the stated number. The use of terms like "first," "second," and "third" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, the number of indicated technical features, or the sequential relationship between indicated technical features.

[0028] Reference Figures 1 to 7 The following are several embodiments of an intelligent control system for a small-diameter pipeline robot according to the present invention.

[0029] A control system for a small-diameter pipeline robot 1 includes a pipeline robot 1, an in-pipe robot end 3 for controlling the pipeline robot 1, and an external control operation end 2. The external control operation end 2 includes a first power line carrier module 23, an industrial PC 21, and a two-degree-of-freedom force feedback operation frame 22. The industrial PC 21 communicates with the first power line carrier module 23 via a network port, and the industrial PC 21 and the two-degree-of-freedom force feedback operation frame 22 are electrically connected to collect image information, sensor information, and current feedback values ​​from the pipeline robot end 1, and send control signals to the pipeline robot end 1. The in-pipe robot end... 3 includes a second power line carrier module 31, a controller 32, and a pipeline robot 1 execution and sensing system. The controller 32 communicates with the second power line carrier module 31 through a network port and supplies power to the pipeline robot 1 execution and sensing system through the second power line carrier module 31. The robot end 3 inside the pipe is connected to the control operation end 2 outside the pipe through a power line. The robot end 3 inside the pipe collects control signals from the control operation end 2 outside the pipe through the network port, the first power line carrier module 23, and the second power line carrier module 31, and sends the collected image information, sensor information, and current feedback value to the control operation end 2 outside the pipe.

[0030] Specifically, such as Figures 1 to 4 As shown, the control system of the pipeline robot 1 consists of an internal pipe section and an external pipe section. The external pipe section includes a control cabinet, an operating system, an image processing system, a visualization system, and a signal transmission system. The visualization system includes a control cabinet, an angle sensor, and a position sensor. The signal transmission system includes an internal pipe end, an external pipe end, and cables. When controlling the pipeline robot 1, the control cabinet is connected to the pipeline robot 1 end. The operating system controls the pipeline robot 1's work tasks and forward or backward commands. The image processing system, visualization system, and signal transmission system work together to feed back signals from the internal pipe section to the control cabinet.

[0031] The pipeline robot has multiple control systems that work together, including a travel system, a steering system, a posture adjustment system, an image acquisition system, an operation system, and a sensing system. The pipeline robot 1 is encased in a frame 228, which contains a flexible shell that drives the steering system to complete the steering commands of the pipeline robot 1. The image acquisition system uses cameras 334 positioned at both ends of the frame 228 to collect signals when the pipeline robot 1 moves forward or backward. This facilitates image processing and feature recognition, allowing the pipeline robot 1 to identify obstacles and cracks within the pipeline. After processing the sensor information, the robot's posture is displayed in real-time on a visual interface using a virtual model. The operation system, equivalent to a robotic arm, can perform multi-dimensional motion commands under control signals to complete corresponding tasks within the pipeline.

[0032] In this control system, two power line carrier modules are used to transmit power and communicate between the robot end 3 inside the pipe and the control system end outside the pipe via power lines. Therefore, only two power lines are needed to connect the robot end 3 inside the pipe and the control system end outside the pipe, which reduces the diameter of the cables and facilitates the movement of the pipe robot 1 inside the pipe. The industrial PC 21 communicates with the power line carrier modules via Ethernet to collect image information, sensor information, and current feedback values ​​from the pipe robot 1 and sends control signals to the pipe robot 1. Subsequently, the image information is processed and feature recognition is performed to determine the characteristics of obstacles and cracks inside the pipe. After the sensor information is calculated, the posture of the pipe robot 1 is displayed in real time on the visualization interface using a virtual model. The current feedback value is calculated and sent to the underlying controller 222. The underlying controller 222 multiplies this value by a certain ratio to control the feedback force of the feedback motor. At the same time, the industrial PC 21 runs the robot operating system and imports the digital 3D model of the pipe robot 1 into its visualization interface. Combined with the information from the corner sensor 335, the posture of the pipe robot 1 inside the pipe can be displayed in real time on the visualization interface. The video information transmitted by the camera 334 of the pipe robot 1 can provide an operational reference for the operator.

[0033] In this embodiment, as Figure 6 As shown, the two-degree-of-freedom force feedback operating frame 22 includes a display screen 227, a bottom controller 222, a DC brushless motor 221, a control handle 223, and a support frame. The display screen 227 is mounted on the top of the support frame. There are two DC brushless motors 221, namely a first DC brushless motor 221 and a second DC brushless motor 221, and the first DC brushless motor 221 and the second DC brushless motor 221 are respectively connected to the support frame and the control handle 223.

[0034] In this embodiment, as Figure 7 As shown, the control handle 223 has degrees of freedom to rotate around the z-axis and x-axis. The control handle 223 is provided with a forward and backward knob 224 for controlling the pipe robot 1 to move forward or backward. The front end of the control handle 223 is also provided with a first button 225 and a second button 226 for controlling the movement of the pipe robot 1's electric cylinders 333, so as to drive the pipe robot 1 to work close to the inner wall of the pipe.

[0035] Specifically, the control handle 223 on the two-DOF force feedback manipulator 22 has degrees of freedom of rotation about the z-axis and x-axis. The degree of freedom of rotation about the z-axis is provided by one motor, and the degree of freedom of rotation about the x-axis is provided by another motor. One rotary motor can control the pipe robot 1 to roll left and right, and the other rotary motor can control the pipe robot 1 to turn left and right. The DC brushless motor 221 is equipped with a Hall sensor and uses FOC (Field Oriented Control) control. The force feedback control of FOC transmits the reaction forces of roll and turn to the control handle 223. Furthermore, The forward and backward knobs 224 on the control handle 223 can control the pipe robot 1 to move forward and backward. The speed of the pipe robot 1 when moving forward or backward varies depending on the degree of rotation of the forward and backward knobs 224. The front end of the control handle 223 is also equipped with a first button 225 and a second button 226. The first button 225 and the second button 226 control the front and rear electric cylinders 333 of the pipe robot, respectively. They are used to drive the pipe robot 1 to stick to the inner wall of the pipe. The force feedback circuit feeds back the reaction force of the inner wall of the pipe on the pipe robot 1 during expansion to the fingers, improving the tactile sensation of operation and adding a layer of tactile perception to the status of the pipe robot 1.

[0036] In this embodiment, as Figure 5 As shown, a potentiometer 24 and a servo motor are provided between the control handle 223 and the bottom controller 222. A slider 25 is connected between the forward / backward knob 224 and the potentiometer 24. A spring 26 is sleeved on the slider 25. One end of the spring 26 is connected to the forward / backward knob 224, and the other end is fixedly connected to the servo motor.

[0037] Specifically, when the button on the control handle 223 is pressed, the slider 25 of the potentiometer 24 will produce a certain displacement, and the amount of button pressing corresponds to the displacement of the slider 25. The displacement of the slider 25 in the potentiometer 24 is multiplied by a certain ratio by the underlying controller 222 and sent to the motor controller 32 to control the motor speed or rotation angle. When the motor is obstructed, the current acquisition module collects the motor current value and multiplies it by a certain ratio by the underlying controller 222 to control the servo motor to rotate a corresponding angle in the direction of the compression spring 26. At this time, the pressure transmitted by the servo motor through the spring 26 increases the resistance of the button to the operator's hand, thereby informing the operator through body sensation that the DC motor has encountered an obstruction and that appropriate action needs to be taken.

[0038] In this embodiment, the execution and sensing system of the pipeline robot 1 includes a drive motor 331, a steering motor 332, an electric cylinder 333, a camera 334, and an angle sensor 335. At least two of each of the drive motor 331, steering motor 332, and electric cylinder 333 are provided, and a current acquisition module is provided in both the electric cylinder 333 and the steering motor 332. Multiple angle sensors 335 are provided, and the angle sensors 335 are installed on each joint of the pipeline robot 1 to collect the angle information of each joint of the pipeline robot 1.

[0039] Specifically, the control system of the small-diameter pipeline robot 1 adopts a visual operation interface. The sensor system can be used to understand the posture of the pipeline robot 1 in the pipeline in real time. With the return images from the robot camera 334, the working status of the pipeline robot 1 can be understood more intuitively.

[0040] In this embodiment, the output terminal of the current acquisition module is connected to the underlying controller 222 so that the current acquisition module can acquire the current value of the steering motor 332 and control the servo motor to rotate in the direction of the compression spring 26 by a certain proportion through the underlying controller 222, so as to form a force feedback control system.

[0041] Specifically, the two-degree-of-freedom force feedback manipulator 22 of the force feedback system operates the robot, enabling each actuator of the pipeline robot 1 to have force feedback function, improving the tactile experience of operation, making operation more intuitive and convenient, adding a layer of tactile perception to the status of the pipeline robot 1, and making the operation more precise and improving operational efficiency in conjunction with the force feedback function.

[0042] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A small-diameter pipe robot intelligent control system, characterized in that, This includes a pipeline robot, an in-pipe robotic end for controlling the pipeline robot, and an external control and operation end; The external control operation terminal includes a first power line carrier module, an industrial PC, and a two-degree-of-freedom force feedback operation frame. The industrial PC communicates with the first power line carrier module through a network port, and the industrial PC and the two-degree-of-freedom force feedback operation frame are electrically connected to collect image information, sensor information, and current feedback values ​​from the pipeline robot end, and send control signals to the pipeline robot end. The in-pipe robot end includes a second power line carrier module, a controller, and a pipeline robot execution and sensing system. The controller communicates with the second power line carrier module through a network port and supplies power to the pipeline robot execution and sensing system through the second power line carrier module. The robot end inside the pipe is connected to the control operation end outside the pipe via a power line. The robot end inside the pipe collects control signals from the control operation end outside the pipe through the network port and the first power line carrier module and the second power line carrier module, and sends the collected image information, sensor information and current feedback value to the control operation end outside the pipe. The two-degree-of-freedom force feedback operating frame includes a display screen, a bottom controller, two brushless DC motors, a control handle, and a frame. The display screen is mounted on the top of the frame. The two brushless DC motors are connected to the frame and the control handle, respectively. The control handle has degrees of freedom to rotate around the z-axis and x-axis, and is equipped with forward and backward knobs for controlling the pipeline robot to move forward or backward. The front end of the control handle is also equipped with a first button and a second button for controlling the forward and backward movement of the pipeline robot's electric cylinders, so as to drive the pipeline robot to work close to the inner wall of the pipeline. A potentiometer and a servo motor are installed between the control handle and the underlying controller. A slider is connected between the forward / backward knob and the potentiometer. A spring is fitted on the slider. One end of the spring is connected to the forward / backward knob, and the other end is fixedly connected to the servo motor. When the button on the control handle is pressed, the slider of the potentiometer will produce a certain displacement. The amount of button pressing corresponds to the amount of slider displacement. The displacement of the slider in the potentiometer is multiplied by a certain ratio by the underlying controller and sent to the motor controller to control the motor speed or rotation angle value. When the motor is obstructed, the current acquisition module collects the motor current value and controls the servo motor to rotate in the direction of compressing the spring by a certain ratio by the underlying controller, thus forming a force feedback control system.

2. The intelligent control system for a small-diameter pipeline robot according to claim 1, characterized in that, The pipeline robot execution and sensing system includes a drive motor, a steering motor, an electric cylinder, a camera, and an angle sensor. There are at least two drive motors, steering motors, and electric cylinders, and each electric cylinder and steering motor is equipped with a current acquisition module. Multiple angle sensors are installed on each joint of the pipeline robot and collect the angle information of each joint.

3. The intelligent control system for a small-diameter pipeline robot according to claim 2, characterized in that, The output of the current acquisition module is connected to the underlying controller so that the current acquisition module can acquire the current value of the steering motor, and the underlying controller can multiply it by a certain ratio to control the servo motor to rotate a corresponding angle in the direction of the compression spring, so as to further refine the force feedback control.

4. The intelligent control system for a small-diameter pipeline robot according to claim 1, characterized in that, The external control terminal also includes a visualization system. This visualization system uses a sensor system to understand the posture of the pipeline robot in the pipeline in real time, and, together with the images transmitted back from the robot's camera, provides a more intuitive understanding of the pipeline robot's working status.

5. The intelligent control system for a small-diameter pipeline robot according to claim 1, characterized in that, The industrial PC also runs a robot operating system, imports the digital 3D model of the pipeline robot into its visualization interface, and displays the posture of the pipeline robot inside the pipe in real time in the visualization interface in combination with the information from the corner sensor.

Images