A large pressure-bearing equipment welding seam surface, near-surface defect repair and re-inspection integrated robot and its operation method

Abstract

The present application relates to the technical field of equipment maintenance, and especially relates to a large pressure-bearing equipment welding seam surface and near-surface defect rework and re-inspection integrated robot and a working method thereof, which comprises a wall-climbing robot, a control box and a magnetic suspension stirring and spraying device are fixedly installed above a bottom plate of the wall-climbing robot, a cross magnetic yoke is fixedly installed below the bottom plate, a black light lamp and a video detection system are installed below a cross magnetic yoke core, a polishing device and a constant force polishing control system are fixedly installed in front of the wall-climbing robot, a laser automatic navigator is fixedly installed on the polishing device, and a fixed-point thickness measuring device is fixedly installed behind the wall-climbing robot. The wall-climbing robot is used for defect positioning of a welding seam, the length and shape of the defect are shown, the defect depth is measured by using the laser navigator, and a polishing head is operated for local polishing operation, and the depth is measured during the polishing process, so that polishing and detection integrated operation is realized, and the working efficiency is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of equipment maintenance, in particular to a large pressure-bearing equipment welding seam surface and near-surface defect repair and re-inspection integrated robot and its operation method. BACKGROUND

[0002] At present, for the maintenance of large pressure-bearing equipment, there is a large pressure-bearing equipment magnetic powder detection robot, which can respectively detect surface defects by magnetic powder detection. If the magnetic powder detection is all qualified, the robot can completely realize automatic operation detection, can save the construction of scaffolding, greatly reduce the operation time and cost, and can ensure the personal safety during operation.

[0003] However, the existing operation robot has the following technical problems in the magnetic powder detection operation process: some large pressure-bearing equipment will detect some surface defects during magnetic powder detection, thereby generating the problem that manual welding seam repair is still needed after the surface defects are found, and scaffolding still needs to be built to perform manual welding seam polishing defects, and then detection is performed again, which makes the previously saved scaffolding construction meaningless, and it is difficult to greatly reduce the operation time and cost and ensure personal safety during operation. SUMMARY

[0004] The main purpose of the present application is to overcome the shortcomings of the prior art, and provide a large pressure-bearing equipment welding seam surface and near-surface defect repair and re-inspection integrated robot and its operation method. The welding seam is positioned by the traveling wall-climbing robot, the length and shape of the defect are displayed, the defect depth is measured by the laser navigator, and the local polishing operation is performed by the polishing head. The depth is measured during polishing to realize integrated polishing and detection operation, and the work efficiency is improved.

[0005] The technical scheme adopted by the present application to achieve the technical purpose is: a large pressure-bearing equipment welding seam surface and near-surface defect repair and re-inspection integrated robot, comprising a wall-climbing robot, the wall-climbing robot comprising a suction module and a wall-climbing walking mechanism;

[0006] A control box and a magnetic suspension stirring and spraying device are fixedly installed above the bottom plate of the wall-climbing robot, and a cross magnetic yoke is fixedly installed below the bottom plate, and a black light and a video detection system are installed below the cross magnetic yoke core crossbeam;

[0007] A polishing device and a constant force polishing control system are fixedly installed in front of the wall-climbing robot, and a laser automatic navigator is fixedly installed on the polishing device;

[0008] The laser automatic navigator has two functions, one is to make the robot automatically walk along the weld, reach the welding defect position, and start the function during polishing movement and detection movement, and the other is to measure the pit surface geometric size parameters by using the array laser method, and the three-dimensional geometric size parameters of the pit surface are obtained in real time by the wall climbing robot walking forward, although the polishing depth control by the polishing head can accurately predict the geometric size of the pit surface after polishing, and the laser measurement can more accurately obtain the geometric size parameters of the pit, so as to accurately and safely evaluate the pit;

[0009] The rear of the wall climbing robot is fixedly provided with a fixed-point thickness measuring device;

[0010] The polishing device is provided with a dustproof partition plate between the cross magnetic yoke;

[0011] When the wall climbing robot works inside the spherical tank, a fall preventer is connected, and the fall preventer is fixedly connected to the flange on the top of the spherical tank;

[0012] An automatic tracking holder is arranged at the bottom of the spherical tank, the automatic tracking holder is connected with an external operation table through a transmission cable, and the external operation table is connected with the control box on the wall climbing robot through a shielding cable;

[0013] The automatic tracking holder is used for monitoring the working condition of the wall climbing robot, the external operation table is used for controlling the action of the wall climbing robot, and the external operation table comprises a display device for displaying the detection result of the video detection system and an external input device for controlling the robot through a single-chip microcomputer.

[0014] Preferably, the wall climbing walking mechanism comprises a driving wheel, a driven wheel, a driving shaft mounting piece and a driving motor, and opposite sides of the wall climbing walking mechanism are provided with light source targets.

[0015] Preferably, the magnetic suspension stirring and spraying device comprises a stirring device, a liquid storage tank, a spraying device and a control device.

[0016] The bottom surface of the liquid storage tank is fixedly connected with a liquid pumping pipe, the liquid pumping pipe is respectively connected with the stirring device and the spraying device, and the stirring device and the spraying device are respectively electrically connected with the control device; the stirring device is used for stirring the magnetic suspension liquid in the liquid storage tank, the spraying device is used for spraying the magnetic suspension liquid, and the control device is used for controlling the start and stop of the stirring device and the spraying device.

[0017] The stirring device comprises a first water pump, a nozzle and a liquid return pipe.

[0018] The first water pump, the nozzle and the bottom surface of the liquid storage tank are communicated through the liquid return pipe and the liquid extraction pipe, the first water pump is electrically connected with the control device, the first water pump extracts the magnetic suspension liquid with high concentration from the bottom of the liquid storage tank and discharges the magnetic suspension liquid through the nozzle, the nozzle is arranged in the liquid storage tank, the spraying direction of the nozzle is parallel to the bottom surface of the liquid storage tank and is tangent to the vertical surface of the liquid storage tank, and the mixing effect is enhanced;

[0019] The spraying device comprises a second water pump, a liquid conveying pipe and a spray head.

[0020] The second water pump, the spray head and the bottom surface of the liquid storage tank are communicated through the liquid conveying pipe and the liquid extraction pipe, the second water pump is electrically connected with the control device, and the second water pump extracts the mixed magnetic suspension liquid from the liquid storage tank and discharges the magnetic suspension liquid through the spray head.

[0021] Preferably, the inside and outside of the liquid storage tank are further provided with a mixing system, the mixing system comprises water baffles arranged in the inside of the liquid storage tank, the water baffles are arranged in two groups and are slidably connected to the upper half of the liquid storage tank through guide rails, one side of the water baffles is fixedly connected with a pull plate, the pull plate penetrates through the opposite water baffles and extends to the outside of the liquid storage tank, and the two groups of water baffles are moved to approach or move away from each other by pulling the pull plate.

[0022] A matched gear housing, a driving gear and a reciprocating motor are fixedly installed on the top of the liquid storage tank, the driving gear is rotationally arranged in the inside of the gear housing and is fixedly connected with a stirring rod, and the stirring rod is rotationally arranged in the inside of the liquid storage tank and is located between the two groups of water baffles.

[0023] Toothed plates are toothedly connected to the two sides of the driving gear, one end of the toothed plate is located between the gear housing and the driving gear, and the other end of the toothed plate is slidably connected with a sliding groove block fixed to the top of the liquid storage tank.

[0024] The outer wall of the upper half of the liquid storage tank is provided with movable plates on the two sides, one end of the movable plate is hingedly connected to the outer wall of the liquid storage tank, the middle end of the movable plate is hingedly connected with the pull plate, and the other end of the movable plate is hingedly connected with the toothed plate.

[0025] Preferably, the constant force polishing control system comprises a polishing force monitoring unit, a polishing position monitoring unit and a total control center.

[0026] The polishing force monitoring unit comprises a force sensor and a constant force module, during the polishing process, the force sensor is used for monitoring the polishing force in real time and feeding back to the constant force module, and the constant force module is used for adjusting and controlling the polishing force to be stable.

[0027] The polishing position monitoring unit comprises a position adjusting module, and during the polishing process, the distance between the polishing head and the surface of the weld to be polished is monitored in real time by the laser automatic navigator and fed back to the position adjusting module, and the position adjusting module adjusts and controls the distance between the polishing head and the surface of the weld to be polished.

[0028] The polishing force self-adaptive calculation module is based on a two-freedom PID control algorithm, and through control of the polishing force and the polishing position, the monitoring and adjustment of the polishing force during the vertical direction feeding process of the polishing head are realized, and the monitoring and adjustment of the polishing position during the feeding process are realized.

[0029] The total control center is provided with a preset polishing allowance, and during the polishing process, the polishing force and the polishing position during the vertical direction feeding process of the polishing head are monitored and adjusted in cycles, and the distance between the polishing head and the surface of the weld to be polished and the preset polishing allowance are analyzed in real time, until the deviation analysis result of the distance between the polishing head and the surface of the weld to be polished and the preset polishing allowance meets the expected value, and then the polishing execution is terminated.

[0030] Preferably, the polishing device is composed of a sliding table mounting plate, a sliding table, a lifting driving motor, a sliding block, a polishing lifting frame, a suspension spring system, a polishing motor and a polishing head.

[0031] The sliding table mounting plate is connected with the wall-climbing walking mechanism through bolts, the sliding table is connected with the sliding table mounting plate through bolts, the polishing lifting frame is installed on the sliding block, the lifting of the polishing lifting frame is controlled by the lifting driving motor, and the pressing force is transmitted to the polishing head through the suspension spring system.

[0032] The polishing motor is fixedly connected to the lower end face of the constant force module, the output end of the polishing motor is connected with the polishing head, the distance between the polishing head and the weld wall surface is detected in real time by the laser automatic navigator and sent to the control box, and the control box controls the gap between the polishing head and the weld wall surface by controlling the lifting driving motor.

[0033] Preferably, the fixed-point thickness measuring device comprises a sleeve, an electromagnet, a probe mounting seat and a thickness gauge probe, the upper end of the sleeve is fixed on the bottom plate, the electromagnet is installed in the sleeve, the lower end of the push rod of the electromagnet extends out of the lower end of the sleeve, the lower end of the push rod is connected with the probe mounting seat, and the thickness gauge probe is installed in the probe mounting seat and fixed by a set screw.

[0034] The application also provides a working method of the large-scale pressure-bearing equipment weld surface and near-surface defect repair and re-inspection integrated robot, which specifically comprises the following steps:

[0035] S1, first mark the defects of the weld by the magnetic powder detection robot, and then drive the wall climbing robot to the marked position to repair and recheck the weld defects;

[0036] S2, the basis for safety evaluation of the weld defects exceeding the standard is to accurately determine the size of the defects;

[0037] The wall climbing robot is used to locate the weld defects, show the length and shape of the defects, and find the positioning point of the specific position of the weld. The defect identification is performed on the entity, and the laser automatic navigator 13 is used to measure the depth of the defect;

[0038] S3, based on the results of the defect positioning, first grind the weld defects and remove the original weld heat affected zone to grind the weld defects;

[0039] The center of the grinding head is completely coincided with the center line of the weld to be repaired, the deviation is adjusted to meet the requirements, the position of the grinding head is adjusted to the position 2mm below the weld defect by the wall climbing robot 37, the grinding motor is started to grind, and the grinding stroke is controlled to be 2mm more than the position of the weld defect;

[0040] After the weld defect is ground by the grinding head, the cross magnetic yoke is used for detection. If there is still crack, the position is marked first;

[0041] S4, the longitudinal weld cracks or transverse weld cracks are removed by layer-by-layer grinding method;

[0042] After all the weld defects in the spherical tank are ground by the grinding head, the wall climbing robot moves quickly to the bottom of the spherical tank, the grinding head is replaced by the pit grinding head. For longitudinal weld cracks, the pit grinding head is adjusted by the wall climbing robot to be above the longitudinal weld cracks and parallel to the longitudinal weld cracks. The position of the pit grinding head is moved to the position 2mm below the weld defect, and the pit grinding head is operated for local grinding operation. When the defect is removed, the grinding is slow. During the grinding process, the wall climbing robot measures the depth by using the laser automatic navigator. When the grinding amount is 30% of the pit depth, it is no longer pressed downward, and the forward rolling grinding is controlled to be 2mm more than the position of the weld defect;

[0043] S5, if there is still crack, the second layer grinding is performed by using the cross magnetic yoke. The grinding amount of the second layer is 50% of the pit depth. After the grinding is completed, the cross magnetic yoke is used for detection. If there is still crack, the third layer grinding is performed. The grinding amount of the third layer is 70% of the pit depth. After the grinding is completed, the cross magnetic yoke is used for detection. If there is still crack, the fourth layer grinding is performed. The grinding amount of the fourth layer is 90% of the pit depth. Until the grinding reaches the maximum value of the determined defect depth, the grinding is stopped;

[0044] For transverse cracks of the weld, the wall-climbing robot rotates by ninety degrees, adjusts the concave grinding head above and parallel to the transverse cracks, and moves the position of the concave grinding head to a position 2mm outside the weld defect, and then processes again in the same way as described above;

[0045] S6, when the grinding depth of the weld reaches the maximum value of the determined defect depth, the remaining weld is detected by the cross magnetic yoke, and it is confirmed that the weld defect is removed.

[0046] Preferably, the grinding head is divided into a flat grinding head and a concave grinding head;

[0047] Wherein, for the concave pit formed by the concave grinding head after the crack grinding is eliminated, the original stress distribution of the container has been changed, so the method of simply using the remaining wall thickness for strength checking cannot be used, and the dimensionless parameter G should be calculated to determine whether the concave pit is within the allowable range, and the specific judgment method is as follows:

[0048] ①Calculate the wall thickness allowance:

[0049] The depth C of the pit formed by the crack, if less than the wall thickness allowance (wall thickness allowance = measured wall thickness - nominal thickness + corrosion allowance), the pit is allowed to exist without repair welding and other treatment, otherwise dimensionless calculation is performed;

[0050] The pit formed after grinding does not need repair welding if it is within the allowable range, which does not affect the classification; otherwise, repair welding or stress analysis can be performed, and after repair welding is qualified or the stress analysis result shows that it does not affect the safe use, it can be classified as two or three levels;

[0051] If the depth of the pit formed after the crack grinding is within the wall thickness allowance, the pit is allowed to exist. Otherwise, the pit is regularized as a semi-ellipsoidal pit with a long axis length of 2A (mm), a short axis length of 2B (mm), and a depth of C (mm), and the dimensionless parameter G0 is calculated, if G0 < 0.10, the pit is within the allowable range;

[0052] ②The pit for dimensionless parameter G0 calculation should meet the following conditions:

[0053] The pit surface is smooth and the transition is gentle, and there is no other surface defect or buried defect around it;

[0054] The pit is not close to the geometric discontinuous area or the area with sharp corners;

[0055] The container does not bear external pressure or fatigue load;

[0056] Thin-walled cylindrical shell with T / R less than 0.18 or thin-walled spherical shell with T / R less than 0.10;

[0057] The material meets the pressure vessel design regulations and no degradation is found.

[0058] The pit depth C is less than 1 / 3 of the wall thickness T and less than 12 mm, and the minimum thickness (T-C) of the pit bottom is not less than 3 mm;

[0059] Pit half-length ;

[0060] The pit half-width B is not less than three times the pit depth C;

[0061] ③Calculation of the non-dimensional parameter G0 of the pit defect:

[0062] ;

[0063] In the formula, T is the wall thickness (mm) of the container at the position of the pit, and R is the average radius (mm) of the container;

[0064] For spherical tanks, before the crack is polished and eliminated, a polishing scheme should be developed and the pit formed after polishing should be calculated. If the pit meets the prerequisites for pit evaluation and the pit is within the allowable range, the pit is polished, otherwise, the polishing scheme is polished.

[0065] When the pit is polished, the maximum allowable pit depth Cmax is calculated when the non-dimensional parameter G is 0.1. The pit depth is less than 1 / 3 of the wall thickness T and less than 12 mm. Under normal circumstances, the wall thickness of the spherical tank is not less than 30 mm, and the maximum allowable pit depth of 10 mm can meet the requirements of the pit depth being less than 1 / 3 of the wall thickness T and less than 12 mm at the same time. Therefore, the polishing height h of the pit polishing head is selected as 10 mm, and the maximum polishing depth is 10 mm according to this polishing. The pit half-width B is not less than 3 times the pit depth C.

[0066] According to the design shape of the pit polishing head, the pit half-width B is

[0067]

[0068] According to this formula, if C is 10 mm, then B is

[0069]

[0070] The pit half-length A is not less than the pit half-width B, and the pit half-length A is

[0071]

[0072] In actual design, R2 is taken as 50 mm, and R1 is taken as 100 mm considering the consistency with the radius of the flat grinding head, so that the key size parameters of the grinding head can be determined, and the pit shape ground by the grinding head fully meets the pit shape size requirements specified in TSG 21-2016 “Fixed Pressure Vessel Safety Technical Regulations”.

[0073] Preferably, the grading grinding technology is adopted in the above operation method, and first, the grinding for removing the weld reinforcement is adopted to grind the defect weld flat with the flat grinding head;

[0074] If the defect is not removed after re-inspection, the maximum pit depth Cmax in the allowable range is calculated according to the dimensionless parameter G to perform grinding;

[0075] Since the larger the pit depth is, the worse the safety factor is, the remaining defect is not directly ground by the maximum allowable pit depth, but the defect is ground by the pit depth as much as possible, and when the grading grinding is designed, whether the smaller maximum pit depth Cmax is greater than 10 mm (when the wall thickness is greater than 30 mm, it is applicable, and when the wall thickness is less than 30 mm, 1 / 3 of the wall thickness T is taken) is compared first, if Cmax is greater than or equal to 10 mm, 10 mm is taken as the base value, and 20%, 50%, 70%, and 90% of the base value are respectively ground, if Cmax is less than 10 mm, Cmax is taken as the base value, and 20%, 50%, 70%, and 90% of the base value are respectively ground. The grading grinding sequence is: the first grinding is performed according to 2 mm or 20% of the maximum allowable pit depth (the smaller value is taken). Then, the magnetic powder detection re-inspection is performed, if the defect is not ground, the maximum allowable pit depth of 5 mm, 7 mm, 9 mm, 50%, 70%, and 90% (the smaller value is taken respectively) is sequentially ground according to the previous method, if the defect is not ground by the maximum allowable pit depth of 90%, the manual scaffold is considered to be built to perform welding repair.

[0076] The pit grinding head is a circular arc bottom, and the width is more than three times of the arc depth h, if Cmax is greater than or equal to 10 mm, the pit shape size formed by the grading grinding of the pit grinding head is respectively:

[0077] C1: 2 mm B1: 14 mm A1: 19.9 mm

[0078] C1: 5 mm B1: 21.8 mm A1: 31.2 mm

[0079] C1: 7 mm B1: 25.5 mm A1: 36.8 mm

[0080] C1: 9 mm B1: 28.6 mm A1: 41.5 mm

[0081] The pit shape and size formed by the step grinding of the pit grinding head are as follows, when Cmax is less than 10mm:

[0082] C1: 20% C max mm

[0083] B1: mm

[0084] A1: mm

[0085] C1: 50% C max mm

[0086] B1: mm

[0087] A1: mm

[0088] C1: 70% C max mm

[0089] B1: mm

[0090] A1: mm

[0091] C1: 90% C max mm

[0092] B1: mm

[0093] A1: mm

[0094] Grinding flatness determination:

[0095] The grinding flatness is mainly controlled by the descending distance of the grinding head. In addition, if sparks are observed at the corners of the grinding head, it can be determined that the weld has been ground flat.

[0096] Pit grinding determination:

[0097] The actual descending distance of the pit polishing head is monitored in real time by the laser automatic navigator, so that the actual descending distance of the pit polishing head can be known and fed back to the position adjusting module.

[0098] Compared with the prior art, the present application has the following beneficial effects:

[0099] The large pressure-bearing equipment weld surface, near-surface defect repair and re-inspection integrated robot can position the defects on the weld by the wall-climbing robot, show the length and shape of the defects, measure the depth of the defects by the laser navigator, and operate the polishing head to perform local polishing operation, so that the polishing and detection are integrated, and the work efficiency is improved.

[0100] The large pressure-bearing equipment weld surface, near-surface defect repair and re-inspection integrated robot provides a polishing head designed according to the polishing requirements of the pressure vessel weld and the safety requirements of the pressure vessel regulations, and the width of the flat polishing head is considered according to the weld width and height, so that the stress condition is better after the weld reinforcement is flattened; and the step-by-step polishing technology is adopted, that is, the weld reinforcement is removed first, and if the defects are not removed after re-inspection, the allowable pit depth in the allowable range is calculated according to the non-dimensional parameter G specified in TSG 21-2016, and if the defects are not removed by polishing at 90% of the maximum allowable pit depth, manual scaffold is considered to be built for welding repair.

[0101] The large pressure-bearing equipment weld surface, near-surface defect repair and re-inspection integrated robot can uniformly spray the magnetic suspension liquid by the magnetic suspension liquid stirring and spraying device, and the existing step-by-step cross magnetic yoke technology is adopted, so that the pit half-length is usually smaller than the effective magnetization area length of the rotating magnetic field formed by the cross magnetic yoke technology, and the detection of the pit surface defects can be completed by one-time magnetization, and in a few cases, the pit half-length is greater than the effective magnetization area length of the rotating magnetic field formed by the cross magnetic yoke technology, and more than two times of step-by-step segmented cross magnetic yoke technology is adopted.

[0102] The large pressure-bearing equipment weld surface, near-surface defect repair and re-inspection integrated robot, on the one hand, enables the robot to automatically walk along the weld to reach the welding defect position, and starts this function when polishing and moving and when detecting, and on the other hand, measures the pit surface geometric size parameters by the array laser method, and obtains the pit surface three-dimensional geometric size parameters in real time by the wall-climbing robot walking forward, so that the pit surface geometric size after polishing can be more accurately predicted by the polishing depth control of the polishing head, and the geometric size parameters of the pit can be more accurately obtained by the laser measurement, so as to accurately and safely evaluate the pit. BRIEF DESCRIPTION OF DRAWINGS

[0103] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiments will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without any creative effort based on these drawings.

[0104] Figure 1 It is a main view structural schematic diagram of the robot overall structure.

[0105] Figure 2 It is a top view structural schematic diagram of the robot partial structure.

[0106] Figure 3 It is a main view structural schematic diagram of the magnetic suspension stirring and spraying device.

[0107] Figure 4 It is a main view and internal section view structural schematic diagram of the magnetic suspension stirring and spraying device.

[0108] Figure 5 It is a top view structural schematic diagram of the toothed plate, gear housing and driving gear.

[0109] Figure 6 It is a main view section view structural schematic diagram of the fixed point thickness measuring device.

[0110] Figure 7 It is a main view structural schematic diagram of the constant force module, force sensor, polishing motor and polishing head.

[0111] Figure 8 It is a main view structural schematic diagram of the pit polishing head.

[0112] Figure 9 It is a structural schematic diagram of the work robot working on the spherical tank.

[0113] Figure 10 It is a schematic diagram of the polishing head polishing different depths on the spherical tank.

[0114] Wherein: 1, mounting plate; 2, lifting drive motor; 3, sliding table; 4, sliding block; 5, polishing lifting frame; 6, polishing device; 7, constant force polishing control system; 8, suspension spring system; 9, spring; 10, fixed shaft; 11, anti-falling device; 12, flange; 13, laser automatic navigator; 14, transmission cable; 15, locking screw; 16, constant force module; 17, force sensor; 18, polishing motor; 19, flat polishing head; 20, mixing system; 2001, water baffle; 2002, guide rail; 2003, pull plate; 2004, movable plate; 2005, toothed plate; 2006, sliding groove block; 2007, gear housing; 2008, drive gear; 2009, reciprocating motor; 21, drive shaft mounting; 22, drive motor; 23, dustproof partition; 24, cross magnetic yoke; 25, black light; 26, spray head; 27, video detection system; 28, driven wheel; 29, automatic tracking holder; 30, external operation table; 31, shielded cable; 32, fixed-point thickness measuring device; 33, control box; 34, bottom plate; 35, wall climbing walking mechanism; 36, magnetic suspension stirring and spraying device; 37, wall climbing robot; 38, driving wheel; 39, light source target; 40, pit polishing head; 41, liquid storage tank; 42, nozzle; 43, liquid return pipe; 44, first water pump; 45, control device; 46, liquid suction pipe; 47, second water pump; 48, liquid delivery pipe; 49, sleeve; 50, electromagnet; 51, probe mounting seat; 52, thickness gauge probe; 53, push rod. DETAILED DESCRIPTION

[0115] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship when the product of the present application is usually placed, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", "third" and the like are only used for differentiation in description and cannot be understood as indicating or implying relative importance.

[0116] In the description of the present application, it should be noted that, unless otherwise explicitly specified and limited, the terms "arrangement", "installation", "connection", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected, it can be mechanically connected, or it can be electrically connected, it can be directly connected, or indirectly connected through an intermediate medium, it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0117] In order to make the objects, technical solutions and advantages of the present application clearer, the present application will be further described in detail below with reference to the drawings and examples. However, it should be understood that the specific examples described herein are only used to explain the present application and are not used to limit the scope of the present application. In addition, in the following description, the description of the known structures and technologies is omitted to avoid unnecessary confusion of the concept of the present application.

[0118] Embodiment 1:

[0119] Please refer to Figure 1 、 2 , 9, a large pressure equipment weld surface, near-surface defect repair and recheck integrated robot, including wall climbing robot 37, wall climbing robot 37 includes adsorption module and wall climbing walking mechanism 35; Wall climbing walking mechanism 35 includes driving wheel 38, driven wheel 28, drive shaft mounting 21 and drive motor 22, the opposite sides of wall climbing walking mechanism 35 are provided with light source target 39; Drive shaft mounting 21 includes drive shaft and shaft mounting, which is connected with driving wheel 38, drive shaft mounting 21, drive motor 22, driving wheel 38 and driven wheel 28 are all fixedly installed under bottom plate 34, wall climbing robot 37 can be adsorbed on the inner wall of spherical tank and walk under the drive of drive motor 22 through adsorption module.

[0120] When wall climbing robot 37 works inside the spherical tank, it is connected with anti-falling device 11, which is fixedly connected on flange 12 at the top of the spherical tank; Automatic tracking holder 29 is arranged at the bottom inside the spherical tank, which is connected with external operation table 30 through transmission cable 14, and external operation table 30 is connected with control box 33 on wall climbing robot 37 through shielded cable 31.

[0121] Automatic tracking holder 29 is used to monitor the working condition of wall climbing robot 37, and external operation table 30 is used to control the action of wall climbing robot 37, which includes display device for displaying the detection results of video detection system 27 and external input device for controlling the robot through single-chip microcomputer.

[0122] Specifically, in use, wall climbing robot 37 is placed on and adsorbed on the inner wall of the spherical tank, automatic winding reel is arranged at the top inlet hole of the spherical tank, the power line and signal line connected with the robot are connected with the automatic winding reel, three-legged support is arranged at the bottom inlet of the spherical tank, automatic tracking holder 29 is arranged on the three-legged support, which can rotate horizontally by 360° and rotate by 180° in pitch, at any time, automatic tracking holder 29 will lock light source target 39 on the robot, the cable of automatic tracking holder 29 is connected to external operation table 30 from the bottom manhole, and the fixed line part of the cable of automatic winding reel is connected to external operation table 30.

[0123] The control box 33 and the magnetic suspension stirring and spraying device 36 are fixedly installed above the bottom plate 34 of the wall-climbing robot 37, and the cross magnetic yoke 24 is fixedly installed below the bottom plate 34. The black light lamp 25 and the video detection system 27 are installed below the cross magnetic yoke 24, and the video detection system 27 comprises a camera and camera shooting accessories.

[0124] The polishing device 6 and the constant-force polishing control system 7 are fixedly installed in front of the wall-climbing robot 37, and the laser automatic navigator 13 is fixedly installed on the polishing device 6.

[0125] The laser automatic navigator 13 has two functions. One is to make the robot automatically walk along the weld to reach the welding defect position, and to start the function when polishing and detecting. The other is to measure the geometric size parameters of the pit surface by using the array laser method, to obtain the three-dimensional geometric size parameters of the pit surface in real time by walking forward through the wall-climbing robot 37. Although the polishing depth control through the polishing head can accurately predict the geometric size of the pit surface after polishing, the laser measurement can more accurately obtain the geometric size parameters of the pit, so as to accurately and safely evaluate the pit.

[0126] The fixed-point thickness measuring device 32 is fixedly installed at the rear of the wall-climbing robot 37, and is mainly used for thickness measurement.

[0127] Further, the dustproof partition plate 23 is arranged between the polishing device 6 and the cross magnetic yoke 24, and is used for blocking the polishing dust.

[0128] Embodiment 2:

[0129] Please refer to Figures 1-5 On the basis of the above embodiment, the large pressure-bearing equipment weld surface, near-surface defect repair and re-inspection integrated robot, the magnetic suspension stirring and spraying device 36 comprises a stirring device, a liquid storage tank 41, a spraying device and a control device 45.

[0130] The bottom surface of the liquid storage tank 41 is fixedly connected with a liquid pumping pipe 46, the liquid pumping pipe 46 is respectively connected with the stirring device and the spraying device, and the stirring device and the spraying device are respectively electrically connected with the control device 45. The stirring device is used for stirring the magnetic suspension liquid in the liquid storage tank 41, the spraying device is used for spraying the magnetic suspension liquid, and the control device 45 is used for controlling the start and stop of the stirring device and the spraying device.

[0131] The stirring device comprises a first water pump 44, a nozzle 42 and a liquid return pipe 43.

[0132] The first water pump 44, the nozzle 42 and the bottom surface of the liquid storage tank 41 are communicated through the liquid return pipe 43 and the liquid suction pipe 46, the first water pump 44 is electrically connected with the control device 45, the first water pump 44 sucks the magnetic suspension liquid with high concentration from the bottom of the liquid storage tank 41, and discharges the magnetic suspension liquid through the nozzle 42, the nozzle 42 is arranged in the liquid storage tank 41, the spraying direction of the nozzle 42 is parallel to the bottom surface of the liquid storage tank 41, and the spraying direction of the nozzle 42 is tangent to the vertical surface of the liquid storage tank 41, so that the mixing effect is enhanced;

[0133] The spraying device comprises a second water pump 47, a liquid conveying pipe 48 and a spray head 26;

[0134] The second water pump 47, the spray head 26 and the bottom surface of the liquid storage tank 41 are communicated through the liquid conveying pipe 48 and the liquid suction pipe 46, the second water pump 47 is electrically connected with the control device 45, and the second water pump 47 sucks the mixed magnetic suspension liquid from the liquid storage tank 41 and discharges the mixed magnetic suspension liquid through the spray head 26.

[0135] Specifically, when the control device 45 controls the stirring device to stir, the first water pump 44 sucks the magnetic suspension liquid with high concentration from the bottom of the liquid storage tank 41 through the liquid suction pipe 46, forms a high-speed jet flow from the nozzle 42 to the liquid storage tank 41 through the liquid return pipe 43, and under the action of the high-speed jet flow and the wall surface of the liquid storage tank 41, the magnetic suspension liquid at the bottom end of the liquid storage tank 41 flows rapidly, so that the magnetic suspension liquid with high concentration is automatically stirred and mixed; and the second water pump 47 sucks the mixed magnetic suspension liquid from the liquid storage tank 41 and discharges the mixed magnetic suspension liquid through the spray head 26.

[0136] Further, the inside and outside of the liquid storage tank 41 are further provided with a mixing system 20, the mixing system 20 comprises a water baffle 2001 arranged in the inside of the liquid storage tank 41, the water baffle 2001 is arranged in two groups and is slidably connected to the upper half of the liquid storage tank 41 through a guide rail 2002, one side of the water baffle 2001 is fixedly connected with a pull plate 2003, the pull plate 2003 penetrates through the opposite water baffle 2001 and extends to the outside of the liquid storage tank 41, and the two groups of water baffles 2001 are moved to approach or move away from each other by pulling the pull plate 2003;

[0137] A matched gear housing 2007, a driving gear 2008 and a reciprocating motor 2009 are fixedly installed on the top of the liquid storage tank 41, the driving gear 2008 is rotationally arranged in the inside of the gear housing 2007 and is fixedly connected with a stirring rod, and the stirring rod is rotationally arranged in the inside of the liquid storage tank 41 and is located between the two groups of water baffles 2001 at the same time;

[0138] The driving gear 2008 is toothedly connected with a toothed plate 2005 at two sides, one end of the toothed plate 2005 is located between the gear housing 2007 and the driving gear 2008, and the other end is slidably connected with a sliding groove block 2006 fixedly arranged on the top of the liquid storage tank 41;

[0139] The outer wall of the upper half of the liquid storage tank 41 is provided with movable plates 2004, one end of the movable plates 2004 is hinged to the outer wall of the liquid storage tank 41, the middle end is hinged to the pull plate 2003, and the other end is hinged to the toothed plate 2005.

[0140] Specifically, in use, when the magnetic suspension in the bottom end portion of the liquid storage tank 41 flows and mixes quickly, the reciprocating motor 2009 is turned on to drive the drive gear 2008 and the stirring rod to stir in the upper half of the liquid storage tank 41, and the toothed plate 2005 moves left and right reciprocally under the drive of the drive gear 2008, thereby driving the movable plate 2004 to move left and right reciprocally. Since the water baffle 2001 is slidably connected to the upper half of the liquid storage tank 41 through the guide rail 2002, the two groups of water baffles 2001 move closer to each other or farther away from each other, so that the magnetic suspension in the upper half of the liquid storage tank 41 is continuously pressed downward and then diffused, so that the magnetic suspension in the liquid storage tank 41 flows completely, avoiding uneven concentration of the magnetic suspension when sprayed.

[0141] The scheme in this embodiment can be selectively combined with the schemes in other embodiments.

[0142] Embodiment 3:

[0143] Please refer to Figure 1 , 7 , 8, on the basis of the above-mentioned embodiments, the large pressure-bearing equipment weld surface, near-surface defect repair and re-inspection integrated robot, the constant force polishing control system 7 includes a polishing force monitoring unit, a polishing position monitoring unit and a total control center;

[0144] The polishing force monitoring unit includes a force sensor 17 and a constant force module 16. During polishing, the force sensor 17 is used to monitor the polishing force in real time and feed back to the constant force module 16, and the constant force module 16 is used to adjust and control the polishing force to be stable;

[0145] The polishing position monitoring unit includes a position adjustment module. During polishing, the distance between the polishing head and the weld surface to be polished is monitored in real time by the laser automatic navigator 13 and fed back to the position adjustment module, and the position adjustment module adjusts and controls the distance between the polishing head and the weld surface to be polished;

[0146] The total control center is provided with a polishing force self-adaptive calculation module. The polishing force self-adaptive calculation module is based on a two-free PID control algorithm. By controlling the polishing force and the polishing position, the monitoring and adjustment of the polishing force during the vertical feeding process of the polishing head are realized, and the monitoring and adjustment of the polishing position during the feeding process are realized;

[0147] The total control center is preset with a polishing allowance, during the polishing process, the polishing head is controlled to cyclically monitor and adjust the polishing force and the polishing position during the vertical direction feeding process, and the distance between the polishing head and the surface of the weld to be polished and the preset polishing allowance are analyzed in real time until the deviation analysis result of the distance between the polishing head and the surface of the weld to be polished and the preset polishing allowance meets the expected value, and then the polishing is terminated.

[0148] The polishing device 6 is composed of a sliding table mounting plate 1, a sliding table 3, a lifting driving motor 2, a sliding block 4, a polishing lifting frame 5, a suspension spring system 8, a polishing motor 18 and a polishing head; the suspension spring system 8 is composed of a spring 9 and a fixed shaft 10;

[0149] The sliding table mounting plate 1 is connected with the wall climbing traveling mechanism 35 through bolts, the sliding table 3 is connected with the sliding table mounting plate 1 through bolts, the polishing lifting frame 5 is installed on the sliding block 4, the lifting of the polishing lifting frame 5 is controlled by the lifting driving motor 2, and the downward pressure is transmitted to the polishing head through the suspension spring system 8;

[0150] The polishing motor 18 is fixedly connected to the lower end surface of the constant force module 16, the output end of the polishing motor 18 is connected with the polishing head, the distance between the polishing head and the weld wall surface is detected in real time by the laser automatic navigator 13 and sent into the control box 33, and the control box 33 controls the gap between the polishing head and the weld wall surface by controlling the lifting driving motor 2.

[0151] Specifically, during use, the lifting of the polishing lifting frame 5 is controlled by the lifting driving motor 2, so that the spring 9 and the fixed shaft 10 move downward to the polishing head to transmit the downward pressure, and the polishing head is driven to polish by the polishing motor 18; meanwhile, the distance between the polishing head and the weld wall surface is detected in real time by the laser automatic navigator 13 and sent into the control box 33, and the control box 33 controls the gap between the polishing head and the weld wall surface by controlling the lifting driving motor 2.

[0152] The scheme in this embodiment can be selectively combined with the scheme in other embodiments.

[0153] Embodiment 4:

[0154] Please refer to Figure 1 、 6 On the basis of the above-mentioned embodiments, the large pressure-bearing equipment weld surface, near-surface defect repair and re-inspection integrated robot, the fixed-point thickness measuring device 32 includes a sleeve 49, an electromagnet 50, a probe mounting seat 51 and a thickness gauge probe 52, the upper end of the sleeve 49 is fixed on the bottom plate 34, the electromagnet 50 is installed in the sleeve 49, the push rod 53 of the electromagnet 50 extends out from the lower end of the sleeve 49, the push rod 53 is connected with the probe mounting seat 51 at the lower end, the thickness gauge probe 52 is installed in the probe mounting seat 51 and is fixed by the set screw 15.

[0155] Specifically, when the electromagnet 50 is powered on, the thickness gauge probe 52 and the probe mounting seat 51 move downward together to contact the metal work surface for thickness measurement; when the electromagnet 50 is powered off, the thickness gauge probe 52 and the probe mounting seat 51 move upward together to return to the original position.

[0156] The scheme in this embodiment can be selectively combined with the scheme in other embodiments.

[0157] Embodiment 5:

[0158] Please refer to Figures 1-10 On the basis of the above-mentioned embodiments, the application further provides a working method of a large pressure-bearing equipment weld surface and near-surface defect repair and re-inspection integrated robot, specifically as follows:

[0159] S1, first mark the defects of the weld through the magnetic powder detection robot, and then drive the wall-climbing robot 37 to the marked position to perform weld defect repair and re-inspection;

[0160] S2, the basis for safety evaluation of the over-standard weld defects is to accurately determine the size of the defects;

[0161] Through the defect positioning of the weld by the wall-climbing robot, the length and shape of the defect are shown, and the positioning point of the specific position of the weld is found out, and the defect identification on the entity is performed, and the defect depth is measured by the laser automatic navigator 13;

[0162] For the short weld defects, the cross magnetic yoke 24 moves to the polished defect position during magnetic powder detection, and is fixed for detection; for the long weld defects, the cross magnetic yoke 24 moves to the lowest position of the polished defect during magnetic powder detection, and is fixed for detection; then it is advanced by a certain distance, and is fixed for detection again; the segmented step-by-step detection mode is realized;

[0163] S3, based on the results of the defect marking positioning, first polish the weld defects and remove the original weld heat affected zone, and then polish the defect weld;

[0164] When centering, the center of the polishing head 19 is completely coincided with the center line of the determined weld to be repaired, the deviation is adjusted to meet the requirements, the position of the polishing head 19 is adjusted to the position 2mm below the weld defect by the wall-climbing robot 37, the polishing motor 18 is started to polish, and the polishing stroke is controlled to be 2mm more than the weld defect position;

[0165] After polishing the weld defect by the polishing head 19, the cross magnetic yoke 24 is used for detection, and if there is still a crack, the position is marked first;

[0166] S4, the longitudinal weld cracks or transverse weld cracks are removed by layer-by-layer polishing method;

[0167] After the defects of all welds in the spherical tank are polished by the polishing head 19, the wall climbing robot 37 quickly moves to the bottom of the spherical tank, and the polishing head 19 is replaced by the pit polishing head 40. For the longitudinal weld cracks, the pit polishing head 40 is adjusted by the wall climbing robot 37 to be above and parallel to the longitudinal weld cracks. The position of the pit polishing head 40 is moved to a position 2 mm below the weld defect. The pit polishing head 40 is operated to perform local polishing operation. When the defect is removed, the polishing is slow. During the polishing process, the wall climbing robot 37 measures the depth by using the laser automatic navigator 13. When the polishing amount is 30% of the pit depth, the polishing is no longer pressed downward. The polishing is rolled forward, and the polishing stroke is controlled to be 2 mm more than the position of the weld defect.

[0168] S5, the detection is performed by the cross magnetic yoke 24. If there are still cracks, the second layer of polishing is performed. The polishing amount of the second layer is 50% of the pit depth. After the polishing is completed, the detection is performed by the cross magnetic yoke 24. If there are still cracks, the third layer of polishing is performed. The polishing amount of the third layer is 70% of the pit depth. After the polishing is completed, the detection is performed by the cross magnetic yoke 24. If there are still cracks, the fourth layer of polishing is performed. The polishing amount of the fourth layer is 90% of the pit depth. Until the polishing reaches the maximum value of the determined defect depth, the polishing is stopped.

[0169] For the transverse weld cracks, the wall climbing robot 37 is rotated by ninety degrees. The pit polishing head 40 is adjusted to be above and parallel to the transverse weld cracks. The position of the pit polishing head 40 is moved to a position 2 mm outside the weld defect. Then the same method is used for processing.

[0170] S6, after the polishing depth of the weld reaches the maximum value of the determined defect depth, the remaining weld is detected by the cross magnetic yoke 24, and it is confirmed that the weld defect is removed.

[0171] It should be noted that the wall thickness of the pit position is checked and calculated: after it is determined that the pit is allowed to exist, it is determined whether the wall thickness of the pit bottom meets the strength requirements of the spherical tank. If the wall thickness of the pit position cannot meet the minimum calculation requirements, the spherical shell wall stress of the pit position is checked. The marking technology of the magnetic powder detection robot uses existing information technology, which will not be described in detail here.

[0172] Specifically, in use, after the wall-climbing robot marks and positions the defects of the weld, the weld defect repair procedure is as follows: the lower weld defects are processed first, then the upper weld defects are processed, the weld defect is ground flat by the grinding and polishing head 19, and then the cross magnetic yoke 24 is used for detection, if there is still a crack, the position is marked first; if there are other weld defects in the spherical tank, the grinding and polishing head 19 is not replaced, the wall-climbing robot 37 is moved to the next weld defect, the weld defect is ground flat by the grinding and polishing head 19, and then the cross magnetic yoke 24 is used for detection, if there is still a crack, the position is marked first; until all the weld defects in the spherical tank are ground flat, the wall-climbing robot 37 is quickly moved to the bottom of the spherical tank, the concave polishing head 40 is used to replace the grinding and polishing head 19, and then the method of layer-by-layer polishing and detection is realized for the marked weld defects with cracks.

[0173] The scheme in this embodiment can be selectively combined with the schemes in other embodiments.

[0174] Embodiment 6:

[0175] Please refer to Figures 1-10 On the basis of the above-mentioned embodiments, the working method of the large pressure-bearing equipment weld surface and near-surface defect repair and re-inspection integrated robot is also provided in the embodiments of the present application, and the polishing head is divided into the grinding and polishing head 19 and the concave polishing head 40.

[0176] The concave pit formed after the crack is polished and eliminated by the concave polishing head 40 has changed the original stress distribution of the container, and therefore the method of checking the strength by using the remaining wall thickness cannot be simply used, and the dimensionless parameter G should be calculated to determine whether the concave pit is within the allowable range, and the specific determination method is as follows:

[0177] ①Calculate the wall thickness allowance:

[0178] The depth C of the concave pit formed by the crack is compared with the wall thickness allowance (wall thickness allowance = measured wall thickness - nominal thickness + corrosion allowance), if the depth C is less than the wall thickness allowance, the concave pit is allowed to exist without repair welding and other treatment, otherwise, the dimensionless calculation is performed;

[0179] If the concave pit formed after polishing is within the allowable range and does not need to be repaired, the level is not affected; otherwise, the repair welding or stress analysis can be performed, and if the repair welding is qualified or the stress analysis result shows that the safety use is not affected, the level can be determined as two or three;

[0180] If the depth of the concave pit formed after the crack is polished is within the wall thickness allowance range, the concave pit is allowed to exist. Otherwise, the concave pit is regularized as a semi-ellipsoidal concave pit with a long axis length of 2A (mm), a short axis length of 2B (mm) and a depth of C (mm) according to the circumscribed rectangle, and the dimensionless parameter G0 is calculated, if G0 < 0.10, the concave pit is within the allowable range;

[0181] ②The pit for non-dimensional parameter G0 calculation should meet the following conditions:

[0182] The pit surface is smooth and the transition is gentle, and there is no other surface defect or buried defect around it;

[0183] The pit is not close to the geometric discontinuous area or the area with sharp corners;

[0184] The container does not bear external pressure or fatigue load;

[0185] Thin-walled cylindrical shell with T / R less than 0.18 or thin-walled spherical shell with T / R less than 0.10;

[0186] The material meets the pressure vessel design requirements and no degradation is found;

[0187] The pit depth C is less than 1 / 3 of the wall thickness T and less than 12mm, and the minimum thickness of the pit bottom (T-C) is not less than 3mm;

[0188] The pit half-length ;

[0189] The pit half-width B is not less than three times the pit depth C;

[0190] ③Calculation of non-dimensional parameter G0 of pit defect:

[0191]

[0192] In the formula, T is the wall thickness of the container at the pit location (the measured wall thickness minus the corrosion amount to the next inspection period, unit: mm), and R is the average radius of the container (unit: mm);

[0193] For spherical tanks, before the crack is polished and eliminated, a polishing scheme should be developed and the pit formed after polishing should be calculated. If the pit meets the prerequisites for pit evaluation and the pit is within the allowable range, polish according to the pit, otherwise, polish according to the repair welding scheme.

[0194] When polishing according to the pit, calculate the maximum allowable pit depth Cmax when the non-dimensional parameter G is 0.1. The pit depth is less than 1 / 3 of the wall thickness T and less than 12mm. Under normal circumstances, the wall thickness of the spherical tank is not less than 30mm, and the maximum allowable pit depth of 10mm can meet the condition that the pit depth is less than 1 / 3 of the wall thickness T and less than 12mm at the same time. Therefore, the polishing height h of the pit polishing head is selected as 10mm. The maximum polishing depth is 10mm according to this, and the pit half-width B is not less than 3 times the pit depth C.

[0195] According to the design shape of the pit polishing head, the pit half-width B is

[0196]

[0197] According to the formula, if C is 10 mm, B is

[0198]

[0199] The pit half-length A is not less than the pit half-width B, and the pit half-length A is

[0200]

[0201] In actual design, R2 is taken as 50 mm, and R1 is taken as 100 mm considering the consistency with the radius of the grinding head, so that the key size parameters of the grinding head can be determined. The pit shape ground by the grinding head completely meets the pit shape size requirements specified in TSG 21-2016 “Fixed Pressure Vessel Safety Technical Regulations”.

[0202] Further, the above operation method adopts a staged grinding technology. First, the weld excess height is removed by grinding, and the defect weld is ground flat by using the flat grinding head 19.

[0203] Among them, if the defect is not removed after re-inspection, the maximum pit depth Cmax in the allowable range is calculated according to the dimensionless parameter G to perform grinding;

[0204] Since the larger the pit depth is, the worse the safety factor is, it is not appropriate to directly use the maximum allowable pit depth to grind the remaining defects, but to grind the defects with the largest possible pit depth. When designing the staged grinding, it is first compared whether the smaller maximum pit depth Cmax is greater than 10 mm (when the wall thickness is greater than 30 mm, it is applicable, and when the wall thickness is less than 30 mm, 1 / 3 of the wall thickness T is taken). If Cmax is greater than or equal to 10 mm, 10 mm is taken as the base value, and 20%, 50%, 70%, and 90% of the base value are respectively ground. If Cmax is less than 10 mm, Cmax is taken as the base value, and 20%, 50%, 70%, and 90% of the base value are respectively ground. The order of staged grinding is: the first grinding is performed according to 2 mm or 20% of the maximum allowable pit depth (the smaller value is taken). Then, the magnetic powder detection is re-inspected, and if the defects are not removed, the grinding is performed according to the above method in turn according to 5 mm, 7 mm, 9 mm, or 50%, 70%, and 90% of the maximum allowable pit depth (the smaller value is taken respectively). If the defects are not removed by grinding according to 90% of the maximum allowable pit depth, manual scaffolding is considered to perform welding repair.

[0205] The pit grinding head 40 is a circular arc bottom with a width of more than 3 times the arc depth h. If Cmax is greater than or equal to 10 mm, the pit shape size formed by the staged grinding of the pit grinding head 40 is respectively:

[0206] C1: 2 mm B1: 14 mm A1: 19.9mm

[0207] C1 : 5 mm B1: 21.8 mm A1: 31.2 mm

[0208] C1 : 7 mm B1: 25.5 mm A1: 36.8 mm

[0209] C1: 9 mm B1: 28.6 mm A1: 41.5 mm

[0210] As Cmax is 10 mm smaller, the recess shape and size formed by the recess grinding head (40) in the grading process are respectively:

[0211] C1: 20% C max mm

[0212] B1: mm

[0213] A1: mm

[0214] C1: 50% C max mm

[0215] B1: mm

[0216] A1: mm

[0217] C1: 70% C max mm

[0218] B1: mm

[0219] A1: mm

[0220] C1: 90% C max mm

[0221] B1: mm

[0222] A1: mm

[0223] Grinding judgment:

[0224] Mainly through the grinding head 19 of the control of the drop distance, in addition, if the grinding head 19 corner has sparks, it can also be determined that the weld has been ground;

[0225] Pit grinding in place judgment:

[0226] Mainly through the pit grinding head 40 of the control of the drop distance, in addition, through the laser automatic navigator 13 real-time monitoring pit depth, it can be known that the pit grinding head 40 actual drop distance, and feedback to the position adjustment module.

[0227] The scheme in this embodiment can be selectively combined with the scheme in other embodiments.

[0228] It should be noted that although the above embodiments have been described in this paper, but not therefore limit the patent protection scope of the present application. Therefore, based on the innovative idea of the present application, the changes and modifications of the embodiments described herein, or the equivalent structure, equivalent process or equivalent function transformation made by using the content of the present application specification and drawings, directly or indirectly, the above technical solutions are applied to other related technical fields, are included in the protection scope of the present application patent.

Claims

1. A large pressure equipment weld surface, near-surface defect repair and reinspection integrated robot, comprising a wall-climbing robot (37), characterized in that: The wall-climbing robot (37) comprises a suction module and a wall-climbing walking mechanism (35); The bottom plate (34) of the wall-climbing robot (37) is fixedly provided with a control box (33) and a magnetic suspension stirring and spraying device (36) above, and is fixedly provided with a cross magnetic yoke (24) below; The front of the wall-climbing robot (37) is fixedly provided with a polishing device (6) and a constant force polishing control system (7), and the polishing device (6) is fixedly provided with a laser automatic navigator (13); The rear of the wall-climbing robot (37) is fixedly provided with a fixed-point thickness measuring device (32); A dustproof partition (23) is arranged between the polishing device (6) and the cross magnetic yoke (24); When the wall-climbing robot (37) works inside the spherical tank, a fall protector (11) is connected, and the fall protector (11) is fixedly connected to a flange (12) at the top of the spherical tank; An automatic tracking holder (29) is arranged at the bottom of the spherical tank, the automatic tracking holder (29) is connected with an external operation table (30) through a transmission cable (14), and the external operation table (30) is connected with the control box (33) on the wall-climbing robot (37) through a shielding cable (31); The magnetic suspension stirring and spraying device (36) comprises a stirring device, a liquid storage tank (41), a spraying device and a control device (45); The inside and outside of the liquid storage tank (41) are further provided with a mixing system (20), the mixing system (20) comprises a water baffle (2001) arranged in the inside of the liquid storage tank (41), the water baffle (2001) is provided with two groups, and is slidably connected to the upper half of the liquid storage tank (41) through a guide rail (2002), one side of the water baffle (2001) is fixedly connected with a pull plate (2003), the pull plate (2003) penetrates through the opposite water baffle (2001) and extends to the outside of the liquid storage tank (41), and pulling the pull plate (2003) enables the two groups of water baffles (2001) to move close to or away from each other; A matching gear housing (2007), a driving gear (2008) and a reciprocating motor (2009) are fixedly arranged on the top of the liquid storage tank (41), the driving gear (2008) is rotatably arranged in the inside of the gear housing (2007) and is fixedly connected with a stirring rod, and the stirring rod is rotatably arranged in the inside of the liquid storage tank (41) and is located between the two groups of water baffles (2001); The driving gear (2008) is rotatably arranged in the inside of the gear housing (2007) and is fixedly connected with a stirring rod, and the stirring rod is rotatably arranged in the inside of the liquid storage tank (41) and is located between the two groups of water baffles (2001); The two sides of the driving gear (2008) are toothedly connected with a toothed plate (2005), one end of the toothed plate (2005) is located between the gear housing (2007) and the driving gear (2008), and the other end is slidably connected with a sliding groove block (2006) fixed on the top of the liquid storage tank (41); The outer wall of the upper half of the liquid storage tank (41) is provided with movable plates (2004) on both sides, one end of the movable plates (2004) is hinged to the outer wall of the liquid storage tank (41), the middle end is hinged to the pull plate (2003), and the other end is hinged to the toothed plate (2005).

2. The welding seam surface and near-surface defect repair and re-inspection integrated robot for large pressure-bearing equipment according to claim 1, characterized in that: The wall-climbing walking mechanism (35) includes a driving wheel (38), a driven wheel (28), a driving shaft mounting member (21), and a driving motor (22), and opposite sides of the wall-climbing walking mechanism (35) are provided with light source targets (39).

3. The welding seam surface and near-surface defect repair and re-inspection integrated robot for large pressure-bearing equipment according to claim 1, characterized in that: The bottom surface of the liquid storage tank (41) is fixedly connected with a liquid pumping pipe (46), the liquid pumping pipe (46) is respectively connected with a stirring device and a spraying device, and the stirring device and the spraying device are electrically connected with a control device (45). The stirring device includes a first water pump (44), a nozzle (42), and a liquid return pipe (43). The first water pump (44), the nozzle (42), and the bottom surface of the liquid storage tank (41) are connected through the liquid return pipe (43) and the liquid pumping pipe (46), the first water pump (44) is electrically connected with the control device (45), the first water pump (44) pumps out the magnetic suspension liquid with high concentration from the bottom of the liquid storage tank (41), and the magnetic suspension liquid is discharged through the nozzle (42), the nozzle (42) is arranged in the liquid storage tank (41), and the spraying direction is parallel to the bottom surface of the liquid storage tank (41). The spraying device includes a second water pump (47), a liquid conveying pipe (48), and a spray head (26). The second water pump (47) and the spray head (26) are connected with the bottom surface of the liquid storage tank (41) through the liquid conveying pipe (48) and the liquid pumping pipe (46), the second water pump (47) is electrically connected with the control device (45), and the second water pump (47) pumps out the mixed magnetic suspension liquid from the liquid storage tank (41) and discharges the magnetic suspension liquid through the spray head (26).

4. The large pressure equipment welding seam surface, near-surface defect repair and re-inspection integrated robot according to claim 1, characterized in that: The constant force polishing control system (7) includes a polishing force monitoring unit, a polishing position monitoring unit, and a total control center. The polishing force monitoring unit includes a force sensor (17) and a constant force module (16), the force sensor (17) is used for monitoring the polishing force in real time and feeding back to the constant force module (16) during the polishing process, and the constant force module (16) is used for adjusting and controlling the polishing force to be stable. The polishing position monitoring unit includes a position adjusting module, the distance between the polishing head and the surface of the weld to be polished is monitored in real time by a laser automatic navigator (13) and fed back to the position adjusting module during the polishing process, and the position adjusting module adjusts and controls the distance between the polishing head and the surface of the weld to be polished. The total control center is provided with a polishing force self-adaptive calculation module, the polishing force self-adaptive calculation module is based on a two-freedom PID control algorithm, the polishing force and the polishing position are controlled, the polishing force is monitored and adjusted during the vertical feeding process of the polishing head, and the polishing position is monitored and adjusted during the feeding process.

5. The large pressure equipment welding seam surface, near-surface defect repair and re-inspection integrated robot according to claim 4, characterized in that: The polishing device (6) is composed of a sliding table mounting plate (1), a sliding table (3), a lifting drive motor (2), a sliding block (4), a polishing lifting frame (5), a suspension spring system (8), a polishing motor (18) and a polishing head; the suspension spring system (8) is composed of a spring (9) and a fixed shaft (10); The sliding table mounting plate (1) is connected with the wall-climbing traveling mechanism (35) through bolts, the sliding table (3) is connected with the sliding table mounting plate (1) through bolts, the polishing lifting frame (5) is installed on the sliding block (4), the lifting of the polishing lifting frame (5) is controlled by the lifting drive motor (2), and the pressing force is transmitted to the polishing head through the suspension spring system (8); The polishing motor (18) is fixedly connected to the lower end surface of the constant force module (16), the output end of the polishing motor (18) is connected with the polishing head, the distance between the polishing head and the weld wall surface is detected in real time through the laser automatic navigator (13) and the detected distance is sent into the control box (33), and the control box (33) controls the gap between the polishing head and the weld wall surface by controlling the lifting drive motor (2).

6. The large pressure equipment welding seam surface, near-surface defect repair and re-inspection integrated robot according to claim 1, characterized in that: The fixed-point thickness measuring device (32) comprises a sleeve (49), an electromagnet (50), a probe mounting seat (51) and a thickness gauge probe (52), the upper end of the sleeve (49) is fixed on the bottom plate (34), the electromagnet (50) is installed in the sleeve (49), the push rod (53) of the electromagnet (50) extends out from the lower end of the sleeve (49), the lower end of the push rod (53) is connected with the probe mounting seat (51), and the thickness gauge probe (52) is installed in the probe mounting seat (51) and is fixed by a set screw (15).

7. A method for operating the robot for repairing and re-inspecting surface and near-surface defects of welds of large pressure-bearing equipment according to any one of claims 1 to 6, characterized in that, Specifically, the steps are as follows: S1, first, mark the defects of the weld by the magnetic powder detection robot, and then drive the wall-climbing robot (37) to the marked position to repair and recheck the weld defects; S2, the basis for the safety evaluation of the weld defects exceeding the standard is to accurately determine the size of the defects; The wall-climbing robot (37) is used to locate the defects of the weld, show the length and shape of the defects, and find the positioning point of the specific position of the weld, and the defects of the weld are marked on the entity, and the depth of the defects is measured by the laser automatic navigator (13); S3, based on the results of the defect positioning, first, polish the weld defects and remove the original weld heat affected zone, and then polish the defects of the weld; The center of the polishing head (19) is completely coincided with the center line of the weld to be repaired, the deviation is adjusted to meet the requirements, the position of the polishing head (19) is adjusted to the position 2mm below the weld defects by the wall-climbing robot (37), the polishing motor (18) is started to polish, and the polishing stroke is controlled to be 2mm more than the position of the weld defects; After the weld defects are polished by the polishing head (19), the cross magnetic yoke (24) is used for detection, and if there are still cracks, the position is marked first; S4, the longitudinal cracks of the weld or the transverse cracks of the weld are removed by the layer-by-layer polishing method. After grinding all the weld defects in the spherical tank with the flat grinding head (19), the wall-climbing robot (37) quickly moves to the bottom of the spherical tank, and the flat grinding head (19) is replaced with the pit grinding head (40). For longitudinal cracks in the weld, the pit grinding head (40) is adjusted by the wall-climbing robot (37) to be above and parallel to the longitudinal cracks. The position of the pit grinding head (40) is moved to a position 2 mm below the weld defect. The pit grinding head (40) is operated for local grinding operation. When the defect is removed, the grinding is slow. During the grinding process, the wall-climbing robot (37) measures the depth using the laser automatic navigator (13). When the grinding amount is 30% of the pit depth, it is no longer pressed down. The forward rolling grinding is controlled to grind 2 mm more than the weld defect position. S5, detect by cross magnetic yoke (24), if there is still crack, then carry out second layer grinding, the second layer grinding amount is 50% of the pit depth respectively, after grinding, detect by cross magnetic yoke (24), if there is still crack, then carry out third layer grinding, the third layer grinding amount is 70% of the pit depth respectively, after grinding, detect by cross magnetic yoke (24), if there is still crack, then carry out fourth layer grinding, the fourth layer grinding amount is 90% of the pit depth respectively, until the grinding reaches the maximum value of the determined defect depth, then stop grinding; For transverse cracks in the weld, the wall-climbing robot (37) is rotated by ninety degrees, and the pit grinding head (40) is adjusted to be above and parallel to the transverse cracks. The position of the pit grinding head (40) is moved to a position 2 mm outside the weld defect, and then the same method is used for processing. S6, when the weld depth reaches the maximum value of the determined defect depth, the remaining weld is detected by the cross magnetic yoke (24) to confirm that the weld defect is removed.

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