A pipeline internal flaw detection robot

Abstract

The application discloses a pipeline internal flaw detection robot, which comprises a shell, a front support rod arranged on the front side of the shell, a rear support rod arranged on the rear side of the shell, a plurality of front supporting legs arranged on the front support rod, a plurality of rear supporting legs arranged on the rear support rod, a driving system arranged in the shell, a front driving mechanism and a rear driving mechanism included in the driving system, the front driving mechanism and the rear driving mechanism being used for driving the front support rod and the rear support rod to move forward and backward respectively, and an ultrasonic detection head arranged on the outer side of the shell. The pipeline internal flaw detection robot can improve the working environment, greatly reduce the labor intensity, greatly reduce the radiation dose, prolong the service life of the equipment and improve the pipeline flaw detection efficiency.

Description

A pipeline internal flaw detection robot Technical Field

[0001] This invention relates to the field of pipeline flaw detection technology, specifically to a pipeline internal flaw detection robot. Background Technology

[0002] As components used in modern society to transport gases, liquids, and liquids containing solid particles, especially when transporting flammable and explosive media such as natural gas, the safety and reliability of pipelines are often critical. Pipelines typically require inspection and maintenance to ensure their reliability.

[0003] During the inspection of long-distance pipelines, there are many welds of the same type, and more than 95% of the welds are in a horizontal hanging state. Since most of the pipelines are already in place, the air circulation inside the pipeline is not good or the pipe diameter is small, so it is impossible for personnel to crawl a long distance inside the pipeline, or even to enter the pipeline at all.

[0004] If X-ray inspection is used, only double-wall double-image radiography can be employed. Compared to central radiography, double-wall double-image radiography requires 8-16 times more radiation energy for the same exposure time, increasing the workload by 6-16 times. Under the same shielding distance, the radiation dose received by workers will be 400-4000 times higher, and the overall working time will generally be 10-30 times longer than central radiography. If an X-ray machine is used as the radiation source, the machine's lifespan will be shortened to 3% of its original lifespan. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a pipeline internal flaw detection robot that replaces most manual operations, thereby improving the working environment, significantly reducing labor intensity, significantly reducing radiation dose, extending equipment lifespan, and improving pipeline flaw detection efficiency.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a pipeline internal flaw detection robot, comprising:

[0007] The housing has a front support rod on its front side and a rear support rod on its rear side. The front support rod has several front support legs, and the rear support rod has several rear support legs.

[0008] Both the front support leg and the rear support leg include a main support leg and a secondary support leg. The ends of the main support leg and the secondary support leg are hinged together. The sides of the main support leg and the secondary support leg are connected by an elastic element. The other end of the secondary support leg is provided with a rotating shaft. The two ends of the rotating shaft are respectively connected to a roller and a friction block through a first connecting shaft and a second connecting shaft, and the first connecting shaft and the second connecting shaft are arranged in opposite directions.

[0009] A drive system is located inside the housing; the drive system includes a front drive mechanism and a rear drive mechanism, which are respectively used to drive the front support rod and the rear support rod to move back and forth;

[0010] An ultrasonic testing head is located on the outside of the housing; the ultrasonic testing head can move in a circular motion along the housing.

[0011] Preferably, there are four front support legs and four rear support legs.

[0012] Preferably, a front support and a rear support are fixed to the front and rear sides of the housing, respectively. The front support rod and the rear support rod are piston-type connected to the front support and the rear support, respectively. The front support and the rear support are respectively provided with long through holes for the front support leg and the rear support leg to move.

[0013] Preferably, the friction block is configured as a T-shaped structure.

[0014] Preferably, the elastic element of the front support leg is disposed on the rear side, and the roller of the front support leg is disposed on the front side; the elastic element of the rear support leg is disposed on the front side, and the roller of the rear support leg is disposed on the rear side.

[0015] Preferably, both the front drive mechanism and the rear drive mechanism include a motor, the motor is fixed inside the housing, the drive shaft of the motor is fixedly connected to the main gear, the main gear is meshed with the middle gear, the middle gear is meshed with the external gear, the external gear is fixedly connected to the drive coupling, the other end of the drive coupling is fixedly connected to the swing rod, and the other end of the swing rod is hinged to the front support rod or the rear support rod.

[0016] Preferably, a cover is movably connected to the drive shaft of the motor, and the main gear, intermediate gear, and external gear are all placed inside the cover. The inside of the cover is provided with a first support plate and a second support plate respectively by bolts. A support shaft is provided on the second support plate. The first support plate and the second support plate are respectively placed outside the external gear and the intermediate gear, and the support shaft is interlocked with the intermediate gear.

[0017] Preferably, the housing is provided with a circular slide rail along its periphery, a slide rail trolley is provided on the circular slide rail, and the ultrasonic detection head is mounted on the slide rail trolley.

[0018] Preferably, it also includes a camera, which is located on the outside of the housing; the camera can move in a circle along the housing.

[0019] Preferably, it also includes a control system for controlling the robot.

[0020] This invention discloses a pipe internal flaw detection machine, which has the following beneficial effects:

[0021] 1. This invention uses an internal pipeline inspection robot to inspect the inside of pipelines. Compared with external pipeline inspection, the inspection results are more detailed. Due to the different materials and sizes of pipelines, the weld formation effect varies. In addition, pipeline welding is carried out on the outside of the pipeline, making it difficult to judge the weld effect on the inner wall of the pipeline. Therefore, internal pipeline inspection is more precise and effective than external pipeline inspection. Moreover, this invention has high accuracy for internal pipeline inspection.

[0022] 2. This invention can visualize and refine the flaw detection results through interaction with the BIM model, making the detection results clearer and more intuitive. When problems occur, they can be precisely marked in the BIM model and fed back to the construction team for timely adjustments.

[0023] 3. This invention can improve the working environment, significantly reduce labor intensity, significantly reduce radiation dose, extend equipment service life, and improve pipeline flaw detection efficiency. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 is a schematic diagram of the overall structure of an embodiment of the present invention;

[0026] Figure 2 is a schematic diagram of the internal structure of an embodiment of the present invention;

[0027] Figure 3 is a schematic diagram of the rear drive mechanism in an embodiment of the present invention;

[0028] Figure 4 is a schematic diagram of the friction block in an embodiment of the present invention;

[0029] Figure 5 is a partial structural schematic diagram of the cover box in an embodiment of the present invention;

[0030] Figure 6 is a schematic diagram of the structure of the ultrasonic detection head in an embodiment of the present invention;

[0031] In the diagram: 1. Housing; 2. Front support rod; 3. Front support leg; 4. Rear support leg; 5. Front support; 6. Rear support; 7. Main support leg; 8. Secondary support leg; 9. Spring; 10. Rotating shaft; 11. First coupling; 12. Second coupling; 13. Roller; 14. Friction block; 15. Motor; 16. Main gear; 17. Middle gear; 18. External gear; 19. Drive coupling; 20. Swing rod; 21. Cover box; 22. First support plate; 23. Second support plate; 24. Ultrasonic detection head; 25. Circular slide rail; 26. Slide rail trolley; 27. Rear support rod. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] This invention provides a pipeline internal flaw detection robot, as shown in Figures 1-6, comprising:

[0034] The housing 1 has a circular overall outline, resembling a yurt, and is slightly smaller than the pipe to facilitate access to the pipe's interior. A front support rod 2 is located on the front side of the housing 1, and a rear support rod 27 is located on the rear side. Several front support legs 3 are fixed to the front support rod 2, and several rear support legs 4 are fixed to the rear support rod 27. Both the front support legs 3 and the rear support legs 4 are inclined.

[0035] In some embodiments, the front support leg 3 and the rear support leg 4 can be configured as four, which are evenly and obliquely fixed to the sides of the front support rod 2 and the rear support rod 27, similar to grippers, so as to enable simultaneous sliding in four directions and improve the overall sliding stability of the robot.

[0036] In some embodiments, a front support 5 and a rear support 6 can be fixed to the front and rear sides of the housing 1, respectively. Both the front support 5 and the rear support 6 have hollow structures. The front support rod 2 and the rear support rod 27 are piston-type connected to the front support 5 and the rear support 6, respectively. The front support leg 3 and the rear support leg 4 are located on the outside of the front support 5 and the rear support 6, and the front support 5 and the rear support 6 are respectively provided with elongated through holes for the front support leg 3 and the rear support leg 4 to move. In this way, the overall structure of the robot can be more tightly connected, further improving the stability of the robot's sliding.

[0037] Furthermore, both the front support leg 3 and the rear support leg 4 include a main support leg 7 and a secondary support leg 8. The ends of the main support leg 7 and the secondary support leg 8 are hinged together, and the sides of the main support leg 7 and the secondary support leg 8 are connected by an elastic element such as a spring 9. The other end of the secondary support leg 8 is provided with a rotating shaft 10, which is rotatably connected to the secondary support leg 8. The two ends of the rotating shaft 10 are respectively connected to the roller 13 and the friction block 14 through a first connecting shaft 11 and a second connecting shaft 12, and the first connecting shaft 11 and the second connecting shaft 12 are arranged opposite to each other. The first connecting shaft 11 and the second connecting shaft 12 are fixedly connected to the ends of the rotating shaft 10. The roller 13 is rotatably connected to the other end of the first connecting shaft 11. The friction block 14 can be set as a T-shaped structure and is fixedly connected to the other end of the second connecting shaft 12. Thus, when the first connecting shaft 11 rotates to the front side of the rotating shaft 10, the second connecting shaft 12 rotates to the rear side of the rotating shaft 10. Furthermore, the spring 9 of the front support leg 3 is located on the rear side, and the roller 13 of the front support leg 3 is located on the front side; the spring 9 of the rear support leg 4 is located on the front side, and the roller 13 of the rear support leg 4 is located on the rear side. Both the roller 13 and the friction block 14 are made of rubber material.

[0038] It also includes a drive system located inside the housing 1; the drive system includes a front drive mechanism and a rear drive mechanism, which are used to drive the front support rod 2 and the rear support rod 3 to move back and forth, respectively.

[0039] In actual operation, in the initial state, the front roller 13 can be in close contact with the inner wall of the pipe, while the rear friction block 14 does not contact the inner wall of the pipe.

[0040] The control of the front drive mechanism drives the front support rod 2 to move forward, first driving the main support leg 7 forward, and then the secondary support leg 8 in conjunction. Since the main support leg 7 and the secondary support leg 8 are hinged and further connected by the spring 9, the front roller 13 is driven to slide forward a certain distance. At the same time, the front roller 13 is squeezed away from the inner wall of the tube, and the front friction block 14 is driven by the rotating shaft 10 to make tight contact with the inner wall of the tube, so that the front support rod 2 is stable.

[0041] When the front support rod 2 moves a certain distance (the movement gap between the front drive and the rear drive can be controlled by the motor to achieve continuous front and rear movement and ensure stable operation of the device), the rear drive mechanism is controlled to drive the rear support rod 27 to move forward, which in turn drives the rear roller 13 to slide forward a certain distance. At the same time, the rear roller 13 is squeezed to make tight contact with the inner wall of the tube, and the rear friction block 14 is driven away from the inner wall of the tube through the rotating shaft 10; the robot completes one forward slide.

[0042] In some embodiments, both the front drive mechanism and the rear drive mechanism may include a motor 15. The motor 15 is fixed inside the housing 1 by a support frame. The drive shaft of the motor 15 is fixedly connected to the main gear 16. The main gear 16 meshes with the intermediate gear 17, and the intermediate gear 17 meshes with the external gear 18. The external gear 18 is fixedly connected to the drive coupling 19. The other end of the drive coupling 19 is fixedly connected to the swing rod 20, and the other end of the swing rod 20 is hinged to the front support rod 2 or the rear support rod 27. Thus, when the motor 15 is turned on, the drive shaft of the motor 15 drives the main gear 16 to rotate, which in turn drives the intermediate gear 17 and the external gear 18 to drive the drive coupling 19 to perform eccentric circular motion. The drive coupling 19 then drives the front support rod 2 or the rear support rod 27 to move back and forth through the swing rod 20, that is, to perform piston-like motion relative to the front support 5 or the rear support 6.

[0043] In some embodiments, the drive shaft of the motor 15 is movably connected to the housing 21, and the outer end of the drive shaft of the motor 15 is mounted inside the housing 21 by bearings. The main gear 16, the intermediate gear 17, and the external gear 18 are all placed inside the housing 21.

[0044] In some embodiments, the interior of the housing 21 can be bolted with a first support plate 22 and a second support plate 23, respectively. A support shaft is provided on the second support plate 23. The first support plate 22 and the second support plate 23 are respectively positioned outside the external gear 18 and the intermediate gear 17, and the support shaft is inserted and connected to the intermediate gear 17. The drive coupling 19 can pass through the first support plate 22 and be connected to the external gear 18.

[0045] It also includes an ultrasonic detection head 24, which is located on the outside of the housing 1 and can move in a circular motion along the housing 1.

[0046] In some embodiments, the housing 1 may be provided with a circular slide rail 25 along its periphery, and a slide rail trolley 26 is mounted on the circular slide rail 25, and the ultrasonic detection head 24 is mounted on the slide rail trolley 26.

[0047] In some embodiments, a camera may also be installed on the slide rail trolley 26.

[0048] It also includes a control system for controlling the motor 15, the slide rail trolley 26, the ultrasonic detection head 24, and the camera; the control system can be a PLC controller, which can be controlled by wireless or wired signals.

[0049] In some embodiments, the flaw detection robot can also visualize and refine the flaw detection results through interaction with the BIM model. This allows for clearer and more intuitive understanding of the results. When problems arise, they can be precisely marked within the BIM model, and the information can be fed back to the construction team for timely adjustments. This can be achieved through the following steps:

[0050] Step 1: Build a high-precision BIM model using BIM software to guide on-site construction and achieve a digital twin to reality;

[0051] Step 2: Extract the weld location (coordinates of the weld location) from the BIM model data, and synchronize the weld location data to the database of the flaw detection robot. The flaw detection robot will then automatically move to the vicinity of the detection location (weld location) based on the data.

[0052] Step 3: Control the robot's walking speed by using a stepless speed regulation device. When the distance to the monitoring point is ≥100mm, a faster speed is used; when the distance is less than 100mm, the robot's movement speed is reduced by stepless speed regulation, and the image recognition function is activated.

[0053] Step 4: After the image recognition function is turned on, the robot's walking distance is controlled by the preset parameters (the parameter is the width of the weld, which will vary depending on the nominal diameter of the pipe being inspected and the pipe material).

[0054] Step 5: The robot uses image recognition to identify signals and scans the image inside the tube with a camera to determine whether there is a weld that needs to be inspected within the detection range;

[0055] Step 6: If the weld is not within the detection range, the control system moves the width of one weld at a time. If the weld enters the detection range, the motor stop device is activated.

[0056] Step 7: By controlling the extension of the legs, the roller 13 is disengaged from the inner wall of the pipe, so that the friction block 14 coincides with the inner wall of the pipe to increase the friction force and prevent the robot from shifting when performing ultrasonic flaw detection.

[0057] Step 8: The ultrasonic testing head 24 moves in a circular motion through the circular slide rail 25 to perform internal pipe flaw detection.

[0058] Step 9: After the inspection is completed, the information is transmitted to the database via a transmission line or wireless signal (the information in the database is an interaction with the high-precision BIM model, and the robot inspection results will be reflected in the BIM software to ensure that the accuracy of the BIM model and the site is consistent).

[0059] Step 10: When the detected weld location is inconsistent with the BIM model, that is, when the image recognition function in step 6 identifies that the weld location in the model does not appear in the actual scene, the control system moves around, each time moving one weld distance. When the weld location is found, the detection result, that is, the weld location, will be promptly fed back to the BIM software model in the database and marked to facilitate personnel inspection and adjustment.

[0060] Step 11: By analyzing the detection results fed back by the robot, the ultrasonic detection data is converted into images. The detection results are judged by analyzing the data information of peaks and troughs. The detection results are fed back into the BIM model in the database and marked for easy analysis and operation by personnel.

[0061] Step 12: Once the detection here is complete, repeat step 3.

[0062] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A pipeline internal flaw detection robot, characterized in that, include: The housing comprises a front support rod on its front side and a rear support rod on its rear side. The front support rod has several front support legs, and the rear support rod has several rear support legs. A front support seat and a rear support seat are fixed to the front and rear sides of the housing, respectively. The front and rear support rods are piston-type connected to the front and rear support seats, respectively. The front and rear support seats each have elongated through holes for the movement of the front and rear support legs. Each front and rear support leg includes a main support leg and a secondary support leg. The ends of the main and secondary support legs are hinged together, and their sides are connected by an elastic element. The other end of the secondary support leg has a rotating shaft. The two ends of the rotating shaft are connected to a roller and a friction block via a first connecting shaft and a second connecting shaft, respectively, with the first and second connecting shafts positioned opposite each other. The elastic element of the front support leg is located on the rear side. The rollers of the front support leg are located on the front side; the elastic element of the rear support leg is located on the front side, and the rollers of the rear support leg are located on the rear side; a drive system is located inside the housing; the drive system includes a front drive mechanism and a rear drive mechanism, which are used to drive the front support rod and the rear support rod to move back and forth, respectively; both the front drive mechanism and the rear drive mechanism include a motor, the motor is fixed inside the housing, the drive shaft of the motor is fixedly connected to the main gear, the main gear is meshed with the middle gear, the middle gear is meshed with the external gear, the external gear is fixedly connected to the drive coupling, the other end of the drive coupling is fixedly connected to the swing rod, and the other end of the swing rod is hinged to the front support rod or the rear support rod; an ultrasonic detection head is located on the outside of the housing; the ultrasonic detection head can move in a circle along the housing.

2. The pipeline internal flaw detection robot according to claim 1, characterized in that: Both the front and rear support legs are configured with four legs.

3. A pipeline internal flaw detection robot according to claim 1 or 2, characterized in that: The friction block is configured with a T-shaped structure.

4. The pipeline internal flaw detection robot according to claim 1, characterized in that: A cover is movably connected to the drive shaft of the motor, and the main gear, intermediate gear, and external gear are all placed inside the cover. The inside of the cover is provided with a first support plate and a second support plate respectively by bolts. A support shaft is provided on the second support plate. The first support plate and the second support plate are respectively placed outside the external gear and the intermediate gear, and the support shaft is interlocked with the intermediate gear.

5. A pipeline internal flaw detection robot according to claim 1 or 2, characterized in that: The housing is provided with a circular slide rail along its periphery, and a slide rail trolley is provided on the circular slide rail. The ultrasonic detection head is installed on the slide rail trolley.

6. A pipeline internal flaw detection robot according to claim 1 or 2, characterized in that: It also includes a camera, which is located on the outside of the housing; the camera can move in a circle along the housing.

7. A pipeline internal flaw detection robot according to claim 1 or 2, characterized in that: It also includes a control system for controlling the robot.

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