Water-turbine generator set rotor maintenance robot, control system and control method

Abstract

The invention provides a water-turbine generator set rotor maintenance robot, a control system and a control method, the water-turbine generator set rotor maintenance robot comprises a mobile chassis and a lifting device, the lifting device is installed on the mobile chassis, the lifting device drives a multi-axis mechanical arm to perform vertical displacement, an execution end of the multi-axis mechanical arm is provided with an actuator, and the actuator is used for cleaning a generator set; through close fit of the multi-axis mechanical arm and the movable chassis and combination of visual guidance of the depth camera, the robot can accurately position and execute cleaning and spraying tasks, the safety and efficiency of operation are greatly improved, and the consistency and high standard of operation quality are ensured. Meanwhile, due to the integrated equipment design, such as the configuration of the cleaning agent charging barrel, the paint charging barrel and the air compressor, the cleaning medium is convenient to supply, and the operation process is smoother. And due to the application of the intelligent control system, the robot can autonomously receive instructions, analyze tasks and cooperate with all the devices to efficiently complete operation, manual intervention is reduced, and the labor cost is reduced.

Description

Technical Field

[0001] The present invention relates to the field of water conservancy engineering equipment maintenance, and in particular to a hydro-generator rotor maintenance robot, a control system and a control method. Background Art

[0002] In view of the severe challenges currently faced in the maintenance of large-scale hydro-generator rotors, especially the sludge problem caused by the accumulation of a mixture of grease and air dust on the rotor surface due to high-speed rotation, this sludge not only significantly increases the thermal resistance of the main insulation layer, exacerbating the risk of overheating, but may also trigger discharge, directly threatening the operating safety and stability of the generator;

[0003] Although the current manual cleaning operation mode has alleviated this problem to a certain extent, it is accompanied by many disadvantages that cannot be ignored. First, workers need to perform high-altitude operations on complex scaffolding, which is not only labor-intensive, but also poses serious safety risks and poses a direct threat to the life and health of workers. Secondly, this cleaning operation is inefficient and requires a lot of time and manpower. Moreover, the quality of cleaning and spraying is unstable and depends on the skills and experience of workers, which makes it difficult to ensure consistency in the quality of operations and affects the maintenance effect. Finally, manual cleaning and spraying cause great environmental pollution, and it is difficult to handle cleaning agents and paints. Summary of the invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a rotor maintenance robot for a hydro-turbine generator set, comprising a mobile chassis and a lifting device, wherein the lifting device is installed on the mobile chassis, and the lifting device can drive a multi-axis robotic arm to perform vertical displacement. An actuator is provided at the execution end of the multi-axis robotic arm, and the actuator is used to clean the generator set.

[0005] Further, the lifting device includes a fixed end and a telescopic end, the fixed end is arranged on the mobile chassis, the lifting end is telescopically sleeved in the inner cavity of the fixed end, a lifting platform is arranged on the telescopic end, and the multi-axis mechanical arm is arranged on the lifting platform;

[0006] Furthermore, a cleaning agent cartridge and a paint cartridge are also provided on the lifting platform, and the cleaning agent cartridge and the paint cartridge are connected to the actuator, and the cleaning agent cartridge and the paint cartridge provide cleaning media for the actuator.

[0007] Furthermore, a depth camera is also arranged on the lifting platform.

[0008] Furthermore, the control cabinet and the air compressor are also arranged on the mobile chassis, and the control cabinet is used to control the multi-axis mechanical arm;

[0009] The air compressor provides a cleaning medium for the actuator.

[0010] Furthermore, a main control computer is also arranged on the mobile chassis, and the main control computer is connected to the depth camera, the lifting device, the mobile chassis, the control cabinet, the multi-axis robotic arm and the actuator.

[0011] The control method of the hydro-generator rotor maintenance robot comprises the following steps:

[0012] The devices are connected and communicated, and the parameters required by the system are input, including communication parameters and robot operation parameters, to prepare for the system initialization operation;

[0013] If the robot is in a normal state, the system will be initialized, the mobile chassis will be repositioned, and the multi-axis robot will return to zero. After the initialization is completed, the robot will enable the operation and start the operation.

[0014] Furthermore, when an abnormality is detected in the robot status, the abnormality is investigated and handled according to the prompts;

[0015] Furthermore, when the control system receives a motion control instruction for the mobile chassis, the mobile chassis will automatically travel according to the set speed, acceleration parameters and preset motion trajectory points until it reaches the specified position or receives a stop command and stops.

[0016] Furthermore, when the control system receives an instruction to control the movement of a multi-axis robotic arm, the control cabinet will guide the robotic arm to accurately perform actions according to preset speed, acceleration parameters and motion trajectory points until the task at the specified trajectory point is completed or a stop signal is received to terminate the action.

[0017] Furthermore, when the control system receives an instruction to perform cleaning and spraying, the control system parses the instruction, extracts the precise position information where the mobile chassis needs to move, and then transmits the position information to the mobile chassis. After receiving the instruction, the mobile chassis moves to the corresponding position, and then the depth camera on the multi-axis robotic arm captures the image of the rotor surface and the image processing software processes it, obtains the operation position information and transmits it to the multi-axis robotic arm, which completes the operation according to the above operation information.

[0018] Furthermore, when the command received by the robot is an emergency stop function, the control system runs the emergency stop program to stop all functional modules of the robot.

[0019] A control system for a rotor maintenance robot for a hydro-turbine generator set, comprising an initialization module, a status display module, a parameter input module, a communication module, a mobile robot motion module, a multi-axis mechanical arm operation function module and an alarm emergency stop module, wherein the initialization module is electrically connected to the communication module, the communication module is electrically connected to the mobile robot motion module, the communication module is electrically connected to the multi-axis mechanical arm operation function module, the mobile robot motion module and the multi-axis mechanical arm operation function module are electrically connected to the status display module, the parameter input module and the alarm emergency stop module respectively;

[0020] The initialization module is used to initialize the control system of the entire maintenance robot.

[0021] Furthermore, the communication module is used for communication between the user terminal and the robot and acquisition of communication parameters.

[0022] Furthermore, the status display module is used to obtain the operating status and various operating parameters of the mobile chassis, obtain the operating status and various operating parameters of the multi-axis robotic arm, and display the real-time data and processed data obtained by each sensor.

[0023] Furthermore, the parameter input module is used to input all communication parameters and operation parameters to the robot system.

[0024] The beneficial effects of the present invention are as follows: through the close cooperation between the multi-axis robotic arm and the mobile chassis, combined with the visual guidance of the depth camera, the robot can accurately locate and perform cleaning and spraying tasks, which not only greatly improves the safety and efficiency of the operation, but also ensures the consistency and high standards of the operation quality. At the same time, the integrated equipment design, such as the configuration of the cleaning agent barrel, paint barrel and air compressor, makes the supply of cleaning media convenient and the operation process smoother. The application of intelligent control systems allows the robot to autonomously receive instructions, parse tasks, and coordinate various equipment to efficiently complete operations, reducing manual intervention and reducing labor costs. In addition, this solution also pays attention to environmental protection, and effectively reduces pollution to the environment by reducing the waste of cleaning agents and paints. In summary, this solution uses automation, integration, and intelligence as means to comprehensively solve the defects of the prior art. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the structure of the present invention;

[0026] Figure 2 For the present invention Figure 1 A magnified schematic diagram of point a;

[0027] Figure 3 It is a rear view of the present invention;

[0028] Figure 4It is a right side view of the present invention;

[0029] Figure 5 A top view of the present invention;

[0030] Figure 6 It is a partial schematic diagram of the present invention;

[0031] Figure 7 It is a control system architecture diagram of the present invention;

[0032] Figure 8 It is a working principle diagram of the present invention.

[0033] Among them, 1. actuator; 2. multi-axis robotic arm; 3. depth camera; 4. lifting device; 41. fixed end; 42. telescopic end; 5. mobile chassis; 6. air compressor; 7. paint barrel; 8. cleaning agent barrel; 9. inverter; 10. control cabinet; 11. lifting platform. DETAILED DESCRIPTION

[0034] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0035] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0036] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0037] Example 1

[0038] like Figure 1-6As shown, a rotor maintenance robot for a hydro-turbine generator set comprises a mobile chassis 5 and a lifting device 4, wherein the lifting device 4 is mounted on the mobile chassis 5, and the lifting device 4 can drive a multi-axis mechanical arm 2 to perform vertical displacement, and an actuator 1 is provided at the execution end of the multi-axis mechanical arm 2, wherein the actuator 1 is used to clean the generator set, and the actuator 1 has multiple cleaning functions and multiple different forms, such as high-pressure water jet cleaning, which can use high-pressure water flow to impact the surface of the generator set to remove attached dirt, oil stains and dust; or chemical cleaning agent spraying, which sprays the cleaning agent (such as solvent, emulsifier, acid and alkali solution, etc.) on the surface of the generator set through the actuator 1. The surface of the generator set is cleaned by chemical action to decompose and remove dirt. The cleaning agent barrel 8 provides the medium for this cleaning method; or steam cleaning uses high-temperature and high-pressure steam to clean the generator set, which can not only effectively remove dirt, but also play a certain role in sterilization and disinfection; or the surface of the generator set can be directly physically scrubbed by actuator components such as mechanical brushes or rotating brush heads, which is suitable for removing stubborn dirt or scaling; or a high-energy laser beam can be used to irradiate the surface of the generator set to instantly vaporize or peel off the dirt; and the air compressor 6 provides high-pressure air as a power source, and the air spray gun as an actuator 1 uses these high-pressure air to spray paint, detergent or other media onto the target surface. Finally, according to the type and degree of dirt on the surface of the generator set, the above-mentioned multiple cleaning methods can be combined to achieve a more thorough and efficient cleaning effect.

[0039] Specifically, the lifting device 4 includes a fixed end 41 and a telescopic end 42, the fixed end 41 and the telescopic end 42 are pile-shaped, and two are symmetrically arranged. The fixed end 41 is arranged on the mobile chassis 5, and the lifting end 42 is telescopically sleeved in the inner cavity of the fixed end 41. A lifting platform 11 is arranged at one end of the two telescopic ends 42, and a frame is arranged on the lifting platform 11, and the multi-axis robot arm 2 is arranged on the frame;

[0040] The lifting platform 11 is also provided with a cleaning agent cartridge 8 and a paint cartridge 7 . The cleaning agent cartridge 8 and the paint cartridge 7 are connected to the actuator 1 . The cleaning agent cartridge 8 and the paint cartridge 7 provide cleaning media for the actuator 1 .

[0041] The lifting platform 11 is also provided with a depth camera 3 .

[0042] The control cabinet 10 and the air compressor 6 are also arranged on the mobile chassis 5, and the control cabinet 10 is used to control the multi-axis robot arm 2;

[0043] The air compressor 6 provides cleaning medium for the actuator 1 .

[0044] A main control computer is also provided on the mobile chassis 5 , and the main control computer is connected to the depth camera 3 , the lifting device 4 , the mobile chassis 5 , the control cabinet 10 , the multi-axis robotic arm 2 and the actuator 1 .

[0045] A control method for a hydro-generator rotor maintenance robot comprises the following steps:

[0046] The devices are connected and communicated, and the parameters required by the system are input, including communication parameters and robot operation parameters, to prepare for the system initialization operation;

[0047] If the robot is detected to be in normal state, the system is initialized, the mobile chassis 5 is repositioned, and the multi-axis robot arm 2 is returned to zero. After the initialization operation is completed, the robot is enabled to operate and starts to operate.

[0048] The operation process of the robot is as follows: the mobile chassis 5 moves to the magnetic pole cleaning (spraying) position, and then the depth camera 3 performs image acquisition. The robot system is positioned according to the image acquired by the depth camera 3, and then the multi-axis robotic arm 2 selects the corresponding actuator 1 to perform the operation. During the operation, when the telescopic end 42 of the lifting device 4 moves up and down, the multi-axis robotic arm 2 also moves up and down accordingly. The multi-axis robotic arm 2 can drive the actuator 1 to perform linear motion on the X, Y, and Z axes, so that the actuator 1 has better flexibility when cleaning (spraying), thereby improving the cleaning (spraying) efficiency.

[0049] like Figure 1-8 As shown, a control system of a rotor maintenance robot for a hydro-turbine generator set includes an initialization module, a status display module, a parameter input module, a communication module, a mobile robot motion module, a multi-axis mechanical arm operation function module and an alarm emergency stop module, wherein the initialization module is electrically connected to the communication module, the communication module is electrically connected to the mobile robot motion module, the communication module is electrically connected to the multi-axis mechanical arm operation function module, the mobile robot motion module and the multi-axis mechanical arm operation function module are electrically connected to the status display module, the parameter input module and the alarm emergency stop module respectively;

[0050] The initialization module is used to initialize the control system of the entire maintenance robot.

[0051] The communication module is used for communication between the user terminal and the robot and acquisition of communication parameters.

[0052] The status display module is used to obtain the operating status and various operating parameters of the mobile chassis 5, obtain the operating status and various operating parameters of the multi-axis robot arm 2, and display the real-time data and processed data obtained by each sensor.

[0053] The parameter input module is used to input all communication parameters and operation parameters to the robot system.

[0054] The user can send operation instructions to the robot control system through the user-side controller. During the entire operation, the positioning of the robot can be divided into the rough positioning of the mobile chassis 5 and the precise positioning of the multi-axis manipulator 2. Since the mobile chassis 5 of the robot has an autonomous movement function, it is necessary to collect a map of the new site before putting it into a new site for operation. In actual operation, the position of the mobile chassis 5 is usually fixed and located at a certain distance directly in front of the rotor pole of the generator. Therefore, on the generated map, a corresponding station can be set. The position of the station is a certain distance directly in front of the rotor pole. After the mobile chassis 5 moves to this position, it can remain motionless to complete the rough positioning. The precise positioning of the multi-axis manipulator 2 is completed by the depth camera 3 and the visual positioning system. The image of the rotor surface is collected by the depth camera 3, and the image is processed by the visual processing software of the main control computer to obtain the position information and posture information of the robot end effector 1 relative to the working surface. The trajectory planning module of the main control computer plans the trajectory of the multi-axis manipulator 2 operation. The multi-axis manipulator 2 carries different robot end effectors and completes the operation according to the above trajectory.

[0055] Example 2

[0056] like Figure 1-8 A control method of a hydro-generator rotor maintenance robot is shown, comprising the following steps:

[0057] The devices are connected and communicated, and the parameters required by the system are input, including communication parameters and robot operation parameters, to prepare for the system initialization operation;

[0058] If the robot is in a normal state, the system is initialized, the mobile chassis 5 is repositioned, and the multi-axis robot arm 2 is returned to zero. After the initialization is completed, the robot is enabled to operate and starts to operate.

[0059] When an abnormality is detected in the robot status, follow the prompts to troubleshoot and handle the abnormality.

[0060] Example 3

[0061] like Figure 1-8 As shown, a control method of a hydro-generator rotor maintenance robot comprises the following steps:

[0062] The devices are connected and communicated, and the parameters required by the system are input, including communication parameters and robot operation parameters, to prepare for the system initialization operation;

[0063] If the robot is in a normal state, the system is initialized, the mobile chassis 5 is repositioned, and the multi-axis robot arm 2 is returned to zero. After the initialization is completed, the robot is enabled to operate and starts to operate.

[0064] When the control system receives a motion control instruction for the mobile chassis 5, the mobile chassis 5 will automatically travel according to the set speed, acceleration parameters and preset motion trajectory points until it reaches the specified position or receives a stop command and stops.

[0065] Example 4

[0066] like Figure 1-8 As shown, a control method of a hydro-generator rotor maintenance robot comprises the following steps:

[0067] The devices are connected and communicated, and the parameters required by the system are input, including communication parameters and robot operation parameters, to prepare for the system initialization operation;

[0068] If the robot is in a normal state, the system is initialized, the mobile chassis 5 is repositioned, and the multi-axis robot arm 2 is returned to zero. After the initialization is completed, the robot is enabled to operate and starts to operate.

[0069] When the control system receives an instruction to control the movement of the multi-axis robot arm 2, the control cabinet 10 will guide the robot arm to accurately perform the action according to the preset speed, acceleration parameters and motion trajectory points until the specified trajectory point task is completed or a stop signal is received and the action is stopped.

[0070] Example 5

[0071] like Figure 1-8 As shown, a control method of a hydro-generator rotor maintenance robot comprises the following steps:

[0072] The devices are connected and communicated, and the parameters required by the system are input, including communication parameters and robot operation parameters, to prepare for the system initialization operation;

[0073] If the robot is in a normal state, the system is initialized, the mobile chassis 5 is repositioned, and the multi-axis robot arm 2 is returned to zero. After the initialization is completed, the robot is enabled to operate and starts to operate.

[0074] When the control system receives the cleaning and spraying instruction, the control system parses the instruction, extracts the precise position information where the mobile chassis 5 needs to move, and then transmits the position information to the mobile chassis 5. After receiving the instruction, the mobile chassis 5 moves to the corresponding position. Then the depth camera 3 on the multi-axis robot 2 captures the image of the rotor surface and processes it with the image processing software. The operation position information is obtained and transmitted to the multi-axis robot 2. The multi-axis robot 2 completes the operation according to the above operation information.

[0075] Example 6

[0076] like Figure 1-8 As shown, a control method of a hydro-generator rotor maintenance robot comprises the following steps:

[0077] The devices are connected and communicated, and the parameters required by the system are input, including communication parameters and robot operation parameters, to prepare for the system initialization operation;

[0078] If the robot is in a normal state, the system is initialized, the mobile chassis 5 is repositioned, and the multi-axis robot arm 2 is returned to zero. After the initialization is completed, the robot is enabled to operate and starts to operate.

[0079] When the command received by the robot is an emergency stop function, the control system runs the emergency stop program to stop all functional modules of the robot.

[0080] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0081] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A hydro-generator rotor maintenance robot, characterized in that: The invention comprises a mobile chassis (5) and a lifting device (4), wherein the lifting device (4) is installed on the mobile chassis (5), and a lifting platform (11) is arranged on the lifting device (4). The lifting platform (11) is provided with a depth camera (3), a multi-axis mechanical arm (2), a cleaning agent bucket (8) and a paint bucket (7); an actuator (1) is provided at the execution end of the multi-axis mechanical arm (2); the cleaning agent bucket (8) and the paint bucket (7) are both connected to the actuator (1); An air compressor (6) is also provided on the mobile chassis (5), and the air compressor (6) is used to transport the cleaning agent and paint in the cleaning agent barrel (8) and the paint barrel (7) to the actuator (1), and spray them out through the actuator (1).

2. The hydro-generator rotor maintenance robot according to claim 1, characterized in that: The lifting device (4) comprises a fixed end (41) and a telescopic end (42); the fixed end (41) is arranged on the mobile chassis (5); the lifting end (42) is telescopically sleeved in the inner cavity of the fixed end (41); and the lifting platform (11) is arranged on the telescopic end (42).

3. The hydro-generator rotor maintenance robot according to claim 1, characterized in that: A control cabinet (10) and a main control computer are also provided on the mobile chassis (5); the main control computer is connected to the depth camera (3), the lifting device (4), the mobile chassis (5), the multi-axis mechanical arm (2) and the actuator (1) through the control cabinet (10).

4. A control method for a hydro-generator rotor maintenance robot, characterized in that: The following steps are involved: Enter communication parameters and robot operation parameters; The user terminal communicates with the robot; And check whether the communication is normal. If the communication is normal, perform initialization operation; if it is abnormal, report an error and stop urgently. After eliminating the abnormality, check whether the communication is normal again; Perform initialization operation. If the initialization is normal, you can send instructions to the robot. If the initialization is abnormal, an error will be reported and an emergency stop will be made. After eliminating the abnormality, check again whether the initialization is normal. After initialization, the user sends instructions to the robot, and the robot performs corresponding actions according to the instructions.

5. The control method of the hydro-generator rotor maintenance robot according to claim 4 is characterized in that: The initialization operation includes the following steps: Repositioning the mobile chassis (5); Perform zero return operation on the multi-axis robot arm (2).

6. The control method of the hydro-generator rotor maintenance robot according to claim 4 is characterized in that: When the robot receives a motion control instruction for the mobile chassis (5), the mobile chassis (5) will automatically move according to the set speed, acceleration parameters and preset motion trajectory points until it reaches a specified position or receives a stop command and stops.

7. The control method of the hydro-generator rotor maintenance robot according to claim 4, characterized in that: When the robot receives an instruction to control the movement of the multi-axis robot arm (2), the control cabinet (10) will guide the robot arm to accurately perform the action according to the preset speed, acceleration parameters and movement trajectory points until the task of the designated trajectory point is completed or a stop signal is received and the action is stopped.

8. The control method of the hydro-generator rotor maintenance robot according to claim 4, characterized in that: When the robot receives a cleaning and spraying instruction, the control system analyzes the instruction, extracts the precise position information of the mobile chassis (5) to be moved, and then transmits the position information to the mobile chassis (5). After receiving the instruction, the mobile chassis (5) moves to the corresponding position, and then the depth camera (3) on the multi-axis robot arm (2) collects images of the rotor surface and transmits them to the image processing software for processing, obtains the operation position information and transmits it to the multi-axis robot arm (2), and the multi-axis robot arm (2) completes the operation according to the above operation information.

9. The control method of the hydro-generator rotor maintenance robot according to claim 4, characterized in that: When the command received by the robot is an emergency stop function, the control system runs the emergency stop program to stop all functional modules of the robot.

10. A control system for a hydro-generator rotor maintenance robot, characterized in that: It includes an initialization module, a status display module, a parameter input module, a communication module, a mobile robot motion module, a multi-axis mechanical arm operation function module and an alarm emergency stop module, wherein the initialization module is electrically connected to the communication module, the communication module is electrically connected to the mobile robot motion module, the communication module is electrically connected to the multi-axis mechanical arm operation function module, the mobile robot motion module and the multi-axis mechanical arm operation function module are electrically connected to the status display module, the parameter input module and the alarm emergency stop module respectively; The initialization module is used to initialize the control system; The communication module is used to transmit communication and communication parameters between the user terminal and the robot; The status display module is used to obtain the operating status and various operating parameters of the mobile chassis (5) and the multi-axis mechanical arm (2), and to display the obtained real-time data and processed data; The parameter input module is used to input all communication parameters and operation parameters to the robot system.

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