Method for aligning bolt through full-automatic electric operating rod

Abstract

The invention relates to the technical field of bolt alignment, in particular to a full-automatic electric operating rod bolt alignment method which comprises the following steps: starting operating equipment which comprises a sensor, a control system and an operating rod; scanning the target area by using a sensor to obtain relative position information between the bolt and the nut; the control system automatically adjusts the position and direction of the operating rod according to the position information fed back by the sensor until the clamping end of the operating rod is aligned with the bolt; and after alignment, the tightening device on the operating rod automatically executes bolt fastening operation. The method has the beneficial effects that the requirement for manual intervention is reduced through automatic equipment, so that the operation process is more standardized and efficient, and the risk caused by improper manual operation is reduced; the sensor can accurately detect the positions of the bolt and the nut and the relative distance between the bolt and the nut, the problem that a high-voltage component needs to be directly contacted in a traditional method is avoided, and the operation safety is improved.

Description

Technical Field

[0001] The invention relates to the technical field of bolt alignment, in particular to a method for fully automatic electric operating rod alignment of bolts. Background Art

[0002] In the maintenance and assembly of high-voltage transmission lines in the power industry, especially in the 35kV indirect operation environment without power outage, operators need to complete precise bolt connection operations in a high-risk live environment. This type of operation has extremely high requirements for personnel safety, operation efficiency and connection accuracy.

[0003] Traditional bolt alignment operations mostly rely on manual operations, usually requiring manual alignment and connection of bolts through insulated operating rods or mechanical tools. This method is not only difficult to operate, but also has extremely high safety risks due to the proximity of personnel to high-voltage power sources, which can easily cause safety accidents such as electric shock. Summary of the invention

[0004] Some simplifications or omissions may be made in this section and the abstract and title of the present application to avoid obscuring the purpose of this section, the abstract and the title of the invention, and such simplifications or omissions shall not be used to limit the scope of the present invention.

[0005] The invention aims to provide a fully automatic electric operating rod aligning bolt method.

[0006] Therefore, the purpose is to solve the problem that traditional bolt alignment operations mostly rely on manual operations, and usually require manual alignment and connection of the bolts through an insulating operating rod or a mechanical tool.

[0007] To solve the above technical problems, the present invention provides the following technical solutions: a fully automatic electric operating rod alignment bolt method, which includes starting an operating device, the operating device includes a sensor, a control system and an operating rod; using the sensor to scan the target area to obtain the relative position information between the bolt and the nut; the control system automatically adjusts the position and direction of the operating rod according to the position information fed back by the sensor until the clamping end of the operating rod is aligned with the bolt; after alignment, the tightening device on the operating rod automatically performs the bolt tightening operation; during the operation, the control system continuously monitors the changes in the electromagnetic environment to ensure the safe operation of the operating equipment.

[0008] As a preferred solution of the method for aligning bolts with a fully automatic electric operating rod of the present invention, the sensor detects the relative position between the bolt and the nut in real time, and the sensor is installed at the front end of the operating rod to obtain the displacement and angular deviation between the bolt and the nut in the horizontal and vertical directions, and transmits these data to the control system.

[0009] As a preferred solution of the method for fully automatic electric operating rod to align bolts of the present invention, the control system sends adjustment instructions to the operating rod through wireless communication or wired connection according to the position data sent by the sensor.

[0010] As a preferred solution of the method for aligning a bolt with a fully automatic electric operating rod of the present invention, the operating rod is designed to have an adjustment function with at least three degrees of freedom, namely, rotation in a horizontal plane, vertical movement in a vertical plane, and extension and retraction along the bolt axis.

[0011] As a preferred solution of the method for aligning a bolt with a fully automatic electric operating rod of the present invention, the control system has a built-in algorithm module, which dynamically calculates the angle and distance that the operating rod needs to be adjusted according to the bolt position changes fed back by the sensor in real time, until the bolt and nut are fully aligned.

[0012] As a preferred solution of the method for aligning bolts with a fully automatic electric operating rod of the present invention, after the bolt and the nut are aligned, the tightening device installed on the operating rod is automatically started to tighten with a set torque value, and the actual torque is monitored by a built-in torque sensor to ensure that the bolt tightening meets the preset torque standard.

[0013] As a preferred solution of the fully automatic electric operating rod alignment bolt method of the present invention, the control system integrates an electromagnetic field monitoring module, which can continuously monitor the changes in the electromagnetic field intensity around the operating equipment under a 35kV high voltage environment.

[0014] As a preferred solution of the fully automatic electric operating rod bolt alignment method of the present invention, the control system is capable of recording the position data collected by the sensor, the torque data emitted by the system and the time information required for the operation during each operation, and uploading it to the server via a USB interface or the network to generate an operation log and analysis report.

[0015] As a preferred solution of the method for fully automatic electric operating rod alignment bolt of the present invention, the operator can remotely start the operating equipment through a dedicated mobile application or computer software, and visually view it through a video stream.

[0016] As a preferred solution of the method for fully automatic electric operating rod alignment bolt of the present invention, the sensor is made of high-pressure resistant material and is subjected to magnetic shielding treatment.

[0017] The beneficial effects of the fully automatic electric operating rod alignment bolt method of the present invention are: reducing the need for manual intervention through automated equipment, making the operation process more standardized and efficient, and reducing the risks caused by improper manual operation.

[0018] The sensor can accurately detect the position of the bolt and nut and the relative distance between them, avoiding the problem of direct contact with high-voltage components in traditional methods and improving the safety of operations.

[0019] The control system realizes the automation of bolt alignment, avoids errors in the manual adjustment process, improves operation accuracy, and significantly shortens operation time and improves work efficiency.

[0020] In high-pressure environments that require long-term monitoring or operation, unattended monitoring can be achieved, avoiding occupational health problems that workers may suffer from being in potentially dangerous areas for a long time. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. Among them:

[0022] Figure 1 It is a system block diagram of the method for fully automatic electric operating rod to align bolts in the present invention.

[0023] Figure 2 It is a flowchart of the method for fully automatic electric operating rod alignment bolt in the present invention.

[0024] In the figure:

[0025] 100, equipment; 101, sensor; 102, control system; 103, operating lever;

[0026] 200. Tightening device. DETAILED DESCRIPTION

[0027] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0028] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0029] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0030] Example 1

[0031] Reference Figure 1 , which is the first embodiment of the present invention, and this embodiment provides a fully automatic electric operating rod alignment bolt method, comprising starting an operating device 100, the operating device 100 comprising a sensor 101, a control system 102 and an operating rod 103; using the sensor 101 to scan a target area to obtain relative position information between a bolt and a nut; the control system 102 automatically adjusts the position and direction of the operating rod 103 according to the position information fed back by the sensor 101 until the clamping end of the operating rod 103 is aligned with the bolt; after alignment, the tightening device 200 on the operating rod 103 automatically performs a bolt tightening operation; during the operation, the control system 102 continuously monitors changes in the electromagnetic environment to ensure that the operating device 100 operates safely and has a fault diagnosis function.

[0032] Specifically, the automation of the startup process reduces the need for human intervention, making the entire operation process more standardized and efficient, and reducing the risks caused by misoperation.

[0033] The sensor 101 can accurately detect the position of the bolt and nut, as well as the relative distance between them. This non-contact measurement method avoids the problem of direct contact with high-voltage components in traditional methods, thereby improving safety. At the same time, the high-precision position information provides a data basis for subsequent automatic alignment. The intervention of the control system 102 realizes the automation of bolt alignment and avoids the errors that may occur during manual adjustment. This not only improves the operation accuracy, but also greatly reduces the operation time and improves work efficiency. The tightening device 200 on the operating rod 103 can automatically complete the bolt tightening work, further reducing manual intervention and ensuring that each tightening meets the standard, thereby ensuring the safety of the connection.

[0034] Electromagnetic interference is a major safety hazard when working in an electrically charged environment. The ability to continuously monitor the electromagnetic environment and make corresponding adjustments helps prevent operating equipment 100 failures or accidents, ensuring stable operation of the equipment. Fault diagnosis allows the system to quickly identify and take action when problems occur, reducing downtime, while also providing maintenance personnel with accurate information to repair problems in a timely manner, further ensuring the safety of operations.

[0035] Here are several possible application scenarios: In a substation, there are many high-voltage devices that require regular maintenance, including the work of tightening bolts. The use of the fully automatic electric operating rod 103 can accurately align and tighten the bolts without interrupting the power supply, avoiding the errors and risks of electric shock caused by manual alignment in traditional methods.

[0036] There are many connection parts on the transmission tower that need to be regularly inspected and bolted, especially in the high-voltage environment of 35kV. Manual operation is not only dangerous but also inefficient. With the fully automatic electric operating lever 103, these tasks can be completed by remote control, reducing the risk of high-altitude operations and improving work efficiency.

[0037] Example 2

[0038] Reference Figure 1-2 , which is the second embodiment of the present invention. Different from the previous embodiment, the sensor 101 detects the relative position between the bolt and the nut in real time. The sensor 101 may include but is not limited to a photoelectric sensor 101, a magnetic sensor 101 or an ultrasonic sensor 101. The sensor 101 is installed at the front end of the operating rod 103 to obtain the displacement and angle deviation between the bolt and the nut in the horizontal and vertical directions, and transmit these data to the control system 102. The control system 102 sends an adjustment instruction to the operating rod 103 through wireless communication or wired connection according to the position data sent by the sensor 101, so that the operating rod 103 is adjusted in multiple degrees of freedom (X-axis, Y-axis and Z-axis directions) to achieve precise alignment between the bolt and the nut. The operating rod 103 is designed to have an adjustment function with at least three degrees of freedom, and can rotate in the horizontal plane, move up and down in the vertical plane, and stretch along the axis direction of the bolt to ensure that the operating rod 103 can achieve millimeter-level fine-tuning and achieve the best alignment state. The control system 102 has a built-in algorithm module, which dynamically calculates the angle and distance that the operating rod 103 needs to be adjusted according to the real-time feedback of the bolt position change from the sensor 101 until the bolt and the nut are completely aligned.

[0039] In this embodiment, the sensor 101 is a very critical link in the entire system, and is responsible for real-time monitoring of the relative position information between the bolt and the nut.

[0040] The sensor 101 may be of various types, such as a photoelectric sensor 101, a magnetic sensor 101 or an ultrasonic sensor 101. Each sensor 101 has its own characteristics. For example, the photoelectric sensor 101 is suitable for non-contact measurement; the magnetic sensor 101 can sense changes in the magnetic field and is suitable for use in a metal material environment; the ultrasonic sensor 101 is not affected by color and surface finish and is suitable for distance measurement in a variable environment.

[0041] The sensor 101 is installed at the front end of the operating rod 103, and can accurately capture the position changes of the bolt and the nut in space, including their horizontal and vertical displacements and possible angular deviations. This information is crucial for subsequent adjustments.

[0042] The operating rod 103 is designed as an actuator with at least three degrees of freedom, that is, it can be adjusted in the three axes of X, Y, and Z. Specifically:

[0043] Rotation in the horizontal plane: allows the operating rod 103 to rotate in the horizontal plane to adapt to nut holes in different directions;

[0044] Using a rotary joint (similar to the rotating axis of an industrial robot), it consists of a module that integrates a precision reducer and a servo motor. The servo motor is responsible for providing power, while the reducer is used to reduce the speed and increase the torque to ensure the stability and precision of the rotational movement.

[0045] Vertical plane up and down movement: enables the operating rod 103 to adjust its height in the vertical direction to adapt to nut holes of different heights;

[0046] Movement in the Z-axis direction can be achieved by linear actuators, common linear actuators include ball screws, rack and pinion, etc. These actuators are also driven by servo motors and equipped with position feedback devices (such as linear encoders) to monitor the position.

[0047] Extension and retraction along the bolt axis direction: This function allows the operating rod 103 to extend and retract along the direction of the bolt to ensure that the bolt can accurately enter the nut hole;

[0048] The bolt axis can be extended and retracted by a built-in extension mechanism, which can be a telescopic cylinder or an electric push rod. This mechanism can quickly adjust the length to ensure that the bolt can smoothly enter the nut hole.

[0049] Such a design enables the operating rod 103 to be flexibly fine-tuned at the millimeter level in a complex environment, thereby achieving high-precision docking of the bolt and the nut.

[0050] The control system 102 integrates an algorithm module, which can dynamically calculate the angle and distance that the operating rod 103 needs to be adjusted according to the real-time data from the sensor 101. The control system 102 is connected to the operating rod 103 wirelessly or wiredly to issue adjustment instructions in a timely manner.

[0051] The algorithm module is the core of the control system 102, such as:

[0052] Geometric transformation matrix: used to describe the position and posture of the actuator of the clamping section of the operating rod 103 relative to the reference coordinate system, so as to facilitate the calculation of the current position of the operating rod 103.

[0053] Inverse Kinematics (IK): Solve the problem of going from the desired gripper actuator position to the joint angle, that is, calculate the angle that each joint needs to rotate to reach the specified position.

[0054] Path planning: According to the current state and the target state, an optimal path is planned to ensure that the operating rod 103 moves according to the predetermined trajectory.

[0055] PID controller: A proportional-integral-differential controller is used to adjust the movement speed of the operating rod 103 to ensure that it reaches the target position smoothly and accurately.

[0056] Among them, the geometric transformation matrix, inverse kinematics (IK) and path planning mentioned in the algorithm module are existing algorithms that have been widely used in the fields of robotics and automation.

[0057] The control system 102 generates specific control instructions by analyzing the results output by the algorithm module, and sends them to the operating rod 103 via wireless or wired communication. This includes but is not limited to parameters such as adjustment angle and moving distance.

[0058] The control system 102 is designed to achieve automated alignment, reduce the need for manual intervention, and improve production efficiency and consistency of quality control. In addition, the control system 102 can also integrate other auxiliary functions, such as fault diagnosis, data recording and analysis, etc., to further enhance the intelligence level of the system.

[0059] The control system 102 can record the data of each assembly process to provide a basis for subsequent quality control and also help engineers optimize the assembly process.

[0060] After the bolt and nut are aligned, the tightening device 200 installed on the operating rod 103 starts automatically, and the motor drives the screw or gear rack mechanism to tighten with the set torque value, and monitors the actual torque through the built-in torque sensor 101 to ensure that the bolt tightening meets the preset torque standard.

[0061] In this embodiment, the tightening device 200 generally includes a motor, which can drive a lead screw or a gear rack mechanism. The motor needs to have an adjustable speed function so as to adjust the speed according to different tightening requirements.

[0062] Lead screw and gear rack are both common transmission methods used to convert the rotational motion of the motor into linear motion or greater rotational torque.

[0063] The torque sensor 101 is used to monitor the torque generated during the tightening process in real time. When the actual torque reaches a preset value, the system will stop the motor to prevent over-tightening or under-tightening.

[0064] Example 3

[0065] Reference Figure 1-2 , which is the third embodiment of the present invention, and this embodiment further provides a fully automatic electric operating rod alignment bolt method. The control system 102 integrates an electromagnetic field monitoring module, which can continuously monitor the changes in the electromagnetic field intensity around the operating device 100 under a 35kV high voltage environment to ensure that the sensor 101 is not subject to electromagnetic interference. At the same time, it has a fault self-detection function. When encountering an abnormal situation, the system will automatically stop all actions and send out an alarm signal through a buzzer or other means. The control system 102 can record the position data collected by the sensor 101 during each operation, the torque data sent by the system, and the time required for the operation, and upload it to the server through a USB interface or a network to generate a detailed operation log and analysis report.

[0066] In this embodiment, an electromagnetic field monitoring module suitable for working in a 35kV high voltage environment is selected.

[0067] The mounting frame is designed to ensure that the sensor 101 is stably mounted on the operating device 100 and does not affect its normal operation.

[0068] Shielding materials are used or shielding structures are designed to protect the sensor 101 from external electromagnetic interference.

[0069] When an abnormal situation is detected, such as the electromagnetic field strength exceeds a preset threshold, the control system 102 should immediately stop the action of the electric operating lever 103 and trigger an alarm mechanism.

[0070] Install a buzzer or other type of alarm device to alert operators when an abnormal condition is detected.

[0071] A data storage module is integrated in the control system 102 to record important data such as position data, torque data, operation time, etc. during each operation.

[0072] A USB interface or network interface is provided to allow data to be uploaded to a server for analysis and archiving.

[0073] The operator can remotely start the operating device 100 through a dedicated mobile application or computer software, and visually view the situation at the operation site through a video stream, thereby reducing the time the operator is directly exposed to the high-voltage environment. The sensor 101 is made of high-voltage resistant materials and is magnetically shielded to ensure that it can maintain stable working performance in a high-voltage operating environment.

[0074] In this embodiment, through remote operation, workers do not need to personally enter high-voltage or extreme environments for maintenance or operation, which significantly reduces the probability of personal injury due to accidents.

[0075] For high-voltage equipment that requires long-term monitoring or operation, the use of high-voltage resistant sensors 101 can achieve unattended monitoring, thereby avoiding the occupational diseases that workers may suffer from due to being in potential danger areas for a long time.

[0076] Importantly, it should be noted that the construction and arrangement of the present application shown in a plurality of different exemplary embodiments are only exemplary. Although only a few embodiments are described in detail in this disclosure, it should be readily understood by those who refer to this disclosure that many modifications are possible (e.g., the size, scale, structure, shape and proportion of various elements, and parameter values ​​(e.g., temperature, pressure, etc.), installation arrangement, use of materials, color, directional changes, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in the application. For example, the element shown as integrally formed can be composed of multiple parts or elements, the position of the element can be inverted or otherwise changed, and the nature or number or position of the discrete element can be changed or changed. Therefore, all such modifications are intended to be included in the scope of the present invention. The order or sequence of any process or method steps can be changed or reordered according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure of performing the function described herein, and is not only structurally equivalent but also equivalent structure. Without departing from the scope of the present invention, other replacements, modifications, changes and omissions can be made in the design, operating conditions and arrangement of the exemplary embodiments. Therefore, the invention is not limited to a specific embodiment, but extends to numerous modifications still falling within the scope of the appended claims.

[0077] Additionally, in order to provide a concise description of exemplary embodiments, all features of an actual embodiment (ie, those features that are not relevant to the best mode presently contemplated for carrying out the invention or those that are not relevant to implementing the invention) may not be described.

[0078] It will be appreciated that in the development of any actual implementation, as in any engineering or design project, numerous implementation-specific decisions may be made. Such a development effort may be complex and time-consuming, but will be a routine task of design, fabrication, and production for those of ordinary skill having the benefit of this disclosure without undue experimentation.

[0079] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A fully automatic electric operating rod alignment bolt method, characterized in that: include, Starting an operating device (100), wherein the operating device (100) comprises a sensor (101), a control system (102) and an operating lever (103); Scanning a target area using a sensor (101) to obtain relative position information between the bolt and the nut; The control system (102) automatically adjusts the position and direction of the operating rod (103) according to the position information fed back by the sensor (101) until the clamping end of the operating rod (103) is aligned with the bolt; After alignment, the tightening device (200) on the operating rod (103) automatically performs the bolt tightening operation; During operation, the control system (102) continuously monitors changes in the electromagnetic environment to ensure safe operation of the operating device (100).

2. The fully automatic electric operating rod alignment bolt method according to claim 1, characterized in that: The sensor (101) detects the relative position between the bolt and the nut in real time. The sensor (101) is installed at the front end of the operating rod (103) to obtain the displacement and angle deviation between the bolt and the nut in the horizontal and vertical directions, and transmits these data to the control system (102).

3. The fully automatic electric operating rod alignment bolt method according to claim 2, characterized in that: The control system (102) sends an adjustment instruction to the operating rod (103) through wireless communication or wired connection according to the position data sent by the sensor (101).

4. The fully automatic electric operating rod alignment bolt method according to claim 3, characterized in that: The operating rod (103) is designed to have at least three degrees of freedom of adjustment, namely, rotation in a horizontal plane, vertical movement in a vertical plane, and extension and retraction along the bolt axis.

5. The fully automatic electric operating rod alignment bolt method according to claim 1, characterized in that: The control system (102) has a built-in algorithm module, which dynamically calculates the angle and distance that the operating rod (103) needs to be adjusted according to the bolt position change fed back in real time by the sensor (101) until the bolt and the nut are completely aligned.

6. The fully automatic electric operating rod alignment bolt method according to claim 5, characterized in that: After the bolt and the nut are aligned, the tightening device (200) installed on the operating rod (103) is automatically started to tighten with a set torque value, and the actual torque is monitored through the built-in torque sensor (101) to ensure that the bolt tightening meets the preset torque standard.

7. The fully automatic electric operating rod alignment bolt method according to claim 6, characterized in that: The control system (102) is integrated with an electromagnetic field monitoring module, and is capable of continuously monitoring changes in electromagnetic field intensity around the operating device (100) in a 35 kV high voltage environment.

8. The fully automatic electric operating rod alignment bolt method according to claim 7, characterized in that: The control system (102) is capable of recording the position data collected by the sensor (101), the torque data emitted by the system, and the time information required for the operation during each operation, and uploading them to the server via a USB interface or a network to generate an operation log and an analysis report.

9. The fully automatic electric operating rod alignment bolt method according to claim 8, characterized in that: The operator can remotely start the operating device (100) through a dedicated mobile application or computer software, and visually view it through a video stream.

10. The fully automatic electric operating rod alignment bolt method according to claim 9, characterized in that: The sensor (101) is made of high-voltage resistant material and is subjected to magnetic shielding treatment.

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