Electric tower climbing operation robot control system and method

Abstract

The invention discloses a control system and method for an electric tower climbing operation robot, and aims to realize reliable climbing and operation of the electric tower climbing operation robot on a tower. The system comprises an airborne power supply module, a climbing operation control unit, a camera monitoring module, a wireless transmission module and a ground control platform. The airborne power supply module is used for supplying power to all electric equipment of the robot; the core of the climbing operation control unit is an onboard control assembly, and the climbing operation control unit is used for planning and controlling climbing and operation of the robot; the camera monitoring module is used for monitoring the climbing and operation states of the robot; the wireless transmission module comprises a wireless data transmission module and a wireless image transmission module and is used for transmitting various data between the robot and the ground control platform; and the ground control platform is used for monitoring and overriding the climbing and operation processes of the robot. According to the electric tower climbing operation robot, multiple solutions are provided for many problems possibly encountered in the climbing operation process of the electric tower climbing operation robot, and the effect is good.

Description

Technical Field

[0001] The invention relates to the technical field of power tower climbing operation robots, and in particular to a control system and method for a power tower climbing operation robot. Background Art

[0002] At present, the construction of the power tower industry is still mainly manual, and there is a high risk of high-altitude operations. The development of power tower climbing robots has become a key direction to solve this problem. At present, the research on power tower climbing robots is still at the stage of structural design and optimization of the robot body, and there is little research on specific climbing robot control systems and methods. Based on the above, in order for the power tower climbing robot to truly replace high-altitude personnel to climb and work on the tower, it is urgent to develop a set of practical climbing robot control systems and methods. Summary of the invention

[0003] The object of the present invention is to provide a control system and method for an electric tower climbing operation robot, so as to realize reliable climbing and operation of the electric tower climbing operation robot on the tower.

[0004] To achieve the purpose of the present invention, the technical solution provided by the present invention is as follows:

[0005] First aspect

[0006] The present invention provides a control system for a power tower climbing operation robot, comprising a robot body and a ground control platform wirelessly connected to the robot body;

[0007] The robot body is used for climbing and working on power towers, and includes an onboard power supply module, a climbing operation control unit, a camera monitoring module, and a wireless transmission module for connecting to a ground control platform network;

[0008] The ground control platform is used to monitor the climbing and operating status of the robot body, and can also control the autonomous control commands of the robot body.

[0009] The onboard power supply module is used to supply power to all power-consuming units and modules on the robot body, including the climbing operation control unit, the camera monitoring module and the wireless transmission module. For devices with different voltage requirements, a voltage regulating and stabilizing module is used for conversion;

[0010] The climbing operation control unit is electrically connected to the wireless transmission module, and the climbing operation control unit includes an airborne control component, a chassis climbing module, a docking piece pressing module, a sensor module, a mechanical arm slide module, a mechanical arm control module and an end operation module;

[0011] The airborne control assembly is electrically connected to the sensor module, chassis climbing module, docking piece clamping module, robotic arm slide module, robotic arm control module and end operation module;

[0012] The chassis climbing module includes an independent clamp and a fixed clamp. The independent clamp and the fixed clamp are opened and closed by an opening and closing motor and can be interlocked. The independent clamp is connected to the lead screw and can move independently by the travel motor. The fixed clamp is connected to the lead screw and the fuselage and can move together with the travel motor. The two clamps are opened and closed alternately and move, so that the power tower climbing robot can climb up and down along the main material of the angle steel.

[0013] The butt joint pressing module is used to realize the pressing and fitting of the outer iron of the electric tower and the main angle steel material;

[0014] The sensor module includes an angle steel obstacle sensor, a foot nail obstacle sensor and a travel limit sensor; wherein the angle steel obstacle sensor is used to detect the crossbeam and diagonal material connected to the angle steel main material on the power tower; the foot nail obstacle sensor is used to detect the foot nail obstacle on the angle steel main material; the travel limit sensor is used to limit the critical travel of the robot chassis climbing module and the robot arm slide module;

[0015] The robot arm slide module includes a slide and a robot arm, and the slide is connected to the robot arm base by screws, so as to realize the movement of the robot arm working position, so that the robot arm reaches the position above the bolt group of the docking piece;

[0016] The robot arm control module is used to control the robot arm to identify the bolt posture along the planned path, locate the bolt through the visual depth algorithm, and control the end of the robot arm to insert the bolt;

[0017] The end operation module includes a depth camera and a sleeve, wherein the depth camera is used for identifying and locating bolts, and the sleeve adopts an adaptive spiral groove design for realizing the tightening operation of the bolts;

[0018] The onboard control component controls the climbing gait and working state of the robot by receiving the sensing information of the sensor module; the onboard control component is used to send control commands to the chassis climbing module motor, and interactively control the opening and closing of the chassis clamp by receiving the real-time torque feedback information of the chassis climbing module clamp opening and closing motor, and interactively control the movement of the chassis by receiving the real-time position feedback information of the chassis climbing module travel motor; the onboard control component is used to send control commands to the docking part clamping module motor, and interactively control the pressurization or stop of the clamping device on the outer iron by receiving the real-time torque feedback information of the docking part clamping module motor; the onboard control component is used to send control commands to the mechanical arm slide module motor, and interactively control the working position of the mechanical arm by receiving the real-time position feedback information of the mechanical arm slide module motor, and send the working command to the mechanical arm control module after the working position is confirmed; the onboard control component is used to send control commands to the end operation module motor, and interactively control the tightening operation of the bolt by receiving the real-time torque feedback information of the end operation module motor, and send the end operation command to the mechanical arm control module after the operation is completed;

[0019] The camera monitoring module is used to monitor the climbing operation in real time, and the ground control platform monitors the entire climbing process in real time through the wireless transmission module.

[0020] Among them, the wireless transmission module includes a wireless data transmission module and a wireless image transmission module; wherein the wireless data transmission module is used for the interactive transmission of data between the climbing operation control unit and the ground control platform, including climbing status information, robotic arm position information and end operation information; the wireless image transmission module is used for the interactive transmission of data between the camera monitoring module and the ground control platform, including videos and images of the robot's climbing and operating status.

[0021] Wherein, the wireless data transmission module adopts the LoRa wireless data transmission radio station.

[0022] Among them, the wireless image transmission module adopts a 5.8G image transmission module.

[0023] Among them, the onboard power module uses a 48V40AH lithium battery.

[0024] Among them, the airborne control component adopts the STM32F4 series control board.

[0025] Wherein, the visual depth algorithm is the YOLOV5 visual depth algorithm.

[0026] Second aspect

[0027] The present invention provides a control method for an electric tower climbing robot. The method is performed by using the control system of the electric tower climbing robot, and comprises the following steps:

[0028] Step 1: The onboard power module powers up the entire tower climbing robot;

[0029] Step 2: The airborne control component controls the chassis climbing module's gripper opening and closing motor and the travel motor to make the robot run on the tower. The two grippers open and close alternately. After the airborne control component determines that the robot has reached the docking operation position through the running stroke, it controls the chassis climbing module to stop moving, and the gripper clasps the main angle steel material. The airborne control component sends a command to press the outer iron to the preset torque to the docking part pressing module. The sensor module senses the obstacles on the tower and the limit position of the chassis climbing module in real time and transmits them to the airborne control component. The camera monitoring module monitors the climbing operation in real time. The ground control platform monitors the entire climbing process in real time through the wireless transmission module.

[0030] Step 3: The onboard control component controls the robot arm slide module to the position above the bolt group of the docking part. The onboard control component sends a running command to the robot arm control module. The robot arm control module controls the robot arm along the planned path to the bolt recognition posture, and realizes the positioning of the bolt through the visual depth algorithm. The end of the robot arm is controlled to insert the bolt. The robot arm control module feeds back a signal to the onboard control component. The onboard control component sends an operation command to the end operation module. The end operation module starts the operation. After the tightening torque is reached, the end operation module stops the operation. The robot arm control module controls the robot arm to return to the bolt recognition posture, inserts and screws the next bolt, until all bolts are tightened. The onboard control component sends a command to return to the original posture to the robot arm control module.

[0031] Step 4: Repeat steps 2 and 3 to tighten the bolts at the next docking position.

[0032] Compared with the prior art, the present invention has the following beneficial effects:

[0033] The present invention proposes a practical control system and method for a robot for climbing a power tower based on the actual working conditions of the tower climbing operation. The present invention adopts a double-claw interlocking and alternating travel control method to achieve reliable operation of the robot on the tower; in view of obstacles such as angle steel and foot nails that need to be crossed during the climbing process, an independent sensor module classification is set to perform obstacle perception; in view of the identification, positioning and insertion of bolts during the operation, it is proposed to use a visual depth algorithm to identify and locate the bolts, and to use an adaptive spiral groove sleeve to achieve flexible insertion of the bolts; in view of possible faults during the autonomous climbing operation, a video monitoring module is set to monitor the robot's climbing operation status in real time, and at the same time, the ground control platform can be used to achieve priority control of the robot. The present invention provides multiple solutions to many problems that the tower climbing robot may encounter during the climbing operation, and the effect is good. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 The figure shows a schematic diagram of the system connection structure provided by an embodiment of the present application;

[0035] Figure 2 The figure shows a schematic diagram of the chassis climbing module structure provided in an embodiment of the present application;

[0036] Figure 3 The figure shows a schematic diagram of the structure of the sensor module provided in the embodiment of the present application;

[0037] Figure 4 The figure is a schematic diagram of the structure of the robot arm slide module provided in the embodiment of the present application;

[0038] Figure 5 The figure shows a schematic diagram of the terminal operation module structure provided in an embodiment of the present application;

[0039] Figure 6 The figure shows a schematic diagram of the structure of a wireless transmission module provided in an embodiment of the present application;

[0040] Figure 7 Shown is a schematic diagram of the method flow provided in an embodiment of the present application. DETAILED DESCRIPTION

[0041] The following is a clear and complete description of the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0042] like Figure 1 As shown, the present application provides a control system for a power tower climbing operation robot, including a robot body and a ground control platform wirelessly connected to the robot body;

[0043] The robot body is used for climbing and working on power towers, and includes an onboard power supply module, a climbing operation control unit, a camera monitoring module, and a wireless transmission module for connecting to a ground control platform network;

[0044] The ground control platform is used to monitor the climbing and operating status of the robot body, and can also control the autonomous control commands of the robot body.

[0045] Preferably, the onboard power module uses a 48V40AH lithium battery to power all power units and modules on the robot body, including the climbing operation control unit, the camera monitoring module and the wireless transmission module. For devices with different voltage requirements, a voltage regulating and stabilizing module is used for conversion, such as 48V-24V / 48V-12V, etc.;

[0046] Preferably, the climbing operation control unit is electrically connected to the wireless transmission module, and the climbing operation control unit includes an airborne control component, a chassis climbing module, a docking piece clamping module, a sensor module, a mechanical arm slide module, a mechanical arm control module and an end operation module, and all operation module motors are drive-control integrated motors;

[0047] Among them, Figure 2 As shown, the chassis climbing module includes an independent clamping claw and a fixed clamping claw, the independent clamping claw and the fixed clamping claw are both opened and closed by an opening and closing motor and can be interlocked, the independent clamping claw is connected to the lead screw and can move independently by the travel motor, the fixed clamping claw is connected to the lead screw and the fuselage, and the travel motor drives the fuselage to move together, the two clamping claws are opened and closed alternately, and move, so that the power tower climbing robot can climb up and down along the main material of the angle steel;

[0048] The butt joint pressing module is used to realize the pressing and fitting of the outer iron of the electric tower and the main angle steel material;

[0049] Among them, Figure 3 As shown, the sensor module includes an angle steel obstacle sensor, a foot nail obstacle sensor and a travel limit sensor; wherein the angle steel obstacle sensor adopts an ultrasonic sensor, which is used to detect obstacles such as beams and diagonal materials connected to the angle steel main material on the power tower; the foot nail obstacle sensor adopts an ultrasonic sensor, which is used to detect foot nail obstacles on the angle steel main material; the travel limit sensor adopts an inductive sensor, which is used to limit the critical travel of the robot chassis climbing module and the robot arm slide module;

[0050] Among them, Figure 4 As shown, the robot arm slide module includes a slide and a robot arm, the slide is connected to the robot arm base by screws, and is used to realize the movement of the robot arm working position, so that the robot arm reaches the position above the bolt group of the docking piece, and the robot arm adopts a six-axis robot arm;

[0051] The robot control module is used to control the robot to identify the bolt posture along the planned path, locate the bolt through the YOLOV5 visual depth algorithm, and control the sleeve at the end of the robot to insert the bolt;

[0052] Among them, Figure 5 As shown, the terminal operation module includes a depth camera and a sleeve. The depth camera adopts a binocular depth camera for identifying and locating bolts. The depth camera is arranged at the lower side of the sleeve and connected to the terminal flange. The sleeve adopts an adaptive spiral groove design for realizing the tightening operation of the bolts.

[0053] Among them, Figure 6As shown, the wireless transmission module includes a wireless data transmission module and a wireless image transmission module; wherein the wireless data transmission module adopts a LoRa wireless data transmission radio, which is used for the interactive transmission of data between the climbing operation control unit and the ground control platform, including climbing status information, robot arm position information and terminal operation information; the wireless image transmission module adopts a 5.8G image transmission module, which is used for the interactive transmission of data between the camera monitoring module and the ground control platform, including videos and images of the robot's climbing and operation status;

[0054] The ground control platform uses a portable notebook to monitor the robot's climbing and operating status, and can also override the robot's autonomous control commands.

[0055] Among them, the onboard control component adopts the STM32F4 series control board, and the onboard control component is electrically connected to the sensor module, chassis climbing module, docking piece clamping module, robotic arm slide module, robotic arm control module and end operation module; the onboard control component controls the robot's climbing gait and operating status by receiving the perception information of the sensor module; the onboard control component is used to send control commands to the chassis climbing module motor, and at the same time, interactively control the opening and closing of the chassis clamp by receiving the real-time torque feedback information of the chassis climbing module clamp opening and closing motor, and interactively control the movement of the chassis by receiving the real-time position feedback information of the chassis climbing module travel motor; the onboard control component is used The onboard control component is used to send control commands to the motor of the docking piece clamping module, and at the same time, interactively control the pressurization or stop of the clamping device on the outer iron by receiving the real-time torque feedback information of the motor of the docking piece clamping module; the onboard control component is used to send control commands to the motor of the robot arm slide module, and at the same time, interactively control the working position of the robot arm by receiving the real-time position feedback information of the motor of the robot arm slide module, and send the working command to the robot arm control module after the working position is confirmed; the onboard control component is used to send control commands to the motor of the end operation module, and at the same time, interactively control the tightening operation of the bolt by receiving the real-time torque feedback information of the motor of the end operation module, and send the end operation command to the robot arm control module after the operation is completed;

[0056] In addition, if Figure 7 As shown, this embodiment also provides a control method for a power tower climbing robot, which is executed using the above-mentioned power tower climbing robot control system and includes the following steps:

[0057] Step 1: The onboard power module powers up the entire tower climbing robot;

[0058] Step 2: The airborne control component controls the chassis climbing module's gripper opening and closing motor and the travel motor to make the robot run on the tower. The two grippers open and close alternately. After the airborne control component determines that the robot has reached the docking operation position through the running stroke, it controls the chassis climbing module to stop moving, and the gripper clasps the main angle steel material. The airborne control component sends a command to press the outer iron to the preset torque to the docking part clamping module. The sensor module senses the obstacles on the tower and the limit position of the chassis climbing module in real time and transmits them to the airborne control component. The camera monitoring module monitors the climbing operation in real time. The ground control platform monitors the entire climbing process in real time through the wireless transmission module. If an abnormal situation occurs, the robot's autonomous control command can be overridden at any time.

[0059] Step 3: The onboard control component controls the robot arm slide module to the position above the bolt group of the docking part. The onboard control component sends a running command to the robot arm control module. The robot arm control module controls the robot arm along the planned path to the bolt recognition posture, and realizes the positioning of the bolt through the visual depth algorithm. The end of the robot arm is controlled to insert the bolt. The robot arm control module feeds back a signal to the onboard control component. The onboard control component sends an operation command to the end operation module. The end operation module starts the operation. After the tightening torque is reached, the end operation module stops the operation. The robot arm control module controls the robot arm to return to the bolt recognition posture, inserts and screws the next bolt, until all bolts are tightened. The onboard control component sends a command to return to the original posture to the robot arm control module.

[0060] Step 4: Repeat steps 2 and 3 to tighten the bolts at the next docking position.

[0061] It should be noted that all solutions not described in detail in this application adopt known technologies.

[0062] Finally, it should be noted that the above embodiments are only used to illustrate and explain the present invention, and are not intended to limit the present invention to the scope of the described embodiments. In addition, those skilled in the art can understand that the present invention is not limited to the above embodiments, and more variations and modifications can be made according to the teachings of the present invention, and these variations and modifications all fall within the scope of the protection claimed by the present invention.

Claims

1. A control system for a tower climbing robot, characterized in that: It includes a robot body and a ground control platform wirelessly connected to the robot body; The robot body is used for climbing and working on power towers, and includes an onboard power supply module, a climbing operation control unit, a camera monitoring module, and a wireless transmission module for connecting to a ground control platform network; The ground control platform is used to monitor the climbing and operating status of the robot body, and can also control the autonomous control commands of the robot body.

2. The control system of a tower climbing robot according to claim 1, characterized in that: The onboard power supply module is used to supply power to all power-consuming units and modules on the robot body, including the climbing operation control unit, the camera monitoring module and the wireless transmission module. For devices with different voltage requirements, a voltage regulating and stabilizing module is used for conversion; The climbing operation control unit is electrically connected to the wireless transmission module, and the climbing operation control unit includes an airborne control component, a chassis climbing module, a docking piece pressing module, a sensor module, a mechanical arm slide module, a mechanical arm control module and an end operation module; The airborne control assembly is electrically connected to the sensor module, chassis climbing module, docking piece clamping module, robotic arm slide module, robotic arm control module and end operation module; The chassis climbing module includes an independent clamp and a fixed clamp. The independent clamp and the fixed clamp are opened and closed by an opening and closing motor and can be interlocked. The independent clamp is connected to the lead screw and can move independently by the travel motor. The fixed clamp is connected to the lead screw and the fuselage and can move together with the travel motor. The two clamps are opened and closed alternately and move, so that the power tower climbing robot can climb up and down along the main material of the angle steel. The butt joint pressing module is used to realize the pressing and fitting of the outer iron of the electric tower and the main angle steel material; The sensor module includes an angle steel obstacle sensor, a foot nail obstacle sensor and a travel limit sensor; wherein the angle steel obstacle sensor is used to detect the crossbeam and diagonal material connected to the angle steel main material on the power tower; the foot nail obstacle sensor is used to detect the foot nail obstacle on the angle steel main material; the travel limit sensor is used to limit the critical travel of the robot chassis climbing module and the robot arm slide module; The robot arm slide module includes a slide and a robot arm, and the slide is connected to the robot arm base by screws, so as to realize the movement of the robot arm working position, so that the robot arm reaches the position above the bolt group of the docking piece; The robot arm control module is used to control the robot arm to identify the bolt posture along the planned path, locate the bolt through the visual depth algorithm, and control the end of the robot arm to insert the bolt; The end operation module includes a depth camera and a sleeve, wherein the depth camera is used for identifying and locating bolts, and the sleeve adopts an adaptive spiral groove design for realizing the tightening operation of the bolts; The onboard control component controls the climbing gait and working state of the robot by receiving the sensing information of the sensor module; the onboard control component is used to send control commands to the chassis climbing module motor, and interactively control the opening and closing of the chassis clamp by receiving the real-time torque feedback information of the chassis climbing module clamp opening and closing motor, and interactively control the movement of the chassis by receiving the real-time position feedback information of the chassis climbing module travel motor; the onboard control component is used to send control commands to the docking part clamping module motor, and interactively control the pressurization or stop of the clamping device on the outer iron by receiving the real-time torque feedback information of the docking part clamping module motor; the onboard control component is used to send control commands to the mechanical arm slide module motor, and interactively control the working position of the mechanical arm by receiving the real-time position feedback information of the mechanical arm slide module motor, and send the working command to the mechanical arm control module after the working position is confirmed; the onboard control component is used to send control commands to the end operation module motor, and interactively control the tightening operation of the bolt by receiving the real-time torque feedback information of the end operation module motor, and send the end operation command to the mechanical arm control module after the operation is completed; The camera monitoring module is used to monitor the climbing operation in real time, and the ground control platform monitors the entire climbing process in real time through the wireless transmission module.

3. A control system for a tower climbing robot as claimed in claim 2, characterized in that: The wireless transmission module includes a wireless data transmission module and a wireless image transmission module; wherein the wireless data transmission module is used for the interactive transmission of data between the climbing operation control unit and the ground control platform, including climbing status information, robotic arm position information and end operation information; the wireless image transmission module is used for the interactive transmission of data between the camera monitoring module and the ground control platform, including videos and images of the robot's climbing and operating status.

4. A control system for a tower climbing robot as claimed in claim 3, characterized in that: The wireless data transmission module adopts the LoRa wireless data transmission radio.

5. The control system of a power tower climbing robot according to claim 3, characterized in that: The wireless image transmission module adopts a 5.8G image transmission module.

6. The control system of a tower climbing robot according to claim 2, characterized in that: The onboard power module uses a 48V40AH lithium battery.

7. The control system of a power tower climbing robot according to claim 2, characterized in that: The onboard control component adopts the STM32F4 series control board.

8. The control system of a power tower climbing robot according to claim 2, characterized in that: The visual depth algorithm is the YOLOV5 visual depth algorithm.

9. A control method for a tower climbing robot, characterized in that: The method is performed using the tower climbing robot control system according to any one of claims 2 to 8, and comprises the following steps: Step 1: The onboard power module powers up the entire tower climbing robot; Step 2: The airborne control component controls the chassis climbing module's gripper opening and closing motor and the travel motor to make the robot run on the tower. The two grippers open and close alternately. After the airborne control component determines that the robot has reached the docking operation position through the running stroke, it controls the chassis climbing module to stop moving, and the gripper clasps the main angle steel material. The airborne control component sends a command to press the outer iron to the preset torque to the docking part pressing module. The sensor module senses the obstacles on the tower and the limit position of the chassis climbing module in real time and transmits them to the airborne control component. The camera monitoring module monitors the climbing operation in real time. The ground control platform monitors the entire climbing process in real time through the wireless transmission module. Step 3: The onboard control component controls the robot arm slide module to the position above the bolt group of the docking part. The onboard control component sends a running command to the robot arm control module. The robot arm control module controls the robot arm along the planned path to the bolt recognition posture, and realizes the positioning of the bolt through the visual depth algorithm. The end of the robot arm is controlled to insert the bolt. The robot arm control module feeds back a signal to the onboard control component. The onboard control component sends an operation command to the end operation module. The end operation module starts the operation. After the tightening torque is reached, the end operation module stops the operation. The robot arm control module controls the robot arm to return to the bolt recognition posture, inserts and screws the next bolt, until all bolts are tightened. The onboard control component sends a command to return to the original posture to the robot arm control module. Step 4: Repeat steps 2 and 3 to tighten the bolts at the next docking position.

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