Wind turbine generator tower drum rust removal robot and operation control method thereof

Abstract

The invention provides a wind turbine generator tower drum rust removal robot and an operation control method thereof. The wind turbine generator tower drum rust removal robot comprises a robot box used for carrying the whole robot, and a moving module for driving the whole robot to move is arranged on the robot box; a cleaning module used for polishing rust is arranged on the bottom end face of the robot box. A sensor module for detecting the environment is arranged on the robot box body; a spraying module for spraying is mounted on the robot box body; the power supply is used for supplying power to the moving module, the cleaning module and the sensor module. A whole set of rust removal process is completed through mutual cooperation of various machines, the working efficiency is greatly improved through an automatic rust removal mode, manual operation in a high-altitude, dangerous or toxic environment can be replaced, and the safety is improved.

Description

Technical Field

[0001] The invention relates to the field of wind turbine tower rust removal, and particularly relates to a wind turbine tower rust removal robot and an operation control method thereof. Background Art

[0002] During long-term operation, wind turbines are affected by the natural environment (such as rain, snow, salt spray, etc.), and their external structures, especially metal parts, are prone to rust. This rust not only affects the appearance of the wind turbine, but more importantly, it reduces the safety and service life of the equipment, thereby affecting the stable operation of the entire wind power system. Therefore, it is particularly important to regularly maintain wind turbines, especially to remove rust.

[0003] Traditional methods for removing rust from wind turbines mainly include manual grinding and sandblasting. These methods have obvious shortcomings. First, they are labor-intensive and manual operation consumes a lot of time and physical strength, which is inefficient. Second, they have a significant impact on the environment. Sandblasting and other methods may generate a lot of dust, which pollutes the environment. Third, they have high safety risks. Workers face high safety risks when working at high altitudes. Finally, the cost of rust removal is high, and long-term reliance on manual maintenance leads to high labor costs. With the continuous advancement of robotics and automation technology, it has become possible to develop robots specifically for cleaning and rust removal of wind turbine components. Such robots can effectively solve the problems of traditional methods and become an important tool for future wind power system maintenance. Summary of the invention

[0004] In order to solve the current technical problems, the main purpose of the present invention is to provide a wind turbine tower rust removal robot and its operation control method, which adopts a variety of machines to cooperate with each other to complete a complete set of rust removal processes. It greatly improves work efficiency through automated rust removal, and can replace manual operations in high altitudes, dangerous or toxic environments to improve safety. Its intelligent sensors and cleaning modules ensure the consistency of cleaning quality and can cover every corner of complex structures. At the same time, the robot has a high degree of flexibility, can work continuously for a long time, reduce labor costs and labor intensity, adapt to rust removal tasks in various complex environments, and has strong practicality.

[0005] In order to realize the above-mentioned technical features, the purpose of the present invention is achieved as follows: a wind turbine tower rust removal robot, comprising a robot box for carrying the entire robot, the robot box is provided with a moving module for driving the entire robot to move; the bottom end surface of the robot box is provided with a cleaning module for grinding rust; the robot box is provided with a sensor module for detecting the environment; the robot box is installed with a spraying module for spraying; and also includes a power supply for powering the moving module, the cleaning module and the sensor module.

[0006] A safety ring is arranged on the top of the robot box, and the safety ring is used to prevent accidental falling through a safety rope when the robot is working.

[0007] The mobile module includes an electromagnetic wheel, a motor and a coupling. The electromagnetic wheel is connected to the motor through the coupling. The motor provides power. The electromagnetic wheel is used to adsorb the robot on the tower of the wind turbine through electromagnetic adsorption and realize the precise movement of the robot through differential steering.

[0008] The cleaning module includes a grinding wheel and a grinding wheel shaft. The grinding wheel is fixed on the grinding wheel shaft. The grinding wheel shaft is connected to the output shaft of the grinding motor and is driven by the grinding wheel shaft to rotate at high speed for grinding rust. The grinding wheel is installed under the robot and can contact and clean the rust during the movement of the robot.

[0009] The sensor module includes an environmental detection sensor and a sensor positioning shaft. The environmental detection sensor is installed in front of the robot through the sensor positioning shaft, and is used to detect rust on the surface of the wind turbine tower in real time, and send the detection results to the processor for processing, thereby guiding the robot to move and perform rust removal operations.

[0010] The spraying module includes a rotating shaft, a nozzle connecting arm and a nozzle. The rotating shaft drives the nozzle connecting arm to rotate at a constant speed within a preset angle range through a driving device arranged inside the robot box. The nozzle receives the anti-rust paint through an external hose and sprays it evenly onto the polished tower surface to prevent the metal from corroding again.

[0011] It also includes a processor, which is used to calculate the walking path of the robot and control the moving module, the cleaning module and the spraying module to achieve precise operation of the robot.

[0012] A method for controlling the operation of a wind turbine tower rust removal robot, comprising: Step 1: Arrangement of the robot on the wind turbine tower: The robot is mounted on the wind turbine tower through a mobile module and powered by a motor. The electromagnetic wheels move on the wind turbine tower through electromagnetic adsorption technology, and the robot is accurately moved through differential steering. Step 2: Inspection of the outer surface of the wind turbine tower: During the movement of the robot, the rust on the surface of the tower is detected by the environmental detection sensor. When the rusted part is detected, the robot is driven by the motor and electromagnetic wheel to move to the rusted part. Step 3: Grinding of rusted parts on the outer surface of the wind turbine tower: After the robot moves to its position, start the cleaning module, and use the grinding wheel to grind away the rust to ensure the surface is clean; Step 4: Spraying of the polished parts on the outer surface of the wind turbine tower: After the rusted parts are polished, start the spraying module and evenly spray the anti-rust paint to the polished area through the nozzle, thus finally completing the repair of the outer surface of the wind turbine tower.

[0013] The robot completes the entire process of rust detection, rust removal and spraying of anti-rust paint through an automated system, ensuring efficient, accurate and safe rust removal operations.

[0014] The control system adjusts the robot's movement path and speed based on the information fed back by the sensors to ensure effective rust removal and spraying on the complex tower surface.

[0015] The present invention has the following beneficial effects: 1. The wind turbine tower rust removal robot and its operation control method of the present invention detect the rust position through a sensor, and then four motors provide different speeds for four wheels to achieve differential steering to accurately control the wind turbine tower rust removal robot to turn on the tower. The electromagnetic wheel adsorbs the robot on the wind turbine tower through electromagnetic adsorption technology. Through the rust position detected by the sensor, the wind turbine tower rust removal robot goes to the rusted area to remove the rust. The grinding wheel under the robot first grinds the rust and then the robot moves forward. The spraying device at the back can spray anti-rust paint on the place that has just been polished to prevent rusting again later.

[0016] 2. The present invention is efficient, accurate and safe, and has significant advantages in the rust removal of wind turbine towers. They can quickly remove rust on the metal surface and spray anti-rust paint, ensuring the consistency and stability of the treatment effect, while reducing the uncertainty and safety hazards caused by manual operation.

[0017] 3. The robot of the present invention is suitable for various complex environments and hard-to-reach locations, thus expanding the scope of operation.

[0018] 4. The robot of the present invention combines rust removal and anti-rust paint spraying into one work, which can save time and financial costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0020] Figure 1 This is a three-dimensional diagram from the first perspective of the present invention.

[0021] Figure 2 This is a three-dimensional diagram from a second viewing angle of the present invention.

[0022] Figure 3 It is the internal structure diagram of the present invention.

[0023] In the figure: nozzle 1, nozzle connecting arm 2, electromagnetic wheel 3, robot box 4, grinding wheel 5, grinding wheel shaft 6, rotating shaft 7, safety ring 8, environment detection sensor 9, sensor positioning shaft 10, coupling 11, motor 12, power supply 13, processor 14. DETAILED DESCRIPTION

[0024] The embodiments of the present invention are further described below in conjunction with the accompanying drawings.

[0025] Embodiment 1: Reference Figure 1-3 A wind turbine tower rust removal robot includes a robot box 4 for carrying the entire robot, a mobile module for driving the entire robot to move is arranged on the robot box 4; a cleaning module for grinding rust is arranged on the bottom end surface of the robot box 4; a sensor module for detecting the environment is arranged on the robot box 4; a spraying module for spraying is installed on the robot box 4; and a power supply 13 for powering the mobile module, the cleaning module and the sensor module. It adopts a variety of machines to cooperate with each other to complete a complete set of rust removal processes. It greatly improves work efficiency through automated rust removal, and can replace manual operations in high altitude, dangerous or toxic environments to improve safety. Its intelligent sensors and cleaning modules ensure the consistency of cleaning quality and can cover every corner of complex structures. At the same time, the robot has a high degree of flexibility, can work continuously for a long time, reduce labor costs and labor intensity, adapt to rust removal tasks in various complex environments, and has strong practicality.

[0026] Furthermore, a safety ring 8 is provided on the top of the robot box 4, and the safety ring 8 is used to prevent accidental falling through a safety rope when the robot is working, thereby ensuring the safety and reliability during the operation.

[0027] Furthermore, the mobile module includes an electromagnetic wheel 3, a motor 12 and a coupling 11. The electromagnetic wheel 3 is connected to the motor 12 through the coupling 11. The motor 12 provides power. The electromagnetic wheel 3 is used to adsorb the robot on the wind turbine tower through electromagnetic adsorption and realize the precise movement of the robot through differential steering. The mobile module can be used to realize the movement and walking of the robot on the wind turbine tower.

[0028] Furthermore, the cleaning module includes a grinding wheel 5 and a grinding wheel shaft 6. The grinding wheel 5 is fixed on the grinding wheel shaft 6. The grinding wheel shaft 6 is connected to the output shaft of the grinding motor, and the grinding wheel 5 is driven by the grinding wheel shaft 6 to rotate at a high speed for grinding the rust. The grinding wheel 5 is installed under the robot and can contact and clean the rust during the robot's movement. The above cleaning module can be used to grind the rusted parts of the wind turbine tower.

[0029] Furthermore, the sensor module includes an environment detection sensor 9 and a sensor positioning shaft 10. The environment detection sensor 9 is installed in front of the robot through the sensor positioning shaft 10, and is used to detect rust on the surface of the wind turbine tower in real time, and send the detection result to the processor 14 for processing, thereby guiding the robot to move and perform rust removal operations. The above-mentioned sensor module can be used to automatically detect the basic surface conditions of the wind turbine tower.

[0030] Furthermore, the spraying module includes a rotating shaft 7, a nozzle connecting arm 2 and a nozzle 1. The rotating shaft 7 drives the nozzle connecting arm 2 to rotate at a constant speed within a preset angle range through a driving device arranged inside the robot box 4. The nozzle 1 receives the anti-rust paint through an external hose and sprays it evenly onto the polished tower surface to prevent the metal from corroding again.

[0031] Furthermore, it also includes a processor 14, which is used to calculate the walking path of the robot and control the moving module, the cleaning module and the spraying module to achieve precise operation of the robot.

[0032] Embodiment 2: A wind turbine tower rust removal robot in this embodiment includes a robot box 4, a power supply 13, a processor 14, an electromagnetic wheel 3, a motor 12, a grinding wheel 5, a grinding wheel shaft 6, an environmental detection sensor 9, a sensor positioning shaft 10, a rotating shaft 7, a nozzle connecting arm 2, and a nozzle 1. The wind turbine tower rust removal robot first detects and identifies the rust on the wind turbine tower through the environmental detection sensor 9 installed on the sensor positioning shaft 10, and then the rust removal robot uses the electromagnetic wheel 3 to use the electromagnetic adsorption technology to adsorb on the wind turbine tower, so that the wind turbine rust removal robot can be adsorbed on the wind turbine tower and will not fall off. After the environmental detection sensor 9 identifies the rust, the result is sent to the processor 14 for processing, and then the four motors 12 are input with a suitable speed to realize the movement of the wind turbine tower rust removal robot. The wind turbine tower rust removal robot will move to the rust and pass through the rust. At this time, the grinding wheel shaft 6 will rotate at high speed and drive the grinding wheel 5 to rotate at high speed. When the rust removal robot passes through the rust, the high-speed rotating grinding wheel 5 will grind it to grind off the rust on the surface of its tower. After the polishing is completed, the wind turbine tower rust removal robot will continue to move forward. At this time, the rotating shaft 7 rotates at a constant speed within a certain angle, and the nozzle connecting arm 2 will rotate together. The nozzle 1 is installed on its nozzle connecting arm 2, and it will rotate at a constant speed with it within a certain angle. A hose will be connected to the outside to connect the nozzle 1 for conveying anti-rust paint. When the wind turbine tower rust removal robot moves forward, the nozzle 1 will spray out the anti-rust paint at a constant speed, and spray the polished area of ​​the wind turbine tower with the anti-rust paint to prevent the metal tower from leaking in the air and prevent it from further corrosion. This wind turbine tower rust removal robot can bring many benefits, mainly reflected in safety, efficiency and environmental protection. The robot can reduce the risk of high-altitude operations and improve the safety of workers. Its efficient working mode can shorten the maintenance time and ensure timely maintenance. In addition, the robot is more consistent in rust removal effect, and can also spray anti-rust paint in time, reducing maintenance costs, and can adapt to wind turbine towers of different models. The use of this wind turbine tower rust removal robot greatly improves the maintenance quality.

[0033] In this embodiment, the mobile module includes an electromagnetic wheel 3, a coupling 11, a power supply 13 and a motor 12. The motor 12 installed inside the wind turbine tower rust removal robot box 4 provides driving force, and the motor accurately controls the speed of the electromagnetic wheel 3 by adjusting the speed of different motor inputs. By adopting the differential steering principle, the robot can achieve flexible steering control. The electromagnetic wheel 3 has a shaft and is connected to the motor 12 through the coupling 12 to form a power transmission system. During the movement, the electromagnetic wheel 3 is driven by the motor 12 to complete the robot's forward, backward and steering functions. In addition, in order to ensure that the robot can be firmly attached to the wind turbine tower, electromagnetic adsorption technology is adopted. The electromagnetic wheel 3 is embedded with an electromagnetic device. When the robot approaches the tower, the electromagnetic device is started and the robot is firmly adsorbed on the tower surface by electromagnetic force. The motor 12 continuously drives the electromagnetic wheel 3 to rotate to realize the movement of the robot. The change in the speed of the motor enables the electromagnetic wheel 3 to move smoothly on the tower surface. At the same time, the effect of electromagnetic adsorption also ensures the stable operation of the robot on complex vertical surfaces, thereby completing the task of wind turbine tower rust removal. In this embodiment, the cleaning module includes a grinding wheel 5 and a grinding wheel shaft 6, which is intended to efficiently remove rust. The grinding wheel 5 is fixed to the grinding wheel shaft 6 and has an irregular frosted surface, so that the grinding wheel 5 can rotate quickly under the drive of the grinding wheel shaft 6, thereby effectively grinding and polishing the rust. The installation position of the grinding wheel 5 is located below the robot to ensure that the rust on the ground can be contacted and processed in time when the robot moves. The robot flexibly adjusts its position through its own motion system to clean rust in different areas. This cleaning module not only improves the rust removal efficiency, but also can achieve a more comprehensive and thorough rust removal effect by precisely controlling the robot's walking path.

[0034] In this embodiment, the sensor module has an environmental detection sensor 9 and a sensor positioning shaft 10 for installing the sensor. The sensor module can improve the intelligence and work efficiency of the wind turbine rust removal robot. The module is equipped with an environmental detection sensor 9, which is installed in front of the robot and can monitor and detect rust in the surrounding environment in real time. When the sensor detects rust, the robot will process automatic positioning in the processor 14 and move in the direction of the rust for precise processing. The robot will use the grinding wheel 5 in its cleaning module to grind and polish the detected rust. This process can not only effectively remove the rust layer, but also prepare for the subsequent anti-rust paint spraying, ensuring that the paint can be evenly attached to the metal surface, thereby extending the service life of the equipment. Through this integrated sensor module, the wind turbine rust removal robot achieves higher work autonomy and intelligence, making the rust removal process more efficient and accurate, and providing a good foundation for subsequent maintenance work.

[0035] In this embodiment, the spray module includes a rotating shaft 7, a nozzle connecting arm 2 and a nozzle 1, and its design includes fixing the nozzle 1 on the connecting arm 2, and enabling the nozzle 1 to rotate flexibly through the cooperation between the connecting arm 2 and the rotating shaft 7. Specifically, the rotating shaft 7 is driven by the power to rotate the connecting arm 2, and the nozzle 1 receives the anti-rust paint through an external hose, and the paint is evenly delivered to the nozzle during the spraying process. During the spraying process, the nozzle can spray the anti-rust paint at a stable speed, and the rotating shaft also rotates at a constant speed within a preset angle range. This design allows the connecting arm to evenly apply the anti-rust paint on the polished tower surface while rotating. In this way, the spray module ensures uniform coverage of the paint, improves the anti-rust effect and the quality of the coating, and meets the needs of efficient spraying.

[0036] Embodiment 3: A method for controlling the operation of a wind turbine tower rust removal robot, comprising: Step 1: Arrangement of the robot on the wind turbine tower: The robot is mounted on the wind turbine tower through the mobile module and powered by the motor 12. The electromagnetic wheel 3 moves on the wind turbine tower through the electromagnetic adsorption technology, and the precise movement of the robot is achieved through differential steering. Step 2: Inspection of the outer surface of the wind turbine tower: During the movement of the robot, the rust on the surface of the tower is detected by the environmental detection sensor 9. When the rusted part is detected, the robot is driven to move to the rusted part by the motor 12 and the electromagnetic wheel 3. Step 3: Grinding of rusted parts on the outer surface of the wind turbine tower: After the robot moves to the position, the cleaning module is started, and the rust is polished by the grinding wheel 5 through the cleaning module to ensure the surface is clean; Step 4: Spraying of the polished parts on the outer surface of the wind turbine tower: After the rusted area is polished, the spraying module is started, and the anti-rust paint is evenly sprayed to the polished area through the nozzle 1, thereby finally completing the repair of the outer surface of the wind turbine tower.

[0037] The robot completes the entire process of rust detection, rust removal and spraying of anti-rust paint through an automated system, ensuring efficient, accurate and safe rust removal operations.

[0038] The control system adjusts the robot's movement path and speed based on the information fed back by the sensors to ensure effective rust removal and spraying on the complex tower surface.

Claims

1. A wind turbine tower rust removal robot, characterized in that: The robot box (4) comprises a robot housing (4) for carrying the entire robot, the robot housing (4) being provided with a moving module for driving the entire robot to move; a cleaning module for polishing rust stains being provided on the bottom end surface of the robot housing (4); a sensor module for detecting the environment being provided on the robot housing (4); a spraying module for spraying being installed on the robot housing (4); and a power source (13) for supplying power to the moving module, the cleaning module and the sensor module.

2. The wind turbine tower rust removal robot according to claim 1, characterized in that: A safety ring (8) is provided on the top of the robot box (4), and the safety ring (8) is used to prevent accidental falling through a safety rope when the robot is working.

3. The wind turbine tower rust removal robot according to claim 1, characterized in that: The mobile module comprises an electromagnetic wheel (3), a motor (12) and a coupling (11); the electromagnetic wheel (3) is connected to the motor (12) via the coupling (11); the motor (12) provides power; the electromagnetic wheel (3) is used to adsorb the robot onto the tower of the wind turbine generator set by electromagnetic adsorption, and to achieve precise movement of the robot by differential steering.

4. The wind turbine tower rust removal robot according to claim 1, characterized in that: The cleaning module comprises a grinding wheel (5) and a grinding wheel shaft (6), wherein the grinding wheel (5) is fixed on the grinding wheel shaft (6), and the grinding wheel shaft (6) is connected to the output shaft of the grinding motor. The grinding wheel shaft (6) drives the grinding wheel (5) to rotate at a high speed, so as to grind away the rust. The grinding wheel (5) is installed below the robot, and can contact and clean the rust when the robot is moving.

5. The wind turbine tower rust removal robot according to claim 1, characterized in that: The sensor module comprises an environment detection sensor (9) and a sensor positioning shaft (10); the environment detection sensor (9) is mounted in front of the robot via the sensor positioning shaft (10) and is used to detect rust on the surface of the wind turbine tower in real time and send the detection result to the processor (14) for processing, thereby guiding the robot to move and perform rust removal operations.

6. The wind turbine tower rust removal robot according to claim 1, characterized in that: The spraying module comprises a rotating shaft (7), a spray head connecting arm (2) and a spray head (1); the rotating shaft (7) drives the spray head connecting arm (2) to rotate at a constant speed within a preset angle range through a driving device arranged inside a robot housing (4); the spray head (1) receives the anti-rust paint through an external hose and sprays it evenly onto the polished tower surface to prevent the metal from corroding again.

7. The wind turbine tower rust removal robot according to claim 1, characterized in that: It also includes a processor (14), wherein the processor (14) is used to calculate the walking path of the robot and control the moving module, the cleaning module and the spraying module to achieve precise operation of the robot.

8. The operation control method of a wind turbine tower rust removal robot according to any one of claims 1 to 7, characterized in that: include: Step 1: Arrangement of the robot on the wind turbine tower: The robot is mounted on the wind turbine tower via a mobile module and powered by a motor (12). The electromagnetic wheel (3) moves on the wind turbine tower via an electromagnetic adsorption technology, and accurate movement of the robot is achieved via differential steering. Step 2: Inspection of the outer surface of the wind turbine tower: During the movement of the robot, the rust on the surface of the tower is detected by the environmental detection sensor (9), and when the rusted part is detected, the robot is driven to move to the rusted part by the motor (12) and the electromagnetic wheel (3); Step 3: Grinding of rusted parts on the outer surface of the wind turbine tower: After the robot moves to the position, the cleaning module is started, and the rust is polished away by the grinding wheel (5) through the cleaning module to ensure the surface is clean; Step 4: Spraying of the polished parts on the outer surface of the wind turbine tower: After the rusted area is polished, the spraying module is started to evenly spray the anti-rust paint onto the polished area through the spray head (1), thereby finally completing the repair of the outer surface of the wind turbine tower.

9. According to the operation control method of a wind turbine tower rust removal robot as described in claim 8, the robot completes the entire process of rust detection, rust removal and spraying of anti-rust paint through an automated system, ensuring efficient, accurate and safe rust removal operations.

10. According to the operation control method of a wind turbine tower rust removal robot as described in claim 8, the control system adjusts the movement path and speed of the robot according to the information fed back by the sensor to ensure effective rust removal and spraying work on the complex tower surface.

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