A robotic system for high-altitude inspection

Abstract

This invention discloses a robot system for high-altitude inspection, belonging to the field of inspection equipment technology. It includes a track, an inspection robot, and an intelligent control platform. The track is a long and narrow steel plate with gear grooves and an anti-fall-off track edge on one side. The track is equipped with fixed columns every few meters for fixing to the equipment to be inspected. The track has a "T" shaped cross-section and includes at least a three-way track and an electric push rod. It is mainly used in the maintenance of chemical equipment.

Description

Technical Field

[0001] This invention belongs to the field of chemical safety production technology, specifically relating to a robot system for high-altitude inspection. Background Technology

[0002] In chemical enterprises, routine inspections are of paramount importance in chemical safety management. These inspections are conducted periodically or randomly during the chemical production and manufacturing process. The purpose is to promptly identify and address safety and quality issues, or to prevent accidents from occurring.

[0003] Generally, chemical companies determine the frequency of inspections based on factors such as plant size, the hazard level of chemicals, the number of personnel, and the level of automation. Our company's ethylene plant undergoes manual inspections at a frequency of 2 hours per inspection, limited to lower areas such as the ground, pipe rack platforms, the three-unit platform, the cracking furnace platform, and the storage tank area. However, the ethylene plant area is large, with numerous towers, the tallest of which is over 100 meters high. Therefore, the company stipulates that inspections of higher areas should be conducted twice a month.

[0004] The Ministry of Emergency Management's Document No. 78 of 2019, "Guidelines for the Investigation and Management of Safety Risks and Hidden Dangers in Hazardous Chemical Enterprises," stipulates that the frequency of safety risk and hidden danger investigations should meet the following requirements: the interval between on-site inspections by plant operators should not exceed 2 hours, and the interval between on-site inspections by operators of production and storage units and areas involving "two key points and one major hazard" should not exceed 1 hour. Ethylene plants happen to fall under the category of "two key points and one major hazard." The current situation cannot meet the new national safety regulatory requirements. Developing machinery capable of performing high-altitude inspections has become an urgent issue.

[0005] Invention patent application number: 202310393219.1 describes a methane leak inspection robot, resembling a robotic dog with four limbs that crawls. It is unsuitable for inspections at heights.

[0006] The utility model patent application number 202421879342.0 describes a rail-mounted intelligent inspection robot. It uses an I-beam rail and has smooth pulleys, making it suitable for indoor warehouses, supermarkets, and other similar environments. However, its performance is poor in harsh outdoor conditions such as frost, rain, and snow.

[0007] Invention Patent Announcement No.: CN115382382B, an unmanned security inspection and explosion-proof robot for use in chemical enterprises, a ground-based vehicle that cannot perform high-altitude inspections.

[0008] The invention announcement number: CN117382933B, a patent for drone inspection, describes a method where inspection tasks are set manually and controlled by humans, but it does not fully realize artificial intelligence.

[0009] In view of the above situation, the problem to be solved by the present invention is: an inspection robot that can perform high-altitude inspections, adapt to severe weather conditions such as rain and snow, is fully intelligent, operates around the clock, is unmanned, and is urgently needed by ethylene plants and other large-scale chemical industries.

[0010] Therefore, the company's production management, instrumentation, safety and information construction, equipment and other professionals worked together to develop an intelligent robot that complements human inspections and can completely replace human inspections even in inclement weather. Summary of the Invention

[0011] To address the technical problems mentioned in the background section, this invention provides a robotic system for high-altitude inspection, employing the following technical solution:

[0012] A robotic system for high-altitude inspection includes a track, an inspection robot, and an intelligent control platform, characterized in that...

[0013] The track is a long and narrow steel plate with gear grooves and an anti-fall-off track edge on one side. The track is equipped with fixed posts every few meters. The fixed posts are used to fix the track to the equipment that needs to be inspected. The track has a "T" shaped cross-section.

[0014] The tracks on the pipe gallery are arranged horizontally and fixed on the tower. They ascend along the tower in a spiral manner. The density of the tracks wound around the tower can be adjusted according to the site conditions to ensure that all manholes, flanges, level gauges, pressure gauges, and easily damaged insulation areas, as well as any places that are prone to leakage or overpressure, require inspection.

[0015] The inspection robot includes a housing containing a drive system. Since the drive system is existing technology, it will not be described in detail here. The output shaft of the drive system is matched with the upper roller to output power. The upper gear has a symmetrical structure, and the housing also has a lower gear. The upper and lower gears are matched with gear slots, and there is a gap between them for meshing on the track. There are two upper gears at the top and one lower gear at the bottom of the track. A fixed shaft is also installed on the housing, which is movably connected to a movable rod via bearings. The lower end of the movable rod is fixedly connected to a smart terminal. The drive system is used to drive the upper gears to rotate forward or backward. With this design, the smart terminal always remains vertically downward under the influence of gravity to detect the real-time status of the corresponding equipment. The inspection robot has three speed settings: high, medium, and low, and also has forward and reverse functions.

[0016] The robot's intelligent terminal has functions such as information input, image recognition, temperature detection, combustible gas detection, and public address intercom.

[0017] The smart terminal includes information input functionality:

[0018] The information terminal pre-loads equipment information for the entire ethylene plant, categorizing equipment into towers, heat exchangers, storage tanks, pumps, large compressors, fans, cracking furnaces, and steam drums. Equipment information includes on-site displays of liquid level, pressure, temperature, and acoustic signature.

[0019] It also includes all the requirements, safety briefing information, and a collection of practical operation videos for the eight hazardous operations (hot work, work at height, confined space work, hoisting work, temporary power supply work, circuit breaking work, earthwork work, and blind flange removal and installation work) in GB 30871-2022 "Safety Specifications for Special Operations of Hazardous Chemical Enterprises".

[0020] It also includes a database of images of on-site safety hazards in chemical enterprises, which can be compared with on-site footage and continuously upgraded and learned under AI guidance to enrich the database.

[0021] The information also includes: all Material Safety Data Sheets (MSDS) for the ethylene plant.

[0022] Image recognition compares information read on-site with pre-recorded information. During routine inspections and checks, images of towers, heat exchangers, storage tanks, pumps, large compressors, fans, pyrolysis furnaces, and steam drums are recognized to determine if displayed liquid levels, pressures, temperatures, and acoustic signatures are within normal ranges. When hazardous operations require continuous robot monitoring, the robot can supervise according to national standards and necessary information. If on-site conditions are not met, it will immediately issue alarms and verbal warnings to stop the operation. In the event of emergencies such as explosions, leaks, or fires, the robot can intelligently assess the situation based on information from the chemical safety data sheets and push information to the dispatch center, providing information for plant-wide emergency response and accident rescue.

[0023] Temperature detection, achieved through temperature sensing instruments, can monitor the temperature of cryogenic and high-temperature towers, promptly detecting leaks or insulation / cold-keeping issues. Combined with image information, it allows for a comprehensive assessment of on-site leak conditions.

[0024] Combustible gas detection can perform accurate quantitative detection based on the unique chemical information of this device, and promptly send alarm information in the event of a strong leak.

[0025] The loudspeaker function allows for communication with on-site personnel during hazardous operations and emergency rescues.

[0026] The core component of this invention also includes at least one three-way rail. The number of three-way rails is set according to the equipment to be inspected. The three-way rail consists of several rails, namely rail one, rail two, rail three, support component one, electric push rod, rail four, and rail five. Rail one and rail two are movably connected by a rotating shaft, and rail two is supported by support component two below. When rail two is in a horizontal state, it forms a connecting channel with rail four.

[0027] Track 3 and track 5 are movably connected by a rotating shaft, and track 5 is equipped with a top rod at the top. The top rod is located directly below track 2 and is spaced apart from track 2 when it is in a horizontal state.

[0028] An electric push rod is installed below track five. The electric push rod is movably connected to support assembly one via a rotating shaft. A contact switch is installed on track four. The extension and retraction of the electric push rod is controlled by the contact switch via a gear.

[0029] The electric actuator is used to push track five upwards and connect it with track four to form a continuous channel.

[0030] Therefore, a three-way, zigzag track needs to be installed for going up the tower and returning to the next tower. This three-way track is suitable for any location where a change of direction is required.

[0031] Preferably, in order to better perform the test and ensure the stability of the equipment, the side of the track is provided with symmetrical slide rails, and the housing is provided with a set of pulley assemblies, which include connecting rods and pulleys, and the pulleys are engaged in the slide rails for sliding.

[0032] This invention can be applied to various large-scale chemical plants because ethylene plants are huge and require several areas to be set up for inspection, with each area forming a series track loop.

[0033] The present invention has the following advantages:

[0034] The structural design of this invention enables rapid real-time detection of various complex environments, promptly avoiding potential safety hazards and providing real-time safety assurance for enterprises. It is mainly applied in various large-scale chemical enterprises. Attached Figure Description

[0035] Figure 1 This is a flowchart of the present invention.

[0036] Figure 2 This is a front view of the inspection robot of the present invention;

[0037] Figure 3 This is a side view of the inspection robot of the present invention;

[0038] Figure 4This is a 3D view of the inspection robot of the present invention;

[0039] Figure 5 This is a diagram of the three-way track structure of the inspection machine of the present invention when it is going uphill;

[0040] Figure 6 This is a diagram of the three-way track structure of the inspection machine of the present invention when going downhill.

[0041] In the diagram: 1. Housing; 2. Movable rod; 3. Rail; 4. Fixed column; 3-1 Rail 1; 3-2 Rail 2; 3-3 Rail 3; 3-4 Support component 1; 3-5 Electric push rod; 3-6 Rail 4; 3-7 Rail 5; 3-8 Top rod; 3-9 Support component 2; 5. Smart terminal; 6. Fixed shaft; 7. Magnetic charging interface; 8. Lower gear; 9. Upper gear. Detailed Implementation

[0042] Example 1

[0043] like Figures 1-3 As shown:

[0044] A robotic system for high-altitude inspection includes a track 3, an inspection robot, and an intelligent control platform, characterized in that...

[0045] The track 3 is a long and narrow steel plate with gear grooves and an anti-fall-off track edge on one side of the steel plate. The track 3 is equipped with a fixed column 4 every few meters. The cross-section of the track 3 is a "T" shaped structure.

[0046] The inspection robot includes a housing 1, inside which is a drive system. The output shaft of the drive device is matched with the upper roller 9 to output power. The upper gear 9 has a symmetrical structure. The housing 1 also has a lower gear 8. The upper gear 9 and the lower gear 8 are matched with gear slots respectively. There is a distance between the upper gear 9 and the lower gear 8 for meshing on the track 3. There are two upper gears 9 on the upper part and one lower gear 8 on the lower part of the track 3. The housing is also equipped with a fixed shaft 6, which is movably connected to a movable rod 2 through a bearing. The lower end of the movable rod 2 is fixedly connected to a smart terminal 5. The drive system is used to drive the upper gear 9 to rotate forward or backward.

[0047] like Figure 4 As shown:

[0048] This invention has special requirements for track 3. The gear groove of track 3 needs to be wide and deep enough to ensure that the entire inspection robot can still work normally when encountering rain or snow. The gears of the inspection robot of this invention also have a self-de-icing function. Even if there is ice, the ice can be removed by the cooperation of the gears and gear grooves of this invention, which can meet the normal inspection requirements in various severe weather conditions.

[0049] like Figure 5 , Figure 6 As shown:

[0050] It also includes a three-way track, which consists of several tracks, namely track 1 3-1, track 2 3-2, track 3-3, support component 1 3-4, electric push rod 3-5, track 4 3-6 and track 5 3-7. Track 1 3-1 and track 2 3-2 are movably connected by a rotating shaft, and track 2 3-2 is supported by support component 2 3-9. When track 2 3-2 is in a horizontal state, it forms a connecting channel with track 4 3-6.

[0051] Track 3-3 and track 5-7 are movably connected by a rotating shaft, and a top rod 3-8 is provided on the upper part of track 5-7. The top rod 3-8 is located directly below track 2-2 and is spaced apart from track 2-2 when it is in a horizontal state.

[0052] Below track 5 3-7 is an electric push rod 3-5. The electric push rod 3-5 is movably connected to support assembly 1 3-4 via a rotating shaft. Track 4 3-6 is equipped with a contact switch. The extension of the electric push rod 3-5 is controlled by the contact of the gear and the contact of the gear. Track 3 3-3 is also equipped with a contact switch. The retraction of the electric push rod 3-5 is controlled by the contact of the gear and the contact of the gear.

[0053] Electric push rod 3-5 is used to push track 5 3-7 upward and connect it with track 4 3-6 to form a continuous channel;

[0054] The track 3 has symmetrical slide rails 3-10 on its side, and the housing 1 has a set of pulley assemblies. The pulley assembly includes a connecting rod 11 and a pulley 12. The pulley 12 is engaged in the slide rail 3-10 for sliding.

[0055] In the early stages of operation of the new unit, the inspection robot continuously collects the acoustic fingerprint information of the unit during normal operation by inspecting the large units (cracking gas compressor, ethylene refrigeration compressor, propylene refrigeration compressor), accumulating a large amount of acoustic fingerprint data. The AI ​​learns and summarizes the normal acoustic fingerprint range of the unit.

[0056] Towards the end of the unit's operation (at the end of a maintenance cycle), the inspection robot collected abnormal acoustic signature information and issued an alarm signal. Using this acoustic signature information as a starting point, on-site inspection and DCS parameter analysis confirmed that the compressor turbine had experienced several vibrations. The cause was then found to be liquid carryover in the compressor turbine steam. Timely process adjustments were made to avoid larger process fluctuations.

[0057] One day, during a high-altitude operation as part of the eight major tasks at the plant site, the on-site workers were not wearing safety belts, and the operating platform was more than 2 meters high. This scene was recognized by the inspection system and violated the safety requirements for hazardous operations. The on-site loudspeaker promptly sounded an alarm and pushed the violation information to the company's dispatch center.

[0058] One day, during a hot work operation, one of the eight major operations, the operation was legal, compliant, and the gas detection was qualified. After obtaining the necessary permits, the hot work began normally. However, during the operation, the safety environment changed. There was a evacuation, replacement, and cleaning operation dozens of meters away, and the air contained flammable gas. The monitoring robot promptly issued an alarm and shouted to stop the operation, while also sending the information to the company's dispatch center.

[0059] When the robot was inspecting the PSA area, it detected a hydrogen leak and pushed the information to the dispatch system, which promptly sent the information to the on-site duty room. Personnel responded in a timely manner and dealt with the leak risk.

[0060] The health voiceprints of the three units in the ethylene plant can be recorded to diagnose compressor faults.

Claims

1. A robotic system for high-altitude inspection, comprising a track (3), an inspection robot, and an intelligent control platform, characterized in that, The track (3) is a long and narrow steel plate with a gear groove and an anti-fall track edge on one side of the steel plate. The track (3) is provided with a fixed column (4) every few meters. The cross section of the track (3) is a "T" shaped structure. The inspection robot includes a housing (1), and a drive system is provided inside the housing (1). The output shaft of the drive device is matched with the upper roller (9) to output power. The upper gear (9) has a left-right symmetrical structure. The housing (1) is also provided with a lower gear (8). The upper gear (9) and the lower gear (8) are matched with the gear slots respectively. There is a distance between the upper gear (9) and the lower gear (8) for meshing on the track (3). The track (3) has two upper gears (9) at the top and one lower gear (8) at the bottom. The housing is also equipped with a fixed shaft (6). The fixed shaft (6) is movably connected to the movable rod (2) through a bearing. The lower end of the movable rod (2) is fixedly connected to the smart terminal (5). The drive system is used to drive the upper gear (9) to rotate forward or backward. It also includes at least one three-way track, which consists of several tracks: track one (3-1), track two (3-2), track three (3-3), support component one (3-4), electric push rod (3-5), track four (3-6), and track five (3-7). Track one (3-1) and track two (3-2) are movably connected by a rotating shaft, and track two (3-2) is supported below by support component two (3-9). When track two (3-2) is in a horizontal state, it forms a connecting channel with track four (3-6). Track 3 (3-3) and track 5 (3-7) are movably connected by a rotating shaft, and a top rod (3-8) is provided on the upper part of track 5 (3-7). The top rod (3-8) is located directly below track 2 (3-2) and is spaced apart from track 2 (3-2) when it is in a horizontal state. An electric push rod (3-5) is located below track 5 (3-7). The electric push rod (3-5) is movably connected to support assembly 1 (3-4) via a rotating shaft. A contact switch is located on track 4 (3-6). The extension of the electric push rod (3-5) is controlled by the contact of the gear with the contact switch. A contact switch is also located on track 3 (3-3). The retraction of the electric push rod (3-5) is controlled by the contact of the gear with the contact switch. The electric push rod (3-5) is used to push track five (3-7) upward and connect it with track four (3-6) to form a continuous channel.

2. The robot system for high-altitude inspection as described in claim 1, characterized in that, A magnetic charging interface (7) is provided on the upper part of the housing (1).

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