Intelligent wall-climbing type welding, detecting and paint spraying integrated robot

Abstract

The invention relates to an intelligent wall-climbing type welding, detecting and paint spraying integrated robot and belongs to the technical field of intelligent robots. By integrating a multi-axis driving mechanism and an electromagnetic adsorption device, the stable adsorption force of the wall-climbing robot on complex surfaces such as rusted surfaces and curved surfaces is enhanced; a positioning sensor and an obstacle avoidance system are combined to detect obstacles in real time and dynamically adjust the motion trail, an integrated operation system is used for achieving multi-task collaborative operation of welding, detection and paint spraying, and operation parameters are remotely monitored and corrected through a man-machine interaction module. Therefore, the problems that traditional manual high-altitude operation is large in potential safety hazard and low in efficiency and existing equipment is single in function, insufficient in adsorption force and poor in environmental adaptability are synchronously solved in super high-rise steel structure construction, full-process automatic, high-precision and uninterrupted intelligent building and maintenance are achieved, full-process automatic and high-precision operation in a high-altitude complex scene is achieved, and the construction efficiency of the super high-rise steel structure is improved. And the efficiency and the safety are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of intelligent robots, and particularly relates to an intelligent wall-climbing integrated welding, inspection and painting robot. Background Art

[0002] In the construction and maintenance of super high-rise buildings and complex steel bridge structures, welding, inspection and painting operations have long relied on manual operations or automated equipment with single functions. Traditional manual workers need to rely on auxiliary tools such as hanging baskets and scaffolding. High-altitude operations face safety hazards such as falling and radiation, and manual work has low efficiency and large quality fluctuations. Problems such as weld offset and uneven coating frequently occur.

[0003] Although existing automated equipment can partially replace manual labor, their functions are scattered and they cannot cooperate in multiple tasks. The adsorption force of wall-climbing robots is insufficient, and they are prone to falling off in areas with rust, curved surfaces or obstacles. The coverage of sensors is limited, and it is difficult to adapt to complex surface environments in real time, resulting in low operation accuracy and frequent process interruptions. In view of the above problems, an intelligent wall-climbing integrated welding, inspection and painting robot is proposed, which solves the problems of poor multi-task coordination, weak adaptability to complex surfaces and insufficient control accuracy. Summary of the Invention

[0004] To solve the above problems existing in the prior art, the present invention provides an intelligent wall-climbing integrated welding, inspection and painting robot, which solves the problems of poor multi-task coordination, weak adaptability to complex surfaces and insufficient control accuracy of existing automated equipment.

[0005] The object of the present invention can be achieved by the following technical solutions:

[0006] An intelligent wall-climbing integrated welding, inspection and painting robot, comprising a robot body, an intelligent wall-climbing system, an integrated operation system, an obstacle avoidance and autonomous planning system, and a human-machine interaction module. The intelligent wall-climbing system is integrated into the robot body and includes a multi-axis drive mechanism, an electromagnetic adsorption device and a positioning sensor, which are used to realize the bidirectional movement and stable adsorption of the robot on the steel structure surface. The integrated operation system is installed at the front end of the robot body and is used to perform welding, inspection and painting tasks and adjust the operation accuracy in real time. The obstacle avoidance and autonomous planning system is distributed at the four corners of the robot body and is used to detect obstacles and trigger obstacle avoidance actions. The human-machine interaction module is connected to the robot body through wireless communication and is used for remote control and status monitoring.

[0007] As a further solution of the present invention, the intelligent wall-climbing system includes a multi-axis motor drive mechanism for bidirectional movement, a distributed electromagnetic adsorption unit for conforming to the steel structure surface, and a radio frequency positioning sensor. The radio frequency positioning sensor is arranged on the chassis of the robot body, and the radio frequency positioning sensor is used to detect the position and adsorption state of the robot in real time.

[0008] As a further solution of the present invention, the electromagnetic attraction units in the distributed electromagnetic attraction unit are adjustable in distance, so as to adapt to different surface curvatures.

[0009] As a further solution of the present invention, the integrated operation system includes a multi-station robotic arm module and a high-precision painting device. The multi-station robotic arm module is used to perform welding, inspection, and painting, and the high-precision sensor is used to feedback and adjust the precision of welding, inspection, and painting.

[0010] As a further solution of the present invention, the high-precision painting device includes a multi-nozzle spray gun, a paint storage tank, and a closed-loop flow control valve. The nozzle diameter of the multi-nozzle spray gun is designed according to the paint viscosity grading, and the 0°-90° angle adjustment is realized by a servo motor.

[0011] As a further solution of the present invention, the multi-station robotic arm module includes a welding actuator, an inspection actuator, and a painting actuator, which are connected in series through rotatable joints.

[0012] As a further solution of the present invention, the integrated operation system further includes a force sensor, which is installed at the connection of the welding actuator, the inspection actuator, and the painting actuator, and is used to feedback the operation pressure and position offset.

[0013] As a further solution of the present invention, the obstacle avoidance and autonomous planning system includes a motor group, a telescopic anti-collision bracket, and a foldable obstacle-crossing wheel group. The telescopic anti-collision bracket is arranged at the four corners of the robot, and a buffer spring and a contact switch are arranged at the end, and after being triggered, it drives the motor group to move in the reverse direction.

[0014] As a further solution of the present invention, the foldable obstacle-crossing wheel group includes two groups of auxiliary rollers and a link mechanism, which are unfolded to cross the raised structure when an obstacle is detected.

[0015] As a further solution of the present invention, the link mechanism adopts a spring reset design and automatically retracts after the obstacle is removed.

[0016] The beneficial effects of the present invention are as follows:

[0017] Enhance the stable adsorption force of the wall-climbing robot on complex surfaces such as rusty and curved surfaces by integrating a multi-axis drive mechanism and an electromagnetic adsorption device. Combine a positioning sensor and an obstacle avoidance system to detect obstacles in real time and dynamically adjust the motion trajectory. Use an integrated operation system to achieve multi-task collaborative operations of welding, detection, and painting. Remotely monitor and correct operation parameters through a human-machine interaction module, so as to synchronously solve the problems of great safety hazards and low efficiency in traditional manual high-altitude operations, as well as the single function, insufficient adsorption force, and poor environmental adaptability of existing equipment in the construction of super-high-rise steel structures, and realize full-process automation, high precision, and uninterrupted intelligent construction and maintenance, achieve full-process automation and high-precision operations in high-altitude complex scenarios, and improve efficiency and safety. Description of the Drawings

[0018] For the convenience of those skilled in the art to understand, the present invention will be further described below with reference to the accompanying drawings.

[0019] Figure 1 It is a control schematic diagram of the intelligent wall-climbing welding, inspection and painting integrated robot system of the present invention. Detailed Embodiments

[0020] To further elaborate on the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the following will describe in detail the specific embodiments, structures, features, and their effects of the present invention with reference to the accompanying drawings and preferred embodiments.

[0021] Please refer to Figure 1 , this embodiment provides an intelligent wall-climbing welding, inspection and painting integrated robot, including a robot body, an intelligent wall-climbing system, an integrated operation system, an obstacle avoidance and autonomous planning system, and a human-machine interaction module. The intelligent wall-climbing system is integrated into the robot body and includes a multi-axis drive mechanism, an electromagnetic adsorption device, and a positioning sensor, which are used to realize the bidirectional movement and stable adsorption of the robot on the steel structure surface. The integrated operation system is installed at the front end of the robot body and is used to perform welding, inspection, and painting tasks and adjust the operation accuracy in real time. The obstacle avoidance and autonomous planning system is distributed at the four corners of the robot body and is used to detect obstacles and trigger obstacle avoidance actions. The human-machine interaction module is connected to the robot body through wireless communication and is used for remote control and status monitoring. The remote control terminal is connected to the robot through a wireless communication module. The terminal is equipped with an emergency stop button and a status indicator light, and realizes remote control and real-time status monitoring through the wireless communication terminal, supports emergency intervention and parameter correction. In high-altitude operations, the risk of manual close-range operation is high, and traditional equipment lacks real-time feedback. The terminal integrates an emergency stop button and a status indicator light, and the operator can remotely adjust the path or spraying parameters. The system automatically records data for optimization, reduces the safety risk of high-altitude operators, and at the same time makes up for the limitations of the autonomous algorithm through remote fine control, improving the overall operation flexibility and reliability.

[0022] At present, in the construction and maintenance of super high-rise buildings above forty floors and complex steel bridge structures, welding, inspection, and painting operations have long relied on manual operations or automated equipment with single functions. Traditional manual work requires the assistance of tools such as hanging baskets and scaffolding. High-altitude operations face safety hazards such as falling and radiation. Moreover, manual efficiency is low, and quality fluctuates greatly. Problems such as weld offset and uneven coating occur frequently. Although existing automated equipment can partially replace manual work, its functions are scattered and it cannot perform multi-task collaboration. The adsorption force of wall-climbing robots is insufficient, and they are prone to falling off in areas with rust, curved surfaces, or obstacles. The coverage of sensors is limited, and it is difficult to adapt to complex surface environments in real time, resulting in low operation accuracy and frequent process interruptions.

[0023] To solve the above problems, in this embodiment, by integrating a multi-axis drive mechanism and an electromagnetic adsorption device, the stable adsorption force of the wall-climbing robot on complex surfaces such as rust and curved surfaces is enhanced. Combining a positioning sensor and an obstacle avoidance system to detect obstacles in real time and dynamically adjust the movement trajectory, and using an integrated operation system to achieve multi-task collaborative operations of welding, inspection, and painting. Through the human-machine interaction module, the operation parameters are remotely monitored and corrected, so as to synchronously solve the problems of high safety hazards and low efficiency of traditional manual high-altitude operations, as well as the single function, insufficient adsorption force, and poor environmental adaptability of existing equipment in the construction of super high-rise steel structures, and realize fully automated, high-precision, and uninterrupted intelligent construction and maintenance.

[0024] To better overcome the defects of insufficient adsorption force of existing equipment and inability to adapt to non-flat surfaces, ensure that the robot can operate stably in complex areas such as welds and rivets of super high-rise buildings or steel bridges, reduce the risk of falling off, and improve the continuity of operations. For this reason, in one embodiment, the intelligent wall-climbing system includes a multi-axis motor drive mechanism for bidirectional movement, a distributed electromagnetic adsorption unit for fitting the surface of the steel structure, and a radio frequency positioning sensor. The radio frequency positioning sensor is arranged on the chassis of the robot body and is used to detect the position and adsorption state of the robot in real time. The electromagnet spacing of the distributed electromagnetic adsorption unit is adjustable to adapt to different surface curvatures. The multi-axis motor drive mechanism includes a vertical drive motor group and a horizontal drive motor group, and the vertical drive motor group and the horizontal drive motor group achieve bidirectional movement through gear-rack transmission; through the multi-axis drive mechanism and the distributed electromagnetic adsorption unit, the stable adsorption and flexible movement of the robot on the complex steel structure surface are realized. Traditional wall-climbing robots rely on a single adsorption method and are prone to falling off in areas with rust, curved surfaces, or obstacles. The multi-axis drive mechanism combined with an electromagnet array with adjustable spacing can dynamically adjust the adsorption force distribution according to the surface curvature and enhance the adaptability.

[0025] Due to the great design and construction difficulties of super high-rise buildings and complex steel bridge structures themselves, the involved engineering technologies are complex, and the requirements for multi-disciplinary collaborative operations are high. Secondly, the high-altitude operation environment is complex, and environmental factors such as wind force and temperature have a greater impact on construction, easily leading to weld offset and difficult control of welding quality. During the construction process, the task coordination difficulty of different types of work and different stages is relatively large, information transmission and communication are not smooth, and collaborative errors are easily generated. Moreover, due to the limitations of high-altitude operation conditions, it is difficult to achieve uniform coating construction, which in turn affects the durability and safety of the overall structure. In this regard, in one embodiment, the integrated operation system includes a multi-station robotic arm module and a high-precision painting device. The multi-station robotic arm module is used to perform welding, inspection, and painting. The design of the multi-station robotic arm module enables it to adapt to the structural characteristics of super high-rise buildings and complex steel bridges, such as flexible operation in environments such as narrow spaces and high-altitude operations. High-precision sensors are used to feedback and adjust the precision of welding, inspection, and painting. The high-precision painting device includes a multi-nozzle spray gun, a paint storage tank, and a closed-loop flow control valve. The nozzle diameter of the multi-nozzle spray gun is designed according to the paint viscosity classification, and 0°-90° angle adjustment is achieved through a servo motor. The nozzle diameter of the multi-nozzle spray gun is designed according to the paint viscosity classification, which can be applicable to different types of paints, increasing the adaptability of the system. By achieving 0°-90° angle adjustment through a servo motor, the direction and range of painting can be precisely controlled, improving the painting effect. The multi-station robotic arm module includes a welding actuator, an inspection actuator, and a painting actuator, which are connected in series through rotatable joints. The multi-station robotic arm connects the welding, inspection, and painting actuators in series through rotatable joints, supporting seamless task switching. The closed-loop flow valve and the multi-nozzle spray gun ensure coating uniformity, and at the same time, real-time data feedback is carried out through high-precision sensors, reducing quality problems such as weld offset and uneven coating.

[0026] External conditions such as the self-weight, wind force, temperature change, and earthquake of high-rise buildings and steel bridges will cause uneven pressure distribution inside the structure. This uneven pressure will make the heat and current distribution uneven during the welding process, thus affecting the welding quality. To solve this problem, in one embodiment, the integrated operation system further includes a mechanical sensor. The mechanical sensor is a strain gauge type sensor, which real-time monitors the welding pressure and painting flow rate. The mechanical sensor is installed at the connection of the welding actuator, the inspection actuator, and the painting actuator, and is used to feedback the operation pressure and position offset. The main controller of the mechanical sensor dynamically adjusts the robotic arm posture and operation parameters. Through data feedback closed-loop control, the subjective error of manual operation is significantly reduced, ensuring that the welding strength and coating thickness meet the process standards and improving the quality consistency.

[0027] In the construction and maintenance of super high-rise buildings and complex steel bridge structures, there are usually a large number of sharp corners, narrow spaces and components with complex shapes in these building structures. For example, obstacles such as raised welds and rivets in complex steel structures make it difficult to implement the movement path planning and obstacle avoidance strategies of robots. Since the design and manufacture of existing robots have not fully considered the operation requirements in these special environments, their mechanical structures and drive systems may not be able to adapt to the changes in complex terrains, resulting in jamming or blocked movement when encountering raised parts or obstacles. To solve this problem, in one embodiment, the obstacle avoidance and autonomous planning system includes a motor group, a telescopic anti-collision bracket and a foldable obstacle-crossing wheel group. The telescopic anti-collision bracket is arranged at the four corners of the robot, and a buffer spring and a contact switch are arranged at the end. After being triggered, it drives the motor group to move in the reverse direction. The foldable obstacle-crossing wheel group includes two groups of auxiliary rollers and a linkage mechanism, which unfolds to cross the raised structure when an obstacle is detected. The linkage mechanism adopts a spring reset design and automatically retracts after the obstacle is cleared. Through the telescopic anti-collision bracket and the foldable obstacle-crossing wheel group, obstacle detection and autonomous obstacle avoidance are realized. By integrating the motor group, the telescopic anti-collision bracket and the foldable obstacle-crossing wheel group, the robot can more flexibly cope with complex environments, reduce the downtime caused by jamming or blocked movement, and thus improve the overall operation efficiency. In addition, the brackets arranged at the four corners of the robot can be triggered by the buffer spring and the contact switch when contacting an obstacle, driving the motor group to move in the reverse direction, avoiding direct collision and reducing damage. When an obstacle is detected, the auxiliary rollers and the linkage mechanism unfold to help the robot cross the raised structure. This design allows the robot to have better adaptability and obstacle-crossing ability when facing obstacles of different heights. The linkage mechanism adopts a spring reset design. When the obstacle is cleared, the obstacle-crossing wheel group can automatically retract without manual intervention, which can ensure that the robot can work continuously and reduce the maintenance and operation costs. Through these designs, the application of the robot in the construction and maintenance of super high-rise buildings and complex steel bridge structures becomes more flexible and efficient.

[0028] The working process and working principle of the present invention:

[0029] The robot scans the surface of the steel structure through radio frequency positioning sensors and vision sensors to generate a three-dimensional environmental map, identify the weld positions, rust areas, and obstacle distributions. The multi-axis drive mechanism of the intelligent wall-climbing system drives the movement in the vertical and horizontal directions. The distributed electromagnetic adsorption unit dynamically adjusts the distance between the electromagnets and the adsorption force according to the surface curvature to ensure stable adhesion. The multi-station robotic arm of the integrated operation system moves along a preset path and sequentially performs welding, inspection, and painting. The mechanical sensors continuously feedback the operation pressure and position offset. The main controller adjusts the parameters in a closed-loop manner. When the telescopic anti-collision bracket detects an obstacle, it triggers the contact switch, the drive motor pauses, and the obstacle-crossing wheel set is deployed to assist the robot in crossing the raised structure. After completion, it resets and continues the operation. The operator can view the operation status in real time through the human-machine interaction module, such as the weld quality and paint film thickness, remotely correct the path or spraying parameters, and the system records data to optimize the subsequent process;

[0030] Through multi-axis drive and dynamic adsorption force adjustment, the intelligent wall-climbing system solves the stability problem of traditional equipment on complex surfaces. The integrated operation system uses the modular design of the robotic arm and the feedback of high-precision sensors to achieve seamless connection and quality closed-loop control of welding, inspection, and painting. The obstacle avoidance system ensures the continuity of the operation through mechanical triggering and the deployment of the obstacle-crossing wheel set. The human-machine interaction module realizes remote intervention through wireless communication to make up for the limitations of the autonomous algorithm, and finally realizes the full-process automated operation in high-altitude complex scenarios.

[0031] The above is only a preferred embodiment of the present invention, and it is not intended to limit the present invention in any form. Although the present invention has been disclosed above with the preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to the equivalent embodiments by using the disclosed technical content within the scope of the technical solution of the present invention. However, as long as it does not depart from the content of the technical solution of the present invention, any brief modification, equivalent change, and modification made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. The intelligent wall-climbing integrated robot for welding detection and painting is characterized in that It includes a robot body, an intelligent wall-climbing system, an integrated operation system, an obstacle avoidance and autonomous planning system, and a human-machine interaction module. The intelligent wall-climbing system is integrated into the robot body and includes a multi-axis drive mechanism, an electromagnetic adsorption device, and a positioning sensor, which are used to realize the bidirectional movement and stable adsorption of the robot on the steel structure surface. The integrated operation system is installed at the front end of the robot body and is used to perform welding, inspection, and painting tasks and adjust the operation accuracy in real time. The obstacle avoidance and autonomous planning system are distributed at the four corners of the robot body and are used to detect obstacles and trigger obstacle avoidance actions. The human-machine interaction module is connected to the robot body through wireless communication and is used for remote control and status monitoring.

2. The intelligent wall-climbing integrated welding detection and painting robot according to claim 1, wherein, The intelligent wall-climbing system includes a multi-axis motor drive mechanism for bidirectional movement, a distributed electromagnetic adsorption unit for adhering to the steel structure surface, and a radio frequency positioning sensor. The radio frequency positioning sensor is set on the chassis of the robot body and is used to detect the robot position and adsorption status in real time.

3. The intelligent wall-climbing integrated welding detection and painting robot according to claim 2, wherein, The electromagnet spacing of the distributed electromagnetic adsorption unit is adjustable to adapt to different surface curvatures.

4. The intelligent wall-climbing integrated welding detection and painting robot according to claim 1, wherein The integrated operation system includes a multi-station robotic arm module and a high-precision painting device. The multi-station robotic arm module is used to perform welding, inspection, and painting, and the high-precision sensor is used to feedback and adjust the accuracy of welding, inspection, and painting.

5. The intelligent wall-climbing integrated welding detection and painting robot according to claim 4, characterized in that, The high-precision painting device includes a multi-nozzle spray gun, a paint storage tank, and a closed-loop flow control valve. The nozzle diameter of the multi-nozzle spray gun is designed according to the paint viscosity classification and realizes 0°-90° angle adjustment through a servo motor.

6. The intelligent wall-climbing integrated welding detection and painting robot according to claim 4, wherein The multi-station robotic arm module includes a welding actuator, an inspection actuator, and a painting actuator, and the three are connected in series through rotatable joints.

7. The intelligent wall-climbing integrated welding detection and painting robot according to claim 6, wherein, The integrated operation system also includes a force sensor, which is installed at the connection of the welding actuator, the inspection actuator, and the painting actuator and is used to feedback the operation pressure and position offset.

8. The intelligent wall-climbing integrated welding detection and painting robot according to claim 1, characterized in that The obstacle avoidance and autonomous planning system includes a motor group, a telescopic anti-collision bracket, and a foldable obstacle-crossing wheel set. The telescopic anti-collision bracket is set at the four corners of the robot, and a buffer spring and a contact switch are set at the end. After being triggered, it drives the motor group to move in the reverse direction.

9. The intelligent wall-climbing integrated welding detection and painting robot according to claim 1, wherein, The foldable obstacle-crossing wheel set includes two groups of auxiliary rollers and a link mechanism, which are unfolded to cross the raised structure when an obstacle is detected.

10. The intelligent wall-climbing integrated welding detection and painting robot according to claim 9, wherein The link mechanism adopts a spring reset design and automatically retracts after the obstacle is removed.

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