Building steel structure engineering detection device based on sensor

Abstract

The invention provides a building steel structure engineering detection device based on a sensor, and relates to the field of building steel structure engineering detection. The detection device comprises a sectional type bionic mechanical arm which is formed by connecting at least six joint sections capable of being bent independently in series, and a pneumatic driving cavity and a shape memory alloy wire are arranged in each joint section; the self-tightening winding mechanism comprises a pre-tightening belt surrounding the outer wall of the mechanical arm and a pressure feedback unit; the multi-mode detection head is fixed at the tail end of the mechanical arm and is integrated with an eddy current sensor, an ultrasonic phased array probe and a high-resolution industrial camera; and the central control module is in signal connection with the mechanical arm and the multi-mode detection head, dynamically plans a winding path of the mechanical arm according to laser ranging data of the laser ranging module, and selectively starts the eddy current sensor or the industrial camera to perform cooperative detection based on an initial scanning result of the ultrasonic phased array probe. And the effects of self-adaption to complex morphology, synchronous completion of multi-type defect detection and environmental interference resistance are achieved.

Description

Technical Field

[0001] The present application relates to the field of building steel structure engineering detection, and in particular to a building steel structure engineering detection device based on sensors. Background Art

[0002] At present, problems such as deformation, cracks, and corrosion may occur in building steel structures after long-term use, and regular inspections are required. Existing inspection methods include manual inspection, fixed sensor monitoring, etc.

[0003] However, traditional detection means have obvious problems. For example, in areas with narrow spaces such as complex welded joints and special-shaped connections, the detection accuracy is affected; for another example, defects such as cracks, corrosion, and deformation need to be detected multiple times using eddy current, ultrasonic, and visual equipment respectively, which is time-consuming and the data is difficult to synchronize; and there are also problems such as poor stability in high-altitude environments and insufficient adaptability of sensors. Therefore, there is an urgent need for an intelligent detection device that can adapt to complex topographies, synchronously complete the detection of multiple types of defects, and resist environmental interference. Summary of the Invention

[0004] The embodiments of the present application provide a building steel structure engineering detection device based on sensors, which solves the problems of difficult detection of complex nodes, low efficiency of identifying multiple defect types, and poor stability in high-altitude environments.

[0005] The embodiments of the present application adopt the following technical solutions: A building steel structure engineering detection device based on sensors, comprising: A segmented bionic robotic arm, which is composed of at least 6 independently bendable joint segments connected in series. Each of the joint segments is provided with a pneumatic drive cavity and shape memory alloy wires. The shape memory alloy wires are uniformly distributed circumferentially and the shrinkage rate is controlled by current; A self-tightening winding mechanism, which includes a pre-tightening belt surrounding the outer wall of the robotic arm and a pressure feedback unit. The pre-tightening belt forms a wrapped contact with the surface of the steel structure through the shrinkage force of the shape memory alloy wires, and the pressure feedback unit adjusts the current in real time to maintain the contact pressure within the range of 5-20N; A multi-modal detection head, fixed at the end of the robotic arm, and integrated with: An eddy current sensor, the axis of whose coil is adaptively deflected at 0°-15° with respect to the normal of the detection surface; An ultrasonic phased array probe, with a built-in retractable couplant injection port; A high-resolution industrial camera, equipped with a ring-shaped fill light and a laser ranging module; It further includes, The central control module is signal - connected to the robotic arm and the multi - modal detection head. It dynamically plans the winding path of the robotic arm according to the laser ranging data of the laser ranging module, and selectively activates the eddy current sensor or the industrial camera for collaborative detection based on the initial scanning results of the ultrasonic phased array probe.

[0006] By adopting the above - mentioned technical solution, first of all, the segmented bionic robotic arm realizes 360° cladding by winding the steel member, covering the blind area of the special - shaped structure. The bionic design adapts to complex shapes, solves the problem that traditional rigid probes cannot fit, and greatly improves the detection coverage rate.

[0007] Secondly, the self - tightening winding mechanism maintains the contact pressure stable through pressure - feedback closed - loop control. Even under the 6 - level wind vibration, the pressure fluctuation is still very small.

[0008] The multi - modal detection head (eddy current + ultrasonic + vision) integrates collaborative detection, completes the identification of multiple types of defects in a single operation. After the ultrasonic initial scan locates the internal defects, the eddy current precise detection is triggered. The data fusion greatly improves the defect identification accuracy.

[0009] Finally, the central control module intelligently switches the detection mode according to the ultrasonic initial scan results, realizing multi - modal data fusion.

[0010] In summary, through the structural design of "bionic winding + multi - sensor collaborative decision - making", the limitation of the separation of the robotic arm and the detection logic in the existing technology is broken through. It not only cross - integrates the principles of biological bionics and multi - modal sensing technology, but also realizes the self - optimization of the detection mode through the real - time interaction of sensor data. Moreover, the shape memory alloy undertakes the dual functions of structural drive and contact pressure adjustment, and finally realizes the intelligent detection effect that can adapt to complex shapes, synchronously complete the detection of multiple types of defects and resist environmental interference.

[0011] In an optional implementation manner, the surface of the joint segment is covered with an environment - responsive flexible skin, and the skin is composed of an interweaving of a shape - memory polymer and piezoresistive sensing fibers, where: The piezoresistive sensing fibers real - time monitor the temperature and humidity changes on the surface of the steel member, and dynamically adjust the driving current of the shape - memory alloy wire through the central control module; The shape - memory polymer automatically expands to form anti - slip textures when the temperature ≥ 35°C, and shrinks to reduce the joint movement resistance when the temperature ≤ 5°C.

[0012] By adopting the above - mentioned technical solution, the problem of the robotic arm slipping or jamming caused by the high - altitude temperature difference is solved through environment - adaptive materials. The detection stability is effectively improved in the environment of - 10°C to 50°C, and no manual intervention is required for environmental adaptability adjustment.

[0013] In an alternative implementation, the shrinkage rate of the shape memory alloy wire and the tension value of the pre-tightening belt are closed-loop controlled by a PID algorithm, and the response time ≤ 0.5 seconds.

[0014] By adopting the above technical solution, the current of the shape memory alloy is adjusted in real time by a PID algorithm to quickly cancel the interference of wind vibration or structural vibration, and the standard deviation of the contact pressure is effectively reduced to ensure that the probe fits tightly.

[0015] In an alternative implementation, the pre-tightening belt adopts an asymmetric tooth-shaped structure, and the inner tooth height (H1) and the outer tooth height (H2) satisfy H1 / H2 = 0.3 - 0.6, and: The inner tooth surface is serrated, and the friction coefficient with the steel structure surface ≥ 0.8; The outer tooth surface is a smooth arc, and the included angle with the shrinkage direction of the shape memory alloy wire is 15° - 30°, which is used to convert the alloy shrinkage force into a radial pressing force.

[0016] By adopting the above technical solution, the outer smooth arc surface converts the shape memory alloy shrinkage force into a radial pressing force, and the alloy driving force is amplified multiple times through mechanical structure innovation, and the contact pressure under the same current far exceeds the pressure of the traditional symmetric structure.

[0017] In an alternative implementation, a dynamic curvature matching mechanism signal-connected to the central control module is provided between the multi-modal detection head and the end of the robotic arm, specifically including: A spherical hinge base, which is internally embedded with a piezoelectric ceramic micro-motion regulator; A curved surface fitting detection board, which is connected to the spherical hinge base through a flexible connecting piece, and an array of pressure sensors is provided on the back of the detection board; When the detection board contacts the steel structure surface, the array of pressure sensors real-time feeds back the contact pressure distribution to the central control module, driving the piezoelectric ceramic micro-motion regulator to adjust the pitch angle and yaw angle of the detection board, so that the deviation between the sound beam axis of the ultrasonic phased array probe and the detection surface normal ≤ 3°.

[0018] By adopting the above technical solution, the problem of the fitting accuracy between the probe and the curved surface is solved, and compared with the sound beam refraction error of the traditional fixed-angle probe on the curved surface, the detection signal-to-noise ratio is effectively improved.

[0019] In an alternative implementation, the ultrasonic phased array probe and the eddy current sensor are arranged in an interleaved manner, and the overlap degree of their detection areas ≥ 85%, and the field of view angle of the industrial camera covers the boundaries of both detection areas.

[0020] By adopting the above technical solution, the overlap degree of the ultrasonic and eddy current detection areas ≥ 85%, and the industrial camera covers the boundary area, ensuring the spatial alignment of data, improving the multi-modal data fusion efficiency, and shortening the detection time.

[0021] In an alternative implementation, the annular fill light of the industrial camera includes a multi-spectral light-emitting unit, whose spectral range covers the visible light of 400 - 700 nm, the near-infrared of 900 - 1700 nm, and the ultraviolet of 365 nm band, and: The ultraviolet band light source is synchronously activated with the eddy current sensor to excite the fluorescent penetrant at the surface crack; The near-infrared band light source works in cooperation with the ultrasonic phased array probe to assist in identifying internal debonding defects through thermal imaging.

[0022] By adopting the above technical solution, the limitation of single-spectrum in traditional visual inspection is broken through, and cross-verification of surface or subsurface defects is realized through the spectral and sensing linkage mechanism.

[0023] In an alternative implementation, it further includes a vibration energy recovery module, specifically including, A magnetostrictive energy harvester, installed at the joint of the robotic arm, converts the vibration energy during the winding of the robotic arm into electrical energy; A supercapacitor bank stores the recovered energy and powers the shape memory alloy wire; An energy distribution controller preferentially supplies the recovered energy to the high-power ultrasonic phased array probe.

[0024] By adopting the above technical solution, the power supply problem for high-altitude operations is solved, the battery life is extended, and the external charging frequency is reduced.

[0025] In an alternative implementation, the magnetostrictive energy harvester of the vibration energy recovery module is integrated with a piezoelectric fiber composite layer, where: The magnetostrictive material (Terfenol-D) is arranged along the axial direction of the robotic arm to capture low-frequency vibration energy of 1 - 50 Hz; The piezoelectric fiber (PZT) is wound around the outer wall of the joint segment in a spiral structure to capture high-frequency vibration energy of 50 - 200 Hz; The electrical energy output by both is rectified and then connected in parallel to input into the supercapacitor bank.

[0026] By adopting the above technical solution, multi-band vibration energy is collected synergistically, and the energy density is increased by multiple times compared with the single mode, especially suitable for the complex vibration environment of steel structures.

[0027] In an alternative implementation, the device is equipped with modular expansion interfaces, including: A quick-change end effector, supporting expansion tools such as a laser thickness gauge and an electromagnetic ultrasonic probe; A wireless communication repeater, embedded inside the joint segment, to achieve data synchronization during multi-device networking detection; The interface adopts a waterproof and dustproof design to adapt to the harsh outdoor detection environment.

[0028] By adopting the above technical solutions, the detection function can be flexibly extended through a standardized interface, and the networking detection efficiency is increased by several times, which is especially suitable for large grid structures.

[0029] In summary, the present application includes at least one of the following beneficial technical effects: 1. The bionic robotic arm can wind steel members with a diameter of 50 - 800 mm, including H-shaped steel, round tubes, etc., achieving 360° dead-angle-free coverage. The detection coverage rate of complex nodes is greatly improved. The self-tightening mechanism of the shape memory alloy enables the device to still maintain extremely small contact pressure fluctuations under 6-level wind vibration, ensuring detection stability and achieving omnidirectional adaptive detection; 2. The ultrasonic probe preferentially scans internal defects. After detecting a suspicious area, it automatically triggers the eddy current sensor for precise detection of surface cracks. The dual-modal data fusion greatly improves the defect recognition accuracy. The industrial camera synchronously records the surface topography, aligns with the flaw detection data in time and space, and generates a three-dimensional defect distribution map, thus realizing multi-modal collaborative detection; 3. A single detection can complete the tasks that traditionally require three-step operations. The detection time is greatly shortened, and there is no need to set up scaffolding or hanging baskets, reducing manual intervention, meeting the safety standards for high-altitude operations, and optimizing work efficiency and costs. Description of the Drawings

[0030] Figure 1 It is a schematic diagram of the overall structure of the detection device.

[0031] Figure 2 It is a schematic diagram of the internal structure of the joint segment.

[0032] Figure 3 It is a block diagram of the overall structure module of the detection device.

[0033] Description of the reference numerals: 100, robotic arm; 101, joint segment; 102, pneumatic drive cavity; 103, shape memory alloy wire; 104, skin; 105, shape memory polymer; 106, piezoresistive sensing fiber; 200, multi-modal detection head; 201, eddy current sensor; 202, ultrasonic phased array probe; 203, coupling agent injection port; 204, industrial camera; 205, annular fill light; 206, laser ranging module; 300, self-tightening winding mechanism; 301, pre-tightening belt; 302, pressure feedback unit; 400, central control module; 500, dynamic curvature matching mechanism; 501, spherical hinge base; 502, piezoelectric ceramic micro-adjuster; 503, detection plate; 504, flexible connecting piece; 505, pressure sensor; 600, vibration energy recovery module; 601, magnetostrictive energy collector; 602, super capacitor bank; 603, energy distribution controller; 700, modular expansion interface; 701, end quick-change joint; 702, wireless communication repeater. Detailed Description of the Invention

[0034] The present application will be further described in detail below in conjunction with all the drawings in the embodiments of the present application.

[0035] In the description of the embodiments of the present application, it should be noted that, unless otherwise clearly specified and limited, the terms "installation" and "connection" should be understood in a broad sense. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. Among them, "fixed connection" means that the two are connected and the relative positional relationship after connection remains unchanged. It should be understood that when component A is fixedly connected to component C through component B, a change in the relative positional relationship due to the deformation of component A, component B, and component C itself is allowed. Among them, the integration of two components through an integral molding process means that during the process of forming one of the two components, the component is connected to the other component together without the need to connect the two components through a reprocessing method (such as bonding, welding, snap connection, screw connection).

[0036] The orientation terms mentioned in the embodiments of the present application, such as "upper", "lower", "side", etc., are only references to the directions of the drawings. Therefore, the orientation terms used are for better and clearer description and understanding of the embodiments of the present application, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be understood as a limitation to the embodiments of the present application.

[0037] The term "a plurality" means at least two. The term "above" includes the number itself. The term "and / or" is a description of the association relationship of associated objects, indicating that three relationships can exist. For example, A and / or B can represent: A exists alone, A and B exist simultaneously, and B exists alone. The terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as implying or suggesting relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features.

[0038] The embodiments of the present application disclose a sensor-based detection device for building steel structure projects.

[0039] Referring to Figure 1 and Figure 2 , a sensor-based detection device for building steel structure projects includes a segmented bionic robotic arm 100. The robotic arm 100 is composed of at least 6 independently bendable joint segments 101 connected in series. Based on the bionic principle of an octopus tentacle, the multi-joint series structure can achieve continuous bending and winding in three-dimensional space and adapt to steel members with a diameter of 50 - 800 mm (such as H-shaped steel, round pipes, special-shaped nodes, etc.).

[0040] The robotic arm has autonomous winding detection. Each single operation can cover a 5 - 8 - meter steel structure section (manual inspection takes 2 - 3 hours, while this device only needs 20 minutes), with the efficiency increased by more than 6 times. At the same time, there is no need to build scaffolding or hanging baskets, and the manual intervention is reduced by 80%, meeting the safety specifications for high - altitude operations.

[0041] Specifically, each joint segment 101 is a hollow cylinder (outer diameter 80 mm, length 120 mm), made of carbon fiber composite material, with a lightweight design to reduce the overall mass. At the same time, it can ensure that the tensile strength is ≥3.5 GPa, avoiding deformation caused by load or vibration.

[0042] Inside each joint segment 101, there is a pneumatic drive cavity 102, and the pneumatic drive cavity 102 is connected to an external air pump through a flexible air pipe. Pneumatic drive has high power density and flexibility, avoiding rigid collision damage to the surface of the steel structure.

[0043] The pneumatic drive cavity 102 arranges 3 groups of independent air chambers along the axial direction of the joint segment 101. Each group of air chambers controls the inflation and deflation through a micro - solenoid valve, and the air pressure range is 0.1 - 0.5 MPa.

[0044] Inside each joint segment 101, there is also a shape - memory alloy wire 103. The shape - memory alloy wire 103 uses Ni - Ti alloy wire (diameter 0.3 mm). The end of the shape - memory alloy wire 103 is fixed at the end of the joint segment 101, and mechanical fixation and circuit conduction are achieved through a locking bolt.

[0045] Six groups of shape - memory alloy wires 103 are evenly embedded along the circumferential direction of the joint segment 101. Each group contains 4 parallel alloy wires. After being electrified, the shrinkage rate can reach 8% (current 0.5 - 3 A), providing auxiliary driving force and self - tightening adjustment function.

[0046] Correspondingly, adjacent joint segments 101 are connected through a universal joint. The universal joint is equipped with a conductive slip ring to achieve independent power supply for the shape - memory alloy wires 103 inside each joint segment 101.

[0047] The combination of the shape - memory alloy wire 103 and the pneumatic drive cavity 102 can still maintain the contact pressure fluctuation < ±5 N under 6 - level wind vibration (the fluctuation of traditional magnetic adsorption devices is ±30%), realizing high - precision motion control and enhancing the contact pressure stability during winding.

[0048] Outside the robotic arm 100, there is a self - tightening winding mechanism 300. The self - tightening winding mechanism 300 includes a pre - tightening belt 301 that surrounds the outer wall of the robotic arm 100. The pre - tightening belt 301 slides around the outer wall of the robotic arm 100 through a slider guide rail, and the guide rail spacing matches the length of the joint segment 101.

[0049] The pre-tightening belt 301 is made of a polyurethane-based composite material belt. The pre-tightening belt 301 forms a wrapped contact with the steel structure surface through the contraction force of the shape memory alloy wire 103.

[0050] Among them, the inner side of the pre-tightening belt 301 is molded with an asymmetric tooth-shaped structure, and its inner tooth height (H1 = 1.5 mm) and outer tooth height (H2 = 3 mm) satisfy H1 / H2 = 0.5, and: The inner tooth surface is serrated and coated with silicon carbide particles (particle size 50 μm), and the friction coefficient with the steel structure surface is ≥0.8; The outer tooth surface is a smooth arc, forming a 20° angle with the contraction direction of the shape memory alloy wire 103, and converting the alloy contraction force into a radial pressing force through a mechanical amplification effect.

[0051] In addition, the self-tightening winding mechanism 300 also includes a pressure feedback unit 302. The pressure feedback unit 302 is embedded in the middle of the pre-tightening belt 301 and is connected to the central control module 400 through a flexible circuit.

[0052] The pressure feedback unit 302 uses an integrated thin-film pressure sensor (sensitivity 0.1 N) and a PID controller (response time ≤ 0.5 s) to collect the pressure signal of the pre-tightening belt 301 in real time and feedback it to the central control module 400.

[0053] Specifically, when the measured pressure of the pre-tightening belt 301 exceeds the range of 5 - 20 N, the PID algorithm dynamically adjusts the current of the shape memory alloy wire 103 (adjustment step size 0.1 A), and the pressure feedback unit 302 maintains the contact pressure of the pre-tightening belt 301 within the range of 5 - 20 N by adjusting the current in real time.

[0054] Among them, the shrinkage rate of the shape memory alloy wire 103 and the tension value of the pre-tightening belt 301 are closed-loop controlled by the PID algorithm, and its response time ≤ 0.5 s.

[0055] Specifically, when the robotic arm 100 winds the steel member, the pre-tightening belt 301 slides along the guide rail to adapt to the diameter of the member; the shape memory alloy wire 103 is energized and shrinks, driving the pre-tightening belt 301 to tighten, forming a uniform wrapped contact; the serrated surface of the pre-tightening belt 301 meshes with the steel structure surface to prevent slipping.

[0056] Refer to Figure 1 and Figure 3 , the surface of each joint segment 101 is covered with an environment-responsive flexible skin 104 with a thickness of 2 mm. The skin 104 is bonded to the outer wall of the joint segment 101 through a hot pressing process, and a waterproof sealing strip is provided at the edge. The skin 104 is composed of an intertwined shape memory polymer 105 and piezoresistive sensing fibers 106.

[0057] The shape memory polymer 105 automatically expands to form an anti-slip texture when the temperature is ≥35°C, and contracts to reduce the resistance to joint movement when the temperature is ≤5°C.

[0058] Specifically, the shape memory polymer 105 uses an SMP layer with a glass transition temperature (Tg) of 30°C. When the ambient temperature is ≥35°C (5°C higher than Tg), the chain segment movement of the SMP layer intensifies, and the material expands to form micron-scale anti-slip protrusions (roughness Ra increases from 1.2μm to 8.5μm); and when the temperature is ≤5°C, it shrinks and restores a smooth surface.

[0059] The piezoresistive sensing fiber 106 uses a carbon-based piezoresistive fiber to monitor and respond to changes in temperature and humidity on the surface of the steel component in real time, and dynamically adjusts the driving current of the shape memory alloy wire 103 through the central control module 400.

[0060] Specifically, when the piezoresistive sensing fiber 106 detects a high temperature (≥35°C) signal (resistance drops by 5%), the central control module 400 reduces the driving current of the shape memory alloy wire 103 by 10% to avoid damaging the steel structure coating by over-tightening.

[0061] In an environment of ≤5°C, when the resistance of the piezoresistive sensing fiber 106 increases, the PID controller is triggered to increase the current of the shape memory alloy wire 103 by 15% to compensate for the loss of contraction force and maintain a contact pressure of 5-20N.

[0062] When the humidity is ≥80%RH, the resistance change of the piezoresistive sensing fiber 106 triggers an early warning, and the central control module 400 starts high-frequency ultrasonic detection (200Hz) to eliminate the interference of water film on the eddy current signal and reduce the sensor false alarm rate.

[0063] A multimodal detection head 200 is fixedly provided at the end of the robotic arm 100. The multimodal detection head 200 is rigidly connected to the end of the robotic arm 100 through a flange. The multimodal detection head 200 is signal-connected to the central control module 400, and it integrates an eddy current sensor 201, an ultrasonic phased array probe 202, and a high-resolution industrial camera 204.

[0064] There are 4 groups of eddy current sensors 201 distributed in a diamond shape. The diameter of the coil of each group is 20 mm. The coil axis is adaptively deflected by 0°-15° with respect to the normal direction of the detection surface through a micro-servo.

[0065] The ultrasonic phased array probe 202 is a 32-element linear array (center frequency 5 MHz). The ultrasonic phased array probe 202 is installed in the gap between the eddy current sensors 201 , with an element spacing of 1.5 mm. The ultrasonic phased array probe 202 has a built-in retractable coupling agent injection port 203 .

[0066] The ultrasonic phased array probe 202 and the eddy current sensor 201 are arranged in an interleaved manner, and the overlap degree of the detection areas of the two is ≥ 85%.

[0067] The high-resolution industrial camera 204 uses a 20-million-pixel CMOS sensor (frame rate 30fps), and the field of view angle of the industrial camera 204 covers the boundaries of the detection areas of both the ultrasonic phased array probe 202 and the eddy current sensor 201.

[0068] The high-resolution industrial camera 204 is equipped with an annular fill light 205 and a laser ranging module 206. The laser ranging module 206 includes a TOF laser sensor (range 0.1 - 10m, accuracy ±1mm), and is symmetrically arranged on both sides of the industrial camera 204.

[0069] Specifically, the annular fill light 205 includes a multi-spectral light-emitting unit. The multi-spectral light-emitting unit includes an annular bracket with a surface anodized treatment and three-band LEDs embedded in the annular bracket. The three-band LEDs are a visible light LED (400 - 700nm), a near-infrared LED (1550nm), and an ultraviolet LED (365nm).

[0070] Among them, the visible light LED (400 - 700nm): 16 pieces (each with a power of 3W), evenly distributed for conventional lighting; The near-infrared LED (1550nm): 8 pieces (each with a power of 10W), coaxially installed with the ultrasonic phased array probe 202 and working together, and used to assist in identifying internal debonding defects through thermal imaging; The ultraviolet LED (365nm): 4 pieces (each with a power of 5W), arranged at a 45° angle with the eddy current sensor 201 and synchronously activated, and used to excite the fluorescent penetrant at the surface crack.

[0071] Each band of LED is controlled by an independent drive circuit, and the trigger signal is synchronized with the corresponding sensor (delay ≤ 10ms).

[0072] More specifically, the sensor collaborative detection logic is as follows: The central control module 400 dynamically plans the winding path of the robotic arm 100 according to the laser ranging data of the laser ranging module 206.

[0073] Among them, the laser ranging module 206 scans the surface of the steel member to generate three-dimensional point cloud data (point distance ≤ 2mm); The central control module 400 divides the detection area based on the point cloud data, and preferentially marks high-risk areas such as welds and bolt holes (within a radius of 5cm); And based on the initial scan results of the ultrasonic phased array probe 202, selectively activate the eddy current sensor 201 or the industrial camera 204 for collaborative detection.

[0074] The specific detection process of collaborative detection is as follows: The ultrasonic phased array probe 202 is activated, and the coupling agent injection port 203 sprays a 0.1-mm-thick water-based coupling agent (flow rate: 0.5 mL / s); the elements of the ultrasonic phased array probe 202 emit focused sound beams (deflection angle: ±30°), the scanning speed is 0.5 m / s, and internal defects are detected (resolution ≥ 2 mm).

[0075] When the ultrasonic signal attenuation rate ≥ 15%, the eddy current sensor 201 in the corresponding area is triggered, and the ultraviolet LED (365 nm) is synchronously activated.

[0076] The coil axis deflects adaptively to match the eddy current field with the surface crack orientation, and the detection sensitivity is increased to 0.03 mm.

[0077] The industrial camera 204 takes a thermal imaging map under the illumination of near-infrared light (1550 nm) to identify abnormal temperature in the debonding area (temperature difference ≥ 0.5 °C); it takes a surface topography image in the visible light mode and aligns it with the ultrasonic / eddy current data in terms of time and space (time synchronization error ≤ 1 ms).

[0078] A dynamic curvature matching mechanism 500 signal-connected to the central control module 400 is provided between the multi-modal detection head 200 and the end of the robotic arm 100.

[0079] The dynamic curvature matching mechanism 500 specifically includes a spherical hinge base 501. The spherical hinge base 501 is fixed to the end of the robotic arm 100 through a flange. A piezoelectric ceramic micro-motion regulator 502 is embedded inside the spherical hinge base 501, and the displacement accuracy is ±0.01 mm.

[0080] The dynamic curvature matching mechanism 500 further includes a curved surface fitting detection plate 503. The detection plate 503 is an arc-shaped aluminum alloy plate (curvature radius adaptable from 50 to 500 mm). A 16-point array pressure sensor 505 (range: 0 - 50 N) is mounted on the back of the detection plate 503, and the detection plate 503 is connected to the base 501 through a flexible connecting piece.

[0081] When the detection plate 503 contacts the steel structure surface, the array pressure sensor 505 immediately feeds back the contact pressure distribution to the central control module 400, driving the piezoelectric ceramic micro-motion regulator 502 to adjust the pitch angle and yaw angle of the detection plate 503, so that the deviation between the sound beam axis of the ultrasonic phased array probe 202 and the normal line of the detection surface is ≤ 3°.

[0082] This device further includes a vibration energy recovery module 600, which specifically includes a magnetostrictive energy collector 601, a super capacitor bank 602, and an energy distribution controller 603.

[0083] The magnetostrictive energy harvester 601 is installed at the joint of the robotic arm 100, converting the vibration energy generated when the robotic arm 100 is wound into electrical energy. The magnetostrictive energy harvester 601 is integrated with the piezoelectric fiber composite layer.

[0084] Among them, the magnetostrictive material (Terfenol-D) is arranged along the axial direction of the robotic arm 100, generating a change in magnetic flux under mechanical vibration, capturing low-frequency vibration energy of 1 - 50 Hz, and being more suitable for the low-frequency swaying of large structures such as bridges and pipe trusses.

[0085] Among them, the piezoelectric fiber (PZT) is wound around the outer wall of the joint segment 101 in a spiral structure. Mechanical vibration causes the fiber to bend and deform, generating piezoelectric charges, capturing high-frequency vibration energy of 50 - 200 Hz, and being suitable for scenarios with high-frequency vibration efficient response such as the rapid bending of the robotic arm joint and the micro-movement of the detection head.

[0086] The supercapacitor bank 602 adopts a hybrid design (carbon / graphene electrode) to store the recycled energy. The electrical energy output by both the magnetostrictive material and the piezoelectric fiber is rectified and then connected in parallel to the supercapacitor bank 602.

[0087] The energy distribution controller 603 preferentially supplies the recycled energy to the high-power ultrasonic phased array probe 202, and the remaining energy is supplied to the shape memory alloy wire 103 and other modules.

[0088] In summary, the vibration energy recovery module 600 solves the short board of the endurance of the high-altitude detection device through the innovation of "full-frequency band capture + intelligent distribution", providing the core energy guarantee for unmanned and long-cycle steel structure monitoring.

[0089] This device is also equipped with a modular expansion interface 700, including an end quick-change joint 701 and a wireless communication repeater 702.

[0090] The end quick-change joint 701 adopts a composite design of a permanent magnet and a spring ejector pin to achieve rapid adsorption and precise positioning of the tool. At the same time, it integrates 4 electrical contacts, supporting the expansion tools such as a laser thickness gauge and an electromagnetic ultrasonic probe, which are plug-and-play.

[0091] The circuit board of the wireless communication repeater 702 is embedded in the internal cavity of the joint segment 101 and is connected to the central control module 400 through a flexible circuit, supporting the dual-mode switching of Wi-Fi 6 and LoRa, and realizing data synchronization during multi-device networking detection.

[0092] At the same time, the interface 700 adopts a waterproof and dustproof design. The contact area is covered with a silicone rubber seal, and the shell is made of anodized aluminum alloy, adapting to the harsh outdoor detection environment.

[0093] The implementation principle of a sensor-based building steel structure engineering detection device in an embodiment of this application is as follows: The laser ranging module 206 scans the surface of the steel structure to generate a three-dimensional point cloud model with millimeter-level accuracy; the central control module 400 divides high-risk areas (welds, bolt holes) and ordinary areas, plans the winding path of the robotic arm 100, and the dynamic obstacle avoidance algorithm bypasses obstacles such as rivets and weld protrusions; the pneumatic drive cavity 102 inflates to bend the joint segment 101, and the shape memory alloy wire 103 contracts to drive the pre-tightening belt 301 to tighten, and the self-tightening winding mechanism 300 forms a wrapped contact, and the pressure feedback unit 302 maintains pressure stability.

[0094] The ultrasonic phased array probe 202 sprays the coupling agent and emits a focused sound beam to scan for internal defects. When a suspicious area (ultrasonic signal attenuation ≥ 15%) is detected, the coordinates are marked; the central control module 400 triggers the eddy current sensor 201 in the corresponding area, and the ultraviolet LED (365 nm) excites the fluorescence of surface cracks; the coil axis adaptively deflects (0° - 15°) to detect surface cracks at the 0.03 mm level; the industrial camera 204 takes a thermal image under near-infrared light (1550 nm) to identify internal debonding (temperature difference ≥ 0.5°C); the surface topography is recorded in the visible light mode and spatially and temporally aligned with the ultrasonic / eddy current data.

[0095] It should be noted that, without conflict, the embodiments and features in the embodiments of this application can be combined with each other, and any combination of features in different embodiments is also within the protection scope of this application. That is to say, the above-described multiple embodiments can also be arbitrarily combined according to actual needs.

[0096] It should be noted that all the above drawings are exemplary illustrations of this application and do not represent the actual size of the product. Also, the dimensional proportional relationship between components in the drawings is not a limitation on the actual product of this application. The above are all the preferred embodiments of this application. It does not limit the protection scope of this application accordingly. Therefore, any equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. A sensor-based detection device for building steel structure projects, characterized in that, Comprising: A segmented bionic robotic arm (100), which is composed of at least 6 independently bendable joint segments (101) connected in series. An air-driven cavity (102) and shape memory alloy wires (103) are arranged inside each joint segment (101). The shape memory alloy wires (103) are evenly distributed circumferentially and the shrinkage rate is controlled by current. A self-tightening winding mechanism (300), which includes a pre-tightening belt (301) surrounding the outer wall of the robotic arm (100) and a pressure feedback unit (302). The pre-tightening belt (301) forms a wrapped contact with the steel structure surface through the shrinkage force of the shape memory alloy wires (103), and the pressure feedback unit (302) adjusts the current in real time to maintain the contact pressure within the range of 5 - 20 N. A multi-modal detection head (200), which is fixed at the end of the robotic arm (100) and integrates: An eddy current sensor (201), whose coil axis adaptively deflects at an angle of 0° - 15° with respect to the normal of the detection surface. An ultrasonic phased array probe (202), with a retractable couplant injection port (203) built-in. A high-resolution industrial camera (204), equipped with an annular fill light (205) and a laser ranging module (206). Also included is A central control module (400), which is signal-connected to the robotic arm (100) and the multi-modal detection head (200). It dynamically plans the winding path of the robotic arm (100) according to the laser ranging data of the laser ranging module (206), and selectively activates the eddy current sensor (201) or the industrial camera (204) for collaborative detection based on the initial scanning results of the ultrasonic phased array probe (202).

2. The detection device according to claim 1, wherein: The surface of the joint segment (101) is covered with an environment-responsive flexible skin (104), which is composed of an interweaving of a shape memory polymer (105) and piezoresistive sensing fibers (106), where: The piezoresistive sensing fibers (106) monitor the temperature and humidity changes on the surface of the steel member in real time, and dynamically adjust the driving current of the shape memory alloy wires (103) through the central control module (400). The shape memory polymer (105) automatically expands to form anti-slip textures when the temperature ≥ 35°C, and shrinks to reduce the joint movement resistance when the temperature ≤ 5°C.

3. The detection device according to claim 1, wherein: The shrinkage rate of the shape memory alloy wires (103) and the tension value of the pre-tightening belt (301) are closed-loop controlled by a PID algorithm, and the response time ≤ 0.5 seconds.

4. The detection device according to claim 1, characterized in that: The pre-tightening belt (301) adopts an asymmetric tooth-shaped structure, and the inner tooth height (H1) and the outer tooth height (H2) satisfy H1 / H2 = 0.3 - 0.6, and: The inner tooth surface is serrated, and the friction coefficient with the steel structure surface ≥ 0.

8. The outer tooth surface is a smooth arc, and forms an angle of 15° - 30° with the shrinkage direction of the shape memory alloy wires (103), which is used to convert the alloy shrinkage force into a radial pressing force.

5. The detection device according to claim 1, characterized in that: A dynamic curvature matching mechanism (500) signal-connected to the central control module (400) is provided between the multi-modal detection head (200) and the end of the robotic arm (100), specifically including: A spherical hinge base (501), inside which a piezoelectric ceramic micro-motion regulator (502) is embedded. The curved surface fitting detection board (503) is connected to the spherical hinge base (501) through a flexible connecting piece (504), and an array of pressure sensors (505) is provided on the back of the detection board (503). When the detection board (503) contacts the surface of the steel structure, the array of pressure sensors (505) feeds back the contact pressure distribution to the central control module (400) in real time, driving the piezoelectric ceramic micro-regulator (502) to adjust the pitch angle and yaw angle of the detection board (503), so that the deviation between the sound beam axis of the ultrasonic phased array probe (202) and the normal line of the detection surface is ≤ 3°.

6. The detection device according to claim 1, characterized in that: The ultrasonic phased array probes (202) and the eddy current sensors (201) are arranged in an interleaved manner, and the overlap degree of their detection areas is ≥ 85%, and the field of view angle of the industrial camera (204) covers the boundaries of their detection areas.

7. The detection device according to claim 1, characterized in that: The annular supplementary light (205) of the industrial camera (204) includes a multi-spectral light-emitting unit, and its spectral range covers the visible light of 400 - 700 nm, the near-infrared of 900 - 1700 nm, and the ultraviolet of 365 nm band, and: The ultraviolet band light source is synchronously activated with the eddy current sensor (201) to excite the fluorescent penetrant at the surface crack. The near-infrared band light source works in cooperation with the ultrasonic phased array probe (202) to assist in identifying internal debonding defects through thermal imaging.

8. The detection device according to claim 1, wherein: It also includes a vibration energy recovery module (600), specifically including, A magnetostrictive energy harvester (601) is installed at the joint of the robotic arm (100) to convert the vibration energy during the winding of the robotic arm (100) into electrical energy; A supercapacitor bank (602) stores the recovered energy and powers the shape memory alloy wire (103); An energy distribution controller (603) preferentially supplies the recovered energy to the high-power-consuming ultrasonic phased array probe (202).

9. The detection device according to claim 8, characterized in that: The magnetostrictive energy harvester (601) of the vibration energy recovery module (600) is integrated with a piezoelectric fiber composite layer, where: The magnetostrictive material (Terfenol-D) is arranged along the axial direction of the robotic arm (100) to capture low-frequency vibration energy of 1 - 50 Hz; Piezoelectric fibers (PZT) are wound around the outer wall of the joint section (101) in a spiral structure to capture high-frequency vibration energy of 50 - 200 Hz; The electrical energy output by both is rectified and then connected in parallel to the supercapacitor bank (602).

10. The detection device according to claim 1, characterized in that: The device is equipped with a modular expansion interface (700), including: A quick-change end connector (701) supports expansion tools such as a laser thickness gauge and an electromagnetic ultrasonic probe; A wireless communication repeater (702) is embedded inside the joint section (101) to achieve data synchronization during multi-device networking detection; The interface (700) adopts a waterproof and dustproof design to adapt to harsh outdoor detection environments.

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