Sensor-based building steel structure engineering detection device

Abstract

The application provides a kind of based on sensor's building steel structure engineering detection device, it is related to building steel structure engineering detection field.Detection device includes: segmented bionic mechanical arm, it is made of at least 6 independently bendable joint section series connection, each joint section is equipped with pneumatic drive cavity and shape memory alloy wire;Self-tight winding mechanism, including pre-tightening band and pressure feedback unit around the outer wall of mechanical arm;Multi-modal detection head, fixed at the end of mechanical arm, integrated with: eddy current sensor, ultrasonic phased array probe, high-resolution industrial camera;Further comprising, central control module, with mechanical arm and multi-modal detection head signal connection, according to the laser ranging data of laser ranging module dynamic planning mechanical arm winding path, and based on the initial scanning result of ultrasonic phased array probe, selectively start eddy current sensor or industrial camera for collaborative detection.Adapt to complex topography, synchronous completion multi-type defect detection and environmental interference resistance effect 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

[0002] At present, building steel structures may have problems such as deformation, cracks, corrosion and the like after long-term use, and need to be regularly detected. The existing detection methods include manual inspection, fixed sensor monitoring and the like.

[0003] However, the traditional detection methods have obvious problems, such as the detection accuracy being affected due to the narrow space in complex welding joints, special-shaped connecting parts and the like; cracks, corrosion, deformation and the like defects needing to be detected by using eddy current, ultrasonic and visual equipment multiple times, which is time-consuming and the data is difficult to be synchronized; and the problems such as poor stability in high-altitude environment, insufficient adaptability of sensors and the like. Therefore, an intelligent detection device capable of self-adapting to complex topography, synchronously completing multiple types of defect detection and resisting environmental interference is urgently needed. SUMMARY

[0004] The embodiment of the present application provides a building steel structure engineering detection device based on sensors, which solves the problems of difficult detection of complex joints, low identification efficiency of multiple defect types and poor stability in high-altitude environment.

[0005] The embodiment of the present application adopts the following technical scheme:

[0006] A building steel structure engineering detection device based on sensors comprises:

[0007] A segmented bionic mechanical arm is composed of at least 6 joints that can be independently bent in series, a pneumatic driving cavity and a shape memory alloy wire are arranged in each joint, the shape memory alloy wire is uniformly distributed in the circumferential direction and the contraction rate is controlled by electric current;

[0008] A self-tight winding mechanism comprises a pre-tightening belt surrounding the outer wall of the mechanical arm and a pressure feedback unit, the pre-tightening belt forms a cladding contact with the surface of the steel structure through the contraction force of the shape memory alloy wire, and the pressure feedback unit adjusts the electric current in real time to maintain the contact pressure in the range of 5-20N;

[0009] A multi-modal detection head is fixed to the end of the mechanical arm and integrates:

[0010] An eddy current sensor, the coil axis of which is adaptively deflected at 0°-15° with the normal of the detection surface;

[0011] An ultrasonic phased array probe, which has a built-in retractable coupling agent injection port;

[0012] A high-resolution industrial camera, which is equipped with a ring-shaped light supplementing lamp and a laser ranging module;

[0013] Also included,

[0014] The central control module is in signal connection with the mechanical arm and the multi-modal 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 for cooperative detection based on initial scanning results of the ultrasonic phased array probe.

[0015] By adopting the technical scheme, the segmented bionic mechanical arm realizes 360° coverage of the steel member through winding, covers the blind area of the special-shaped structure, and solves the problem that the traditional rigid probe cannot be attached, so that the detection coverage is greatly improved.

[0016] Secondly, the self-tight winding mechanism maintains stable contact pressure through pressure feedback closed-loop control, and the pressure fluctuation is still small even under 6-level wind vibration.

[0017] And the multi-modal detection head (eddy current + ultrasonic + vision) integrates cooperative detection, completes multi-type defect identification in a single operation, triggers eddy current fine measurement after ultrasonic initial scanning positioning, and data fusion greatly improves defect identification accuracy.

[0018] Finally, the central control module intelligently switches the detection mode according to the ultrasonic initial scanning result to realize multi-modal data fusion.

[0019] In summary, through the structural design of "bionic winding + multi-sensor cooperative decision", the limitations of separation of mechanical arm and detection logic in the prior art are broken through, not only the principles of bionics and multi-modal sensing technology are cross-integrated, but also the detection mode is self-optimized through real-time interaction of sensor data, and the shape memory alloy simultaneously undertakes the functions of structure driving and contact pressure adjustment, finally realizing intelligent detection effect of self-adapting to complex topography, synchronously completing multi-type defect detection and resisting environmental interference.

[0020] In an optional implementation, the surface of the joint segment is covered with an environment-responsive flexible skin composed of shape memory polymer and piezoresistive sensing fiber, wherein:

[0021] The piezoresistive sensing fiber monitors the temperature and humidity changes of the surface of the steel member in real time, and dynamically adjusts the driving current of the shape memory alloy wire through the central control module;

[0022] The shape memory polymer automatically expands to form anti-slip texture when the temperature is greater than or equal to 35℃, and shrinks to reduce the joint movement resistance when the temperature is less than or equal to 5℃.

[0023] By adopting the technical scheme, the environmental adaptive material solves the problem of mechanical arm slipping or jamming caused by high-altitude temperature difference, effectively improves the detection stability in-10℃ to 50℃ environment, and does not need manual intervention for environmental adaptability adjustment.

[0024] In an optional implementation, the contraction 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 is ≤0.5 seconds.

[0025] By adopting the technical scheme, the shape memory alloy current is adjusted in real time by the PID algorithm, the wind vibration or structural vibration interference is quickly offset, the standard deviation of the contact pressure is effectively reduced, and the probe is ensured to be closely attached.

[0026] In an optional implementation, the pre-tightening belt adopts an asymmetric tooth structure, the inner side tooth height (H1) and the outer side tooth height (H2) satisfy H1 / H2=0.3-0.6, and:

[0027] The inner side tooth surface is sawtooth-shaped, and the friction coefficient with the steel structure surface is ≥0.8;

[0028] The outer side tooth surface is a smooth arc, and the angle between the smooth arc and the contraction direction of the shape memory alloy wire is 15°-30°, which is used for converting the alloy contraction force into a radial compression force.

[0029] By adopting the technical scheme, the smooth arc on the outer side converts the shape memory alloy contraction force into a radial compression force, the alloy driving force is amplified by multiple times through mechanical structure innovation, and the contact pressure greatly exceeds the pressure of the traditional symmetric structure under the same current.

[0030] In an optional implementation, a dynamic curvature matching mechanism connected with the central control module is arranged between the multi-modal detection head and the end of the mechanical arm, and specifically includes:

[0031] A spherical hinge base, in which a piezoelectric ceramic micro-motion regulator is embedded;

[0032] A curved surface detection plate connected with the spherical hinge base through a flexible connecting piece, and an array type pressure sensor is arranged on the back surface of the detection plate;

[0033] When the detection plate contacts the surface of the steel structure, the array type pressure sensor feeds back the contact pressure distribution to the central control module in real time, and the piezoelectric ceramic micro-motion regulator is driven to adjust the pitch angle and the yaw angle of the detection plate, so that the deviation between the acoustic beam axis of the ultrasonic phased array probe and the normal line of the detection surface is ≤3°.

[0034] By adopting the technical scheme, the precision of the probe and the curved surface is solved, the acoustic beam refraction error of the traditional fixed-angle probe on the curved surface is compared, and the detection signal-to-noise ratio is effectively improved.

[0035] In an optional implementation, the ultrasonic phased array probe and the eddy current sensor are arranged in a staggered manner, the coincidence degree of the detection areas of the two is ≥85%, and the field angle of the industrial camera covers the boundaries of the detection areas.

[0036] By adopting the technical scheme, the coincidence degree of ultrasonic detection and eddy current detection is greater than or equal to 85%, an industrial camera covers a boundary area, data space alignment is ensured, multi-modal data fusion efficiency is improved, and detection time is shortened.

[0037] In an optional implementation, the annular light supplement lamp of the industrial camera comprises a multi-spectrum light emitting unit, a spectrum range of the multi-spectrum light emitting unit covers a visible light 400-700 nm, a near-infrared 900-1700 nm and an ultraviolet 365 nm wave band, and

[0038] The ultraviolet wave band light source is synchronously activated with the eddy current sensor, and is used for exciting a fluorescent penetrant at a surface crack;

[0039] The near-infrared wave band light source cooperates with the ultrasonic phased array probe, and internal debonding defects are identified through thermal imaging assistance.

[0040] By adopting the technical scheme, the limitation of a single spectrum in traditional visual detection is broken through, and cross verification of surface or subsurface defects is realized through a spectrum and sensing linkage mechanism.

[0041] In an optional implementation, the vibration energy recovery module specifically comprises,

[0042] A magnetostrictive energy collector is installed at a joint of the mechanical arm, and converts vibration energy when the mechanical arm is wound into electrical energy;

[0043] A super capacitor group stores recovered energy and supplies power to the shape memory alloy wire;

[0044] An energy distribution controller preferentially supplies recovered energy to the ultrasonic phased array probe with high power consumption.

[0045] By adopting the technical scheme, a power supply problem in high-altitude operation is solved, a continuous operation time is prolonged, and an external charging frequency is reduced.

[0046] In an optional implementation, the magnetostrictive energy collector of the vibration energy recovery module is integrated with a piezoelectric fiber composite layer, wherein:

[0047] A magnetostrictive material (Terfenol-D) is arranged in an axial direction of the mechanical arm, and captures low-frequency vibration energy 1-50 Hz;

[0048] A piezoelectric fiber (PZT) is wound on an outer wall of a joint section in a spiral structure, and captures high-frequency vibration energy 50-200 Hz;

[0049] Output electrical energy of the two is rectified and then input into the super capacitor group in parallel.

[0050] By adopting the technical scheme, multi-frequency band vibration energy is cooperatively collected, energy density is improved by multiple times compared with a single mode, and the technical scheme is especially suitable for a complex vibration environment of a steel structure.

[0051] In an optional implementation, the device is equipped with a modular expansion interface, comprising:

[0052] An end quick-change connector supports laser thickness gauges and electromagnetic ultrasonic probe expansion tools;

[0053] A wireless communication repeater is embedded in the joint segment to achieve data synchronization during multi-device networking detection.

[0054] The interface adopts a waterproof and dustproof design to adapt to outdoor harsh detection environments.

[0055] By using the above technical solutions, the detection function is flexibly expanded through a standardized interface, and the networking detection efficiency is improved by multiple times, especially for large net rack structures.

[0056] In summary, the present application includes at least one of the following beneficial technical effects:

[0057] 1. The bionic mechanical arm can wrap around steel members with a diameter of 50-800mm, including H-shaped steel, round pipes, etc., achieving 360° coverage without dead angles, greatly improving the detection coverage of complex nodes. The self-tightening mechanism of shape memory alloy ensures that the device maintains minimal contact pressure fluctuations under 6-level wind vibration, ensuring detection stability and achieving omnidirectional adaptive detection.

[0058] 2. The ultrasonic probe preferentially scans internal defects, and automatically triggers the eddy current sensor for surface crack precision measurement after detecting suspicious areas. Dual-mode data fusion greatly improves defect identification accuracy, and an industrial camera synchronously records the surface topography, aligning with the defect detection data in space and time to generate a three-dimensional defect distribution map, thereby realizing multi-modal collaborative detection.

[0059] 3. A single detection can complete the traditional 3-step task, greatly reducing the detection time, and eliminating the need for scaffolding or hangers, reducing human intervention, meeting high-altitude operation safety standards, and optimizing work efficiency and cost. BRIEF DESCRIPTION OF DRAWINGS

[0060] Figure 1 is a schematic diagram of the overall structure of the detection device.

[0061] Figure 2 is a schematic diagram of the internal structure of the joint segment.

[0062] Figure 3 is a block diagram of the overall structure of the detection device.

[0063] Explanation of reference signs: 100, mechanical arm; 101, joint segment; 102, pneumatic driving 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, ring-shaped fill light; 206, laser ranging module; 300, self-tight 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-motion regulator; 503, detection plate; 504, flexible connecting sheet; 505, pressure sensor; 600, vibration energy recovery module; 601, magnetostrictive energy harvester; 602, super capacitor group; 603, energy distribution controller; 700, modular expansion interface; 701, end quick-change connector; 702, wireless communication repeater. DETAILED DESCRIPTION

[0064] The application will be further described below in conjunction with all the accompanying drawings in the embodiments of the application.

[0065] In the description of the embodiments of the application, it should be explained that, unless otherwise explicitly specified and limited, the terms “mounting”, “connection” should be understood in a broad sense, for example, “connection” can be detachable connection, or can be non-detachable connection; can be direct connection, or can be indirect connection through intermediate medium. Among them, “fixed connection” refers to the connection of each other and the relative position relationship after the connection does not change. It should be understood that when component A is fixedly connected with component C through component B, the relative position relationship change due to the deformation of component A, component B and component C is allowed. Among them, the two components are integrated into an integrated structure by an integrated molding process, which means that during the formation of one of the two components, the component is connected with the other component, and the two components do not need to be connected together by reprocessing (such as bonding, welding, buckling connection, screw connection) method.

[0066] The orientation terms mentioned in the embodiments of the application, such as “upper”, “lower”, “lateral” and the like, are only the directions of the drawings, therefore, the orientation terms used are for better and clearer illustration and understanding of the embodiments of the application, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, therefore, it cannot be understood as a limitation on the embodiments of the application.

[0067] The term "plurality" means at least two. The term "above" includes the number itself. The term "and / or" is a description of an association relationship between associated objects, indicating that three relationships may exist. For example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone. Terms such as "first" and "second" are used for descriptive purposes only and cannot be understood as implying or suggesting relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features.

[0068] The embodiment of the present application discloses a sensor-based building steel structure engineering detection device.

[0069] Reference Figure 1 and Figure 2 A sensor-based building steel structure engineering inspection device includes a segmented bionic robotic arm 100, which is composed of at least 6 independently bendable joint segments 101 connected in series. Based on the bionic principles of octopus tentacles, the multi-joint series structure can achieve continuous bending and winding in three-dimensional space, and is suitable for steel components with a diameter of 50-800mm (such as H-shaped steel, round tubes, special-shaped nodes, etc.).

[0070] The robotic arm can conduct autonomous winding inspection, and a single operation can cover a 5-8 meter steel structure section (manual inspection takes 2-3 hours, while this device only takes 20 minutes), increasing efficiency by more than 6 times. At the same time, there is no need to build scaffolding or hanging basket, and manual intervention is reduced by 80%, complying with safety regulations for high-altitude operations.

[0071] Specifically, each joint segment 101 is a hollow cylinder (outer diameter 80 mm, length 120 mm), made of carbon fiber composite material, and adopts a lightweight design to reduce the overall mass while also ensuring a tensile strength ≥ 3.5 GPa to avoid deformation due to load or vibration.

[0072] Each joint segment 101 is provided with a pneumatic drive cavity 102, which is connected to an external air pump via a flexible air tube. Pneumatic drive has high power density and flexibility, preventing rigid collision from damaging the steel structure surface.

[0073] The pneumatic drive cavity 102 is provided with three groups of independent air cavities along the axial direction of the joint segment 101. The inflation and deflation of each group of air cavities are controlled by a micro electromagnetic valve, and the air pressure range is 0.1-0.5 MPa.

[0074] A shape memory alloy wire 103 is also provided in each joint segment 101. The shape memory alloy wire 103 is made of Ni-Ti alloy wire (diameter 0.3 mm). The end of the shape memory alloy wire 103 is fixed to the end of the joint segment 101, and mechanical fixation and circuit conduction are achieved by locking bolts.

[0075] The shape memory alloy wire 103 is uniformly embedded along the circumference of the joint segment 101 in 6 groups, each group containing 4 parallel alloy wires, and the shrinkage rate can reach 8% (current 0.5-3A) after being electrified, providing auxiliary driving force and self-tightening adjustment function.

[0076] Correspondingly, adjacent joint segments 101 are connected through universal joints, and the universal joints are built-in conductive slip rings to realize independent power supply of the shape memory alloy wires 103 in each joint segment 101.

[0077] The shape memory alloy wire 103 is combined with the pneumatic driving cavity 102, which can still maintain a contact pressure fluctuation of <±5N (traditional magnetic attraction device fluctuation ±30%) under 6 levels of wind vibration, realize high-precision motion control, and enhance the contact pressure stability during winding.

[0078] The mechanical arm 100 is provided with a self-tightening winding mechanism 300, and the self-tightening winding mechanism 300 comprises a pre-tightening belt 301 surrounding the outer wall of the mechanical arm 100. The pre-tightening belt 301 slides around the outer wall of the mechanical arm 100 through a sliding block guide rail, and the guide rail spacing matches the length of the joint segment 101.

[0079] The pre-tightening belt 301 adopts a polyurethane-based composite material belt, and the pre-tightening belt 301 forms a cladding contact with the surface of the steel structure through the shrinkage force of the shape memory alloy wire 103.

[0080] Among them, the inside of the pre-tightening belt 301 is molded with an asymmetric tooth structure, the inside tooth height (H1=1.5mm) and the outside tooth height (H2=3mm) satisfy H1 / H2=0.5, and:

[0081] The inside tooth surface is sawtooth-shaped, coated with silicon carbide particles (particle size 50μm), and the friction coefficient with the surface of the steel structure is ≥0.8;

[0082] The outside tooth surface is a smooth arc, and the angle between the shrinkage direction of the shape memory alloy wire 103 and the outside tooth surface is 20°, which converts the alloy shrinkage force into radial compression force through mechanical amplification effect.

[0083] In addition, the self-tightening winding mechanism 300 also comprises a pressure feedback unit 302, and the pressure feedback unit 302 is embedded in the middle of the pre-tightening belt 301 and is connected with a central control module 400 through a flexible circuit.

[0084] The pressure feedback unit 302 adopts an integrated thin film pressure sensor (sensitivity 0.1N) and a PID controller (response time ≤0.5 seconds), which can collect the pressure signal of the pre-tightening belt 301 in real time and feed back to the central control module 400.

[0085] Specifically, when the measured pressure of the pre-tensioning band 301 exceeds the range of 5-20N, the PID algorithm dynamically adjusts the current of the shape memory alloy wire 103 (adjustment step 0.1A), and the pressure feedback unit 302 maintains the contact pressure of the pre-tensioning band 301 within the range of 5-20N by adjusting the current in real time.

[0086] The shrinkage rate of the shape memory alloy wire 103 and the tension value of the pre-tightening belt 301 are controlled in a closed loop by a PID algorithm, and the response time is ≤0.5 seconds.

[0087] Specifically, when the robotic arm 100 wraps around a steel structure, the pre-tensioning belt 301 slides along the guide rail and adapts to the diameter of the structure; the shape memory alloy wire 103 contracts when energized, driving the pre-tensioning belt 301 to tighten, forming a uniform wrapping contact; the serrated surface of the pre-tensioning belt 301 engages with the surface of the steel structure to prevent slippage.

[0088] Reference Figure 1 and Figure 3 Each joint segment 101 is covered with an environmentally responsive flexible skin 104, 2 mm thick. This skin 104 is bonded to the outer wall of the joint segment 101 via a heat-pressing process, with a waterproof seal around the edges. The skin 104 is constructed from a shape memory polymer 105 interwoven with piezoresistive sensing fibers 106.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] When the humidity is greater than or equal to 80% RH, the resistance change of the piezoresistive sensing fiber 106 triggers a pre-warning, and the central control module 400 starts high-frequency ultrasonic detection (200 Hz) to exclude the interference of the water film on the eddy current signal, thereby reducing the false alarm rate of the sensor.

[0095] The mechanical arm 100 is fixed at the end with a multi-modal detection head 200, which is rigidly connected to the end of the mechanical arm 100 through a flange. The multi-modal detection head 200 is signal connected to the central control module 400, and is integrated with an eddy current sensor 201, an ultrasonic phased array probe 202, and a high-resolution industrial camera 204.

[0096] The eddy current sensor 201 has four groups in a diamond distribution, each group having a coil diameter of 20 mm, and the coil axis is adaptively deflected by 0°-15° from the normal direction of the detection surface through a micro steering engine.

[0097] The ultrasonic phased array probe 202 is a 32-element linear array (center frequency 5 MHz), which is installed in the gap between the eddy current sensor 201, with an element spacing of 1.5 mm. The ultrasonic phased array probe 202 is provided with a built-in retractable coupling agent jet port 203.

[0098] The ultrasonic phased array probe 202 and the eddy current sensor 201 are arranged in a staggered manner, and the coincidence degree of the detection areas of the two is greater than or equal to 85%.

[0099] The high-resolution industrial camera 204 uses a 20 million pixel CMOS sensor (frame rate 30 fps), and the field of view of the industrial camera 204 covers the boundary of the detection areas of the ultrasonic phased array probe 202 and the eddy current sensor 201.

[0100] The high-resolution industrial camera 204 is equipped with a ring-shaped light supplement lamp 205 and a laser ranging module 206. The laser ranging module 206 includes a TOF laser sensor (range 0.1-10 m, accuracy ±1 mm), which is symmetrically arranged on both sides of the industrial camera 204.

[0101] Specifically, the ring-shaped light supplement lamp 205 includes a multi-spectral light emitting unit, which comprises a ring-shaped bracket with surface anodic oxidation treatment and three-waveband LEDs embedded in the ring-shaped bracket. The three-waveband LEDs are visible light LEDs (400-700 nm), near-infrared LEDs (1550 nm), and ultraviolet LEDs (365 nm).

[0102] Among them, the visible light LED (400-700 nm): 16 (each power 3W), uniformly distributed for regular lighting;

[0103] The near-infrared LED (1550 nm): 8 (each power 10W), coaxially installed with the ultrasonic phased array probe 202 and cooperatively working, and assisting in identifying internal debonding defects through thermal imaging.

[0104] UV LED (365nm): 4 pieces (5W each), arranged at a 45° angle with the eddy current sensor 201 and activated synchronously, for exciting fluorescent penetrant at surface cracks.

[0105] Each waveband LED is controlled by an independent drive circuit, and the trigger signal is synchronized with the corresponding sensor (delay ≤10ms).

[0106] More specifically, the sensor coordination detection logic is:

[0107] The central control module 400 dynamically plans the winding path of the mechanical arm 100 according to the laser ranging data of the laser ranging module 206.

[0108] Wherein, the laser ranging module 206 scans the surface of the steel member to generate three-dimensional point cloud data (point distance ≤2mm);

[0109] The central control module 400 divides the detection area based on the point cloud data, and preferentially marks high-risk areas (radius 5cm range) such as welds and bolt holes;

[0110] And based on the initial scanning results of the ultrasonic phased array probe 202, the eddy current sensor 201 or the industrial camera 204 is selectively started for cooperative detection.

[0111] The specific detection process of cooperative detection is: the ultrasonic phased array probe 202 is started, the coupling agent spraying port 203 sprays 0.1mm thick water-based coupling agent (flow rate 0.5mL / s); the ultrasonic phased array probe 202 array element emits focused sound beam (deflection angle ±30°), scanning speed 0.5m / s, detects internal defects (resolution ≥2mm).

[0112] When the ultrasonic signal attenuation rate is ≥15%, the corresponding area of the eddy current sensor 201 is triggered, and the UV LED (365nm) is activated synchronously.

[0113] The coil axis is self-adaptive to deflect, so that the eddy current field matches the surface crack direction, and the detection sensitivity is improved to 0.03mm.

[0114] The industrial camera 204 takes a thermal imaging picture under near-infrared light (1550nm) irradiation, identifies temperature anomalies (temperature difference ≥0.5℃) in debonding areas; in visible light mode, the surface topography is photographed, and the ultrasonic / eddy current data is spatio-temporally aligned (time synchronization error ≤1ms).

[0115] A dynamic curvature matching mechanism 500 connected to the central control module 400 is provided between the multi-modal detection head 200 and the end of the mechanical arm 100.

[0116] The dynamic curvature matching mechanism 500 specifically comprises a spherical joint base 501 fixed at the end of the mechanical arm 100 through a flange, and a piezoelectric ceramic micro-motion adjuster 502 embedded in the spherical joint base 501, with a displacement accuracy of ±0.01 mm.

[0117] The dynamic curvature matching mechanism 500 further comprises a curved surface fitting detection plate 503, which is an arc-shaped aluminum alloy plate (with a curvature radius adaptively 50-500 mm), and a 16-point array type pressure sensor 505 (with a measuring range of 0-50 N) attached to the back of the detection plate 503. The detection plate 503 is connected to the base 501 through a flexible connecting piece.

[0118] When the detection plate 503 contacts the surface of the steel structure, the array type pressure sensor 505 feeds back the contact pressure distribution to the central control module 400 in real time, and the piezoelectric ceramic micro-motion adjuster 502 adjusts the pitch angle and yaw angle of the detection plate 503, so that the acoustic beam axis of the ultrasonic phased array probe 202 deviates from the normal of the detection surface by ≤3°.

[0119] The device further comprises a vibration energy recovery module 600, specifically including a magnetostrictive energy harvester 601, a super capacitor group 602, and an energy distribution controller 603.

[0120] The magnetostrictive energy harvester 601 is installed at the joint of the mechanical arm 100, and converts the vibration energy generated when the mechanical arm 100 is wound into electrical energy. The magnetostrictive energy harvester 601 is integrated with the piezoelectric fiber composite layer.

[0121] The magnetostrictive material (Terfenol-D) is arranged in the axial direction of the mechanical arm 100, and generates a change in magnetic flux under mechanical vibration, capturing low-frequency vibration energy 1-50 Hz, which is suitable for low-frequency shaking of large structures such as bridges and pipe trusses.

[0122] The piezoelectric fiber (PZT) is wound in a spiral structure on the outer wall of the joint segment 101, and the mechanical vibration causes the fiber to bend and deform, generating piezoelectric charge, capturing high-frequency vibration energy 50-200 Hz, which is suitable for high-frequency vibration efficient response scenarios such as rapid bending of the mechanical arm joint and micro-motion of the detection head.

[0123] The super capacitor group 602 adopts a hybrid design (carbon / graphene electrode) to store and recover energy. The output electrical energy of the magnetostrictive material and the piezoelectric fiber is rectified and then input into the super capacitor group 602 in parallel.

[0124] The energy distribution controller 603 preferentially supplies the recovered energy to the ultrasonic phased array probe 202 with high power consumption, and supplies the remaining energy to the shape memory alloy wire 103 and other modules.

[0125] In summary, the vibration energy recovery module 600 solves the short endurance of high-altitude detection devices through the "full-band capture + intelligent distribution" innovation, and provides core energy support for unmanned and long-period steel structure monitoring.

[0126] The device is also equipped with a modular expansion interface 700, including a terminal quick-change connector 701 and a wireless communication repeater 702.

[0127] The terminal quick-change connector 701 adopts a composite design of permanent magnet and spring thimble, realizes rapid adsorption and accurate positioning of tools, and simultaneously integrates 4 electrical contacts to support laser thickness gauges and electromagnetic ultrasonic probe extension tools, that is, plug and play.

[0128] The circuit board of the wireless communication repeater 702 is embedded in the internal cavity of the joint segment 101, is connected with the central control module 400 through a flexible circuit, supports Wi-Fi 6 and LoRa dual-mode switching, and realizes data synchronization in multi-device networking detection.

[0129] Meanwhile, the interface 700 adopts a waterproof and dustproof design, the contact area is covered with a silica gel sealing ring, and the shell adopts an anodized aluminum alloy, which is suitable for outdoor harsh detection environments.

[0130] The implementation principle of the building steel structure engineering detection device based on a sensor according to an embodiment of the present 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 precision; the central control module 400 divides high-risk areas (welds, bolt holes) and ordinary areas, plans a winding path of the mechanical arm 100, and a dynamic obstacle avoidance algorithm bypasses obstacles such as rivets and weld protrusions; the pneumatic driving cavity 102 inflates the curved joint segment 101, the shape memory alloy wire 103 shrinks to drive the pre-tightening belt 301 to tighten, the self-tightening winding mechanism 300 forms a cladding contact, and the pressure feedback unit 302 maintains stable pressure.

[0131] The ultrasonic phased array probe 202 sprays a coupling agent, emits a focused sound beam to scan internal defects, and marks coordinates when a suspicious area (ultrasonic signal attenuation ≥ 15%) is detected; the central control module 400 triggers the eddy current sensor 201 in the corresponding area, the ultraviolet LED (365 nm) excites surface crack fluorescence; the coil axis is adaptively deflected (0°-15°) to detect 0.03 mm level surface cracks; the industrial camera 204 shoots a thermal imaging graph under near-infrared light (1550 nm) to identify internal debonding (temperature difference ≥ 0.5℃); and the surface morphology is recorded in the visible light mode, and is spatiotemporally aligned with the ultrasonic / eddy current data.

[0132] It should be noted that, in the case of no conflict, the embodiments in the present application and the features in the embodiments can be combined with each other, and any combination of features in different embodiments is also within the protection scope of the present application, that is, the multiple embodiments described above can also be combined as needed.

[0133] It should be noted that all the above drawings are exemplary illustrations of the present application, and do not represent the actual size of the product. The size ratio relationship between the components in the drawings is not limited to the actual product of the present application

[0134] The above are preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. Therefore, equivalent changes made in the structure, shape, and principle of the present application should be covered within the protection scope of the present application.

Claims

1. A sensor-based building steel structure engineering detection device, characterized in that, The application relates to a segmented bionic mechanical arm (100) which is composed of at least six independently bendable joint segments (101) in series, each of the joint segments (101) is internally provided with a pneumatic driving cavity (102) and a shape memory alloy wire (103), the shape memory alloy wire (103) is uniformly distributed in the circumferential direction and the contraction rate of the shape memory alloy wire (103) is controlled by electric current; a self-tight winding mechanism (300) which comprises a pre-tightening belt (301) surrounding the outer wall of the mechanical arm (100) and a pressure feedback unit (302), the pre-tightening belt (301) forms a cladding contact with the surface of the steel structure through the contraction force of the shape memory alloy wire (103), and the pressure feedback unit (302) adjusts the electric current in real time to maintain the contact pressure in the range of 5-20 N; a multi-modal detection head (200) which is fixed to the end of the mechanical arm (100) and is integrated with a vortex sensor (201), the coil axis of the vortex sensor (201) is adaptively deflected at an angle of 0-15 DEG with the normal of the detection surface; an ultrasonic phased array probe (202) which is internally provided with a retractable coupling agent spraying port (203); a high-resolution industrial camera (204) which is equipped with a ring-shaped light supplementing lamp (205) and a laser ranging module (206); a central control module (400) which is in signal connection with the mechanical arm (100) and the multi-modal detection head (200), dynamically plans the winding path of the mechanical arm (100) according to the laser ranging data of the laser ranging module (206), and selectively starts the vortex sensor (201) or the industrial camera (204) for cooperative detection based on the initial scanning result of the ultrasonic phased array probe (202); a dynamic curvature matching mechanism (500) which is in signal connection with the central control module (400) and is arranged between the multi-modal detection head (200) and the end of the mechanical arm (100) and specifically comprises a spherical hinge base (501) which is internally embedded with a piezoelectric ceramic micro-motion regulator (502); a curved surface fitting detection plate (503) which is connected with the spherical hinge base (501) through a flexible connecting sheet (504), and the back surface of the detection plate (503) is provided with an array type pressure sensor (505); when the detection plate (503) contacts the surface of the steel structure, the array type pressure sensor (505) feeds back the contact pressure distribution to the central control module (400) in real time, the piezoelectric ceramic micro-motion regulator (502) is driven to adjust the pitch angle and the 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 of the detection surface is less than or equal to 3 DEG; a vibration energy recovery module (600) which specifically comprises a magnetostrictive energy collector (601) which is installed at the joint of the mechanical arm (100) and converts the vibration energy during the winding of the mechanical arm (100) into electric energy; a super capacitor group (602) which stores the recovered energy and supplies power to the shape memory alloy wire (103); and an energy distribution controller (603) which preferentially supplies the recovered energy to the ultrasonic phased array probe (202) with high power consumption. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 2. The detection device of claim 1, wherein: The joint segment (101) is covered with an environmentally responsive flexible skin (104) composed of shape memory polymer (105) interwoven with piezoresistive sensing fiber (106), wherein: The piezoresistive sensing fiber (106) monitors the temperature and humidity changes on the surface of the steel structure in real time and dynamically adjusts the driving current of the shape memory alloy wire (103) through the central control module (400); The shape memory polymer (105) automatically expands to form an anti-skid texture when the temperature is greater than or equal to 35℃, and shrinks to reduce the resistance of joint movement when the temperature is less than or equal to 5℃.

3. The detection device of claim 1, wherein: The contraction 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, with a response time of less than or equal to 0.5 seconds.

4. The detection device of claim 1, wherein: The pre-tightening belt (301) adopts an asymmetric tooth shape structure, with the inner tooth height (H1) and the outer tooth height (H2) satisfying H1 / H2=0.3-0.6, and: The inner tooth surface is sawtooth-shaped, with a friction coefficient greater than or equal to 0.8 with the surface of the steel structure; The outer tooth surface is a smooth arc, with an angle of 15°-30° with the contraction direction of the shape memory alloy wire (103), used to convert the alloy contraction force into radial compression force.

5. The detection device of claim 1, wherein: The ultrasonic phased array probe (202) and the eddy current sensor (201) are arranged alternately, with a coincidence degree of the detection areas of both greater than or equal to 85%, and the field angle of the industrial camera (204) covers the boundaries of the detection areas of both.

6. The detection device of claim 1, wherein: The annular light supplement lamp (205) of the industrial camera (204) contains a multi-spectral light emitting unit, with a spectral range covering visible light 400-700nm, near-infrared 900-1700nm, and ultraviolet 365nm waveband, and: The ultraviolet waveband light source is activated synchronously with the eddy current sensor (201), used to excite the fluorescent penetrant at the surface crack; The near-infrared waveband light source works cooperatively with the ultrasonic phased array probe (202), assisting in identifying internal debonding defects through thermal imaging.

7. The detection device of claim 1, wherein: The magnetostrictive energy harvester (601) of the vibration energy recovery module (600) is integrated with the piezoelectric fiber composite layer, wherein: The magnetostrictive material (Terfenol-D) is arranged axially along the mechanical arm (100) to capture low-frequency vibration energy 1-50Hz; The piezoelectric fiber (PZT) is wound in a spiral structure on the outer wall of the joint segment (101) to capture high-frequency vibration energy 50-200Hz; The output electric energy of both is rectified and input into the super capacitor group (602) in parallel.

8. The detection device of claim 1, wherein: The device is equipped with a modular expansion interface (700), including: End quick-change connector (701) supporting laser thickness gauge, electromagnetic ultrasonic probe expansion tools; Wireless communication repeater (702) embedded in the joint segment (101) to realize data synchronization in multi-device networking detection; The interface (700) adopts waterproof and dustproof design, suitable for outdoor harsh detection environment.

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