An ultrasonic-based control cabinet inspection and alarm method

Abstract

The application provides an ultrasonic-based control cabinet inspection and alarm method: S1, component-level inspection, connection-level inspection, environment-level inspection, and performance-level inspection. The connection-level inspection includes detecting the fastening state of the connections, terminals, and plugs between components in the underground / semi-underground sewage plant control cabinet by a control inspection robot, and the specific steps are as follows: detecting the connections, terminals, and plugs in the underground / semi-underground sewage plant control cabinet by an ultrasonic detection probe, obtaining the instant echo signals, comparing the instant echo signals with the normal echo signals of the corresponding types of connections, terminals, or plugs, and determining whether the connection parts have poor contact.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electronic information, and particularly relates to a control cabinet inspection and alarm method based on ultrasonic waves. BACKGROUND

[0002] With the continuous development of cities, land resources are increasingly scarce, and the layout of urban sewage treatment plants has also changed significantly. They are gradually moving from the urban fringe to the urban core area, and in order to effectively save construction land, underground / semi-underground sewage treatment plants have emerged. In underground / semi-underground sewage treatment plants, the implementation of the treatment process, the operation of biochemical tanks, and various instruments and equipment, control cabinets, etc. are all placed inside the box. The box is relatively complex in environmental conditions due to the moisture and odor generated by sewage treatment. Under this background, using robots to inspect facilities and equipment has become the development direction of the intelligent development and operation of future sewage treatment plants. The ACU (Regional Control Unit) control cabinet, as the core equipment of the intelligent management of underground / semi-underground sewage plants, with its outstanding characteristics of high integration and intelligence, is like a "central nerve" that effectively ensures the safe and efficient operation of underground / semi-underground sewage plants.

[0003] In the prior art, there are related technologies for automatically inspecting control cabinets by robots, such as CN118707213A, an intelligent inspection device for control cabinet operation and maintenance status, etc. The intelligent inspection device can accurately detect data, programs, and status. However, in the field of control cabinets, especially underground / semi-underground sewage plant control cabinets, due to the need for dehumidification, ventilation, and drainage operations. Therefore, underground / semi-underground sewage plant control cabinets will generate greater vibrations compared to other control cabinets, and with use, these vibrations can easily cause the fastening state of the wiring, terminals, and plugs in the underground / semi-underground sewage plant control cabinet to become loose, resulting in malfunctions. According to records, the loosening of the fastening state of the wiring, terminals, and plugs is the main factor leading to control cabinet failures and even sparks. SUMMARY

[0004] The purpose of the present application is to solve the above problems and provide a control cabinet inspection and alarm method based on ultrasonic waves.

[0005] The technical solution of the present application is as follows:

[0006] The present application provides a control cabinet inspection and alarm method based on ultrasonic waves, comprising the following steps:

[0007] S1, component level inspection, connection level inspection, environment level inspection and performance level inspection, wherein the component level inspection comprises controlling the inspection robot to detect the state of relays, circuit breakers and frequency converter components in the underground / semi-underground sewage plant control cabinet;The connection level inspection comprises controlling the inspection robot to detect the fastening state of the connection, terminal and plug between the components in the underground / semi-underground sewage plant control cabinet;The environment level inspection comprises controlling the inspection robot to detect the temperature, humidity and dust content in the underground / semi-underground sewage plant control cabinet;The performance level inspection comprises controlling the inspection robot to analyze the operation data in the underground / semi-underground sewage plant control cabinet and evaluate its working efficiency and stability;

[0008] The control inspection robot detects the fastening state of the connection, terminal and plug between the components in the underground / semi-underground sewage plant control cabinet, and specifically comprises:

[0009] The connection, terminal and plug in the underground / semi-underground sewage plant control cabinet are detected by the ultrasonic detection probe, the real-time echo signal is obtained, the real-time echo signal is compared with the normal echo signal of the corresponding type of connection, terminal or plug, and it is judged whether the connection part exists poor contact and alarm.

[0010] The application further provides a control cabinet inspection and alarm method based on ultrasonic waves, comprising the following steps:

[0011] S1, connection level inspection, wherein the connection level inspection comprises controlling the inspection robot to detect the fastening state of the connection, terminal and plug between the components in the underground / semi-underground sewage plant control cabinet, and specifically comprises:

[0012] The connection, terminal and plug in the underground / semi-underground sewage plant control cabinet are detected by the ultrasonic detection probe, the real-time echo signal is obtained, the real-time echo signal is compared with the normal echo signal of the corresponding type of connection, terminal or plug, and it is judged whether the connection part exists poor contact and alarm.

[0013] The advantages or beneficial effects of the above technical solutions at least include:

[0014] Ultrasonic testing probes perform non-contact testing, eliminating the need for direct contact with live components or disassembly of equipment. This testing method can be performed during normal equipment operation, significantly improving safety and efficiency. Inspectors do not need to come into direct contact with high-voltage or high-temperature components, reducing safety risks. Ultrasonic testing technology accurately determines whether a connection is poorly connected based on received echo signals. This technology utilizes the reflection properties of ultrasound at interfaces between different media. When a connection is poor, such as a wire, terminal, or plug, the ultrasonic signal reflects at the interface, resulting in an echo signal significantly different from that received when the connection is normal. Analysis of these echo signals allows the precise location of the poor connection to be quickly identified, providing clear guidance for subsequent repairs and enabling maintenance personnel to address the issue quickly and accurately. Ultrasonic testing technology can detect abnormal signals at the earliest stages of poor contact. Even slight changes in the contact state of a wire, terminal, or plug can be detected by an ultrasonic probe, providing early warning of faults. This enables maintenance personnel to take measures and carry out repairs in advance before the fault develops to a serious level, effectively preventing accidents such as short circuits and overheating caused by poor contact, and ensuring the stable operation of underground / semi-underground sewage treatment plant control cabinets.

[0015] Finally, by comparing the time and frequency domain characteristics of the immediate echo signal and the normal echo signal, the tightness of the connection can be quantitatively assessed. For example, by using a dynamic time warping algorithm to calculate the time domain similarity distance and the frequency domain Euclidean distance, the connection status can be converted into specific numerical indicators. Based on these quantitative indicators, it is possible to accurately determine whether the tightness of the connection meets the requirements, providing a scientific and objective basis for equipment maintenance and management. DETAILED DESCRIPTION

[0016] An embodiment of the present invention provides an ultrasonic control cabinet inspection and alarm method, comprising the following steps:

[0017] S1, component-level inspection, connection-level inspection, environment-level inspection and performance-level inspection, wherein the component-level inspection includes controlling the inspection robot to perform status detection on the relays, circuit breakers and inverter components in the control cabinet of the underground / semi-underground sewage treatment plant; the connection-level inspection includes controlling the inspection robot to detect the fastening status of the wiring, terminals and plugs between the components in the control cabinet of the underground / semi-underground sewage treatment plant; the environment-level inspection includes controlling the inspection robot to detect the temperature, humidity and dust content in the control cabinet of the underground / semi-underground sewage treatment plant; the performance-level inspection includes controlling the inspection robot to analyze the operating data in the control cabinet of the underground / semi-underground sewage treatment plant to evaluate its work efficiency and stability;

[0018] The control of the patrol robot on the fastening state of the wiring, terminal, and plug among components in the underground / semi-underground sewage plant control cabinet specifically includes:

[0019] The wiring, terminal, and plug in the underground / semi-underground sewage plant control cabinet are detected by an ultrasonic detection probe, and an instant echo signal is obtained. The instant echo signal is compared with a normal echo signal of the corresponding type of wiring, terminal, or plug to determine whether the connection part has poor contact and to alarm.

[0020] As a further improvement, the detection of the wiring, terminal, and plug in the underground / semi-underground sewage plant control cabinet by the ultrasonic detection probe, the acquisition of the instant echo signal, the comparison of the instant echo signal with the normal echo signal of the corresponding type of wiring, terminal, or plug, and the determination of whether the connection part has poor contact specifically include:

[0021] S1a, extracting time domain features and frequency domain features of the instant echo signal and the normal echo signal;

[0022] S1b, calculating the similarity of the normal echo signal and the instant echo signal in the time domain by using a dynamic time warping algorithm to obtain a similarity distance D DTW ;

[0023] S1c, calculating the Euclidean distance D PSD of the normal echo signal and the instant echo signal in the frequency domain:

[0024] wherein PSD normal (f) and PSD actual (f) are the power spectral densities PSD of the normal echo signal and the instant echo signal, respectively.

[0025] S1d, judging the similarity of the instant echo signal and the normal echo signal according to pre-set similarity thresholds T DTW and T PSD . If D DTW >T DTW or D PSD >T PSD , it is determined that the connection part has poor contact, otherwise, it is determined that the connection part is normal.

[0026] In one embodiment, in the S1a step, the extraction of the time domain features of the instant echo signal and the normal echo signal specifically includes:

[0027] The mean μ and the variance σ of the instant echo signal and the normal echo signal are calculated by the following formula: 2, peak s peak statistical features of at least one of the following: skewness or kurtosis K

[0028] ;

[0029] ;

[0030] ;

[0031] ;

[0032] where s(t i ) is the time-domain signal, t is the time variable, N is the number of sampling points of the signal, and E[] represents the expectation operation.

[0033] In one of the embodiments, in the S1a step, the extracting the frequency-domain features of the immediate echo signal and the normal echo signal specifically includes:

[0034] performing fast Fourier transform on the immediate echo signal or the normal echo signal to obtain a frequency-domain representation thereof, denoted as S(f), where f is the frequency variable, and calculating the power spectral density PSD of the signal:

[0035] ;

[0036] Then, the frequency band energy and the dominant frequency feature are extracted from the power spectral density PSD(f).

[0037] In one of the embodiments, in the underground / semi-underground sewage plant control cabinet, due to the large number of wires, terminals and plugs, it is impossible to inspect all the wires, terminals and plugs in the underground / semi-underground sewage plant control cabinet during the actual inspection process, which is time-consuming and laborious. Therefore, the present application creatively proposes that the vibration signals of each point in the underground / semi-underground sewage plant control cabinet are obtained by a vibration sensor, and then the vibration distribution area with a vibration intensity greater than a threshold value in the underground / semi-underground sewage plant control cabinet is fitted according to the vibration signals of the points, and the wires, terminals and plugs in the vibration distribution area are inspected, thereby greatly improving the inspection efficiency.

[0038] Specifically, the vibration signals of a plurality of points {P1, P2, …, P M} in the underground / semi-underground sewage plant control cabinet are collected by an inspection robot, the vibration intensity of each point is {I1, I2, …, I M}, and a two-dimensional grid is defined to divide the interior of the underground / semi-underground sewage plant control cabinet into N x ×N y grid units, and the position of each unit is (x i,y i ). Each collection point P j The position in the grid can be expressed as a coordinate (x j ,y j ).

[0039] Assume that the vibration intensity I of four adjacent points is known k , the vibration intensity of any point (x,y) among the four adjacent points can be calculated by the following formula:

[0040] , where (x1,y1),(x2,y2),(x3,y3),(x4,y4) are the coordinates of the four adjacent points.

[0041] Then, according to the fitted vibration intensity distribution I(x,y), extract the vibration intensity greater than the threshold I th Region:

[0042] .

[0043] Furthermore, it is also necessary to identify the position of the wiring, terminals, and plugs through a visual sensor. Specifically, the image obtained by the visual sensor is defined as I visual (x,y); use edge detection algorithm to identify the target component within the vibration distribution area:

[0044] , that is, using edge detection algorithms to extract the contours of the target parts.

[0045] Then, use image processing algorithms (such as contour extraction) to determine the location of wires, terminals, and plugs. The center position of the extracted contour is defined as:

[0046] .

[0047] Finally, the vibration distribution area Ω is compared with the target component position (x c k ,y c k ) to match, screen out the locations of important components in the vibration distribution area, and carry out targeted inspections and maintenance.

[0048] As a further improvement, in one embodiment, controlling the inspection robot to perform status detection on relays, circuit breakers, and inverter components in the control cabinet of the underground / semi-underground sewage treatment plant specifically includes:

[0049] S11, using a high-resolution camera, taking a photo of the relay, circuit breaker, and frequency converter components in the underground / semi-underground sewage plant control cabinet, and analyzing the appearance state of the components through image recognition algorithm to identify whether the components have obvious physical damage such as deformation, damage, and ablation;

[0050] S12, using an infrared thermal imager to detect the infrared thermal image of the components, and analyzing the temperature distribution on the surface of the components to determine whether the components have overheating failure;

[0051] S13, monitoring the vibration of the components through a vibration sensor, and determining the frequency and amplitude of the vibration through frequency spectrum analysis of the vibration signal to determine whether the components have failure.

[0052] As a further improvement, in one embodiment, the step of controlling the inspection robot to detect the temperature, humidity, and dust content in the underground / semi-underground sewage plant control cabinet specifically includes:

[0053] detecting the temperature, humidity, and dust content in the underground / semi-underground sewage plant control cabinet through temperature and humidity sensors and dust sensors, and comparing the detected data with the temperature, humidity, and dust data in the underground / semi-underground sewage plant control cabinet to detect the stability of the sensors in the underground / semi-underground sewage plant control cabinet.

[0054] As a further improvement, in one embodiment, the step of controlling the inspection robot to analyze the operation data in the underground / semi-underground sewage plant control cabinet and evaluate its working efficiency and stability specifically includes:

[0055] obtaining the operation data in the underground / semi-underground sewage plant control cabinet through the inspection robot, then establishing a regional operation data network according to the position of the underground / semi-underground sewage plant control cabinet, comparing the operation data differences between adjacent underground / semi-underground sewage plant control cabinets to obtain the overall working efficiency and stability of the regional operation data network.

[0056] It can be realized through the following steps:

[0057] The inspection robot can collect the following operation data from each underground / semi-underground sewage plant control cabinet: current I, voltage V, power P, frequency f, and temperature T, and represent these data as a vector as follows:

[0058] where i represents the i-th underground / semi-underground sewage plant control cabinet.

[0059] According to the geographical position of the underground / semi-underground sewage plant control cabinet, a graph G(V, E) is constructed, where: V is the node set, each node represents an underground / semi-underground sewage plant control cabinet. E is the edge set, each edge represents the connection relationship between two control cabinets. Assuming that the connection between control cabinets is based on geographical distance, if the distance between two control cabinets is less than a certain threshold d, there is an edge between them. The adjacency matrix A ij represents such a connection relationship:

[0060] .

[0061] For adjacent control cabinets i and j, calculate the operating data difference between the two control cabinets:

[0062] where k represents each parameter (current, voltage, etc.) in the data vector.

[0063] In one embodiment thereof, the overall working efficiency of the control cabinet is evaluated by the average power factor cosθ of the control cabinet:

[0064] where Q i is the reactive power, which can be calculated by the phase difference of voltage and current; P i is.

[0065] Therefore, as a further improvement, the overall working efficiency of the region can be represented as the average power factor of all control cabinets:

[0066] where |V| is the total number of control cabinets.

[0067] In addition, for the overall stability, the fluctuation of each parameter can be considered to evaluate its stability. Specifically, for each parameter k, calculate its standard deviation in all control cabinets:

[0068] where μ k is the average value of all control cabinets on parameter k. Therefore, the overall stability can be defined as the weighted sum of the standard deviations of all parameters:

[0069] where α k is the weight of each parameter, which can be set according to its importance to the stability of the system.

[0070] Further, in order to further optimize the patrol alarm method of the present application, in other embodiments, the embodiment of the present application further provides an ultrasonic-based control cabinet patrol alarm method, comprising the following steps:

[0071] S1', connection level inspection, wherein the connection level inspection comprises controlling the inspection robot to detect the fastening state of the connection, terminal and plug between components in the underground / semi-underground sewage plant control cabinet, specifically comprising:

[0072] The connection, terminal and plug in the underground / semi-underground sewage plant control cabinet are detected respectively by the ultrasonic detection probe, the real-time echo signal is obtained, the real-time echo signal is compared with the normal echo signal of the corresponding type of connection, terminal or plug, whether the connection part exists poor contact is judged and alarm is given. Wherein, the basic method and steps of connection level inspection are the same as those in step S1, which will not be repeated here.

[0073] Those skilled in the art should understand that the above embodiments are only for clearly illustrating the present application, and do not limit the scope of the present application. Based on the above disclosure, other changes or modifications can also be made by those skilled in the art, and these changes or modifications are still within the scope of the present application.

Claims

1. A control cabinet inspection alarm method based on ultrasonic wave, characterized by: The following steps are involved: S1, component-level inspection, connection-level inspection, environment-level inspection and performance-level inspection, wherein the component-level inspection includes controlling the inspection robot to perform status detection on the relays, circuit breakers and inverter components in the control cabinet of the underground / semi-underground sewage treatment plant; the connection-level inspection includes controlling the inspection robot to detect the fastening status of the wiring, terminals and plugs between the components in the control cabinet of the underground / semi-underground sewage treatment plant; the environment-level inspection includes controlling the inspection robot to detect the temperature, humidity and dust content in the control cabinet of the underground / semi-underground sewage treatment plant; the performance-level inspection includes controlling the inspection robot to analyze the operating data in the control cabinet of the underground / semi-underground sewage treatment plant to evaluate its work efficiency and stability; The control inspection robot detects the tightness of the wiring, terminals, and plugs between components in the control cabinet of the underground / semi-underground sewage treatment plant, specifically including: Use ultrasonic detection probes to detect the wiring, terminals, and plugs in the control cabinet of underground / semi-underground sewage treatment plants, obtain their instantaneous echo signals, and compare the instantaneous echo signals with the normal echo signals of the corresponding types of wiring, terminals, or plugs to determine whether there is poor contact at the connection points and issue an alarm; The ultrasonic detection probe is used to detect the wiring, terminals, and plugs in the underground / semi-underground sewage treatment plant control cabinet, obtain their instant echo signals, and compare the instant echo signals with the normal echo signals of the corresponding types of wiring, terminals, or plugs to determine whether there is poor contact at the connection parts, specifically including: Extracting time domain features and frequency domain features of the instantaneous echo signal and the normal echo signal; The dynamic time warping algorithm is used to calculate the similarity between the normal echo signal and the immediate echo signal in the time domain, and the similarity distance D is obtained. DTW ; Calculate the Euclidean distance D between the normal echo signal and the immediate echo signal in the frequency domain PSD : , among which, PSD normal (f) and PSD actual (f) are power spectral densities PSD of the normal echo signal and the prompt echo signal, respectively, where f is a frequency variable; According to the pre-set similarity threshold T DTW and T PSD , judge the similarity between the instantaneous echo signal and the normal echo signal, if D DTW >T DTW or D PSD >T PSD , it is judged that there is poor contact at the connection part; otherwise, it is judged that the connection part is in normal state.

2. The ultrasonic control cabinet inspection and alarm method according to claim 1, characterized in that: The step of extracting the time domain features of the immediate echo signal and the normal echo signal specifically includes: The mean μ and variance σ of the instantaneous echo signal and the normal echo signal are calculated by the following formula: 2 , peak value s peak Or at least one of the statistical characteristics of kurtosis K: ； ； ； ； Among them, s(t i ) is the time domain signal, t is the time variable, N is the number of sampling points of the signal, and E[] represents the expected operation.

3. The ultrasonic control cabinet inspection and alarm method according to claim 2, characterized in that: The extracting of the frequency domain features of the immediate echo signal and the normal echo signal specifically includes: Perform fast Fourier transform on the instantaneous echo signal or the normal echo signal to obtain its frequency domain representation: S(f), where f is the frequency variable, and calculate the power spectral density PSD of the signal: ； Then, the frequency band energy and main frequency characteristics are extracted from the power spectrum density PSD(f).

4. The ultrasonic control cabinet inspection and alarm method according to claim 1, characterized in that: The controlling the inspection robot to perform status detection on the relays, circuit breakers, and inverter components in the control cabinet of the underground / semi-underground sewage treatment plant specifically includes: S11, using a high-resolution camera to photograph relays, circuit breakers, and inverter components in the control cabinet of the underground / semi-underground sewage treatment plant, and using an image recognition algorithm to analyze the appearance of the components to identify whether the components have obvious physical damage such as deformation, breakage, or ablation; S12, using an infrared thermal imager to perform infrared thermal imaging inspection on the component, and by analyzing the temperature distribution on the surface of the component, determine whether the component has an overheating fault; S13, monitoring the vibration of the component through a vibration sensor, determining the frequency and amplitude of the vibration by performing spectrum analysis on the vibration signal, and thus determining whether the component is faulty.

5. The control cabinet inspection and alarm method based on ultrasonic waves according to claim 1 is characterized in that: The step of controlling the inspection robot to detect the temperature, humidity, and dust content in the control cabinet of the underground / semi-underground sewage treatment plant specifically includes: The temperature, humidity and dust content in the underground / semi-underground sewage treatment plant control cabinet are detected by temperature and humidity sensors and dust sensors, and the detected data are compared with the temperature, humidity and dust data in the underground / semi-underground sewage treatment plant control cabinet to detect the stability of the sensors in the underground / semi-underground sewage treatment plant control cabinet.

6. The control cabinet inspection and alarm method based on ultrasonic waves according to claim 1 is characterized in that: The step of controlling the inspection robot to analyze the operating data in the control cabinet of the underground / semi-underground sewage treatment plant and evaluating its working efficiency and stability specifically includes: The inspection robot is used to obtain the operating data in the control cabinet of the underground / semi-underground sewage treatment plant. Then, according to the location of the control cabinet of the underground / semi-underground sewage treatment plant, a regional operating data network is established, and the operating data differences in the control cabinets of adjacent underground / semi-underground sewage treatment plants are compared to obtain the overall working efficiency and stability of the regional operating data network.

7. The control cabinet inspection and alarm method based on ultrasonic waves according to claim 1 is characterized in that: The inspection robot further includes a vibration sensor, which acquires vibration signals from various points in the control cabinet of the underground / semi-underground sewage treatment plant.

8. The control cabinet inspection and alarm method based on ultrasonic waves according to claim 7 is characterized in that: The inspection robot further fits the vibration distribution area in the underground / semi-underground sewage treatment plant control cabinet where the vibration intensity is greater than a threshold value based on the vibration signals of the various points.

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