Ultra-high voltage transmission line strain clamp X-ray detection robot and operation method

Abstract

The invention discloses an X-ray detection robot for a strain clamp of an ultra-high voltage transmission line and an operation method, and the robot comprises a machine body frame module which comprises a pair of semicircular supports, and one end of one semicircular support is rotatably connected with one end of the other semicircular support; the walking mechanism module is arranged in the machine body frame module and comprises at least one pair of drum-shaped driving wheels and driven supporting wheels and a clamping adjusting mechanism, the drum-shaped driving wheels and the driven supporting wheels are arranged on the power transmission wires, and the clamping adjusting mechanism is used for enabling the drum-shaped driving wheels and the driven supporting wheels to be automatically matched with the power transmission wires and clamping the power transmission wires; the X-ray detection module is arranged in the machine body frame module; and the control system and the power supply module are used for coordinated control and data management of robot movement and positioning detection actions. Rapid adaptation of the robot to different power transmission wires and split arrangement structures is achieved, and through the light-weight high-strength frame and module integrated layout, the equipment weight is greatly reduced, and the high-altitude operation convenience is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of X-ray detection robots, and in particular to an X-ray detection robot and an operating method for ultra-high voltage transmission line tension clamps. Background Art

[0002] In ultra-high voltage transmission lines, tension clamps are crucial hardware for carrying conductor tension and securing them. Their mechanical performance is directly linked to the safe and reliable operation of the transmission lines. Over their long service lives, tension clamps are susceptible to mechanical loads, climate change, material aging, and other factors, potentially leading to internal cracks, corrosion, fatigue, and other hidden dangers. If not discovered and addressed promptly, these can easily cause serious faults such as conductor slippage and breakage, resulting in widespread power outages.

[0003] Currently, routine inspections of transmission lines rely primarily on ground-based visual inspections, drones equipped with visible light or infrared imaging equipment, and helicopters for high-altitude inspections. While these methods can detect obvious external defects such as conductors and insulator strings, they have inherent limitations in identifying internal defects in tension clamps, making it difficult to promptly detect microcracks, metal fatigue, and corrosion damage within the hardware.

[0004] In response to the need for internal inspection of tension clamps, some studies have proposed the use of X-ray fluoroscopy to detect hidden defects through non-destructive imaging of the internal structure of the hardware. However, existing X-ray inspection technology for tension clamps often has the following limitations: On the one hand, some existing tension clamp inspection robots are typically designed for a single conductor specification, making them difficult to adapt to conductors of varying diameters and arrangements (e.g., single-strand, double-strand, and quadruple-strand). Because different transmission lines utilize varying conductor types, arrangements, and spacing, a non-adjustable clamping mechanism can easily lead to problems such as mounting failure, unstable clamping, and derailment, limiting the device's application across diverse line conditions.

[0005] On the other hand, existing X-ray inspection robots are large and heavy, often due to the high-power X-ray source and imaging plate they carry, which inevitably increases the overall weight. Because UHV transmission lines are located at high altitudes and tension clamps are often difficult to access, inspection equipment must be transported to the operating location via manual tower climbing, specialized hoists, or drones. Due to the weight and size limitations of existing equipment, deployment and retrieval are cumbersome, increasing workload and safety risks while reducing inspection efficiency.

[0006] For example, an existing transmission line inspection robot (such as patent CN109713497A) can walk along the conductors, but it is mainly used for single-strand conductors, and the wheel set is fixed and cannot be adjusted, which cannot adapt to various conductor split arrangement structures; at the same time, the robot design is mainly based on a large metal frame, the overall weight is large, and it is inconvenient to move and install, which makes it difficult to meet the requirements of miniaturization, lightweight and high adaptability of equipment in actual engineering applications.

[0007] Therefore, the existing technology still has the following urgent problems to be solved in the online X-ray detection of tension clamps: it cannot adapt to a variety of wire diameters and split structures, and its scope of application is limited; the robot's clamping and walking stability is insufficient, affecting the detection accuracy and safety; the overall weight and volume of the equipment are large, making deployment and recovery difficult and the operating efficiency low. Summary of the Invention

[0008] The purpose of the present invention is to overcome the defects of the prior art in which tension clamps cannot be adapted to a variety of wire diameters and split structures during online X-ray inspection, resulting in a limited scope of application; the robot's clamping and walking stability is insufficient, affecting the inspection accuracy and safety; the overall weight and volume of the equipment are large, deployment and recovery are difficult, and the operating efficiency is low. The present invention provides an X-ray inspection robot and an operating method for tension clamps for ultra-high voltage transmission lines.

[0009] The purpose of the present invention is achieved through the following technical solutions: X-ray inspection robot for UHV transmission line tension clamps, including: The body frame module includes a pair of semicircular brackets, one end of each semicircular bracket being rotatably connected to one end of the other semicircular bracket; A walking mechanism module is disposed within the machine frame module and includes at least one pair of drum drive wheels and driven support wheels and a clamping adjustment mechanism. The drum drive wheels and driven support wheels are disposed on the power transmission line. The clamping adjustment mechanism is used to automatically adapt the drum drive wheels and driven support wheels to the power transmission line and clamp them. The X-ray detection module is installed in the body frame module and is used to perform internal X-ray imaging of the tension clamp during detection operations; the control system and power supply module are used for coordinated control and data management of the robot's movement, positioning and detection actions, and at the same time provide power to the body frame module, walking mechanism module and X-ray detection module.

[0010] Preferably, the control system and power supply module include a main control unit, a motion controller and a detection controller. The main control unit is connected to the motion controller and the detection controller at the same time. The motion controller is also connected to the body frame module and the walking structure module. The detection controller is also connected to the X-ray detection module.

[0011] Preferably, the UHV transmission line tension clamp X-ray inspection robot also includes a wireless communication module, which is connected to the control system and the power supply module, and is used to receive remote control instructions, transmit detection data, monitor and feedback system status, and back up and switch communication links.

[0012] Preferably, the wireless communication module includes a main module, a radio frequency front end, a built-in antenna and a status indication interface. The main module is connected to the radio frequency front end and the status indication interface at the same time. The radio frequency front end is connected to the built-in antenna, and the built-in antenna is used to transmit and receive wireless signals.

[0013] Preferably, the control system, power supply module and wireless communication module are arranged together in an electromagnetic shielding box.

[0014] The operation method of the X-ray inspection robot for ultra-high voltage transmission line tension clamps is based on the X-ray inspection robot for ultra-high voltage transmission line tension clamps, and includes the following steps: Step 1: The semicircular bracket is in an unfolded state, and the robot is mounted on the target transmission line by a drone. The drum wheel group is automatically adapted to the diameter of the transmission line and clamped by the clamping adjustment mechanism; Step 2: The control system and the power module drive the walking mechanism module to make the robot move along the transmission line and locate it near the target tension clamp through the preset camera; Step 3: The control system and power module send control commands to retract the semicircular bracket and drive the imaging plate to the specified position via the transmission chain on the body frame module. At the same time, the X-ray detection module is driven by the rotary motor to complete the alignment adjustment. Step 4: The X-ray detection module emits a beam of rays and synchronously triggers the detector to collect image data to complete the internal perspective imaging of the tension clamp.

[0015] Preferably, the operating method of the X-ray inspection robot for ultra-high voltage transmission line tension clamps further includes step 5, in which image data of the internal perspective imaging of the tension clamp is transmitted back to the remote terminal via the wireless communication module.

[0016] Preferably, the operating method of the UHV transmission line tension clamp X-ray inspection robot also includes step 6. After the inspection is completed, the control system and the power module send a control command to unfold the bracket, and the robot continues to move to the next inspection point or to the recovery point. If it moves to the next inspection point, steps 1-5 are repeated. If it drives to the recovery point, it is lifted by the drone and returned to the ground to complete the operation process.

[0017] The beneficial effects of the present invention are as follows: the present invention realizes the rapid adaptation of the robot to different transmission lines and split arrangement structures by designing an adjustable walking mechanism module; greatly reduces the weight of the equipment and improves the convenience of high-altitude operations through the lightweight and high-strength frame and module integrated layout; and realizes accurate perspective imaging of internal defects of tension clamps by integrating a small and efficient X-ray non-destructive testing module, thereby effectively improving the scope, efficiency and accuracy of online detection of internal defects of transmission line hardware, and enhancing the safety assurance capability of power grid operation and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a structural schematic diagram of the present invention; Figure 2 It is a flow chart of the present invention.

[0019] Among them: 100, tension clamp, 101, transmission line, 200, body frame module, 201, transmission chain, 202, imaging plate, 300, walking mechanism module, 301, drum drive wheel, 302, driven support wheel, 303, clamping adjustment mechanism, 400, X-ray detection module, 500, control system and power supply module, 600, wireless communication module. DETAILED DESCRIPTION

[0020] Example embodiments will now be described more fully with reference to the accompanying drawings. However, example embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this application will be thorough and complete and will fully convey the concepts of the example embodiments to those skilled in the art.

[0021] In addition, described feature, structure or characteristic can be combined in one or more embodiments in any suitable manner.In the following description, many specific details are provided so as to provide a full understanding of the embodiments of the present application. However, it will be appreciated by those skilled in the art that the technical scheme of the present application can be put into practice without one or more of the specific details, or other methods, components, devices, steps etc. can be adopted. In other cases, known methods, devices, implementations or operations are not shown or described in detail to avoid blurring the various aspects of the application.

[0022] The flowcharts shown in the accompanying drawings are for illustrative purposes only and do not necessarily include all contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps may be decomposed, while others may be combined or partially combined. Therefore, the actual execution order may vary depending on the actual situation.

[0023] Example: X-ray inspection robot for UHV transmission line tension clamps, such as Figure 1As shown, including: The body frame module 200 includes a pair of semicircular brackets, one end of each semicircular bracket is rotatably connected to one end of the other semicircular bracket, a transmission chain 201 is provided in the semicircular bracket, and an imaging plate 202 is provided axially extending from the semicircular bracket; The traveling mechanism module 300 is disposed within the machine frame module and includes at least one pair of drum drive wheels 301 and driven support wheels 302, as well as a clamping and adjustment mechanism 303. The drum drive wheels and driven support wheels are disposed on the power transmission line. The clamping and adjustment mechanism is used to automatically adapt the drum drive wheels and driven support wheels to the power transmission line 101 and clamp them. An X-ray detection module 400 is provided in the body frame module and is used to perform internal perspective imaging of the tension clamp 100 during the inspection operation; The control system and power supply module 500 is used for coordinated control and data management of the robot's motion, positioning and detection actions, and also provides power to the body frame module, walking mechanism module, and X-ray detection module; The wireless communication module 600 is connected to the control system and the power module, and is used to receive remote control instructions, transmit detection data, monitor and feedback system status, and back up and switch communication links.

[0024] The control system and power supply module include a main control unit, a motion controller and a detection controller. The main control unit is connected to the motion controller and the detection controller at the same time. The motion controller is also connected to the body frame module and the walking structure module. The detection controller is also connected to the X-ray detection module.

[0025] The wireless communication module includes a main module, a radio frequency front end, a built-in antenna and a status indication interface. The main module is connected to the radio frequency front end and the status indication interface at the same time. The radio frequency front end is connected to the built-in antenna, and the built-in antenna is used to transmit and receive wireless signals.

[0026] The control system, power supply module and wireless communication module are arranged together in an electromagnetic shielding box.

[0027] The operation method of the X-ray inspection robot for ultra-high voltage transmission line tension clamps is based on the X-ray inspection robot for ultra-high voltage transmission line tension clamps, such as Figure 2 As shown, the following steps are included: Step 1: The semicircular bracket is in an unfolded state, and the robot is mounted on the target transmission line by a drone. The drum wheel group is automatically adapted to the diameter of the transmission line and clamped by the clamping adjustment mechanism; Step 2: The control system and the power module drive the walking mechanism module to make the robot move along the transmission line and locate it near the target tension clamp through the preset camera; Step 3: The control system and power module send control commands to retract the semicircular bracket and drive the imaging plate to the specified position via the transmission chain on the body frame module. At the same time, the X-ray detection module is driven by the rotary motor to complete the alignment adjustment. Step 4: The X-ray detection module emits a beam of rays and synchronously triggers the detector to collect image data to complete the internal perspective imaging of the tension clamp.

[0028] The operating method of the X-ray inspection robot for ultra-high voltage transmission line tension clamps also includes step 5, in which image data of the internal perspective imaging of the tension clamp is transmitted back to the remote terminal via the wireless communication module.

[0029] The operation method of the X-ray inspection robot for ultra-high voltage transmission line tension clamps also includes step 6. After the inspection is completed, the control system and the power module issue a control command to unfold the bracket, and the robot continues to move to the next inspection point or to the recovery point. If it moves to the next inspection point, steps 1-5 are repeated. If it drives to the recovery point, it is lifted by the drone and returned to the ground to complete the operation process.

[0030] The timing of the robot operation is as follows: T0: System initialization phase After power-on, the system completes self-test, the communication link is established, and the motor servo is ready.

[0031] T1: Starting stage The control system and power module send instructions to start the walking mechanism, and the robot begins to move at a constant speed along the wire.

[0032] T2: Detection point identification stage The robot reaches the preset detection position, automatically decelerates and stops accurately.

[0033] T3: Detection and deployment phase The semicircular bracket is folded, and the X-ray detection module and the imaging plate are aligned to both sides of the tension clamp.

[0034] T4: Detection and data collection stage Start X-ray exposure and synchronously collect detector image data.

[0035] T5: Detection completion and recycling stage The bracket unfolds, the X-ray detection module returns to its initial state, and the robot is lifted by the drone and returned to the ground, completing the mission.

[0036] The actions at each stage are centrally scheduled and managed by the main control unit to ensure the correct sequence of actions and the coordinated operation of each sub-module, thus guaranteeing the stability and efficiency of the operation process.

[0037] A preferred embodiment of the present invention is described in detail below.

[0038] Robot preparation and mounting First, the robot is transported to the target transmission line inspection section via a drone. The lightweight design of the robot frame module keeps the overall weight within a range suitable for manual portability or mounting on a small drone. The robot is then mounted on the target conductor surface. The travel mechanism module adjusts the spacing between the drum drive wheels to ensure the arc-shaped grooves on the wheel rims match the conductor's outer diameter. Once adjusted, the clamping mechanism applies a preset clamping force, ensuring the robot's stable mounting on the conductor without slipping or damaging it.

[0039] Autonomous driving and positioning detection The robot system starts up, and the control system and power module complete a power-on self-test and initialize all functional modules (corresponding to time sequence T0). The control system sends instructions to the travel mechanism module, driving the drum wheel assembly to travel at a constant speed along the conductor (corresponding to phase T1). During this process, the operator uses a camera to identify the position of the robot and the tension clamp to be inspected. If the robot detects proximity to the predetermined inspection area, it slows down to a low speed and accurately stops at the target tension clamp area (corresponding to phase T2).

[0040] Deploy the detection device and perform X-ray inspection After the robot stops steadily, the control system and the power module send instructions to control the folding frame action (corresponding to the T3 stage). After folding, the X-ray imaging plate will be driven by the transmission chain to the side of the specified tension clamp, and the rotating motor will drive the X-ray source to rotate and align to ensure that the ray beam penetrates the target area of ​​the clamp and is effectively received by the detector. Subsequently, the control system synchronously starts the X-ray generator to emit a conical beam of rays, and at the same time controls the detector to start collecting transmission image data (corresponding to the T4 stage). The exposure time and acquisition parameters are preset according to the material and thickness of the tension clamp to ensure that the imaging clarity meets the defect identification requirements. During the inspection process, the detector continuously collects one or more images and sends the original image data to the control system cache to complete a single inspection task.

[0041] Image data processing and transmission After the inspection is complete, the control system module performs preliminary processing on the collected image data, such as image enhancement and format packaging. Subsequently, the image data is transmitted back to the ground monitoring terminal in real time through the wireless communication module for remote technicians to view and analyze.

[0042] Folding detection device and continuing to move forward After the image data transmission is complete, the control system sends a command to deploy the telescopic bracket, retracting the X-ray inspection module to its stowed position. Based on the pre-set task plan, the robot continues along the conductor to perform the next tension clamp inspection task, or it moves to a convenient location for recovery, awaiting drone lift and recovery (corresponding to stage T5).

[0043] During the entire process, the robot can repeatedly perform multiple inspection cycles according to actual needs, adapting to the needs of continuous inspection operations over long distances and with multiple tension clamps.

[0044] In summary, since this solution adopts a drum wheel set and an adjustable clamping mechanism design, the wheel set spacing and clamping force can be flexibly adjusted according to different conductor diameters and split structures. Therefore, the robot can adapt to various line structures such as single-strand conductors, double-split conductors, and quad-split conductors, stably mount and move, and ultimately achieve universal adaptability to different types of conductor environments, greatly improving the robot's application range and operational flexibility on various transmission lines.

[0045] Because this solution incorporates comprehensive anti-electromagnetic interference design in the control module, power supply system, and signal transmission link, including metal shielding, filtering suppression, and signal isolation, the robot is able to maintain stable operation of its motion control, X-ray inspection, and wireless communication systems in the extremely strong electric and induced magnetic fields and pulse interference environments surrounding 1000kV UHV transmission lines. This ultimately ensures the reliability of tension clamp inspection tasks and the accuracy of inspection data in live high-voltage environments, avoiding operation interruptions or data errors caused by environmental interference.

[0046] Because this solution uses lightweight materials (such as carbon fiber composites and aluminum alloy structures) and optimizes the overall structural topology, while compactly integrating functional modules, the overall weight of the robot is controlled within a reasonable range, making it convenient for manual carrying or lifting by drone, and reducing the additional load hanging on the wires. Ultimately, it effectively improves the convenience of on-site deployment and operational safety of the robot, making it suitable for a variety of complex operating environments such as high-altitude and high-voltage lines.

[0047] Those skilled in the art will readily conceive of other embodiments of the present application after considering the specification and practicing the embodiments disclosed herein. This application is intended to cover any variations, uses, or adaptations of the present application that follow the general principles of this application and include common knowledge or customary techniques in the art that are not disclosed herein.

[0048] It should be understood that the present application is not limited to the exact structures described above and shown in the drawings, and that various modifications and changes may be made without departing from the scope thereof. The scope of the present application is limited only by the appended claims.

Claims

1. An X-ray inspection robot for ultra-high voltage transmission line tension clamps, comprising: The body frame module includes a pair of semicircular brackets, one end of each semicircular bracket being rotatably connected to one end of the other semicircular bracket; A walking mechanism module is disposed within the machine frame module and includes at least one pair of drum drive wheels and driven support wheels and a clamping adjustment mechanism. The drum drive wheels and driven support wheels are disposed on the power transmission line. The clamping adjustment mechanism is used to automatically adapt the drum drive wheels and driven support wheels to the power transmission line and clamp them. The X-ray detection module is installed in the body frame module and is used to perform internal X-ray imaging of the tension clamp during detection operations; the control system and power supply module are used for coordinated control and data management of the robot's movement, positioning and detection actions, and at the same time provide power to the body frame module, walking mechanism module and X-ray detection module.

2. The UHV transmission line tension clamp X-ray inspection robot according to claim 1 is characterized in that: The control system and power supply module include a main control unit, a motion controller and a detection controller. The main control unit is connected to the motion controller and the detection controller at the same time. The motion controller is also connected to the body frame module and the walking structure module. The detection controller is also connected to the X-ray detection module.

3. The X-ray inspection robot for ultra-high voltage transmission line tension clamps according to claim 1 is characterized in that: It also includes a wireless communication module, which is connected to the control system and the power supply module and is used to receive remote control instructions, transmit detection data, monitor and feedback system status, and back up and switch communication links.

4. The X-ray inspection robot for ultra-high voltage transmission line tension clamps according to claim 3 is characterized in that: The wireless communication module includes a main module, a radio frequency front end, a built-in antenna and a status indication interface. The main module is connected to the radio frequency front end and the status indication interface at the same time. The radio frequency front end is connected to the built-in antenna, and the built-in antenna is used to transmit and receive wireless signals.

5. The UHV transmission line tension clamp X-ray inspection robot according to claim 3 or 4, characterized in that: The control system, power supply module and wireless communication module are arranged together in an electromagnetic shielding box.

6. An operating method of an X-ray inspection robot for ultra-high voltage transmission line tension clamps, based on the X-ray inspection robot for ultra-high voltage transmission line tension clamps according to claim 1, characterized in that: The following steps are involved: Step 1: The semicircular bracket is in an unfolded state, and the robot is mounted on the target transmission line by a drone. The drum wheel group is automatically adapted to the diameter of the transmission line and clamped by the clamping adjustment mechanism; Step 2: The control system and the power module drive the walking mechanism module to make the robot move along the transmission line and locate it near the target tension clamp through the preset camera; Step 3: The control system and power module send control commands to retract the semicircular bracket and drive the imaging plate to the specified position via the transmission chain on the body frame module. At the same time, the X-ray detection module is driven by the rotary motor to complete the alignment adjustment. Step 4: The X-ray detection module emits a beam of rays and synchronously triggers the detector to collect image data to complete the internal perspective imaging of the tension clamp.

7. The operating method of the X-ray inspection robot for ultra-high voltage transmission line tension clamps according to claim 6, characterized in that: The invention also includes step 5, in which the image data of the internal perspective imaging of the tension clamp is transmitted back to the remote terminal via the wireless communication module.

8. The operating method of the X-ray inspection robot for ultra-high voltage transmission line tension clamps according to claim 7, characterized in that: It also includes step 6. After the inspection is completed, the control system and the power module send a control command to unfold the bracket, and the robot continues to move to the next inspection point or to the recovery point. If it moves to the next inspection point, steps 1-5 are repeated. If it drives to the recovery point, it is lifted by the drone and returned to the ground to complete the operation process.

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