Nut removal device and system

Abstract

The application provides a nut dismounting device and system, and relates to the technical field of electric power. The nut dismounting device comprises a main control module, a heating module, a sleeve module and an infrared image acquisition module. The main control module is used for acquiring an infrared image collected after a target nut is heated, determining the rust degree of the target nut according to the infrared image, determining the initial environmental temperature of the environment where the target nut is located before being heated according to an initial environmental image and the infrared image, dynamically adjusting the heating power adjustment amount output by the heating module according to the initial environmental temperature and the rust degree, controlling the heating module to heat the target nut, so that the target nut generates a thermal expansion difference to loosen the rust layer, controlling the sleeve module to move to be sleeved on the target nut, and after it is determined that the sleeve module is sleeved on the outer periphery of the target nut, controlling the sleeve module to rotate and tighten, so that the target nut is rotated out of the bolt. That is, the heating expansion difference effect and the sleeve rotation are combined to replace the traditional violent damage mode.

Description

Technical Field

[0001] This application relates to the field of power technology, and more specifically, to a nut removal device and system. Background Technology

[0002] In live-line work on power distribution networks, nut removal is a fundamental and crucial operation in the maintenance and replacement of electrical equipment. Because distribution network lines are exposed to the outdoor environment for extended periods, they are highly susceptible to corrosion and seizing between nuts and bolts due to rain, moisture, salt spray, and dust. This corrosion is particularly severe in coastal areas, industrially polluted zones, or high-humidity environments, making it difficult to unscrew the nuts and significantly increasing the difficulty of maintenance work.

[0003] Currently, the main technology for disassembling rusted nuts is a cutting-type destruction device. The working principle is to align the nut with a special through groove and apply shearing force through the cutters on both sides to destroy it, thereby completing the task of disassembling the nut.

[0004] However, when shearing severely corroded or large nuts, the device requires extremely high shearing force, which necessitates that the tool structure possess high strength and rigidity. This results in a large overall size and weight of the device, increasing the load on the robotic arm and affecting its operational flexibility, positioning accuracy, and working range. Summary of the Invention

[0005] The purpose of this application is to provide a nut removal device and system to address the shortcomings of the prior art, thereby solving the technical problems existing in the existing cutter-type destruction method.

[0006] To achieve the above objectives, the technical solutions adopted in the embodiments of this application are as follows:

[0007] In a first aspect, embodiments of this application provide a nut removal device, which includes: a main control module, a heating module, a sleeve module, and an infrared image acquisition module; the main control module is communicatively connected to the heating module, the infrared image acquisition module, and the sleeve module respectively;

[0008] The infrared image acquisition module is used to acquire an initial environmental image of the environment in which the target nut is located before heating and send the initial environmental image to the main control module.

[0009] The main control module is used to control the heating module to heat the target nut, acquire infrared images collected by the infrared image acquisition module after the target nut is heated, determine the degree of corrosion of the target nut based on the infrared images, and determine the initial ambient temperature of the environment in which the target nut was located before heating based on the initial ambient image and the infrared images; dynamically adjust the heating power output of the heating module based on the initial ambient temperature and the degree of corrosion, and control the heating module to heat the target nut based on the heating power adjustment to generate a thermal expansion difference to loosen the rust layer, control the sleeve module to move to fit onto the target nut, and after determining that the sleeve module is fitted onto the outer circumference of the target nut, control the sleeve module to rotate and tighten to unscrew the target nut from the bolt.

[0010] Optionally, controlling the heating module to heat the target nut includes:

[0011] The heating module is controlled to heat the target nut for a preset heating time.

[0012] The step of dynamically adjusting the heating output of the heating module based on the initial ambient temperature and the degree of corrosion includes:

[0013] The degree of corrosion of the target nut and the initial ambient temperature are input into a pre-built heating temperature model to determine the set heating temperature value to which the target nut should be heated;

[0014] Acquire the current infrared image of the target nut during the heating process, acquired by the infrared image acquisition module;

[0015] Based on the current infrared image, determine the current temperature value of the target nut;

[0016] The difference between the set heating temperature value and the current temperature value is used as the heating error temperature value;

[0017] The heating power output of the heating module is dynamically adjusted based on the heating error temperature value and the preset adjustment coefficient.

[0018] Optionally, the heating temperature model includes:

[0019] Heating set temperature value = (450 + 2 * (T0 - 25) + 100 * K )℃;

[0020] Wherein, 450 is the preset target temperature base value, T0 is the initial ambient temperature, and K is the degree of corrosion of the target nut.

[0021] Optionally, determining the degree of corrosion of the target nut based on the infrared image includes:

[0022] Based on the temperature value of each pixel in the infrared image, the average temperature value of the infrared image is determined, and the pixels in the infrared image with a temperature value higher than the average temperature value are marked as nut pixels, and the number of nut pixels is determined.

[0023] Determine the first average temperature value of all nut pixels in the infrared image, and identify nut pixels in the infrared image that are below the first average temperature value as rust pixels;

[0024] The number of rusted pixels in the infrared image is determined, and the degree of rust on the target nut is calculated based on the number of nut pixels and the number of rusted pixels.

[0025] Optionally, determining the initial ambient temperature of the environment where the target nut is located based on the initial environmental image and the infrared image includes:

[0026] Based on the pixel coordinates of all nut pixels in the infrared image, the temperature value corresponding to each nut pixel in the initial environmental image is determined, and the second average temperature value of all nut pixels in the initial environmental image is taken as the initial environmental temperature.

[0027] Optionally, the nut removal device further includes: an image acquisition module; the image acquisition module is communicatively connected to the main control module;

[0028] The main control module is also connected to the industrial control computer in the live-line working robot.

[0029] The image acquisition module is used to acquire images of the working environment in real time during the movement of the robotic arm and the nut removal device, and send the images to the industrial control computer. The industrial control computer then uses the images to spatially locate the target nut, obtains the target position of the target nut, generates a movement path for the robotic arm based on the target position of the target nut, and controls the robotic arm to move the nut removal device to directly below the target nut, so that the target nut is aligned with the sleeve module.

[0030] Optionally, the nut removal device further includes: a slide lifting module and a distance detection module;

[0031] The sleeve module is fixed to the slide table lifting module via a connector, and the distance detection module is mounted on the slide table lifting module; both the slide table lifting module and the distance detection module are communicatively connected to the main control module.

[0032] The control of the sleeve module to move and fit onto the target nut includes:

[0033] The image of the nut acquired by the image acquisition module and the first displacement information of the slide lifting module when it descends, detected by the distance detection module, are obtained. Based on the nut image and the first displacement information, it is determined whether the target nut has completely entered the sleeve in the sleeve module.

[0034] If so, the slide lifting module is controlled to descend, thereby moving the sleeve module to below the heating module, and the target nut is located at the center of the coil of the heating module.

[0035] Optionally, determining whether the target nut is fully inserted into the sleeve module based on the nut image and the displacement information includes:

[0036] Determine whether the target nut in the nut image is aligned with the sleeve outline;

[0037] If so, and the first displacement information reaches the set threshold, then it is determined that the target nut has completely entered the sleeve module.

[0038] Optionally, the nut removal device further includes a magnetic induction sensor;

[0039] The control of the sleeve module to rotate and tighten in order to unscrew the target nut from the bolt includes:

[0040] After heating is completed, the sliding table lifting module is controlled to rise so that the sleeve module is re-aligned with the target nut. The second displacement information of the sliding table lifting module during its rise, detected by the distance detection module, is obtained. Based on the second displacement information, it is determined that the target nut will re-enter the sleeve module. The sleeve module is then controlled to rotate and tighten so that it engages with the target nut. The sleeve module is then controlled to perform a disassembly action. During disassembly, the rotation state of the sleeve module, collected by the magnetic induction sensor, is obtained. Based on the rotation state of the sleeve module, it is determined whether to unscrew the target nut from the bolt.

[0041] Secondly, this application also provides a nut removal system, which includes: the nut removal device described in the first aspect and a live-line working robot, wherein the nut removal device is assembled to the end of the robotic arm of the live-line working robot;

[0042] The live-line working robot is used to move the nut removal device to the working position where the target nut to be removed is located and to perform the removal operation.

[0043] The beneficial effects of this application are:

[0044] This application provides a nut removal device and system. The nut removal device includes a main control module, a heating module, a sleeve module, and an infrared image acquisition module. Before removing the target nut, the infrared image acquisition module acquires an initial environmental image of the target nut's environment before heating. Then, the heating module heats the target nut, and the infrared image acquisition module acquires an infrared image of the target nut after heating. Based on the infrared image, the degree of corrosion of the target nut is calculated. Using the initial environmental image and the degree of corrosion, the heating power output of the heating module is dynamically adjusted to achieve precise control of the heating process, improve heating efficiency, and reduce energy consumption. Simultaneously, heating the target nut causes the rust layer on the target nut to crack, reducing the torque required for removal. Then, the main control module controls the sleeve module to be fitted onto the target nut, achieving automatic alignment between the sleeve module and the nut, ensuring stable and reliable operation. The main control module then controls the sleeve module to start rotating and tightening to unscrew the nut from the bolt, improving work efficiency and safety. Therefore, this application combines the thermal expansion difference effect and sleeve rotation in the entire nut disassembly process, replacing the traditional violent destruction method, and solving the key technical problems of low efficiency, complex operation, great safety hazards and poor equipment reliability in the process of disassembling rusted nuts in live-line work of power distribution networks. Attached Figure Description

[0045] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0046] Figure 1 This is a schematic diagram of a nut removal device provided in an embodiment of this application;

[0047] Figure 2 This is a schematic diagram of the disassembly process of a nut removal device provided in an embodiment of this application;

[0048] Figure 3 This is a schematic diagram of the disassembly process of another nut removal device provided in an embodiment of this application;

[0049] Figure 4 This is a schematic diagram of another nut removal device provided in an embodiment of this application;

[0050] Figure 5 This is a schematic diagram of the structure of another nut removal device provided in the embodiments of this application;

[0051] Figure 6 This is a schematic diagram of the disassembly process of another nut removal device provided in an embodiment of this application;

[0052] Figure 7 A schematic diagram illustrating the disassembly process of another nut removal device provided in this application embodiment;

[0053] Figure 8 This is a schematic diagram of another nut removal device provided in an embodiment of this application;

[0054] Figure 9 This is a front view of a nut removal device provided in an embodiment of this application;

[0055] Figure 10 This is a front view of the slide lifting module in a nut removal device provided in an embodiment of this application;

[0056] Figure 11 This is a side view of a nut removal device provided in an embodiment of this application;

[0057] Figure 12 This is a bottom view of a nut removal device provided in an embodiment of this application;

[0058] Figure 13 This is a schematic diagram of a nut removal system provided in an embodiment of this application;

[0059] Figure 14 A schematic diagram illustrating the information interaction between the nut removal device provided in this embodiment of the application and the live-line working robot network via a wireless network;

[0060] Figure 15 The schematic diagram of the nut removal system software architecture provided in the embodiments of this application consists of three main parts: application control, exception handling, and data interaction.

[0061] Icons: 100-Nut removal device; 1-Main control module; 2-Heating module; 3-Sleeve module; 4-Infrared image acquisition module; 5-Image acquisition module; 6-Slide lifting module; 7-Distance detection module; 8-Magnetic induction sensor; 200-Nut removal system; 9-Live-line working robot. Detailed Implementation

[0062] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It should be understood that the accompanying drawings in this application are for illustrative and descriptive purposes only and are not intended to limit the scope of protection of this application. Furthermore, it should be understood that the schematic drawings are not drawn to scale. The flowcharts used in this application illustrate operations implemented according to some embodiments of this application. It should be understood that the operations in the flowcharts may not be implemented in sequence, and steps without logical contextual relationships may be reversed or implemented simultaneously. In addition, those skilled in the art, guided by the content of this application, may add one or more other operations to the flowcharts, or remove one or more operations from the flowcharts.

[0063] Furthermore, the described embodiments are merely some, not all, of the embodiments of this application. The components of the embodiments of this application described and illustrated herein can typically be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0064] First, the background technology involved in this application will be introduced.

[0065] Currently, the main technology for disassembling rusted nuts is a cutting-type destruction device. The working principle is to align the nut with a special through groove and apply shearing force through the cutters on both sides to destroy it, thereby completing the task of disassembling the nut.

[0066] However, traditional nut removal methods mainly rely on mechanical methods that directly destroy the nut with a cutter. This method has the following problems when facing complex on-site environments such as severe corrosion, limited space, and blind spots:

[0067] 1. High structural strength requirements and bulky equipment

[0068] Cutting-type breaking devices must withstand extremely high shearing forces, especially when handling severely corroded or large nuts. The internal structure (gears, lead screws, supports, cutters, etc.) must be robust and heavy to resist the immense stress, resulting in a large and heavy overall device. Secondly, the heavy device increases the load on the robot arm, affecting its maneuverability, positioning accuracy, and working range. The reaction forces and vibrations generated by high-intensity operations not only test the device's own structure but also challenge the robot platform and positioning stability, affecting the equipment's lifespan. High power requirements increase the robot's energy consumption and heat dissipation pressure.

[0069] 2. Difficulty in nut positioning and alignment

[0070] Obstructions such as crossarms in the power distribution network environment, along with limitations in the device's structure (especially when viewed from the front), make it difficult for operators / systems to obtain clear and complete real-time images of the nut's front (facing the robot) and its surrounding environment. Therefore, precisely guiding and inserting irregularly shaped or severely corroded nuts into narrow dismantling slots without sufficient visual feedback is an extremely challenging and delicate operation. Furthermore, the repeated attempts at alignment are tedious and time-consuming, significantly reducing the overall efficiency of live-line work. Poor alignment may result in the cutter failing to fully penetrate the nut's effective position (e.g., only cutting the edge) or accidentally cutting the bolt threads (making replacement impossible and requiring complete bolt replacement), leading to disassembly failure or even bolt damage.

[0071] 3. The cutting process is uncontrollable and prone to leaving residues.

[0072] Under high shear forces, nuts (especially those that are rusted and seized) are not always cleanly cut and separated. More commonly, the nut undergoes severe plastic deformation during the extrusion and cutting process. The deformed nut remnant easily becomes further engaged and adhered to the bolt threads or forms a snap-fit ​​structure (such as "flash" wrapping around the threads), making it impossible to remove the nut from the bolt even after it has been cut. This is one of the most significant failure modes of this approach. Removing such deformed nuts often requires more complex follow-up operations (such as secondary damage, hammering, forced tightening, etc.), increasing the complexity, danger, and time consumption of operations in a high-altitude, electrified environment.

[0073] 4. Lack of status feedback mechanism

[0074] The aforementioned cutter-type breaking device lacks sufficient sensors (such as force sensors, high-precision position sensors, and internal vision probes) to monitor and provide feedback on key process information in real time, such as the magnitude of the cutting force, the degree of nut deformation, the depth of the cutting position, and the wear status of the cutter. This makes it impossible to accurately determine whether the cutter has completely cut off the nut, whether it has hit the effective part, whether the cutter has chipped or the nut has been severely squeezed and deformed.

[0075] Furthermore, the lack of robust status feedback prevents the system from intelligently adjusting cutting strategies (such as pausing, fine-tuning angles, and changing force) based on real-time working conditions (e.g., hard points, abnormal friction). It can only rely on preset programs or the operator's indirect experience, reducing the success rate and level of intelligence. Typically, it's only after attempting to pull the device or observing that the nut has been successfully removed, making it impossible to immediately ascertain the effectiveness and final status of the operation, thus affecting the smoothness of the workflow.

[0076] To address the aforementioned problems, this application proposes a nut removal device 100, which includes a main control module 1, a heating module 2, a sleeve module 3, and an infrared image acquisition module 4. The main control module 1 controls the heating module 2 to heat the nut to be removed, causing the rust layer to crack and reducing the torque required for removal. Then, the main control module 1 controls the sleeve module 3 to rotate and perform the removal operation, improving work efficiency and safety. Therefore, this application, through a combination of thermal expansion difference effect and sleeve rotation in the entire nut removal process, replaces the traditional violent destruction method, solving the key technical problems of low efficiency, complex operation, significant safety hazards, and poor equipment reliability in the removal of rusted nuts during live-line work in power distribution networks using traditional nut removal methods.

[0077] Optionally, such as Figure 1 The diagram shown is a structural schematic of a nut removal device 100 provided in this application. Figure 1 As shown, the nut removal device 100 includes: a main control module 1, a heating module 2, a sleeve module 3, and an infrared image acquisition module 4.

[0078] For example, the main control module 1 is an electronic device with data processing function. It is the core hub in the nut removal device 100 and is mainly responsible for coordinating, managing and executing the key control functions of the system. By integrating data processing, decision logic and communication scheduling, it realizes unified monitoring and instruction distribution of each module, ensuring the efficient and stable operation of the entire system.

[0079] Heating module 2 can be a heating coil. When high-frequency alternating current is passed through the heating coil, an alternating magnetic field is generated. The nut itself will induce eddy currents, and due to its own resistance, its electrical energy will be converted into heat. By controlling the current frequency, the heating temperature and depth can be controlled, and the nut can be heated precisely. The nut will expand thermally through heating. By utilizing the expansion difference between the metal substrate and the rust layer, the rust layer will be cracked, thereby greatly reducing the torque required for disassembly.

[0080] The sleeve module 3 includes a metal sleeve with threads on its inner wall, which is fitted onto the outer periphery of the nut to tighten or loosen the nut by controlling the rotation of the sleeve module 3. The sleeve module 3 can be adapted to nuts of different sizes.

[0081] The infrared image acquisition module 4 is located inside the tool directly below the sleeve module 3. It can be an infrared thermal imaging sensor. The infrared thermal imaging sensor converts the temperature signal into an image signal, which is then processed by hardware and transmitted to the main control module 1 for algorithm processing to provide temperature information.

[0082] Continue to refer to Figure 1As shown, the main control module 1 is communicatively connected to the heating module 2, the infrared image acquisition module 4, and the sleeve module 3, respectively. For example, the main control module 1 can communicate with the heating module 2, the infrared image acquisition module 4, and the sleeve module 3 through a wireless communication network (such as WIFI or ZIGBee).

[0083] The infrared image acquisition module 4 is used to acquire an initial environmental image P0 of the environment in which the target nut is located before heating, and send the initial environmental image P0 to the main control module 1.

[0084] The main control module 1 is used to control the heating module 2 to heat the target nut, and to acquire the infrared image P1 acquired by the infrared image acquisition module 4 after the target nut is heated. The module determines the degree of corrosion K of the target nut based on the infrared image P1, and determines the initial ambient temperature T0 of the environment in which the target nut was located before heating based on the initial ambient image P0 and the infrared image P1. The module dynamically adjusts the heating power output of the heating module 2 based on the initial ambient temperature T0 and the degree of corrosion K, and controls the heating module 2 to heat the target nut to generate a thermal expansion difference to loosen the rust layer. The module also controls the sleeve module 3 to move and fit onto the target nut. After determining that the sleeve module 3 is fitted onto the outer circumference of the target nut, the module controls the sleeve module 3 to rotate and tighten to unscrew the target nut from the bolt.

[0085] Therefore, this application combines the thermal expansion difference effect and sleeve rotation in the entire nut disassembly process, replacing the traditional violent destruction method, and solving the key technical problems of low efficiency, complex operation, great safety hazards and poor equipment reliability in the process of disassembling rusted nuts in live-line work of power distribution networks.

[0086] In summary, this application provides a nut disassembly device, which includes a main control module, a heating module, a sleeve module, and an infrared image acquisition module. Before disassembling the target nut, the infrared image acquisition module acquires an initial environmental image of the target nut's environment before heating. Then, the heating module heats the target nut, and the infrared image acquisition module acquires an infrared image of the target nut after heating. Based on the infrared image, the degree of corrosion of the target nut is calculated. Using the initial environmental image and the degree of corrosion, the heating power output of the heating module is dynamically adjusted to achieve precise control of the heating process, improve heating efficiency, and reduce energy consumption. Simultaneously, heating the target nut causes the rust layer on the target nut to crack, reducing the torque required for disassembly. Then, the main control module controls the sleeve module to be fitted onto the target nut, achieving automatic alignment between the sleeve module and the nut, ensuring stable and reliable operation. The main control module then controls the sleeve module to start rotating and tightening to unscrew the nut from the bolt, improving work efficiency and safety. Therefore, this application combines the thermal expansion difference effect and sleeve rotation in the entire nut disassembly process, replacing the traditional violent destruction method, and solving the key technical problems of low efficiency, complex operation, great safety hazards and poor equipment reliability in the process of disassembling rusted nuts in live-line work of power distribution networks.

[0087] Optionally, refer to Figure 2 As shown, the above-mentioned control heating module heats the target nut, including:

[0088] S101. Control the heating module to heat the target nut according to the preset heating time.

[0089] In one feasible approach, for example, with a pre-set heating time of 5 minutes, the main control module 1 controls the heating coil in the heating module 2 to generate an alternating magnetic field. This creates an alternating magnetic field inside the coil, causing free electrons in the metal within the coil to move under the influence of the magnetic field, thus generating heat to heat the nut. This heating of the target nut causes it to expand thermally, and by utilizing the expansion difference between the metal substrate and the rust layer, the microstructure of the rust layer breaks down, significantly reducing the required disassembly torque (heating at 300℃ can reduce the disassembly torque by 40%-60%, and heating at 600℃ can reduce it by more than 70%), ensuring that the nut is not damaged. This method enables low-torque, controllable disassembly of corroded nuts, fundamentally avoiding massive load impacts on the device structure and robot platform. It is particularly suitable for scenarios with confined spaces or large nuts, significantly improving equipment miniaturization, weight reduction, and operational safety. Furthermore, the heating method proposed in this application is effective for nuts with varying degrees of corrosion. Even heavily corroded nuts can be easily and smoothly disassembled by rotating the sleeve after heating. This method avoids the risks of direct cutting leading to nut deformation and debris adhering to the bolt (such as a "seized" state). The disassembly process is more controllable and does not damage the bolt threads, ensuring the feasibility of subsequent maintenance (such as bolt replacement).

[0090] The heating output of the heating module is dynamically adjusted based on the initial ambient temperature and the degree of corrosion, including:

[0091] S102. Input the degree of corrosion of the target nut and the initial ambient temperature into the pre-built heating temperature model to determine the set heating temperature value to which the target nut should be heated.

[0092] The heating temperature model was constructed based on a large number of nuts with different degrees of corrosion and the initial ambient temperature obtained in advance.

[0093] S103. Obtain the current infrared image of the target nut during the heating process, which is acquired by the infrared image acquisition module.

[0094] In this method, the temperature of the nut is detected by heating it using an infrared thermal imaging sensor.

[0095] S104. Determine the current temperature value of the target nut based on the current infrared image.

[0096] In one feasible approach, the set heating temperature T to which the target nut is to be heated can be calculated using the degree of corrosion of the target nut and the initial ambient temperature. During the heating process of the target nut by the heating module 2, the infrared image acquisition module 4 acquires the current infrared image of the target nut in real time, and uses the current infrared image to calculate the current temperature value of the target nut, i.e., the actual heating temperature value.

[0097] S105. The difference between the set heating temperature value and the current temperature value is used as the heating error temperature value.

[0098] S106. Based on the heating error temperature value and the preset adjustment coefficient, dynamically adjust and determine the heating power adjustment amount output by the heating module 2.

[0099] The preset adjustment coefficients include: proportional coefficient, integral coefficient, and derivative coefficient.

[0100] In one feasible approach, a PID control algorithm is used to dynamically adjust the heating power output of heating module 2. Specifically, the difference between the set heating temperature value and the current temperature value is taken as the heating error temperature value, and the PID algorithm is applied to adjust the heating error temperature value. That is, the product of the heating error temperature value and the adjustment coefficient is calculated, and the product result is used as the adjustment amount of the heating power output of heating module 2 to eliminate steady-state error and improve heating control accuracy.

[0101] Therefore, in this embodiment, a temperature detection data processing algorithm is used to dynamically calculate the target heating temperature for different degrees of corrosion and different ambient temperatures in real time. This can reduce heating power consumption while ensuring heating effect, thereby saving electricity.

[0102] Optionally, the heating temperature model includes the following formula (1):

[0103] Heating set temperature value = (450 + 2 * (T0 - 25) + 100 * K)℃ (1)

[0104] Where 450 is the preset target temperature base value, T0 is the initial ambient temperature, and K is the degree of corrosion of the target nut.

[0105] In one feasible approach, the initial ambient temperature T0 calculated above and the degree of corrosion K of the target nut can be substituted into the above formula (1) to calculate the heating set temperature value.

[0106] The heating setting temperature value takes into account both ambient temperature and degree of corrosion, so that the heating module 2 can minimize energy consumption while ensuring heating effect.

[0107] Optionally, refer to Figure 3 As shown, the degree of corrosion of the target nut is determined based on infrared images, including:

[0108] S201. Based on the temperature value of each pixel in the infrared image, determine the average temperature value of the infrared image, mark the pixels in the infrared image with a temperature value higher than the average temperature value as nut pixels, and determine the number of nut pixels.

[0109] S202. Determine the first average temperature value of all nut pixels in the infrared image, and take the nut pixels in the infrared image that are lower than the first average temperature value as rust pixels.

[0110] S203. Determine the number of rust pixels in the infrared image, and calculate the degree of rust on the target nut based on the number of nut pixels and the number of rust pixels.

[0111] In one feasible approach, the degree of corrosion of the target nut can be calculated using infrared images. Specifically, the temperature value Ti of each pixel in the infrared image is determined, and the sum of the temperature values ​​of all pixels in the infrared image is calculated. The ratio of the sum of the temperature values ​​of all pixels to the number of pixels is used as the average temperature value T1 of the infrared image. Then, pixels in the infrared image with a temperature value higher than the average temperature are marked as nut pixels, and the number N of nut pixels is calculated.

[0112] Calculate the first average temperature value T2 of all nut pixels in the infrared image, and take the nut pixels in the infrared image that are lower than the first average temperature value T2 as rust pixels, and count the number of rust pixels n in the infrared image. Based on the number of nut pixels and the number of rust pixels, calculate the degree of corrosion of the target nut, that is, the corrosion degree coefficient K = ((n / N) - 0.5) * 2.

[0113] Optionally, based on the initial environmental image and the infrared image, the initial ambient temperature of the environment where the target nut is located is determined, including:

[0114] Based on the pixel coordinates of all nut pixels in the infrared image, the temperature value corresponding to each nut pixel in the initial environmental image is determined, and the second average temperature value of all nut pixels in the initial environmental image is taken as the initial environmental temperature.

[0115] In one feasible approach, based on the pixel coordinates of all nut pixels in the aforementioned infrared image, the temperature value corresponding to each nut pixel in the initial environmental image can be found. Then, the second average temperature value of all nut pixels in the initial environmental image is taken as the initial environmental temperature T0.

[0116] Optionally, refer to Figure 4 As shown, the nut removal device 100 also includes: an image acquisition module 5; the image acquisition module 5 is communicatively connected to the main control module 1; the main control module 1 is also communicatively connected to the industrial control computer in the live-line working robot 9;

[0117] For example, the image acquisition module 5 can be a depth camera, used to acquire video images of the location and provide network video streaming services using the RTSP protocol, providing real-time images to operators while also providing image data to support robot vision.

[0118] Image acquisition module 5 is used to acquire images of the working environment during the movement of the robotic arm and the nut removal device 100 in real time, and send the images to the industrial control computer so that the industrial control computer can spatially locate the target nut based on the images, obtain the target position of the target nut, generate the movement path of the robotic arm based on the target position of the target nut, and control the robotic arm to move the nut removal device 100 to directly below the target nut so that the target nut is aligned with the sleeve module 3.

[0119] In one feasible approach, to achieve visual positioning of the target nut, the nut disassembly device 100 further includes an image acquisition module 5. This module 5 can acquire images of the working environment in real time and transmit them to an industrial control computer. The industrial control computer analyzes and processes the images using an image recognition algorithm to determine the target position of the target nut, thus achieving spatial positioning of the target nut. Then, based on the target position of the target nut, the industrial control computer plans the movement path of the robotic arm and controls the robotic arm to move the nut disassembly device 100 directly below the target nut, ensuring alignment between the target nut and the sleeve module 3. This achieves precise alignment of the target nut and the sleeve module 3 under complex visual conditions, greatly improving operational accuracy and effectively solving the problem of blind spots caused by crossarm obstruction.

[0120] Optionally, refer to Figure 5 As shown, the nut removal device 100 also includes: a slide lifting module 6 and a distance detection module 7;

[0121] Among them, the sleeve module 3 is fixed to the slide table lifting module 6 by a connector, and the distance detection module is set on the slide table lifting module 6; both the slide table lifting module 6 and the distance detection module are communicatively connected to the main control module 1.

[0122] For example, the slide table lifting module 6 includes a slide table, a slide table motor, and a slide table transmission gear set. The sleeve module 3 can be fixed to the slide table by a connector. By controlling the rotation of the slide table motor, the slide table transmission gear set is driven to move the sleeve module 3 on the slide table up and down. Therefore, the slide table lifting module 6 is used for the extension and retraction of the sleeve before and after the nut is heated; that is, the slide table lifting module 6 is actually a movable base for the sleeve module 3.

[0123] In this embodiment, after the target nut and the sleeve module 3 are aligned, the slide lifting module 6 can be used to move up and down to drive the sleeve module 3 to be fitted onto the outer periphery of the target nut.

[0124] refer to Figure 6 As shown, the control sleeve module 3 moves to fit onto the target nut, including:

[0125] S301. Obtain the nut image acquired by the image acquisition module and the first displacement information detected by the distance detection module when the slide lifting module descends, and determine whether the target nut has completely entered the sleeve in the sleeve module based on the nut image and the first displacement information.

[0126] S302. If so, control the slide lifting module to descend, so as to move the sleeve module to the bottom of the heating module, and the target nut is located at the center of the heating module's coil.

[0127] In one feasible approach, during the up-and-down movement of the sliding table lifting module 6, the image of the nut acquired by the image acquisition module 5 and the first displacement information of the sliding table lifting module 6 when it descends, detected by the distance detection module, can be acquired in real time. Based on the nut image and the first displacement information of the sliding table lifting module 6 when it descends, it is jointly determined whether the target nut has completely entered the sleeve in the sleeve module 3. That is, by controlling the up-and-down movement of the sliding table lifting module 6, the sleeve and the nut are aligned. If it is determined that the target nut has completely entered the sleeve in the sleeve module 3, the sliding table lifting module 6 is controlled to descend, so as to move the sleeve module 3 to the bottom of the heating module 2, and the target nut is located at the center of the coil of the heating module 2.

[0128] In another feasible approach, the first displacement information during the descent of the sliding table lifting module 6 can be used to determine whether a nut is being pressed against the edge of the sleeve. If such a situation exists, a sleeve rotation command is executed to allow the target nut to enter the sleeve. Therefore, the distance detection module provides calibration information for sleeve movement and error detection.

[0129] Optionally, refer to Figure 7 As shown, based on the nut image and displacement information, it is determined whether the target nut has completely entered the sleeve module, including:

[0130] S401. Determine whether the target nut and the sleeve outline are aligned in the nut image.

[0131] S402. If so, and the first displacement information reaches the set threshold, then it is determined that the target nut has completely entered the sleeve module.

[0132] In one feasible approach, an image processing algorithm can be used to perform edge detection on the nut image to determine whether the target nut and the sleeve outline are aligned. If so, and the first displacement information reaches a set threshold, it can be determined that the target nut has completely entered the sleeve module 3. Therefore, through the cooperation of visual recognition, the sliding table lifting module 6, and the distance detection module, precise alignment of the target nut and sleeve engagement under complex visual conditions are achieved, ensuring stable and reliable operation.

[0133] Optionally, refer to Figure 8As shown, the nut removal device 100 also includes a magnetic induction sensor 8;

[0134] Controlling the sleeve module 3 to rotate and tighten to unscrew the target nut from the bolt includes:

[0135] After heating is completed, the sliding table lifting module 6 is raised so that the sleeve module 3 is re-aligned with the target nut. The second displacement information of the sliding table lifting module 6 when it rises is obtained by the distance detection module. Based on the second displacement information, it is determined that the target nut has re-entered the sleeve module 3. The sleeve module 3 is then rotated and tightened so that it is engaged with the target nut. The sleeve module 3 is then controlled to perform a disassembly action. During disassembly, the rotation state of the sleeve module 3 is obtained by the magnetic induction sensor 8. Based on the rotation state of the sleeve module 3, it is determined whether to unscrew the target nut from the bolt.

[0136] In one feasible approach, after heating is completed, the sliding table lifting module 6 is raised to realign the sleeve module 3 with the target nut. The second displacement information of the sliding table lifting module 6 during its rise is obtained again by the distance detection module. Based on the second displacement information, it is determined whether the target nut has re-entered the sleeve module 3. If so, the sleeve module 3 is rotated and tightened to fit the sleeve with the target nut. The sleeve module 3 is then controlled to begin rotating and tightening. During disassembly, the rotation state of the sleeve module 3 is acquired by the magnetic induction sensor 8. Based on the rotation state of the sleeve module 3, it is determined whether the nut has been unscrewed from the bolt. If so, it is determined that the target nut has been successfully unscrewed from the bolt, thus improving operational efficiency.

[0137] In another possible approach, if it is determined that there is a misalignment between the target nut and the sleeve based on the second displacement information, the main control module 1 continues to adjust the rotation of the sleeve to ensure that the sleeve and the target nut are accurately engaged.

[0138] Optionally, refer to Figures 9-12 The images shown are views of the nut removal device 100 provided in this application from different angles. Figure 9 The image shown is a front view of the nut removal device 100. Figure 9 It can be observed that the nut removal device 100 includes two image acquisition modules 5. The heating module 2 is an AC heating coil spirally wound around the outside of the sleeve module 3. The infrared temperature sensor inside the sleeve module 3 can monitor the temperature at the middle position of the coil in real time and feed the data back to the main control module 1. The main control module 1 dynamically adjusts the current with a PID algorithm to make the nut reach the target temperature (600℃). After reaching the set temperature, the heating program ends and the power is automatically cut off.

[0139] like Figure 10 The image shown is a front view of the slide lifting module 6 in the nut removal device 100; as shown... Figure 11 The image shown is a side view of the nut removal device 100; as shown... Figure 12 The image shown is a bottom view of the nut removal device 100. Figure 12 As shown, the infrared image acquisition module 4 is located at the bottom center of the sleeve module 3, and can monitor the temperature at the middle position of the coil in real time.

[0140] Optionally, refer to Figure 13 The figure shows a schematic diagram of a nut removal system 200 provided in this application. As shown, the nut removal system 200 includes: a nut removal device 100 provided in the above embodiment and a live-line working robot 9. The nut removal device 100 is assembled to the end of the robotic arm of the live-line working robot 9.

[0141] The live-line working robot 9 is used to move the nut removal device 100 to the working position where the target nut to be removed is located and to perform the removal operation.

[0142] In one feasible approach, the nut removal device 100 is attached to the end effector of the robotic arm of the live-line working robot 9, and the end effector is controlled to move along a planned path to move the nut removal device 100 to the working position of the target nut to be removed and perform the removal operation.

[0143] Optionally, refer to Figure 14 As shown, according to Figure 14 The network protocol diagram shown illustrates that the nut removal device 100 is connected to the robot network to ensure normal network operation. The nut removal device 100 interacts with the robot network via a wireless network. The user terminal can observe all tool information in real time through the control terminal. The robot obtains tool visual information through the wireless network, thereby realizing real-time planning and adjustment of the robotic arm's motion path. The tool wireless network has been deeply optimized based on system resources to achieve a high-real-time network communication protocol.

[0144] Optionally, refer to Figure 15 The diagram illustrates the application control, anomaly detection, and information interaction of the nut removal system 200 during operation. The software architecture of the nut removal system 200 consists of three main parts: application control, anomaly detection, and information interaction. The operational steps of the nut removal system 200's software architecture are as follows:

[0145] Step 1: Power on the device and initialize it; all modules in each system perform self-tests; system self-test.

[0146] Step Two: According to Figure 14 The diagram shows a network protocol. The nut removal device 100 is connected to the robot network to ensure the network operates normally.

[0147] Step 3: Run as follows Figure 15 The application control service, anomaly detection service, and information interaction service shown are as follows;

[0148] Step 4: Information Interaction. The image acquisition unit transmits the working environment images captured in real time to relevant nodes in the robot network, processes and responds to control commands received from the network, and transmits data from the tool end to the robot system in real time.

[0149] Step 5: Application Control. This involves parsing control commands and executing corresponding actions. The application control process includes the overall interactive control of sub-modules such as heating module 2, infrared image acquisition module 4, sleeve module 3, slide lifting module 6, distance detection module, magnetic induction sensor 8, and electronic control module.

[0150] Step Six: Heating Module 2. (Example) Figure 9 The heating module 2 is an AC heating coil spirally wound around the outside of the sleeve. The infrared image acquisition module 4 inside the nut removal device 100 can monitor the temperature at the middle position of the coil in real time and feed the data back to the control system. The main control module 1 uses a PID algorithm to dynamically adjust the current so that the nut reaches the target temperature (600℃). After the set temperature is reached, the heating program ends and the power is automatically cut off.

[0151] Step 7: Anomaly detection mechanism. For example... Figure 14 The system shown is a real-time diagnostic system based on multi-sensor fusion. It detects problems such as execution timeout, position abnormality, current abnormality, power abnormality and communication abnormality based on the data of each sub-module and the software status, and interacts with the communication interface.

[0152] Optionally, a unified main control system software architecture is used to realize efficient communication, data exchange and coordinated operation mechanism between various functional modules, thereby realizing efficient communication, data exchange and coordinated operation mechanism between various modules in the nut removal device 100.

[0153] Among them, the main control module 1 adopts a single-threaded loop mode combined with interrupts and state machines to facilitate interaction between various software sub-modules. For sub-modules with high real-time requirements, timer interrupts are used to make their response time accuracy reach the millisecond level.

[0154] The communication control module is divided into two layers: the transmission layer is responsible for receiving and sending data packets, and the application layer is responsible for parsing packets and implementing application functions.

[0155] Communication data is stored in a circular queue, and the push and pop operations of the circular queue are controlled by a software state machine.

[0156] When there is no message to process, the software state machine is in the "idle state" for receiving. When a valid communication data identifier is received, the software state machine first checks whether the circular queue is full. If the queue is full, it reports this status and ignores the communication message. If the queue is not full, it switches the receiving state to the "receive state" and starts the receiving timeout timer at the same time (if the receiving time of a message exceeds a certain value, it is determined to be a transmission timeout exception, the receiving of the message ends and the status is reported). When the received data meets the length information, the receiving state is changed to the "verification state", and the correctness of the message data is verified by the built-in data verification algorithm.

[0157] If the verification fails, this status is reported and the communication message is ignored; if the verification passes, it indicates that the data reception is normal, and the message is passed to the application layer and the transport layer continues to work.

[0158] After receiving the data, the application layer parses and judges the data step by step according to the protocol content, checks the correctness of each different instruction, and finally feeds back the execution result based on the software's judgment.

[0159] By combining wireless communication protocols, the entire nut disassembly process—including target nut identification and positioning, precise temperature control of the heating area, judgment of the disassembly operation status after heating, linkage execution of the robotic arm and disassembly tools, and real-time feedback of the operation effect—is intelligently planned and controlled in a closed loop. Ultimately, this achieves a fully automated and intelligent operation chain from target identification to disassembly completion, forming a fully digital operation process.

[0160] Optionally, the specific steps involved in the nut removal process will be described in detail through the following embodiments:

[0161] The nut removal system 200 includes a live-line working robot 9 and a nut removal device 100. The nut removal device 100 includes a main control module 1, an image acquisition module 5, a wireless WiFi module, a heating module 2, an infrared image acquisition module 4, a sleeve module 3, a slide lifting module 6, a distance detection module, a magnetic induction sensor 8, and an electronic speed control module.

[0162] Step 1: Connect the nut removal device 100 to the power distribution network live-line working robot 9 system. The nut removal device 100 periodically sends its own status information to the live-line working robot 9 via wireless network.

[0163] Step 2: The nut removal device 100 transmits the working environment image acquired by the image acquisition module 5 to the robot. The robot performs spatial positioning by recognizing the feature points of the nut image, and then plans a route to automatically move to the bottom of the nut. After the nut is aligned with the "sleeve module 3", the robotic arm moves upward. The robot determines whether the nut has completely entered the rotating sleeve by combining the visual image with the distance detection module of the tool slide lifting mechanism.

[0164] Step 3: The distance detection module of the sliding table lifting mechanism can track the position of the sliding table in real time. When the sleeve and nut are misaligned, the distance sensor data determines whether the nut is being pushed against the edge of the sleeve. If this is the case, the sleeve rotation command is executed to make the nut enter the sleeve.

[0165] Step 4: Control the slide table lifting mechanism to descend, and the rotating sleeve will retract accordingly until it is below the heating mechanism coil, with the nut at the center of the heating mechanism coil;

[0166] Step 5: Control the heating module 2 to start working, heat the rusted nut to make it expand due to heat, and the heating is completed after the set temperature is reached;

[0167] Step 6: Control the slide lifting mechanism to rise, rotate the sleeve to rise to the initial position, and the nut re-enters the sleeve;

[0168] Step 7: Control the sleeve module 3 to rotate and tighten so that the sleeve and nut are accurately engaged;

[0169] Step 8: Control the sleeve module 3 to continue rotating to perform the nut removal action. During this process, the sleeve begins to rotate and retracts inward, which will drive the nut to unscrew the bolt.

[0170] Therefore, the nut removal system 200 proposed in this application provides an intelligent solution that integrates machine vision, wireless communication and thermodynamic processing. It removes rusty nuts by combining the principle of heating expansion with mechanical control. It is designed to solve the problems of low efficiency and high safety hazards in the process of removing rusty nuts during live-line work in power distribution networks.

[0171] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

[0172] It will be apparent to those skilled in the art that this application is not limited to the details of the exemplary embodiments described above, and that this application can be implemented in other specific forms without departing from the spirit or essential characteristics of this application. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this application is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this application. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A nut removal device, characterized in that, The nut removal device includes: a main control module, a heating module, a sleeve module, and an infrared image acquisition module; the main control module is communicatively connected to the heating module, the infrared image acquisition module, and the sleeve module respectively; The infrared image acquisition module is used to acquire an initial environmental image of the environment in which the target nut is located before heating and send the initial environmental image to the main control module. The main control module is used to control the heating module to heat the target nut, acquire an infrared image captured by the infrared image acquisition module after the target nut is heated, determine the degree of corrosion of the target nut based on the infrared image, and determine the initial ambient temperature of the environment in which the target nut was located before heating based on the initial ambient image and the infrared image; dynamically adjust the heating power output of the heating module based on the initial ambient temperature and the degree of corrosion, and control the heating module to heat the target nut based on the heating power adjustment to generate a thermal expansion difference to loosen the rust layer, control the sleeve module to move to fit onto the target nut, and after determining that the sleeve module is fitted onto the outer circumference of the target nut, control the sleeve module to rotate and tighten to unscrew the target nut from the bolt; The process of controlling the heating module to heat the target nut includes: The heating module is controlled to heat the target nut for a preset heating time. Based on the initial ambient temperature and the degree of corrosion, the heating output of the heating module is dynamically adjusted, including: The degree of corrosion of the target nut and the initial ambient temperature are input into a pre-built heating temperature model to determine the set heating temperature value to which the target nut should be heated; Acquire the current infrared image of the target nut during the heating process, acquired by the infrared image acquisition module; Based on the current infrared image, determine the current temperature value of the target nut; The difference between the set heating temperature value and the current temperature value is used as the heating error temperature value; The heating power output of the heating module is dynamically adjusted and determined based on the heating error temperature value and the preset adjustment coefficient. The determination of the degree of corrosion of the target nut based on the infrared image includes: Based on the temperature value of each pixel in the infrared image, the average temperature value of the infrared image is determined, and the pixels in the infrared image with a temperature value higher than the average temperature value are marked as nut pixels, and the number of nut pixels is determined. Determine the first average temperature value of all nut pixels in the infrared image, and identify nut pixels in the infrared image that are below the first average temperature value as rust pixels; The number of rusted pixels in the infrared image is determined, and the degree of rust on the target nut is calculated based on the number of nut pixels and the number of rusted pixels. The determination of the initial ambient temperature of the environment where the target nut is located, based on the initial environmental image and the infrared image, includes: Based on the pixel coordinates of all nut pixels in the infrared image, the temperature value corresponding to each nut pixel in the initial environmental image is determined, and the second average temperature value of all nut pixels in the initial environmental image is taken as the initial environmental temperature. The nut removal device further includes an image acquisition module; the image acquisition module is communicatively connected to the main control module. The main control module is also connected to the industrial control computer in the live-line working robot. The image acquisition module is used to acquire images of the working environment in real time as the robotic arm in the live-line working robot moves the nut removal device, and send the images to the industrial control computer. The industrial control computer then uses the images to spatially locate the target nut, obtains the target position of the target nut, generates a movement path for the robotic arm based on the target position of the target nut, and controls the robotic arm to move the nut removal device to directly below the target nut, so that the target nut is aligned with the sleeve module. The nut removal device further includes: a slide lifting module and a distance detection module; The sleeve module is fixed to the slide table lifting module via a connector, and the distance detection module is mounted on the slide table lifting module; both the slide table lifting module and the distance detection module are communicatively connected to the main control module. Controlling the movement of the sleeve module to fit onto the target nut includes: The image of the nut acquired by the image acquisition module and the first displacement information of the slide lifting module when it descends, detected by the distance detection module, are obtained. Based on the nut image and the first displacement information, it is determined whether the target nut has completely entered the sleeve in the sleeve module. If so, the slide lifting module is controlled to descend, so as to move the sleeve module to below the heating module, and the target nut is located at the center of the coil of the heating module; The process of determining whether the target nut is fully inserted into the sleeve module based on the nut image and the displacement information includes: Determine whether the target nut in the nut image is aligned with the sleeve outline; If so, and the first displacement information reaches the set threshold, then it is determined that the target nut has completely entered the sleeve module; The nut removal device further includes a magnetic induction sensor; Controlling the sleeve module to rotate and tighten to unscrew the target nut from the bolt includes: After heating is completed, the sliding table lifting module is controlled to rise so that the sleeve module is re-aligned with the target nut. The second displacement information of the sliding table lifting module during its rise, detected by the distance detection module, is obtained. Based on the second displacement information, it is determined that the target nut will re-enter the sleeve module. The sleeve module is then controlled to rotate and tighten so that it engages with the target nut. The sleeve module is then controlled to perform a disassembly action. During disassembly, the rotation state of the sleeve module, collected by the magnetic induction sensor, is obtained. Based on the rotation state of the sleeve module, it is determined whether to unscrew the target nut from the bolt.

2. The apparatus according to claim 1, characterized in that, The heating temperature model includes: Heating set temperature value = (450 + 2 * (T0 - 25) + 100 * K) ℃; Wherein, 450 is the preset target temperature base value, T0 is the initial ambient temperature, and K is the degree of corrosion of the target nut.

3. A nut removal system, characterized in that, The nut removal system includes: the nut removal device as described in claim 1 or 2 above and a live-line working robot, wherein the nut removal device is assembled to the end of the robotic arm of the live-line working robot; The live-line working robot is used to move the nut removal device to the working position where the target nut to be removed is located and to perform the removal operation.

Images