Defect identification and positioning spraying device and method

Abstract

The invention relates to the field of weld joint recognition devices, in particular to a defect recognition and positioning spraying device and method. The device comprises an operation table, an identification assembly and a polishing and spraying assembly. Magnetic attraction moving assemblies are arranged at four top corners of the bottom of the operation table, and positioning radars are dispersedly arranged on the side walls. The recognition assembly is arranged on the side wall of the operation table and staggered with the positioning radar in position, and tracking recognition is conducted on the container welding seam through a multi-section type rotating structure. The polishing and spraying assembly is arranged at the bottom of the operation table and rotates through a connecting piece to drive a polishing piece and a spraying piece at the two ends to alternately ascend and descend, and the purpose of polishing and then spraying a weld joint is achieved. By means of collaborative innovation of magnetic attraction moving positioning, multi-degree-of-freedom visual tracking, a cross-shaped deformation position executing mechanism and a dust and gas dual-recovery system, high precision, high efficiency and high environmental protection performance of weld joint repairing under complex working conditions are achieved, and an effective solution is provided for intelligent maintenance of a pressure container and a pipeline.

Description

Technical Field

[0001] This invention relates to the field of weld identification devices, and more particularly to a defect identification and positioning spraying device and method. Background Technology

[0002] Precisely locating welds is fundamental to ensuring the correct connection of all components in a container, and also provides clear targets for subsequent defect detection (such as porosity, cracks, etc.). Grinding welds can remove surface defects such as weld beads, spatter, and oxide scale, allowing for a smooth transition between the weld and the base material, reducing stress concentration and corrosion risks, and meeting the surface quality requirements for non-destructive testing. Repairing internal defects (such as lack of fusion or incomplete penetration) can restore the mechanical properties of the weld, ensuring that its strength and toughness match the base material, and preventing fatigue fracture or leakage accidents caused by local weakness.

[0003] Chinese patent document CN115533387B discloses a wall-climbing robot for weld inspection, including a top plate, a flaw detection mechanism, a magnetic wheel mechanism, a sensor assembly, a liquid supply mechanism, a gravity feedback mechanism, and a controller. The industrial camera in the sensor assembly detects the weld. Based on the weld detection results, the controller drives four sets of magnetic wheel mechanisms to rotate for weld tracking. Based on the gravity detection results, the gravity feedback mechanism drives the water pump in the liquid supply mechanism to continuously spray magnetic suspension liquid onto the weld to be inspected. The first servo motor in the flaw detection mechanism drives the magnetic particle flaw detector to move down and continuously inspect the weld to be inspected.

[0004] The aforementioned device utilizes magnetic particle inspection. However, rough weld surfaces, oil stains, oxide scale, or coatings can hinder the flow of magnetic particles and mask defect signals, requiring pretreatment (such as grinding and cleaning), which may introduce human-caused damage. After inspection, the workpiece may retain residual magnetism, attracting iron filings or affecting subsequent processing (such as welding and painting), requiring demagnetization, which increases process costs and fails to achieve the purpose of repairing the weld. Summary of the Invention

[0005] To address the problems existing in the background technology, a defect identification and positioning spraying device and method are proposed. Through the synergistic innovation of magnetic suction mobile positioning, multi-degree-of-freedom visual tracking, cross-shaped displacement actuator and dust and gas dual recovery system, high precision, high efficiency and high environmental protection of weld repair under complex working conditions are achieved, providing an effective solution for intelligent maintenance of pressure vessels and pipelines.

[0006] This invention proposes a defect identification and positioning spraying device, including an operating table, an identification component, and a grinding and spraying component. Magnetic moving components are installed at the four corners of the bottom of the operating table, and positioning radars are distributed along the side walls. The identification component is located on the side wall of the operating table, staggered with the positioning radars, and uses a multi-segment rotating structure to track and identify the container weld seam. The grinding and spraying component is located at the bottom of the operating table; through the rotation of connecting parts, it drives the grinding and spraying components at both ends to alternately rise and fall, achieving the purpose of grinding the weld seam before spraying.

[0007] Preferably, the operating table is disc-shaped, with mounting slot one and mounting slot two alternately arranged on the side wall; the positioning radar is installed in mounting slot one; and the identification component is installed in mounting slot two.

[0008] Preferably, the identification component includes a rotating shaft 1 rotatably disposed within the mounting groove 2; a drive seat is disposed on the rotating shaft 1; a multi-segment rotating structure is disposed on the connecting rod 1; the multi-segment rotating structure includes a rotating shaft rotatably disposed on the drive seat; a connecting rod 2 rotatably disposed on the connecting rod 1; and an identification head disposed on the connecting rod 2.

[0009] Preferably, the grinding and spraying assembly includes a rotating platform rotatably positioned at the center of the bottom of the operating table; mounting brackets are provided on both sides of the rotating platform; connecting parts are provided on the mounting brackets; the connecting parts include a second rotating shaft rotatably positioned on the mounting brackets; telescopic drive components are provided on both sides of the second rotating shaft with their telescopic ends in opposite directions; the grinding component and the spraying component are respectively connected to two sets of telescopic ends; the telescopic drive component consists of two sets of cylinders that telescopic in opposite directions, and the telescopic drive component and the second rotating shaft form a cross-shaped structure.

[0010] Preferably, the grinding component includes a rotating frame located on the telescopic rod of a cylinder on one side; a rotating table is provided on the rotating frame; and a grinding head is provided on the rotating table.

[0011] Preferably, a liquid storage tank is provided on the top of the rotating platform; the spraying part includes a nozzle located on another set of cylinder extension rods; the nozzle is connected to the liquid storage tank through a pipe.

[0012] Preferably, the second rotating shaft has a hollow structure, and a dust collection head connected to the hollow structure is provided at the bottom of the side wall; a dust collection box connected to the hollow structure is provided on the mounting frame; and an air pump is provided on the dust collection box.

[0013] Preferably, the magnetic moving assembly includes a telescopic column located at the bottom of the operating table; a steering seat is provided at the bottom of the telescopic column; a magnetic platform is provided at the bottom of the steering seat; and a moving wheel is provided at the bottom of the magnetic platform.

[0014] This invention further proposes a defect identification and positioning spraying method, employing the aforementioned defect identification and positioning spraying device, with the following steps:

[0015] S1. The device crawls along the wall of the container;

[0016] S2. The positioning radar identifies physical obstacles in the pipe weld area in real time and establishes the robot's pose coordinate system in a closed / complex environment without GPS; it also adjusts the path based on the trajectory prediction of moving obstacles.

[0017] S3. The identification head tracks the surrounding weld seams;

[0018] S4. When the weld position is detected, the magnetic moving component is used to rotate and extend, so that the operating table is located at the end of the weld.

[0019] S5. The rotating frame and rotating table rotate independently, in conjunction with the extension and retraction of the cylinder, to drive the grinding head to perform multi-directional and wide-range grinding pretreatment on the weld; during the grinding process, the dust collection head collects the flying dust.

[0020] S6. The worktable can be moved to grind and spray paint at the same time. Alternatively, the entire grinding process can be completed before moving in the opposite direction to spray paint. During spraying, the nozzle can extend, retract, and rotate, while the dust collection head collects the sprayed liquid.

[0021] Compared with the prior art, the present invention has the following beneficial technical effects:

[0022] The defect identification and positioning spraying device proposed in this invention achieves a fully automated closed-loop process for weld maintenance through multi-system collaborative innovation. The magnetic moving component, combined with a telescopic column and magnetic platform, provides an adsorption force of ≥500N, enabling the disc-shaped operating platform to adaptively crawl along the curved surface of the pipe and maintain a horizontal position. Simultaneously, the positioning radar detects obstacles within 5m in real time using the 77GHz frequency band, ensuring path safety through a 200ms-level obstacle avoidance response. The identification component employs a multi-segment robotic arm structure (rotating shaft one, connecting rod one, and connecting rod two rotating in multiple directions), driving the vision camera identification head to form a spherical working area, achieving sub-millimeter-level weld positioning. The grinding and spraying component innovatively designs a cross-shaped displacement mechanism; rotating shaft two drives two sets of counter-rotating cylinders, allowing for rapid switching between the grinding head and the spray nozzle. Through multi-axis linkage, the weld is precisely ground to 0±0.2mm, and anti-corrosion material is sprayed, achieving a coating uniformity of ±10μm. The integrated hollow dust collection system captures dust during grinding and switches to a recycling mode during spraying to reduce paint volatilization, significantly improving environmental friendliness. Through the synergistic innovation of magnetic motion positioning, multi-degree-of-freedom visual tracking, cross-shaped displacement actuator, and dust and gas dual recovery system, this device achieves high precision, high efficiency, and high environmental protection in weld repair under complex working conditions, providing an effective solution for intelligent maintenance of pressure vessels and pipelines. Attached Figure Description

[0023] Figure 1 A bottom view of the defect identification and positioning spraying device;

[0024] Figure 2 Top view of the defect identification and positioning spraying device;

[0025] Figure 3 To identify the component structure diagram;

[0026] Figure 4 Top view of the polished and coated components;

[0027] Figure 5 A bottom view of the components being sanded and coated;

[0028] Figure 6 This is a structural diagram of the magnetic moving component.

[0029] Reference numerals: 1. Control panel; 2. Positioning radar; 3. Identification component; 301. Drive base; 302. Rotating shaft one; 303. Connecting rod one; 304. Connecting rod two; 305. Identification head; 4. Magnetic moving component; 401. Telescopic column; 402. Steering seat; 403. Moving wheel; 404. Magnetic table; 5. Grinding and spraying component; 501. Liquid tank; 502. Rotating table; 503. Mounting bracket; 504. Telescopic drive component; 505. Spray head; 506. Pipe; 507. Rotating frame; 508. Rotating table; 509. Dust collection box; 510. Rotating shaft two; 511. Dust collection head. Detailed Implementation

[0030] Example 1: This invention proposes a defect identification and positioning spraying device, such as... Figures 1-2 As shown, the system includes an operating platform 1, an identification component 3, and a grinding and spraying component 5. Magnetic moving components 4 are installed at the four corners of the bottom of the operating platform 1, and positioning radars 2 are distributed along the side walls. The identification component 3 is located on the side walls of the operating platform 1, staggered with the positioning radars 2, and uses a multi-segment rotating structure to track and identify the container weld seam. The grinding and spraying component 5 is located at the bottom of the operating platform 1; through the rotation of connecting parts, the grinding and spraying components at both ends alternately rise and fall, achieving the purpose of grinding the weld seam before spraying it.

[0031] It should be further explained that the operating platform 1 is disc-shaped, with alternating mounting slots 1 and 2 on its side walls; the positioning radar 2 is installed in mounting slot 1; the identification component 3 is installed in mounting slot 2; the positioning radar 2 uses the 77GHz frequency band to detect obstacles (such as valves / weld beads) within 5m in real time, ensuring path safety through a 200ms-level obstacle avoidance response, and establishing a robot pose (position + attitude) coordinate system in closed / complex environments without GPS. The path is adjusted based on the predicted trajectories of moving obstacles (such as personnel, mobile equipment).

[0032] like Figure 3As shown, the identification component 3 includes a rotating shaft 302 rotatably disposed in the mounting groove 2; a drive seat 301 is disposed on the rotating shaft 302; a multi-segment rotating structure is disposed on the connecting rod 303; the multi-segment rotating structure includes a rotating shaft 302 rotatably disposed on the drive seat 301; a connecting rod 304 rotatably disposed on the connecting rod 303; and an identification head 305 disposed on the connecting rod 304.

[0033] The recognition head 305 uses a vision camera positioning system to track the surrounding weld seams. During tracking, the motor drives the rotating shaft 302, connecting rod 303, and connecting rod 304 to rotate in multiple directions, allowing the recognition head 305 to rotate flexibly and achieve the purpose of comprehensive and efficient identification of weld seams.

[0034] like Figures 4-5 As shown, the grinding and spraying assembly 5 includes a rotating table 502 rotatably mounted at the center of the bottom of the operating table 1; mounting brackets 503 are provided on both sides of the rotating table 502; connecting parts are provided on the mounting brackets 503; the connecting parts include a second rotating shaft 510 rotatably mounted on the mounting bracket 503; telescopic drive parts 504 are provided on both sides of the second rotating shaft 510 with the telescopic ends facing opposite directions; the grinding part and the spraying part are respectively connected to two sets of telescopic ends.

[0035] It should be further explained that the telescopic drive component 504 consists of two sets of cylinders that telescopic in opposite directions, and the telescopic drive component 504 and the rotating shaft 510 form a cross-shaped structure.

[0036] Driven by a motor, the rotating shaft 510 rotates, and two sets of cylinders rotate alternately in an arc-shaped trajectory to achieve movement and lifting, making grinding and spraying flexible and covering a wide range.

[0037] It should be further explained that the grinding component includes a rotating frame 507 located on the telescopic rod of a cylinder on one side; a rotating table 508 is provided on the rotating frame 507; and a grinding head is provided on the rotating table 508.

[0038] The rotating frame 507 and the rotating table 508 are driven independently by corresponding motors. Combined with the extension and retraction of the cylinders, they drive the grinding head to perform multi-directional, large-area grinding pretreatment on the weld. Grinding removes porosity, slag inclusions, spatter, and oxide scale from the weld area, preventing these defects from corroding and expanding under the coating. It can grind the weld reinforcement (0-3mm) to be flush with the base material, eliminating stress concentration points and preventing coating cracking at raised areas. Grinding also enhances coating adhesion and prevents uneven coating thickness caused by abrupt changes in weld geometry (such as insufficient film thickness at reinforced areas or liquid accumulation and corrosion in recesses).

[0039] It should be further explained that a liquid storage tank 501 is provided on the top of the rotating table 502; the spraying part includes a nozzle 505 located on another set of cylinder telescopic rods; the nozzle 505 is connected to the liquid storage tank 501 through a pipe 506.

[0040] The extension, retraction, and rotation of the nozzle 505 allow for comprehensive spraying of the ground weld seam to form an anti-corrosion coating. The ground and sprayed parts are aligned in a straight line, ensuring more precise positioning during the subsequent grinding and spraying process, resulting in high efficiency.

[0041] It should be further explained that the rotating shaft 510 has a hollow structure, and a dust collection head 511 connected to the hollow structure is provided at the bottom of the side wall; a dust collection box 509 connected to the hollow structure is provided on the mounting bracket 503; and an air pump is provided on the dust collection box 509.

[0042] It should be further explained that the dust collection heads 511 are arranged in a matrix.

[0043] When the rotating shaft 510 rotates for grinding, the dust collected by the dust collection head 511 is used to collect the flying dust, reducing pollution. After spraying, the flying spray liquid is collected by the dust collection head 511, reducing air pollution, promoting air circulation, and accelerating the drying and forming of the anti-corrosion coating.

[0044] like Figure 6 As shown, the magnetic moving assembly 4 includes a telescopic column 401 located at the bottom of the operating platform 1; a steering seat 402 is provided at the bottom of the telescopic column 401; a magnetic platform 404 is provided at the bottom of the steering seat 402; and a moving wheel 403 is provided at the bottom of the magnetic platform 404. The position of the operating platform 1 is adjusted by the housing of the telescopic column 401 to keep it always horizontal. The device provides an attraction force of ≥500N through magnetic attraction technology, allowing it to crawl along the walls of containers such as pipes and storage tanks.

[0045] Example 2: This example proposes a defect identification and positioning spraying method, using the defect identification and positioning spraying device described in Example 1. The steps are as follows:

[0046] S1. The device crawls along the walls of containers such as pipelines and storage tanks;

[0047] S2, the positioning radar 2 identifies physical obstacles (such as supports, valves, weld beads, temporary equipment, etc.) in the pipeline weld area in real time, and establishes the robot pose (position + attitude) coordinate system in a closed / complex environment without GPS; and adjusts the path according to the trajectory prediction of moving obstacles (such as personnel, mobile equipment);

[0048] S3. The recognition head 305 uses a vision camera positioning system to track the surrounding weld seams. During tracking, the motor drives the rotating shaft 302, connecting rod 303, and connecting rod 304 to rotate in multiple directions, so that the recognition head 305 can rotate flexibly to achieve the purpose of comprehensive and efficient recognition of weld seams.

[0049] S4. When the weld position is detected, the magnetic moving component 4 is rotated and extended to make the operating table 1 located at the end of the weld.

[0050] S5, the rotating frame 507, and the rotating table 508 are driven independently by corresponding motors. Combined with the extension and retraction of the cylinders, they drive the grinding head to perform multi-directional, large-area grinding pretreatment of the weld. Grinding removes porosity, slag inclusions, spatter, and oxide scale from the weld area, preventing these defects from corroding and expanding under the coating. It can grind the weld reinforcement (0-3mm) to be flush with the base material, eliminating stress concentration points and preventing coating cracking at protrusions. Grinding enhances coating adhesion and prevents uneven coating thickness caused by abrupt changes in weld geometry (such as insufficient film thickness at reinforcement points or liquid accumulation and corrosion in depressions). During grinding, the dust collection head 511 collects airborne dust, reducing pollution.

[0051] S6. The operating table 1 moves and grinds while spraying, or it can move in the opposite direction to spray after the entire grinding is completed. During spraying, the nozzle 505 extends, retracts and rotates to spray the ground weld seam. At the same time, the dust collection head 511 collects the flying spray liquid, reducing air pollution, promoting air circulation, and accelerating the drying and forming of the anti-corrosion coating.

[0052] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention.

Claims

1. A defect identification and positioning spraying device, characterized in that, include: The control panel (1) has magnetic moving components (4) at the four corners of its bottom and positioning radars (2) scattered on its side walls. The identification component (3) is set on the side wall of the operating table (1) and is staggered with the position of the positioning radar (2). Through a multi-segment rotating structure, it tracks and identifies the weld seam of the container. And the grinding and spraying component (5), which is set at the bottom of the operating table (1). By rotating the connector, the grinding and spraying components at both ends are alternately raised and lowered to achieve the purpose of grinding and spraying the weld first.

2. The defect identification and positioning spraying device according to claim 1, characterized in that, The operating table (1) is set in a disc shape, with mounting slot one and mounting slot two alternately arranged on the side wall; the positioning radar (2) is set in mounting slot one; the identification component (3) is set in mounting slot two.

3. The defect identification and positioning spraying device according to claim 2, characterized in that, The identification component (3) includes a rotating shaft (302) rotatably disposed in the mounting groove 2; a drive seat (301) is provided on the rotating shaft (302); and a multi-segment rotating structure is provided on the connecting rod (303); The multi-segment rotating structure includes a rotating mounting on the drive seat (301); a second connecting rod (304) rotating on the first connecting rod (303); and an identification head (305) mounted on the second connecting rod (304).

4. The defect identification and positioning spraying device according to claim 3, characterized in that, The grinding and spraying assembly (5) includes a rotating table (502) rotatably set at the center of the bottom of the operating table (1); mounting brackets (503) are set on both sides of the rotating table (502); and connecting parts are set on the mounting brackets (503). The connecting components include a rotating shaft two (510) rotatably mounted on the mounting bracket (503); telescopic drive components (504) are located on both sides of the rotating shaft two (510) with the telescopic ends facing opposite directions; and grinding and spraying components are respectively connected to the two sets of telescopic ends. The telescopic drive (504) consists of two sets of cylinders that telescopic in opposite directions. The telescopic drive (504) and the rotating shaft (510) form a cross-shaped structure.

5. The defect identification and positioning spraying device according to claim 4, characterized in that, The grinding component includes a rotating frame (507) located on the telescopic rod of a cylinder on one side; a rotating table (508) is provided on the rotating frame (507); and a grinding head is provided on the rotating table (508).

6. The defect identification and positioning spraying device according to claim 5, characterized in that, A liquid storage tank (501) is provided on the top of the rotating platform (502); The sprayed part includes a nozzle (505) located on another set of cylinder telescopic rods; the nozzle (505) is connected to the reservoir (501) via a pipe (506).

7. The defect identification and positioning spraying device according to claim 6, characterized in that, The rotating shaft 2 (510) has a hollow structure, and a dust collection head (511) connected to the hollow structure is provided at the bottom of the side wall; The mounting bracket (503) is equipped with a dust collection box (509) with a hollow structure; the dust collection box (509) is equipped with an air pump.

8. The defect identification and positioning spraying device according to claim 7, characterized in that, The magnetic moving assembly (4) includes a telescopic column (401) located at the bottom of the operating table (1); a steering seat (402) is provided at the bottom of the telescopic column (401); a magnetic platform (404) is provided at the bottom of the steering seat (402); and a moving wheel (403) is provided at the bottom of the magnetic platform (404).

9. A defect identification and positioning spraying method, characterized in that, The defect identification and positioning spraying device according to claim 8 comprises the following steps: S1. The device crawls along the wall of the container; S2, Positioning radar (2) identifies physical obstacles in the pipe weld area in real time, establishes robot pose coordinate system in closed / complex environment without GPS; adjusts path based on the trajectory prediction of moving obstacles; S3, the identification head (305) tracks the surrounding weld seams; S4. When the weld position is detected, the magnetic moving component (4) is turned and extended so that the operating table (1) is located at the end of the weld. S5, the rotating frame (507) and the rotating table (508) rotate independently, and in conjunction with the extension and retraction of the cylinder, drive the grinding head to perform multi-directional and large-range grinding pretreatment on the weld; during the grinding process, the dust collection head (511) collects the flying dust. S6. The operating table (1) moves and grinds while spraying. It can also be moved in the opposite direction to spray after the entire grinding is completed. During spraying, the nozzle (505) extends, retracts and rotates, and the flying spray liquid is collected through the dust collection head (511).

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