Full-automatic electric precipitator polar plate system inspection device and control method thereof

Abstract

The embodiment of the invention provides a full-automatic electric precipitator polar plate system inspection device and a control method thereof, and belongs to the technical field of electric precipitation. The device comprises a device main body which is provided with a battery, a processor and an acceleration sensor; the imaging device is used for acquiring internal image data of the electric precipitator; the adsorption walking devices are arranged at two ends of the device main body and are used for moving the device along the surface of the anode plate and finishing a plate crossing action; the distance measuring device is arranged on the other side of the device main body and is used for measuring the distance between the anode plate and the cathode wire; the anti-falling device is connected with the acceleration sensor and is used for releasing an air bag to buffer impact when the device is detected to fall due to weightlessness; wherein the processor is used for analyzing image data acquired by the imaging device so as to identify corresponding fault information. According to the scheme, full-process closed-loop control of automatic inspection, abnormity identification and safety protection of the polar plate system in the narrow high-dust environment of the electric dust remover is realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric dust removal, in particular to a full-automatic electric dust collector electrode plate system inspection device and a control method of the full-automatic electric dust collector electrode plate system inspection device. BACKGROUND

[0002] In the industrial flue gas treatment process of thermal power plants, metallurgical plants and the like, the electric dust collector as a key equipment for controlling particulate matter emission, its running state is directly related to whether the emission meets the standard. The inside of the electric dust collector is composed of multiple electric field units, and a high-voltage electric field structure composed of an anode plate and a cathode wire is arranged in each electric field for electrostatic capture of dust particles. However, in the long-term operation of the electric dust collector, affected by high temperature, high pressure, high dust and other factors, electrode deformation, electrode wire fracture, loose connection or foreign matter falling and the like are prone to occur. Once the internal structure of the electric field is problematic, the dust removal efficiency is reduced, or the electric field is stopped, resulting in emission exceeding the standard, which seriously affects the environmental protection compliance of the enterprise.

[0003] At present, the inspection of the electric dust collector still mainly relies on manual entry for inspection. Since the typical distance between the anode plate and the cathode wire is only 150 to 225 mm, a work platform cannot be set up on site, and the inspection personnel need to rely on safety ropes to move in a narrow space and visually identify structural abnormalities at close range. This method has two outstanding problems: first, the working space is extremely cramped, and the inspection personnel cannot achieve comprehensive observation and effective operation, which is easy to form a detection blind area; second, the internal environment of the electric dust collector is harsh, with high dust concentration, poor ventilation, and insufficient light, which seriously affects the inspection efficiency and personnel safety. More importantly, due to the locality and subjectivity of manual detection, the discovery of faults is often lagging behind the performance degradation process, making it difficult to achieve early warning and early intervention. The above problems are increasingly prominent under the background of ultra-low emission normalization, and a new type of inspection scheme that is more suitable for closed, narrow and high-dust spaces is urgently needed to solve the problem. SUMMARY

[0004] The purpose of the embodiments of the present application is to provide a full-automatic electric dust collector electrode plate system inspection device and a control method thereof, to at least solve the problems of narrow internal inspection space of existing electric dust collectors, blind area of manual detection and susceptibility to environmental interference, and to improve the inspection efficiency and accuracy of fault identification.

[0005] In order to achieve the above-mentioned purpose, the first aspect of the present application provides a full-automatic electric dust collector electrode plate system inspection device, which comprises: a device main body, which is internally provided with a battery, a processor and an acceleration sensor; an imaging device arranged on one side of the device main body, which is used for acquiring internal image data of the electric dust collector; an adsorbing walking device arranged at both ends of the device main body, which is used for moving the device along the surface of the anode plate and completing the cross-plate action; a distance measuring device arranged on the other side of the device main body, which is used for measuring the distance between the anode plate and the cathode wire; a fall-preventing device connected with the acceleration sensor, which is used for releasing an air bag to buffer the impact when the device is detected to fall due to weightlessness; wherein the processor is used for analyzing the image data collected by the imaging device to identify corresponding fault information.

[0006] Optionally, the imaging device comprises: an infrared thermal imager, a visible light network camera, an auxiliary light source, a lens cleaning wiper, a baffle for shielding dust and a fixing seat of the imaging device; the infrared thermal imager and the visible light network camera are respectively installed at both ends of the fixing seat through a spherical hinge; the auxiliary light source is arranged below the visible light network camera; the lens cleaning wiper is hinged above the visible light network camera and is driven by a motor; and the baffle is installed on the top of the infrared thermal imager and the visible light network camera.

[0007] Optionally, the adsorbing walking device comprises: a track, a permanent magnet block, a driving wheel of the adsorbing walking device, a supporting wheel, a belt supporting wheel, a driving sprocket, a driven sprocket, a chain and a bracket; the inner side of each track is provided with a groove, and the permanent magnet block is inlaid in the groove; the driving sprocket is installed in the middle of the bracket and is connected with a motor; the chain is used for connecting the driving sprocket and the driven sprocket; the driven sprocket is coaxially arranged at both ends of the bracket with the driving wheel; and the driving wheel is engaged with the track to drive it to rotate circularly.

[0008] Optionally, the permanent magnet block is made of a neodymium-iron-boron permanent magnet.

[0009] Optionally, the distance measuring device comprises: a distance measuring sensor, a sensor mounting plate of the distance measuring device, a protective cover, a protective top plate, a glass baffle and a glass baffle cleaning wiper; the distance measuring sensor is fixedly installed on the sensor mounting plate and is located in a closed space formed by the protective cover, the protective top plate and the sensor mounting plate; the glass baffle is installed at the stepped opening of the protective top plate; and the glass baffle cleaning wiper is hinged to the upper surface of the protective top plate and is driven by a motor.

[0010] Optionally, the processor is configured to: receive image data collected by the imaging device, and extract image feature information based on a preset image recognition algorithm; identify a suspicious fault point according to the image feature information, the suspicious fault point including at least one of electrode deformation, polar line connector fracture or foreign matter falling; determine whether an abnormal state exists in the current detection area based on the type and severity of the suspicious fault point; if it is determined that an abnormal state exists, control the device to record current electrode plate position information, and pack the suspicious fault image and the corresponding position information and upload them to a background server.

[0011] The second aspect of the application provides a control method of a full-automatic electrostatic precipitator electrode plate system inspection device, which is applied to the full-automatic electrostatic precipitator electrode plate system inspection device described above, is executed by a processor, and includes the following steps: receiving image data collected by an imaging device, and extracting image feature information based on an image recognition algorithm; identifying a suspicious fault point including electrode deformation, polar line connector fracture or foreign matter falling according to the image feature information; determining whether an abnormal state exists in the current inspection area based on the type and distribution characteristics of the suspicious fault point; if an abnormal state exists, recording inspection position information of a corresponding electrode plate, and packing image data and position information; uploading the packed fault information to a background server, and controlling an adsorption walking device to perform a cross-plate action to continue the next electrode plate inspection when a cross-plate condition is met.

[0012] Optionally, the method further includes: receiving distance data between an anode plate and a cathode line output by a distance measuring device; comparing the distance data with a preset standard distance range; if the distance data is out of the standard distance range, identifying a cathode line fracture and lap abnormality, recording current detection position information, and uploading the abnormality information and the position information to a background server.

[0013] Optionally, the method further includes: receiving a running acceleration value monitored by an acceleration sensor in real time; comparing the current acceleration value with a preset safe acceleration threshold; if the acceleration value exceeds the safe acceleration threshold, triggering a fall prevention control process, sending an ignition control instruction to a gas generator; controlling a gas bag structure to complete rapid inflation and pop out, for buffering the impact of the device falling, and generating an alarm signal and uploading it to a background server.

[0014] In another aspect, the application provides a computer readable storage medium, which stores instructions that, when executed on a computer, cause the computer to execute the control method of the full-automatic electrostatic precipitator electrode plate system inspection device described above.

[0015] By the technical scheme, the application achieves automatic inspection of the electrode plate system in the narrow and high-dust environment of the electric dust collector. The imaging device acquires image data and the processor performs recognition analysis, which can realize accurate recognition of structural faults such as electrode deformation and connector fracture, and avoid blind areas of manual detection. The adsorption walking device ensures that the device can stably adhere to and cross the electrode plate, realizing full coverage path inspection. The distance measuring device can judge the distance between the anode and the cathode in real time, assisting in identifying fracture or abnormal lap joint. The acceleration sensor and the anti-falling device construct a safety protection mechanism, which automatically releases the air bag to buffer the impact when falling under weightlessness, ensuring the safe operation of the device body, thereby improving the continuity and reliability of the inspection in complex environments.

[0016] Other features and advantages of the embodiments of the present application will be described in detail in the following detailed description. BRIEF DESCRIPTION OF DRAWINGS

[0017] The accompanying drawings are included to provide a further understanding of the embodiments of the present application, and constitute a part of the specification, and are used together with the following detailed description to explain the embodiments of the present application, but do not constitute a limitation on the embodiments of the present application. In the drawings: Figure 1 is a structural schematic diagram of the full-automatic electrode plate system inspection device of the electric dust collector provided by an embodiment of the present application; Figure 2 is a structural schematic diagram of the imaging device provided by an embodiment of the present application; Figure 3 is a structural schematic diagram of the adsorption walking device and the main frame provided by an embodiment of the present application; Figure 4 is a structural schematic diagram of the distance measuring device provided by an embodiment of the present application; Figure 5 is a step flow chart of the control method of the full-automatic electrode plate system inspection device of the electric dust collector provided by an embodiment of the present application.

[0018] Explanation of reference signs 1-device body; 2-imaging device; 3-adsorption walking device; 4-distance measuring device; 5-infrared thermal imager; 6-visible light network camera; 7-assistant light source; 8-lens cleaning wiper; 9-fixing seat; 10-baffle; 11-track; 12-permanent magnet block; 13-driving wheel; 14-riding wheel; 15-tow wheel; 16-driving sprocket; 17-driven sprocket; 18-chain; 19-bracket; 20-sensor mounting plate; 21-protection cover; 22-protection top plate; 23-glass baffle cleaning wiper; 24-glass baffle; 25-distance measuring sensor. DETAILED DESCRIPTION

[0019] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0020] Figure 1 This is a structural diagram of a fully automatic electrostatic precipitator electrode plate system inspection device provided in one embodiment of the present invention. Figure 1 As shown, this invention provides a fully automatic electrostatic precipitator electrode plate system inspection device. The device includes: a main body 1, which houses a battery, a processor, and an acceleration sensor; an imaging device 2 located on one side of the main body 1 for acquiring image data of the electrostatic precipitator's interior; adsorption and walking devices 3 located at both ends of the main body 1 for moving the device along the anode plate surface and completing plate-crossing actions; a distance measuring device 4 located on the other side of the main body 1 for measuring the distance between the anode plate and the cathode wire; and an anti-fall device connected to the acceleration sensor for releasing an airbag to cushion the impact when the device is detected to be falling due to weightlessness. The processor analyzes the image data acquired by the imaging device 2 to identify corresponding fault information. In this embodiment of the invention, a fully automatic electrostatic precipitator plate system inspection device is provided, suitable for the narrow, high-dust, and low-illuminance internal environment of an electrostatic precipitator. The device includes a main body 1, which integrates a battery, a processor, and an accelerometer. The battery continuously powers the internal components, supporting long-term autonomous operation; the processor executes data acquisition, image recognition, and control commands; and the accelerometer monitors the device's operating status in real time and detects any abnormalities such as gravity-induced displacement.

[0021] Imaging device 2 is installed on one side of the main body 1 of the device and is used to collect image data of the anode plate and cathode wire area. Imaging device 2 specifically includes an infrared thermal imager 5 and a visible light network camera 6, used to cope with the smoke and high dust environment inside the electrostatic precipitator, ensuring image clarity and identifiability. The image data collected by imaging device 2 will be transmitted to the processor inside the device. The processor executes a preset image recognition algorithm to judge and mark structural faults such as electrode deformation, broken electrode wire connectors, and foreign object falls, facilitating subsequent remote troubleshooting and maintenance decisions.

[0022] The main body 1 is equipped with adsorption and walking devices 3 at both ends, which adopt a track structure 11. The track 11 has embedded permanent magnet blocks 12, which enables the device to adhere to the surface of vertically or inclined anode plates and move. This structure not only has stable adhesion ability, but also has a certain obstacle-crossing ability, and can cross the structural gaps between the anode plates to achieve continuous mobile inspection.

[0023] The ranging device 4 is installed on the other side of the main body 1 of the device and is used to measure the distance between the anode plate and the cathode wire in real time. The current distance between the plates is collected by the point laser ranging sensor 25. If the distance is found to be less than or greater than the set standard, the processor can determine whether there is a structural abnormality such as a broken or overlapping cathode wire.

[0024] To address magnetic failure or other unexpected drops, the anti-fall device is linked to an acceleration sensor. When the acceleration sensor detects that the device's acceleration exceeds a safety threshold, it triggers a gas generator to release compressed gas, causing the airbag on the back of the device to expand rapidly and form a buffer layer, slowing down the device's descent and reducing the risk of damage.

[0025] This device, through the collaborative operation of multiple modules, is suitable for the internal structural inspection of electrostatic precipitators in unattended, high-risk areas, significantly improving the detection coverage, accuracy, and operational safety, and possesses good engineering adaptability and promotional value.

[0026] Preferred, such as Figure 2 The imaging device 2 includes: an infrared thermal imager 5, a visible light network camera 6, an auxiliary light source 7, a lens cleaning wiper 8, a baffle 10 for blocking dust, and a mounting base 9 for the imaging device 2; the infrared thermal imager 5 and the visible light network camera 6 are respectively mounted on both ends of the mounting base 9 via ball joints; the auxiliary light source 7 is located below the visible light network camera 6; the lens cleaning wiper 8 is hinged above the visible light network camera 6 and driven by a motor; the baffle 10 is mounted on the top of the infrared thermal imager 5 and the visible light network camera 6.

[0027] In this embodiment of the invention, the imaging device 2 is used to acquire high-penetration, high-resolution images of the internal space of the electrostatic precipitator to meet the fault identification requirements under high dust and low visibility conditions. The imaging device 2 includes an infrared thermal imager 5, a visible light network camera 6, an auxiliary light source 7, a lens cleaning wiper 8, a baffle 10 for blocking dust, and a mounting base 9 for the imaging device 2. The infrared thermal imager 5 and the visible light network camera 6 are symmetrically mounted on the left and right ends of the mounting base 9 via ball joints. The ball joint structure allows the camera module to be adjusted vertically and within a certain horizontal range to adapt to the imaging needs of the electrode targets at different angles, enhancing the image coverage. The mounting base 9 is made of metal and is fixed to the main body 1 by threaded connections or welding to ensure that no relative displacement occurs during movement, vibration, or crossing of plates.

[0028] To improve the image clarity in a strong dust environment, an auxiliary light source 7 is installed below the visible light network camera 6, preferably using a high-brightness LED matrix, and the light emitting angle and illumination parameters are optimized through experiments, which can provide effective light compensation in low illumination areas and make up for the lack of internal light source in the electric dust collector. The infrared thermal imager 5 does not need to rely on external light conditions and can directly obtain images based on thermal radiation signals to realize thermal field imaging through smoke and dust, and together with the visible light image, it forms a dual-channel image input for multi-modal analysis of subsequent image recognition algorithms.

[0029] A lens cleaning wiper 8 is provided above the visible light network camera 6, which is driven by a small motor to drive the arm to realize reciprocating wiping action on the surface of the lens. The wiper structure preferably uses flexible scraping strip material to fit the glass surface of the arc lens, ensuring no residue and no scratches during cleaning. The wiper motor is usually linked to the processor for control, and the cleaning process is automatically started during the crossing stage to avoid image blur caused by long-term dust deposition.

[0030] To prevent large particles of dust or loose animal matter from directly impacting the imaging device, a baffle 10 is also provided on the top of the infrared thermal imager 5 and the visible light network camera 6, respectively, preferably using an arc-shaped metal shell and installed on the upper structure of the camera through a quick-release structure. The baffle 10 not only provides structural shielding, but also plays a buffering and deflection role during dust impact, reducing the risk of pollution and damage.

[0031] The above imaging device 2 has a compact structure and clear function differentiation, and can work stably in the complex and severely polluted working conditions inside the electric dust collector, ensuring the continuity and accuracy of image acquisition and providing a reliable visual input basis for subsequent fault identification.

[0032] Preferably, as Figure 3 , the adsorbing walking device 3 comprises a track 11, a permanent magnet block 12, a driving wheel 13 of the adsorbing walking device 3, a supporting wheel 14, a belt supporting wheel 15, a driving sprocket 16, a driven sprocket 17, a chain 18 and a bracket 19; the inner side of each section of the track 11 is provided with a groove, and the permanent magnet block 12 is embedded in the groove; the driving sprocket 16 is installed in the middle of the bracket 19 and connected with the motor; the chain 18 is used to connect the driving sprocket 16 and the driven sprocket 17; the driven sprocket 17 is coaxially arranged at both ends of the bracket 19 with the driving wheel 13; the driving wheel 13 is engaged with the track 11 to drive it to rotate circularly.

[0033] In the embodiment of the application, the device adopts a scheme of arranging two side tracks 11 in parallel, each track 11 being articulated by a plurality of high-temperature-resistant and wear-resistant polyamide base segments. In order to firmly lock the magnetic attraction on the surface of the anode plate, a dovetail-shaped groove with the same length as the segment is formed on the inner side of each track 11, the groove width being slightly smaller than the width of the neodymium-iron-boron permanent magnet block 12 by about 0.2 mm, and the neodymium-iron-boron permanent magnet block 12 is inlaid and fixed through interference fit, which not only avoids displacement of the magnet due to running vibration, but also saves additional fasteners and reduces dust dead angles. The permanent magnet blocks 12 are arranged continuously along the full length of the track 11, and the single magnetic flux density is designed to be about 1.25 T, which is still maintained at more than 90% residual magnetism at a high temperature of 200°C, ensuring that the device is still stable under high-temperature and high-dust working conditions.

[0034] The driving part adopts a three-stage power chain of “chain transmission-wheel meshing-track loop”. The driving sprocket 16 is installed in the middle of the support 19 through a key connection mode, and the sprocket is coaxially fixed with the output shaft of the 24W brushless DC motor, in order to avoid dust invasion into the motor bearing, a graphite filler labyrinth dustproof seal is installed at the shaft end. The sprocket and the driven sprocket 17 use 06B-1 single-row roller chains, and the chain links are phosphated and then coated with a molybdenum disulfide lubricating layer to improve wear resistance and dust adhesion resistance. The chain tensioning is completed through the eccentric tensioning shaft arranged on the support 19, and the chain tension can be adjusted without disassembling the chain, which is convenient for daily maintenance.

[0035] The driven sprocket 17 at both ends of the support 19 and the driving wheel 13 are machined with the same solid shaft, and a hexagonal positioning groove is arranged on the outer side face, which is convenient for quick locking with a sleeve during disassembly and assembly. The outer circle of the driving wheel 13 is processed into a 12-tooth involute tooth shape, and the addendum circle diameter is strictly matched with the pitch of the track 11, so that stable meshing can still be ensured even in the presence of dust. After the driving wheel 13 meshes with the track 11, the track 11 is driven to rotate in a loop, and the lower surface of the track 11 forms a continuous magnetic adsorption surface with the anode plate, so that the device does not slip or separate due to slight distortion of the plate during forward movement.

[0036] In order to keep the track 11 tensioned and in position during the crossing of the plate, two groups of supporting wheels 14 are arranged along the curve of the track 11 below the support 19, and supporting wheels are coaxially arranged above the track. The supporting wheels 14 are made of wear-resistant PEEK material, and the rim is chamfered by 60°, which can smoothly pass through the gap step of 2-5 mm between the two plates. The surface of the supporting wheel is covered with a fluororubber ring, which reduces the vibration of the track 11 during return and provides a secondary dust removal effect on the back of the track 11, reducing the dust entering the meshing area of the sprocket.

[0037] The whole set of adsorption walking device 3 weight control in 1.1kg below, permanent magnet adsorption force one side about 160N, by FEM simulation and 1:1 test bench test, can realize continuous travel under 45° inclination plate, scouring wind speed condition and not drop chain. Drive motor at 12V, full power state, endurance more than 90min. For the whole machine in high temperature dust, narrow seam staggered electric precipitator internal environment to provide reliable mobile foundation, and then guarantee the continuity and integrity of subsequent imaging acquisition and fault identification.

[0038] Preferably, the permanent magnet block 12 is made of neodymium iron boron permanent magnet.

[0039] In the embodiment of the application, the permanent magnet block 12 is made of neodymium iron boron permanent magnet, adopts N35 grade isometric sintering forming process, has high magnetic energy product and excellent remanence stability; the shape is processed into a rectangular block, and both sides are chamfered to adapt to the groove embedding structure of the track 11, so that stable adsorption performance is ensured under high temperature (not less than 200℃) and high dust environment, and magnetic decay or falling phenomenon does not occur.

[0040] Preferably, as Figure 4 , the distance measuring device 4 comprises a distance measuring sensor 25, a sensor mounting plate 20 of the distance measuring device 4, a protective cover 21, a protective top plate 22, a glass baffle 24 and a glass baffle cleaning wiper 23; the distance measuring sensor 25 is fixedly installed on the sensor mounting plate 20 and located in an enclosed space formed by the protective cover 21, the protective top plate 22 and the sensor mounting plate 20; the glass baffle 10 is installed at the stepped opening of the protective top plate 22; and the glass baffle cleaning wiper 23 is hinged to the upper surface of the protective top plate 22 and driven by a motor.

[0041] In the embodiment of the application, the distance measuring device 4 is used to obtain the relative distance information between the anode plate and the cathode wire, so as to realize rapid identification of structural abnormalities such as loosening, lapping or fracture of the cathode wire. The device structure comprises a distance measuring sensor 25, a sensor mounting plate 20, a protective cover 21, a protective top plate 22, a glass baffle 24 and a glass baffle cleaning wiper 23, and the overall layout is compact, which is convenient for integration in the distance measuring module area on one side of the device main body 1 structure.

[0042] The distance measuring sensor 25 preferably adopts a point laser triangulation structure, and the measurement accuracy is controlled within ±0.5 mm, the working distance range covers the typical interval of plate spacing variation (150-225 mm), and the reflectivity adaptive compensation function is supported to adapt to the large difference in reflectivity of the internal plates of the electric dust collector, the serious dust accumulation and other environmental influences. In order to avoid dust interference with the laser path, the sensor is fixedly installed on the sensor mounting plate 20 by screwing, the mounting plate is made of hard aluminum alloy material and is treated by oxidation, and has good structural rigidity and corrosion resistance. The working window of the distance measuring sensor 25 faces outward and is integrally packaged in the closed cavity formed by the protective cover 21, the protective top plate 22 and the mounting plate, forming a stable measurement environment.

[0043] The protective cover 21 adopts a semi-closed groove structure, and the bottom of the cover body is fixed and sealed between the sensor mounting plate 20 through a threaded column and a gasket, and the top is provided with a light passage to cooperate with the installation of the protective top plate 22. The protective top plate 22 is processed with a stepped rectangular opening, and the glass baffle 24 is installed in the stepped groove by full-rubber bonding, which ensures that the laser path is seamlessly out, and at the same time, the edge of the glass baffle 24 does not protrude from the outer surface of the top plate, avoiding dust accumulation in the corner. The glass baffle 10 adopts high-transmittance quartz glass with a transmittance of not less than 95%, and the thickness is controlled within 2 mm, which not only ensures the structural strength, but also reduces the refraction distortion of the laser signal, which is beneficial to improve the distance measuring accuracy.

[0044] In order to ensure that the distance measuring light path is not blocked by dust in long-term operation, a glass baffle cleaning wiper 23 is arranged outside the glass baffle 24, one end of the wiper is hinged to the upper surface of the protective top plate 22 through a spherical joint, the other end is connected with a micro DC motor, and a swing arm driving structure is adopted. Under the driving of the motor, the wiper can clean the glass surface in an arc shape, the scraping strip is made of polyurethane flexible material, has good adhesion and high temperature resistance, can effectively remove dust, oil film or attached particles on the glass surface, ensure that the optical channel is always in a transparent state during distance measuring, and avoid distance measuring error caused by window blockage.

[0045] Preferably, the processor is configured to: receive image data collected by the imaging device 2, and extract image feature information based on a preset image recognition algorithm; identify a suspected fault point according to the image feature information, the suspected fault point including at least one of electrode deformation, pole line connector fracture or foreign matter falling; judge whether an abnormal state exists in the current detection area based on the type and severity of the suspected fault point; if it is judged that the abnormal state exists, the control device records the current plate position information, and packs and uploads the suspected fault image and the corresponding position information to the background server.

[0046] In the embodiment of the application, the visible light frame and the infrared frame synchronously output by the imaging device 2 are received, and written into a ring buffer according to a frame number-time stamp-plate number triple; then a preset image recognition algorithm is called to process each frame in a channel: the visible light frame adopts a edge line feature detection network based on a conventional CNN, and the infrared frame introduces a temperature partition threshold segmentation module, and the two are spliced in a feature fusion layer to generate a 256-dimensional feature vector. The feature vector is input into a fault candidate generator, and through K-Means aggregation and Mahalanobis distance measurement, a suspicious fault point list is output, and each list entry is stored in the form of {category, electrode number, confidence, position coordinates}. The category field is limited to three types of electrode deformation (DEF), pole line breakage (BRK) or foreign object drop (FOD); the confidence threshold is 0.85 by default, and can be manually lowered to 0.75 in the debugging mode to expand the recall.

[0047] The processor further reads the category and confidence of the suspicious fault point, and performs abnormality judgment in combination with a preset severity mapping table: if the category is BRK and the confidence is greater than or equal to 0.9, or the category is DEF and the confidence is greater than or equal to 0.95, it is directly marked as “serious abnormality”; if the category is FOD or other combined confidence is between 0.75-0.9, it is marked as “general abnormality”. After the judgment is completed, the processor further queries the current position mapping table, encapsulates the current plate ID, longitudinal coordinate and cross-plate count together, generates a JSON structure {plate ID, longitudinal coordinate, cross-plate number, category, confidence, time stamp} and writes it into a local abnormality queue.

[0048] When the abnormality queue is not empty, the data packaging process is started: the processor first calls an image encoder to perform H.265+PNG-Alpha double-stream compression on the corresponding visible light and infrared frames; then the compressed images and the JSON structure are combined into a ZIP package, and the naming rule is “ECP-YYYYMMDD-HHMMSS-plate ID.zip”, and the file size is controlled within 512 kB to meet the on-site Wi-Fi bandwidth. After the packaging is completed, the processor uploads the ZIP package to the background server specified Topic by using the MQTT protocol with QOS1 level; at the same time, an upload record is inserted into the local SQLite cache table, including the file name, upload time, server feedback code, etc., for breakpoint retransmission and subsequent data checking.

[0049] If the upload success reply code is 200, the processor marks the current exception queue item as "synchronized"; if the reply is timed out or returns an error, it is automatically retried for 3 times with an interval of 10 s; after continuous failure, it is switched to an offline cache mode, and then batch uploading is performed again when the device returns to a signal stable area. The closed-loop process realizes automatic fault identification, accurate location binding and reliable reporting without increasing additional manual intervention, ensures that the background operation and maintenance personnel can obtain the abnormal image and metadata in the first time, so as to quickly locate the problem and develop a maintenance plan.

[0050] Figure 5 is a method flowchart of a control method of the full-automatic electric dust collector electrode plate system inspection device provided by an embodiment of the present application. As shown in Figure 5 The embodiment of the present application provides a control method of a full-automatic electric dust collector electrode plate system inspection device, and the method comprises the following steps: Step S10: receiving image data collected by an imaging device, and extracting image feature information based on an image recognition algorithm.

[0051] Specifically, the imaging device outputs a frame of visible light image and a frame of infrared thermal image at the same time stamp, and the two are written into a ring buffer in a three-tuple of frame number-electrode plate number-time stamp; then the processor calls a multi-modal preprocessing pipeline, performs histogram equalization and CLAHE on the visible light image, and performs temperature pseudo-color mapping and 3*3 median filtering on the infrared thermal image, so as to ensure that the signal-to-noise ratios of the two channels are consistent. After preprocessing, the high-dimensional feature vectors are extracted by a lightweight CNN Backbone (MobileNet-V3 structure) respectively, and the 256-dimensional joint features are obtained by splicing in the feature fusion layer; the processor performs L2 regularization on the feature vectors, and finally forms a unified input tensor for the subsequent fault candidate generator to call. Through the process, the electrode, the electrode line and the background contour information can be stably extracted under the conditions of dust interference and light variation, thereby providing a basis for the next step of fault detection.

[0052] Step S20: identifying suspicious fault points including electrode deformation, electrode line connector fracture or foreign matter falling according to the image feature information.

[0053] Specifically, the processor calls a small target detection network based on YOLO-v5s, and the initial anchor size is optimized by secondary clustering according to the surface texture characteristics of the anode plate; after the network outputs the candidate frame, the Soft-NMS is used to eliminate the overlapping redundancy, and the high-confidence candidate is screened according to the confidence threshold of 0.85. The candidate frame category is limited to three categories of electrode deformation (DEF), pole line breakage (BRK) and foreign matter falling (FOD), and rectangular frame, polyline frame and circular frame are used for pseudo-color rendering labeling on the visible light image. Each suspicious fault point is written in the fault list in the format of {category, center coordinates, length, width, height, confidence}, and is mapped back to the infrared frame and the average temperature rise ΔT is extracted for reference for subsequent severity calculation. The identification process can complete single-frame inference within 200 ms, ensuring real-time performance.

[0054] Step S30: judging whether the current inspection area has an abnormal state based on the type and distribution characteristics of the suspicious fault point.

[0055] Specifically, the processor first counts the number n and category distribution of the fault points on the same pole plate; then refers to the severity mapping table: when the BRK category appears and the confidence is >0.9 or the DEF category appears and the ΔT is >15 ℃, it is directly determined as a serious abnormality; if only FOD and n≥3, it is determined as a general abnormality; if only FOD and n<3 or BRK confidence <0.9, it is marked as needing review. The determination result is written in the abnormal queue in the format of {plate ID, abnormal level, fault point index list}. If the current inspection area is determined to be normal, the adsorbing walking device is instructed to maintain the speed and continue to move straight; if it is marked as needing review, the walking speed is reduced and an additional high-resolution shooting is added; if it is determined to be abnormal, the recording and uploading process is triggered.

[0056] Step S40: if there is an abnormal state, recording the inspection position information of the corresponding pole plate and associating and packaging the image data and the position information.

[0057] Specifically, the processor reads the current cross-plate count, longitudinal travel distance and IMU attitude angle from the pose solving module, and combines to generate a position information structure body {plate ID, cross-plate number, longitudinal distance, roll angle, timestamp}; at the same time, the image encoder is called to compress the visible light and infrared frames into H.265-Main and PNG-Alpha formats respectively. Then, a temporary ZIP package with the file name of “ECP-YYYYMMDD-HHMMSS-plate ID.zip” is established, and the compressed images, fault list JSON and position information structure body are written together, and an MD5 check file is added in the package to ensure the integrity of the received backend. Finally, the ZIP package is moved to the local “upload-cache” directory and inserted into the upload task table, waiting for the network thread scheduling.

[0058] Step S50: uploading the packaged fault information to a background server, and when the cross-plate condition is met, controlling the adsorption walking device to perform a cross-plate action to continue the next plate inspection.

[0059] Specifically, the network thread adopts the MQTT QOS1 mode to connect the field AP, if the link delay is less than 200 ms and the RSSI is greater than-65 dBm, then all the ZIP packages of the current task table are uploaded at one time; after the server returns the 200 response, the corresponding cache is deleted locally and the log is recorded as "DONE"; if the uploading fails for three times in succession, then the offline cache mode is switched to and waits for signal recovery for uploading. When the uploading is completed or the network is poor but the reset timer expires, the processor queries the cross-plate map: if the current longitudinal distance is greater than or equal to the set cross-plate threshold and the next plate exists, then the walking device is instructed to enter the "cross-plate" mode, the imaging and ranging are closed, and the crawler belt is driven to pass through the gap between the plates in a low-speed and large-torque posture; after the cross-plate is successfully completed, the imaging device is reactivated and the longitudinal distance count is reset, the inspection cycle of the next plate is entered, and efficient closed-loop inspection is realized.

[0060] Preferably, the method further comprises: receiving distance data between the anode plate and the cathode wire output by the ranging device; comparing the distance data with a preset standard interval range; if the distance data is out of the standard interval range, identifying that the cathode wire is in a broken and overlapped abnormality, recording the current detection position information, and uploading the abnormality information and the position information to the background server.

[0061] In the embodiment of the application, based on the real-time distance data between the anode plate and the cathode wire output by the ranging device, the identification and reporting of the interval abnormality are completed. Specifically, the ranging device outputs the current measurement distance value at a fixed sampling period (such as 50 ms), which is encoded as a floating point in millimeters, and is transmitted into the processing module together with the time stamp. In order to enhance the robustness, the method first performs median filtering on the continuous five frames of ranging data to remove the instantaneous jitter, and performs sliding mean smoothing on the sampling points to obtain the stable current distance value D current . Then, the distance value is compared with the preset standard interval range [150 mm, 225 mm], if D current is less than 150 mm or greater than 225 mm, it is determined that the current detection section has an interval abnormality.

[0062] To further reduce the false positive probability, the method introduces a distance anomaly persistence judgment mechanism, that is, if the continuous three frames of data all meet the over-limit condition, the subsequent anomaly processing process is triggered. At this time, the current plate number, cross-plate counter value, ranging sensor attitude angle and other inspection position information are read to generate a structured position information field {plate ID, cross-plate number, longitudinal displacement, ranging value, anomaly type}, wherein the anomaly type is uniformly coded as "SPC-ERR" (indicating distance over-limit). The field is packed into the anomaly upload data packet, and is archived synchronously with the current timestamp and ranging image frame.

[0063] The image frame is output by the ranging device synchronously or is taken by the main camera through event triggering to enhance the abnormality description. Subsequently, the image is compressed into a ZIP package together with the position information and anomaly field, and the naming method follows the "ECP-YYYYMMDD-HHMMSS-SPCERR.zip" format, and is written into the local upload cache directory.

[0064] After the data is packed, the communication thread is called to upload to the background server, and the MQTT protocol or HTTP POST request is used to ensure that the anomaly information can be synchronized to the remote within 5 seconds. After receiving the ZIP package, the server can automatically decompress and store it into the "spacing-alerts" table for subsequent statistical analysis and maintenance scheduling. Through the method, real-time monitoring and anomaly capture of the structure spacing between the anode and the cathode are realized, the position is locked and the data is archived at the initial stage of the cathode wire joint and fracture, and reliable data support is provided for emergency handling of anomalies and fault point repair.

[0065] Preferably, the method further comprises: receiving an acceleration sensor real-time monitored running acceleration value; comparing the current acceleration value with a preset safe acceleration threshold; if the acceleration value exceeds the safe acceleration threshold, triggering a fall prevention control process, and sending an ignition control instruction to the gas generator; controlling the airbag structure to complete rapid inflation and pop out for buffering the impact of the device falling, and generating an alarm signal uploaded to the background server.

[0066] In the implementation of the present application, based on the running acceleration value output by the three-axis acceleration sensor in real time, the device posture stability is dynamically monitored and the fall prevention protection is quickly triggered when the weightlessness falling sign is detected. Specifically, the acceleration sensor continuously outputs the X, Y and Z three-axis original acceleration vectors {ax, ay, az} at a sampling rate of 1 kHz. The method first performs first-order Butterworth low-pass filtering on the original data, and the cutoff frequency is set to 25 Hz to remove the track vibration and motor harmonic interference; then the modulus is calculated. To exclude the instantaneous acceleration fluctuation in the normal cross-plate process of the device, the method uses a 50 ms sliding window to calculate the modulus modAverage the values and calculate the variance over the window When When the average drops below 0.3 g and the variance is below 0.05, a free fall is determined.

[0067] The current average acceleration is compared to a preset safety acceleration threshold If the average is less than a th , the anti-fall control process is triggered. The process first activates the independently powered ignition control module, sends the "IGNITE = 1" command through the CAN bus, and drives the laminated bridge ignition sheet in the gas generator to be powered instantaneously. The ignition sheet has a resistance of 10 Ω, a current of 2 A, and a heat output of 40 J, which can ignite the mixed gas generating agent to produce about 6 L of nitrogen gas. The high-pressure nitrogen gas is reduced in pressure through a first-order pressure relief hole plate and then injected into the back fabric airbag along a soft conduit. The airbag is made of double-layer TPU fabric and has a volume of 3 L and a maximum expansion thickness of 80 mm. To prevent the airbag from bursting, a 0.8 mm orifice is provided at the end of the conduit to stabilize the inflation time within the range of 80-100 ms. After inflation is complete, the airbag forms a flexible cushion on the back of the device, which can reduce the 3 m free fall impact acceleration to less than 50 g, ensuring that the internal sensors and exposed optical elements are not damaged.

[0068] During the airbag inflation process, the acceleration sensor still outputs; the method detects that a mod rises again and the peak exceeds 2 g, it is determined that the device has contacted the obstacle and slowed down. At this time, an alarm message structure {timestamp, board ID, longitudinal position, , fall duration} is generated, encoded into JSON, and written to the safety event queue. The communication thread immediately encapsulates the MQTT message when the event queue is not empty, sets the QOS level to 1, marks the Topic as "fall ", and switches to offline buffering mode after three retransmissions without ACK within 5 s; successfully uploaded, add a "fall " entry to the local event log, which contains the server response code 200 and the processing delay, for maintenance personnel to trace back later.

[0069] At the same time, to ensure that the device can still be locally forensically investigated at night or in a weak network scenario, the method controls the auxiliary light source to be forcibly turned on at the same time as the airbag inflation is triggered, and calls the imaging device to perform a 1 / 1000 s shutter snapshot. The image at the moment of falling is saved together with the alarm JSON in the "fall " directory of the MicroSD card. When the card capacity is less than 10%, the method automatically deletes the historical event files 30 days ago to prevent log from occupying image cache.

[0070] The embodiment of the present application further provides a computer readable storage medium, which stores instructions, and the instructions make the computer execute the control method of the full-automatic electric dust collector plate system inspection device when the instructions are run on the computer.

[0071] Those skilled in the art can understand that all or part of the steps of the method for implementing the above-mentioned embodiments can be completed by programs instructing relevant hardware, the programs are stored in a storage medium, and the programs include a plurality of instructions for making a single-chip microcomputer, a chip or a processor execute all or part of the steps of the method described in each embodiment of the present application. The foregoing storage medium includes various storage media capable of storing program codes, such as a U disk, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk.

[0072] The optional embodiments of the present application are described in detail above in combination with the drawings, but the embodiments of the present application are not limited to the specific details in the above-mentioned embodiments, and various simple modifications can be made to the technical solutions of the embodiments of the present application within the technical concept range of the embodiments of the present application, and the simple modifications all belong to the protection range of the embodiments of the present application. In addition, it should be noted that each specific technical feature described in the above-mentioned specific embodiments can be combined in any appropriate manner without contradiction. In order to avoid unnecessary repetition, the embodiments of the present application will not be described again for various possible combination manners.

[0073] In addition, various different embodiments of the present application can also be combined in any manner, as long as the combination does not deviate from the technical concept of the embodiments of the present application, and the combination should also be regarded as the disclosed content of the embodiments of the present application.

Claims

1. A full-automatic electrical dust collector electrode plate system inspection device, characterized in that, The device comprises: a device body internally provided with a battery, a processor and an acceleration sensor; an imaging device arranged on one side of the device body for acquiring internal image data of the electric dust collector; an adsorptive walking device arranged at both ends of the device body for moving the device along the surface of the anode plate and completing the cross-plate action; a distance measuring device arranged on the other side of the device body for measuring the distance between the anode plate and the cathode wire; a fall-preventing device connected with the acceleration sensor for releasing an airbag to buffer the impact when detecting that the device is falling due to weight loss; wherein the processor is configured to analyze the image data collected by the imaging device to identify corresponding fault information.

2. The apparatus of claim 1, wherein, The imaging device comprises: an infrared thermal imager, a visible light network camera, an auxiliary light source, a lens cleaning wiper, a baffle for shielding dust, and a fixing seat of the imaging device; the infrared thermal imager and the visible light network camera are respectively installed at both ends of the fixing seat through a spherical hinge; the auxiliary light source is arranged below the visible light network camera; the lens cleaning wiper is hinged above the visible light network camera and driven by a motor; the baffle is installed on the top of the infrared thermal imager and the visible light network camera.

3. The apparatus of claim 1, wherein, The adsorptive walking device comprises: a track, a permanent magnet block, a driving wheel of the adsorptive walking device, a supporting wheel, a belt supporting wheel, a driving sprocket, a driven sprocket, a chain, and a bracket; the inner side of each section of the track is provided with a groove, and the permanent magnet block is inlaid in the groove; the driving sprocket is installed in the middle of the bracket and connected with a motor; the chain is used to connect the driving sprocket and the driven sprocket; the driven sprocket is coaxially arranged at both ends of the bracket with the driving wheel; the driving wheel is engaged with the track to drive it to rotate circularly.

4. The apparatus of claim 3, wherein, The permanent magnet block is made of neodymium-iron-boron permanent magnet.

5. The apparatus of claim 1, wherein, The distance measuring device comprises: a distance measuring sensor, a sensor mounting plate of the distance measuring device, a protective cover, a protective top plate, a glass baffle, and a glass baffle cleaning wiper; the distance measuring sensor is fixedly installed on the sensor mounting plate and located in an enclosed space formed by the protective cover, the protective top plate, and the sensor mounting plate; the glass baffle is installed at the stepped opening of the protective top plate; the glass baffle cleaning wiper is hinged to the upper surface of the protective top plate and driven by a motor.

6. The apparatus of claim 1, wherein, The processor is configured to: receive the image data collected by the imaging device, and extract image feature information based on a preset image recognition algorithm; identify suspicious fault points according to the image feature information, the suspicious fault points including at least one of electrode deformation, polar line connector fracture, or foreign matter falling; determine whether there is an abnormal state in the current detection area based on the type and severity of the suspicious fault points; if it is determined that there is an abnormal state, record the current polar plate position information, and pack and upload the suspicious fault image and the corresponding position information to a background server.

7. A control method of a full-automatic electric dust collector electrode plate system inspection device, characterized in that, The method is applied to the full-automatic electric dust collector polar plate system inspection device of any one of claims 1-6, the method is executed by a processor, and the method comprises: receiving image data collected by an imaging device, and extracting image feature information based on an image recognition algorithm; According to the image feature information, a suspicious fault point including electrode deformation, polar line connector fracture or foreign matter falling is identified; Based on the type and distribution characteristics of the suspicious fault point, it is judged whether there is an abnormal state in the current inspection area; If there is an abnormal state, the inspection position information of the corresponding electrode plate is recorded, and the image data and the position information are associated and packaged; The packaged fault information is uploaded to the background server, and when the cross-plate condition is met, the adsorption walking device is controlled to perform a cross-plate action to continue the next electrode plate inspection.

8. The method of claim 7, wherein, The method further comprises: Receiving distance data between the anode plate and the cathode line output by the distance measuring device; Comparing the distance data with the preset standard distance range; If the distance data exceeds the standard distance range, it is identified as a cathode line fracture and overlap abnormality, the current detection position information is recorded, and the abnormal information and the position information are uploaded to the background server.

9. The method of claim 7, wherein, The method further comprises: Receiving the running acceleration value monitored by the acceleration sensor in real time; Comparing the current acceleration value with the preset safe acceleration threshold value; If the acceleration value exceeds the safe acceleration threshold value, a fall prevention control process is triggered, and an ignition control instruction is sent to the gas generator; The airbag structure is controlled to complete rapid inflation and pop out to buffer the impact of the device falling, and an alarm signal is generated and uploaded to the background server.

10. A computer-readable storage medium, characterized in that, The computer readable storage medium stores instructions, which when executed on a computer, cause the computer to perform the control method of the full-automatic electrode plate system inspection device of the electrostatic precipitator according to any one of claims 7-9. The computer readable storage medium stores instructions, which when executed on a computer, cause the computer to perform the control method of the full-automatic electrode plate system inspection device of the electrostatic precipitator according to any one of claims 7-9.

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