An insulator replacement device and method based on heavy-load unmanned aerial vehicle

Abstract

The application discloses an insulator replacement device and method based on a heavy-load unmanned aerial vehicle, and the insulator replacement device based on the heavy-load unmanned aerial vehicle comprises an unmanned aerial vehicle platform, four groups of hoisting rope winders, ropes, a control platform, a grabbing arm and a circular cage frame device. The flexible connecting ropes are covered by the frame device and a work protection space is provided, the posture of the frame is lowered synchronously and accurately by four ropes, and the insulator string is fixed in cooperation with the internal clamping mechanism and the grabbing arm, so that stable, accurate and safe work under heavy-load conditions is realized, and the replacement efficiency is significantly improved and the safety risk is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of equipment installed in or on an aircraft, and in particular to an insulator replacement device and method based on a heavy-load unmanned aerial vehicle. BACKGROUND

[0002] High-voltage transmission line insulator strings are exposed to the outdoors for a long time and need to be regularly maintained and replaced. At present, the work is mainly performed by manually climbing the tower or using large machinery, which has the problems of low efficiency, high risk, poor adaptability to complex terrain, etc. Although there have been attempts to use unmanned aerial vehicles for power inspection, replacing the insulator string requires a larger load (usually more than 100 kg) and more precise and stable operation, and existing unmanned aerial vehicle systems cannot meet the requirements. SUMMARY

[0003] The purpose of the present application is to provide an insulator replacement device based on a heavy-load unmanned aerial vehicle, which aims to solve the technical problems of low efficiency, high safety risk, poor adaptability to complex terrain, and insufficient heavy-load precise operation of existing insulator replacement technologies.

[0004] To solve the above problems, according to one aspect of the present application, an insulator replacement device based on a heavy-load unmanned aerial vehicle is provided, comprising:

[0005] An unmanned aerial vehicle platform adopts an eight-axis sixteen-rotor layout and is equipped with a multi-redundancy power supply system and a multi-redundancy power system;

[0006] Four groups of rope winches are symmetrically fixed to the four corner points of the power cabin at the bottom of the unmanned aerial vehicle platform, and each group of winches is internally provided with an independent servo motor and a brake;

[0007] Four high-strength ropes, the top end of each rope is wound and connected to a group of the rope winches, and the bottom end is fixed to a control platform;

[0008] A control platform is suspended below the unmanned aerial vehicle platform by the ropes, and is provided with two groups of split-type grabbing arms thereon;

[0009] A circular cage frame device is wrapped around the outside of the ropes and rope winches, the top thereof is fixedly connected to the bottom frame of the unmanned aerial vehicle platform through a quick-release interface, and the bottom opening thereof is provided with an adjustable clamping mechanism and a rubber buffer layer;

[0010] The control platform is located at the inner center of the frame device, and the grabbing end of the grabbing arm faces the bottom opening of the frame device;

[0011] A self-locking safety bolt is arranged at the quick-release interface at the top of the frame device, which is matched with an electronic lock catch at the bottom of the unmanned aerial vehicle platform, and automatic locking and unlocking are realized through the command of the flight control system.

[0012] In some embodiments, the frame device is composed of carbon fiber composite material and aviation aluminum alloy through modular splicing, and anti-torsion pin positioning and high-strength bolt fastening are adopted at the module interface.

[0013] In some embodiments, the servo motor of the hoisting rope reel is electrically connected to the flight control system of the unmanned aerial vehicle, receives the synchronous winding and unwinding instructions issued by the flight control system, and each set of reel is provided with an encoder for real-time feedback of the rope length.

[0014] In some embodiments, the grabbing arm is a hydraulic driving three-finger claw structure, and a pressure sensor is embedded in the inner side of the claw, and the pressure sensor signal is connected to the PLC controller in the control platform.

[0015] In some embodiments, the PLC controller in the control platform interacts with the flight control system of the unmanned aerial vehicle platform through a wireless communication module, receives target position instructions and feeds back grabbing state information.

[0016] In some embodiments, the adjustable clamping mechanism at the inner bottom end of the frame device comprises four circumferentially uniformly distributed hydraulic clamps, the clamping surface of the hydraulic clamp is lined with a rubber buffer layer, and each clamp is independently connected to a linear servo module to realize radial movement.

[0017] In some embodiments, the multi-redundant power supply system of the unmanned aerial vehicle platform comprises two independent lithium battery groups and an oil-fired generator, and the multi-redundant power system comprises sixteen independent electronic governors and motor combinations, and when any battery or motor fails, the system can automatically redistribute power to maintain stable flight.

[0018] In some embodiments, the rope is a double-layer braided structure, the inner layer is an aramid fiber force-bearing core, and the outer layer is coated with a high-wear-resistant polyethylene coating.

[0019] The embodiment of the present application also provides a method for replacing insulators using the insulator replacement device based on the heavy-load unmanned aerial vehicle, which comprises the following steps:

[0020] S1: the unmanned aerial vehicle flies to the upper side of the insulator string, and is positioned by a laser radar and a visual recognition system;

[0021] S2: four groups of hoisting rope reels synchronously lower the ropes, so that the frame device is lowered to cover the insulator string;

[0022] S3: the adjustable clamping mechanism in the frame device acts to tightly hold the insulator string from four sides;

[0023] S4: the grabbing arm is closed to firmly hold the end fitting of the insulator string;

[0024] S5: the operator remotely controls to release the connecting latch of the insulator string.

[0025] S6: The rope reel recovers the rope, lifts the disassembled insulator string and transports it back.

[0026] In some embodiments, in step S2, if the environmental wind force causes the frame device to swing, the flight control system independently adjusts the lowering speed difference of the four groups of rope reels according to the attitude sensor data to generate a reverse moment to suppress the swing.

[0027] Compared with the prior art, the insulator replacement device based on heavy-load unmanned aerial vehicle has at least the following beneficial effects:

[0028] Modular frame design and flexible connection: The circular cage-shaped frame device adopts a carbon fiber-aluminum alloy composite structure, which takes into account strength and lightweight, and the modular design facilitates transportation and assembly. The rope and the unmanned aerial vehicle are flexibly connected, which can buffer the impact and sway during operation.

[0029] Multi-rope cooperative precise control: Through four groups of independently controlled rope reels, cooperating with the flight control algorithm, the frame swing can be actively suppressed, and precise lowering and positioning can be realized, which is the core of stable operation.

[0030] Multiple clamping and safety guarantee: The internal adjustable clamping mechanism cooperates with the special grabbing arm to fix the insulator string from different positions, ensuring the safety of operation. Multiple redundant power and power supply systems greatly improve the overall reliability.

[0031] Operation process optimization: The operation method defined by the present application is clear, safe and efficient, which is significantly better than the traditional manual operation mode.

[0032] The above description is only a summary of the technical solutions of the present application. In order to more clearly understand the technical means of the present application, and can be implemented according to the content of the specification, the following will be described in detail with the preferred embodiments of the present application and with the help of the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0033] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of these drawings.

[0034] Fig. 1 is a structural schematic view of the insulator replacement device based on heavy-load unmanned aerial vehicle of the present application;

[0035] Fig. 2 is a structural schematic view of the insulator replacement device based on heavy-load unmanned aerial vehicle of the present application in another state.

[0036] Explanation of reference signs:

[0037] 1, UAV platform; 2, frame device; 3, rope; 4, rope winding device; 5, control platform; 6, grabbing arm; 7, rotor. DETAILED DESCRIPTION

[0038] In order to further clarify the technical means and effects taken by the present application to achieve the predetermined object of the application, the specific embodiments, structures, features and effects according to the present application are described in detail below in combination with the drawings and preferred embodiments. In the following description, different "an embodiment" or "embodiments" do not necessarily refer to the same embodiment. In addition, the specific features, structures or characteristics in one or more embodiments can be combined in any suitable form.

[0039] In the description of the present application, it should be clear that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and do not necessarily describe a specific order or sequence; the terms "vertical", "horizontal", "longitudinal", "front", "back", "left", "right", "up", "down", "horizontal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application, and do not mean that the device or element referred to must have a specific orientation or position, therefore it cannot be understood as a limitation on the present application.

[0040] In the description of the present application, it should be noted that unless otherwise specified and limited, the terms "mounting", "connecting", "connecting" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0041] As Figs. 1-2 shown, the embodiment of the present application provides an insulator replacement device based on heavy-load unmanned aerial vehicle, which comprises:

[0042] The unmanned aerial vehicle platform 1 adopts eight-axis sixteen-rotor 7 layout, carries multiple redundant power supply system and multiple redundant power system;

[0043] Four groups of rope winding devices 4 are symmetrically fixed to four corner points of the power cabin at the bottom of the unmanned aerial vehicle platform 1, and each group of winding device is provided with an independent servo motor and a brake;

[0044] Four high-strength ropes 3, the top end of each rope 3 is wound and connected to a group of the rope winding device 4, and the bottom end is fixedly connected to a control platform 5;

[0045] A control platform 5 is suspended below the UAV platform 1 by the ropes 3, and two sets of open-type grabbing arms 6 are installed on the control platform 5;

[0046] A circular cage-shaped frame device 2 is wrapped outside the ropes 3 and the rope winding device 4, and the top thereof is fixedly connected to the bottom frame of the UAV platform 1 through a quick-release interface, and an adjustable clamping mechanism and a rubber buffer layer are arranged at the bottom opening of the frame device 2;

[0047] The control platform 5 is located in the inner center of the frame device 2, and the grabbing end of the grabbing arm 6 faces the bottom opening of the frame device 2;

[0048] A self-locking safety bolt is arranged at the top quick-release interface of the frame device 2, and the bolt is matched with an electronic lock buckle at the bottom of the UAV platform 1, and automatic locking and unlocking are realized through the instruction of the flight control system.

[0049] In the embodiment, the UAV platform 1 adopts an eight-axis sixteen-rotor 7 layout, carries a multi-redundancy power supply system and a multi-redundancy power system, can carry ≥200 kg load to meet the heavy load demand of insulator replacement, four sets of rope winding devices 4 are symmetrically fixed at four corner points of the bottom power cabin of the UAV platform 1, an independent servo motor and a brake are arranged inside each set, and the rope 3 can be independently controlled; the top end of the four high-strength ropes 3 is wound on the rope winding device 4, and the bottom end is fixed to the control platform 5; the rope 3 has a double-woven structure, the inner aramid fiber bearing core guarantees the bearing strength, and the outer high-wear-resistant polyethylene coating can reduce friction loss and environmental corrosion; the control platform 5 is suspended below the UAV platform 1 through the ropes 3, two sets of open-type grabbing arms 6 are installed on the control platform 5, the grabbing arm 6 has a hydraulic driving three-finger claw structure, and a pressure sensor is embedded in the inner side; the circular cage-shaped frame device 2 is wrapped outside the ropes 3 and the rope winding device 4, the top thereof is connected to the bottom frame of the UAV platform 1 through a quick-release interface, an adjustable clamping mechanism and a rubber buffer layer are arranged at the bottom opening of the frame device 2, the frame device 2 is modularly spliced by carbon fiber composite material and aviation aluminum alloy, the module interface is positioned by anti-torsion nails and fastened by high-strength bolts, the control platform 5 is located in the inner center of the frame device 2, and the grabbing end of the grabbing arm 6 faces the bottom opening of the frame device 2.

[0050] During operation, the unmanned aerial vehicle platform 1 first locates above the insulator string by means of a laser radar and a visual recognition system, and is stably suspended by virtue of a multi-redundant power system; then four groups of hoisting rope winders 4 receive synchronous instructions from a flight control system, servo motors drive the winders to lower the ropes 3, the control platform 5 and the frame device 2 are slowly lowered, an encoder feeds back the length of the ropes 3 to the flight control system in real time, and the four ropes are synchronously wound and unwound to ensure that the frame remains horizontal; if the frame device 2 swings due to wind force, the flight control system adjusts the speed difference of the four groups of winders to generate a reverse torque to suppress the swing until the frame device 2 completely covers the insulator string. After the frame is in place, four hydraulic clamping jaws of an adjustable clamping mechanism inside the frame are driven by a linear servo module to radially clamp the insulator string from all around, and a rubber buffer layer prevents the insulator from being damaged; meanwhile, the grabbing arms 6 are closed under hydraulic drive, a pressure sensor inside the fingers transmits a contact pressure signal to a PLC controller of the control platform 5, the PLC interacts with the flight control system through a wireless communication module, and after confirming that the grabbing is firm, an operator remotely releases the insulator string connecting pin; finally, the hoisting rope winders 4 recover the ropes 3, the disassembled insulator string is lifted, and is transported back to the takeoff point by the unmanned aerial vehicle platform 1; if a new insulator string needs to be installed, the new insulator string is only needed to be placed into the frame device 2 at the takeoff point, and the above process is repeated. The whole scheme does not need manual tower climbing, avoids high-altitude operation risks, and guarantees operation safety by means of a multi-redundant system and a double fixing structure, improves efficiency and adaptability by means of modular design and precise control, and is suitable for complex terrains and climates.

[0051] A self-locking safety pin is arranged at a quick-release interface at the top of the frame device 2, the safety pin is matched with an electronic lock catch at the bottom of the unmanned aerial vehicle platform 1, the two are automatically locked and unlocked by sending instructions from the flight control system of the unmanned aerial vehicle platform 1, and the frame device 2 still has the structural characteristics of modular assembly of carbon fiber composite materials and aviation aluminum alloy, the quick-release interface and the modular modules are positioned by anti-torsion pegs and fastened by high-strength bolts, and the overall structure is stable.

[0052] During the operation preparation stage, a technician transports the disassembled frame device 2 modules to the takeoff point, first completes the modular assembly of the frame device 2 by means of anti-torsion pegs and high-strength bolts, then operates the unmanned aerial vehicle platform 1 to land at the specified position, switches the bottom electronic lock catch to the “unlocked standby” state by means of the flight control system, at this time, the electronic lock catch indicator light is green and always on, indicating that the interface can be docked. The technician holds the frame device 2, aligns the quick-release interface at the top of the frame device 2 with the interface position at the bottom of the unmanned aerial vehicle platform 1, the guide boss built-in the quick-release interface assists accurate docking, when the interfaces are fitted, the self-locking safety pin is automatically clamped into the annular clamping groove of the electronic lock catch under the pushing force of the internal reset spring, and preliminary pre-fixing is realized. The flight control system detects that the pin has been clamped into the clamping groove through the position sensor of the electronic lock catch, immediately displays “pre-locking completed” on the remote operation terminal, and sends a prompt signal to the technician.

[0053] After confirming the pre-locked state, the technician sends a "formal locking" command through the flight control system, and the electromagnetic drive mechanism in the electronic lock buckle at the bottom of the UAV platform 1 is immediately started to generate an electromagnetic force to push the lock tongue out, which is accurately inserted into the lock hole of the self-locking safety bolt, forming a double locking structure. At the same time, the pressure sensor of the electronic lock buckle detects the compression force of the lock tongue on the bolt in real time. When the pressure reaches the preset threshold (adapted to the total weight of the frame device 2 and the insulator string, to ensure stable bearing), the pressure sensor feeds back the signal to the flight control system, which records the "locking success" state and synchronously enhances the electromagnetic holding force of the electronic lock buckle to prevent the lock tongue from loosening due to vibration during operation. At this time, the frame device 2 and the UAV platform 1 are firmly connected and can withstand the load and impact in the subsequent insulator replacement operation.

[0054] During the operation, the UAV platform 1 carrying the frame device 2 takes off, hovers and lands, and the flight control system continuously receives the state feedback signal of the electronic lock buckle. If it encounters strong wind or airflow disturbance, causing the frame device 2 to produce slight shaking, the displacement sensor of the electronic lock buckle will detect the slight deviation of the self-locking safety bolt and immediately transmit the "locking deviation" signal to the flight control system. The flight control system responds quickly, on the one hand, it controls the UAV platform 1 to adjust the flight attitude to reduce the shaking amplitude, and on the other hand, it enhances the electromagnetic driving force of the electronic lock buckle to make the lock tongue further press the bolt hole, offset the deviation force and ensure that the bolt is always in the locked state, avoiding the frame device 2 from falling off.

[0055] After the insulator replacement operation is completed, the UAV platform 1 carrying the frame device 2 returns to the take-off point and lands smoothly, and the technician sends an "unlocking" command through the flight control system. The flight control system first verifies that the UAV is in a stationary state, and then sends a command to the electronic lock buckle. The electromagnetic drive mechanism is reversely energized to drive the lock tongue back to the initial position, releasing the constraint on the self-locking safety bolt. After the reset sensor of the electronic lock buckle detects that the lock tongue is completely retracted, it sends an "unlocking allowed" signal to the local control module of the frame device 2, which drives the micro motor inside the bolt to compress the reset spring and pull the bolt out of the electronic lock buckle. The flight control system detects that the bolt has exited and displays "unlocking completed" on the terminal, and the technician can easily remove the frame device 2 from the bottom of the UAV platform 1. Subsequently, the frame device 2 module can be disassembled for transportation, or the internal insulator string can be directly replaced, preparing for the next operation.

[0056] This structure not only retains the convenience of the modular design of the frame device 2, but also improves the docking stability and operation safety through the cooperative control of the self-locking safety bolt and the electronic lock buckle, avoiding the time-consuming and loose problems of traditional manual bolt fixation. At the same time, relying on the flight control system for automatic control, it forms a linkage with the multiple redundant systems of the UAV platform 1, further ensuring the operation reliability in complex environments.

[0057] In some embodiments, the frame device 2 is composed of carbon fiber composite material and aviation aluminum alloy through modular splicing, and anti-torsion pin positioning and high-strength bolt fastening are adopted at the module interface.

[0058] The carbon fiber composite material is T800 high-strength carbon fiber and epoxy resin formed through autoclave process, the fiber lay-up adopts [0° / 90° / 45° / -45°]s symmetrical lay-up design, and a glue-riveting composite connection structure is adopted at the connection with the aviation aluminum alloy.

[0059] In the present embodiment, the frame device 2 is composed of carbon fiber composite material and aviation aluminum alloy through modular splicing, and anti-torsion pin positioning and high-strength bolt fastening are adopted at the module interface.

[0060] During operation, the frame device 2 can be disassembled into multiple modules during the transportation stage, facilitating transportation in complex terrains such as mountains and water areas, and reducing the difficulty of material transportation; after arriving at the work site, the modules are quickly aligned and positioned through anti-torsion pins, and then high-strength bolts are used to fasten the modules, quickly assembling them into a complete circular cage structure. After assembly, the lightweight characteristics of the carbon fiber composite material reduce the load pressure of the unmanned aerial vehicle platform 1, and in combination with the high strength of the aviation aluminum alloy, the frame device 2 can be ensured not to be easily deformed and damaged when wrapping the insulator string, bearing the clamping force and responding to external impact; if the frame device 2 is partially damaged later, the damaged module can be individually disassembled and replaced, without the need for overall replacement, greatly reducing maintenance costs, and the modular design also enables the frame device 2 to adapt to insulator strings of different sizes, improving the versatility of the equipment.

[0061] The tensile strength of T800 carbon fiber reaches 5.49 GPa, and the use of the lay-up angle can balance the stiffness in each direction, avoiding stress concentration. The autoclave process ensures the quality of resin infiltration and curing. The metal connection part is first coated with a high-temperature resistant epoxy adhesive and then riveted, which utilizes the glue layer to reduce vibration and avoid electrochemical corrosion, significantly improving the frame fatigue life and environmental adaptability.

[0062] In some embodiments, the hoisting rope reel 4 is electrically connected to the flight control system of the unmanned aerial vehicle, receives the synchronous winding and unwinding instructions issued by the flight control system, and each group of reels is equipped with an encoder to real-time feedback the length of the rope 3.

[0063] The flight control system is built-in with an adaptive anti-swing control algorithm, which is based on the feedback data of the four groups of encoders and the inertial measurement unit data of the unmanned aerial vehicle, and through real-time solving of the swing mode of the frame device 2, independently adjusts the output torque of each servo motor to achieve active vibration suppression.

[0064] In this embodiment, the servo motor of the hoisting rope reel 4 is electrically connected to the UAV flight control system, can receive the synchronous winding and unwinding instructions issued by the flight control system, and each set of reel is provided with an encoder to feedback the length of the rope 3 in real time. When running, after the UAV platform 1 locates the insulator string through laser radar and visual recognition, the flight control system calculates the required unwinding length of the rope 3 according to the height of the insulator string, sends synchronous winding and unwinding instructions to the servo motors of the four sets of hoisting rope reels 4, and the servo motors drive the reels to operate to unwind the rope 3. During the unwinding process, the encoder of each reel detects the unwinding length of the rope 3 in real time and feeds back the data to the flight control system in real time. The flight control system compares the length data of the four sets of ropes 3, and if there is a length deviation, immediately adjusts the speed of the corresponding servo motor to ensure that the four sets of ropes 3 are synchronously wound and unwound, so that the control platform 5 and the frame device 2 always maintain a horizontal state to descend or ascend, avoid the equipment from tilting due to the inconsistent length of the ropes 3, and ensure that the frame device 2 can accurately cover the insulator string, laying a foundation for subsequent stable operation.

[0065] The adaptive anti-swing control algorithm is a modern control algorithm based on a state space model. The system collects rope 3 length encoder data and IMU attitude data in real time, constructs an observer of the frame swing state, and calculates the optimal torque output of each motor through LQR optimization to actively suppress load swing. The effect is to reduce manual intervention, improve the controllability and positioning accuracy in turbulence.

[0066] In some embodiments, the grabbing arm 6 is a hydraulic drive type three-finger claw structure, and a pressure sensor is embedded in the inner side of the claw. The pressure sensor signal is connected to the PLC controller in the control platform 5.

[0067] The hydraulic drive system adopts a double-redundancy hydraulic source design, the main hydraulic source is an electric pump, the standby hydraulic source is an accumulator, and the two are switched through an electromagnetic reversing valve; the tip part of the three-finger claw structure is embedded with a tungsten carbide alloy tooth with anti-slip texture, and the opening and closing range of the claw can be steplessly adjusted between 150mm-300mm.

[0068] In the embodiment, the grabbing arm 6 is a hydraulic driving three-jaw structure, and a pressure sensor is embedded in the inner side of the jaw. The signal of the pressure sensor is connected to the PLC controller in the control platform 5. When the frame device 2 covers the insulator string and the adjustable clamping mechanism inside holds the insulator string, the control platform 5 controls the hydraulic system of the grabbing arm 6 to start, drives the three-jaw structure to slowly close, and approaches the end fittings of the insulator string. During the grabbing process, the pressure sensor on the inner side of the jaw detects the contact pressure with the fittings in real time, and transmits the pressure signal to the PLC controller. The PLC controller judges the grabbing state according to the preset pressure threshold value: if the pressure is insufficient, the hydraulic system is controlled to increase the driving force to ensure that the fittings are firmly grabbed to prevent falling; if the pressure is too large, the driving force is reduced to avoid crushing the fittings or the insulator string, realizing flexible and firm grabbing of the insulator string, providing stable protection for subsequent lifting, transportation and pin disassembly operations, and reducing the risk of damage or falling of the insulator string during the operation process.

[0069] The double hydraulic sources ensure that the grabbing arm 6 can still work normally when one set of system fails, preventing the insulator from falling off due to pressure loss. The electric pump is the main power source, and the accumulator is used as an emergency power reserve. The tungsten carbide alloy teeth provide high wear resistance and anti-skid property. The stepless adjustment of the opening and closing of the jaw is realized through the servo valve control of the hydraulic cylinder, so that it can adapt to fittings of different sizes.

[0070] In some embodiments, the PLC controller in the control platform 5 interacts with the flight control system of the UAV platform 1 through a wireless communication module, receives target position instructions and feeds back grabbing state information.

[0071] The wireless communication module adopts a dual-band redundant design, the main frequency band is 2.4 GHz, the standby frequency band is 900 MHz, and the communication protocol adopts a TDMA mechanism based on time triggering, ensuring the real-time and reliability of the control instructions.

[0072] In the embodiment, the PLC controller in the control platform 5 interacts with the flight control system of the UAV platform 1 through a wireless communication module, receives target position instructions and feeds back grabbing state information.

[0073] During operation, the UAV platform 1 flight control system determines the target gripping position of the insulator string through laser radar and visual recognition, and sends the position command to the PLC controller of the control platform 5 through the wireless communication module. The PLC controller adjusts the angle and position of the gripping arm 6 according to the command to ensure that the gripping arm 6 accurately aligns with the end fitting of the insulator string. During the gripping process of the gripping arm 6, the pressure sensor transmits the pressure data to the PLC controller, and the PLC controller processes the state information such as whether the gripping is firm and whether the pressure meets the standard, and feeds back to the flight control system through the wireless communication module. The flight control system judges whether to perform the next operation according to the feedback information: if the gripping is not firm, send an adjustment command to the PLC controller to control the gripping arm 6 to re-adjust the gripping; if the gripping is stable, allow the operator to perform subsequent pin disassembly operations, realize the cooperative control of the UAV and the gripping arm 6, and improve the operation accuracy and safety.

[0074] The 2.4 GHz frequency band is used for high-speed data transmission, and the 900 MHz frequency band has strong penetration and serves as a backup signal to ensure uninterrupted communication in complex environments. The TDMA mechanism divides the communication time into time slots and allocates fixed time periods for different control commands, avoiding data packet collisions and ensuring the real-time and deterministic nature of command issuance and state feedback, thus meeting the high reliability control requirements.

[0075] In some embodiments, the adjustable clamping mechanism at the inner bottom end of the frame device 2 includes four circumferentially uniformly distributed hydraulic clamps, the clamping surfaces of the hydraulic clamps are lined with rubber buffer layers, and each clamp is independently connected to a linear servo module for radial movement.

[0076] The linear servo module uses ball screw transmission and is equipped with an absolute value encoder; the clamping force of the four hydraulic clamps can be independently controlled, and the maximum clamping force is not less than 5kN; the rubber buffer layer is made of polyurethane material with a Shore hardness of 70A and a thickness of 5mm.

[0077] In this embodiment, the adjustable clamping mechanism at the inner bottom end of the frame device 2 includes four circumferentially uniformly distributed hydraulic clamps, the clamping surfaces of the hydraulic clamps are lined with rubber buffer layers, and each clamp is independently connected to a linear servo module for radial movement.

[0078] During operation, after the frame device 2 is lowered to cover the insulator string, the PLC controller of the control platform 5 sends instructions to the four linear servo modules respectively. The linear servo modules drive the corresponding hydraulic clamps to move radially to the insulator string according to the diameter of the insulator string. During the movement, the four clamps evenly approach the insulator string from all around until the clamping surface is in contact with the surface of the insulator string. The rubber buffer layer forms a buffer between the clamp and the insulator string to avoid direct contact between the clamp and the insulator string, which may cause surface wear or damage to the insulator. After clamping is completed, the hydraulic system maintains a stable pressure to ensure that the insulator string is fixed in the frame device 2 and does not move during operation due to equipment shaking, providing stable conditions for the arm 6 to accurately grasp the end fittings of the insulator string and subsequent pin disassembly operations. At the same time, it is suitable for insulator strings of different diameters and improves the versatility of the equipment.

[0079] The ball screw transmission has high efficiency and accurate positioning, and can realize closed-loop control of the radial position of the clamp by cooperating with an absolute value encoder, with a repeat positioning accuracy of ±0.1 mm. Independent control of the clamping force of each clamp can prevent damage to the insulator due to uneven stress. The Shore hardness of the polyurethane buffer layer is 70A, which can provide sufficient clamping force while effectively protecting the glaze layer on the surface of the ceramic or composite insulator.

[0080] In some embodiments, the multi-redundant power supply system of the UAV platform 1 includes two independent lithium battery groups and an oil-fired generator, and the multi-redundant power system includes sixteen independent electronic speed controllers and motor combinations. When any battery or motor fails, the system can automatically redistribute power to maintain stable flight.

[0081] The oil-fired generator is a rotor engine with a rated power of 15 kW, and its exhaust pipe extends to the outside of the UAV platform 1 and bends downward to avoid interference with the airflow of the rotor 7.

[0082] In this embodiment, the multi-redundant power supply system of the UAV platform 1 includes two independent lithium battery groups and an oil-fired generator, and the multi-redundant power system includes sixteen independent electronic speed controllers and motor combinations. When any battery or motor fails, the system can automatically redistribute power to maintain stable flight.

[0083] In operation, before the UAV platform 1 takes off, the multi-redundant power supply system is started, and the two groups of lithium battery packs and the fuel generator are in standby state at the same time. The lithium battery packs are used preferentially to ensure environmental protection and silent operation, and the fuel generator is used as a backup power supply. During flight and operation, if one of the lithium battery packs is depleted or fails, the system automatically switches to the other lithium battery pack for power supply. If both lithium battery packs are abnormal, the fuel generator is started immediately to ensure uninterrupted power supply. In the multi-redundant power system, sixteen sets of electronic governors and motor combinations drive the corresponding rotors 7 to operate. If any motor or electronic governor fails, the system detects the failed unit in real time, quickly distributes the power of the failed unit to other normal units, adjusts the speed of the normal motors to compensate for power loss, and maintains the stability of the flight attitude of the UAV platform 1. This design avoids the UAV crashing due to power or power supply failure, ensures the safety of high-altitude operation, and is especially suitable for long-term operation under complex weather conditions, improving the reliability of the equipment.

[0084] The rotor engine has high power density and small vibration, which is suitable for aviation applications. The exhaust pipe of the rotor engine is extended and bent downward to guide the high-temperature exhaust gas away from the downward airflow generated by the rotors 7, avoiding the exhaust gas being sucked into the power system to cause engine power attenuation or unstable combustion, ensuring the reliability of the backup power supply and the stability of the power output.

[0085] In some embodiments, the rope 3 has a double-layer braided structure, the inner layer is an aramid fiber load-bearing core, and the outer layer is coated with a high-wear-resistant polyethylene coating.

[0086] The aramid fiber is para-aramid, the linear density is 1580 dtex, and the breaking strength is not less than 23 cN / dtex; the polyethylene coating contains an anti-ultraviolet additive, and the coating thickness is 0.5 mm.

[0087] In this embodiment, the rope 3 has a double-layer braided structure, the inner layer is an aramid fiber load-bearing core, and the outer layer is coated with a high-wear-resistant polyethylene coating. In operation, the top end of the rope 3 is wound on the hoisting rope reel 4, and the bottom end is connected to the control platform 5. The hoisting rope reel 4 drives the rope 3 to complete the winding and unwinding action, and bears the weight of the control platform 5, the frame device 2 and the insulator string. The aramid fiber load-bearing core in the inner layer has high strength characteristics and can stably bear heavy load pressure, avoiding the rope 3 from breaking due to excessive load, ensuring the safety of the equipment and the insulator string; the high-wear-resistant polyethylene coating in the outer layer reduces the friction loss with the internal structure of the hoisting rope reel 4 and the frame device 2 during the winding and unwinding of the rope 3, prolonging the service life of the rope 3. At the same time, the polyethylene coating has certain corrosion resistance and can resist the erosion of rain, dust and corrosive gases in the outdoor operation environment, ensuring that the rope 3 maintains stable performance in long-term outdoor use, avoiding operation interruption caused by damage to the rope 3, and providing reliable protection for the stable lifting of the frame device 2 and the control platform 5.

[0088] The embodiment of the present application also provides a method for replacing an insulator by using the heavy-load unmanned aerial vehicle based insulator replacement device, comprising the following steps:

[0089] S1: the unmanned aerial vehicle flies to the top of the insulator string, and is positioned by a laser radar and a visual identification system;

[0090] S2: four groups of rope winches 4 synchronously lower the ropes 3, so that the frame device 2 is lowered to cover the insulator string;

[0091] S3: the adjustable clamping mechanism in the frame device 2 acts to tightly hold the insulator string from all sides;

[0092] S4: the grabbing arm 6 is closed to firmly hold the end fitting of the insulator string;

[0093] S5: an operator remotely controls to release the connecting pin of the insulator string;

[0094] S6: the rope winches 4 recover the ropes 3 to lift and transport the removed insulator string.

[0095] Between steps S3 and S4, a step S3a is added: after confirming that the insulator string is completely located in the center of the frame device 2 by laser scanning, the flight control system controls the self-locking safety pin at the top of the frame device 2 to extend and lock with the unmanned aerial vehicle platform 1 to form a rigid connection.

[0096] In the embodiment, the process of replacing the insulator by using the device is sequentially carried out as follows: first, the unmanned aerial vehicle flies to the top of the insulator string, is accurately positioned and stably hovers by the laser radar and the visual identification system, and determines the reference position for subsequent operation; then, the four groups of rope winches 4 synchronously lower the ropes 3 to drive the frame device 2 to slowly descend until the frame device 2 completely covers the insulator string, and the flight control system monitors the attitude of the frame device 2 in real time during the lowering process; subsequently, the adjustable clamping mechanism in the frame device 2 acts to tightly hold the insulator string from all sides, and the rubber buffer layer protects the insulator from being damaged; then, the grabbing arm 6 is closed to firmly hold the end fitting of the insulator string, and the pressure sensor feeds back the grabbing state to ensure stability; again, the operator remotely controls to release the connecting pin of the insulator string to complete the preparation for disassembly; finally, the rope winches 4 recover the ropes 3 to stably lift the removed insulator string, and the unmanned aerial vehicle carries the insulator string to fly back to the take-off point. If new insulator strings need to be installed, the new insulator strings only need to be placed into the frame device 2 at the take-off point, and the positioning, lowering, fixing and connecting steps are repeated, so that the whole process does not need to build a temporary platform or manually climb the tower, greatly shortens the operation time, reduces the safety risk and improves the replacement efficiency.

[0097] The rigid connection confirmation step S3a is a newly added safety confirmation link. After confirming that the insulator string is in the center of the frame by the laser scanner (such as a 2D LIDAR) built in the frame, the rigid lock is triggered. This converts the connection between the UAV and the load from flexible to rigid, greatly enhancing the rigidity and stability of the entire system during subsequent disassembly operations, reducing shaking, and facilitating precise operation.

[0098] In some embodiments, in step S2, if the environmental wind causes the frame device 2 to swing, the flight control system independently adjusts the lowering speed difference of the four groups of hoisting rope winders 4 according to the attitude sensor data to generate a reverse moment to suppress the swing.

[0099] The flight control system uses an algorithm based on model predictive control (MPC), and the internal model is a rigid-flexible coupling multi-body dynamics model of the frame device 2. The model is obtained through pre-system identification, the prediction time domain is set to 10 steps, and the control time domain is set to 5 steps.

[0100] In the step of lowering the frame device 2 in this embodiment, if the environmental wind causes the frame device 2 to swing, the flight control system of the UAV will receive the data transmitted by the attitude sensor in real time, and quickly analyze the direction and amplitude of the swing. Then the flight control system independently adjusts the lowering speed of the four groups of hoisting rope winders 4 according to the analysis results, and generates a speed difference: for example, when the frame device 2 swings to the left, the flight control system controls the two groups of hoisting rope winders 4 on the left to appropriately slow down the lowering speed, and the two groups on the right maintain the original speed or slightly speed up, thereby generating a reverse moment to the right through the speed difference of the two sides of the rope 3; if the frame device 2 swings forward and backward, the speed of the front and rear two groups of hoisting rope winders 4 is adjusted correspondingly. Through this dynamic adjustment mode, the influence of the wind on the frame device 2 is offset in real time, the swing is suppressed, the frame device 2 always maintains a stable state, the insulator string is precisely covered, the collision and damage of the frame device 2 and the insulator string caused by the swing are avoided, or the positioning deviation is avoided to ensure normal operation, and the operation stability in complex wind environment is improved.

[0101] The model predictive control (MPC) algorithm is an advanced process control algorithm. Based on the identified system dynamics model, it predicts the system behavior in the future 10 sampling time domains, and calculates the optimal control amount (such as the lowering speed) in the 5 control time domains, and realizes the lead control through rolling optimization. Compared with the traditional PID, MPC can better handle multivariable coupling and system constraints, and has better wind disturbance resistance.

[0102] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working process of the above-described devices, apparatuses and units can refer to the corresponding process in the foregoing method embodiments, which will not be repeated here.

[0103] The above merely illustrates the specific embodiments of the present application, but the protection scope of the present application is not limited thereto, and any skilled person in the art can easily think of various equivalent modifications or replacements within the technical range disclosed by the present application, and these modifications or replacements shall be covered within the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. A heavy-duty drone-based insulator replacement device, characterized by, The unmanned aerial vehicle platform (1) adopts an eight-axis sixteen-rotor (7) layout, carries a multi-redundant power supply system and a multi-redundant power system. Four groups of hoisting rope winders (4) are symmetrically fixed to four corner points of the power cabin at the bottom of the unmanned aerial vehicle platform (1), each group of winders is internally provided with an independent servo motor and a brake. Four high-strength ropes (3) are each wound and connected to a group of the hoisting rope winders (4) at the top end, and are fixed to a control platform (5) at the bottom end. The control platform (5) is suspended below the unmanned aerial vehicle platform (1) through the ropes (3), and is provided with two groups of split type grabbing arms (6) thereon. A circular cage frame device (2) is wrapped outside the ropes (3) and the hoisting rope winders (4), the top thereof is fixedly connected to the bottom frame of the unmanned aerial vehicle platform (1) through a quick release interface, and the bottom opening thereof is provided with an adjustable clamping mechanism and a rubber buffer layer. The control platform (5) is located at the inner center of the frame device (2), and the grabbing end of the grabbing arm (6) faces the bottom opening of the frame device (2). A self-locking safety bolt is arranged at the quick release interface at the top of the frame device (2), the bolt is matched with an electronic lock buckle at the bottom of the unmanned aerial vehicle platform (1), and automatic locking and unlocking is realized through the flight control system instruction. The frame device (2) is composed of carbon fiber composite material and aviation aluminum alloy through modular splicing, and an anti-torsion pin is positioned and a high-strength bolt is fastened at the module interface. The servo motor of the hoisting rope winder (4) is electrically connected to the flight control system of the unmanned aerial vehicle, receives the synchronous winding and unwinding instruction issued by the flight control system, and each group of winders is provided with an encoder for real-time feedback of the length of the rope (3). The flight control system is internally provided with an adaptive anti-swing control algorithm based on model predictive control, which is used to independently adjust the unwinding speed difference of the four groups of hoisting rope winders (4) in real time according to the feedback data of the four groups of encoders and the inertial measurement unit data of the unmanned aerial vehicle, so as to generate a reverse torque to actively suppress the swing of the frame device (2). The grabbing arm (6) is a hydraulic drive type three-finger claw structure, a pressure sensor is embedded in the inner side of the claw, and the pressure sensor signal is connected to a PLC controller in the control platform (5).

2. The heavy duty drone based insulator replacement device of claim 1, wherein, The PLC controller in the control platform (5) exchanges data with the flight control system of the unmanned aerial vehicle platform (1) through a wireless communication module, receives a target position instruction and feeds back a grabbing state information.

3. The heavy duty drone based insulator replacement device of claim 2, wherein, The adjustable clamping mechanism at the inner bottom end of the frame device (2) comprises four circumferentially uniformly distributed hydraulic clamps, the clamping surface of the hydraulic clamp is lined with a rubber buffer layer, and each clamp is independently connected to a linear servo module to realize radial movement.

4. The heavy duty drone based insulator replacement device of claim 1, wherein, The multi-redundant power supply system of the unmanned aerial vehicle platform (1) comprises two groups of independent lithium battery groups and an oil-fired generator, and the multi-redundant power system comprises sixteen independent electronic speed controllers and motor combinations, when any battery or motor fails, the system can automatically redistribute power to maintain stable flight.

5. The heavy duty drone based insulator replacement device of claim 1, wherein, The rope (3) has a double-layer braided structure, the inner layer is an aramid fiber load-bearing core, and the outer layer is coated with a high-wear-resistant polyethylene coating.

6. The heavy duty drone based insulator replacement device of claim 1, wherein, The steps include:

7. A method of replacing an insulator using the heavy-duty drone-based insulator replacement device according to any one of claims 1-6, characterized in that, ​ S1: The UAV flies above the insulator string, and the laser radar and visual recognition system are used for positioning; S2: Four groups of hoisting rope winders (4) are used to synchronously lower the ropes (3), so that the frame device (2) is lowered to cover the insulator string; S3: The adjustable clamping mechanism in the frame device (2) is actuated to tightly embrace the insulator string from all sides; S4: The gripping arms (6) are closed to firmly grip the end fittings of the insulator string; S5: The operating personnel remotely control the disconnection of the connecting latch of the insulator string; S6: The hoisting rope winders (4) are used to recover the ropes (3), so that the disassembled insulator string is lifted and transported back.

8. The method of replacing an insulator of claim 7, wherein, In step S2, if the environmental wind force causes the frame device (2) to swing, the flight control system independently adjusts the lowering speed difference of the four groups of hoisting rope winders (4) according to the attitude sensor data, so as to generate a reverse moment to suppress the swing.

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