A pipe repair device and method

Abstract

The application belongs to the technical field of pipeline robots, and particularly relates to a pipeline repairing device and method. The device comprises a repairing mechanism, a power mechanism, multiple sets of walking mechanisms, a brake mechanism and a supporting mechanism. Multiple X-ray sensors are evenly distributed on the outer circumferences of sensor supporting bodies at the front end of the supporting mechanism. A Hall speed measurement module is arranged on the walking mechanism. The X-ray sensors and the Hall speed measurement module are connected with a signal processor arranged on a front shell. The signal processor is connected with a controller arranged on the front shell. The controller is connected with the power mechanism, the repairing mechanism and the supporting mechanism respectively. The X-ray sensors, the Hall speed measurement module, the signal processor and the controller are connected with a power module arranged on the front shell. The application highly integrates detection, walking, positioning, repairing, control and power systems into one, and realizes full-process automatic operation from pipeline defect identification and positioning to repairing.

Description

Technical Field

[0001] This invention belongs to the field of pipeline robot technology, and specifically relates to a pipeline repair device and method. Background Technology

[0002] Pipelines are critical infrastructure for transporting important media such as oil, gas, and water, and their safe operation is of paramount importance. Currently, pipeline repair technologies mainly fall into two categories: open-cut repair and trenchless repair. Open-cut repair has a long construction cycle, high costs, and significant environmental impact; trenchless repair technologies are gradually becoming mainstream, especially the use of pipeline robots for internal repairs.

[0003] Existing pipeline repair robots typically possess basic functions such as walking, inspection, and repair, but they have the following drawbacks:

[0004] 1. Simple repair action: Most devices use simple radial extrusion or static spraying methods, which cannot fully adhere the repair material to complex curved surfaces (such as local corrosion pits and circumferential cracks), resulting in uneven coverage, poor adhesion, and easy creation of repair blind spots.

[0005] 2. Lack of compliant control: The repair head is usually rigidly pushed in, lacking precise sensing and control of the contact force with the pipe wall. During the repair process, excessive pressure can easily cause secondary damage to the already fragile pipe wall, or insufficient pressure can lead to incomplete filling of the repair material, resulting in poor reliability.

[0006] 3. Low level of automation: The delivery and application of repair materials are often carried out by a preset program to move them to a fixed position, which is difficult to adapt to changes in different pipe diameters and requires frequent manual intervention.

[0007] 4. Power dependence on external traction: Many robots rely on external cable winches for traction, which limits their range of motion and makes the cables prone to tangling, making them unsuitable for long-distance pipeline operations.

[0008] 5. Inefficient self-driving methods: Although devices driven by screw wheels or tracks can move on their own, their speed is greatly affected by the fluid flow rate inside the pipeline. When the flow rate fluctuates, the robot may "suddenly stop" or "run wildly," making it impossible to park stably at the defect point for precise repair, resulting in poor positioning accuracy.

[0009] 6. Low energy efficiency: Relying entirely on its own motor for propulsion consumes a lot of energy, limiting the robot's continuous working time and distance. Summary of the Invention

[0010] To address the shortcomings of existing technologies, this invention provides a pipeline repair device and method that can achieve automatic identification, precise positioning, force-controlled repair, and intelligent speed adjustment of pipeline defects, thereby improving repair efficiency and quality and reducing manual intervention and operational risks.

[0011] A pipeline repair device includes a central support shaft with a front cover and a rear cover at its two ends. A repair mechanism is fixedly connected to the middle of the central support shaft for repairing pipeline defects. A front housing and a rear housing are fixedly connected to the front and rear covers and the repair mechanism, respectively, to isolate internal components from the external environment. A power mechanism is located at the rear end of the rear cover to provide power for the repair device to move forward. Multiple sets of walking mechanisms are symmetrically arranged on the front and rear covers along the repair mechanism. A braking mechanism is provided on each walking mechanism. A support mechanism is located at the front end of the front cover to support the repair device within the pipeline and fix it in place during repair. A sensor support body is located at the front end of the support mechanism, with a front plate at its front end. Multiple X-ray sensors are evenly distributed on the outer circumference of the sensor support body for detecting pipeline defects. A Hall effect speed measurement module is located on the walking mechanism to detect the travel speed. The X-ray sensors, the Hall effect speed measurement module, and a signal processor are connected to a controller located on the front housing. The controller is connected to the power mechanism, the repair mechanism, and the support mechanism. The X-ray sensors, the Hall effect speed measurement module, the signal processor, and the controller are connected to a power module located on the front housing.

[0012] The repair mechanism includes a fixed frame and a rotating frame. The fixed frame is mounted on a central support shaft, and the rotating frame is connected to the fixed frame via bearings. The rotating frame is fixed to the front and rear housings via an external sealing bearing and an external sealing ring. A rotating frame gear ring is fixedly connected to one side of the rotating frame. The inner side of the rotating frame gear ring meshes with gear I. Gear I is connected to the output shaft of motor I fixed on the rear housing. Motor I is connected to a motor drive module, and the motor drive module is connected to a controller.

[0013] A primary connector is installed on the circumference of the rotating frame, a secondary connector is slidably connected to the primary connector, a repair head is installed at the top of the secondary connector, and a leather sleeve is fitted on the repair head.

[0014] A liquid medicine cylinder is fixedly connected to the intermediate support shaft. The liquid medicine cylinder is connected to the fixed frame via a liquid medicine pump. The fixed frame, rotating frame, primary connector, secondary connector, and repair head are equipped with liquid medicine channels. The liquid medicine pump is connected to a controller.

[0015] Two dual-head motors are fixedly connected to the rotating frame. The output shaft of the dual-head motors is connected to gear II. The two sides of the secondary connector are provided with racks. Gear II meshes with the racks for the movement of the secondary connector. The dual-head motors are provided with current sensors, which are connected to a signal processor. The dual-head motors are connected to a motor drive module, which is connected to a controller.

[0016] The power mechanism includes a base, a perforated plate, baffles, and pressure plates. The base is mounted on the rear guide plate, which is fixed to the rear cover by a cup. The base has several evenly distributed bosses I. The perforated plate has the same number of slots as the bosses I. One end of each baffle is rotatably connected to a boss I, and the other end is connected to a slot in the perforated plate. One side of the perforated plate has a tooth profile I, which meshes with gear III. Gear III is connected to the output shaft of motor II mounted on the rear cover. A pressure plate is fixedly connected to the top of the perforated plate and to the rear cover. Motor II is connected to a motor drive module, which is connected to a controller.

[0017] The baffle plate has an arc-shaped structure, with a circular hole at one end and a boss II at the other end. The circular hole is hinged to a boss I on the base, and the boss II is connected to a slot with a perforated plate. There are n baffle plates, and adjacent baffle plates are at an angle θ. The adjacent bosses I and the slots in the perforated plate are spaced apart by an angle θ.

[0018] The support mechanism includes a support ring, a slotted plate, a motor III, a gear IV, a support arm, and a sliding plate. The support ring is fixed to the front cover, and the slotted plate is fitted onto the support ring. A gear II is fixedly connected to the slotted plate, meshing with the gear IV. The gear IV is connected to the output shaft of the motor III, which is fixed to the front cover. The support arm is slidably connected to the slotted plate, and moves up and down along a sliding groove on the sliding plate. The sliding plate is fixed to the sensor support and also fixedly connected to the front cover. A current sensor is installed on the motor III, which is connected to a signal processor. The motor III is connected to a motor drive module, which is connected to a controller.

[0019] The slotted plate has four arc-shaped slots. One end of the support arm has a boss III, and the other end has a support plate. The sliding plate has a sliding groove corresponding to the support arm. The boss III slides in the arc-shaped slot of the slotted plate, and the support arm slides in the sliding groove of the sliding plate to adjust the position of the support plate.

[0020] The walking mechanism is provided in three groups, each group being 120 degrees apart. Each group includes two walking components symmetrically arranged along the repair mechanism. The walking component includes a traveling wheel connecting rod, a traveling wheel, and a spring. The traveling wheel connecting rod is hinged to the front cover or the rear cover. The traveling wheel is fixedly connected to the end of the traveling wheel connecting rod. A spring is connected to the middle of the traveling wheel connecting rod, and the other end of the spring is fixed to the front housing or the rear housing.

[0021] The braking mechanism is connected to the traveling assembly fixed on the rear cover. The braking mechanism includes a motor IV, a slotted shaft, a brake lever, and a brake housing. The brake housing is mounted on the traveling wheel connecting rod. The motor IV and the slotted shaft are installed inside the brake housing. The output shaft of the motor IV is connected to the slotted shaft. The brake lever is slidably connected in the slot of the slotted shaft, and the brake lever acts on the traveling wheel. The brake housing has an arc-shaped groove. The boss IV on the brake lever slides in the arc-shaped groove, thereby driving the brake lever to slide in the slot of the slotted shaft, realizing the extension and retraction of the brake lever. The motor IV is connected to a motor drive module, and the motor drive module is connected to a controller.

[0022] A pipe repair method includes several steps:

[0023] Step 1: Set the forward speed range of the repair device. The signal processor identifies the data from the Hall speed measurement module and sends a signal to the controller. The controller adjusts the opening and closing angles of multiple baffles in the power mechanism by adjusting the meshing of motor II, gear III and tooth profile I on the perforated plate, thereby changing the effective area of ​​the fluid and adjusting the thrust of the fluid on the repair device, and thus adjusting the forward speed of the repair device.

[0024] Step 2: The X-ray sensor determines whether there is a defect inside the pipe. When a defect is detected, the device continues to move, moves the repair mechanism to the defect location, and the braking mechanism is activated, stopping the entire device from moving.

[0025] Step 3: The current sensors on motor III and the dual-head motor monitor the current information. The signal processor identifies the current information and sends a signal to the controller. The controller judges the magnitude of the current information and the contact threshold current. When the current information is greater than the contact threshold current, it is determined that the support arm and the repair head have contacted the pipe wall. The controller calculates the contact pressure between the support arm, the repair head and the pipe wall, and compares the contact pressure with the target support force. Finally, the controller uses the PID force feedback control algorithm to calculate the control command signal. According to the control command signal, the controller controls motor III in the support mechanism, so that gear II meshes with gear IV, thereby moving the support arm outward along the slide plate, and fixing the support plate on the support arm to the inner wall of the pipe, so that the entire device remains stationary. Then, the controller controls the dual-head motor in the repair mechanism to rotate, so that the secondary connector slides on the primary connector, and the repair head moves towards the pipe wall and is in close contact with the inner wall of the pipe.

[0026] Step 4: The controller controls the working of the liquid pump, so that the liquid in the liquid tank gradually enters the repair head and then squeezes out the liquid. At the same time, the motor I works, so that the rotating frame drives the repair head to rotate, so that the liquid is evenly applied to the damaged pipe area.

[0027] Step 5: After the pipeline repair is completed, the repair head of the repair mechanism and the support arm of the support mechanism return to their original positions, the brake mechanism retracts, the power mechanism adjusts the travel speed, and the device continues to move forward. Repeat steps 1 to 4 to complete the repair of all pipelines.

[0028] Beneficial technical effects of the present invention:

[0029] 1. By monitoring the travel speed in real time through Hall sensors and adjusting the opening and closing degree of the baffle of the power mechanism through feedback from the controller, the fluid thrust is intelligently controlled, enabling the device to operate stably within the preset speed range and adapt to pipeline environments with different flow rates. This solves the problems of unstable travel and inaccurate positioning during repair caused by fluid fluctuations.

[0030] 2. In the two key actions of supporting arm extension and repair head feeding, PID force feedback control algorithm is used to ensure that the device can provide firm support and close fit without causing excessive compression or damage to the inner wall of the pipeline, thus achieving smooth and safe operation, which is especially important for the repair of old and fragile pipelines.

[0031] 3. Internal defects are detected using X-ray sensors, resulting in high accuracy. A dual-motor, gear, and rack transmission mechanism precisely controls the radial movement of the repair head, allowing it to adapt to different pipe diameters and ensuring a perfect fit between the repair head and the pipe wall. The repair mechanism combines circumferential rotation with radial feed, and, in conjunction with the metered delivery of the chemical solution pump, ensures that the repair material (chemical solution) is evenly and precisely applied to the defect area, greatly improving the uniformity and reliability of the repair.

[0032] 4. This invention highly integrates detection, movement, positioning, repair, control and power systems into one, realizing fully automated operation from pipeline defect identification and positioning to repair. It significantly reduces manual intervention, improves repair efficiency and safety, has a compact structure, complete functions, and is suitable for a variety of pipeline repair scenarios. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall structure of a pipeline repair device according to the present invention;

[0034] Figure 2 This is a three-dimensional structural diagram of the repair mechanism of a pipeline repair device according to the present invention;

[0035] Figure 3 This is a cross-sectional view of the repair mechanism of a pipeline repair device according to the present invention;

[0036] Figure 4 This is a schematic diagram showing the position of the power mechanism of a pipeline repair device according to the present invention;

[0037] Figure 5 This is an exploded view of the power mechanism of a pipeline repair device according to the present invention;

[0038] Figure 6 This is an exploded view of the support mechanism of a pipeline repair device according to the present invention;

[0039] Figure 7 This is a schematic diagram of the braking mechanism of a pipeline repair device according to the present invention;

[0040] Figure 8 This is a control block flowchart of a pipeline repair device control system according to the present invention;

[0041] 1. Intermediate support shaft; 2. Repair mechanism; 201. Fixed frame; 202. Rotating frame; 203. Gear I; 204. Rotating frame gear ring; 205. Motor I; 206. Medicine pump; 207. Medicine cylinder; 208. Dual-head motor; 209. Gear II; 210. Primary connector; 211. Secondary connector; 212. Repair head; 213. Leather sleeve; 214. Snap ring; 215. Front sealing bearing; 216. Rear sealing bearing; 217. Inner sealing ring; 218. Outer sealing bearing; 219. Outer sealing ring; 220. Cover plate; 3. Power mechanism; 301. Pressing plate; 302. Perforated plate; 303. Gear III; 304. Motor II; 305. Baffle plate; 306. Base; 3 07. Boss I; 308. Groove; 309. Boss II; 4. Support Mechanism; 401. Support Ring; 402. Groove Plate; 403. Motor III; 404. Gear IV; 405. Support Arm; 406. Slide Plate; 407. Tooth Profile II; 408. Boss III; 409. Support Plate; 5. Walking Components; 501. Spring; 502. Traveling Wheel Linkage; 503. Traveling Wheel; 6. Front Housing; 7. Front Cover; 8. Rear Housing; 9. Rear Cover; 10. Leather Cup; 11. Front Plate; 12. Sensor Support; 13. X-ray Sensor; 14. Rear Deflector; 15. Braking Mechanism; 1501. Motor IV; 1502. Groove Shaft; 1503. Brake Lever; 1504. Brake Housing. Detailed Implementation

[0042] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. These embodiments are implemented based on the technical solution of the present invention, but the scope of protection of the present invention is not limited to the following embodiments.

[0043] like Figures 1-8As shown, a pipe repair device includes a central support shaft 1, with a front cover 7 and a rear cover 9 at its two ends. A repair mechanism 2 is fixedly connected to the middle of the central support shaft 1 for repairing pipe defects. A front housing 6 and a rear housing 8 are fixedly connected to the front cover 7 and the rear cover 9, respectively, to isolate internal components from the external environment. A power mechanism 3 is provided at the rear end of the rear cover 9 to provide power for the repair device to move forward. Multiple sets of traveling mechanisms are symmetrically arranged on the front cover 7 and the rear cover 9 along the repair mechanism 2. A braking mechanism 15 is provided on the traveling mechanism. A support mechanism 4 is provided at the front end of the front cover 7 to support and fix the repair device inside the pipe during repair. The support mechanism 4 is stationary; a sensor support body 12 is provided at the front end of the support mechanism 4, and a front plate 11 is provided at the front end of the sensor support body 12. Multiple X-ray sensors 13 are evenly distributed on the outer circumference of the sensor support body 12 for detecting pipeline defects. A Hall speed measurement module is provided on the walking mechanism for detecting the traveling speed. The X-ray sensors 13 and the Hall speed measurement module are connected to a signal processor provided on the front housing 6. The signal processor is connected to a controller provided on the front housing. The controller is connected to the power mechanism 3, the repair mechanism 2 and the support mechanism 4 respectively. The X-ray sensors 13, the Hall speed measurement module, the signal processor and the controller are connected to a power module provided on the front housing 6.

[0044] In this embodiment, the Hall effect speed measurement module monitors the speed of the walking mechanism and feeds it back to the controller after passing through the signal processor. The controller controls the power of the power mechanism. At the same time, when the X-ray sensor 13 detects a pipeline that needs to be repaired, the controller controls the support mechanism 4 and the repair mechanism 2 to work. After the repair is completed, the walking mechanism continues to move forward, thereby completing the detection and repair of the entire pipeline.

[0045] The repair mechanism 2 includes a fixed frame 201 and a rotating frame 202. The fixed frame 201 is mounted on the intermediate support shaft 1. The rotating frame 202 is connected to the fixed frame 201 through a front sealing bearing 215, a rear sealing bearing 216, and an inner sealing ring 217. The rear sealing bearing 216 is connected to the fixed frame 201 through a snap ring 214 to prevent the rear sealing bearing 216 from sliding axially and falling off. The rotating frame 202 is fixed to the front housing 6 and the rear housing 8 through an outer sealing bearing 218 and an outer sealing ring 219. A rotating frame gear ring 204 is fixedly connected to one side of the rotating frame 202. The inner side of the rotating frame gear ring 204 meshes with a gear I 203. The gear I 203 is connected to the output shaft of a motor I 205 fixed on the rear housing 8. The motor I 205 is connected to a motor drive module, and the motor drive module is connected to a controller.

[0046] A primary connector 210 is installed on the circumference of the rotating frame 202. A secondary connector 211 is slidably connected to the primary connector 210. A repair head 212 is installed at the top of the secondary connector 211. A leather sleeve 213 is fitted onto the repair head 212.

[0047] In this embodiment, the secondary connector 211 drives the repair head 212 to slide on the primary connector 210, thereby adjusting the repair head 212 to be close to the pipe wall. The motor I 205 works, and the gear I 203 meshes with the rotating frame gear ring 204, causing the rotating frame 202 to rotate, thereby causing the repair head 212 to slide on the circumference of the pipe wall, thus making the damaged pipe repair uniform. The sleeve 213 is used for contact at the soft friction point to prevent hard friction between metals.

[0048] Two dual-head motors 208 are fixedly connected to the rotating frame 202. The output shaft of the dual-head motor 208 is connected to a gear II 209. The two sides of the secondary connector 211 are provided with racks. The gear II 209 meshes with the racks for the movement of the secondary connector 211. The two dual-head motors are placed in motor slots respectively. The motor slots are provided with cover plates 220 for sealing the motor slots. The dual-head motors 208 are provided with current sensors. The current sensors are connected to a signal processor. The dual-head motors 208 are connected to a motor drive module. The motor drive module is connected to a controller.

[0049] In this embodiment, the dual-head motor 208 drives the gear II 209 to move. The gear II 209 meshes with the rack, so that the repair head 212 is close to the pipe wall. At the same time, the dual-head motor 208 is equipped with a current sensor. The controller uses a PID force feedback control algorithm to make the repair head 212 fit tightly against the inner wall of the damaged pipe without excessively squeezing the pipe.

[0050] A liquid medicine cylinder 207 is fixedly connected to the intermediate support shaft 1. The liquid medicine cylinder 207 is connected to the fixed frame 201 through the liquid medicine pump 206. The fixed frame 201, the rotating frame 202, the primary connector 210, the secondary connector 211, and the repair head 212 are provided with liquid medicine channels. The liquid medicine pump 206 is connected to the controller.

[0051] In this embodiment, the controller drives the liquid pump 206 to deliver the liquid to the repair head 212 through the liquid channel, and evenly apply the liquid to the damaged pipe area.

[0052] The power mechanism 3 includes a base 306, a perforated plate 302, baffles 305, and a pressure plate 301. The base 306 is mounted on the rear guide plate 14, which is fixed to the rear cover 9 by a cup 10. The base 306 has several evenly distributed bosses I 307. The perforated plate 302 has the same number of slots 308 as the bosses I 307. One end of each baffle 305 is rotatably connected to the bosses I 307, and the other end is connected to the slots 308 of the perforated plate 302. One side of the perforated plate 302 has a tooth profile I, and a gear III 303 meshes with the tooth profile I. The gear III 303 is connected to the output shaft of the motor II 304 mounted on the rear cover 9. The pressure plate 301 is fixedly connected to the top of the perforated plate 302 and is fixedly connected to the rear cover 9. The motor II 304 is connected to a motor drive module, which is connected to a controller.

[0053] In this embodiment, several baffles 305 are connected to the base 306 and the perforated plate 302, respectively, so that the multiple baffles 305 are stacked in a cross pattern to form a ring-like structure. The motor II 304 drives the gear III 303 to move, thereby rotating the perforated plate 302 and changing the opening angle of the baffles 305. The fluid acts on the multiple baffles 305. When the opening angle of the baffles 305 changes, the area of ​​the fluid acting on them also changes, thereby adjusting the force on the device and thus adjusting the travel speed.

[0054] The baffle plate 305 has an arc-shaped structure, with a circular hole at one end and a boss II 309 at the other end. The circular hole is hinged to the boss I 307 on the base. The boss II 309 is connected to the slot 308 of the perforated plate 302. There are n baffle plates 305, boss I 307, and slots 308. Adjacent baffle plates 305 are at an angle θ. The adjacent bosses I307 and the slots 308 in the perforated plate 302 are all spaced apart by an angle θ.

[0055] The support mechanism 4 includes a support ring 401, a slotted plate 402, a motor III 403, a gear IV 404, a support arm 405, and a sliding plate 406. The support ring 401 is fixed to the front cover 7. The slotted plate 402 is fitted onto the support ring 401. A gear II 407 is fixedly connected to the slotted plate 402. The gear II 407 meshes with the gear IV 404. The gear IV 404 is connected to the output shaft of the motor III 403, which is fixed to the front cover 7. The support arm 405 is slidably connected to the slotted plate 402. The support arm 405 moves up and down along the sliding groove on the sliding plate 406. The sliding plate 406 is fixed to the sensor support 12 and is also fixedly connected to the front cover 7. A current sensor is provided on the motor III 403. The current sensor is connected to a signal processor. The motor III 403 is connected to a motor drive module. The motor drive module is connected to a controller.

[0056] The slotted plate 402 has four arc-shaped slots. One end of the support arm 405 has a boss III 408, and the other end has a support plate 409. The sliding plate 406 has a sliding groove corresponding to the support arm 405. The boss III 408 slides in the arc-shaped slot of the slotted plate 402, and the support arm 405 slides in the sliding groove of the sliding plate 406 to adjust the position of the support plate 409.

[0057] In this embodiment, motor III 403 is activated, driving gear IV 404 to rotate. Tooth profile II 407 meshes with gear IV 404, causing the slot plate 402 to rotate. The boss III 408 on the support arm 405 slides in the arc-shaped slot of the slot plate 402 and moves up and down along the slide rail on the slide plate 406, thereby adjusting the support plate 409 to fit tightly against the pipe wall. At the same time, a current sensor is provided on motor III 403, and the controller uses a PID force feedback control algorithm to ensure that the support plate 409 fits tightly against the inner wall of the damaged pipe without excessively squeezing the pipe.

[0058] The walking mechanism is provided in three groups, each group being 120 degrees apart. Each group includes two walking components 5 symmetrically arranged along the repair mechanism 2. The walking component 5 includes a traveling wheel connecting rod 502, a traveling wheel 503, and a spring 501. The traveling wheel connecting rod 502 is hinged to the front cover 7 or the rear cover 9. The traveling wheel 503 is fixedly connected to the end of the traveling wheel connecting rod 502. The spring 501 is connected to the middle of the traveling wheel connecting rod 502. The other end of the spring 501 is fixed to the front housing 6 or the rear housing 8.

[0059] The braking mechanism 15 is connected to the walking assembly 5 fixed on the rear cover 9. The braking mechanism 15 includes a motor IV 1501, a slotted shaft 1502, a brake lever 1503, and a brake housing 1504. The brake housing 1504 is mounted on the traveling wheel connecting rod 502. The motor IV 1501 and the slotted shaft 1502 are installed inside the brake housing 1504. The output shaft of the motor IV 1501 is connected to the slotted shaft 1502. The brake lever 1503 is slidably connected in the slot of the slotted shaft 1502. The brake housing 1504 is formed by two half-shells fixedly connected together. The two half-shells are respectively provided with arc-shaped grooves. The arc-shaped grooves on the two half-shells are symmetrically arranged. The boss IV on the brake lever 1503 slides in the arc-shaped groove, thereby driving the brake lever 1503 to slide in the slot of the slotted shaft 1502, thereby realizing the extension and retraction of the brake lever 1503. The motor IV is connected to the motor drive module, and the motor drive module is connected to the controller.

[0060] In this embodiment, the motor IV 1501 is started, driving the slot shaft 1502 to rotate, causing the boss IV on the brake lever 1503 to slide on the arc-shaped groove of the brake housing 1504, thereby driving the brake lever 1503 to slide and extend within the slot of the slot shaft 1502, thereby adjusting the extension length of the brake lever 1503, and thus controlling the brake lever 1503 to act on the travel wheel 503 to control the stop of the device.

[0061] A pipe repair method includes several steps:

[0062] Step 1: When the device is located inside the pipeline to be repaired, it relies on the thrust of the fluid inside the pipeline as its primary driving force. A speed range is set for the device's movement. During its movement, a Hall effect speed sensor module mounted on the traveling wheel 503 detects the speed in real time and sends the speed signal to a signal processor. The signal processor then transmits the processed speed information to the controller. The controller controls the motor II 304 in the power mechanism 3 to operate, driving the gear III 303 to rotate, which in turn drives the perforated plate 302 to move. The slots 308 on the perforated plate 302 drive the n baffles 305 to rotate, placing them at a suitable opening and closing angle to form a suitable fluid action area. The fluid flowing through generates thrust, propelling the device forward at the set speed.

[0063] If the actual speed is detected to be lower than the preset lower speed limit, the controller issues a command to drive motor II 304 to operate, adjusting the baffle 305 to reduce its opening and closing angle, thereby increasing the fluid contact area, which in turn increases the force-bearing area and thrust, causing the device to accelerate. If the actual speed is detected to be higher than the preset upper speed limit, the controller drives motor II 304 to operate in the opposite direction, adjusting the baffle 305 to increase its opening and closing angle, reducing the fluid contact area, which in turn reduces the force-bearing area and thrust, causing the device to decelerate. Through this closed-loop feedback control, the device can automatically stabilize its travel speed within a preset reasonable range.

[0064] Step 2: During the movement, the X-ray sensor 13 installed at the front of the device continuously scans and detects the inner wall of the pipe. When a defect is detected, feedback is sent to the controller to control the device to continue moving; when the travel distance calculated by the Hall speed measurement module confirms that the device has reached directly above the defect location, the controller controls the braking mechanism 15 to act on the traveling wheel 503, thereby stopping the entire device.

[0065] Step 3: Upon reaching the defect point, motor III 403 starts, causing gear IV 404 to drive gear II 407 to rotate, thereby causing support arm 405 to move outward along slide plate 406 and extend support arm 405. During this process, the current i of motor III is monitored in real time by current sensor. s When the support plate 409 on the initial support arm 405 does not contact the pipe wall, the current in motor III 403 is the no-load current i. s0 When the current of motor III is greater than the preset contact threshold current i c At that time, i s >i c Upon determining that support arm 405 has contacted the pipe wall, the controller switches to force control mode. Contact pressure F s The relationship with current is: Fs = k s *(i s - i s0 ), where k s This is the calibration coefficient. The contact pressure F is used as the calibration factor. s For feedback, with the target force F st In comparison, the controller calculates the control command signal U using a PID force feedback control algorithm. s :U s = P s *(F st - F s ) + I s *∫(F st - F s )dt+D s *d(F st - F s ) / dt, where t represents time, and then the controller follows the control command signal U s By adjusting motor Ⅲ403 through the motor drive module, the current of motor Ⅲ is ultimately stabilized at i. s :i s = i s0 + F st / k s This allows for precise control of the support force;

[0066] Among them, P s I is the proportionality coefficient; s D is the coefficient of the integral term; s These are the coefficients of the differential term;

[0067] Once the support mechanism 4 is stable, the dual-head motor 208 starts, causing gear II 209 to move the rack on the secondary connector 211, which in turn drives the repair head 212 to move. During this process, the current sensor on the dual-head motor 208 monitors the current i of the dual-head motor in real time. r When the initial repair head 212 has not yet contacted the pipe wall, the current in the dual-head motor 208 is the no-load current i. r0 When the current of the dual-head motor 208 exceeds the preset contact threshold current i b At that time, i r >i b Upon determining that the repair head 212 has contacted the pipe wall, the controller switches to force control mode. Contact pressure F r The relationship with current is: F r = k r *(i r - i r0 ); with F r = k r *(i r - i r0As feedback, the controller uses a PID force feedback control algorithm to control another set of PID parameters P. r I r D r Calculate control command signal U r Then the controller follows the control specification signal U r The dual-head motor 208 is adjusted via the motor drive module to stabilize the contact pressure of the final repair head 212 at the target value F. rt ;where P r I r D r These represent the proportional term coefficient, integral term coefficient, and differential term coefficient, respectively.

[0068] Step 4: Once the contact pressure stabilizes and the repair head is fully in contact with the pipe, the controller starts motor I205, which drives the rotating frame gear ring 204 via gear I203, causing the entire rotating frame (including the primary connector, secondary connector, repair head, etc.) to rotate uniformly around the central support shaft 1. Simultaneously, the controller starts the chemical pump 206, delivering the repair solution from the chemical cylinder 207 through the chemical channel to the primary connector 210, then flowing into the hollow secondary connector 211 and the repair head 212, and finally evenly seeping out through the micropores on the surface of the repair head 212 to the sheath. The rotating repair head 212 continuously and evenly coats the defective area on the inner wall of the pipe with the chemical solution. The rotation speed and the liquid supply speed are matched and controlled by the controller to ensure the formation of a uniformly thick repair coating that completely covers the defect.

[0069] Step 5: After the repair is completed, the controller executes the exit sequence: shuts off the liquid pump 206 to stop the liquid supply; controls the dual-head motor 208 to reverse, causing the repair head 212 to retract radially and detach from the pipe wall; controls motor III 403 to reverse, driving the support arm 405 to retract radially and detach from the pipe wall; the baffle 305 of the power mechanism 3 returns to a smaller opening, and the thrust of the pipeline fluid acts on the device again, pushing the device to continue moving forward to find the next defect or until the inspection and repair task of the entire pipeline is completed.

[0070] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A pipe repair device, characterized in that, The device includes a central support shaft with a front cover and a rear cover at each end. A repair mechanism is fixedly connected to the middle of the central support shaft for repairing pipe defects. A front housing and a rear housing are fixedly connected to the repair mechanism, respectively, to isolate internal components from the external environment. A power mechanism is located at the rear end of the rear cover to provide power for the repair device to move forward. Multiple walking mechanisms are symmetrically arranged on the front and rear covers along the repair mechanism. A braking mechanism is provided on each walking mechanism. A support mechanism is located at the front end of the front cover to support the repair device within the pipe and keep it stationary during repair. A sensor support body is located at the front end of the support mechanism, with a front plate at the front end. Multiple X-ray sensors are evenly distributed on the outer circumference of the sensor support body for detecting pipe defects. A Hall effect speed measurement module is located on the walking mechanism to detect the travel speed. The X-ray sensors, the Hall effect speed measurement module, and a signal processor are connected to a controller located on the front housing. The controller is connected to the power mechanism, the repair mechanism, and the support mechanism. The X-ray sensors, the Hall effect speed measurement module, the signal processor, and the controller are connected to a power module located on the front housing. The repair mechanism includes a fixed frame and a rotating frame. The fixed frame is mounted on a central support shaft, and the rotating frame is connected to the fixed frame via bearings. The rotating frame is fixed to the front and rear housings via an external sealing bearing and an external sealing ring. A rotating frame gear ring is fixedly connected to one side of the rotating frame. The inner side of the rotating frame gear ring meshes with gear I. Gear I is connected to the output shaft of motor I fixed on the rear housing. Motor I is connected to a motor drive module, and the motor drive module is connected to a controller. A primary connector is installed on the circumference of the rotating frame, a secondary connector is slidably connected to the primary connector, a repair head is installed at the top of the secondary connector, and a leather sleeve is fitted on the repair head. A liquid medicine cylinder is fixedly connected to the intermediate support shaft. The liquid medicine cylinder is connected to the fixed frame through a liquid medicine pump. The fixed frame, rotating frame, primary connector, secondary connector, and repair head are equipped with liquid medicine channels. The liquid medicine pump is connected to the controller. The power mechanism includes a base, a perforated plate, baffles, and pressure plates. The base is mounted on the rear guide plate, which is fixed to the rear cover by a diaphragm. The base has several evenly distributed bosses I. The perforated plate has the same number of slots as the bosses I. One end of each baffle is rotatably connected to a boss I, and the other end is connected to a slot in the perforated plate. One side of the perforated plate has a tooth profile I, and a gear III meshes with the tooth profile I. The gear III is connected to the output shaft of a motor II mounted on the rear cover. A pressure plate is fixedly connected to the top of the perforated plate and is fixedly connected to the rear cover. The motor II is connected to a motor drive module, and the motor drive module is connected to a controller. The support mechanism includes a support ring, a slotted plate, a motor III, a gear IV, a support arm, and a sliding plate. The support ring is fixed to the front cover, and the slotted plate is fitted onto the support ring. A gear II is fixedly connected to the slotted plate, meshing with the gear IV. The gear IV is connected to the output shaft of the motor III, which is fixed to the front cover. The support arm is slidably connected to the slotted plate, and moves up and down along a sliding groove on the sliding plate. The sliding plate is fixed to the sensor support and also fixedly connected to the front cover. A current sensor is installed on the motor III, which is connected to a signal processor. The motor III is connected to a motor drive module, which is connected to a controller.

2. The pipeline repair device according to claim 1, characterized in that, Two dual-head motors are fixedly connected to the rotating frame. The output shaft of the dual-head motors is connected to gear II. The two sides of the secondary connector are provided with racks. Gear II meshes with the racks for the movement of the secondary connector. The dual-head motors are provided with current sensors, which are connected to a signal processor. The dual-head motors are connected to a motor drive module, which is connected to a controller.

3. The pipeline repair device according to claim 1, characterized in that, The baffle plate has an arc-shaped structure, with a circular hole at one end and a boss II at the other end. The circular hole is hinged to a boss I on the base, and the boss II is connected to a slot with a perforated plate. There are n baffle plates, and adjacent baffle plates are at an angle θ. The adjacent boss I and the slots in the perforated plate are spaced apart by an angle θ.

4. The pipeline repair device according to claim 1, characterized in that, The slotted plate has four arc-shaped slots. One end of the support arm has a boss III, and the other end has a support plate. The sliding plate has a sliding groove corresponding to the support arm. The boss III slides in the arc-shaped slot of the slotted plate, and the support arm slides in the sliding groove of the sliding plate to adjust the position of the support plate.

5. A pipeline repair device according to claim 1, characterized in that, The walking mechanism is provided in three groups, each group being 120 degrees apart. Each group includes two walking components symmetrically arranged along the repair mechanism. The walking component includes a traveling wheel connecting rod, a traveling wheel, and a spring. The traveling wheel connecting rod is hinged to the front cover or the rear cover. The traveling wheel is fixedly connected to the end of the traveling wheel connecting rod. A spring is connected to the middle of the traveling wheel connecting rod, and the other end of the spring is fixed to the front housing or the rear housing.

6. A pipeline repair device according to claim 1, characterized in that, The braking mechanism is connected to the traveling assembly fixed on the rear cover. The braking mechanism includes a motor IV, a slotted shaft, a brake lever, and a brake housing. The brake housing is mounted on the traveling wheel connecting rod. The motor IV and the slotted shaft are installed inside the brake housing. The output shaft of the motor IV is connected to the slotted shaft. The brake lever is slidably connected in the slot of the slotted shaft, and the brake lever acts on the traveling wheel. The brake housing has an arc-shaped groove. The boss IV on the brake lever slides in the arc-shaped groove, thereby driving the brake lever to slide in the slot of the slotted shaft, realizing the extension and retraction of the brake lever. The motor IV is connected to a motor drive module, and the motor drive module is connected to a controller.

7. A pipeline repair method, comprising the pipeline repair device according to claim 1, characterized in that, It includes several steps: Step 1: Set the forward speed range of the repair device. The signal processor identifies the data from the Hall speed measurement module and sends a signal to the controller. The controller adjusts the opening and closing angles of multiple baffles in the power mechanism by adjusting the meshing of motor II, gear III and tooth profile I on the perforated plate, thereby changing the effective area of ​​the fluid and adjusting the thrust of the fluid on the repair device, and thus adjusting the forward speed of the repair device. Step 2: The X-ray sensor determines whether there is a defect inside the pipe. When a defect is detected, the device continues to move, moves the repair mechanism to the defect location, and the braking mechanism is activated, stopping the entire device from moving. Step 3: The current sensors on motor III and the dual-head motor monitor the current information. The signal processor identifies the current information and sends a signal to the controller. The controller judges the magnitude of the current information and the contact threshold current. When the current information is greater than the contact threshold current, it is determined that the support arm and the repair head have contacted the pipe wall. The controller calculates the contact pressure between the support arm, the repair head and the pipe wall, and compares the contact pressure with the target support force. Finally, the controller uses the PID force feedback control algorithm to calculate the control command signal. According to the control command signal, the controller controls motor III in the support mechanism, so that gear II meshes with gear IV, thereby moving the support arm outward along the slide plate, and fixing the support plate on the support arm to the inner wall of the pipe, so that the entire device remains stationary. Then, the controller controls the dual-head motor in the repair mechanism to rotate, so that the secondary connector slides on the primary connector, and the repair head moves towards the pipe wall and is in close contact with the inner wall of the pipe. Step 4: The controller controls the working of the liquid pump, so that the liquid in the liquid tank gradually enters the repair head and then squeezes out the liquid. At the same time, the motor I works, so that the rotating frame drives the repair head to rotate, so that the liquid is evenly applied to the damaged pipe area. Step 5: After the pipeline repair is completed, the repair head of the repair mechanism and the support arm of the support mechanism return to their original positions, the brake mechanism retracts, the power mechanism adjusts the travel speed, and the device continues to move forward. Repeat steps 1 to 4 to complete the repair of all pipelines.

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