Intelligent thickness measurement robot and method for buried storage tanks based on ultrasonic detection

Abstract

This invention provides an intelligent thickness measurement robot and method for buried storage tanks based on ultrasonic testing. The robot comprises: a buoyancy attitude system including a ballast tank, an explosion-proof pump, a venting hose, and a liquid level sensor; a power system including multiple thrusters installed at the rear and middle sections of the pressure-resistant and corrosion-resistant hull; a navigation and positioning system including a dual-frequency identification sonar, a high-definition camera, an inertial measurement unit, and an ultra-wideband beacon; and an electrical and communication system including a power module and a composite communication module. The control system is connected to the buoyancy attitude system, the power system, the electromagnetic ultrasonic testing system, the navigation and positioning system, and the electrical and communication system. The method includes: beacon deployment and robot deployment; environmental modeling and path planning; autonomous navigation and adaptive detection; generation of wall thickness distribution cloud maps and intensified scanning of defect areas; robot retrieval and report generation. This invention enables safe, efficient, and comprehensive non-contact wall thickness measurement of buried storage tanks made of various materials.

Description

Technical Field

[0001] This invention belongs to the field of safety inspection technology for hazardous chemical storage tanks, specifically an intelligent thickness measurement robot and method for buried storage tanks based on ultrasonic testing. Background Technology

[0002] Buried storage tanks are widely used in chemical enterprises, especially paint production and sales companies, to store various hazardous chemicals such as organic solvents and diluents. Because the tank body of buried storage tanks is completely covered by neutral sand or fine soil and is in an underground environment for a long time, it is susceptible to the effects of high temperature and humidity climates and complex geological conditions, and faces serious safety risks such as tank corrosion and leakage, and failure of the anti-seepage system.

[0003] Currently, wall thickness testing of buried storage tanks mainly relies on open-tank inspection or external excavation. Open-tank inspection requires emptying and cleaning the tank, forcing personnel into a confined space for testing, posing risks of poisoning, suffocation, and explosion, and is also costly and involves long downtime. External excavation is a large-scale and time-consuming process, severely damaging the working environment and making it difficult to comprehensively assess internal wall corrosion. While existing technologies such as wall-climbing robots can be used for inspection, they rely on magnetic adsorption, are only suitable for carbon steel tanks, and also require emptying the tank before testing, limiting their applicability.

[0004] Therefore, developing an intelligent inspection robot capable of safely, efficiently, and accurately inspecting buried storage tanks of various materials without excavating the soil or emptying the tank contents has become a pressing technical problem in this field. Summary of the Invention

[0005] To address the problems existing in the prior art, this invention provides an intelligent thickness measurement robot and method for buried storage tanks based on ultrasonic testing. The robot features a simple structure, low manufacturing cost, high automation, and ideal thickness measurement accuracy. It can perform safe, efficient, and comprehensive non-contact corrosion detection on the inner walls of buried storage tanks made of various materials without excavating the backfill, emptying the tank, or requiring personnel entry. The method is simple to implement and highly intelligent, enabling safe, efficient, in-service, and online inspection of buried storage tanks made of various materials.

[0006] To achieve the above objectives, the present invention provides an intelligent thickness measurement robot for buried storage tanks based on ultrasonic detection. The thickness measurement robot includes a pressure-resistant and corrosion-resistant cabin, a buoyancy attitude system, a power system, an electromagnetic ultrasonic detection system, a navigation and positioning system, an electrical and communication system, and a control system.

[0007] The buoyancy attitude system includes a ballast tank, an explosion-proof pump, a venting hose, and a liquid level sensor. The ballast tank and the explosion-proof pump are housed within the inner cavity of a pressure-resistant and corrosion-resistant tank. The two working ports of the explosion-proof pump are respectively connected to an inner liquid outlet at the bottom of the ballast tank and an outer liquid outlet on the surface of the pressure-resistant and corrosion-resistant tank. The lower end of the venting hose is connected to a vent at the top of the ballast tank, and its upper end extends out of the pressure-resistant and corrosion-resistant tank and connects to a float. The liquid level sensor is installed inside the ballast tank.

[0008] The power system includes multiple thrusters, which are respectively installed at the rear end and side of the pressure-resistant and corrosion-resistant hull;

[0009] The electromagnetic ultrasonic testing system includes multiple testing probes, which are respectively installed at the front end and middle section of the pressure-resistant and corrosion-resistant cabin.

[0010] The navigation and positioning system includes a dual-frequency identification sonar, a high-definition camera, an inertial measurement unit, and an ultra-wideband beacon; the dual-frequency identification sonar and the high-definition camera are installed alternately at the front end of the pressure-resistant and corrosion-resistant tank; the inertial measurement unit is installed inside the pressure-resistant and corrosion-resistant tank; and the ultra-wideband beacons are installed at the manholes of the storage tank.

[0011] The electrical and communication system is installed inside the pressure-resistant and corrosion-resistant cabin and includes a power module and a composite communication module.

[0012] The control system is installed in the inner cavity of the pressure-resistant and corrosion-resistant cabin and is connected to the buoyancy attitude system, power system, electromagnetic ultrasonic detection system, navigation and positioning system, and electrical and communication system.

[0013] In this invention, the two working ports of the explosion-proof pump are connected to the inner liquid outlet on the ballast tank and the outer liquid outlet on the pressure-resistant and corrosion-resistant tank body, respectively. This facilitates the use of the explosion-proof pump in both forward and reverse operations to draw liquid from or drain it from the ballast tank, thereby enabling the thickness measurement robot to dive and surface. The lower end of the venting hose is connected to the vent at the top of the ballast tank, and a float is attached to its upper end. This allows the buoyancy of the float to keep the upper end of the venting hose above the liquid surface. Thus, during the operation of the explosion-proof pump, the synchronous intake or exhaust of air through the venting hose effectively balances the pressure within the ballast tank. The liquid level sensor allows for real-time acquisition of the liquid level signal within the ballast tank, enabling closed-loop control of the explosion-proof pump's forward, reverse, and start / stop actions based on the liquid level data. This allows for precise adjustment of the liquid level within the ballast tank, precisely controlling the thickness measurement robot's buoyancy, dive, suspension, and attitude adjustment movements within the liquid. Multiple thrusters are installed simultaneously at the rear and sides of the pressure-resistant and corrosion-resistant tank. This allows for coordinated operation of multiple thrusters, providing omnidirectional propulsion and ensuring the stability of the power system while also enabling flexible maneuverability. Multiple detection probes are installed at the front and middle sections of the pressure-resistant and corrosion-resistant tank, facilitating the measurement of tank wall thickness from different angles. This ensures wider detection coverage, effectively improving detection efficiency and quality. Electromagnetic ultrasonic probes are used for non-contact, high-precision thickness measurement of tank walls made of various materials, including carbon steel, stainless steel, and others. The navigation and positioning system incorporates dual-frequency identification sonar, a high-definition camera, an inertial measurement unit, and an ultra-wideband beacon. This facilitates precise navigation by combining multi-source detection data and allows for the use of fused SLAM technology, ensuring accurate positioning and autonomous path planning even in signal-blocked and low-visibility environments within the tank. The electrical and communication system includes both a power module and a composite communication module, ensuring a stable and reliable power supply while maintaining safety and reliable data transmission in hazardous environments through multiple communication links. By configuring the control system, data from various systems can be received and processed in real time, facilitating autonomous decision-making and obtaining precise control commands. This ensures the thickness measurement robot can stably and efficiently complete inspection tasks under complex conditions. Specifically, the control system dynamically coordinates the buoyancy attitude system to adjust the robot's posture, the power system to provide the necessary propulsion, the electromagnetic ultrasonic testing system to start and stop the probe for scanning, and the navigation and positioning system to correct the position in real time, ensuring a seamless and reliable inspection process. Simultaneously, it can integrate real-time position and posture information provided by the navigation and positioning system with inspection data collected by the electromagnetic ultrasonic testing system for rapid analysis to assess inspection quality and adjust inspection strategies accordingly.

[0014] This invention, through the coordinated operation of a power system, a buoyancy attitude system, an electromagnetic ultrasonic detection system, a navigation and positioning system, and a control system, can not only achieve omnidirectional movement at any position and height inside the tank, but also achieve stable levitation at any position. Furthermore, it can perform tank wall thickness detection in a non-contact manner during movement and levitation. In addition, it can further integrate measurement data from dual-frequency identification sonar, high-definition camera, and inertial measurement unit in the navigation and positioning system, and perform autonomous navigation and path planning through a fused SLAM algorithm, acquiring detection data in real time and transmitting it to a data processing terminal on the ground.

[0015] This robot has a simple structure, low manufacturing cost, high degree of automation, and ideal thickness measurement accuracy. It can perform safe, efficient, and full-coverage non-contact corrosion detection on the inner walls of buried storage tanks of various materials without excavation, emptying of materials, or personnel entry.

[0016] Furthermore, in order to ensure good attitude stability of the pressure-resistant and corrosion-resistant hull during surfacing, diving, and hovering, the number of ballast tanks is four, and the four ballast tanks are distributed in a rectangular shape at the bottom of the internal cavity of the pressure-resistant and corrosion-resistant hull. At the same time, the four ballast tanks are interconnected.

[0017] Furthermore, to ensure the maneuverability, flexibility, and stability of the power system, the multiple thrusters include one main thruster and four auxiliary thrusters; the main thruster is installed at the rear end of the pressure-resistant and corrosion-resistant hull; the four auxiliary thrusters are divided into two pairs and are respectively installed on opposite sides of the front section of the pressure-resistant and corrosion-resistant hull and on opposite sides of the rear section of the pressure-resistant and corrosion-resistant hull.

[0018] Furthermore, to improve detection accuracy, multiple detection probes, including detection probe A and detection probe B, are provided, the surfaces of which are covered with a zirconia ceramic wear-resistant layer; one or more detection probes A are installed at the front end of the pressure-resistant and corrosion-resistant chamber; and multiple detection probes B are circumferentially installed around the exterior of the middle section of the pressure-resistant and corrosion-resistant chamber.

[0019] As a preferred embodiment, the power module is an intrinsically safe lithium battery pack; the composite communication module includes an explosion-proof 5G module, an underwater acoustic wave communication module, and an underwater UWB communication module.

[0020] Furthermore, to facilitate the real-time generation of wall thickness detection cloud maps and comprehensive detection reports, and to facilitate the real-time storage of detection data, a data processing terminal is also included. The control system includes a controller and a storage module; the data processing terminal is located above ground and is connected to the control system through a composite communication module.

[0021] As a preferred embodiment, the top of the pressure-resistant and corrosion-resistant chamber is provided with a control compartment, a battery compartment, and a communication compartment at intervals; the control system is installed in the control compartment; the power module is installed in the battery compartment; and the composite communication module and the inertial measurement unit are installed in the communication compartment.

[0022] To ensure service life, the outer contour of the pressure-resistant and corrosion-resistant chamber adopts a streamlined design and is capsule-shaped. The pressure-resistant and corrosion-resistant chamber has a three-layer composite structure, including an inner pressure-bearing layer made of 316L stainless steel, an intermediate potting layer made of epoxy resin, and an outer anti-corrosion layer made of ultra-high molecular weight polyethylene.

[0023] This invention also provides an intelligent thickness measurement method for buried storage tanks based on ultrasonic detection, employing an intelligent thickness measurement robot for buried storage tanks based on ultrasonic detection, including the following steps:

[0024] Step 1: Beacon deployment and robot deployment; Install ultra-wideband beacons at the manhole of the storage tank, and place the thickness measurement robot into the storage tank through the manhole;

[0025] Step 2: Environmental Modeling and Path Planning; Combining design data and measured data, construct a high-precision 3D data model to support the detection path planning; Construct an initial environmental map inside the tank using a navigation and positioning system, and match it with the high-precision 3D data model to generate a globally planned detection path;

[0026] Step 3: Autonomous Navigation and Adaptive Detection; The control power system is activated, and combined with navigation information from the navigation and positioning system, the pressure-resistant and corrosion-resistant tank is driven to move along the planned detection path; At the same time, the power system, in conjunction with the buoyancy attitude system, dynamically maintains the optimal detection distance between the thickness measurement robot and the tank wall; Simultaneously, non-contact wall thickness detection is performed using an electromagnetic ultrasonic detection system, and online calibration and dynamic sound velocity compensation are used to ensure the accuracy of the detection data. The detection data is then simultaneously sent to the data processing terminal via a composite communication module.

[0027] Step 4: Generation of wall thickness distribution cloud map and encrypted scanning of defect area; S41: The data processing terminal generates a wall thickness distribution cloud map based on the detection data, automatically marks defect areas with wall thickness less than the set thickness threshold, and sends an encrypted scanning command containing the location information of the defect area to the thickness measuring robot; S42: The thickness measuring robot performs encrypted scanning of the defect area according to the encrypted scanning command, and sends the detection data to the external data processing terminal through the composite communication module;

[0028] Step 5: Robot Retrieval and Report Generation; After the inspection is completed, the thickness measuring robot automatically returns to the area below the manhole, where the operator retrieves the thickness measuring robot and the ultra-wideband beacon; at the same time, a comprehensive inspection report for the storage tank is generated through the data processing terminal.

[0029] As a preferred embodiment, in steps 3 and 4, the thickness measuring robot stores the obtained detection data in the storage module in real time.

[0030] This invention provides an intelligent thickness measurement method for buried storage tanks based on ultrasonic testing. First, by deploying ultra-wideband beacons at the manhole of the tank, high-precision positioning of the thickness measurement robot is provided in the complex environment inside the tank, ensuring centimeter-level positioning even in large tanks, laying a solid foundation for subsequent accurate inspection. Next, by constructing a high-precision three-dimensional data model, the optimal detection path can be efficiently and accurately generated by combining real-time environmental detection data, thus avoiding missed and duplicate detections and greatly improving inspection efficiency. Furthermore, the control system precisely controls the movement of the power system based on navigation information, enabling the robot to move autonomously within the tank. Simultaneously, by dynamically adjusting the buoyancy attitude system, the thickness measurement robot maintains the optimal detection distance from the tank wall, ensuring the stability and data reliability of ultrasonic testing. In addition, non-contact detection and online calibration technologies further guarantee detection accuracy. Furthermore, by generating a wall thickness distribution cloud map in real time, the condition of the tank can be visually displayed. Intensified scanning based on automatically identified defect areas ensures that no potential risk points are missed, improving the comprehensiveness and accuracy of the inspection. Finally, the robot automatically returns after testing, facilitating timely retrieval. A comprehensive testing report is automatically generated after each test, effectively saving manual processing time and significantly improving work efficiency.

[0031] This invention is applicable to non-contact wall thickness detection of buried storage tanks in chemical enterprises, and has the following advantages compared with existing technologies:

[0032] 1. This invention adopts a submarine-style design, which enables the robot to move autonomously inside the storage tank through buoyancy adjustment and propulsion system. It does not rely on magnetic attraction and solves the problem of the wall-climbing robot's strong dependence on the storage tank material (which must be carbon steel). It is suitable for inspection operations of storage tanks of various materials.

[0033] 2. Testing can be carried out without excavating the tank area and covering it with soil, avoiding damage to the tank area and tank body, realizing non-destructive testing, and reducing the amount of work and testing costs.

[0034] 3. The robot can work directly inside storage tanks filled with organic solvents without the need to empty the tank or perform cleaning and replacement procedures. This avoids the safety risks and economic losses associated with tank cleaning operations, reduces testing costs, and improves testing efficiency.

[0035] 4. It achieves unmanned inspection, avoids the need for manual entry into confined spaces to perform operations, completely eliminates safety risks such as poisoning and suffocation, and significantly improves the safety of inspection operations.

[0036] 5. It adopts advanced autonomous navigation and adaptive control algorithms to achieve accurate detection with full coverage and no blind spots in complex tank environments.

[0037] 6. The use of electromagnetic ultrasonic technology enables dry coupling detection without the need for coupling agent, and it can maintain stable detection accuracy even in organic solvent environments, thus solving the problem of unstable coupling in traditional ultrasonic detection in liquid environments.

[0038] 7. Supports real-time data transmission and remote control, enabling online monitoring of the detection process and results, timely detection and early warning of dangerous areas, and providing accurate data support for tank safety assessment.

[0039] 8. The application of this invention can provide a comprehensive understanding of the corrosion and thinning of storage tanks, especially for old storage tanks. It can provide direct data support, assist in making scientific usage decisions, and effectively prevent leakage accidents.

[0040] This method is simple to implement and highly intelligent, enabling safe, efficient, in-service, and online inspection of buried storage tanks made of various materials. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the structure of the present invention;

[0042] Figure 2 This is a schematic diagram of the thickness measurement robot in the storage tank in this invention.

[0043] Figure 3 This is a block diagram of the control section in this invention.

[0044] In the diagram: 1. Pressure-resistant and corrosion-resistant hull; 2. Ballast tank; 3. Explosion-proof pump; 4. Ventilation hose; 5. Main thruster; 6. Auxiliary thruster; 7. Dual-frequency identification sonar; 8. High-definition camera; 9. Ultra-wideband beacon; 10. Inner pressure-bearing layer; 11. Intermediate potting layer; 12. Outer anti-corrosion layer; 13. Storage tank; 14. Float; 15. Planned detection path; 16. Manhole; 17. Thickness measuring robot; 18. Detection probe A; 19. Detection probe B; 20. Control compartment; 21. Battery compartment; 22. Communication compartment. Detailed Implementation

[0045] The invention will now be further described with reference to the accompanying drawings.

[0046] like Figures 1 to 3 As shown, the present invention provides an intelligent thickness measuring robot for buried storage tanks based on ultrasonic detection. The thickness measuring robot 17 includes a pressure-resistant and corrosion-resistant cabin 1, a buoyancy attitude system, a power system, an electromagnetic ultrasonic detection system, a navigation and positioning system, an electrical and communication system, and a control system.

[0047] The buoyancy attitude system includes a ballast tank 2, an explosion-proof pump 3, a venting hose 4, and a liquid level sensor. The ballast tank 2 and the explosion-proof pump 3 are located inside the pressure-resistant and corrosion-resistant chamber 1. The two working ports of the explosion-proof pump 3 are respectively connected to the inner liquid outlet at the bottom of the ballast tank 2 and the outer liquid outlet on the surface of the pressure-resistant and corrosion-resistant chamber 1. The lower end of the venting hose 4 is connected to the vent at the top of the ballast tank 2, and its upper end extends out of the pressure-resistant and corrosion-resistant chamber 1 and is connected to a float 14. The float 14 is used to ensure that the upper end of the venting hose 4 is always above the liquid surface through buoyancy. Preferably, the pressure-resistant and corrosion-resistant chamber 1 is provided with a sealed channel for the venting hose 4 to pass through. After the venting hose 4 is inserted into the sealed channel, the connection is sealed to prevent liquid from entering the interior of the pressure-resistant and corrosion-resistant chamber 1 through the sealed channel. The liquid level sensor is installed inside the ballast tank 2 to collect the liquid level signal of the ballast tank 2.

[0048] The power system includes multiple thrusters, which are respectively installed at the rear end and side of the pressure-resistant and corrosion-resistant chamber 1, and are used to enable the thickness measuring robot 17 to move omnidirectionally and make fine attitude adjustments in the liquid through mutual cooperation;

[0049] The electromagnetic ultrasonic testing system includes multiple testing probes, which are respectively installed at the front end and middle section of the pressure-resistant and corrosion-resistant chamber 1;

[0050] The navigation and positioning system includes a dual-frequency identification sonar 7, a high-definition camera 8, an inertial measurement unit (IMU), and an ultra-wideband beacon 9. The dual-frequency identification sonar 7 and the high-definition camera 8 are installed alternately at the front end of the pressure-resistant and corrosion-resistant cabin 1. The IMU is installed inside the pressure-resistant and corrosion-resistant cabin 1. The ultra-wideband beacon 9 is installed at the manhole 16 of the storage tank 13. Preferably, the high-definition camera 8 is an anti-glare high-definition camera. To ensure navigation effectiveness, the navigation and positioning system uses the SLAM algorithm to achieve autonomous navigation and path planning.

[0051] The electrical and communication system is installed inside the pressure-resistant and corrosion-resistant cabin 1, and includes a power supply module and a composite communication module;

[0052] The control system is installed in the inner cavity of the pressure-resistant and corrosion-resistant cabin 1 and is connected to the buoyancy attitude system, power system, electromagnetic ultrasonic detection system, navigation and positioning system and electrical and communication system respectively.

[0053] In this invention, the two working ports of the explosion-proof pump are connected to the inner liquid outlet on the ballast tank and the outer liquid outlet on the pressure-resistant and corrosion-resistant tank body, respectively. This facilitates the use of the explosion-proof pump in both forward and reverse operations to draw liquid from or drain it from the ballast tank, thereby enabling the thickness measurement robot to dive and surface. The lower end of the venting hose is connected to the vent at the top of the ballast tank, and a float is attached to its upper end. This allows the buoyancy of the float to keep the upper end of the venting hose above the liquid surface. Thus, during the operation of the explosion-proof pump, the synchronous intake or exhaust of air through the venting hose effectively balances the pressure within the ballast tank. The liquid level sensor allows for real-time acquisition of the liquid level signal within the ballast tank, enabling closed-loop control of the explosion-proof pump's forward, reverse, and start / stop actions based on the liquid level data. This allows for precise adjustment of the liquid level within the ballast tank, precisely controlling the thickness measurement robot's buoyancy, dive, suspension, and attitude adjustment movements within the liquid. Multiple thrusters are installed simultaneously at the rear and sides of the pressure-resistant and corrosion-resistant tank. This allows for coordinated operation of multiple thrusters, providing omnidirectional propulsion and ensuring the stability of the power system while also enabling flexible maneuverability. Multiple detection probes are installed at the front and middle sections of the pressure-resistant and corrosion-resistant tank, facilitating the measurement of tank wall thickness from different angles. This ensures wider detection coverage, effectively improving detection efficiency and quality. Electromagnetic ultrasonic probes are used for non-contact, high-precision thickness measurement of tank walls made of various materials, including carbon steel, stainless steel, and others. The navigation and positioning system incorporates dual-frequency identification sonar, a high-definition camera, an inertial measurement unit, and an ultra-wideband beacon. This facilitates precise navigation by combining multi-source detection data and allows for the use of fused SLAM technology, ensuring accurate positioning and autonomous path planning even in signal-blocked and low-visibility environments within the tank. The electrical and communication system includes both a power module and a composite communication module, ensuring a stable and reliable power supply while maintaining safety and reliable data transmission in hazardous environments through multiple communication links. By configuring the control system, data from various systems can be received and processed in real time, facilitating autonomous decision-making and obtaining precise control commands. This ensures the thickness measurement robot can stably and efficiently complete inspection tasks under complex conditions. Specifically, the control system dynamically coordinates the buoyancy attitude system to adjust the robot's posture, the power system to provide the necessary propulsion, the electromagnetic ultrasonic testing system to start and stop the probe for scanning, and the navigation and positioning system to correct the position in real time, ensuring a seamless and reliable inspection process. Simultaneously, it can integrate real-time position and posture information provided by the navigation and positioning system with inspection data collected by the electromagnetic ultrasonic testing system for rapid analysis to assess inspection quality and adjust inspection strategies accordingly.

[0054] This invention, through the coordinated operation of a power system, a buoyancy attitude system, an electromagnetic ultrasonic detection system, a navigation and positioning system, and a control system, can not only achieve omnidirectional movement at any position and height inside the tank, but also achieve stable levitation at any position. Furthermore, it can perform tank wall thickness detection in a non-contact manner during movement and levitation. In addition, it can further integrate measurement data from dual-frequency identification sonar, high-definition camera, and inertial measurement unit in the navigation and positioning system, and perform autonomous navigation and path planning through a fused SLAM algorithm, acquiring detection data in real time and transmitting it to a data processing terminal on the ground.

[0055] This robot has a simple structure, low manufacturing cost, high degree of automation, and ideal thickness measurement accuracy. It can perform safe, efficient, and full-coverage non-contact corrosion detection on the inner walls of buried storage tanks of various materials without excavation, emptying of materials, or personnel entry.

[0056] To ensure good attitude stability of the pressure-resistant and corrosion-resistant hull during surfacing, diving, and hovering, four ballast tanks 2 are provided, arranged in a rectangular shape at the bottom of the inner cavity of the pressure-resistant and corrosion-resistant hull 1, and are interconnected. Preferably, the bottoms of adjacent ballast tanks 2 are connected by a straight-through pipe. The explosion-proof pump 3 is a reversible pump; one working port of the explosion-proof pump 3 is connected to an internal liquid outlet at the bottom of one ballast tank 2 via an internal connecting pipe, and its other working port is connected to an external liquid outlet pre-reserved on the side of the pressure-resistant and corrosion-resistant hull 1 via an external connecting pipe. Furthermore, a solenoid valve is included, connected in series on the external connecting pipe.

[0057] To ensure the maneuverability, flexibility and stability of the power system, multiple thrusters include one main thruster 5 and four auxiliary thrusters 6; the main thruster 5 is installed at the rear end of the pressure-resistant and corrosion-resistant hull 1; the four auxiliary thrusters 6 are divided into two pairs and are respectively installed on opposite sides of the front section of the pressure-resistant and corrosion-resistant hull 1 and opposite sides of the rear section of the pressure-resistant and corrosion-resistant hull 1.

[0058] To improve detection accuracy, multiple detection probes, including probe A18 and probe B19, are used. The surfaces of probes A18 and B19 are covered with a zirconia ceramic wear-resistant layer, which greatly enhances durability in complex tank environments and reduces wear interference with detection. One or more probes A18 are installed at the front end of the pressure-resistant and corrosion-resistant chamber 1; multiple probes B19 are circumferentially installed around the exterior of the middle section of the pressure-resistant and corrosion-resistant chamber 1. Thus, the electromagnetic ultrasonic testing system, by setting multiple detection channels, can effectively cover a large detection area. Preferably, the electromagnetic ultrasonic testing system is equipped with a dedicated ultrasonic signal processing module, which amplifies, filters, and digitizes the acquired ultrasonic signals, and extracts accurate wall thickness information. Simultaneously, the electromagnetic ultrasonic testing system incorporates a miniature standard thickness test block, which periodically triggers an online automatic calibration program during the testing process to correct errors caused by environmental changes or equipment drift in real time, ensuring that the measurement data is always accurate and reliable. Therefore, through the synergy of hardware and algorithms, efficient, stable, and high-precision buried storage tank wall thickness detection is achieved.

[0059] As a preferred embodiment, the power module is an intrinsically safe lithium battery pack; wherein, the circuit boards connected to the intrinsically safe lithium battery pack are all encapsulated using a potting process, conforming to IECEx explosion-proof standards, to ensure safe and stable operation in explosive gas environments.

[0060] The composite communication module includes an explosion-proof 5G module, an underwater acoustic communication module, and an underwater UWB communication module. This enables multi-link transmission of data and commands, ensuring communication reliability.

[0061] To facilitate the real-time generation of wall thickness detection cloud maps and comprehensive inspection reports, a data processing terminal is also included. The control system includes a controller and a storage module. The data processing terminal is located above ground and is connected to the control system via a composite communication module. The storage module facilitates real-time data storage and historical data retrieval.

[0062] As a preferred embodiment, the top of the inner cavity of the pressure-resistant and corrosion-resistant chamber 1 is provided with a control compartment 20, a battery compartment 21, and a communication compartment 22 arranged sequentially at intervals; the control system is installed in the control compartment 20; the power module is installed in the battery compartment 21; and the composite communication module and the inertial measurement unit are installed in the communication compartment 22.

[0063] To ensure service life, the outer contour of the pressure-resistant and corrosion-resistant chamber 1 adopts a streamlined, capsule-shaped design. The pressure-resistant and corrosion-resistant chamber 1 has a three-layer composite structure, including an inner pressure-bearing layer 10 made of 316L stainless steel, an intermediate potting layer 11 made of epoxy resin, and an outer anti-corrosion layer 12 made of ultra-high molecular weight polyethylene. This modular three-layer composite structure allows the pressure-resistant and corrosion-resistant chamber 1 to maintain excellent sealing performance and durability under high pressure and corrosive environments.

[0064] This invention also provides an intelligent thickness measurement method for buried storage tanks based on ultrasonic detection, employing an intelligent thickness measurement robot for buried storage tanks based on ultrasonic detection, including the following steps:

[0065] Step 1: Beacon deployment and robot deployment;

[0066] An ultra-wideband beacon 9 is installed at the manhole 16 of the storage tank 13, and the thickness measurement robot 17 is placed into the storage tank 13 through the manhole 16.

[0067] Step 2: Environmental modeling and path planning;

[0068] Combining design data and measured data, a high-precision three-dimensional data model is constructed to support the planning of the detection path; an initial environmental map inside the storage tank 13 is constructed through a navigation and positioning system and matched with the high-precision three-dimensional data model to generate a globally planned detection path 15.

[0069] Step 3: Autonomous navigation and adaptive detection;

[0070] The control power system starts working, and combined with the navigation information fed back by the navigation and positioning system, it drives the pressure-resistant and corrosion-resistant chamber 1 to move along the planned inspection path 15; at the same time, the power system, in conjunction with the buoyancy attitude system, dynamically maintains the optimal inspection distance between the thickness measuring robot 17 and the tank wall of the storage tank 13.

[0071] Meanwhile, non-contact wall thickness detection is performed using an electromagnetic ultrasonic testing system, and online calibration and dynamic sound velocity compensation are used to ensure the accuracy of the test data. The test data is then sent to the data processing terminal via a composite communication module.

[0072] Step 4: Generation of wall thickness distribution cloud map and intensified scanning of defect area;

[0073] S41: The data processing terminal generates a wall thickness distribution cloud map based on the detection data, automatically marks defect areas with wall thickness less than the set thickness threshold, and sends an encrypted scanning command containing the location information of the defect area to the thickness measuring robot 17.

[0074] S42: Thickness measuring robot 17 performs encrypted scanning of the defect area according to the encrypted scanning instruction, and sends the detection data to the external data processing terminal through the composite communication module;

[0075] Step 5: Robot Retrieval and Report Generation;

[0076] After the inspection is completed, the thickness measuring robot 17 automatically returns to the area below the manhole 16, where the operator retrieves the thickness measuring robot 17 and the ultra-wideband beacon 9; at the same time, a comprehensive inspection report for the storage tank 13 is generated through the data processing terminal.

[0077] As a preferred embodiment, in steps 3 and 4, the thickness measuring robot 17 stores the obtained detection data in real time into the storage module.

[0078] This invention provides an intelligent thickness measurement method for buried storage tanks based on ultrasonic testing. First, by deploying ultra-wideband beacons at the manhole of the tank, high-precision positioning of the thickness measurement robot is provided in the complex environment inside the tank, ensuring centimeter-level positioning even in large tanks, laying a solid foundation for subsequent accurate inspection. Next, by constructing a high-precision three-dimensional data model, the optimal detection path can be efficiently and accurately generated by combining real-time environmental detection data, thus avoiding missed and duplicate detections and greatly improving inspection efficiency. Furthermore, the control system precisely controls the movement of the power system based on navigation information, enabling the robot to move autonomously within the tank. Simultaneously, by dynamically adjusting the buoyancy attitude system, the thickness measurement robot maintains the optimal detection distance from the tank wall, ensuring the stability and data reliability of ultrasonic testing. In addition, non-contact detection and online calibration technologies further guarantee detection accuracy. Furthermore, by generating a wall thickness distribution cloud map in real time, the condition of the tank can be visually displayed. Intensified scanning based on automatically identified defect areas ensures that no potential risk points are missed, improving the comprehensiveness and accuracy of the inspection. Finally, the robot automatically returns after testing, facilitating timely retrieval. A comprehensive testing report is automatically generated after each test, effectively saving manual processing time and significantly improving work efficiency.

[0079] This invention is applicable to non-contact wall thickness detection of buried storage tanks in chemical enterprises, and has the following advantages compared with existing technologies:

[0080] 1. This invention adopts a submarine-style design, which enables the robot to move autonomously inside the storage tank through buoyancy adjustment and propulsion system. It does not rely on magnetic attraction and solves the problem of the wall-climbing robot's strong dependence on the storage tank material (which must be carbon steel). It is suitable for inspection operations of storage tanks of various materials.

[0081] 2. Testing can be carried out without excavating the tank area and covering it with soil, avoiding damage to the tank area and tank body, realizing non-destructive testing, and reducing the amount of work and testing costs.

[0082] 3. The robot can work directly inside storage tanks filled with organic solvents without the need to empty the tank or perform cleaning and replacement procedures. This avoids the safety risks and economic losses associated with tank cleaning operations, reduces testing costs, and improves testing efficiency.

[0083] 4. It achieves unmanned inspection, avoids the need for manual entry into confined spaces to perform operations, completely eliminates safety risks such as poisoning and suffocation, and significantly improves the safety of inspection operations.

[0084] 5. It adopts advanced autonomous navigation and adaptive control algorithms to achieve accurate detection with full coverage and no blind spots in complex tank environments.

[0085] 6. The use of electromagnetic ultrasonic technology enables dry coupling detection without the need for coupling agent, and it can maintain stable detection accuracy even in organic solvent environments, thus solving the problem of unstable coupling in traditional ultrasonic detection in liquid environments.

[0086] 7. Supports real-time data transmission and remote control, enabling online monitoring of the detection process and results, timely detection and early warning of dangerous areas, and providing accurate data support for tank safety assessment.

[0087] 8. The application of this invention can provide a comprehensive understanding of the corrosion and thinning of storage tanks, especially for old storage tanks. It can provide direct data support, assist in making scientific usage decisions, and effectively prevent leakage accidents.

[0088] This method is simple to implement and highly intelligent, enabling safe, efficient, in-service, and online inspection of buried storage tanks made of various materials.

Claims

1. An ultrasonic detection-based intelligent thickness measuring robot for buried storage tanks, the thickness measuring robot (17) comprising a pressure-resistant and corrosion-resistant cabin body (1), characterized in that, It also includes buoyancy posture system, power system, electromagnetic ultrasonic detection system, navigation positioning system, electrical and communication system and control system; The buoyancy posture system includes ballast tanks (2), explosion-proof pumps (3), air hoses (4) and liquid level sensors; the ballast tanks (2) and explosion-proof pumps (3) are arranged in the inner cavity of the pressure-resistant and corrosion-resistant cabin body (1); the two working ports of the explosion-proof pump (3) are respectively connected with the inner liquid passage at the bottom of the ballast tank (2) and the outer liquid passage on the surface of the pressure-resistant and corrosion-resistant cabin body (1); the lower end of the air hose (4) is connected with the air port at the top of the ballast tank (2), and the upper end of the air hose (4) is connected with the float (14) after penetrating out of the pressure-resistant and corrosion-resistant cabin body (1); the liquid level sensor is installed inside the ballast tank (2); The power system includes a plurality of propellers, which are respectively installed at the rear end and the side of the pressure-resistant and corrosion-resistant cabin body (1); The electromagnetic ultrasonic detection system includes a plurality of detection probes, which are respectively installed at the front end and the middle section of the pressure-resistant and corrosion-resistant cabin body (1); The navigation positioning system includes a dual-frequency identification sonar (7), a high-definition camera (8), an inertial measurement unit and an ultra-wideband beacon (9); the dual-frequency identification sonar (7) and the high-definition camera (8) are installed at the front end of the pressure-resistant and corrosion-resistant cabin body (1) in an interval manner; the inertial measurement unit is installed inside the pressure-resistant and corrosion-resistant cabin body (1); the ultra-wideband beacon (9) is installed at the manhole (16) of the storage tank (13); The electrical and communication system is installed inside the pressure-resistant and corrosion-resistant cabin body (1), which includes a power module and a composite communication module; The control system is installed in the inner cavity of the pressure-resistant and corrosion-resistant cabin body (1) and is connected with the buoyancy posture system, the power system, the electromagnetic ultrasonic detection system, the navigation positioning system and the electrical and communication system respectively; The plurality of detection probes includes detection probe A (18) and detection probe B (19), and the surfaces of the detection probe A (18) and the detection probe B (19) are covered with zirconia ceramic wear-resistant layers; one or more detection probe A (18) is installed at the front end of the pressure-resistant and corrosion-resistant cabin body (1); a plurality of detection probe B (19) is installed circumferentially on the outside of the middle section of the pressure-resistant and corrosion-resistant cabin body (1); The power module is an intrinsically safe lithium battery pack; the composite communication module includes an explosion-proof 5G module, an underwater acoustic communication module and an underwater UWB communication module; It also includes a data processing terminal, and the control system includes a controller and a storage module; the data processing terminal is located above the ground and is connected with the control system through the composite communication module.

2. The intelligent thickness measuring robot based on ultrasonic detection for buried storage tank according to claim 1, characterized in that, The number of the ballast tanks (2) is four, and the four ballast tanks (2) are distributed in a rectangular manner at the bottom of the inner cavity of the pressure-resistant and corrosion-resistant cabin body (1), and the four ballast tanks (2) are communicated with each other.

3. The intelligent thickness measuring robot based on ultrasonic detection for buried storage tank according to claim 1, characterized in that, The plurality of propellers includes one main propeller (5) and four auxiliary propellers (6); the main propeller (5) is installed at the rear end of the pressure-resistant and corrosion-resistant cabin body (1); the four auxiliary propellers (6) are divided into two pairs and are respectively installed on the opposite sides of the front section cabin body and the opposite sides of the rear section cabin body of the pressure-resistant and corrosion-resistant cabin body (1).

4. The intelligent thickness measuring robot based on ultrasonic detection for buried storage tank according to claim 3, characterized in that, The top of the inner cavity of the pressure-resistant and corrosion-resistant cabin body (1) is sequentially and spacedly provided with a control cabin (20), a battery cabin (21) and a communication cabin (22); the control system is installed in the control cabin (20); the power supply module is installed in the battery cabin (21); and the composite communication module and the inertial measurement unit are installed in the communication cabin (22).

5. The intelligent thickness measuring robot based on ultrasonic detection for buried storage tank according to claim 4, characterized in that, The outer contour of the pressure-resistant and corrosion-resistant cabin body (1) adopts a streamlined design and is in a capsule shape. The pressure-resistant and corrosion-resistant cabin body (1) is a three-layer composite structure, comprising an inner pressure-bearing layer (10) made of 316L stainless steel, a middle potting layer (11) made of epoxy resin and an outer corrosion-resistant layer (12) made of ultra-high molecular weight polyethylene.

6. An intelligent thickness measurement method for a buried storage tank based on ultrasonic detection, using the intelligent thickness measurement robot for a buried storage tank based on ultrasonic detection according to any one of claims 1 to 5, characterized in that, The method comprises the following steps: Step 1: beacon deployment and robot deployment; an ultra-wideband beacon (9) is installed at a manhole (16) of a storage tank (13), and a thickness measuring robot (17) is placed into the storage tank (13) through the manhole (16); Step 2: environment modeling and path planning; a high-precision three-dimensional data model supporting detection path planning is constructed in combination with design data and measured data; an initial environment map in the storage tank (13) is constructed through a navigation positioning system, and is matched with the high-precision three-dimensional data model to generate a global planning detection path (15); Step 3: autonomous navigation and adaptive detection; a power system is controlled to start working, navigation information fed back by the navigation positioning system is combined, and the pressure-resistant and corrosion-resistant cabin body (1) is driven to move along the planning detection path (15); at the same time, the power system is used to dynamically keep the best detection distance of the thickness measuring robot (17) and the tank wall of the storage tank (13) in cooperation with a buoyancy attitude system; at the same time, non-contact wall thickness detection is performed through an electromagnetic ultrasonic detection system, and detection data accuracy is ensured through online calibration and dynamic sound velocity compensation, and the detection data is synchronously sent to a data processing terminal through a composite communication module; Step 4: generation of a wall thickness distribution cloud map and encryption scanning of a defect area, comprising: S41: a data processing terminal generates a wall thickness distribution cloud map according to detection data, automatically marks a defect area with a wall thickness less than a set thickness threshold, and sends an encryption scanning instruction containing position information of the defect area to the thickness measuring robot (17); S42: the thickness measuring robot (17) performs encryption scanning on the defect area according to the encryption scanning instruction, and sends detection data to the external data processing terminal through the composite communication module; Step 5: robot recovery and report generation; after the detection work is completed, the thickness measuring robot (17) automatically returns to an area below the manhole (16), and the thickness measuring robot (17) and the ultra-wideband beacon (9) are recovered by an operator; at the same time, a comprehensive detection report of the storage tank (13) is generated through the data processing terminal.

7. The method for intelligent thickness measurement of buried storage tank based on ultrasonic detection according to claim 6, characterized in that, In steps three and four, the thickness measuring robot (17) stores detection data in a storage module in real time after obtaining the detection data.

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