UPS direct-current battery automatic replacement robot and control system thereof

Abstract

The invention relates to the field of power equipment maintenance, and discloses a UPS direct-current battery automatic replacement robot and a control system thereof.The UPS direct-current battery automatic replacement robot comprises a replacement frame installed on a supporting frame through a moving frame; the replacing mechanism is used for replacing the battery; the nut taking mechanism is used for disassembling the nut; the connecting line fixing mechanism is used for fixing a connecting line; the voltage monitoring mechanism is used for detecting voltage; the voltage monitoring mechanism comprises a fixing block, a first electric push rod is fixedly connected to the interior of the fixing block, and the output end of the first electric push rod is fixedly connected with a first rotating frame. The output end of a first electric push rod drives a first rotating frame to move, so that the first rotating frame pushes a push rod to rotate on a second rotating frame and pushes a first sliding block to move, the first sliding block slides on a first limiting rod, the position of a connecting pipe is adjusted, and the effect of detecting batteries of different specifications is achieved.

Description

Technical Field

[0001] This disclosure relates to the field of power equipment maintenance technology, and in particular to a UPS DC battery automatic replacement robot and its control system. Background Technology

[0002] In today's power systems, zero downtime, high efficiency, and security are critical requirements for businesses, especially in the DC battery replacement operations of UPS (Uninterruptible Power Supply) backup power systems. Traditionally, battery replacement has largely relied on manual labor. However, this method faces many problems.

[0003] Human error is prone to occur. For example, when installing or removing a battery, the operator may forget certain steps or make improper connections. This can cause the battery to malfunction or even pose a greater safety hazard.

[0004] Manually changing batteries is extremely inefficient. Batteries need to be replaced regularly; however, in practice, manual replacement is not only time-consuming but also incurs high labor costs. In emergency situations, many companies have to increase manpower to replace batteries quickly, but a reasonable allocation of human resources cannot be guaranteed.

[0005] Traditional monitoring methods are limited. Existing equipment often relies on simple voltage or temperature measurements, lacking comprehensive fault early warning capabilities. Abnormal temperatures, poor contact, and other conditions are difficult to detect in a timely manner, often resulting in equipment damage and higher maintenance costs.

[0006] Lack of real-time monitoring capabilities. Traditional methods struggle to achieve real-time data statistics and feedback, complicating remote management. Operators cannot immediately grasp battery status, leading to decision-making delays. Summary of the Invention

[0007] To address the aforementioned technical problems, this disclosure provides an automatic DC battery replacement machine for UPS systems.

[0008] To achieve the above objectives, the present invention provides the following technical solution: an automatic DC battery replacement machine for a UPS, comprising: A replacement frame, which is mounted on a support frame via a movable frame; A battery replacement mechanism, mounted on the lower surface of the replacement rack, is used for battery replacement. A nut removal mechanism, installed at one end of the replacement frame, is used to remove nuts; A connecting wire fixing mechanism, which is installed inside the connecting wire fixing mechanism, is used to fix the connecting wire; A voltage monitoring mechanism, installed on one side of the connecting wire fixing mechanism, is used to detect voltage; The voltage monitoring mechanism includes a fixed block, inside which a first electric push rod is fixedly connected. The output end of the first electric push rod is fixedly connected to a first rotating frame. The outer wall of the first rotating frame is rotatably connected to a push rod. One end of the push rod is rotatably connected to a second rotating frame. The lower surface of the second rotating frame is fixedly connected to a first sliding block. The inside of the first sliding block is slidably connected to a first limiting rod. The lower surface of the first sliding block is fixedly connected to a connecting tube. The inside of the connecting tube is slidably connected to a probe. The probe and the outer wall of the connecting tube are both fixedly connected to a first limiting plate. A spring is fixedly connected between the two first limiting plates.

[0009] Preferably, the replacement mechanism includes a second limiting plate, a seventh electric push rod is fixedly connected to the outer wall of the second limiting plate, a first connecting block is fixedly connected to the output end of the seventh electric push rod, and a support plate is fixedly connected to the outer wall of the first connecting block.

[0010] Preferably, a fixing rod is fixedly connected to the lower surface of the support plate, a sixth electric actuator is fixedly connected to the upper surface of the fixing rod, a connecting plate is fixedly connected to the output end of the sixth electric actuator, a clamp is fixedly connected to the lower surface of the outer wall of the connecting plate, and the outer wall of the support plate is slidably connected to the inside of the support plate.

[0011] Preferably, the cap-removing mechanism includes a first motor fixedly connected to the outer wall of a third sliding block, a first gear fixedly connected to the output end of the first motor, a first rack meshing with the outer wall of the first gear, a third electric push rod fixedly connected inside the third sliding block, a first connecting frame fixedly connected to the output end of the third electric push rod, a second motor fixedly connected to the outer wall of the first connecting frame, and a sleeve fixedly connected to the output end of the second motor.

[0012] Preferably, a storage box is fixedly connected to the lower surface of the first connecting frame, one end of the storage box is rotatably connected to the outer wall of the sleeve, a fifth electric actuator is fixedly connected to the lower surface of the first connecting frame, a push plate is fixedly connected to the output end of the fifth electric actuator, the outer wall of the push plate is slidably connected to the inside of the storage box, a fourth electric actuator is fixedly connected to the lower surface of the first connecting frame, and a push block is fixedly connected to the output end of the fourth electric actuator.

[0013] Preferably, the connecting wire fixing mechanism includes a first connecting rod, one end of which is fixedly connected to a second sliding block, the inside of which is slidably connected to a third limiting rod, the outer wall of which is fixedly connected to a second limiting rod, the lower surface of which is fixedly connected to a second electric push rod, the output end of which is fixedly connected to a pressure plate, and the outer wall of which is mostly connected to the outer wall of the second limiting rod.

[0014] Preferably, one end of the replacement frame is fixedly connected to a second connecting frame, the outer wall of the second connecting frame is fixedly connected to a limiting frame, the outer wall of the limiting frame is fixedly connected to a thermal imaging device, the outer wall of the limiting frame is slidably connected to the inside of a third sliding block, the outer wall of the second connecting frame is fixedly connected to a fixing frame, the outer wall of the fixing frame is fixedly connected to the outer wall of the limiting frame, the inside of the fixing frame is fixedly connected to a fixing block, the outer wall of the fixing frame is fixedly connected to both ends of a first limiting rod and a third limiting rod, the outer walls of the first limiting rod and the third limiting rod are fixedly connected to a second connecting rod, and the inside of the second connecting rod is fixedly connected to a camera.

[0015] Preferably, a second connecting block is slidably connected inside the replacement frame, the lower surface of the second connecting block is fixedly connected to the upper surface of the second limiting plate, a fourth motor is fixedly connected to the upper surface of the second connecting block, a second gear is fixedly connected to the output end of the fourth motor, a second rack is meshed with the outer wall of the second gear, and the outer wall of the second rack is fixedly connected to the inner wall of the replacement frame.

[0016] Preferably, a movable frame is fixedly connected to the outer wall of the replacement frame, a third motor is fixedly connected to the outer wall of the movable frame, a drive wheel is fixedly connected to the output end of the third motor, the outer wall of the drive wheel is rotatably connected to the inside of the movable frame, the outer wall of the drive wheel is slidably connected to the outer wall of the support frame, support rods are slidably connected to both ends of the support frame, and support columns are slidably connected to both ends of the support rods.

[0017] A UPS DC battery automatic replacement robot control system includes: The image acquisition module processes the visual information acquired by the camera (15) for positioning. The thermal imaging acquisition module processes the visual information acquired by the thermal imaging device (21) for temperature anomaly detection. The voltage detection module acquires the voltage data collected by the voltage monitoring mechanism (5); The main control module receives visual information and voltage data, makes decisions, and sends control commands to each execution module. The movement control module moves according to control commands; The execution control module replaces the battery according to control commands; The remote interaction module allows operators to remotely monitor the robot's status and issue commands.

[0018] The technical solution provided in this disclosure has the following advantages compared with the prior art: 1. This invention uses the output end of a first electric push rod to drive a first rotating frame to move, causing the first rotating frame to push a push rod to rotate on a second rotating frame, which in turn pushes a first sliding block to move. The first sliding block then slides on a first limiting rod, thereby adjusting the position of the connecting tube to achieve the effect of detecting batteries of different specifications. The movement of the first limiting rod drives the first connecting rod to move, and the movement of the fixing frame causes the probe to contact both ends of the battery. This causes the probe to drive the first limiting plate to move, thereby compressing the spring and causing the probe to slide inside the connecting tube, thus preventing the probe from damaging the battery and collecting voltage data.

[0019] 2. In this invention, the first connecting rod drives the second sliding block to slide on the third limiting rod, thereby moving the second limiting rod so that it is inserted below the connecting line. The second electric push rod then pushes the pressure plate to move, causing the pressure plate to slide on the second limiting rod, thus achieving the effect of fixing the connecting line.

[0020] 3. This invention incorporates image acquisition and thermal imaging technologies to ensure real-time monitoring of battery status and ambient temperature. The image acquisition module accurately captures image information of the battery and terminals, analyzes it using advanced image processing algorithms, and precisely locates the spatial position of the target object. The thermal imaging device monitors the battery surface temperature in real time, promptly detecting overheating or abnormal conditions. Compared to existing detection methods, this combination of technologies can identify potential faults in advance, reducing the probability of accidents and effectively preventing equipment damage caused by high temperatures or short circuits, thus improving system reliability and safety. Attached Figure Description

[0021] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0022] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a perspective view of an embodiment of the present disclosure; Figure 2 This is a schematic diagram of the mobile frame described in an embodiment of this disclosure; Figure 3 This is a schematic diagram of the fixing frame described in an embodiment of this disclosure; Figure 4 This is a schematic diagram of the second limiting rod in an embodiment of this disclosure; Figure 5This is a schematic diagram of the limiting frame described in an embodiment of the present disclosure; Figure 6 This is a schematic diagram of the storage box described in an embodiment of this disclosure; Figure 7 This is a cross-sectional view of the replacement frame described in an embodiment of this disclosure; Figure 8 This is a schematic diagram of the gripper described in an embodiment of the present disclosure; Figure 9 This is a schematic diagram of the system framework described in an embodiment of this disclosure.

[0024] The components include: 1. Support frame; 2. Support rod; 3. Support column; 4. Replacement frame; 5. Voltage monitoring mechanism; 501. Fixing block; 502. First electric push rod; 503. First rotating frame; 504. Push rod; 505. Second rotating frame; 506. First sliding block; 507. Spring; 508. Probe; 509. First limiting plate; 5010. First limiting rod; 5011. Connecting pipe; 6. Connecting wire fixing mechanism; 601. First connecting rod; 602. Second sliding block; 603. Second electric push rod; 604. Second limiting rod; 605. Pressure plate; 606. Third limiting rod; 7. Cap removal mechanism; 701. Third sliding block; 702. First motor; 703. First gear; 704. First rack; 705. Third electric push rod. 706. Rod; 707. First connecting frame; 708. Second motor; 709. Sleeve; 7010. Storage box; 7010. Fourth electric push rod; 7011. Fifth electric push rod; 7012. Push block; 7013. Push plate; 8. Changing mechanism; 801. Support plate; 802. Fixed rod; 803. Sixth electric push rod; 804. Second limit plate; 805. Seventh electric push rod; 806. First connecting block; 807. Connecting plate; 808. Gripper; 9. Moving frame; 10. Third motor; 11. Drive wheel; 12. Second connecting frame; 13. Fixed frame; 14. Second connecting rod; 15. Camera; 16. Limit frame; 17. Second connecting block; 18. Second gear; 19. Fourth motor; 20. Second rack; 21. Thermal imaging equipment. Detailed Implementation

[0025] To better understand the above-mentioned objectives, features, and advantages of this disclosure, the solutions disclosed herein will be further described below. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0026] Numerous specific details are set forth in the following description in order to provide a full understanding of this disclosure, but this disclosure may also be implemented in other ways different from those described herein; obviously, the embodiments in the specification are only some, and not all, of the embodiments of this disclosure.

[0027] include: Replacement frame 4 is mounted on support frame 1 via movable frame 9; A third motor 10 is fixedly connected to the outer wall of the movable frame 9. A drive wheel 11 is fixedly connected to the output end of the third motor 10. The outer wall of the drive wheel 11 is rotatably connected to the inside of the movable frame 9. The outer wall of the drive wheel 11 is slidably connected to the outer wall of the support frame 1. Support rods 2 are slidably connected to both ends of the support frame 1. Support columns 3 are slidably connected to both ends of the support rods 2. Specifically, by starting the third motor 10, the drive wheel 11 is driven to rotate, causing the drive wheel 11 to rotate on the support frame 1, and driving the movable frame 9 to move on the support frame 1, thereby causing the movable frame 9 to move the replacement frame 4. The position and height of the spring support frame 1 are thus adjusted by sliding the support frame 1 on the support rod 2 and the support rod 2 on the support column 3.

[0028] Figure 8 The replacement mechanism 8 is installed on the lower surface of the replacement frame 4 and is used for replacing the battery. The replacement mechanism 8 includes a second limiting plate 804. A seventh electric actuator 805 is fixedly connected to the outer wall of the second limiting plate 804. A first connecting block 806 is fixedly connected to the output end of the seventh electric actuator 805. A support plate 801 is fixedly connected to the outer wall of the first connecting block 806. A fixing rod 802 is fixedly connected to the lower surface of the support plate 801. A sixth electric actuator 803 is fixedly connected to the upper surface of the fixing rod 802. A connecting plate 807 is fixedly connected to the output end of the sixth electric actuator 803. The outer wall of the connecting plate 807 is fixedly connected to the lower surface of the support plate 801. A gripper 808 is fixedly connected to the surface, and the outer wall of the support plate 801 is slidably connected to the inside of the support plate 801; a second connecting block 17 is slidably connected to the inside of the replacement frame 4, the lower surface of the second connecting block 17 is fixedly connected to the upper surface of the second limiting plate 804, a fourth motor 19 is fixedly connected to the upper surface of the second connecting block 17, a second gear 18 is fixedly connected to the output end of the fourth motor 19, a second rack 20 is meshed with the outer wall of the second gear 18, and the outer wall of the second rack 20 is fixedly connected to the inner wall of the replacement frame 4; Specifically, the output end of the seventh electric push rod 805 drives the first connecting block 806 to move, which in turn drives the support plate 801 to move. The support plate 801 then drives the gripper 808 to move, thereby adjusting the height. The sixth electric push rod 803 drives the connecting plate 807 to move, which in turn drives the gripper 808 to slide inside the support plate 801, thereby gripping the battery. The fourth motor 19 is started to drive the second gear 18 to rotate, which in turn rotates on the second rack 20, thereby driving the second connecting block 17 to move inside the replacement frame 4. The second connecting block 17 then drives the second limiting plate 804 to move, thereby replacing the battery.

[0029] Figure 5 and Figure 6 ; This is the cap removal mechanism 7, which is installed at one end of the replacement frame 4 and is used to remove the cap; The cap-removing mechanism 7 includes a third sliding block 701 with a first motor 702 fixedly connected to its outer wall, a first gear 703 fixedly connected to the output end of the first motor 702, a first rack 704 meshing with the outer wall of the first gear 703, a third electric push rod 705 fixedly connected inside the third sliding block 701, a first connecting frame 706 fixedly connected to the output end of the third electric push rod 705, a second motor 707 fixedly connected to the outer wall of the first connecting frame 706, and a sleeve 708 fixedly connected to the output end of the second motor 707. A storage box 709 is fixedly connected to the lower surface of the first connecting frame 706. One end of the storage box 709 is rotatably connected to the outer wall of the sleeve 708. A fifth electric push rod 7011 is fixedly connected to the lower surface of the first connecting frame 706. A push plate 7013 is fixedly connected to the output end of the fifth electric push rod 7011. The outer wall of the push plate 7013 is slidably connected to the inside of the storage box 709. A fourth electric push rod 7010 is fixedly connected to the lower surface of the first connecting frame 706. A push block 7012 is fixedly connected to the output end of the fourth electric push rod 7010. Specifically, when removing the nut, the first motor 702 is activated to drive the first gear 703 to rotate, causing the first gear 703 to rotate on the first rack 704. This, in turn, moves the third sliding block 701, simultaneously moving the third electric actuator 705 to move the first connecting bracket 706. This, in turn, drives the second motor 707 to adjust the position of the sleeve 708, aligning the sleeve 708 with the nut. The output end of the third electric actuator 705 then pushes the first connecting bracket 706 to move, allowing the sleeve 708 to insert into the nut. The cap is placed on the sleeve 708 and the second motor 707 is started to remove the cap. The output end of the fourth electric push rod 7010 drives the push block 7012 to slide inside the sleeve 708, pushing the cap into the storage box 709 for storage. During installation, the output end of the fifth electric push rod 7011 drives the push plate 7013 to slide inside the storage box 709, thereby pushing the cap into the sleeve 708. The cap is installed by rotating the sleeve 708. Thermal imaging data of the battery is collected by the thermal imaging device 21.

[0030] Figure 4The connecting wire fixing mechanism 6 is installed inside the connecting wire fixing mechanism 6 and is used to fix the connecting wire. The connecting wire fixing mechanism 6 includes a first connecting rod 601, a second sliding block 602 is fixedly connected to one end of the first connecting rod 601, a third limiting rod 606 is slidably connected inside the second sliding block 602, a second limiting rod 604 is fixedly connected to the outer wall of the second sliding block 602, a second electric push rod 603 is fixedly connected to the lower surface of the second sliding block 602, a pressure plate 605 is fixedly connected to the output end of the second electric push rod 603, and the outer wall of the pressure plate 605 is connected to the outer wall of the second limiting rod 604. A second connecting frame 1 is fixedly connected to one end of the replacement frame 4. 2. A limiting frame 16 is fixedly connected to the outer wall of the second connecting frame 12. A thermal imaging device 21 is fixedly connected to the outer wall of the limiting frame 16. The outer wall of the limiting frame 16 is slidably connected to the inside of the third sliding block 701. A fixing frame 13 is fixedly connected to the outer wall of the second connecting frame 12. The outer wall of the fixing frame 13 is fixedly connected to the outer wall of the limiting frame 16. The inside of the fixing frame 13 is fixedly connected to the fixing block 501. The outer wall of the fixing frame 13 is fixedly connected to both ends of the first limiting rod 5010 and the third limiting rod 606. A second connecting rod 14 is fixedly connected to the outer walls of the first limiting rod 5010 and the third limiting rod 606. A camera 15 is fixedly connected to the inside of the second connecting rod 14. Specifically, the second connecting frame 12 fixes the fixed frame 13 and the limiting frame 16. The movement of the support frame 1 drives the replacement frame 4, which in turn causes the second connecting frame 12 to move the fixed frame 13. This, in turn, causes the third limiting rod 606 to move the second sliding block 602. The first connecting rod 601 drives the second sliding block 602 to slide on the third limiting rod 606, thereby moving the second limiting rod 604. The second limiting rod 604 is then inserted below the connecting wire. The second electric push rod 603 pushes the pressure plate 605 to move, causing the pressure plate 605 to slide on the second limiting rod 604, thus fixing the connecting wire and facilitating its repositioning. Image information is then captured by the camera 15.

[0031] Figure 3 Voltage monitoring mechanism 5, which is installed on one side of the connecting wire fixing mechanism 6, is used to detect voltage; The voltage monitoring mechanism 5 includes a fixed block 501. A first electric push rod 502 is fixedly connected inside the fixed block 501. A first rotating frame 503 is fixedly connected to the output end of the first electric push rod 502. A push rod 504 is rotatably connected to the outer wall of the first rotating frame 503. A second rotating frame 505 is rotatably connected to one end of the push rod 504. A first sliding block 506 is fixedly connected to the lower surface of the second rotating frame 505. A first limiting rod 5010 is slidably connected inside the first sliding block 506. A connecting tube 5011 is fixedly connected to the lower surface of the first sliding block 506. A probe 508 is slidably connected inside the connecting tube 5011. A first limiting plate 509 is fixedly connected to the outer wall of both the probe 508 and the connecting tube 5011. A spring 507 is fixedly connected between the two first limiting plates 509.

[0032] Specifically, the output end of the first electric push rod 502 drives the first rotating frame 503 to move, causing the first rotating frame 503 to push the push rod 504 to rotate on the second rotating frame 505, and push the first sliding block 506 to move, causing the first sliding block 506 to slide on the first limiting rod 5010, thereby adjusting the position of the connecting tube 5011. The movement of the first limiting rod 5010 drives the first connecting rod 601 to move, and the movement of the fixing frame 13 causes the probe 508 to contact both ends of the battery, thereby causing the probe 508 to drive the first limiting plate 509 to move, thereby squeezing the spring 507 and causing the probe 508 to slide inside the connecting tube 5011, thereby preventing the probe 508 from damaging the battery, and thus collecting voltage data.

[0033] Working principle: First, image information and thermal imaging data are acquired through 15 and 21. Then, the support frame 1 slides on the support rod 2, and the support rod 2 slides on the support column 3. The position and height of the spring support frame 1 are adjusted by starting the third motor 10 to drive the drive wheel 11 to rotate. The drive wheel 11 rotates on the support frame 1 and drives the moving frame 9 to move on the support frame 1, thereby moving the changing frame 4. The height of the support frame 1 is adjusted to drive the replacement frame 4, which in turn causes the second connecting frame 12 to move the fixed frame 13. The output end of the first electric push rod 502 drives the first rotating frame 503 to move, which in turn pushes the push rod 504 to rotate on the second rotating frame 505 and pushes the first sliding block 506 to move. The first sliding block 506 slides on the first limiting rod 5010, thereby adjusting the position of the connecting tube 5011. The movement of the first limiting rod 5010 drives the first connecting rod 601 to move. The movement of the fixed frame 13 causes the probe 508 to contact both ends of the battery, which in turn causes the probe 508 to move the first limiting plate 509, thereby squeezing the spring 507 and causing the probe 508 to slide inside the connecting tube 5011, thus preventing the probe 508 from damaging the battery and collecting voltage data. The support frame 1 slides on the support rod 2 to adjust its position. The first connecting rod 601 drives the second sliding block 602 to slide on the third limiting rod 606, thereby moving the second limiting rod 604 so that it is inserted below the connecting wire. The second electric push rod 603 pushes the pressure plate 605 to move, causing the pressure plate 605 to slide on the second limiting rod 604, thus fixing the connecting wire. At the same time, the first motor 702 is started to drive the first gear 703 to rotate, causing the first gear 703 to rotate on the first rack 704. This causes the third sliding block 701 to move, and simultaneously causes the third electric push rod 705 to move the first connecting frame 706, thereby causing the second motor 707 to adjust the position of the sleeve 708 so that the sleeve 708 is aligned with the nut. The output end of the third electric push rod 705 pushes the first connecting frame 706 to move, so that the sleeve 708 is inserted into the nut. The second motor 707 is started to make the sleeve 708 remove the nut. The output end of the fourth electric push rod 7010 is started to drive the push block 7012 to slide inside the sleeve 708, pushing the nut into the storage box 709 for storage. The output end of the seventh electric push rod 805 drives the first connecting block 806 to move, which in turn drives the support plate 801 to move. The support plate 801 then drives the gripper 808 to move, thereby adjusting the height. The sixth electric push rod 803 drives the connecting plate 807 to move, which in turn drives the gripper 808 to slide inside the support plate 801, thereby gripping the battery. The fourth motor 19 is started to drive the second gear 18 to rotate, which in turn rotates on the second rack 20, thereby driving the second connecting block 17 to move inside the replacement frame 4. The second connecting block 17 then drives the second limiting plate 804 to move, thereby replacing the battery. During installation, the output end of the fifth electric actuator 7011 drives the push plate 7013 to slide within the storage box 709, thereby pushing the nut into the sleeve 708, and installing the nut by rotating the sleeve 708.

[0034] Figure 9 The present invention also provides a UPS DC battery automatic replacement robot control system, comprising: The image acquisition module processes the visual information acquired by the camera (15) for positioning. Specifically, the image acquisition module includes a camera 15, which is installed inside the second connecting rod 14. The two ends of the second connecting rod are fixedly connected to the first limiting rod 5010 of the voltage monitoring mechanism 5 and the third limiting rod 606 of the connecting wire fixing mechanism 6. This design ensures that the camera is always centered in the battery operating area, enabling it to capture real-time images of the battery and terminal blocks in the working environment.

[0035] During implementation, the image acquisition module first activates camera 15 to capture an image of the target battery. Subsequently, the image undergoes preprocessing, format conversion, and noise removal, and is processed using a built-in image processing algorithm. The algorithm used can be a convolutional neural network (CNN) or a morphological image segmentation algorithm to extract the target region.

[0036] After target recognition, the system calculates the spatial position deviation of the target object. Specifically, it first establishes the mapping relationship between the pixel coordinate system, camera coordinate system, and tool coordinate system. The relevant variables are set as follows: Pixel coordinates of the target object in the image Preset pixel coordinates of the target point (such as the center of the image); ; ; Calculate the deviation in the image This deviation is then converted into physical displacement of the robot's movement.

[0037] The thermal imaging acquisition module processes the visual information acquired by the thermal imaging device (21) for temperature anomaly detection. Specifically, the thermal imaging acquisition module includes a thermal imaging device 21, which is fixedly connected to a limiting frame 16. One end of the limiting frame 16 is connected to a second connecting frame 12, and the other end is connected to a support frame 1. This structural design allows the thermal imaging device to accurately cover the battery and its connection area during operation, achieving effective temperature monitoring.

[0038] During implementation, the thermal imaging device is first activated and acquires thermal images of the target area using non-contact infrared sensing technology. The temperature information of each pixel is converted into a corresponding thermal image, and the thermal radiation value of each pixel in the thermal image represents its temperature.

[0039] The thermal imaging module processes the thermal image data in real time to achieve accurate temperature measurement of the battery and connecting cables. The temperature data of each pixel in the thermal image can be represented as... ,in and These are the coordinates of the pixels in the heatmap. After obtaining the heat map data, the system will create a temperature anomaly detection model. First, a temperature threshold will be set. This serves as a performance safety limit. The model aims to automatically identify pixels that exceed this threshold to determine if they are overheating.

[0040] The specific temperature anomaly detection algorithm is based on the following logic: Generate heat map data and calculate the temperature value of each pixel.

[0041] Compare and

[0042] ; In the formula, It represents the x-coordinate of a pixel in the image, indicating its position in the horizontal direction.

[0043] The vertical coordinate represents the ordinate of a pixel in the image, while the vertical coordinate represents its position.

[0044] This indicates that the coordinates in the image are... The temperature value of a pixel is usually measured by a thermal imaging device.

[0045] This represents the temperature threshold, a set reference value used to determine whether the temperature is abnormal.

[0046] This indicates the action to be taken when the temperature at a certain point exceeds a threshold, which could be issuing an alarm, marking it on a graph, or notifying the user.

[0047] The output of the thermal imaging module can be sent to the main control module via the communication interface. When an abnormal temperature is detected, the main control module will trigger corresponding safety measures based on this information, such as shutdown, alarm activation, or adjustment of the robot's operating mode.

[0048] The voltage detection module acquires the voltage data collected by the voltage monitoring mechanism 5; Specifically, by controlling the voltage monitoring mechanism 5, the first sliding block 506 slides on the first limiting rod 5010, thereby adjusting the position of the connecting tube 5011. The movement of the fixing frame 13 causes the probe 508 to contact the two ends of the battery, thereby collecting voltage data.

[0049] The main control module receives visual information and voltage data, makes decisions, and sends control commands to each execution module. Specifically, in terms of the processing flow, the main control module first receives battery voltage data from the voltage detection module. If the voltage value is within the safe range, the main control module continues the task flow. Next, the module calls the data from the thermal imaging acquisition module to check the temperature status of the battery and its connected areas.

[0050] In the next steps, the main control module needs to integrate information from different modules. First, based on the voltage value... and temperature threshold Establish a security judgment model. If Less than the set safe voltage threshold or temperature exceeds The main control module will determine that the battery status is abnormal and then issue an alarm signal.

[0051] Once the battery passes inspection, the main control module activates the image acquisition module to identify the target battery and its wiring locations. The main control module calculates the spatial coordinates of the target battery and the robot, and generates corresponding control commands. This process includes steps such as image processing algorithms, target recognition, and position deviation correction.

[0052] After image recognition, the main control module calculates the ideal position of the robot's end effector and compares it with the current actual position. Next, based on this information, the main control module generates motion control commands to adjust the robot's movement, ensuring it is precisely aligned with the target battery.

[0053] During execution, the main control module continuously performs monitoring tasks in a loop, receiving feedback information from various sensors and modules. This feedback is used not only to adjust the motion process but also to evaluate the working status after battery replacement, thereby optimizing subsequent operating procedures.

[0054] In practice, for example, in the final stage of a battery replacement operation, the main control module will instruct the robot to securely fix the new battery in place. Once the operation is complete, the module will monitor the status of the new battery to ensure its normal operation.

[0055] The movement control module moves according to control commands; Specifically, the movement control module controls the support frame 1 to slide on the support rod 2, and the support rod 2 to slide on the support column 3, thereby controlling the position and height of the spring support frame 1.

[0056] The third motor 10 drives the drive wheel 11 to rotate, causing the drive wheel 11 to rotate on the support frame 1, and driving the movable frame 9 to move on the support frame 1, thereby causing the movable frame 9 to move the replacement frame 4, thus achieving the adjustment of the position of the replacement frame 4.

[0057] The execution control module replaces the battery according to control commands; Specifically, the battery voltage is detected by receiving control commands and controlling the voltage monitoring mechanism 5. The connecting wire is fixed by the connecting wire fixing mechanism 6 and the nut is removed by the nut removal mechanism 7. The battery is then replaced by the replacement mechanism 8. The connecting wire and nut are then reinstalled by the connecting wire fixing mechanism 6 and the nut removal mechanism 7.

[0058] The remote interaction module allows operators to remotely monitor the robot's status and issue commands; Specifically, the remote interaction module first establishes internal communication with the main control module. This module periodically receives operating status, sensor data, and battery status information reported by the main control module. Subsequently, the remote interaction module processes and integrates this information to ensure the accuracy and completeness of the transmitted data.

[0059] Then, the remote interaction module uploads the processed information to the server or cloud platform via the data communication unit. This process is based on network protocols, ensuring the security and stability of data transmission. Users can view relevant status information in real time through a client application.

[0060] During remote interaction, the system will receive control commands from the user. These commands can be adjustments to the operating procedures, feedback on fault handling, or the initiation of specific tasks. The remote interaction module will transmit the user-inputted commands to the main control module for appropriate action to be taken.

[0061] For example, when a user observes an abnormal state in the remote monitoring system, they can issue an operation command through the client program, requesting the system to stop the current task. After receiving the command, the main control module executes the corresponding measures and feeds back the results to the remote interaction module.

[0062] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0063] The above description is merely a specific embodiment of this disclosure, enabling those skilled in the art to understand or implement it. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this disclosure. Therefore, this disclosure is not to be limited to the embodiments described herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A UPS DC battery automatic replacement robot, characterized in that, include: Replacement frame (4), which is mounted on support frame (1) via movable frame (9); A replacement mechanism (8) is installed on the lower surface of the replacement frame (4) for replacing batteries; The cap removal mechanism (7) is installed at one end of the replacement frame (4) and is used to remove the cap; A connecting wire fixing mechanism (6) is installed inside the connecting wire fixing mechanism (6) for fixing the connecting wire; A voltage monitoring mechanism (5) is installed on one side of the connecting wire fixing mechanism (6) for detecting voltage; The voltage monitoring mechanism (5) includes a fixed block (501), a first electric push rod (502) is fixedly connected inside the fixed block (501), a first rotating frame (503) is fixedly connected to the output end of the first electric push rod (502), a push rod (504) is rotatably connected to the outer wall of the first rotating frame (503), a second rotating frame (505) is rotatably connected to one end of the push rod (504), a first sliding block (506) is fixedly connected to the lower surface of the second rotating frame (505), a first limiting rod (5010) is slidably connected inside the first sliding block (506), a connecting tube (5011) is fixedly connected to the lower surface of the first sliding block (506), a probe (508) is slidably connected inside the connecting tube (5011), a first limiting plate (509) is fixedly connected to the outer wall of both the probe (508) and the connecting tube (5011), and a spring (507) is fixedly connected between the two first limiting plates (509).

2. The UPS DC battery automatic replacement robot according to claim 1, characterized in that, The replacement mechanism (8) includes a second limiting plate (804), and a seventh electric push rod (805) is fixedly connected to the outer wall of the second limiting plate (804). The output end of the seventh electric push rod (805) is fixedly connected to a first connecting block (806), and a support plate (801) is fixedly connected to the outer wall of the first connecting block (806).

3. The UPS DC battery automatic replacement robot according to claim 2, characterized in that, A fixing rod (802) is fixedly connected to the lower surface of the support plate (801), and a sixth electric actuator (803) is fixedly connected to the upper surface of the fixing rod (802). A connecting plate (807) is fixedly connected to the output end of the sixth electric actuator (803). A gripper (808) is fixedly connected to the lower surface of the outer wall of the connecting plate (807). The outer wall of the support plate (801) is slidably connected to the inside of the support plate (801).

4. The UPS DC battery automatic replacement robot according to claim 1, characterized in that, The cap removal mechanism (7) includes a first motor (702) fixedly connected to the outer wall of a third sliding block (701), a first gear (703) fixedly connected to the output end of the first motor (702), a first rack (704) meshing with the outer wall of the first gear (703), a third electric push rod (705) fixedly connected inside the third sliding block (701), a first connecting frame (706) fixedly connected to the output end of the third electric push rod (705), a second motor (707) fixedly connected to the outer wall of the first connecting frame (706), and a sleeve (708) fixedly connected to the output end of the second motor (707).

5. The UPS DC battery automatic replacement robot according to claim 4, characterized in that, A storage box (709) is fixedly connected to the lower surface of the first connecting frame (706). One end of the storage box (709) is rotatably connected to the outer wall of the sleeve (708). A fifth electric push rod (7011) is fixedly connected to the lower surface of the first connecting frame (706). A push plate (7013) is fixedly connected to the output end of the fifth electric push rod (7011). The outer wall of the push plate (7013) is slidably connected to the inside of the storage box (709). A fourth electric push rod (7010) is fixedly connected to the lower surface of the first connecting frame (706). A push block (7012) is fixedly connected to the output end of the fourth electric push rod (7010).

6. The UPS DC battery automatic replacement robot according to claim 1, characterized in that, The connecting wire fixing mechanism (6) includes a first connecting rod (601), one end of which is fixedly connected to a second sliding block (602), the inside of which is slidably connected to a third limiting rod (606), the outer wall of which is fixedly connected to a second limiting rod (604), the lower surface of which is fixedly connected to a second electric push rod (603), the output end of which is fixedly connected to a pressure plate (605), and the outer wall of which is mostly connected to the outer wall of the second limiting rod (604).

7. The UPS DC battery automatic replacement robot according to claim 1, characterized in that, One end of the replacement frame (4) is fixedly connected to a second connecting frame (12). The outer wall of the second connecting frame (12) is fixedly connected to a limiting frame (16). The outer wall of the limiting frame (16) is fixedly connected to a thermal imaging device (21). The outer wall of the limiting frame (16) is slidably connected to the inside of a third sliding block (701). The outer wall of the second connecting frame (12) is fixedly connected to a fixing frame (13). The outer wall of the fixing frame (13) is fixedly connected to the outer wall of the limiting frame (16). The inside of the fixing frame (13) is fixedly connected to a fixing block (501). The outer wall of the fixing frame (13) is fixedly connected to both ends of a first limiting rod (5010) and a third limiting rod (606). The outer walls of the first limiting rod (5010) and the third limiting rod (606) are fixedly connected to a second connecting rod (14). The inside of the second connecting rod (14) is fixedly connected to a camera (15).

8. The UPS DC battery automatic replacement robot according to claim 1, characterized in that, The replacement frame (4) is internally slidably connected to a second connecting block (17). The lower surface of the second connecting block (17) is fixedly connected to the upper surface of the second limiting plate (804). The upper surface of the second connecting block (17) is fixedly connected to a fourth motor (19). The output end of the fourth motor (19) is fixedly connected to a second gear (18). The outer wall of the second gear (18) is meshed with a second rack (20). The outer wall of the second rack (20) is fixedly connected to the inner wall of the replacement frame (4).

9. The UPS DC battery automatic replacement robot according to claim 1, characterized in that, The outer wall of the movable frame (9) is fixedly connected to a third motor (10), the output end of the third motor (10) is fixedly connected to a drive wheel (11), the outer wall of the drive wheel (11) is rotatably connected to the inside of the movable frame (9), the outer wall of the drive wheel (11) is slidably connected to the outer wall of the support frame (1), the two ends of the support frame (1) are slidably connected to support rods (2), and the two ends of the support rods (2) are slidably connected to support columns (3).

10. A UPS DC battery automatic replacement robot control system, applied to a UPS DC battery automatic replacement robot as described in any one of claims 1-9, characterized in that, include; The image acquisition module processes the visual information acquired by the camera (15) for positioning. The thermal imaging acquisition module processes the visual information acquired by the thermal imaging device (21) for temperature anomaly detection. The voltage detection module acquires the voltage data collected by the voltage monitoring mechanism (5); The main control module receives visual information and voltage data, makes decisions, and sends control commands to each execution module. The movement control module moves according to control commands; The execution control module replaces the battery according to control commands; The remote interaction module allows operators to remotely monitor the robot's status and issue commands.

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