A composite robot for detecting apparent diseases of a complex bridge structure and a working method thereof

Abstract

This invention discloses a composite robot and its working method for detecting surface defects in complex bridge structures, belonging to the technical field of bridge surface defect detection robots. It includes a rail-mounted robot body and a magnetic adsorption robot. The rail-mounted robot body is suspended from a track installed on the bridge structure. The robot body is equipped with a detection extension arm and a storage compartment telescopic arm. A storage compartment is installed at the end of the storage compartment telescopic arm. The storage compartment is used to retrieve and store the magnetic adsorption robot and to charge or provide power to the magnetic adsorption robot via a cable. The detection extension arm and the magnetic adsorption robot work together to detect bridge defect information in real time. This invention has low operational difficulty, can improve bridge inspection coverage and intelligence level, and overcomes the shortcomings of single rail-mounted inspection robots or magnetic adsorption robots.

Description

Technical Field

[0001] This invention relates to a composite robot and its working method for detecting surface defects in complex bridge structures, belonging to the technical field of bridge surface defect detection robots. Background Technology

[0002] Steel structure bridges are crucial hubs in transportation networks. Leveraging their high strength and long spans, they are widely used on highways and railways. However, being exposed to the elements for extended periods, they are susceptible to corrosion, weld cracking, and component deformation due to weathering, vehicle load impacts, and temperature fluctuations. Failure to detect these issues promptly can lead to structural safety hazards and even major accidents such as bridge collapses. Therefore, efficient and comprehensive bridge inspections are a core requirement for ensuring safe transportation operations and a critical aspect that urgently needs optimization in the engineering field.

[0003] Traditional manual inspections often require inspectors to use elevated equipment or suspended ropes to work. Given the complex structures of bridges, such as trusses and box girders, the working space is narrow and the risks are extremely high. Furthermore, manual inspections rely on experience-based judgment, easily missing minor defects such as tiny cracks. The inspection process is also slow; it can take several weeks to complete the inspection of a large bridge, severely impacting traffic flow.

[0004] Currently, rail-mounted inspection robots move along preset tracks for inspection. While this method offers high stability, track installation is severely constrained by the bridge structure. For special sections of steel bridges, such as curved supports and cable anchors, tracks cannot be laid, creating blind spots in these high-risk areas. Furthermore, track installation and dismantling are costly, and tracks need to be customized for different bridges, making it difficult to adapt to diverse bridge structures.

[0005] Magnetic robots rely on electromagnetic or permanent magnets to adhere to steel structure surfaces for movement. They do not require specific tracks and have strong adaptability. While existing magnetic robots can traverse obtuse-angled steel structures, they struggle with sharp angles, resulting in numerous blind spots. Maintaining the adhesion and driving the robot's movement consumes extremely high energy. Limited by lightweight design, battery capacity cannot be significantly increased, with most magnetic robots having a single-charge runtime of only 1-2 hours. Frequent shutdowns for battery replacements are necessary during inspections, disrupting the inspection process and preventing continuous, full-coverage inspections of large bridges, severely limiting inspection efficiency.

[0006] In summary, existing traditional steel structure bridge inspection methods suffer from drawbacks such as high risks associated with manual operations, limited inspection range of a single rail-mounted robot, insufficient battery life, numerous blind spots, and high operational difficulty for personnel. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a composite robot and working method for detecting apparent defects in complex bridge structures. It is easy to operate, can improve the coverage and intelligence level of bridge inspection, and solves the defects of single rail-mounted inspection robots or magnetic robots.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0009] In a first aspect, the present invention provides a composite robot for detecting apparent defects in complex bridge structures, comprising a rail-mounted robot body and a magnetic adsorption robot. The rail-mounted robot body is suspended on a track installed on the bridge body. The rail-mounted robot body is provided with a detection extension arm and a storage compartment telescopic arm. A storage compartment is installed at the end of the storage compartment telescopic arm. The storage compartment is used to retrieve and store the magnetic adsorption robot and to charge or supply power to the magnetic adsorption robot via a cable. The detection extension arm and the magnetic adsorption robot work together to detect bridge defect information in real time.

[0010] The main body of the rail-mounted robot is equipped with a drive wheel and a clamping wheel, which are located on the upper and lower sides of the bottom steel plate of the track, respectively. The main body of the rail-mounted robot is equipped with a first drive motor. The output shaft of the first drive motor drives the transmission shaft to rotate through a reversing reducer. Both ends of the transmission shaft are equipped with active synchronous pulleys. A driven wheel is connected to the outer side of the drive wheel. The active synchronous pulley drives the driven wheel to rotate through a synchronous belt, thereby transmitting power to the drive wheel.

[0011] The detection extension arm has a multi-stage unfolding structure, including two primary extension arms. A second drive motor is provided on the main body of the rail-mounted robot. The second drive motor drives the two primary extension arms to rotate synchronously through gear transmission. A secondary extension arm is provided on the outside of the primary extension arms and is driven to rotate by a third drive motor. Detection camera modules are distributed on the primary and secondary extension arms.

[0012] The detection camera module is a camera, and gimbals are provided on the first-level extension arm and the second-level extension arm, with the camera mounted on the gimbals.

[0013] The storage bin telescopic arm includes a rotating base, which is driven to rotate by a fourth drive motor mounted on the main body of the rail-mounted robot. The rotating base is connected to one end of the first-stage telescopic arm, the other end of the first-stage telescopic arm is connected to an intermediate connecting plate, the intermediate connecting plate is connected to one end of the second-stage telescopic arm, and the other end of the second-stage telescopic arm is connected to an end flange, which is used to install the storage bin.

[0014] The storage compartment includes a main body and a magnetic detachment device. The main body has charging contacts for charging the magnetically attached robot. The main body has a servo motor-driven connecting rod. The magnetic detachment device is mounted on the main body via the connecting rod. The servo motor can drive the connecting rod to flip the magnetic detachment device upwards, so that the main body is in a closed position. The upper surface of the magnetic detachment device has a slope to facilitate the magnetically attached robot entering the main body.

[0015] The magnetic adsorption robot is equipped with a lidar and a detection device. The lower part of the magnetic adsorption robot is provided with several magnetic wheels, each of which is driven by an independent fifth drive motor.

[0016] Secondly, the present invention provides a working method for a composite robot for detecting apparent defects in complex bridge structures, comprising the following steps:

[0017] The main body of the track-mounted robot carries all the equipment forward along the track, and the detection extension arm is controlled to be in the extended state. The detection extension arm performs real-time detection of bridge defects in all directions.

[0018] Based on the preset delivery point and the visual recognition of the main body of the rail-mounted robot, the telescopic arm of the storage bin is controlled to extend and retract to the vicinity of the magnetic adsorption robot's delivery point.

[0019] After the storage compartment is extended and retracted to its designated position, the magnetic adsorption robot drives out of the storage compartment and climbs onto the bridge steel structure.

[0020] The magnetic adsorption robot moves according to a pre-set trajectory, performs path planning and autonomous navigation, and carries its own detection equipment for autonomous detection.

[0021] After the magnetic adsorption robot completes the inspection of the bridge steel structure segment, it plans its return path based on its current location and the location of the storage bin, and returns to the vicinity of the storage bin via the optimal path, and then enters the return storage bin.

[0022] The telescopic arm of the storage compartment is controlled to return to its initial position, and the rail-mounted robot body carries the equipment to the next segment for inspection.

[0023] The beneficial effects of this invention are as follows: This invention provides a composite robot and its working method for detecting surface defects in complex bridge structures. By laying tracks across the entire bridge at the side span locations, a collaborative structure is designed with a track-mounted robot with a storage compartment and a retractable magnetic adsorption robot. Combining the storage compartment's charging or cable-driven power supply mode with LiDAR, the magnetic adsorption robot can be deployed at fixed points in the bridge side span track area and multi-segment climbing area. The magnetic adsorption robot can autonomously crawl and complete areas that a single robot cannot reach. This allows the composite robot to cover both the bridge side span track area and segment climbing area, autonomously completing cross-region detection and recharging, achieving efficient, safe, and comprehensive detection of steel arch rib structure bridges. In addition, for high-altitude side spans and complex segmental structures of bridges, it can replace manual labor to complete the detection of surface defects in high-risk areas, avoiding the risks of manual climbing and suspended operations, and ensuring the safety and stability of the detection. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of a composite robot for detecting apparent defects in complex bridge structures according to the present invention.

[0025] Figure 2 This is a schematic diagram of the upper part of the main body of the rail-mounted robot in this invention;

[0026] Figure 3 This is a schematic diagram of the lower part of the main body of the rail-mounted robot in this invention;

[0027] Figure 4 This is a schematic diagram of the structure for detecting the extendable arm in this invention:

[0028] Figure 5 This is a schematic diagram of the storage compartment telescopic arm in this invention:

[0029] Figure 6 This is a schematic diagram of the storage compartment in this invention:

[0030] Figure 7 This is a schematic diagram of the magnetic adsorption robot in this invention;

[0031] The reference numerals in the diagram are as follows: 1-track; 2-main body of the track-mounted robot; 3-detection extension arm; 4-storage bin telescopic arm; 5-storage bin; 6-magnetic adsorption robot; 7-bridge body; 201-clamping wheel; 202-drive wheel; 203-driven wheel; 204-active synchronous wheel; 205-second drive motor; 206-first drive motor; 207-reversing reducer; 208-drive shaft; 301-secondary extension arm; 302-primary extension arm; 303-detection camera module; 401-rotating base; 402-primary telescopic arm; 403-intermediate connecting plate; 404-secondary telescopic arm; 405-end flange; 501-storage bin main body; 502-charging contact; 503-connecting rod; 504-magnetic detachment device; 601-LiDAR; 602-detection device; 603-magnetic wheel; 604-fifth drive motor. Detailed Implementation

[0032] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to illustrate the technical solution of the present invention more clearly, and should not be used to limit the scope of protection of the present invention.

[0033] Example 1

[0034] like Figure 1 As shown, this invention discloses a composite robot for detecting apparent defects in complex bridge structures, comprising a track-mounted robot body 2 and a magnetic adsorption robot 6. The track-mounted robot body 2 is suspended on a track 1 installed on the bridge body 7. The track-mounted robot body 2 is equipped with a detection extension arm 3 and a storage compartment telescopic arm 4, with a storage compartment 5 installed at the end of the storage compartment telescopic arm 4. The track-mounted robot body 2, with one or more storage compartments 5, is an integrated robot base station used for storing, transporting, and deploying the magnetic adsorption robot 6, while also serving as a power supply or charging function and a data communication relay function. The storage compartment 5 is used to retrieve and store the magnetic adsorption robot 6 and to charge or provide power to the magnetic adsorption robot 6 via a cable. For small-angle spaces, where the magnetic adsorption robot 6 cannot turn or enter flexibly, the composite robot of this invention can deliver the magnetic adsorption robot 6 to the corresponding position in the small-angle area via the storage compartment telescopic arm 4. The detection extension arm 3 and the magnetic adsorption robot 6 work together to detect bridge defect information in real time. The magnetic adsorption robot 6 communicates with the track-mounted robot body 2 in real time, and its position information, detection information, etc., are transmitted back to the back-end management center in real time.

[0035] The main body 2 of the rail-mounted robot can deploy the magnetic adsorption robot 6 onto the bridge structure 7. For the upper area, the magnetic adsorption robot 6 can reach it in two ways: either it can climb up from the obtuse angle on the right, or it can be directly delivered to the upper position via the storage compartment telescopic arm 4. At other small angles or complex steel structure locations, the magnetic adsorption robot 6 can be directly delivered to the appropriate position via the storage compartment telescopic arm 4, and then autonomously move to other locations. In addition to carrying detection equipment, the magnetic adsorption robot 6 and the main body 2 of the rail-mounted robot can be extended to carry a small robotic arm for general bridge repairs.

[0036] like Figure 2 and Figure 3 As shown, the main body 2 of the track-mounted robot is equipped with a drive wheel 202 and a clamping wheel 201. The drive wheel 202 and the clamping wheel 201 are located on the upper and lower sides of the bottom steel plate of the track 1, respectively, and are tightly pressed against the track 1. The main body 2 of the track-mounted robot is equipped with a first drive motor 206. The output shaft of the first drive motor 206 drives the transmission shaft 208 to rotate through a reversing reducer 207. The two ends of the transmission shaft 208 are equipped with active synchronous pulleys 204. The outer side of the drive wheel 202 is connected to a driven wheel 203. The active synchronous pulley 204 drives the driven wheel 203 to rotate through a synchronous belt, thereby transmitting power to the drive wheel 202. Therefore, when the first drive motor 206 is powered, it can drive the main body 2 of the track-mounted robot to move along the track 1.

[0037] like Figure 4 As shown, the detection extension arm 3 of the rail-mounted robot has a multi-stage deployment structure. The detection extension arm 3 includes two primary extension arms 302. A second drive motor 205 is mounted on the main body 2 of the rail-mounted robot. The second drive motor 205 drives the two primary extension arms 302 to rotate synchronously via gear transmission. A secondary extension arm 301, driven to rotate by a third drive motor, is mounted on the outer side of the primary extension arms 302. Detection camera modules 303 are distributed on the primary and secondary extension arms 302 and 301. The detection camera module 303 is a high-definition camera, mounted on a gimbal, capable of multi-directional rotation to adapt to multi-directional detection work.

[0038] like Figure 5As shown, the storage bin telescopic arm 4 includes a rotating base 401, which is driven to rotate by a fourth drive motor mounted on the main body 2 of the rail-mounted robot. The rotating base 401 is connected to one end of the primary telescopic arm 402, and the other end of the primary telescopic arm 402 is connected to an intermediate connecting plate 403. The intermediate connecting plate 403 is connected to one end of the secondary telescopic arm 404, and the other end of the secondary telescopic arm 404 is connected to an end flange 405, which is used to mount the storage bin 5. The storage bin telescopic arm 4 can move the storage bin 5 within a spatial range. Under visual guidance, it can move the storage bin 5 closer to the deployment point of the magnetic adsorption robot 6 on each segment of the steel bridge, so that the magnetic adsorption robot 6 can travel from the storage bin 5 to the bridge structure to perform inspection work.

[0039] like Figure 6 As shown, the storage compartment 5 includes a main body 501 and a magnetic detachment device 504. The main body 501 has sufficient space for the storage and transportation of the magnetically adsorbed robot 6. The main body 501 is equipped with charging contacts 202 for charging the magnetically adsorbed robot 6, or the main body 501 can directly supply power to the magnetically adsorbed robot 6 via a cable. A servo-driven connecting rod 503 is mounted on the main body 501. The magnetic detachment device 504 is installed on the main body 501 via the connecting rod 503. After the magnetically adsorbed robot 6 returns to the storage compartment 5, the servo can drive the connecting rod 503 to flip the magnetic detachment device 504 upwards, so that the main body 501 is in a closed state, ensuring that the magnetically adsorbed robot 6 will not detach from or fall out of the storage compartment 5 during overall movement. The upper surface of the magnetic detachment device 504 is provided with a slope to facilitate the magnetic adsorption robot 6 entering the storage chamber body 501. When the magnetic adsorption robot 6 returns to the storage chamber 5, the slope guides the magnetic adsorption robot 6 to smoothly detach from the steel structure surface and enter the storage chamber 5.

[0040] like Figure 7 As shown, the magnetic adsorption robot 6 is equipped with a lidar 601 and a detection device 602, enabling it to autonomously navigate and plan paths to inspect bridge structures. The robot 6 has several magnetic wheels 603 at its lower part, allowing it to firmly adhere to the steel bridge structure. Each magnetic wheel 603 is individually driven by a separate fifth drive motor 604, ensuring that the front and rear wheels can adjust their speed accordingly when the robot traverses right-angle or large-angle steel structures, adapting to changes in the steel structure. The magnetic adsorption robot 6 can perform path planning and autonomous navigation based on the characteristics of the steel structure.

[0041] This invention utilizes a structure that integrates a track-mounted robot with a storage compartment and a retractable magnetic adsorption robot, laid along the entire bridge's side span. By combining the storage compartment's charging or cable-driven power supply with LiDAR, and adapting to both the bridge's side span track area and multi-segment climbing areas, the invention enables the precise deployment of the magnetic adsorption robot. The robot autonomously crawls through these areas, addressing the limitations of a single robot in certain regions. This allows the composite robot to cover both the bridge's side span track area and segmental climbing areas, autonomously performing cross-regional inspections and recharging, thus achieving efficient, safe, and comprehensive inspection of steel arch rib structure bridges.

[0042] Example 2

[0043] This embodiment, based on Embodiment 1, discloses a working method for a composite robot for detecting apparent defects in complex bridge structures, including the following steps:

[0044] Step 1: The main body 2 of the track-mounted robot moves forward along the track with all the equipment, and the detection extension arm 3 is controlled to be in the extended state. The camera carried on the detection extension arm 3 is driven by the gimbal to detect bridge defects in real time in all directions.

[0045] Step 2: Based on the preset delivery point and the visual recognition of the main body 2 of the rail-mounted robot, control the telescopic arm 4 of the storage compartment to extend and retract to the vicinity of the delivery point of the magnetic adsorption robot 6.

[0046] Step 3: After the storage compartment 5 extends and retracts to its final position, the magnetic adsorption robot 6 drives out of the storage compartment 5 and climbs onto the bridge steel structure.

[0047] Step four: The magnetic adsorption robot 6 moves according to a pre-set trajectory, performing path planning and autonomous navigation, and carries its own detection equipment for autonomous detection. The main body of the rail-mounted robot 2 and the magnetic adsorption robot 6 transmit the images of suspected defects back to the control center. The control center, based on the defect database neural network model, can autonomously identify the corresponding defects and, by integrating relevant algorithms, output the geometric dimensions of the defects (such as the area of ​​paint peeling, crack width and length, etc.).

[0048] Step 5: After the magnetic adsorption robot 6 completes the inspection of the bridge steel structure segment, it plans its return path based on its current location and the location of the storage bin 5, and returns to the vicinity of the storage bin 5 via the optimal path, and then enters the return storage bin 5.

[0049] Step six: Control the storage bin telescopic arm 4 to return to the initial position, and the rail-mounted robot body 2 carries the equipment to the next segment for inspection.

[0050] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A composite robot for detecting apparent defects of a complex bridge structure, characterized by: The system includes a rail-mounted robot body (2) and a magnetic adsorption robot (6). The rail-mounted robot body (2) is suspended on a track (1) installed on the bridge body (7). The rail-mounted robot body (2) is equipped with a detection extension arm (3) and a storage compartment telescopic arm (4). A storage compartment (5) is installed at the end of the storage compartment telescopic arm (4). The storage compartment (5) is used to retrieve and store the magnetic adsorption robot (6) and to charge or power the magnetic adsorption robot (6) via a cable. The detection extension arm (3) and the magnetic adsorption robot (6) work together to detect bridge defects in real time. The detection extension arm (3) has a multi-stage unfolding structure and includes two first-stage extension arms (302). The rail-mounted robot body (2) is equipped with a second drive motor (205). The second drive motor (205) drives the two first-stage extension arms (302) through gear transmission. The first-stage telescopic arm (302) rotates synchronously. A second-stage telescopic arm (301) driven to rotate by a third drive motor is provided on the outside of the first-stage telescopic arm (302). Detection camera modules (303) are distributed on the first-stage telescopic arm (302) and the second-stage telescopic arm (301). The storage compartment telescopic arm (4) includes a rotating base (401). The rotating base (401) is driven to rotate by a fourth drive motor provided on the main body (2) of the rail-mounted robot. The rotating base (401) is connected to one end of the first-stage telescopic arm (402). The other end of the first-stage telescopic arm (402) is connected to an intermediate connecting plate (403). The intermediate connecting plate (403) is connected to one end of the second-stage telescopic arm (404). The other end of the second-stage telescopic arm (404) is connected to an end flange (405). The end flange (405) is used to install the storage compartment (5). The working method of the composite robot for detecting apparent defects in complex bridge structures includes the following steps: The main body (2) of the track-mounted robot carries all the equipment forward along the track, and controls the detection extension arm (3) to be in the extended state. The detection extension arm (3) performs real-time detection of bridge defects in all directions. According to the preset delivery point and the visual recognition of the main body of the rail-mounted robot (2), the telescopic arm (4) of the storage bin is controlled to extend and retract to the vicinity of the delivery point of the magnetic adsorption robot (6); After the storage bin (5) extends and retracts into place, the magnetic adsorption robot (6) drives out of the storage bin (5) and climbs onto the bridge steel structure; The magnetic adsorption robot (6) walks according to a pre-set trajectory, performs path planning and autonomous navigation, and carries its own detection equipment for autonomous detection. After the magnetic adsorption robot (6) has completed the inspection of the current segment of the bridge steel structure, it plans the return route according to its current location and the location of the storage bin (5), and returns to the vicinity of the storage bin (5) via the optimal route and enters the return storage bin (5); Control the telescopic arm (4) of the storage bin to return to the initial position, and the main body (2) of the rail-mounted robot takes the equipment to the next segment for inspection.

2. The composite robot for apparent distress detection of complex bridge structures according to claim 1, characterized in that: The main body (2) of the rail-mounted robot is provided with a drive wheel (202) and a clamping wheel (201). The drive wheel (202) and the clamping wheel (201) are located on the upper and lower sides of the bottom steel plate of the track (1), respectively. The main body (2) of the rail-mounted robot is provided with a first drive motor (206). The output shaft of the first drive motor (206) drives the transmission shaft (208) to rotate through a reversing reducer (207). The two ends of the transmission shaft (208) are provided with active synchronous wheels (204). The outer side of the drive wheel (202) is connected to a driven wheel (203). The active synchronous wheel (204) drives the driven wheel (203) to rotate through a synchronous belt, and then transmits power to the drive wheel (202).

3. The composite robot for detecting apparent defects in complex bridge structures according to claim 1, characterized in that: The detection camera module (303) is a camera, and gimbals are provided on the first-level extension arm (302) and the second-level extension arm (301), and the camera is mounted on the gimbals.

4. The composite robot for detecting apparent defects in complex bridge structures according to claim 1, characterized in that: The storage compartment (5) includes a storage compartment body (501) and a magnetic detachment device (504). The storage compartment body (501) is provided with charging contacts (502) for charging the magnetic adsorption robot (6). The storage compartment body (501) is provided with a servo motor driven connecting rod (503). The magnetic detachment device (504) is installed on the storage compartment body (501) through the connecting rod (503). The servo motor can drive the connecting rod (503) to make the magnetic detachment device (504) flip upward so that the storage compartment body (501) is in a closed state. The upper surface of the magnetic detachment device (504) is provided with a slope to facilitate the magnetic adsorption robot (6) to enter the storage compartment body (501).

5. The composite robot for detecting apparent defects in complex bridge structures according to claim 1, characterized in that: The magnetic adsorption robot (6) is equipped with a laser radar (601) and a detection device (602). The lower part of the magnetic adsorption robot (6) is provided with several magnetic wheels (603), and the several magnetic wheels (603) are driven by independent fifth drive motors (604).

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