A capsule type inspection robot and an inspection method

Abstract

This invention relates to the field of inspection robot technology, specifically a capsule-type inspection robot and inspection method. It employs an openable outer shell structure combined with a sealed / semi-closed inner body design, resulting in a compact and small-sized inspection robot that can flexibly adapt to the inspection of small-diameter pipelines. Simultaneously, it effectively protects the internal electrical control and drive components from the harsh environment of the pipeline, such as moisture, oil, and dust, improving the components' anti-interference capabilities and service life. This solves the problem of traditional wheeled / tracked robots being too large and difficult to operate in small-diameter pipelines. Furthermore, a single-axis gimbal mechanical structure consisting of a servo motor, servo motor disk, and camera housing is installed on the inner body. One side of the camera housing is connected to the servo motor disk, and the other side is hinged to the first or second inner frame, allowing the camera housing to rotate flexibly. The included IMU module provides a stable mechanical transmission basis for attitude feedback compensation.

Description

Technical Field

[0001] This invention relates to the field of inspection robot technology, specifically a capsule-type inspection robot and inspection method. Background Technology

[0002] In urban infrastructure construction, industrial fluid transportation, and municipal utilities, pipeline systems serve as the core carrier, widely used in drainage, water supply, gas supply, chemical media transmission, and other industries. The safety and reliability of their operation directly affect the normal operation of cities, the continuous operation of production enterprises, and the safety of the public environment. With the acceleration of urbanization and the continuous expansion of industrial scale, the laying density, length, and service life of various pipelines are constantly increasing. During long-term operation, pipelines inevitably experience various problems such as aging, corrosion, deformation, cracks, and leakage. Some older pipelines may also suffer from serious problems such as misalignment and fractures caused by geological subsidence. If these problems are not detected and addressed in a timely manner, they can lead to media leakage and resource waste, or even serious safety accidents, environmental pollution, and significant economic losses and social impacts. Traditional pipeline inspection methods often rely on manual excavation, blind inspection, or simple portable instruments. This not only consumes a large amount of manpower, resources, and time, resulting in high construction costs and low efficiency, but also suffers from problems such as numerous blind spots, low detection accuracy, and non-standard data recording, making it difficult to meet the needs of efficient inspection of large-scale, long-distance, and complex pipelines.

[0003] While some pipeline inspection equipment has emerged in the current technology, most of the equipment still has shortcomings:

[0004] Firstly, the equipment lacks adaptability. Traditional inspection robots are mostly designed for pipelines of a single specification and material. When faced with pipelines of different diameters, materials (such as concrete, steel pipes, and PE pipes), different bending angles, and complex working conditions, their versatility is poor, they cannot flexibly adjust their operating posture, and it is difficult to operate stably in complex pipeline environments.

[0005] Secondly, the walking mechanism has limitations. Some equipment uses a single drive structure, which can easily slip or get stuck when encountering mud and sand accumulation, oil pollution, or wet and slippery surfaces inside the pipeline, leading to the interruption of inspection. In addition, the fit and grip of the inner wall of the pipeline are insufficient, making it impossible to guarantee stable straight-line driving and steering control.

[0006] Third, the detection and imaging functions are not perfect. The detection modules of existing equipment are mostly simple and cannot fully cover the identification needs of various types of defects such as pipeline corrosion, cracks, deformation, and blockage. At the same time, the imaging components lack a stable posture compensation mechanism. When there is insufficient light in the pipeline, slight shaking of the robot, or changes in posture, the acquired images are prone to blurring and distortion, resulting in the inability to clearly capture key defect details, which seriously affects the accuracy of subsequent defect judgment.

[0007] Fourth, there are shortcomings in communication and control technology. In the closed environment of the pipeline, some equipment is prone to signal transmission delays, packet loss or even interruption, making it impossible to achieve remote real-time control and data feedback. At the same time, there is a lack of effective safety protection mechanisms. When encountering sudden failures, sudden obstacles in the pipeline or emergencies, it is difficult to respond in time and perform safe shutdown operations, which can easily cause equipment damage or failure of inspection tasks.

[0008] Fifth, the installation and maintenance process is cumbersome. The assembly, debugging and subsequent maintenance of most inspection equipment are complicated and rely on professional personnel. This makes it difficult to deploy quickly and conduct on-site emergency inspections, and also makes it impossible to achieve efficient troubleshooting and equipment recovery.

[0009] These issues make it difficult to achieve efficient, accurate, and safe full-process control of pipeline inspection work, failing to meet the urgent needs of modern pipeline operation and maintenance management for intelligence, precision, and efficiency. Therefore, developing a pipeline inspection robot and its supporting inspection methods that are highly adaptable, stable in movement, comprehensive in detection, provide clear imaging, have reliable communication, and are easy to operate is of significant practical importance and application value for improving pipeline defect detection efficiency, reducing inspection costs, ensuring the safe operation of pipeline systems, and promoting the intelligent upgrading of urban infrastructure and industrial pipeline operation and maintenance technologies. Summary of the Invention

[0010] The purpose of this invention is to provide a capsule-type inspection robot and inspection method to address the problems mentioned above.

[0011] The technical solution adopted in this invention is as follows: a capsule-type inspection robot, comprising an outer shell and an inner body, wherein the inner body is disposed in the outer shell, and wherein the inner body is provided with a drive assembly, a power switch assembly, a support rail assembly and a control sensing assembly;

[0012] The power switch assembly is used to provide power for the power management, switch control and other components of the inspection robot;

[0013] The support rail assembly is used to provide structural support for the inspection robot;

[0014] The drive component is mounted on the support rail assembly and is used to realize the differential speed movement, steering control and traction adjustment of the inspection robot, and drive the outer shell to roll.

[0015] The control and perception component is used to realize the intelligent control, posture perception and imaging acquisition of the inspection robot;

[0016] The outer shell can be opened and closed.

[0017] Furthermore, the outer casing includes a first rolling housing and a second rolling housing, both of which have rolling surfaces and can roll under the inner casing, with the first rolling housing able to fit against the second rolling housing.

[0018] Furthermore, the supporting guide rail assembly includes a first inner frame, a second inner frame, a housing support, and guide rail components;

[0019] The first inner frame and the second inner frame are detachably connected, and the first inner frame and the second inner frame form a cavity that can accommodate the outer shell support and guide rail components;

[0020] The outer shell support is located inside the cavity and is detachably connected to the first inner frame and the second inner frame.

[0021] The guide rail component is mounted on the housing bracket.

[0022] Furthermore, the guide rail component includes guide rail units, and the inspection robot includes at least one guide rail unit.

[0023] Furthermore, the guide rail unit includes an electric push rod, a first guide rail, a second guide rail, a connecting block, and a movable motor bracket;

[0024] The electric push rod can be housed inside the housing support, and the power output end of the electric push rod is connected to the connecting block;

[0025] The first and second guide rails are mounted on the housing support and located on both sides of the power output end of the electric push rod;

[0026] The connecting block is connected to the movable motor bracket and can move between the first guide rail and the second guide rail;

[0027] The movable motor bracket can hold the drive components.

[0028] Furthermore, the drive assembly includes a first DC geared motor, a second DC geared motor, a first coupling, and a second coupling;

[0029] The power output end of the first DC geared motor is connected to the first coupling, and is connected to the center of the first rolling housing through the first coupling;

[0030] The power output end of the second DC geared motor is connected to the second coupling, and is connected to the center of the second rolling housing through the second coupling. The power output end of the second DC geared motor is arranged back to back with the power output end of the first DC geared motor.

[0031] Furthermore, the guide rail component also includes a fixed motor bracket, which is mounted on the housing bracket;

[0032] The first DC geared motor is mounted on the housing support;

[0033] The second DC geared motor is mounted on a fixed motor bracket.

[0034] Furthermore, the control and sensing components include a control board, a camera housing, a servo motor, a servo motor disk, a relay module, and an IMU module;

[0035] The camera housing is mounted on the first inner frame or the second inner frame, and a camera is mounted inside the camera housing. The camera can collect images and video data inside the pipe after the first rolling housing and the second rolling housing are separated.

[0036] The relay module is located inside the cavity and serves as the gate control device for the inspection robot.

[0037] The IMU module is located inside the cavity and can collect the posture, acceleration and gyroscope data of the inspection robot;

[0038] The control board is located inside the cavity and can receive the posture, acceleration and gyroscope data of the inspection robot, and control the rotation of the servo motor;

[0039] The servo motor is located inside the cavity and is connected to the camera housing via a servo motor disk;

[0040] The servo disk is mounted on the first inner frame or the second inner frame and is connected to the camera housing.

[0041] Furthermore, the power switch assembly includes a power switch, a switching switch, a battery, a power board, and an aviation socket;

[0042] The power board is located inside the cavity and is used for power mode and power management.

[0043] The power switch is located on the first inner frame or the second inner frame and is used to control the power on and off of the inspection robot.

[0044] The switching switch is located on the first inner frame or the second inner frame and is used to switch the power mode of the inspection robot. The power mode includes charging mode and working mode.

[0045] The aviation socket is located on the first internal rack or the second internal rack and is used for charging the battery;

[0046] The battery is used to power the drive components and control sensing components, and the battery is located inside the housing support.

[0047] This application also provides a cable reel inspection method, which is based on the above-mentioned capsule-type inspection robot and includes the following steps:

[0048] S1. Initialize the inspection robot. After the inspection robot is powered on, it is in a safe state, preparing for inspection.

[0049] S2. Security authorization and access control activation: Activate the inspection robot via wireless authorization;

[0050] S3. Inspection execution and motion control: The first and second rolling housings are adjusted to adapt to the pipe diameter by adjusting the support guide rail assembly; the control sensing component collects image or video data inside the pipe diameter.

[0051] S4. End and maintenance: Close the access control wirelessly. After the component is powered off, switch the power mode or disassemble for maintenance.

[0052] The beneficial effects of the present invention include at least one of the following;

[0053] 1. A capsule-type inspection robot is provided, which adopts an overall structure with an openable and closable outer shell and a sealed / semi-closed internal body design, making the inspection robot compact and small in size. It can flexibly adapt to the inspection of small-diameter pipelines, while effectively protecting the internal electrical control and drive components from the corrosion of harsh environments such as moisture, oil, and dust in the pipeline, improving the anti-interference ability and service life of the components, and solving the problem that traditional wheeled / tracked robots are too large and difficult to operate in small-diameter pipelines.

[0054] 2. A telescopic support / clamping mechanical structure composed of an electric push rod, a guide rail, and a movable motor bracket is designed. The electric push rod pushes the movable motor bracket to slide along the guide rail, which can flexibly adjust the relative position of the rolling shell and the inner wall of the pipe, and achieve precise control of the pipe wall contact pressure. This not only adapts to the inspection needs of pipes with different diameters, improving the robot's versatility, but also effectively increases traction friction, significantly reducing the probability of the robot slipping or getting stuck in wet, slippery, or muddy conditions, thus improving its travel stability.

[0055] 3. A dual-support differential drive structure layout with a fixed motor support and a movable motor support is adopted. The first rolling shell and the second rolling shell are driven by independent DC geared motors through couplings, forming independent left and right differential drive mechanisms. This not only makes the robot's turning movements more flexible and can adapt to the complex working conditions of pipe bends, but also provides a stable structural foundation for wheel speed detection and hardware support for straight-line driving consistency correction, thus ensuring the realization of straight-line anti-deviation from a structural perspective.

[0056] 4. The power connection structure with two rolling housings and a coupling allows the power of the DC geared motor to be smoothly transmitted to the rolling housings, reducing mechanical losses during power transmission. At the same time, the flexible connection characteristics of the coupling can buffer the slight collisions between the robot and the inner wall of the pipe during the robot's movement, reducing the wear of mechanical parts and improving the durability of the drive structure.

[0057] 5. A single-axis gimbal mechanical structure consisting of a servo motor, a servo motor disk, and a camera housing is installed on the inner body. One side of the camera housing is connected to the servo motor disk, and the other side is hinged to the first or second inner frame, allowing the camera housing to rotate flexibly. At the same time, the IMU module provides a stable mechanical transmission basis for attitude feedback compensation.

[0058] 6. The device adopts a split outer shell combined with a modular internal structure. Core components such as batteries, electric actuators, and motors are centrally supported by two metal internal frames. IMU modules, relays, gimbal servos, and other devices are centrally fixed in one internal frame, while the main control board, power supply board, and other electronic control components are centrally located in the other internal frame. Each component is independently fixed in its respective area without interfering with each other. This modular layout of mechanical and electronic control components greatly simplifies on-site assembly, debugging, and subsequent maintenance. Damaged components can be disassembled and replaced individually, improving the ease of maintenance and scalability of the equipment. Attached Figure Description

[0059] Figure 1 A schematic diagram of a capsule-type inspection robot;

[0060] Figure 2 A schematic diagram of a capsule-type inspection robot when it is opened;

[0061] Figure 3 A schematic diagram of a capsule-type inspection robot when it is opened, from another perspective;

[0062] Figure 4 A schematic diagram of the exploded structure of a capsule-type inspection robot;

[0063] Figure 5 This is a schematic diagram of the internal structure;

[0064] Figure 6 This is a schematic diagram of the organism's structure from another perspective;

[0065] Figure 7 This is a schematic diagram of the internal structure of the internal unit;

[0066] Figure 8 This is a flowchart of an inspection method.

[0067] In the picture:

[0068] 1 is the inner unit, 101 is the first inner frame, 102 is the second inner frame, 2 is the power switch, 301 is the control board, 302 is the power board, 4 is the switch, 501 is the first slider, 502 is the second slider, 503 is the third slider, 504 is the fourth slider, 601 is the first motor drive module, 602 is the second motor drive module, 7 is the miniature bearing, 8 is the movable motor bracket, 9 is the outer shell, 901 is the first rolling shell, 902 is the second rolling shell, 1001 is the first coupling, 1002 is the second coupling, 1101 is the first DC geared motor, 1102 is the second DC geared motor, 12 is the IMU. Module 1301 is the first guide rail, 1302 is the second guide rail, 1401 is the first DC fan, 1402 is the second DC fan, 15 is the power display module, 16 is the camera, 17 is the connecting block, 18 is the housing bracket, 19 is the battery, 20 is the electric push rod, 21 is the relay module, 22 is the fixed motor bracket, 23 is the aviation socket, 24 is the servo motor, 25 is the remote control image transmission receiver, 26 is the servo motor disk, and 27 is the camera housing. Detailed Implementation

[0069] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0070] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0071] It should be noted that, unless otherwise specified, the embodiments and features described in this invention can be combined with each other.

[0072] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0073] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. In addition, the terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0074] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0075] like Figures 1 to 3 As shown, a capsule-type inspection robot includes an outer shell 9 and an inner body 1. The inner body 1 is disposed in the outer shell 9, and the inner body 1 is provided with a drive assembly, a power switch assembly, a support rail assembly and a control sensing assembly.

[0076] The power switch assembly is used to provide power for the power management, switch control and other components of the inspection robot;

[0077] The support rail assembly is used to provide structural support for the inspection robot;

[0078] The drive component is mounted on the support rail assembly and is used to realize the differential speed movement, steering control and traction adjustment of the inspection robot, and drive the outer shell 9 to roll.

[0079] The control and perception component is used to realize the intelligent control, posture perception and imaging acquisition of the inspection robot;

[0080] The outer shell 9 can be opened and closed.

[0081] The purpose of this design is to use an openable outer shell structure combined with a sealed / semi-closed internal body design, making the inspection robot compact and small in size. This allows it to flexibly adapt to the inspection of small-diameter pipes, while effectively protecting the internal electrical control and drive components from the harsh environment of the pipes, such as moisture, oil, and dust. This improves the components' anti-interference ability and service life, solving the problem that traditional wheeled / tracked robots are too large and difficult to operate in small-diameter pipes.

[0082] At the same time, such as Figures 4 to 7 As shown, this embodiment provides a specific structure of an outer shell, wherein the outer shell 9 includes a first rolling shell 901 and a second rolling shell 902, and both the first rolling shell 901 and the second rolling shell 902 have rolling surfaces and can roll under the inner body 1, and the first rolling shell 901 can fit into the second rolling shell 902.

[0083] It should be noted that, in order to adapt to its working environment inside the pipeline, the first and second rolling shells can be designed as capsule-like structures, consisting of a cylindrical section and a semi-circular section. They can be opened and closed under the control of internal power components, and can also rotate and roll inside the pipeline.

[0084] In this embodiment, the support rail assembly includes a first inner frame 101, a second inner frame 102, an outer shell support 18, and a rail component;

[0085] The first inner frame 101 and the second inner frame 102 are detachably connected, and the first inner frame 101 and the second inner frame 102 form a cavity that can accommodate the outer shell support 18 and the guide rail components.

[0086] The outer shell support 18 is disposed in the cavity and is detachably connected to the first inner frame 101 and the second inner frame 102.

[0087] The guide rail component is mounted on the housing bracket 18.

[0088] Furthermore, in this embodiment, the specific structure of the guide rail component and the guide rail unit is provided. The guide rail component includes the guide rail unit, and the inspection robot includes at least one guide rail unit. The guide rail unit includes an electric push rod 20, a first guide rail 1301, a second guide rail 1302, a connecting block 17, and a movable motor bracket 8.

[0089] The electric push rod 20 can be housed inside the housing support 18, and the power output end of the electric push rod 20 is connected to the connecting block 17.

[0090] The first guide rail 1301 and the second guide rail 1302 are mounted on the housing support 18 and located on both sides of the power output end of the electric push rod 20.

[0091] The connecting block 17 is connected to the movable motor bracket 8 and can move between the first guide rail 1301 and the second guide rail 1302;

[0092] The movable motor bracket 8 can hold the drive assembly.

[0093] The purpose of this design is to create a retractable support / clamping mechanical structure composed of an electric push rod, a guide rail, and a movable motor bracket. By pushing the movable motor bracket along the guide rail with the electric push rod, the relative position of the rolling housing and the inner wall of the pipe can be flexibly adjusted, achieving precise control of the pipe wall contact pressure. This not only adapts to the inspection needs of pipes with different diameters, improving the robot's versatility, but also effectively increases traction friction, significantly reducing the probability of the robot slipping or getting stuck in wet, slippery, or muddy conditions, thus improving its movement stability.

[0094] It should also be noted that, in actual use, in order to enable the movable motor bracket 8 to move better on the first guide rail 1301 and the second guide rail 1302, four sliders are respectively provided on the first guide rail 1301 and the second guide rail 1302, namely the first slider 501, the second slider 502, the third slider 503 and the fourth slider 504. These four sliders are symmetrically arranged on the two guide rails and connected to the bottom of the movable motor bracket 8, so that it can move smoothly along the extension direction of the guide rail.

[0095] Meanwhile, in this embodiment, the drive assembly includes a first DC geared motor 1101, a second DC geared motor 1102, a first coupling 1001, and a second coupling 1002;

[0096] The power output end of the first DC geared motor 1101 is connected to the first coupling 1001, and is connected to the center of the first rolling housing 901 through the first coupling 1001;

[0097] The power output end of the second DC geared motor 1102 is connected to the second coupling 1002 and is connected to the center of the second rolling housing 901 through the second coupling 1002. The power output end of the second DC geared motor 1102 is arranged back to back with the power output end of the first DC geared motor 1101.

[0098] The purpose of this design is to adopt a dual-support differential drive structure layout with a fixed motor support and a movable motor support. The first rolling shell and the second rolling shell are driven by independent DC geared motors through couplings, forming independent left and right differential drive mechanisms. This not only makes the robot's turning movements more flexible and adaptable to the complex working conditions of pipe bends, but also provides a stable structural foundation for wheel speed detection and hardware support for straight-line driving consistency correction, thus structurally ensuring the realization of straight-line anti-deviation.

[0099] Meanwhile, the power connection structure of the two rolling housings with the coupling allows the power of the DC geared motor to be smoothly transmitted to the rolling housings, reducing mechanical losses during power transmission. At the same time, the flexible connection characteristics of the coupling can buffer the slight collisions between the robot and the inner wall of the pipe during the robot's movement, reduce the wear of mechanical parts, and improve the durability of the drive structure.

[0100] In this embodiment, a specific structure of a control sensing component is provided, wherein the control sensing component includes a control board 301, a camera housing 27, a servo motor 24, a servo motor disk 26, a relay module 21, and an IMU module 12;

[0101] The camera housing 27 is mounted on the first inner frame 101 or the second inner frame 102. The camera housing 27 contains a camera 16, and the camera 16 can collect images and video data inside the pipe after the first rolling housing 901 and the second rolling housing 902 are separated.

[0102] The relay module 21 is located inside the cavity and serves as a door control device for the inspection robot.

[0103] The IMU module 12 is located inside the cavity and can collect the posture, acceleration and gyroscope data of the inspection robot;

[0104] The control board 301 is located inside the cavity and can receive the posture, acceleration and gyroscope data of the inspection robot, and control the servo motor 24 to rotate.

[0105] The servo motor 24 is located inside the cavity and is connected to the camera housing 27 via the servo motor disk 26;

[0106] The servo disk 26 is mounted on the first inner frame 101 or the second inner frame 102 and is connected to the camera housing 27.

[0107] The purpose of this design is to install a single-axis gimbal mechanical structure consisting of a servo motor, a servo motor disk, and a camera housing on the inner body. One side of the camera housing is connected to the servo motor disk, and the other side is hinged to the first or second inner frame, allowing the camera housing to rotate flexibly. At the same time, the IMU module provides a stable mechanical transmission basis for attitude feedback compensation.

[0108] It should be noted that, in order to improve the sensitivity of the camera housing 27 in rotating on the first inner frame 101 or the second inner frame 102 during use, a miniature bearing 7 is used to connect it to the inner frame.

[0109] It should also be noted that the control sensing component may also include a first motor drive module 601 and a second motor drive module 602, and the first motor drive module 601 controls the first DC geared motor 1101, and the second motor drive module 602 controls the second DC geared motor 1102.

[0110] It should also be noted that the control board 301 uses the ESP32-S3 as the core controller, and is connected to:

[0111] First motor drive module 601 and second motor drive module 602: drive two motors through PWM and direction control signals to achieve differential speed movement;

[0112] Encoder: Reads the left and right wheel speeds or increments via a pulse counting / speed measurement interface for straight-line consistency correction;

[0113] Remote input: Receives SBUS remote control signals via UART and parses channel values, using them as inputs for throttle, steering, and actuator control;

[0114] Attitude sensor: Reads IMU acceleration / gyroscope data via I2C to calculate attitude information such as pitch angle;

[0115] Servo motor: The gimbal angle is controlled by the servo motor's PWM output to achieve adjustment and stabilization of the imaging view.

[0116] Linear actuator drive: The extension / retraction of the electric actuator is controlled by two lines;

[0117] Access control: By receiving authorization commands via BLE and controlling the access control device (relay module 21), a hardware / system-level security mechanism is formed, which is "power-on default shutdown - authorized operation - shutdown at any time".

[0118] In this embodiment, the power switch assembly includes a power switch 2, a switching switch 4, a battery 19, a power board 302, and an aviation socket 23;

[0119] The power board 302 is located inside the cavity and is used for power mode and power management.

[0120] The power switch 2 is located on the first inner frame 101 or the second inner frame 102 and is used to control the power on and off of the inspection robot.

[0121] The switching switch 4 is located on the first inner frame 101 or the second inner frame 102 and is used to switch the power mode of the inspection robot. The power mode includes charging mode and working mode.

[0122] The aviation socket 23 is located on the first inner frame 101 or the second inner frame 102 and is used to charge the battery 19.

[0123] The battery 19 is used to power the drive assembly and the control sensing assembly, and the battery 19 is located inside the housing support 18.

[0124] The purpose of this design is to adopt a split outer shell combined with a modular internal structure. The core components such as batteries, electric actuators, and motors are centrally supported by two metal internal frames. The IMU module, relays, gimbal servos, and other devices are centrally fixed in one internal frame, while the main control board, power board, and other electronic control components are centrally arranged in the other internal frame. Each component is independently fixed in its own area and does not interfere with each other. This achieves a modular layout of mechanical components and electronic control components, which greatly simplifies the on-site assembly, debugging, and subsequent maintenance procedures. Damaged components can be disassembled and replaced individually, improving the equipment's maintenance convenience and scalability.

[0125] It should also be noted that, in order to enable the entire inspection robot to cope with complex environments, a first DC fan 1401 and a second DC fan 1402 are installed on the inner body 1. The two DC fans are used to cool the working components in the inner body, and the battery 19 is used to power the DC fans.

[0126] like Figure 8 As shown, this embodiment also provides an inspection method, which is based on the capsule-type inspection robot in the above embodiment, and includes the following steps:

[0127] S1. Initialize the inspection robot. After the inspection robot is powered on, it is in a safe state, preparing for inspection.

[0128] S2. Security authorization and access control activation: Activate the inspection robot via wireless authorization;

[0129] S3. Inspection execution and motion control: The first rolling housing 901 and the second rolling housing 902 are adjusted to adapt to the pipe diameter by adjusting the support guide rail assembly; the control sensing component collects image or video data inside the pipe diameter.

[0130] S4. End and maintenance: Close the access control wirelessly. After the component is powered off, switch the power mode or disassemble for maintenance.

[0131] In practical use, first switch 4 to the working mode and press the power switch 2. At this time, the control board 301 will automatically start the system gate control. Only the control board 301 is started in the whole system, and all other motors and devices are in a power-off state.

[0132] At this time, after connecting to the main control BLE via an external remote controller and switching the gate control state, the entire system starts up. The remote control image transmission receiver 25 automatically powers on and connects to the remote controller. The motor and electric push rod are powered on and enter the braking state. The camera 16 transmits images to the remote controller via the remote control image transmission receiver 25.

[0133] The extension and retraction of the electric push rod can be controlled via an external remote control, as can the rotation of the two rolling housings, enabling the robot to move forward, backward, turn left, and turn right. During robot movement, the servo motor 24 is controlled based on real-time data from the IMU module 12, ensuring that the camera 16 driven by the servo motor 24 always faces forward. When the inspection robot is not in use, switching the gate control state via the external remote control shuts down the motors, receiver, and other components, automatically putting the control board into a low-power state. To completely shut it down, the power switch 2 can be used. For charging, use a dedicated charger connected to the aviation plug 23, turn off the power switch, and switch 4 to charging mode.

[0134] In this embodiment, a specific control method for implementing the above method is also provided. First, the control method is implemented based on a control system, which is organized into five layers: "safety-input-decision-execution-feedback" to ensure consistency between engineering implementation and patent description. The main functions of each layer are shown in the table below:

[0135] hierarchy name Main functions L1 Security layer It is responsible for detecting and locking faults such as emergency stop, undervoltage, stall, and communication timeout, and performing safe shutdown under abnormal conditions. L2 Input layer It collects signals such as remote control / access authorization, IMU, encoder, push rod feedback, system voltage, and communication status. L3 decision-making level The access control state machine and the running state machine are executed to generate differential speed commands, gimbal target angle commands, and push rod action commands. L4 Execution layer The decision layer output is mapped to left and right motor PWM, direction position, servo pulse width and push stick control signals. L5 Feedback layer Speed ​​consistency correction and attitude compensation are performed using encoder and IMU feedback to improve straight-line stability.

[0136] Meanwhile, a "two-layer state machine" structure is adopted, with the access control state machine used to manage the system's enable boundaries and the running state machine used to manage the execution of authorized actions and fault exit.

[0137] The states are defined in the following table:

[0138] Status number Status Name Entry conditions Main actions / exit conditions G0 Power-on initialization Main controller power-on reset Perform GPIO safety initialization; after completion, switch to G1. G1 Peripheral self-test G0 Complete Detects IMU, encoder, communication and power supply; via G2, not via Gf. G2 Access control authentication G1 Re-enter after passing or clearing the fault Verify authorization signal, key handshake, and emergency stop release; otherwise, switch to G3 and wait. G3 Authorized standby G2 passed The actuator is powered on but the motion output is zero; upon receiving a start command, it switches to R1. R1 Operation control G3 received the startup command The cycle executes sampling-estimation-control-output; a stop command returns to G3; a fault transfers to Gf. Gf Fault Lockout Arbitrary state fault triggering Perform a safe shutdown and lock the system; after manual troubleshooting, return to G2 for re-authentication.

[0139] In practical implementation, the control parts for the first and second rolling housings are described using left and right drive wheels for ease of description. The differential turning control algorithm and calculation process are as follows. First, the relevant symbols are defined as shown in the table below:

[0140] symbol Physical meaning Unit / Explanation r Drive wheel radius m B Center distance between left and right drive wheels (wheelbase) m v Robot longitudinal linear velocity (body coordinate system) m / s <![CDATA[ω z ]]> robot yaw rate rad / s <![CDATA[ω L 、oh R ]]> Target angular velocities of left and right wheels rad / s <![CDATA[n L 、n R ]]> Target speeds of left and right wheels rpm eenc Left and right wheel speed consistency error rad / s or rpm

[0141] In the distribution of the robot's body speed to the angular velocities of the left and right wheels, let the robot's longitudinal linear velocity be v, and the robot's yaw angular velocity be ω. z Then the linear velocities of the left and right wheels satisfy:

[0142] ;

[0143] ;

[0144] Converting the linear velocity to angular velocity from the radius r of the driving wheel, we get:

[0145] ;

[0146] ;

[0147] If the speed value used for driver calibration is required, it can be further converted to:

[0148] ;

[0149] ;

[0150] When ω z When the value is not zero, the inspection robot performs a turning motion. With respect to the geometric center of the vehicle body, the instantaneous turning radius ρ satisfies:

[0151] ;

[0152] Therefore, at the same linear velocity, increasing |ω z | will reduce the turning radius; increasing v will increase the turning radius at the same yaw rate.

[0153] Regarding the camera control section, this embodiment employs a single-axis gimbal through attitude estimation, target angle generation, speed limiting smoothing, and PWM mapping calculation processes to stabilize the camera's line of sight and suppress vehicle pitch disturbances. The relevant symbols are defined as follows:

[0154] symbol Physical meaning Unit / Explanation <![CDATA[a x 、a y 、a z ]]> IMU module triaxial acceleration m / s² <![CDATA[ω y ]]> IMU module pitch axis angular velocity rad / s <![CDATA[b g ]]> Gyroscope zero bias estimate rad / s <![CDATA[T s ]]> Control cycle s <![CDATA[θ acc ]]> Acceleration tilt angle estimate rad <![CDATA[θ est ]]> Fusion pitch angle estimate rad <![CDATA[θ cmd ]]> Gimbal target angle rad <![CDATA[θ out ]]> Actual angle of gimbal release rad <![CDATA[τ pwm ]]> Servo PWM pulse width μs

[0155] First, estimate the pitch angle by calculating the static pitch angle based on the acceleration vector:

[0156] ;

[0157] Then, perform discrete integral prediction based on the gyroscope angular velocity:

[0158] ;

[0159] Complementary filtering is used to fuse the acceleration tilt angle and gyro integral results:

[0160] ;

[0161] The coefficient α is usually taken as 0.90 to 0.98, which is used to balance dynamic response and anti-drift capability.

[0162] Then, the gimbal target angle is generated, which is obtained by superimposing the mechanical midpoint angle, the body attitude compensation term, and the optional velocity feedforward term:

[0163] ;

[0164] Where θ0 is the median angle, K c K is the attitude compensation coefficient. d K is the damping coefficient.f is the feedforward coefficient, and sat(·) is the mechanical angle limiting function.

[0165] Since only basic stability is required, it can be simplified to:

[0166] ;

[0167] Next, speed limiting smoothing and jitter suppression are performed. To reduce servo micro-jitter and rapid reverse impact, an angular velocity limit is added to the gimbal angle command. Let the maximum allowable angular velocity of the servo be Ωmax, then:

[0168] ;

[0169] ;

[0170] Finally, the mapping from the gimbal angle to the servo PWM is performed, and the servo mechanical angle range [θ] is calculated. min , θ max Corresponding pulse width range [τ] min , τ max A linear mapping can be used:

[0171] ;

[0172] It can also be written in the form of midpoint angle calibration:

[0173] ;

[0174] Both of the above expressions can be directly matched with actual servo drive parameters (e.g., 500 to 2500 μs).

[0175] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A capsule-type inspection robot, comprising an outer shell (9) and an inner body (1), wherein the inner body (1) is disposed within the outer shell (9), characterized in that, The inner body (1) is provided with a drive assembly, a power switch assembly, a support rail assembly and a control sensing assembly; The power switch assembly is used to provide power for the power management, switch control and other components of the inspection robot; The support rail assembly is used to provide structural support for the inspection robot; The drive assembly is mounted on the support rail assembly to realize the differential travel, steering control and traction adjustment of the inspection robot, and to drive the outer shell (9) to roll. The control and perception component is used to realize the intelligent control, posture perception and imaging acquisition of the inspection robot; The outer shell (9) can be opened and closed.

2. The capsule-type inspection robot according to claim 1, characterized in that, The outer shell (9) includes a first rolling shell (901) and a second rolling shell (902), and both the first rolling shell (901) and the second rolling shell (902) have rolling surfaces and can roll under the inner body (1). The first rolling shell (901) can fit into the second rolling shell (902).

3. The capsule-type inspection robot according to claim 2, characterized in that, The support rail assembly includes a first inner frame (101), a second inner frame (102), an outer shell support (18), and rail components; The first inner frame (101) and the second inner frame (102) are detachably connected, and the first inner frame (101) and the second inner frame (102) form a cavity that can accommodate the outer shell support (18) and the guide rail components; The outer shell support (18) is located inside the cavity and is detachably connected to the first inner frame (101) and the second inner frame (102); The guide rail component is mounted on the housing bracket (18).

4. The capsule-type inspection robot according to claim 3, characterized in that, The guide rail component includes guide rail units, and the inspection robot includes at least one guide rail unit.

5. A capsule-type inspection robot according to claim 4, characterized in that, The guide rail unit includes an electric push rod (20), a first guide rail (1301), a second guide rail (1302), a connecting block (17), and a movable motor bracket (8). The electric push rod (20) can be installed inside the outer casing bracket (18), and the power output end of the electric push rod (20) is connected to the connecting block (17); The first guide rail (1301) and the second guide rail (1302) are mounted on the housing support (18) and located on both sides of the power output end of the electric push rod (20); The connecting block (17) is connected to the movable motor bracket (8) and can move between the first guide rail (1301) and the second guide rail (1302); The drive assembly can be placed on the movable motor bracket (8).

6. A capsule-type inspection robot according to claim 5, characterized in that, The drive assembly includes a first DC geared motor (1101), a second DC geared motor (1102), a first coupling (1001), and a second coupling (1002). The power output end of the first DC geared motor (1101) is connected to the first coupling (1001) and is connected to the center of the first rolling housing (901) through the first coupling (1001); The power output end of the second DC geared motor (1102) is connected to the second coupling (1002) and is connected to the center of the second rolling housing (901) through the second coupling (1002). The power output end of the second DC geared motor (1102) is set back to back with the power output end of the first DC geared motor (1101).

7. A capsule-type inspection robot according to claim 6, characterized in that, The guide rail component also includes a fixed motor bracket (22), which is mounted on the outer casing bracket (18); The first DC geared motor (1101) is mounted on the housing bracket (18); The second DC geared motor (1102) is mounted on the fixed motor bracket (22).

8. A capsule-type inspection robot according to claim 3, characterized in that, The control and sensing components include a control board (301), a camera housing (27), a servo motor (24), a servo motor disk (26), a relay module (21), and an IMU module (12). The camera housing (27) is mounted on the first inner frame (101) or the second inner frame (102). The camera housing (27) contains a camera (16), and the camera (16) can collect images and video data inside the pipe after the first rolling housing (901) and the second rolling housing (902) are separated. The relay module (21) is located inside the cavity and serves as the gate control device for the inspection robot; The IMU module (12) is located inside the cavity and can collect the posture, acceleration and gyroscope data of the inspection robot; The control board (301) is located inside the cavity and can receive the posture, acceleration and gyroscope data of the inspection robot and control the servo motor (24) to rotate. The servo motor (24) is located inside the cavity and is connected to the camera housing (27) via the servo motor disk (26); The servo disk (26) is mounted on the first inner frame (101) or the second inner frame (102) and is connected to the camera housing (27).

9. A capsule-type inspection robot according to claim 8, characterized in that, The power switch assembly includes a power switch (2), a switching switch (4), a battery (19), a power board (302), and an aviation socket (23). The power board (302) is located inside the cavity and is used for power mode and power management; The power switch (2) is located on the first inner frame (101) or the second inner frame (102) and is used to control the power on and off of the inspection robot. The switching switch (4) is located on the first inner frame (101) or the second inner frame (102) and is used to switch the power mode of the inspection robot. The power mode includes charging mode and working mode. The aviation socket (23) is located on the first inner rack (101) or the second inner rack (102) and is used to charge the battery (19); The battery (19) is used to power the drive assembly and the control sensing assembly, and the battery (19) is located inside the housing support (18).

10. An inspection method, implemented based on a capsule-type inspection robot according to any one of claims 2 to 9, characterized in that, Includes the following steps: S1. Initialize the inspection robot. After the inspection robot is powered on, it is in a safe state, preparing for inspection. S2. Security authorization and access control activation: Activate the inspection robot via wireless authorization; S3. Inspection execution and motion control: by adjusting the support guide rail assembly, the first rolling housing (901) and the second rolling housing (902) are changed to adapt to the pipe diameter, and the control sensing component collects image or video data inside the pipe diameter; S4. End and maintenance: Close the access control wirelessly. After the component is powered off, switch the power mode or disassemble for maintenance.

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