Robotic system for detecting hydrogen leaks and method of detecting hydrogen leaks

Abstract

The application relates to a robot system for detecting hydrogen leakage and a detection method of hydrogen leakage, and the system comprises a moving module, a navigation module, a detection module and a control module. The moving module is used for controlling the robot to be adsorbed on the surface of a to-be-detected generator and to move on the surface of the to-be-detected generator in all directions. The navigation module is used for collecting the position coordinates of the robot, constructing a three-dimensional point cloud map according to the environment of the to-be-detected generator and navigating to the to-be-detected generator according to the three-dimensional point cloud map and a preset inspection path. The detection module is used for collecting hydrogen concentration data of the to-be-detected generator and temperature and humidity data of the environment. The control module is used for positioning the hydrogen leakage position of the to-be-detected generator according to the hydrogen concentration data, the temperature and humidity data of the environment and the position coordinates of the robot. Thus, the problems of low detection efficiency, existing detection blind area, high safety risk and inaccurate positioning of manual detection of hydrogen leakage of a large hydrogen-cooled generator are solved, and full-scene coverage detection of the surface of the generator and rapid positioning of the leakage point are realized.

Description

Technical Field

[0001] This application relates to the field of intelligent testing and robotics technology for power equipment, and in particular to a robotic system and method for detecting hydrogen leaks. Background Technology

[0002] Large hydrogen-cooled generators are core equipment in power systems. They are filled with high-pressure hydrogen as a cooling medium. Hydrogen leaks not only reduce cooling efficiency but can also cause serious safety accidents such as fires and explosions. Currently, hydrogen leak detection in generators mainly relies on periodic manual inspections using handheld leak detectors, which has significant limitations: First, it is inefficient. Large generators have large surface areas and complex structures, making manual inspections extremely labor-intensive and difficult to achieve continuous monitoring around the clock. Second, there are many blind spots. Hidden areas and confined spaces such as the top and bottom of the generator, the gaps between the lead bars, and behind the excitation and steam end bearings are difficult to reach, and working at heights also poses safety risks to personnel. Third, the detection accuracy depends on human experience, making it prone to missed or false detections, and the extent of the leak cannot be quantified. Fourth, the response is slow; manual inspections are time-consuming and difficult to quickly detect sudden leaks.

[0003] While some gas detection robots in existing technologies can replace manual labor in completing certain inspection tasks, they still suffer from systemic defects: most robots lack sufficient mobility to adapt to the complex curved surfaces of generators and various working postures such as vertical and inverted positions; their sensor layout is simplistic, failing to consider the impact of environmental factors on detection accuracy, resulting in large errors in leak source localization; their navigation and positioning accuracy is low, making it difficult to achieve full-area coverage without blind spots; and their functions are fragmented, lacking a complete closed-loop design of "detection-localization-alarm-data management," leading to low data utilization. Therefore, developing a hydrogen leak detection robot system with strong mobility adaptability, high-precision detection and positioning capabilities, and full-process intelligence to address the pain points of existing technologies such as "limited mobility, inaccurate detection, and delayed response" is of significant practical importance for ensuring the safe and stable operation of generators. Summary of the Invention

[0004] This application provides a robotic system and a method for detecting hydrogen leaks, which solves the problems of low efficiency, blind spots, high safety risks, and inaccurate positioning in manual detection of hydrogen leaks in large hydrogen-cooled generators. It enables full-scene coverage detection of the generator surface and rapid location of leak points, thereby improving the reliability of power system operation.

[0005] A first aspect of this application provides a robot system for detecting hydrogen leaks, comprising: a movement module, a navigation module, a detection module, and a control module. The control module is communicatively connected to the movement module, the navigation module, and the detection module. The movement module controls the robot to adhere to the surface of a generator under inspection and to move the robot omnidirectionally across the surface of the generator. The navigation module collects the robot's position coordinates, constructs a three-dimensional point cloud map based on the environment of the generator under inspection, and navigates to the generator based on the three-dimensional point cloud map and a preset inspection path. The detection module collects hydrogen concentration data of the generator under inspection and temperature and humidity data of the surrounding environment. The control module controls the movement of the movement module and locates the hydrogen leak location of the generator under inspection based on the collected hydrogen concentration data, temperature and humidity data, and the robot's position coordinates.

[0006] Optionally, in some embodiments, the navigation module includes: a map building unit for scanning the environment of the generator under inspection and generating a three-dimensional point cloud map of the environment of the generator under inspection; a positioning unit, which is communicatively connected to the map building unit, for locating the position coordinates of the robot on the surface of the generator under inspection; and a path planning unit for controlling the robot to move along a preset inspection path and, when a hydrogen leak is detected, controlling the robot to move to the location where the hydrogen leak exists.

[0007] Optionally, in some embodiments, the detection module includes: a detection unit, located at the end of the robot's cross arm, for collecting hydrogen concentration data from different directions of the generator under test and temperature and humidity data of the surrounding environment; and a calibration unit, connected to the detection unit, for verifying the detection accuracy of the detection unit.

[0008] Optionally, in some embodiments, the detection unit includes: a hydrogen detection subunit for collecting hydrogen concentration data of the generator under test; and an environmental detection subunit for collecting temperature and humidity data of the environment in which the generator under test is located.

[0009] Optionally, in some embodiments, the control module includes: a data fusion unit, which performs filtering, noise reduction, and fusion processing on the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the surrounding environment, and the operation data of the robot; a leak source location unit, which analyzes and locates the hydrogen leak location of the generator under test based on the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the surrounding environment, and the position coordinates of the robot; and a control unit, which controls the moving module to move on the surface of the generator under test according to a preset inspection path, and controls the moving module to move towards the location where there is a hydrogen leak.

[0010] Optionally, in some embodiments, the control module further includes: a monitoring unit for monitoring the operating status of the robot and the status of the detection unit; and a data storage unit for storing the robot's inspection path, the hydrogen concentration data, the temperature and humidity data, and the location of the hydrogen leak.

[0011] Optionally, in some embodiments, an alarm module is included, disposed on the surface of the robot, the alarm module comprising a local alarm unit and a remote alarm unit, the local alarm unit being used to perform an acoustic alarm and / or an optical alarm when the robot detects a hydrogen leak location; the remote alarm unit being used to send alarm information to a monitoring center based on the hydrogen leak location.

[0012] Optionally, in some embodiments, the moving module includes: a magnetic attraction unit and a protective unit, wherein the magnetic attraction unit adopts a tracked structure, the track wheels have built-in magnets, the tracks are symmetrically arranged on the left and right sides of the body, and the track surface is provided with anti-slip protrusions for controlling the robot to adhere to the surface of the generator to be tested; the protective unit includes a shell made of flame-retardant insulating polymer material, the shell contains an explosion-proof electrical junction box, and the shell surface is coated with a dustproof and waterproof coating for short-circuit and electrostatic protection of the robot's internal circuits and components; and a drive unit for driving the robot to move according to the control commands of the control unit.

[0013] Optionally, in some embodiments, the system further includes: a wireless communication module, which is communicatively connected to the detection module, the navigation module, the control module, and the alarm module, respectively. The wireless communication module is used to transmit the robot's position coordinates, hydrogen concentration data, temperature and humidity data, status information of the detection unit, and alarm records of the alarm module to the monitoring center; a power supply unit and an expansion interface, wherein the power supply unit and the expansion interface are both communicatively connected to the control module, the expansion interface is located on the side of the robot, the power supply unit is used to supply power to the robot, and the expansion interface is used to export data and import the robot's configuration parameters.

[0014] A second aspect of this application provides a method for detecting hydrogen leaks, employing the aforementioned robot system for detecting hydrogen leaks. The method includes: acquiring the robot's position coordinates and constructing a three-dimensional point cloud map based on the environment of the generator under test; navigating to the generator under test based on the three-dimensional point cloud map and a preset inspection path; acquiring hydrogen concentration data of the generator under test and temperature and humidity data of the surrounding environment; and locating the hydrogen leak location of the generator under test based on the acquired hydrogen concentration data, temperature and humidity data, and the robot's position coordinates.

[0015] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0016] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a schematic diagram of a robotic system for detecting hydrogen leaks according to an embodiment of this application; Figure 2 This is a schematic diagram of a robotic system for detecting hydrogen leaks according to a specific embodiment of this application; Figure 3 This is a schematic diagram of the robot system workflow according to an embodiment of this application; Figure 4 This is a flowchart illustrating the phased operation of a robot system according to an embodiment of this application. Figure 5 This is a schematic flowchart of a hydrogen leak detection method according to an embodiment of this application. Detailed Implementation

[0017] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0018] The following description, with reference to the accompanying drawings, describes a robot system and method for detecting hydrogen leaks according to embodiments of this application. Addressing the issues of low efficiency, blind spots, high safety risks, and inaccurate positioning associated with manual detection of hydrogen leaks in large hydrogen-cooled generators mentioned in the background art, this application provides a robot system and method for detecting hydrogen leaks. In this system, a movement module controls the robot to adhere to the surface of the generator under inspection and moves it omnidirectionally across the surface. A navigation module collects the robot's position coordinates and constructs a three-dimensional point cloud map based on the generator's environment. The robot then navigates to the generator based on the three-dimensional point cloud map and a preset inspection path. A detection module collects hydrogen concentration data from the generator and temperature and humidity data of the surrounding environment. A control module controls the movement of the movement module and locates the hydrogen leak location of the generator based on the collected hydrogen concentration data, environmental temperature and humidity data, and the robot's position coordinates. This solves the problems of low efficiency, blind spots, high safety risks, and inaccurate location of hydrogen leaks in large hydrogen-cooled generators, enabling full-scene coverage detection of generator surfaces and rapid location of leak points, thus improving the reliability of power system operation.

[0019] Specifically, Figure 1 This is a schematic diagram of a robotic system for detecting hydrogen leaks, provided as an embodiment of this application.

[0020] like Figure 1 As shown, the robot system 10 for detecting hydrogen leaks includes: a movement module 100, a navigation module 200, a detection module 300, and a control module 400.

[0021] The control module 400 is communicatively connected to the movement module 100, navigation module 200, and detection module 300. The movement module 100 controls the robot to adhere to the surface of the generator under test and moves the robot omnidirectionally on the surface of the generator under test. The navigation module 200 collects the position coordinates of the robot and constructs a three-dimensional point cloud map based on the environment of the generator under test. It then navigates to the generator under test 400 based on the three-dimensional point cloud map and a preset inspection path. The detection module 300 collects hydrogen concentration data of the generator under test and temperature and humidity data of the surrounding environment. The control module 400 controls the movement of the movement module 100 and locates the hydrogen leak location of the generator under test based on the collected hydrogen concentration data of the generator under test, temperature and humidity data of the surrounding environment, and the position coordinates of the robot.

[0022] Optionally, in some embodiments, the moving module 100 includes: a magnetic attraction unit and a protective unit, wherein the magnetic attraction unit adopts a tracked structure, the track wheels have built-in magnets, the tracks are symmetrically arranged on the left and right sides of the body, and the track surface is provided with anti-slip protrusions for controlling the robot to adhere to the surface of the generator to be tested; the protective unit includes a shell made of flame-retardant insulating polymer material, an explosion-proof electrical junction box is provided inside the shell, and the surface of the shell is coated with a dustproof and waterproof coating for short-circuit and electrostatic protection of the robot's internal circuits and components; and a drive unit for driving the robot to move according to the control instructions of the control unit.

[0023] The specific structure of the robot system is as follows: Figure 2 As shown, the mobility module 100 is used to provide the robot with mobility support and environmental adaptation capabilities, that is... Figure 2 The mobile platform 7 and mobile module 100 specifically include: (1) Magnetic adsorption tracked chassis (i.e. magnetic adsorption unit): The chassis adopts a tracked structure with strong magnets built into the track wheels, which can be tightly adsorbed onto the metal shell surface of the generator under inspection, achieving stable movement in horizontal, vertical and inverted states, and adapting to complex installation angles of the generator; the track surface is provided with anti-slip protrusions, which can easily cross small protrusions such as bolts and welds ≤10mm on the generator surface, meeting the obstacle crossing requirements of complex working conditions.

[0024] (2) Explosion-proof protection structure (i.e. protection unit): The main body is made of flame-retardant insulating material. The internal circuit is protected against short circuits and static electricity to avoid becoming an ignition source in the hydrogen environment. The outer shell is coated with dustproof and waterproof coating to resist dust and short-term moisture corrosion in the generator room and adapt to harsh outdoor and industrial environments.

[0025] (3) Drive unit: includes a dual motor drive module and a speed adjustment circuit (such as using dual DC servo motors + reduction mechanism), used to receive direction and speed commands from the control module 400, realize precise control of robot forward movement, turning, starting and stopping and speed, and ensure smooth movement.

[0026] in, Figure 2The diagram showcases the structure of a robotic system for detecting hydrogen leaks. The robot's main body is a rectangular prism with a compact layout adapted to operation on generator surfaces. The top of the robot features, in sequence: 1-LiDAR, 3-Alarm device, and 2-Depth camera. The LiDAR scans the environment and constructs a high-precision 3D point cloud map, providing a basis for path planning. The alarm device uses red, yellow, and green warning lights to visually indicate the gas leak status. The depth camera captures color images and distance information of the environment, assisting in obstacle recognition and robot localization. The sides of the robot integrate: 4-Charging port, 5-USB port, and 6-Main switch. The charging port replenishes the robot's internal power supply; the USB port supports exporting detection data and configuring device parameters; the main switch controls the robot's overall start and stop. A cross-shaped sensor array is located on the outer side of the robot, arranged in a cross shape at the ends of the top cross arms, including helium sensors (8 and 9), hydrogen sensors (12), and sulfur hexafluoride sensors (10 and 11). This array can simultaneously collect target gas concentration data from different directions, quickly pinpointing the leak source by analyzing the concentration differences between the sensors. The robot is equipped with a 7-mobile platform at its bottom, which adopts a tracked structure and can be tightly attached to the surface of the generator's metal casing to achieve stable movement in multiple postures, including horizontal and vertical planes. It can also cross small protrusions such as bolts and welds on the surface of the generator to be inspected.

[0027] Optionally, in some embodiments, the detection module 300 includes: a detection unit, located at the end of the robot's cross arm, for collecting hydrogen concentration data from different directions of the generator under test and temperature and humidity data of the surrounding environment; and a calibration unit, connected to the detection unit, for verifying the detection accuracy of the detection unit.

[0028] Optionally, in some embodiments, the detection unit includes: a hydrogen detection subunit for collecting hydrogen concentration data of the generator under test; and an environmental detection subunit for collecting temperature and humidity data of the environment in which the generator under test is located.

[0029] The detection module 300 is the core detection unit, enabling accurate hydrogen concentration acquisition and environmental sensing, including: (1) Hydrogen sensor array (i.e., hydrogen detection subunit): Employs one high-sensitivity hydrogen sensor, such as Figure 2 Structure 12 in the sensor can simultaneously collect hydrogen concentration data from different directions and quickly locate the leak source by measuring the concentration difference. The sensor has a built-in anti-interference filter circuit to reduce the impact of on-site electromagnetic interference on detection accuracy.

[0030] (2) Environmental detection subunit: integrates SF6 gas sensor (adapted to SF6 tracer leak detection scenario), helium sensor, temperature and humidity sensor and high-definition PTZ camera; temperature and humidity sensor collects environmental temperature and humidity data to correct gas concentration detection results and improve accuracy; high-definition PTZ camera with night vision function can rotate and adjust 360° to capture the surrounding environment of the leak point in real time and transmit it to the monitoring center.

[0031] (3) Calibration unit: Built-in microcontroller (MCU) and self-calibration circuit (such as signal amplification circuit and AD conversion circuit) to automatically check the sensor detection accuracy periodically. When the detection value deviation exceeds the threshold, a calibration prompt is sent through the wireless communication module to ensure data reliability.

[0032] Optionally, in some embodiments, the navigation module 200 includes: a map building unit for scanning the environment of the generator under inspection and generating a three-dimensional point cloud map of the environment of the generator under inspection; a positioning unit, which is communicatively connected to the map building unit, for locating the position coordinates of the robot on the surface of the generator under inspection; and a path planning unit for controlling the robot to move along a preset inspection path and, when a hydrogen leak is detected, controlling the robot to move to the location where the hydrogen leak exists.

[0033] Navigation Module 200: Enables precise robot positioning and full-area coverage inspection, including: (1) Map building unit: Equipped with SLAM lidar-1 and depth camera-2, the lidar is installed at the center of the top of the robot, and the depth camera is installed next to the lidar (e.g., Figure 2 As shown in the figure, after powering on, it automatically scans the environment of the generator under test and generates a high-precision 3D point cloud map of the generator body and its surroundings, providing a basis for path planning; the depth camera simultaneously acquires color images and distance information to help identify environmental obstacles.

[0034] (2) Positioning unit: Integrating laser SLAM and visual odometry data, it can achieve centimeter-level precise positioning of the generator surface under inspection, and provide real-time feedback of the robot's position coordinates to ensure accurate and traceable positioning of the leak point. The structure of the positioning unit can be a main control chip (ARM / FPGA) + visual odometry unit + inertial measurement unit (IMU).

[0035] (3) Path planning unit: Supports dual-mode path planning of "global inspection + local search"; During global inspection, the preset inspection path (such as the preset "zigzag" or spiral path) covers all areas of the generator to be inspected, ensuring no dead angles. When a leak is detected, a local fine detection path is dynamically generated, and dense scanning is performed around the suspicious area to improve the positioning accuracy. The path planning unit can adopt a structure that uses a processor, or FPGA or DSP chip, and is electrically connected to the positioning unit, data fusion unit and drive unit.

[0036] Optionally, in some embodiments, the control module 400 includes: a data fusion unit, which performs filtering, noise reduction, and fusion processing on the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the surrounding environment, and the robot's operating data; a leak source location unit, which analyzes and locates the hydrogen leak location of the generator under test based on the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the surrounding environment, and the robot's position coordinates; and a control unit, which controls the moving module 100 to move on the surface of the generator under test according to a preset inspection path, and controls the moving module 100 to move towards the location where there is a hydrogen leak.

[0037] Control Module 400: This is the core control center of the robot, enabling data fusion, decision-making, and control, including: (1) Data fusion unit: receives data from the detection module 300 and the navigation module 200, performs filtering, noise reduction and fusion processing, removes interference data and extracts effective information; correlates hydrogen concentration data with temperature and humidity data of the environment to correct the influence of the environment on the detection results. The structure of the data fusion unit can be: main control processing chip + signal preprocessing circuit. The main control processing chip adopts ARM processor / MCU / DSP chip. The signal preprocessing circuit includes: AD conversion circuit, filtering circuit and signal isolation circuit.

[0038] (2) Leakage source localization unit: Based on the core logic of "hill climbing algorithm", it analyzes the concentration gradient change of the sensor array in real time, guides the robot to move along the direction of increasing concentration until the concentration peak point (leakage source) is locked, effectively shortening the localization time; it supports the identification of multiple leakage sources and locates multiple leakage points in sequence.

[0039] The structure of the leak source location unit can include a main control processing chip, a signal input interface circuit, a data buffer unit, and a control command output interface circuit. The main control processing chip is integrated into the control module 400 and is electrically connected to the data fusion unit. The signal input interface circuit is used to receive the fused hydrogen concentration data, robot position coordinate data, and temperature and humidity compensation data. The data buffer unit is used to temporarily store the concentration values ​​and position information of multi-directional sensors. The output interface circuit is connected to the movement module 100 and outputs movement commands.

[0040] Specifically, the method for locating the leak source is as follows: During the robot's inspection of the generator surface, the hydrogen concentration data in the front, back, left, and right directions are collected in real time by a cross-shaped array of hydrogen sensors; at the same time, the current ambient temperature and humidity data are collected by temperature and humidity sensors; and the real-time position coordinates of the robot on the generator's 3D map are output by the autonomous navigation module.

[0041] Since temperature and humidity can cause drift in the detection accuracy of electrochemical hydrogen sensors, the data fusion unit uses real-time collected temperature and humidity data to correct and calculate the original values ​​of hydrogen concentration in the four channels, eliminating environmental interference and obtaining true and reliable hydrogen concentration values.

[0042] The leak source location unit performs pairwise comparisons of the corrected four hydrogen concentrations, calculating the concentration difference and concentration gradient: If the hydrogen concentration in a certain direction sensor is significantly higher than in other directions, it indicates that the leak source is located in that direction. Based on this, a directional guidance command is generated, and the mobile module drives the robot to move in the direction of increasing concentration. During the movement, the robot continuously updates its position coordinates and the hydrogen concentration in the four directions, constantly recalculates the gradient and adjusts its direction of travel, gradually approaching the area with higher concentration.

[0043] When the robot moves to a certain position, the difference between the concentration values ​​of the four hydrogen sensors is less than the preset judgment threshold, indicating that the leaked gas has been distributed approximately evenly around the robot, and the center of the robot has reached the peak point of hydrogen concentration.

[0044] At this point, the leak source location unit marks the location coordinates corresponding to this point as the hydrogen leak location of the generator, and records the peak concentration, environmental parameters, and corresponding generator area information at that point.

[0045] If the hydrogen concentration in all directions is low and the difference is small, it indicates that there is no obvious leakage in the current area.

[0046] (3) Control unit: Under normal conditions, the robot is controlled to perform inspections along a preset path. When a leak is detected, the global task is paused and a local search mode is started. The location of the hydrogen leak in the generator under inspection is located based on the collected hydrogen concentration data of the generator under inspection, the temperature and humidity data of the environment, and the robot's position coordinates. After the location is completed, the inspection can be automatically resumed or the robot can return to the starting point.

[0047] Optionally, in some embodiments, the control module 400 further includes: a monitoring unit for monitoring the robot's operating status and the status of the detection unit; and a data storage unit for storing the robot's inspection path, hydrogen concentration data, temperature and humidity data, and hydrogen leak location.

[0048] The monitoring unit monitors the robot's own status (battery level, sensor health) in real time. When the battery is low, it automatically plans a return path. When a sensor fails, it triggers a self-test alarm. The monitoring unit has a built-in threshold comparison circuit with a built-in reference threshold, which is used to determine whether there is an abnormality based on the robot's operating status and the status of the monitoring unit.

[0049] The data storage unit has a built-in high-capacity storage chip that can classify and store inspection path data, gas concentration data, leak point coordinates, alarm records, etc. It supports binding data with timestamps and generator models for easy traceability.

[0050] Optionally, in some embodiments, the system includes: an alarm module disposed on the surface of the robot, the alarm module including a local alarm unit and a remote alarm unit, the local alarm unit being used to provide acoustic and / or optical alarms when the robot detects a hydrogen leak location; and the remote alarm unit being used to send alarm information to a monitoring center based on the hydrogen leak location.

[0051] Alarm module: Enables rapid early warning of leakage events, including: (1) Local alarm unit: The top of the robot is equipped with red, yellow, and green LED warning lights and a high-decibel buzzer; during normal inspection, the green light is always on, the yellow light flashes when a leak is suspected, and the red light flashes and the buzzer sounds when a hydrogen leak is confirmed, which facilitates on-site personnel to quickly locate the robot's position, such as Figure 2 The alarm device-3 is shown in the image.

[0052] (2) Remote alarm unit: Sends alarm information to the monitoring center via wireless communication module, including the coordinates of the hydrogen leak location, concentration value, and on-site image; supports SMS and APP push alarm notifications to ensure timely response by maintenance personnel and prevent the accident from escalating.

[0053] Optionally, in some embodiments, the system further includes: a wireless communication module, which is communicatively connected to the detection module 300, navigation module 200, control module 400, and alarm module, respectively. The wireless communication module is used to transmit the robot's position coordinates, hydrogen concentration data, temperature and humidity data, status information of the detection unit, and alarm records of the alarm module to the monitoring center; a power supply unit and an expansion interface, wherein both the power supply unit and the expansion interface are communicatively connected to the control module 400, and the expansion interface is located on the side of the robot. The power supply unit is used to supply power to the robot; the expansion interface is used to export data and import the robot's configuration parameters.

[0054] Wireless communication module: Enables real-time data interaction between the robot and the monitoring center, including: (1) Multi-mode communication unit: compatible with 5G and Wi-Fi dual-mode communication, with priority given to 5G transmission to ensure signal stability and low-latency data transmission in complex factory environments; supports long-distance data transmission to meet the communication needs of large generator rooms and outdoor scenarios.

[0055] (2) Data transmission unit: Real-time transmission of robot position coordinates, hydrogen concentration data, sensor status information, real-time camera images and alarm signals; receiving remote control commands (such as starting inspection, pausing task, adjusting parameters, etc.) issued by the monitoring center to realize remote scheduling.

[0056] Auxiliary function modules: These ensure the stable operation of the robot and include: (1) Power supply unit: It adopts a high-capacity explosion-proof lithium battery, with a single charge life of ≥6 hours and supports fast charging mode; it has a built-in power monitoring module to provide real-time feedback on the remaining power, and automatically sends a low power prompt and plans a return path when the power is below 20%.

[0057] (2) Extended interfaces: such as Figure 2 As shown in the diagram, there are charging ports 4, USB ports 5, and a main switch 6. A sensor expansion slot is reserved, which can be equipped with temperature sensors, acoustic sensors, etc., to realize multiple application scenarios such as transformer overheat detection and equipment abnormal noise monitoring, thereby improving equipment utilization. A USB port is provided to support data export and parameter configuration.

[0058] Based on the aforementioned autonomous mobile robot system for detecting hydrogen leaks in generators, the specific workflow is as follows: 1. Equipment Preparation and Pre-processing: Move the robot next to the generator and deploy its anti-slip support legs for secure mounting. Turn on the main switch; the robot will automatically start its self-test program, checking the status of sensors, navigation module 200, communication module, and drive system. After passing the self-test, input and save the generator model, rated parameters, tester information, and test date via the touchscreen. Initiate map building mode; the SLAM lidar and depth camera simultaneously scan the environment of the generator under test, generating a high-precision 3D point cloud map and completing the preset inspection path (default zigzag path, manually adjustable).

[0059] 2. Global Inspection Startup: Select "Global Inspection" mode on the touchscreen, confirm the parameters, and start the task. The robot attaches to the generator casing via a magnetically adsorbed tracked chassis and moves autonomously along the preset inspection path, traversing obstacles such as surface bolts and welds. The detection module 300 continuously collects hydrogen concentration, temperature, and humidity data, while a high-definition camera captures real-time inspection footage, which is simultaneously transmitted to the monitoring center via a wireless communication module. The control module 400 analyzes the data in real time to determine if any leaks are present.

[0060] 3. Leak Detection and Location: When the hydrogen sensor array detects a concentration value exceeding a preset threshold, the control module 400 determines it as a suspected leak, immediately suspends global inspection, and initiates a local search mode. Based on the "hill-climbing algorithm," the robot adjusts its direction and moves towards an area with higher hydrogen concentration, comparing the concentration changes of each sensor in real time and dynamically correcting its path; simultaneously, a high-definition gimbal camera zooms in on the suspected area, and SLAM lidar accurately locates the current position. When the pairwise difference between the detection values ​​of the four sensors is less than the preset threshold, it is determined to be a leak source, and the coordinates of this location are recorded and marked.

[0061] 4. Alarm and Data Processing: Once the leak source is located, the robot immediately triggers a local alarm (flashing red light + buzzer sound), and simultaneously sends remote alarm information to the monitoring center, including the leak point coordinates, real-time concentration data, and on-site video feed. A notification is also pushed to the maintenance personnel's mobile app. The control module 400 binds and stores the detection data, location results, alarm records, and generator parameters, generating a detection log. Maintenance personnel can remotely view the real-time situation through the monitoring center and schedule the robot to perform intensive scanning around the leak point to further confirm the leak's extent.

[0062] 5. Data Archiving and Equipment Storage: After the testing task is completed, the robot returns to the starting point along the planned path. The testing records can be viewed on the touchscreen. Electronic data can be exported via USB interface, or a testing report containing leak point information, concentration change curves, and alarm records can be printed directly. Disconnect the robot's power, clean dust from the sensor surfaces, organize the equipment, and store it in the designated storage location to complete the testing operation.

[0063] Figure 3 This is a schematic diagram of the robot system's workflow, which specifically includes the following steps: S1: Start the device. The system powers on and enters the initialization state.

[0064] S2: Equipment preparation and preprocessing. The robot performs a self-test procedure to verify the status of each sensor and functional module; the operator enters information such as generator parameters; subsequently, the robot uses its onboard Simultaneous Localization and Mapping (SLAM) module to scan the working environment, generate a high-precision 3D point cloud map, and pre-set a global inspection path covering the entire surface of the generator.

[0065] S3: Global Inspection Initiated. The robot attaches to the generator casing via a magnetically adsorbed chassis and moves autonomously along a preset inspection path. During movement, its detection module 300 continuously collects data such as hydrogen concentration and environmental images, and transmits this data back to the remote monitoring center in real time via a wireless communication module.

[0066] S4: Leakage Detection. The central control and data processing module analyzes sensor data in real time to determine whether the hydrogen concentration exceeds the preset safety threshold.

[0067] S5: Leak Detection and Location. If the concentration exceeds the standard, the global inspection task is paused, and a local precise location mode is activated. Based on the "hill-climbing algorithm" logic, the robot analyzes the concentration gradient of the multi-sensor array, autonomously adjusts its movement direction, and approaches the leak source along the concentration increase path until the precise location of the leak point is locked.

[0068] S6: Alarm and Data Processing. Upon confirmation of the leak source, the system immediately triggers a local audible and visual alarm and simultaneously sends alarm information, including the leak point coordinates, concentration value, and on-site visuals, to the remote monitoring center. All relevant data is stored after being bound to generator parameters, forming a traceable detection record.

[0069] S7: Path Decision and Loop. If no concentration exceedance is detected, continue the pre-set global path inspection until all set areas are covered.

[0070] S8: Data Archiving and Equipment Storage. After completing the full-area inspection or handling of specific leak points, the robot automatically returns to the starting point. The system generates a structured inspection report, supporting data export or printing. Finally, the equipment is cleaned and stored, and the process ends.

[0071] Appendix Figure 4 A schematic diagram illustrating the workflow for phased hydrogen leak detection in a robotic system.

[0072] The process begins with the "Start Operation" command, then enters the first stage "Preparation and Initialization", which completes equipment self-check, parameter entry, and environmental scanning and high-precision map construction based on SLAM (Simultaneous Localization and Mapping) technology.

[0073] The process then moves to the second stage, "global inspection," where the robot moves autonomously and performs a full-coverage scan on the generator surface according to a preset inspection path, during which a multi-sensor array continuously collects environmental data.

[0074] In the third stage, the control module 400 analyzes sensor data in real time and performs threshold judgment on hydrogen concentration. If the concentration exceeds the standard, the fourth stage, "Alarm and Handling," is triggered. The system suspends global inspection, initiates a local precise positioning mode based on a "hill-climbing algorithm" to locate the leak source, and simultaneously executes local and remote multi-level alarms. Meanwhile, the process also includes the logic for continuing execution if no anomalies are detected. Finally, regardless of whether a leak is detected, the process leads to the fifth stage, "End and Archiving," where the detection data is bound and stored, structured reports are generated, and the equipment is automatically returned for storage, achieving a closed-loop task.

[0075] Taking the hydrogen leak detection of a 300MW large hydrogen-cooled generator as an example, the usage process of this system is explained in detail: Equipment Preparation and Map Building: Move the robot next to the generator and deploy its anti-slip support legs for secure mounting; connect the power supply and turn on the main switch. The robot will automatically start its self-test program to check the sensors, cameras, LiDAR, and communication functions for proper operation. After passing the self-test, the map building mode will be activated. The SLAM LiDAR and depth camera will simultaneously scan the generator room environment to generate a high-precision 3D point cloud map of the generator and its surroundings; input the generator model, rated parameters, and test personnel information via the touchscreen to complete data binding.

[0076] Global Inspection Startup: Select the "Global Inspection" mode on the touchscreen. The robot begins to move along the generator surface in a preset zigzag path. The magnetically adsorbed tracked chassis adheres tightly to the outer shell and smoothly crosses surface bolts and welds. The detection module 300 continuously collects hydrogen concentration, temperature, and humidity data, while the high-definition camera captures the inspection footage in real time and transmits it to the monitoring center via the 5G module. The control module 400 analyzes the concentration data in real time to determine if there is a leak.

[0077] Leak Detection and Location: When the robot moves near the generator excitation flange, if the hydrogen concentration in one direction of the cross-shaped sensor array is significantly higher than in other directions and exceeds a preset threshold, the control module 400 determines it as a suspected leak, immediately suspends the global inspection, and initiates a local search mode. Based on the "hill-climbing algorithm," the robot adjusts its direction to move towards the area with higher concentration, continuously comparing the concentration changes of each sensor and dynamically correcting its path. Simultaneously, a high-definition pan-tilt camera is aimed at the suspected area, magnifying and capturing details of the flange connection. When the robot moves to the peak concentration point, the pairwise differences between the four sensor values ​​are all less than the preset threshold, indicating a leak source, and the coordinates of this location are recorded.

[0078] Alarm and Data Transmission: Once the leak source is located, the robot immediately triggers a local alarm, with a flashing red light and a buzzer sounding. Simultaneously, it sends alarm information to the monitoring center via wireless communication, including the leak point coordinates, real-time concentration data, and a high-definition image of the flange connection. An alarm notification is also pushed to the maintenance personnel's mobile app. Monitoring center staff can view the leak details through a visual interface and remotely dispatch the robot to conduct intensive scanning around the leak point to further confirm the leak's extent.

[0079] Data archiving and task completion: After the leak detection is completed, the robot returns to the starting point along the planned path. The control module 400 categorizes and stores the inspection path data, leak point information, concentration change curves, alarm records, etc., and binds them to the generator parameters. After the maintenance personnel arrive on site, they can query detailed data through the touch screen, export electronic files through the USB interface, or directly print the detection report. After the handling is completed, the robot power is turned off, the equipment is organized and stored, and the detection task is completed.

[0080] In summary, the beneficial effects of this application are as follows: (1) Strong mobility and full scene coverage: The magnetic adsorption tracked chassis can move stably on the horizontal plane, vertical plane and inverted state of the generator, cross small protruding obstacles, effectively cover hidden areas and high-altitude positions that are difficult for humans to reach, completely eliminate blind spots in detection, and solve the problem of limited movement of traditional manual detection and existing robots.

[0081] (2) Accurate detection and positioning, improving operation and maintenance efficiency: Through the collaboration of cross-shaped sensor array and "hill climbing algorithm", the leak is accurately located, greatly reducing the positioning time and significantly shortening the troubleshooting time; the sensor data combined with temperature and humidity correction improves the detection accuracy, avoids misjudgment caused by environmental interference, and solves the defects of inaccurate positioning and low detection accuracy of existing technologies.

[0082] (3) Safe and reliable, reducing operational risks: The robot adopts an explosion-proof design to avoid becoming an ignition source, replaces human beings in potentially dangerous environments, and ensures personnel safety; it has multiple built-in protection mechanisms (overcurrent, overvoltage, overtemperature), monitors the equipment status in real time, and automatically stops and alarms when a fault occurs, reducing the risk of equipment damage and accident expansion.

[0083] (4) Intelligent full-process and optimized data management: It integrates the full-process functions of "inspection-detection-location-alarm-archiving" and can complete automated operations without manual intervention; the detection data is bound and stored with the generator parameters, and supports real-time transmission, local query and export to form a complete digital archive, which solves the problems of data fragmentation and poor traceability in the traditional way, and helps the power plant to upgrade its intelligent management.

[0084] (5) Flexible function expansion and high cost performance: The reserved sensor expansion slot can be adapted to multiple scenarios such as SF6 tracer detection and equipment overheating monitoring. One device can meet multiple operation and maintenance tasks and reduce the procurement cost of power plant equipment; the dual-mode communication and long-endurance design can be adapted to generator rooms of different sizes and outdoor scenarios, and is highly practical.

[0085] According to the embodiments of this application, a robot system for detecting hydrogen leaks comprises a movement module for controlling the robot to adhere to the surface of the generator under inspection and to move the robot omnidirectionally on the surface of the generator under inspection. A navigation module is used to collect the robot's position coordinates and construct a 3D point cloud map based on the environment of the generator under inspection. The robot then navigates to the generator under inspection based on the 3D point cloud map and a preset inspection path. A detection module is used to collect hydrogen concentration data of the generator under inspection and temperature and humidity data of the surrounding environment. A control module controls the movement of the movement module and locates the hydrogen leak location of the generator under inspection based on the collected hydrogen concentration data, temperature and humidity data, and robot position coordinates. This solves the problems of low efficiency, blind spots, high safety risks, and inaccurate positioning in manual detection of hydrogen leaks in large hydrogen-cooled generators, achieving full-scene coverage detection of the generator surface and rapid location of leak points, thus improving the reliability of power system operation.

[0086] Next, with reference to the accompanying drawings, a method for detecting hydrogen leakage according to an embodiment of this application is described.

[0087] like Figure 5 As shown, the method for detecting hydrogen leaks employs the aforementioned robotic system for detecting hydrogen leaks, wherein the method includes: In S501, the robot's position coordinates are collected, and a 3D point cloud map is constructed based on the environment of the generator under inspection. The robot then navigates to the generator under inspection based on the 3D point cloud map and the preset inspection path.

[0088] In S502, hydrogen concentration data of the generator under test and temperature and humidity data of the surrounding environment are collected.

[0089] In S503, the location of hydrogen leakage in the generator under test is determined by the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the surrounding environment, and the position coordinates of the robot.

[0090] It should be noted that the foregoing explanation of the robot system embodiment for detecting hydrogen leaks also applies to the hydrogen leak detection method of this embodiment, and will not be repeated here.

[0091] The hydrogen leak detection method proposed in this application involves collecting the robot's position coordinates and constructing a 3D point cloud map based on the environment of the generator under inspection. The robot then navigates to the generator using the 3D point cloud map and a pre-set inspection path. The method also collects hydrogen concentration data from the generator and temperature and humidity data from the surrounding environment. Finally, it locates the hydrogen leak position on the generator based on the collected hydrogen concentration data, ambient temperature and humidity data, and the robot's position coordinates. This method solves the problems of low efficiency, blind spots, high safety risks, and inaccurate positioning in manual detection of hydrogen leaks in large hydrogen-cooled generators. It achieves full-scene coverage detection of the generator surface and rapid leak point location, thereby improving the reliability of the power system.

[0092] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0093] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0094] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0095] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequential list of executable instructions for implementing logical functions, and can be specifically implemented in any computer program product for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer program product" can be any means that can contain, store, communicate, propagate, or transmit a program for use by, or in conjunction with, an instruction execution system, apparatus, or device. More specific examples of computer program products (a non-exhaustive list) include the following: an electrical connection having one or N wires (electronic device), a portable computer disk drive (magnetic device), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic device, and portable optical disc read-only memory (CDROM). Furthermore, the computer program product can even be paper or other suitable medium on which the program can be printed, because the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in a computer memory.

[0096] It should be understood that the various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0097] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer program product, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0098] Furthermore, the functional units in the various embodiments of this application can be integrated into a processing module, or each unit can exist physically separately, or two or more units can be integrated into a module. The integrated module can be implemented in hardware or as a software functional module. If the integrated module is implemented as a software functional module and sold or used as an independent product, it can also be stored in a computer program product.

[0099] The aforementioned computer program product may be a read-only memory, a disk, or an optical disk, etc. Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of this application.

Claims

1. A robotic system for detecting hydrogen leaks, characterized in that, include: The system includes a mobile module, a navigation module, a detection module, and a control module, wherein the control module is communicatively connected to the mobile module, the navigation module, and the detection module, respectively. The mobile module is used to control the robot to adhere to the surface of the generator to be inspected, and to control the robot to move in all directions on the surface of the generator to be inspected. The navigation module is used to collect the position coordinates of the robot, construct a three-dimensional point cloud map based on the environment of the generator under inspection, and navigate to the generator under inspection based on the three-dimensional point cloud map and a preset inspection path. The detection module is used to collect hydrogen concentration data of the generator under test and temperature and humidity data of the surrounding environment. The control module is used to control the movement of the mobile module and locate the hydrogen leak location of the generator under test based on the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the environment, and the position coordinates of the robot.

2. The robotic system for detecting hydrogen leaks according to claim 1, characterized in that, The navigation module includes: The map building unit is used to scan the environment of the generator under test and generate a three-dimensional point cloud map of the environment of the generator under test. A positioning unit, which is communicatively connected to the map building unit, is used to locate the position coordinates of the robot on the surface of the generator to be inspected. The path planning unit is used to control the robot to move along a preset inspection path, and to control the robot to move to the location where the hydrogen leak is detected.

3. The robotic system for detecting hydrogen leaks according to claim 1, characterized in that, The detection module includes: The detection unit is located at the end of the robot's cross arm and is used to collect hydrogen concentration data from different directions of the generator under test and temperature and humidity data of the surrounding environment. A calibration unit is provided, and the detection unit is connected to the calibration unit to verify the detection accuracy of the detection unit.

4. The robotic system for detecting hydrogen leaks according to claim 3, characterized in that, The detection unit includes: The hydrogen detection subunit is used to collect hydrogen concentration data of the generator under test. The environmental monitoring subunit is used to collect temperature and humidity data of the environment in which the generator under test is located.

5. The robotic system for detecting hydrogen leaks according to claim 1, characterized in that, The control module includes: The data fusion unit performs filtering, noise reduction, and fusion processing on the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the surrounding environment, and the operation data of the robot. The leak source location unit is used to analyze and locate the hydrogen leak location of the generator under test based on the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the environment, and the position coordinates of the robot. The control unit is used to control the mobile module to move on the surface of the generator under inspection according to a preset inspection path, and to control the mobile module to move to the location where there is a hydrogen leak.

6. The robotic system for detecting hydrogen leaks according to claim 5, characterized in that, The control module further includes: A monitoring unit is used to monitor the operating status of the robot and the status of the detection unit; The data storage unit is used to store the robot's inspection path, the hydrogen concentration data, the temperature and humidity data, and the location of the hydrogen leak.

7. The robotic system for detecting hydrogen leaks according to claim 6, characterized in that, include: An alarm module is installed on the surface of the robot. The alarm module includes a local alarm unit and a remote alarm unit. The local alarm unit is used to provide acoustic and / or optical alarms when the robot detects a hydrogen leak location. The remote alarm unit is used to send alarm information to the monitoring center based on the location of the hydrogen leak.

8. The robotic system for detecting hydrogen leaks according to claim 1, characterized in that, The moving module includes: a magnetic suction unit and a protective unit, wherein, The magnetic suction unit adopts a tracked structure with magnets built into the track wheels. The tracks are symmetrically arranged on the left and right sides of the machine body, and the track surface is provided with anti-slip protrusions to control the robot to adhere to the surface of the generator to be inspected. The protective unit includes a shell made of flame-retardant and insulating polymer material. An explosion-proof electrical junction box is installed inside the shell, and the surface of the shell is coated with a dustproof and waterproof coating to protect the internal circuits and components of the robot from short circuits and static electricity. A drive unit is used to drive the robot to move according to the control instructions of the control unit.

9. The robotic system for detecting hydrogen leaks according to claim 8, characterized in that, Also includes: The wireless communication module is communicatively connected to the detection module, the navigation module, the control module, and the alarm module. The wireless communication module is used to transmit the robot's position coordinates, hydrogen concentration data, temperature and humidity data, the status information of the detection unit, and alarm records from the alarm module to the monitoring center. The system includes a power supply unit and an expansion interface, both of which are communicatively connected to the control module. The expansion interface is located on the side of the robot. The power supply unit is used to supply power to the robot, and the expansion interface is used to export data and import configuration parameters of the robot.

10. A method for detecting hydrogen leakage, characterized in that, The robotic system for detecting hydrogen leaks as described in any one of claims 1-9 is used, wherein the method includes: The robot's position coordinates are collected, and a three-dimensional point cloud map is constructed based on the environment of the generator under inspection. The robot is then navigated to the generator under inspection based on the three-dimensional point cloud map and a preset inspection path. Collect hydrogen concentration data of the generator under test and temperature and humidity data of the surrounding environment; The location of the hydrogen leak in the generator under test is determined by the collected hydrogen concentration data of the generator under test, the temperature and humidity data of the surrounding environment, and the position coordinates of the robot.

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