A composite material component double-side cooperative detection robot and detection method

Abstract

The application discloses a kind of composite material component double-side cooperative detection robot and detection method, belong to composite material detection robot technical field.The application is respectively placed in component two sides by detection robot and driven robot, and position coupling is formed by array electromagnet mutual adsorption across material;Detection robot adopts omni-directional movement of Mecanum wheel initiative, and driven robot adopts passive follow-up of universal wheel;Detection mechanical arm tail end is equipped with quick release interface, can replace image sensor or ultrasonic sensor according to material characteristic, respectively realize the visual transmission detection of light-transmitting material and the ultrasonic detection of non-light-transmitting material.Control system fuses robot pose, electromagnet state and detection signal, generates defect coordinate, type, size detection report, and with low confidence area automatic reinspection function.The application detection efficiency is high, adaptability is strong, result is traceable, applicable to large composite material component such as wind power blade.

Description

Technical Field

[0001] This invention belongs to the field of inspection robot technology, specifically relating to a two-sided collaborative inspection robot and inspection method for composite material components, which is applicable to non-destructive testing of large composite material components such as wind turbine blades. Background Technology

[0002] Wind turbine blades are typically composed of glass fiber reinforced composite materials, a resin matrix, a core material, and localized reinforcing structures. During blade manufacturing, processes such as layup, infusion, curing, molding, and bonding can introduce internal defects. For example, insufficient resin impregnation can create dry fiber areas, inadequate vacuum infusion can form bubbles or pores, localized delamination can occur between the core material and the skin, and foreign matter or inclusions can affect subsequent service strength. Once these defects enter service, they can expand into structural damage under alternating loads, wind and sand erosion, and temperature cycling.

[0003] Existing inspection methods typically rely on manual visual inspection, handheld ultrasonic probes, sampling verification, or fixed inspection fixtures. When there are significant variations in blade or web thickness, curvature, or material system differences, manual inspection is prone to problems such as unstable probe positioning, discontinuous inspection paths, and difficulty in aligning the positions on both sides. In particular, it is difficult to efficiently, continuously, and traceably detect manufacturing defects such as bubbles, delamination, dry fibers, inclusions, localized debonding, and poor adhesion. Summary of the Invention

[0004] To address the problems of existing inspection methods, such as difficulty in aligning the positions of both sides, discontinuous inspection paths, and limited adaptability to different material properties, this invention provides a bilateral collaborative inspection robot and method for composite material components. The inspection robot and the driven robot are positioned on opposite sides of the composite material component, respectively. An electromagnet array forms a material-separated adsorption and positional coupling, and Mecanum wheels / universal wheels enable synchronous movement. Simultaneously, a replaceable end effector module allows the bilateral collaborative inspection robot to perform visual transmission inspection on translucent or semi-translucent materials such as fiberglass, as well as ultrasonic inspection on opaque materials such as carbon fiber. The inspection method selects either image detection or ultrasonic detection based on the characteristics of different composite materials such as fiberglass and carbon fiber, fusing robot pose, array electromagnetic adsorption state, and image or ultrasonic signals for defect identification and localization.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] This invention first provides a bilateral collaborative inspection robot for composite material components, including an inspection robot, a driven robot, an inspection robotic arm, and a control system; the inspection robot and the driven robot are respectively arranged on opposite sides of the composite material component;

[0007] The inspection robot includes a double-layer chassis, a first electromagnet array, and a Mecanum wheel mechanism; the first electromagnet array is fixed to the bottom surface of the double-layer chassis; multiple Mecanum wheel mechanisms are respectively fixed to the bottom of the double-layer chassis and each Mecanum wheel mechanism is driven independently;

[0008] The detection robotic arm includes a four-degree-of-freedom robotic arm mounted on the detection robot. The end of the four-degree-of-freedom robotic arm is provided with a quick-release interface for detachably connecting an image sensor or an ultrasonic sensor.

[0009] The driven robot includes a driven robot chassis, a second electromagnet array, an area array LED backlight, and multiple omnidirectional wheel mechanisms; the second electromagnet array is fixed on the driven robot chassis, and the second electromagnet array and the first electromagnet array are magnetically coupled through a composite material component; the multiple omnidirectional wheel mechanisms are respectively fixed to the bottom of the driven robot chassis; the area array LED backlight is mounted on the driven robot chassis through a support rod mechanism;

[0010] The control system is connected to the detection robot and the slave robot respectively, and is used to control the robot's movement, electromagnet attraction, and defect identification of composite material components.

[0011] Furthermore, the first electromagnet array includes a first electromagnet bracket and a plurality of first electromagnet units fixed on the first electromagnet bracket, the first electromagnet bracket being fixed on the double-layer chassis; the second electromagnet array includes a second electromagnet bracket and a plurality of second electromagnet units fixed on the second electromagnet bracket, the second electromagnet bracket being fixed on the driven robot chassis; the number of second electromagnet units is the same as that of first electromagnet units and their distribution positions correspond.

[0012] Furthermore, the end of the first electromagnet unit is provided with a first electromagnet foot pad made of Teflon material, and the end of the second electromagnet unit is provided with a second electromagnet foot pad made of Teflon material.

[0013] Furthermore, the Mecanum wheel mechanism includes a drive wheel bracket, a drive motor, and a Mecanum wheel. The drive wheel bracket is fixed to the bottom of the double-layer chassis, the drive motor is fixed on the drive wheel bracket, and the drive motor is connected to the Mecanum wheel through a coupling.

[0014] Furthermore, the support rod mechanism includes a follower bracket, a first manual adjustment bolt, a support rod, and a second manual adjustment bolt; the follower bracket is fixedly connected to the chassis of the driven robot, one end of the support rod is connected to the follower bracket through the first manual adjustment bolt, and the other end of the support rod is connected to the area array LED backlight through the second manual adjustment bolt.

[0015] Furthermore, the inspection robot also includes an inspection robot control module, which has a wired interface for powering the inspection robot and exchanging data with the control system; the slave robot also includes a slave robot control module, which has a wired interface for powering the slave robot and exchanging data with the control system.

[0016] This invention also provides a method for bilateral collaborative inspection of composite material components, which is implemented using the aforementioned bilateral collaborative inspection robot, and includes the following steps:

[0017] S1. Establish a detection coordinate system based on the size and material type of the composite material component, and plan the monitoring area and detection path;

[0018] S2. Place the inspection robot on one side of the composite material component, place the driven robot on the opposite side of the composite material component, and set the inspection robot and the driven robot opposite each other at the starting point;

[0019] S3. Activate the first electromagnet array of the detection robot and the second electromagnet array of the driven robot, adjust the adsorption current so that the detection robot and the driven robot can adsorb each other through the composite material component and maintain their relative positions, thus completing the initial alignment;

[0020] S4. The inspection robot actively moves along the planned path by relying on multiple Mecanum wheel mechanisms, and the driven robot follows through the universal wheel mechanism under the magnetic adsorption coupling.

[0021] S5. Select the testing method based on the light transmittance of the composite material component:

[0022] S51. If the composite material component is made of a light-transmitting or semi-light-transmitting material, an image sensor is installed at the end of the four-degree-of-freedom robotic arm, and the area array LED backlight on the slave robot is turned on; the image sensor collects transmitted light images, and the control system processes the collected transmitted light images to identify internal defects in the component.

[0023] S52. If the composite material component is made of opaque material, an ultrasonic sensor is installed at the end of the four-degree-of-freedom robotic arm. The four-degree-of-freedom robotic arm adjusts its posture so that the ultrasonic sensor is in contact with the surface of the component in the monitoring area to collect ultrasonic echo signals. The control system identifies internal defects of the component based on the echo signals.

[0024] S6. During the detection process, the control system records the pose data, path information, working status of the electromagnet array, and detection data collected by the image sensor or ultrasonic sensor in real time. The control system integrates the multi-source information to obtain the detection results and generate a detection report.

[0025] Furthermore, the inspection report includes the defect number, defect location coordinates, defect type, defect size, and confidence level.

[0026] Furthermore, for detection areas where the confidence level is below the threshold or the synchronization deviation between the two sides exceeds the range in the detection results, the control system adjusts the robot's posture, the magnetic adsorption force of the electromagnet array, or the detection path, and controls the robot to return to step S4 to re-inspect the detection area.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] This invention arranges a detection robot and a slave robot on opposite sides of a composite material component, and uses arrayed electromagnets on both sides to form a material-separated adsorption and positional coupling relationship. This allows the slave robot to move synchronously on the other side when the detection robot moves actively on one side, reducing problems such as unstable probe positioning, discontinuous detection paths, and difficulty in aligning the positions on both sides during manual handheld detection, thereby improving the continuity and stability of the detection process.

[0029] This invention features arrays of electromagnets on both the detection robot and the driven robot, with multiple electromagnet units forming an array-like adsorption area. By adjusting the on / off state of the electromagnet units, the adsorption current, and the zoned adsorption method, the detection robot and the driven robot can maintain a relative positional correspondence across the composite material component, reducing misalignment caused by changes in component curvature, thickness, or motion deviation.

[0030] The inspection robot uses Mecanum wheels as the active movement mechanism, which can move forward, backward, lateral, diagonally, and turn in place, facilitating path tracking and attitude correction on the surface of composite material components; the driven robot uses omnidirectional wheels as the follow-up movement mechanism, which reduces motion resistance during synchronous movement.

[0031] The present invention features a quick-release interface at the end of the robotic arm, through which both the image sensor and the ultrasonic sensor can be quickly replaced. This allows the invention to be used for visual transmission detection of translucent / semi-translucent materials such as fiberglass, as well as ultrasonic detection of opaque materials such as carbon fiber, significantly improving the applicability of the inspection robot.

[0032] This invention provides a dual-mode signal processing path, enabling more comprehensive and accurate defect identification. In visual transmission mode, brightness normalization, background subtraction, and abnormal region segmentation are performed on the acquired transmitted light image, clearly identifying area-type or volume-type defects such as bubbles, dry fibers, inclusions, resin enrichment, or resin depletion. In ultrasonic detection mode, multi-dimensional features such as echo time, amplitude, phase, and scanning angle are extracted to accurately determine deep internal defects such as delamination, debonding, porosity, and thickness anomalies. The two detection methods complement each other, avoiding the omission of specific types of defects by a single method and significantly improving the defect detection rate.

[0033] This invention not only collects image data or ultrasonic echo data, but also combines robot pose, detection path, electromagnet status and detection signals to output quantitative results such as defect number, location coordinates, type, size, and depth, forming a continuous and traceable inspection report, overcoming the limitations of manual recording or single-point sampling.

[0034] The detection method of this invention introduces a feedback closed loop based on confidence level and synchronization deviation. When the system determines that the confidence level of the detection result in a certain area is low (such as image blurring or insufficient ultrasonic signal-to-noise ratio) or the synchronization deviation between the two robots exceeds a threshold, it can automatically adjust the relative position of the two robots, the electromagnet adsorption current, the end effector sensor posture, or the local detection path, and perform a re-inspection. This adaptive re-inspection mechanism is particularly suitable for areas where the curvature of the component changes abruptly, the thickness changes drastically, or the local material is uneven, which are prone to detection uncertainty, and significantly improves the robustness and reliability of the detection.

[0035] This invention uses a wired power supply method, which is not limited by battery capacity and is suitable for long-term continuous testing of large-sized composite material components such as wind turbine blades and webs.

[0036] In summary, this invention has made systematic innovations from multiple aspects, including dual-sided collaborative structure, heterogeneous wheel-type motion, modular detection end, material adaptation method, multi-information fusion positioning, and adaptive re-inspection mechanism. It effectively solves common technical problems in non-destructive testing of large composite material components, such as low efficiency, poor accuracy, limited adaptability, and untraceable results, and has significant technological progress and industrial practical value. Attached Figure Description

[0037] Figure 1 This is a schematic flowchart of a method for bilateral collaborative detection of composite material components according to an embodiment of the present invention.

[0038] Figure 2 This is a schematic diagram of the overall structure of a composite material component dual-sided collaborative robot according to an embodiment of the present invention.

[0039] Figure 3 This is a three-dimensional structural diagram of the detection robot described in an embodiment of the present invention.

[0040] Figure 4 This is a three-dimensional structural diagram of the detection robotic arm described in an embodiment of the present invention.

[0041] Figure 5 This is an exploded view of the detection robotic arm described in an embodiment of the present invention.

[0042] Figure 6 This is a three-dimensional structural diagram of the driven robot described in an embodiment of the present invention (shown with the bottom facing up).

[0043] Figure 7 This is a schematic diagram of the assembly state when a dual-sided collaborative robot of a composite material component is inspecting the composite material component according to an embodiment of the present invention. Detailed Implementation

[0044] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0045] Example 1:

[0046] like Figures 2 to 7 As shown, this embodiment is a two-sided collaborative inspection robot for composite material components, including an inspection robot 1, an inspection robotic arm 2, a driven robot 3, and a control system 4.

[0047] like Figure 3 As shown, the inspection robot 1 includes a double-layer chassis, an inspection robot control module 8, a first electromagnet bracket 9, a first electromagnet unit 10, a Mecanum wheel 11, a coupling 12, a drive motor 13, a drive wheel bracket 14, and a first electromagnet foot pad 15. The double-layer chassis includes a lower chassis 5, an upper chassis 6, and a supporting connecting column 7. The upper chassis 6 is fixedly connected to the lower chassis 5 via the supporting connecting column 7, and the inspection robot arm 2 is fixed to the upper chassis 6. The inspection robot control module 8 is fixed to the upper chassis 6 and has a wired interface for powering the inspection robot 1 and exchanging data with the control system 4. The first electromagnet bracket 9 is fixed to the bottom surface of the lower chassis 5 and ensures that the magnetic attraction can provide sufficient downward pressure on the inspection robot. Multiple first electromagnet units 10 are fixed to the first electromagnet bracket 9 to form a first electromagnet array. Each first electromagnet unit 10 has a first electromagnet foot pad 15 made of Teflon material fixed to its end. The first electromagnet foot pad 15 is used to reduce friction and prevent scratches on the composite material. Four Mecanum wheel mechanisms are respectively fixed to the bottom of the lower chassis 5 and each Mecanum wheel mechanism is driven independently.

[0048] Preferably, each Mecanum wheel mechanism includes a drive wheel bracket 14, a drive motor 13, and a Mecanum wheel 11. The drive wheel bracket 14 is fixed to the bottom of the lower chassis 5, and the drive motor 13 is fixed on the drive wheel bracket 14. The drive motor 13 is connected to the Mecanum wheel 11 through a coupling 12. The Mecanum wheels 11 of the four Mecanum wheel mechanisms are independently controlled by their respective drive motors 13, enabling forward, backward, lateral, oblique, and in-situ turning movements, allowing the inspection robot to perform small-range posture adjustments and continuous scanning on one side of the composite material component.

[0049] like Figure 4 , Figure 5As shown, the detection robotic arm 2 includes a robotic arm base 16 fixed on the detection robot 1, a four-degree-of-freedom robotic arm fixed on the robotic arm base 16, and a quick-release interface 25 located at the end of the four-degree-of-freedom robotic arm. The quick-release interface 25 is used to detachably install an image sensor 26 or an ultrasonic sensor 27. The image sensor 26 or the ultrasonic sensor 27 can be installed according to the material type of the composite material component. When detecting light-transmitting or semi-light-transmitting materials such as fiberglass, the image sensor 26 is installed; when detecting opaque materials such as carbon fiber, the ultrasonic sensor 27 is installed. The four-degree-of-freedom robotic arm can adjust the distance, angle, and detection posture of the image sensor 26 or the ultrasonic sensor 27 by controlling the servo motor, servo motor, or linear actuator.

[0050] Preferably, the four-degree-of-freedom robotic arm includes a rotary base 17, a first joint motor 18, a rotary motor 19, a first arm segment 20, a second joint motor 21, a second arm segment 22, a third joint motor 23, and a third arm segment 24. The rotary base 17 is rotatably connected to the robotic arm base 16. The rotary base 17, the first arm segment 20, the second arm segment 22, and the third arm segment 24 are rotatably connected in sequence. The rotary motor 19 drives the rotary base 17 to rotate relative to the robotic arm base 16. The first joint motor 18 drives the first arm segment 20 to rotate relative to the rotary base 17. The second joint motor 21 drives the second arm segment 22 to rotate relative to the first arm segment 20. The third joint motor 23 drives the third arm segment 24 to rotate relative to the second arm segment 22. Through the driving of the rotary motor 19, the first joint motor 18, the second joint motor 21, and the third joint motor 23, the four degrees of freedom of the four-degree-of-freedom robotic arm can achieve movement. The end of the third arm segment 24 is provided with a quick-release interface 25, which is used for detachably mounting an image sensor 26 or an ultrasonic sensor 27.

[0051] like Figure 6As shown, the driven robot 3 includes a driven robot chassis 28, a driven robot control module 29, a support rod mechanism, an LED backlight 34, a caster wheel mechanism, a second electromagnet bracket 37, a second electromagnet unit 38, and second electromagnet feet 39. The driven robot control module 29 is fixed to the driven robot chassis 28. The driven robot control module 29 is equipped with a wired interface for powering the driven robot and exchanging data with the control system 4. The support rod mechanism is mounted on the driven robot chassis 28, and the LED backlight 34 is mounted at the end of the support rod mechanism. Four caster wheels are respectively fixed to the bottom of the driven robot chassis 28. The second electromagnet bracket 37 is fixedly connected to the driven robot chassis 28. Multiple second electromagnet units 38 are fixed on the second electromagnet bracket 37 to form a second electromagnet array. The number of second electromagnet units 38 in the second electromagnet array is the same as the number of first electromagnet units 10 in the first electromagnet array on the detection robot 1, and their distribution positions correspond. Each second electromagnet unit 38 has a Teflon second electromagnet foot pad 39 at its end to reduce friction and prevent scratching the composite material. The second electromagnet array cooperates with the first electromagnet array to form a magnetic adsorption coupling between the detection robot 1 and the driven robot 3 on opposite sides of the composite material component.

[0052] Preferably, the support rod mechanism includes a follower bracket 30, a first manual adjustment bolt 31, a support rod 32, and a second manual adjustment bolt 33; the follower bracket 30 is fixedly connected to the driven robot chassis 28, one end of the support rod 32 is connected to the follower bracket 30 through the first manual adjustment bolt 31, and the area array LED backlight 34 is connected to the other end of the support rod 32 through the second manual adjustment bolt 33. The angle of the area array LED backlight 34 can be adjusted through the support rod mechanism.

[0053] Preferably, the caster wheel mechanism includes a caster wheel bracket 35 fixed below the driven robot chassis 28 and a caster wheel 36 rotatably connected to the caster wheel bracket 35 via a bearing. The caster wheel mechanism enables the driven robot 3 to flexibly follow the component on the other side under the magnetic coupling effect of the detection robot 1 and its own follow-up control, reducing the motion resistance when the two robots move synchronously.

[0054] The control system 4 exchanges data with the detection robot 1 and the slave robot 3 via a wired connection. It is used to control the movement of the robots, the electromagnet adsorption of the electromagnet array, the switching of the light source, and the identification of defects in composite material components.

[0055] The working principle of this embodiment is briefly described below:

[0056] Inspection robot 1 and slave robot 3 are respectively positioned on opposite sides of the composite material component to be inspected (such as wind turbine blade shell or web). ("Opposite sides" can be understood as the two sides of the blade shell, the two sides of the web, the mold side and the free surface side, or other opposite sides that can form a corresponding relationship across the composite material to be inspected.) Inspection robot 1, as the active side, is responsible for active movement, path execution, inspection data acquisition, and result transmission. Slave robot 3, as the follower side, is primarily responsible for maintaining a corresponding position with the inspection robot on the other side of the component. By adjusting the on / off sequence, adsorption current, and adsorption zones of the second and first electromagnet arrays, a stable magnetic adsorption coupling is formed between slave robot 3 and inspection robot 1.

[0057] During operation, the detection robot 1 and the driven robot 3 are first placed at the initial detection points on both sides of the component, with them facing each other. The control system 4 supplies power to the two robots and sends commands via a wired connection. The first array of electromagnets on the detection robot 1 and the second array of electromagnets on the driven robot 3 are activated. The two sets of electromagnets are arranged opposite each other across the composite material component. After being energized, they generate mutual attraction, forming a stable magnetic adsorption coupling relationship between the two robots. The electromagnet feet are made of Teflon material, which reduces friction and prevents scratches when in contact with the component surface. Because the first and second electromagnet arrays are arranged in an array pattern (the number of electromagnet units is the same and their positions correspond), the adsorption force is evenly distributed in the chassis area, effectively preventing relative deflection or slippage of the two robots during movement.

[0058] After the magnetic adsorption coupling is established, the inspection robot 1 begins to move actively. Four Mecanum wheel structures are mounted on the lower chassis 5 of the inspection robot 1. Each Mecanum wheel is driven by its independent drive motor 13 via a coupling 12. The control system 4 controls the speed and direction of the four drive motors according to the planned path, enabling the inspection robot to achieve omnidirectional movement, including forward, backward, lateral translation, diagonal movement, and turning in place. During movement, the inspection robot 1 adjusts the posture of its end effector (image sensor 26 or ultrasonic sensor 27) using its inspection robotic arm 2, ensuring it remains aligned with the area to be inspected.

[0059] While the detection robot 1 moves, the slave robot 3 is pulled by the electromagnetic attraction above and moves flexibly on the other side of the component via its omnidirectional wheel mechanism. The omnidirectional wheel mechanism can freely change direction, so the slave robot 3 does not require a separate drive motor and can follow the movement trajectory of the detection robot with low resistance. The control system 4 collects the attraction status of the first and second electromagnet arrays (such as current feedback and gap changes) and the pose data of the two robots in real time. When necessary, it fine-tunes the on / off sequence of the electromagnet units or the attraction current partitioning to ensure that the two robots remain relatively stable in both the normal (perpendicular to the surface) and tangential (along the surface direction) directions when the curvature or thickness of the component changes.

[0060] Based on the material properties of composite components, the testing methods are divided into two categories:

[0061] When inspecting components made of translucent or semi-translucent materials such as fiberglass, an image sensor 26 is installed on the quick-release interface 25 at the end of the inspection robotic arm 2. The angles of the support rod 32 and the area-array LED backlight 34 are adjusted on the driven robot 3 using two manual adjustment bolts, ensuring the backlight faces the inspection area. The light emitted by the area-array LED backlight 34 passes through the translucent composite material component and is received by the image sensor 26 on the other side. When defects such as bubbles, delamination, dry fibers, or inclusions exist inside the component, the light will be absorbed, scattered, or blocked, forming dark spots, shadows, or abnormal brightness in the acquired image. The control system identifies the defects based on this information.

[0062] When inspecting components made of opaque materials such as carbon fiber, the image sensor 26 at the end of the inspection robotic arm 2 is replaced with an ultrasonic sensor 27. The inspection robotic arm 2 adjusts its posture using its four degrees of freedom to ensure that the ultrasonic sensor 27 is in close contact with the surface of the component. The ultrasonic sensor emits sound waves and receives echo signals, and determines whether there are internal defects such as delamination, debonding, or porosity based on parameters such as echo time, amplitude, and phase. At this time, the backlight module on the slave robot 3 can be turned off, but the second electromagnet array remains attracted to ensure follow-up positioning.

[0063] Throughout the inspection process, the control system 4 acquires the pose, path information, and electromagnet array working status of the inspection robot 1 in real time via a wired interface, as well as the inspection data collected by the image sensor 26 or ultrasonic sensor 27. After fusing the multi-source information, the control system generates an inspection report containing information such as defect coordinates, type, size, and depth. If the confidence level of the inspection result in a certain area is low or if there is a synchronous deviation on both sides, the control system can automatically adjust the movement path of the inspection robot, the electromagnet attraction current, or the end effector posture of the robotic arm, and control the robot to return to that area for re-inspection.

[0064] In summary, this dual-sided collaborative inspection robot achieves efficient, stable, and continuous dual-sided collaborative inspection of composite material components of different materials through the active omnidirectional movement of the inspection robot and the electromagnetic coupling of the slave robot, combined with a replaceable end-effector inspection module.

[0065] Example 2:

[0066] like Figure 1 As shown, this embodiment is a method for bilateral collaborative inspection of composite material components, implemented using the bilateral collaborative inspection robot described in Embodiment 1, and includes the following steps:

[0067] S1. Establish a detection coordinate system and plan the monitoring area and detection path based on the size and material type (e.g., fiberglass or carbon fiber) of the composite material components (blades, webs, etc.).

[0068] S2. Place the inspection robot 1 on one side of the composite material component (such as the outer surface), place the driven robot 3 on the opposite side of the composite material component (such as the inner surface), and set the inspection robot 1 and the driven robot 3 opposite each other at the starting point.

[0069] S3. Activate the first electromagnet array of the detection robot 1 and the second electromagnet array of the slave robot 3, adjust the adsorption current so that the detection robot and the slave robot can be attracted to each other through the composite material component and maintain their relative positions, thus completing the initial alignment.

[0070] S4. The inspection robot 1 actively moves along the planned path using four Mecanum wheel mechanisms, while the slave robot 3 follows through a universal wheel mechanism under the magnetic attraction coupling of the electromagnet array. The control system 4 finely adjusts the relative positions of the two robots in real time based on the electromagnet feedback signals and the pose data of the two robots.

[0071] S5. Select the testing method based on the light transmittance of the composite material component:

[0072] S51. If the composite material component is made of a light-transmitting or semi-light-transmitting material (e.g., fiberglass), an image sensor 26 is installed at the end of the four-degree-of-freedom robotic arm 2, and the area array LED backlight 34 on the slave robot 3 is turned on. The image sensor 26 acquires transmitted light images. When there are defects such as bubbles, delamination, dry fibers, or inclusions inside the component, the light will be absorbed, scattered, or blocked, forming dark spots, shadows, or abnormal brightness in the acquired image. The control system processes the acquired transmitted light images, including brightness normalization, background subtraction, and abnormal region segmentation, to identify the location and size of defects such as bubbles, dry fibers, and inclusions inside the component.

[0073] S52. If the composite material component is made of an opaque material (e.g., carbon fiber), an ultrasonic sensor 27 is installed at the end of the four-degree-of-freedom robotic arm. The four-degree-of-freedom robotic arm adjusts its posture to make the ultrasonic sensor fit against the surface of the component in the monitoring area, collects ultrasonic echo signals, and the control system identifies defects such as delamination, debonding, pores, inclusions, or thickness abnormalities inside the component based on the echo characteristics such as echo time, amplitude, and phase of the echo signal and the scanning angle.

[0074] S6. During the inspection process, the control system records in real time the pose data of the two robots, path information, working status of the electromagnet array, and inspection data collected by the image sensor 26 or ultrasonic sensor 27. After fusing the multi-source information, the control system obtains the inspection results and finally generates an inspection report with information such as defect number, defect location coordinates, defect type, defect size, defect depth, or confidence level. Preferably, for inspection areas where the confidence level is lower than the threshold or the synchronization deviation between the two sides exceeds the range, the control system automatically adjusts the robot posture, the magnetic attraction force of the electromagnet array, or the inspection path, and controls the robot to return to step S4 for re-inspection of the inspection area.

[0075] The composite material component bilateral collaborative inspection robot and its inspection method provided by this invention can efficiently and stably perform bilateral collaborative non-destructive testing on large composite material components such as wind turbine blades and webs. It is adaptable to different material properties and can realize the visualization, coordinateization and traceability of inspection results, and has good prospects for industrial application.

Claims

1. A robot for bilateral collaborative inspection of composite material components, characterized in that, It includes an inspection robot (1), a slave robot (3), an inspection robotic arm (2), and a control system (4); the inspection robot (1) and the slave robot (3) are respectively arranged on opposite sides of the composite material component; The detection robot (1) includes a double-layer chassis, a first electromagnet array, and a Mecanum wheel mechanism; the first electromagnet array is fixed to the bottom surface of the double-layer chassis; multiple Mecanum wheel mechanisms are respectively fixed to the bottom of the double-layer chassis and each Mecanum wheel mechanism is driven independently; The detection robotic arm (2) includes a four-degree-of-freedom robotic arm mounted on the detection robot (1). The end of the four-degree-of-freedom robotic arm is provided with a quick-release interface (25), which is used to detachably connect an image sensor (26) or an ultrasonic sensor (27). The driven robot (3) includes a driven robot chassis (28), a second electromagnet array, an LED backlight (34), and multiple caster wheel mechanisms; the second electromagnet array is fixed on the driven robot chassis (28), and the second electromagnet array and the first electromagnet array are magnetically coupled through composite material components; the multiple caster wheel mechanisms are respectively fixed to the bottom of the driven robot chassis (28); the LED backlight (34) is mounted on the driven robot chassis (28) through a support rod mechanism; The control system (4) is connected to the detection robot (1) and the slave robot (3) respectively, and is used to control the robot's movement, electromagnet adsorption, and defect identification of composite material components.

2. The composite material component dual-sided collaborative inspection robot as described in claim 1, characterized in that, The first electromagnet array includes a first electromagnet bracket (9) and a plurality of first electromagnet units (10) fixed on the first electromagnet bracket (9), the first electromagnet bracket (9) being fixed on the double-layer chassis; the second electromagnet array includes a second electromagnet bracket (37) and a plurality of second electromagnet units (38) fixed on the second electromagnet bracket (37), the second electromagnet bracket (37) being fixed on the driven robot chassis (28); the number of second electromagnet units (38) is the same as that of first electromagnet units (10) and their distribution positions correspond.

3. The composite material component dual-sided collaborative inspection robot as described in claim 2, characterized in that, The first electromagnet unit (10) is provided with a first electromagnet foot pad (15) made of Teflon material at its end, and the second electromagnet unit (38) is provided with a second electromagnet foot pad (39) made of Teflon material at its end.

4. The composite material component dual-sided collaborative inspection robot as described in claim 1, characterized in that, The Mecanum wheel mechanism includes a drive wheel bracket (14), a drive motor (13), and a Mecanum wheel (11). The drive wheel bracket (14) is fixed to the bottom of the double-layer chassis, and the drive motor (13) is fixed on the drive wheel bracket (14). The drive motor (13) is connected to the Mecanum wheel (11) through a coupling (12).

5. The composite material component dual-sided collaborative inspection robot as described in claim 1, characterized in that, The support rod mechanism includes a follower bracket (30), a first manual adjustment bolt (31), a support rod (32), and a second manual adjustment bolt (33). The follower bracket (30) is fixedly connected to the slave robot chassis (28). One end of the support rod (32) is connected to the follower bracket (30) through the first manual adjustment bolt (31), and the other end of the support rod (32) is connected to the area array LED backlight (34) through the second manual adjustment bolt (33).

6. The composite material component dual-sided collaborative inspection robot as described in claim 1, characterized in that, The detection robot (1) also includes a detection robot control module (8), which has a wired interface for powering the detection robot (1) and exchanging data with the control system (4); the slave robot (3) also includes a slave robot control module (29), which has a wired interface for powering the slave robot and exchanging data with the control system (4).

7. A method for bilateral collaborative inspection of composite material components, implemented using the bilateral collaborative inspection robot described in claim 1, characterized in that, Includes the following steps: S1. Establish a detection coordinate system based on the size and material type of the composite material component, and plan the monitoring area and detection path; S2. Place the inspection robot on one side of the composite material component, place the driven robot on the opposite side of the composite material component, and set the inspection robot and the driven robot opposite each other at the starting point; S3. Activate the first electromagnet array of the detection robot and the second electromagnet array of the driven robot, adjust the adsorption current so that the detection robot and the driven robot can adsorb each other through the composite material component and maintain their relative positions, thus completing the initial alignment; S4. The inspection robot actively moves along the planned path by relying on multiple Mecanum wheel mechanisms, and the driven robot follows through the universal wheel mechanism under the magnetic adsorption coupling. S5. Select the testing method based on the light transmittance of the composite material component: S51. If the composite material component is made of a light-transmitting or semi-light-transmitting material, an image sensor is installed at the end of the four-degree-of-freedom robotic arm, and the area array LED backlight on the slave robot is turned on; the image sensor collects transmitted light images, and the control system processes the collected transmitted light images to identify internal defects in the component. S52. If the composite material component is made of opaque material, an ultrasonic sensor is installed at the end of the four-degree-of-freedom robotic arm. The four-degree-of-freedom robotic arm adjusts its posture so that the ultrasonic sensor is in contact with the surface of the component in the monitoring area to collect ultrasonic echo signals. The control system identifies internal defects of the component based on the echo signals. S6. During the detection process, the control system records the pose data, path information, working status of the electromagnet array, and detection data collected by the image sensor or ultrasonic sensor in real time. The control system integrates the multi-source information to obtain the detection results and generate a detection report.

8. The method for bilateral collaborative detection of composite material components as described in claim 7, characterized in that, The inspection report includes the defect number, defect location coordinates, defect type, defect size, and confidence level.

9. The method for bilateral collaborative detection of composite material components as described in claim 8, characterized in that, For detection areas where the confidence level is below the threshold or the synchronization deviation between the two sides exceeds the range, the control system adjusts the robot's posture, the magnetic adsorption force of the electromagnet array, or the detection path, and controls the robot to return to step S4 to re-inspect the detection area.

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