An automated ultrasonic inspection robot

Abstract

The application relates to the technical field of nondestructive testing, and discloses an automatic ultrasonic detection robot, which is characterized in that a first detection vehicle and a second detection vehicle are connected through guide rails, a driving unit in the vehicle body cooperates with a control module, and an X-axis servo motor, a Z-axis servo motor and a Y-axis servo motor of the guide rail on the detection vehicle can be used to flexibly adjust the position and the posture, a detection personnel does not need to enter a limited space, the detection difficulty of an area that cannot be reached by manual work is solved, and the defect missing detection caused by single surface detection of only the outer surface is avoided. Meanwhile, the ultrasonic detection device of the control module linkage driving unit and the detection unit can automatically move the detection component according to the law, replaces manual movement of a probe, reduces a large amount of labor cost, and through adjustment of the servo motor, it can be ensured that the ultrasonic detection device fully covers the detected part, the detection comprehensiveness and efficiency are improved, and the ultrasonic detection labor cost is reduced.

Description

Technical Field

[0001] This invention belongs to the field of nondestructive testing technology, specifically an automated ultrasonic testing robot. Background Technology

[0002] Ultrasonic nondestructive testing (NDT) utilizes the differences in acoustic properties between materials and their internal defects to examine the energy changes in the reflection and penetration time of ultrasonic waves during ultrasonic wave propagation. During testing, the operator often needs to move the ultrasonic probe in a specific pattern to ensure the ultrasonic waves cover as much of the inspected area as possible. For example, when using an A-type ultrasonic tester to inspect longitudinal defects in a circumferential butt weld of a pipe, the operator needs to place the probe perpendicular to the weld on the inspection surface and scan along the weld in a "zigzag" path, slightly rotating the probe during the scan.

[0003] However, some ultrasonic testing operations are conducted in confined spaces, such as the ultrasonic testing of pressure vessels. Some areas may be inaccessible to personnel, requiring the equipment to inspect only the outer surface of the component. If only one side of the component is inspected, some defects may be missed. Furthermore, most ultrasonic testing is currently done manually, which consumes significant manpower when dealing with large volumes of work. To enable ultrasonic testing in confined areas and reduce labor costs, it is necessary to develop an automated ultrasonic testing robot. Summary of the Invention

[0004] This invention provides an automated ultrasonic testing robot that solves the problem of missed detections in existing ultrasonic testing operations.

[0005] To achieve the above objectives, the present invention provides the following technical solution: An automated ultrasonic testing robot includes a guide rail, with a first testing vehicle and a second testing vehicle connected to both ends of the guide rail. Both the first and second testing vehicles include a vehicle body, and a drive unit and a control module are installed inside the vehicle body. A testing unit and a Y-axis servo motor are installed on the guide rail, and a Z-axis servo motor and an X-axis servo motor are installed on both the first and second testing vehicles. The control module is electrically connected to the drive unit and the testing unit, and an ultrasonic testing device is installed on the testing unit.

[0006] Preferably, the wheels of the first and second inspection vehicles are Mecanum wheels, and the Mecanum wheels are equipped with electromagnet devices.

[0007] Preferably, there are two drive units, and each drive unit is connected to two Mecanum wheels.

[0008] Preferably, the detection unit includes a vision module for identifying and capturing features of the inspected component.

[0009] Preferably, the bottom of the detection unit is connected to a probe and a coupling agent brush arranged in parallel.

[0010] Preferably, when the detection unit moves, the coupling agent is brushed in front of the probe.

[0011] Preferably, the top of the probe is connected to a rotatable probe clip.

[0012] Preferably, the detection unit is provided with pulleys that are connected to the guide rail.

[0013] Preferably, the detection unit is equipped with a communication module.

[0014] A method for using an automated ultrasonic inspection robot, characterized by comprising: placing the robot near the part to be inspected; remotely controlling the robot to reach a designated inspection position; the inspection unit capturing the features of the part to be inspected and formulating an inspection strategy based on preset process parameters; the control module controlling the drive unit to move the trolley in multiple directions, while adjusting the angle between the drive unit and the trolley to ensure that the wheels are in contact with the inspection surface; the inspection unit recognizing the image information of the part to be inspected in real time and positioning the relative position of the inspection unit and the part to be inspected, transmitting the information to the control module via the communication module; the control module controlling the inspection unit to translate along the guide rail; the inspection unit performing ultrasonic scanning; when crossing obstacles or inspection surfaces, the X-axis servo motor lifting one inspection trolley from another, the Z-axis servo motor rotating the trolley, and the Y-axis servo motor adjusting the orientation of the wheels of the lifted trolley; and the inspection unit converting the inspection signals and image information into digital signals and transmitting them to the inspection personnel.

[0015] Compared with existing technologies, the present invention has the following advantages: The present invention provides an automated ultrasonic testing robot. A first testing vehicle and a second testing vehicle are connected by a guide rail. The drive unit inside the vehicle, in conjunction with the control module, and the X-axis and Z-axis servo motors on the testing vehicle and the Y-axis servo motor on the guide rail, can flexibly adjust its position and posture. This eliminates the need for personnel to enter confined spaces, solving the problem of testing areas inaccessible to humans and avoiding missed defects caused by only inspecting the outer surface. Simultaneously, the control module, in conjunction with the drive unit and the ultrasonic testing device of the testing unit, can automatically move the testing components according to a set pattern, replacing manual probe movement and significantly reducing manpower costs. Furthermore, the servo motor adjustment ensures that the ultrasonic testing device fully covers the inspected area, improving the comprehensiveness and efficiency of the inspection and reducing the labor costs of ultrasonic testing. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of an automatic ultrasonic testing robot according to the present invention; Figure 2 This is a schematic side view of the structure of an automatic ultrasonic testing robot according to the present invention; In the diagram, 1-first inspection vehicle, 2-second inspection vehicle, 3-body, 4-drive unit, 5-inspection unit, 6-guide rail, 7-vision module, 8-probe, 9-probe clip, 10-coupling brush, 11-Mecanum wheel, 12-X-axis servo motor, 13-Y-axis servo motor, 14-Z-axis servo motor, 15-power module, 16-control module, 17-communication module, 18-inspection module. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0020] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0021] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this invention, it should be noted that unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," and "set up" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components.

[0022] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0023] like Figure 1 As shown, this embodiment of the invention provides an automatic ultrasonic testing robot, including a guide rail 6. A first testing vehicle 1 and a second testing vehicle 2 are connected to both ends of the guide rail 6. Both the first testing vehicle 1 and the second testing vehicle 2 include a vehicle body 3. A drive unit 4 and a control module 16 are installed inside the vehicle body 3. A testing unit 5 and a Y-axis servo motor 13 are installed on the guide rail 6. A Z-axis servo motor 14 and an X-axis servo motor 12 are installed on both the first testing vehicle 1 and the second testing vehicle 2. The control module 16 is electrically connected to the drive unit 4 and the testing unit. An ultrasonic testing device is installed on the testing unit 5.

[0024] The first inspection vehicle 1 and the second inspection vehicle 2 are connected by guide rail 6. The drive unit 4 inside the vehicle body 3, in conjunction with the control module 16, and the X-axis servo motor 12, Z-axis servo motor 14 on the inspection vehicle and the Y-axis servo motor 13 on the guide rail 6, can flexibly adjust its position and posture. This eliminates the need for inspection personnel to enter confined spaces such as the interior of pressure vessels, solving the problem of inspection in areas inaccessible to humans and avoiding missed defects caused by inspection of only one side of the outer surface. At the same time, the control module 16, in conjunction with the ultrasonic testing device of the drive unit 4 and the inspection unit 5, can automatically move the inspection components according to a pattern, replacing manual movement of the probe, reducing a large amount of manpower consumption. Furthermore, the adjustment of the servo motors ensures that the ultrasonic testing device fully covers the inspected area, improving the comprehensiveness and efficiency of the inspection and reducing the labor cost of ultrasonic testing.

[0025] The detailed structure is as follows: The wheels of the first inspection vehicle 1 and the second inspection vehicle 2 are Mecanum wheels 11, and electromagnets are installed in the Mecanum wheels 11. The advantage of this design is that the Mecanum wheels 11 themselves have flexible multi-directional movement capabilities, enabling forward, backward, left, right and diagonal movement, adapting to complex inspection paths; while the electromagnets enable the wheels to be firmly attached to the surface of ferromagnetic materials, effectively preventing the robot from slipping even when working on vertical or inclined parts being inspected, thus enhancing operational stability in special scenarios such as confined spaces.

[0026] There are two drive units 4, each connected to two Mecanum wheels 11. The advantage of this structure is that by controlling the corresponding Mecanum wheels 11 separately through two independent drive units 4, the speed and direction of each wheel can be independently adjusted, improving the accuracy and flexibility of the robot's movement; at the same time, the cooperation of multiple wheels can distribute the weight of the robot body 3, improving its adaptability to different detection surfaces and ensuring stable movement even on uneven surfaces.

[0027] The inspection unit 5 includes a vision module 7, which is used to identify and capture the features of the inspected component. Its advantage is that the vision module 7 can automatically acquire feature information such as the shape and welds of the inspected component without the need for manual pre-marking. It can assist the control module 16 in quickly locating the inspection area and formulating a scanning strategy, reducing manual intervention and improving the automation level of the inspection. It is especially suitable for inspected components with complex shapes or diverse structures.

[0028] The bottom of the detection unit 5 is connected to a probe 8 and a coupling agent brush 10 arranged in parallel. The advantage of this design is that the parallel layout fixes the relative position of the coupling agent brush 10 and the probe 8, ensuring that the coupling agent applied by the coupling agent brush 10 evenly covers the area to be detected by the probe 8, avoiding poor coupling caused by positional deviation between the two, providing stable acoustic conduction conditions for ultrasonic testing, and improving the accuracy of the detection signal.

[0029] When the detection unit 5 moves, the coupling agent brush 10 is positioned in front of the probe 8. This arrangement ensures that the coupling agent brush 10 applies the coupling agent to the detection surface before the probe 8 during the movement of the detection unit 5, allowing sufficient time for the coupling agent to adhere evenly. This prevents the probe 8 from directly contacting the dry surface, thus avoiding signal attenuation or distortion and effectively reducing detection errors caused by coupling issues.

[0030] The top of the probe 8 is connected to a rotatable probe clip 9. Its advantage is that the rotation function of the probe clip 9 can flexibly adjust the tilt angle and orientation of the probe 8, which can meet the needs of "zigzag" scanning such as when inspecting circumferential butt welds of pipes, where the probe 8 needs to be slightly rotated, so that the ultrasonic beam can more comprehensively cover the inspected area and reduce the missed defects caused by a fixed angle.

[0031] The detection unit 5 is equipped with pulleys that connect to the guide rail 6. The advantage of this design is that the pulleys cooperate with the guide rail 6, allowing the detection unit 5 to move smoothly and accurately along the guide rail 6, ensuring the regularity and consistency of the scanning path, avoiding path deviations that occur when the probe 8 is moved manually. This is especially suitable for detection scenarios that require full coverage along a fixed trajectory, thus improving the uniformity of the detection.

[0032] The detection unit 5 is equipped with a communication module 17. Its advantage is that the communication module 17 can transmit data such as image information captured by the vision module 7 and ultrasonic signals acquired by the detection module 18 to an external terminal in real time, enabling the inspection personnel to remotely monitor the operation process; in scenarios where personnel cannot enter, such as confined spaces, it can ensure timely feedback of detection data, which not only protects personnel safety but also improves the efficiency and controllability of the inspection operation.

[0033] Another embodiment of the present invention provides an automated ultrasonic testing robot, comprising four main parts: a first testing vehicle 1, a second testing vehicle 2, a testing unit 5, and a guide rail 6. The first testing vehicle 1 and the second testing vehicle 2 each comprise five main parts: a vehicle body 3, a drive unit 4, Mecanum wheels 11, a Z-axis servo motor 14, and an X-axis servo motor 12. The vehicle body 3 comprises two main parts: a power module 15 and a control module 16. The testing unit 5 comprises five main parts: a vision module 7, a coupling agent brush 10, a probe clip 9, a testing module 18, and a communication module 17. The guide rail 6 comprises one main part: a Y-axis servo motor 13.

[0034] Each vehicle body 3 has two drive units 4 connected to each side, and each drive unit 4 is connected to two Mecanum wheels 11. Each Mecanum wheel 11 can rotate independently at different speeds and directions under the action of the drive device. The drive device is powered by a power module 15 inside the vehicle body 3, and the rotational speed of each Mecanum wheel 11 is input and controlled by a control module 16 inside the vehicle body 3. The four Mecanum wheels 11 of the vehicle can achieve forward and backward movement, left and right translation, and diagonal movement under different rotational speed combinations.

[0035] Furthermore, the angle between the two drive units of each vehicle and the vehicle body 3 can be adjusted. An electromagnet is installed in the Mecanum wheel 11, allowing the vehicle to adhere to a ferromagnetic material.

[0036] The two ends of guide rail 6 are connected to two trolleys respectively.

[0037] The detection unit 5 is mounted on the guide rail 6. The detection unit 5 is designed with a pulley structure, and can move horizontally along the guide rail 6 under the joint control of the power module 15 and the control module 16 inside the trolley body 3.

[0038] The detection unit 5 is equipped with a vision module 7. The function of the vision module 7 is to identify the image information of the inspected part and to locate the relative position between the detection unit 5 and the inspected part. The obtained information is transmitted to the control module 16, and the control module 16 makes a control strategy based on the information captured by the vision module 7.

[0039] The detection unit 5 is equipped with a detection module 18. The function of the detection module 18 is to realize the function of ultrasonic detection. It can integrate the function of ultrasonic detection or the function of phased array ultrasonic detection.

[0040] The detection unit 5 is equipped with a communication module 17, which converts the detected signals and image information obtained by the vision module 7 into digital signals and transmits them to the inspection personnel for communication with the outside world. In addition, the communication module 17 is also responsible for information transmission with the control module 16 on the vehicle.

[0041] The detection unit 5 is equipped with a coupling agent brush 10, which is used to apply coupling agent to the detection surface.

[0042] The detection unit 5 is equipped with a probe clamp 9, which is used to fix the probe 8 and ensure that the probe 8 fits well with the detection surface during the detection process. The probe clamp 9 has a rotation function, which can adjust the direction of the probe 8.

[0043] The on-site implementation process for this device is as follows: The inspector places the robot near the part to be inspected and remotely controls it to reach the designated inspection position. The vision module 7 of the inspection unit 5 can capture the features of the inspected part and, combined with pre-input process parameters, automatically formulate an inspection strategy.

[0044] The car's wheels, or Mecanum wheels 11, are ferromagnetic and attract to ferromagnetic materials. The drive units 4 connected to both sides of the car body 3 are powered by the power module 15 inside the car body 3. Under the control of the control module 16, each Mecanum wheel 11 is driven to rotate independently at different speeds and directions. The four Mecanum wheels 11 of the car achieve forward and backward movement, left and right translation, and diagonal movement by coordinating different speeds.

[0045] The angle between the two drive units of each vehicle and the vehicle body 3 can be adjusted in real time to ensure that the wheels always have good contact with the detection surface, thereby obtaining good grip.

[0046] In addition, the automated ultrasonic inspection robot is equipped with three servo motors. Each cart has one servo motor (X-axis servo motor 12) that rotates around the X-axis, enabling one cart to lift another. Each cart also has one servo motor (Z-axis servo motor 14) that rotates around the Z-axis, allowing the cart body 3 to rotate around the axis of the Z-axis servo motor 14. A servo motor (Y-axis servo motor 13) that rotates around the Y-axis is mounted on the guide rail 6, adjusting the wheel orientation of the lifted cart. Through the coordination of these three servo motors in different directions, the cart has a certain obstacle-crossing capability, allowing it to traverse gaps between inspection surfaces.

[0047] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the scope of the invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0048] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can be appropriately combined to form other embodiments that can be understood by those skilled in the art. The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. An automated ultrasonic testing robot, characterized in that, The system includes a guide rail (6), with a first inspection vehicle (1) and a second inspection vehicle (2) connected to both ends of the guide rail (6). Both the first inspection vehicle (1) and the second inspection vehicle (2) include a vehicle body (3). A drive unit (4) and a control module (16) are installed inside the vehicle body (3). A detection unit (5) and a Y-axis servo motor (13) are installed on the guide rail (6). A Z-axis servo motor (14) and an X-axis servo motor (12) are installed on both the first inspection vehicle (1) and the second inspection vehicle (2). The control module (16) is electrically connected to the drive unit (4) and the detection unit. An ultrasonic detection device is installed on the detection unit (5).

2. The automated ultrasonic testing robot according to claim 1, characterized in that, The wheels of the first inspection vehicle (1) and the second inspection vehicle (2) are Mecanum wheels (11), and an electromagnet device is provided in the Mecanum wheel (11).

3. The automated ultrasonic testing robot according to claim 1, characterized in that, There are two drive units (4), and each drive unit (4) is connected to two Mecanum wheels (11).

4. The automated ultrasonic testing robot according to claim 1, characterized in that, The detection unit (5) includes a vision module (7) for identifying and capturing features of the inspected component.

5. An automated ultrasonic testing robot according to claim 1, characterized in that, The bottom of the detection unit (5) is connected to a probe (8) and a coupling agent brush (10) arranged in parallel.

6. An automated ultrasonic testing robot according to claim 5, characterized in that, When the detection unit (5) moves, the coupling agent brush (10) is in front of the probe (8).

7. An automated ultrasonic testing robot according to claim 5, characterized in that, The probe (8) is connected to a rotatable probe clip (9) at the top.

8. An automated ultrasonic testing robot according to claim 1, characterized in that, The detection unit (5) is equipped with a pulley that is connected to the guide rail (6).

9. An automated ultrasonic testing robot according to claim 1, characterized in that, The detection unit (5) is equipped with a communication module (17).

10. A method of using an automated ultrasonic testing robot, characterized in that, An automatic ultrasonic inspection robot based on any one of claims 1-9 includes: placing the robot near the part to be inspected, remotely controlling the robot to reach the designated inspection position, the inspection unit (5) capturing the features of the part to be inspected and formulating an inspection strategy in combination with preset process parameters, the control module (16) controlling the drive unit (4) to make the trolley move in multiple directions, while adjusting the angle between the drive unit (4) and the body (3) to ensure that the wheels are in contact with the inspection surface, the inspection unit (5) identifying the image information of the part to be inspected in real time and positioning the relative position of the inspection unit (5) and the part to be inspected, the control module (16) controlling the inspection unit (5) to translate along the guide rail (6), the inspection unit (5) performing ultrasonic scanning, when crossing obstacles or crossing the inspection surface, the X-axis servo motor (12) lifting one inspection trolley to another inspection trolley, the Z-axis servo motor (14) rotating the trolley, the Y-axis servo motor (13) adjusting the wheel orientation of the lifted trolley, and the inspection unit (5) converting the inspection signal and image information into digital signals and transmitting them to the inspection personnel.

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