A safety redundancy protection system for adsorption-type painting robots in power substations to prevent loss of attachment.

Abstract

This invention relates to the field of power equipment maintenance technology, specifically to a safety redundancy protection system for adsorption-type painting robots in power substations. The system includes: a data acquisition module for acquiring multi-source sensing data from the robot; and a reliability calculation and fusion module for calculating the negative pressure adsorption reliability and magnetic adsorption reliability of each zone based on the multi-source sensing data. This invention integrates multi-source sensing data such as real-time negative pressure, magnetic current, robot tilt angle, air leakage in the sealing cavity, and wall roughness level to establish a roughness-reference negative pressure mapping and attenuation-reliability function. This transforms the physical state into numerical indicators of negative pressure adsorption reliability and magnetic adsorption reliability. A weighted fusion algorithm is used to calculate the overall adsorption safety margin, quantifying the robot's adsorption safety margin on complex and rough walls, thus solving the problem that traditional systems cannot assess comprehensive adsorption risk.

Description

Technical Field

[0001] This invention relates to the field of power equipment maintenance technology, specifically to a safety redundancy protection system for the loss of attachment of an adsorption-type spray painting robot in a power substation. Background Technology

[0002] With the rapid development of power infrastructure construction, the outdoor steel structures of substations are exposed to the outdoor environment for extended periods, making them susceptible to oxidation and corrosion. Regular anti-corrosion coating is necessary to extend their service life. However, due to the complex structure of substation equipment and the presence of dangerous factors such as high voltage and strong magnetic fields in the working environment, manual high-altitude work poses significant risks. Therefore, using adsorption-type painting robots to replace manual labor for wall-mounted work has become an industry trend.

[0003] Existing adsorption-type painting robots typically use negative pressure adsorption or magnetic adsorption principles to fix themselves to the wall. However, the steel structure surface of substations often has rust, welding slag or old paint, resulting in uneven wall roughness. In addition, outdoor operations are often accompanied by severe weather such as strong winds. Traditional robot adsorption control systems mostly use a single negative pressure feedback mechanism or simple magnetic constant current control, lacking the ability to comprehensively perceive the wall condition.

[0004] Furthermore, in actual operation, if a certain adsorption zone of the robot leaks air due to aging of the sealing strip or unevenness of the wall, traditional systems often cannot identify and compensate for it in time, which can easily trigger a chain reaction that causes the entire machine to detach. Or, when the adsorption force is about to fail, the system can only make a binary decision of continuing operation or emergency shutdown, lacking graded early warning and progressive redundant control methods. Once deadsorption occurs, it will not only cause expensive equipment damage, but may also cause paint leakage that contaminates the insulation equipment, or even lead to serious safety accidents such as falling objects from heights injuring people. Summary of the Invention

[0005] To achieve the above objectives, the present invention provides the following technical solution: a safety redundancy protection system for adsorption-type spray painting robots in power substations, comprising:

[0006] The data acquisition module is used to acquire multi-source sensor data of the robot;

[0007] The reliability calculation fusion module is used to calculate the negative pressure adsorption reliability and magnetic adsorption reliability of each zone based on multi-source sensing data; and to fuse the negative pressure adsorption reliability and magnetic adsorption reliability to obtain the overall adsorption safety margin.

[0008] The first-level redundancy compensation module is used to compare the overall adsorption safety margin with the first safety threshold of the corresponding roughness level. If it is lower than the first safety threshold, a first-level redundancy trigger signal is generated. Based on the first-level redundancy trigger signal, the leakage over-limit zone is closed and the negative pressure setting value of the adjacent zone is increased. At the same time, the power supply current of the magnetic adsorption unit is increased, and a first-level compensation control command is output.

[0009] The secondary redundancy switching module is used to reacquire multi-source sensing data and update the overall adsorption safety margin after the execution of the primary compensation control command. If the updated overall adsorption safety margin is lower than the second safety threshold of the corresponding roughness level, a secondary redundancy trigger signal is generated. Based on the secondary redundancy trigger signal, the negative pressure supply source is switched to the emergency gas storage device, and a deceleration control command for the spraying device is generated.

[0010] The three-level redundancy locking module is used to update the overall machine adsorption safety margin again after generating the two-level redundancy trigger signal. If the updated overall machine adsorption safety margin is lower than the third safety threshold of the corresponding roughness level, a three-level redundancy trigger signal is generated. Based on the three-level redundancy trigger signal, the mechanical self-locking hook drive command and the spray gun locking command are output to perform mechanical locking and cut off the paint supply.

[0011] Preferably, the multi-source sensing data includes the real-time negative pressure value of each independent negative pressure adsorption zone, the real-time current value of the magnetic adsorption unit, the body tilt angle, the air leakage of the sealing cavity of each zone, and the roughness level of the current working wall surface.

[0012] The reliability of negative pressure adsorption in each zone is calculated based on multi-source sensing data, including:

[0013] Obtain the roughness level of the current working wall surface from the multi-source sensing data, and find the reference negative pressure value of each zone corresponding to the roughness level from the preset roughness-reference negative pressure mapping table;

[0014] The negative pressure deviation value of each partition is obtained by subtracting the real-time negative pressure value of each partition from the corresponding baseline negative pressure value.

[0015] The leakage of the sealed cavity in each partition is obtained from the multi-source sensing data. The absolute value of the negative pressure deviation value is weighted and summed with the leakage of the sealed cavity to obtain the negative pressure attenuation of each partition.

[0016] Based on the negative pressure attenuation, the negative pressure adsorption reliability of each partition is calculated through a preset attenuation-reliability mapping function; whereby the negative pressure adsorption reliability is negatively correlated with the negative pressure attenuation.

[0017] Preferably, the magnetic adsorption reliability of each partition is calculated based on multi-source sensing data, including:

[0018] The rated operating current of the magnetic adsorption unit in the vertical adsorption state on a flat wall is obtained as the reference current;

[0019] The current sustaining ratio is obtained by comparing the real-time current value in the multi-source sensing data with the reference current.

[0020] Obtain the fuselage tilt angle from multi-source sensing data, and calculate the cosine value of the fuselage tilt angle as the normal component coefficient of the adsorption force;

[0021] The reliability of magnetic adsorption is obtained by multiplying the current maintenance ratio by the normal component coefficient of the adsorption force.

[0022] Preferably, the reliability of negative pressure adsorption and the reliability of magnetic adsorption are combined to obtain the overall adsorption safety margin, including:

[0023] The minimum value of the negative pressure adsorption reliability in all partitions is taken as the worst reliability of the negative pressure system.

[0024] The weighted fusion of the worst-case reliability of the negative pressure system and the reliability of magnetic adsorption is used as the overall adsorption safety margin output.

[0025] The sum of the weights of the negative pressure system and the magnetic system is 1.

[0026] Preferably, the overall adsorption safety margin is compared with a first safety threshold corresponding to the roughness level. If it is lower than the first safety threshold, a first-level redundant trigger signal is generated, including:

[0027] From the preset roughness-safety threshold mapping table, obtain the first safety threshold, the second safety threshold, and the third safety threshold corresponding to the roughness level, respectively; wherein the first safety threshold, the second safety threshold, and the third safety threshold decrease sequentially.

[0028] The overall adsorption safety margin is numerically compared with the first safety threshold.

[0029] When the overall adsorption safety margin is less than the first safety threshold, a first-level redundant trigger signal is generated.

[0030] Preferably, based on the primary redundancy trigger signal, the leakage-over-limit zone is closed and the negative pressure setpoint of the adjacent zone is increased. Simultaneously, the power supply current of the magnetic adsorption unit is increased, and a primary compensation control command is output, including:

[0031] In response to the first-level redundancy trigger signal, the leakage of the sealing cavity of each zone is compared, and the zone whose sealing cavity leakage exceeds the preset leakage threshold is marked as the leakage over-limit zone.

[0032] Send a shut-off command to the solenoid valve corresponding to the zone where leakage exceeds the limit;

[0033] Identify several zones that are spatially adjacent to the zone with excessive leakage, and increase the negative pressure setting value of the adjacent zones by a preset compensation ratio based on the original baseline negative pressure value.

[0034] Send a current boost command to the power supply module of the magnetic adsorption unit to increase the power supply current to a preset multiple of the rated current;

[0035] The above instructions are summarized into a first-level compensation control instruction and output.

[0036] Preferably, after the first-level compensation control command is executed, multi-source sensing data is reacquired and the overall adsorption safety margin is updated. If the updated overall adsorption safety margin is lower than the second safety threshold corresponding to the roughness level, a second-level redundancy trigger signal is generated, including:

[0037] After a preset waiting period following the execution of the first-level compensation control command, the real-time negative pressure value of each independent negative pressure adsorption zone, the real-time current value of the magnetic adsorption unit, the body tilt angle, and the air leakage of the sealing cavity of each zone are re-acquired to generate new multi-source sensing data.

[0038] Based on the new multi-source sensing data, the overall adsorption safety margin is recalculated as the updated overall adsorption safety margin;

[0039] The updated overall adsorption safety margin is numerically compared with the second safety threshold.

[0040] When the updated overall adsorption safety margin is less than the second safety threshold, a secondary redundancy trigger signal is generated.

[0041] Preferably, based on the secondary redundancy trigger signal, the negative pressure supply source is switched to the emergency gas storage device, and a deceleration control command for the spraying device is generated, including:

[0042] In response to the secondary redundancy trigger signal, a switching command is sent to the gas supply switching valve of the explosion-proof vacuum supply unit to switch the negative pressure supply source from the main vacuum pump to the emergency gas storage device.

[0043] The deceleration ratio of the spraying device is determined based on the difference between the updated overall adsorption safety margin and the second safety threshold. The larger the difference, the higher the deceleration ratio.

[0044] Based on the deceleration ratio, a deceleration control command for the spraying device is generated and sent to the adaptive spraying execution module to reduce the travel speed of the spraying operation and the paint output flow rate.

[0045] Preferably, after generating the secondary redundancy trigger signal, the overall adsorption safety margin is updated again. If the updated overall adsorption safety margin is lower than the third safety threshold corresponding to the roughness level, a tertiary redundancy trigger signal is generated, including:

[0046] After a preset waiting period following the generation of the secondary redundancy trigger signal, multi-source sensing data is collected again.

[0047] Based on the multi-source sensing data that was re-collected, the overall adsorption safety margin was recalculated again, which became the updated overall adsorption safety margin.

[0048] The updated overall adsorption safety margin is compared numerically with the third safety threshold.

[0049] When the overall adsorption safety margin of the updated unit is less than the third safety threshold, a level 3 redundancy trigger signal is generated.

[0050] Preferably, based on the three-level redundant trigger signal, a mechanical self-locking hook drive command and a spray gun locking command are output to perform mechanical locking and cut off the paint supply, including:

[0051] In response to the three-level redundant trigger signal, a drive command to pop out and lock is sent to the drive motor of the mechanical self-locking hook, so that the self-locking hook is hooked to the attachment point on the wall.

[0052] Send a closing command to the paint valve of the explosion-proof spraying linkage unit to cut off the paint supply;

[0053] Send a locking command to the robotic arm locking mechanism of the spray gun to lock the robotic arm in its current position;

[0054] An alarm signal is generated and the audible and visual alarm device is triggered.

[0055] Compared with the prior art, the beneficial effects of the present invention are:

[0056] (1) This invention integrates multi-source sensing data such as real-time negative pressure, magnetic current, body tilt angle, air leakage of sealing cavity and wall roughness level, and uses the roughness-reference negative pressure mapping and attenuation-reliability function to transform the fuzzy physical state into numerical indicators of negative pressure adsorption reliability and magnetic adsorption reliability. Furthermore, a weighted fusion algorithm is used to calculate the overall adsorption safety margin, which can accurately quantify the adsorption safety margin of the robot on complex rough walls and solve the problem that traditional systems cannot assess the comprehensive adsorption risk.

[0057] (2) By constructing a three-level progressive redundant protection mechanism, the present invention automatically isolates the leakage zone, enhances the negative pressure of adjacent zones and increases the magnetic current when the safety margin initially decreases, and uses the remaining adsorption potential for self-rescue to maintain the continuity of operation to the greatest extent. When the first-level compensation fails, it switches to the emergency gas storage device and actively reduces the speed, sacrificing efficiency for safety to prevent the desorption from expanding. In critical moments, it triggers the mechanical self-locking hook and spray gun locking to perform physical locking and cut off the paint supply, thereby improving the robot's survivability and fall prevention reliability under extreme working conditions.

[0058] (3) By introducing the wall surface roughness level as the core variable, this invention not only dynamically adjusts the reference negative pressure and safety threshold according to the roughness, but also specifically increases the set value of adjacent zones in the first-level compensation. This enables the system to adapt to the complex environment of rust, welding slag, old paint and other substances on the surface of the steel structure of the substation. Compared with the traditional fixed parameter control system, this invention can effectively avoid misjudgment or omission caused by uneven wall surface, and ensure the universality and stability in different working environments. Attached Figure Description

[0059] Figure 1 This is a schematic diagram of the overall system architecture in one embodiment of the present invention.

[0060] In the diagram: 1. Data acquisition module; 2. Reliability calculation and fusion module; 3. First-level redundancy compensation module; 4. Second-level redundancy switching module; 5. Third-level redundancy locking module. Detailed Implementation

[0061] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0062] Example 1, please refer to Figure 1 This invention provides a technical solution: a safety redundancy protection system for adsorption-type spray painting robots in power substations, comprising:

[0063] Data acquisition module 1 is used to acquire multi-source perception data of the robot;

[0064] The reliability calculation fusion module 2 is used to calculate the negative pressure adsorption reliability and magnetic adsorption reliability of each zone based on multi-source sensing data; and to fuse the negative pressure adsorption reliability and magnetic adsorption reliability to obtain the overall adsorption safety margin.

[0065] The first-level redundancy compensation module 3 is used to compare the overall adsorption safety margin with the first safety threshold of the corresponding roughness level. If it is lower than the first safety threshold, a first-level redundancy trigger signal is generated. Based on the first-level redundancy trigger signal, the leakage over-limit zone is closed and the negative pressure setting value of the adjacent zone is increased. At the same time, the power supply current of the magnetic adsorption unit is increased, and a first-level compensation control command is output.

[0066] The secondary redundancy switching module 4 is used to reacquire multi-source sensing data and update the overall adsorption safety margin after the execution of the primary compensation control command. If the updated overall adsorption safety margin is lower than the second safety threshold of the corresponding roughness level, a secondary redundancy trigger signal is generated. Based on the secondary redundancy trigger signal, the negative pressure supply source is switched to the emergency gas storage device, and a deceleration control command for the spraying device is generated.

[0067] The three-level redundancy locking module 5 is used to update the overall machine adsorption safety margin again after generating the two-level redundancy trigger signal. If the updated overall machine adsorption safety margin is lower than the third safety threshold of the corresponding roughness level, a three-level redundancy trigger signal is generated. Based on the three-level redundancy trigger signal, a mechanical self-locking hook drive command and a spray gun locking command are output to perform mechanical locking and cut off the paint supply.

[0068] It should be noted that multi-source sensing data refers to the set of raw data collected in real time by various heterogeneous sensors installed on the robot body, reflecting the robot's own state and the characteristics of the external environment. In this invention, it specifically includes the real-time negative pressure value of each independent negative pressure adsorption zone, the real-time current value of the magnetic adsorption unit, the body tilt angle, the air leakage of the sealing cavity of each zone, and the roughness level of the current working wall surface. For example, when the robot is working on the substation structure, the pressure sensor measures the negative pressure of zone A to be -60kPa, the current sensor measures the electromagnet current to be 5A, the gyroscope measures the body tilt to be 15 degrees, the flow meter measures the air leakage of zone B to be 0.5L / min, and the vision sensor identifies the current wall surface as heavily corroded (roughness level 4). The set of these data is the multi-source sensing data.

[0069] Negative pressure adsorption reliability is a probability or confidence index that characterizes the negative pressure adsorption system's ability to maintain adsorption capacity under current operating conditions, calculated based on the degree of negative pressure decay. This indicator is negatively correlated with the amount of negative pressure attenuation. The greater the amount of negative pressure attenuation, the lower the actual negative pressure or the more air leakage, and the lower the reliability. For example, if the baseline negative pressure is set to -80 kPa, and the measured negative pressure of a certain zone is -75 kPa with a small amount of air leakage, the calculated amount of negative pressure attenuation is small, and the reliability is 0.95 (high). If the measured negative pressure suddenly drops to -50 kPa with a large amount of air leakage, the attenuation is large, and the reliability drops to 0.3 (low), meaning that there is a 70% probability that the zone will fail. The magnetic adsorption reliability is an indicator that characterizes the effectiveness of the magnetic adsorption system, calculated based on the working state of the magnetic unit. It comprehensively considers the influence of the current maintenance ratio and the body tilt angle on the normal component of the adsorption force. The overall adsorption safety margin is a comprehensive value obtained by weighted fusion of the negative pressure adsorption reliability and the magnetic adsorption reliability. It is used to quantitatively evaluate the robot's ability to resist the risk of falling off under the current wall surface and posture. The larger this value, the more sufficient the safety margin.

[0070] Roughness grade refers to the pre-defined grade standard based on the degree of unevenness of the wall surface. It is usually divided into smooth, slightly rough, moderately rough, and heavily rough grades. Different grades correspond to different reference negative pressure and safety thresholds. Independent negative pressure adsorption zone refers to dividing the robot's adsorption plate surface into several sealed chambers with independent air paths. Each zone has an independent air path control valve and pressure sensor to achieve zone control and fault isolation. Leakage exceeding limit zone refers to the negative pressure adsorption zone where the air leakage of the sealed chamber exceeds the preset safety threshold. This zone is judged to be adsorption failure or about to fail and needs to be isolated. Emergency gas storage devices are high-pressure gas tanks or accumulators used as backup gas sources. They are used to provide high-pressure, high-flow-rate gas instantly to maintain or temporarily increase the adsorption force when the main vacuum pump fails or the gas supply is insufficient due to gas leakage. Mechanical self-locking hooks are purely mechanical auxiliary locking devices, usually with a hook claw structure driven by a spring or motor. Before or when the adsorption force is completely lost, they actively hook onto the attachment point on the wall, such as angle steel or bolt holes, to provide physical support. Spray gun locking refers to the control action of cutting off the paint supply pipeline of the spray gun and locking the spray gun trigger to prevent paint from being accidentally sprayed out during the process of loss of adhesion or falling, causing equipment contamination or personal injury.

[0071] In an optional embodiment, the multi-source sensing data includes the real-time negative pressure value of each independent negative pressure adsorption zone, the real-time current value of the magnetic adsorption unit, the body tilt angle, the air leakage of the sealing cavity of each zone, and the roughness level of the currently working wall surface.

[0072] The reliability of negative pressure adsorption in each zone is calculated based on multi-source sensing data, including:

[0073] Obtain the roughness level of the current working wall surface from the multi-source sensing data, and find the reference negative pressure value of each zone corresponding to the roughness level from the preset roughness-reference negative pressure mapping table;

[0074] It should be noted that the roughness-reference negative pressure mapping table is a standard parameter comparison table pre-calibrated according to the flatness of the wall surface. Its core logic is that the rougher the wall surface, the higher the theoretical negative pressure value required to maintain adsorption, in order to compensate for the airtightness loss caused by microscopic gaps. The reference negative pressure value is the minimum negative pressure target value required to maintain a specific roughness level under ideal sealing conditions. For example, the preset mapping table divides roughness into levels 1 to 5, where level 1 represents a smooth new paint surface (reference negative pressure -60kPa), level 3 represents slight rust (reference negative pressure -75kPa), and level 5 represents severe corrosion (reference negative pressure -90kPa). When the visual sensor identifies the current wall surface as level 3 roughness, the system automatically retrieves the corresponding -75kPa as the reference line for subsequent calculations.

[0075] The negative pressure deviation value of each partition is obtained by subtracting the real-time negative pressure value of each partition from the corresponding baseline negative pressure value.

[0076] It should be noted that the negative pressure deviation value is a physical quantity that can be positive or negative. It is used to characterize the degree of deviation of the real-time negative pressure from the ideal reference. A negative value indicates insufficient actual adsorption force, while a positive value indicates excessive adsorption force. Its absolute value directly reflects the degree of deviation from the ideal state and is a primary indicator for measuring the dynamic performance of the adsorption system. For example, when operating on a wall with a roughness of level 3 (reference negative pressure -75 kPa), if the actual negative pressure measured by a sensor in a certain zone is -70 kPa, the deviation value is +5 kPa, indicating insufficient negative pressure with a gap of 5 kPa; if the actual measurement is -80 kPa, the deviation value is -5 kPa, indicating excessive negative pressure exceeding 5 kPa. This step provides a preliminary quantitative comparison between environmental factors and real-time conditions.

[0077] The leakage of the sealed cavity in each partition is obtained from the multi-source sensing data. The absolute value of the negative pressure deviation value is weighted and summed with the leakage of the sealed cavity to obtain the negative pressure attenuation of each partition.

[0078] It should be noted that negative pressure attenuation is a comprehensive loss indicator that integrates pressure deficit and gas leakage rate. It combines the fault characteristics of static pressure insufficiency and dynamic gas leakage using a weighted summation algorithm. The weighting coefficients are set according to the contribution of leakage to adsorption failure, with leakage typically having a higher weight. A larger attenuation indicates a more severe degradation of the adsorption capacity of that zone. For example, setting the weight of negative pressure deviation to 1.0 and leakage to 0.5; if the absolute value of the deviation in zone A is 5 kPa and the leakage rate is 0.2 L / min, then the attenuation = 5 × 1.0 + 0.2 × 0.5 = 5.1; if the absolute value of the deviation in zone B is 2 kPa and the leakage rate is 1.5 L / min, then the attenuation = 2 × 1.0 + 1.5 × 0.5 = 2.75. This indicates that although zone A has a large pressure deficit, zone B may have a higher overall attenuation risk due to severe leakage.

[0079] Based on the negative pressure attenuation, the negative pressure adsorption reliability of each partition is calculated through a preset attenuation-reliability mapping function; where the negative pressure adsorption reliability is negatively correlated with the negative pressure attenuation.

[0080] It should be noted that the decay-reliability mapping function is a mathematical model that converts physical loss parameters into probabilistic confidence levels. It usually adopts a piecewise linear function or an exponential decay function to map the negative pressure decay amount to a dimensionless value in the interval [0,1]. The closer the negative pressure adsorption reliability is to 1, the healthier the adsorption state is, and the closer it is to 0, the more likely it is to fail. This negative correlation design allows the system to intuitively assess the risk probability. For example, the preset function rules are: when the decay amount is 0-5, the reliability is 1.0-0.8; when the decay amount is 5-10, the reliability is 0.8-0.4; and when the decay amount is greater than 10, the reliability is less than 0.4. If the calculated decay amount is 6, the reliability obtained by looking up the table or calculation is 0.75, which means that the partition has a 75% probability of maintaining adsorption and a 25% risk of desorption. If the decay amount reaches 12, the reliability drops to 0.2, and the system determines that the partition has basically failed.

[0081] In an optional embodiment, calculating the magnetic adsorption reliability of each partition based on multi-source sensing data includes:

[0082] The rated operating current of the magnetic adsorption unit in the vertical adsorption state on a flat wall is obtained as the reference current;

[0083] It should be noted that the reference current refers to the standard operating current required to generate the rated adsorption force by a magnetic adsorption unit such as an electromagnet or permanent magnet under ideal working conditions, i.e., when the wall surface is completely flat and the robot body is perpendicular to the wall at a 90-degree angle. This value is usually obtained from the equipment's factory parameters or on-site calibration and serves as a reference benchmark for measuring the health status of the magnetic system. For example, if a certain type of electromagnet requires 10A of current to generate an adsorption force of 2000N when perpendicularly adsorbed onto a smooth steel plate, then 10A is the reference current. All subsequent evaluations of real-time currents will be converted to this as the full score standard.

[0084] The current sustaining ratio is obtained by comparing the real-time current value in the multi-source sensing data with the reference current.

[0085] It should be noted that the current sustaining ratio is a dimensionless percentage coefficient used to characterize the degree to which the current electrical output capability of the magnetic unit is maintained relative to its rated state. This ratio directly reflects the magnetic attenuation caused by coil heating, power supply fluctuations, or magnetic circuit aging. The lower the ratio, the weaker the output capability of the magnetic source. For example, if the reference current is 10A, but the real-time current collected by the sensor drops to 8A due to power supply voltage fluctuations, then the current sustaining ratio is 8 / 10=0.8, which means that the magnetic unit can currently only output 80% of its rated magnetic potential energy.

[0086] Obtain the fuselage tilt angle from multi-source sensing data, and calculate the cosine value of the fuselage tilt angle as the normal component coefficient of the adsorption force;

[0087] It should be noted that the normal component coefficient of the adsorption force is a correction coefficient introduced based on the principle of mechanical vector decomposition. Since the direction of the magnetic adsorption force is always perpendicular to the magnetic pole surface, when the robot body is tilted relative to the wall, the effective component force that actually resists gravity falling off will decrease as the tilt angle increases. The cosine function precisely describes this nonlinear attenuation relationship. For example, when the angle between the robot body and the wall normal is 0 degrees (completely perpendicular), cos0°=1, and the effective adsorption force is 100%. If the robot body tilts by 60 degrees due to uneven wall or external disturbance, then cos60°=0.5, which means that only 50% of the magnetic force can effectively act in the normal direction of the wall, and the remaining component force is converted into lateral shear force.

[0088] The reliability of magnetic adsorption is obtained by multiplying the current maintenance ratio by the normal component coefficient of the adsorption force.

[0089] It should be noted that magnetic adsorption reliability is a comprehensive risk indicator that integrates electrical performance and geometric attitude. By multiplying the current maintenance ratio by the normal component coefficient, the actual anti-detachment capability of the magnetic system in a non-vertical attitude can be accurately quantified. The closer the value is to 1, the more stable the magnetic adsorption is; the closer it is to 0, the more likely the magnetic adsorption is to fail in the current attitude. For example, if the current maintenance ratio is 0.8 (80% electrical performance) and the fuselage tilt angle is 30 degrees (cos30°≈0.866), then the magnetic adsorption reliability = 0.8 × 0.866 ≈ 0.693. If the fuselage tilts further to 60 degrees (cos60°=0.5), the reliability drops to 0.8 × 0.5 = 0.4. Based on this, the system determines that magnetic adsorption is no longer sufficient to maintain the safety of the entire machine on its own.

[0090] In an optional embodiment, the reliability of negative pressure adsorption and the reliability of magnetic adsorption are combined to obtain the overall adsorption safety margin, including:

[0091] The minimum value of the negative pressure adsorption reliability in all partitions is taken as the worst reliability of the negative pressure system.

[0092] It should be noted that the worst-case reliability of the negative pressure system refers to the reliability value of the lowest-valued partition among all independent negative pressure adsorption partitions of the robot. The core logic is that the safety of the entire negative pressure adsorption system depends on the partition in the worst condition, not the average value, because the failure of even one partition may cause the entire machine to overturn. This indicator is used to characterize the weakest link of the negative pressure adsorption subsystem under the current working conditions. For example, assuming that the robot's adsorption plate is divided into four partitions: upper left, upper right, lower left, and lower right, and the calculated negative pressure adsorption reliability of each partition is 0.95, 0.92, 0.88, and 0.75, respectively, the system directly selects the minimum value of 0.75 as the worst-case reliability of the negative pressure system. This means that although the other partitions are in good condition, the high risk of the lower left partition determines the safety upper limit of the entire negative pressure system.

[0093] The weighted fusion of the worst-case reliability of the negative pressure system and the reliability of magnetic adsorption is used as the overall adsorption safety margin output.

[0094] The sum of the weights of the negative pressure system and the magnetic system is 1.

[0095] It should be noted that weighted fusion refers to assigning different weight coefficients to the two adsorption methods according to their importance under specific working conditions, and then performing linear combination calculations. The overall adsorption safety margin is a comprehensive scoring index used to quantify the robot's overall ability to resist detachment. The allocation of weights reflects the system's dependence on different adsorption sources, and the sum of the weights of the two methods must be 1 to ensure normalization. For example, in general steel structure operations, where negative pressure adsorption is the primary method and magnetic adsorption is secondary, the negative pressure system is assigned a weight of 0.6, and the magnetic system a weight of 0. 0.4 (0.6+0.4=1); If the worst-case negative pressure reliability is 0.75 and the magnetic reliability is 0.8, then the overall adsorption safety margin = 0.75×0.6+0.8×0.4=0.45+0.32=0.77; If operating in a strong wind environment, the system may dynamically adjust the weights to negative pressure 0.4 and magnetic force 0.6 to rely more on magnetic force to resist shear. At this time, the safety margin = 0.75×0.4+0.8×0.6=0.3+0.48=0.78, reflecting the difference in safety assessment under different strategies.

[0096] In an optional embodiment, the overall adsorption safety margin is compared with a first safety threshold corresponding to the roughness level. If it is lower than the first safety threshold, a first-level redundant trigger signal is generated, including:

[0097] From the preset roughness-safety threshold mapping table, obtain the first safety threshold, the second safety threshold, and the third safety threshold corresponding to the roughness level, respectively; wherein the first safety threshold, the second safety threshold, and the third safety threshold decrease sequentially.

[0098] It should be noted that the roughness-safety threshold mapping table is a pre-configured library of graded warning standards based on the physical characteristics of the wall surface. Its core logic is that the higher the wall roughness, the more difficult it is to maintain adsorption, and the lower the system's allowable safety margin threshold. However, to prevent misjudgment, the three safety thresholds maintain a strict stepwise decreasing relationship: first safety threshold > second safety threshold > third safety threshold, corresponding to warning, danger, and emergency states, respectively. The first safety threshold is the initial risk warning line set by the system. When the safety margin falls below this line, it means that the adsorption force is insufficient to cope with the current environment, and compensation must be initiated immediately. For example, for a level 1 smooth wall surface, the system sets the first safety threshold to 0.8, the second safety threshold to 0.6, and the third safety threshold to 0.4. For a level 5 heavily rough wall surface, due to the greater difficulty in achieving the adsorption benchmark, the system may lower the first safety threshold to 0.6, the second safety threshold to 0.4, and the third safety threshold to 0.2. Regardless of the roughness, the three thresholds always decrease in order to ensure that a more stringent second-level protection is triggered after the first-level compensation fails.

[0099] The overall adsorption safety margin is numerically compared with the first safety threshold.

[0100] When the overall adsorption safety margin is less than the first safety threshold, a first-level redundant trigger signal is generated;

[0101] It should be noted that the first-level redundancy trigger signal is the first action command of the safety protection system, marking the robot's switch from normal operation mode to active defense mode. The generation of this signal depends solely on whether the real-time calculated comprehensive safety margin falls below the first line of defense in the corresponding environment. Once generated, the system will no longer rely solely on passive adsorption, but will actively mobilize resources, such as increasing current and closing the leakage area for self-rescue. For example, assuming the robot is operating on a wall with a roughness of level 3, the first safety threshold is set to 0.7, and the real-time calculated overall adsorption safety margin is 0.65, since 0.65 < 0.7, the system determines that there is a risk of de-adsorption and immediately generates a first-level redundancy trigger signal. This signal acts as a master switch to activate a series of compensation control commands, such as zone closure, adjacent zone pressurization, and magnetic enhancement.

[0102] In an optional embodiment, the leakage-over-limit zone is closed based on a primary redundancy trigger signal, and the negative pressure setting value of adjacent zones is increased. Simultaneously, the power supply current of the magnetic adsorption unit is increased, and a primary compensation control command is output, including:

[0103] In response to the first-level redundancy trigger signal, the leakage of the sealing cavity of each zone is compared, and the zone whose sealing cavity leakage exceeds the preset leakage threshold is marked as the leakage over-limit zone.

[0104] It should be noted that a leakage-exceeding zone refers to a negative pressure chamber where the gas leakage rate exceeds the system's tolerance limit due to damaged sealing strips, foreign object obstruction, or excessive wall gaps. The preset leakage threshold is a safe leakage limit calibrated based on the suction cup area and air pump flow rate. The purpose of marking this zone is to accurately locate the source of the fault and physically isolate it from the adsorption system, preventing continuous consumption of negative pressure resources and resulting in overall unit depressurization. For example, if the system sets the leakage threshold to 1.0 L / min, and the sensor in zone A detects a leakage rate of 1.5 L / min while zone B only detects 0.3 L / min, then the system determines that zone A is a leakage-exceeding zone, meaning that this zone can no longer effectively maintain negative pressure and must be shut down immediately.

[0105] Send a shut-off command to the solenoid valve corresponding to the zone where leakage exceeds the limit;

[0106] It should be noted that the shut-off command is an electrical signal that controls the opening and closing of the gas path. It is usually sent to the normally closed solenoid valve on the independent gas path of the zone. After receiving the command, the valve cuts off the gas path, disconnecting the zone from the main vacuum pump. This not only prevents the negative pressure from continuing to leak, but also avoids the waste of gas source.

[0107] Identify several zones that are spatially adjacent to the zone with excessive leakage, and increase the negative pressure setting value of the adjacent zones by a preset compensation ratio based on the original baseline negative pressure value.

[0108] It should be noted that adjacent zones refer to areas that are physically adjacent to the faulty zone. Since the faulty zone has lost its support, the suction force of the adjacent areas needs to be increased to fill the support gap. The preset compensation ratio is a pressure boosting coefficient calculated based on mechanical balance, usually 10%-30%. The purpose is to use the remaining suction potential of the healthy zones to compensate for the isolated faulty zones. For example, if the lower left zone is isolated, the system increases the negative pressure setting of its adjacent zones to its right and top (lower right and upper left) by 20% from the baseline of -75kPa to -90kPa, thereby enhancing the surrounding suction force to prevent the robot from tilting due to the lack of support points.

[0109] Send a current boost command to the power supply module of the magnetic adsorption unit to increase the power supply current to a preset multiple of the rated current;

[0110] It should be noted that the current boost command is a control signal for the power module of the magnetic unit, designed to increase the magnetic induction intensity of the electromagnet in a short time. The preset multiplier is usually set between 1.1 and 1.5 times, balancing the increase in attraction force with the heating of the coil. This operation utilizes the rapid response characteristics of magnetic attraction to compensate for the shear resistance lost by the negative pressure system due to isolation failure. For example, if the rated current of the magnetic unit is 10A, the system sends a command to increase it to 1.2 times, or 12A, increasing the electromagnetic attraction force from 2000N to 2400N, providing the robot with additional normal attraction force to cope with the crisis.

[0111] The above instructions are summarized into a first-level compensation control instruction and output.

[0112] It should be noted that the first-level compensation control command is a comprehensive command package containing multiple control signals. It packages actions such as zone gas path cutoff, adjacent zone pressurization, and magnetic force enhancement into an atomic operation sequence and issues them simultaneously to ensure coordinated action of each actuator and avoid control lag caused by command execution sequence or time difference. For example, the system generates a control frame containing three specific commands: "close solenoid valve V3", "set the negative pressure of zone V2 / V4 to -90kPa", and "set the magnetic current to 12A", and sends it to the underlying actuator at once via the CAN bus.

[0113] In an optional embodiment, after the execution of the first-level compensation control command, multi-source sensing data is reacquired and the overall adsorption safety margin is updated. If the updated overall adsorption safety margin is lower than the second safety threshold corresponding to the roughness level, a second-level redundancy trigger signal is generated, including:

[0114] After a preset waiting period following the execution of the first-level compensation control command, the real-time negative pressure value of each independent negative pressure adsorption zone, the real-time current value of the magnetic adsorption unit, the body tilt angle, and the air leakage of the sealing cavity of each zone are re-acquired to generate new multi-source sensing data.

[0115] It should be noted that the preset waiting period refers to the buffer time set by the system to ensure that the first-level compensation action is fully effective and reaches a steady state. It is usually several hundred milliseconds to several seconds. The purpose is to avoid data collection during system transient fluctuations, which may lead to misjudgment. The new multi-source sensing data is a real-time snapshot of the robot's actual state after the compensation measures are executed, which is used to verify the compensation effect. For example, after the system executes the commands to close the leak zone, pressurize the adjacent zone, and increase the magnetic force, it does not immediately make a judgment, but waits for 2 seconds to allow the air pressure to stabilize and the magnetic current to rise to the required level. Then, it reads the current real negative pressure, actual current, and body posture of each zone through the sensors again. This set of data is the new multi-source sensing data. If it is collected immediately, it may read a false low pressure value because the pressure is still rising.

[0116] Based on the new multi-source sensing data, the overall adsorption safety margin is recalculated as the updated overall adsorption safety margin;

[0117] It should be noted that the updated overall adsorption safety margin is a comprehensive risk indicator based on a re-quantitative assessment of the compensated system state. The calculation logic is the same as the initial one, but the input parameters have changed. This value directly reflects the actual effectiveness of the first-level redundancy compensation strategy and is the core basis for determining whether a higher level of protection needs to be activated. For example, assuming the overall adsorption safety margin before first-level compensation is 0.65, which is lower than the first safety threshold of 0.7, after closing the leakage area and pressurizing compensation, the system recalculates based on the newly collected data and obtains an updated safety margin of 0.72, indicating that the compensation is effective; or the recalculated value is 0.68, indicating that the compensation is insufficient and the system is still in the risk zone.

[0118] The updated overall adsorption safety margin is numerically compared with the second safety threshold.

[0119] When the updated overall adsorption safety margin is less than the second safety threshold, a secondary redundancy trigger signal is generated.

[0120] It should be noted that the second safety threshold is a more stringent risk warning line than the first safety threshold. It represents the bottom line of safety tolerance that the system cannot maintain even after implementing the first-level self-rescue measures. Once this line is breached, it means that simple air circuit and current regulation can no longer reverse the decline, and the second-level redundancy involving hardware switching must be activated. The second-level redundancy trigger signal is the instruction for the system to enter the emergency maintenance mode, indicating that the robot must give up some operational capabilities in exchange for survival. For example, when working on a wall with a roughness of level 3, if the second safety threshold is set to 0.5, and the updated overall adsorption safety margin calculation result is 0.6, which is higher than 0.5, the system will maintain the first-level compensation state and continue to observe. If the calculation result is 0.45, which is lower than 0.5, the system will determine that the first-level compensation has failed, immediately generate the second-level redundancy trigger signal, and prepare to execute the air source switching and deceleration actions.

[0121] In an optional embodiment, based on a secondary redundancy trigger signal, the negative pressure supply source is switched to the emergency gas storage device, and a deceleration control command for the spraying device is generated, including:

[0122] In response to the secondary redundancy trigger signal, a switching command is sent to the gas supply switching valve of the explosion-proof vacuum supply unit to switch the negative pressure supply source from the main vacuum pump to the emergency gas storage device.

[0123] It should be noted that explosion-proof vacuum supply units are specifically designed for flammable and explosive environments, such as vacuum generating equipment in substations. Their motors and circuits are encapsulated with explosion-proof structures to prevent electric sparks from igniting surrounding gases. Emergency gas storage devices are pressure vessels or accumulators that pre-store high-negative-pressure gas as a backup gas source independent of the main vacuum pump. Gas supply switching valves are typically three-way or four-way solenoid valves used to switch the gas path between the main and backup paths. The core logic of this action is that when the main pump cannot maintain negative pressure due to overheating, blockage, or power failure, the pre-stored high-pressure gas instantly takes over the adsorption task, ensuring uninterrupted adsorption. For example, volatile gases may exist in substations, and the electric arc during the startup of a regular vacuum pump may cause an explosion. Therefore, explosion-proof units must be used. When the system determines that the first-level compensation has failed (second-level trigger), it immediately sends a 24V level signal to the gas supply switching valve. The valve actuates within 0.5 seconds, cutting off the main vacuum pump's gas path and connecting the emergency gas storage device. The pre-stored high-pressure gas in the tank continues to supply gas to the adsorption plate, providing 3-5 minutes of emergency handling time.

[0124] The deceleration ratio of the spraying device is determined based on the difference between the updated overall adsorption safety margin and the second safety threshold. The larger the difference, the higher the deceleration ratio.

[0125] It should be noted that the difference range refers to the specific numerical difference between the real-time calculated overall machine adsorption safety margin and the second safety threshold. This difference directly reflects the degree to which the current risk exceeds the warning line. The deceleration ratio refers to the coefficient used to reduce the robot's travel speed and paint flow rate. This strategy is based on the risk hedging principle: the more insufficient the adsorption force, the larger the difference, and the more easily the robot will lose adsorption due to spraying reaction force or inertia. Therefore, the workload and dynamic interference must be reduced as much as possible. For example, if the second safety threshold is set to 0.5, and the updated safety margin is 0.45, the difference is 0.05, which is a slight exceedance of the limit. The system judges the risk to be small and only a small speed reduction is needed, setting the deceleration ratio to 20%. If the safety margin drops sharply to 0.2, the difference is 0.3, which is a serious exceedance of the limit. The system judges the risk to be extremely high and a significant speed reduction is needed to reduce inertial impact and paint recoil force, setting the deceleration ratio to 70% or even close to stopping.

[0126] Based on the deceleration ratio, a deceleration control command for the spraying device is generated and sent to the adaptive spraying execution module to reduce the travel speed of the spraying operation and the paint output flow rate.

[0127] It should be noted that the adaptive spraying execution module is a comprehensive execution unit integrating a walking drive motor, a spray gun lifting mechanism, and a paint supply pump, possessing independent speed and flow rate adjustment interfaces. The deceleration control command includes specific speed and flow rate setpoints. The purpose of this command is to reduce the dynamic load on the robot under high-risk conditions by sacrificing efficiency for safety, preventing loss of adhesion and falls due to excessive movement. For example, during normal operation, the robot's walking speed is 0.5 m / s, and the paint flow rate is 100 ml / min. When a secondary redundancy trigger signal is received and the calculated deceleration ratio is 60%, the system generates a command to limit the speed to 0.2 m / s and simultaneously reduce the paint pump speed, lowering the flow rate to 40 ml / min. Upon receiving the command, the adaptive spraying execution module decelerates the walking motor and reduces the spray gun's oscillation amplitude, thereby minimizing disturbance to the robot body when suction force is insufficient.

[0128] In an optional embodiment, after generating the secondary redundancy trigger signal, the overall adsorption safety margin is updated again. If the updated overall adsorption safety margin is lower than the third safety threshold corresponding to the roughness level, a tertiary redundancy trigger signal is generated, including:

[0129] After a preset waiting period following the generation of the secondary redundancy trigger signal, multi-source sensing data is collected again.

[0130] It should be noted that re-collecting data means starting a new round of sensor data acquisition cycle, obtaining a snapshot of the latest environment and equipment status after the secondary intervention; for example, after the system performs the secondary switch, i.e., switches to the emergency gas tank, a 3-second waiting time is set. After the emergency gas source pressure stabilizes and the robot decelerates, the sensor array is restarted to read the negative pressure, magnetic current, and body tilt angle of each zone at this time. This set of data will be used to determine whether the secondary intervention is effective.

[0131] Based on the multi-source sensing data that was re-collected, the overall adsorption safety margin was recalculated again, which became the updated overall adsorption safety margin.

[0132] It should be noted that the updated overall adsorption safety margin is based on the latest multi-source data after the secondary intervention. It is calculated using the same algorithm as the initial one, namely, negative pressure reliability calculation, magnetic reliability calculation, and weighted fusion to obtain the latest comprehensive score. This value is the final report on the effectiveness of the secondary redundancy measures and is used to determine whether the highest level of physical protection needs to be activated. For example, assuming the safety margin before the secondary intervention is 0.45, which is lower than the second safety threshold of 0.5, after switching to the emergency gas source and slowing down, the system recalculates based on the newly collected data. If it gets 0.55, it means that the safety margin has been recovered. If it only gets 0.3, it means that the situation continues to deteriorate. This 0.3 is the updated overall adsorption safety margin.

[0133] The updated overall adsorption safety margin is compared numerically with the third safety threshold.

[0134] It should be noted that the third safety threshold is the highest warning level set by the system. Its value is usually set to an extremely low value close to the physical limit of adsorption force (such as 0.2-0.3), which means that the system can no longer maintain adsorption by conventional pneumatic or electromagnetic means and must immediately take hard physical locking measures. This threshold is dynamically adjusted according to the roughness level. The higher the roughness, the lower the third safety threshold. For example, when working on a level 5 heavily rough wall surface, the third safety threshold set by the system may be 0.25. When the updated safety margin calculation result is 0.3, the system considers it still sustainable. If the calculation result drops to 0.2, it means that the final safety bottom line has been breached.

[0135] When the overall adsorption safety margin of the updated machine is less than the third safety threshold, a level 3 redundancy trigger signal is generated.

[0136] It should be noted that the Level 3 redundancy trigger signal is the highest command level of the safety protection system, indicating that the robot is in an extremely dangerous state with a countdown to loss of attachment. At this time, the system will abandon all attempts to maintain normal operation and instead execute the locking procedure, that is, forcibly locking and cutting off the source of danger through a purely mechanical structure. This signal has the highest priority and cannot be interrupted by normal manual operation. For example, when the safety margin drops to 0.18, which is lower than the third safety threshold of 0.25, the system determines that the pneumatic and electromagnetic adsorption are about to completely fail and immediately generates a Level 3 trigger signal to forcibly start the mechanical hook locking and paint cutting procedure. Even if the robot has already started to slide slightly at this time, it will be forcibly pulled back by the mechanical structure.

[0137] In an optional embodiment, based on a three-level redundant trigger signal, a mechanical self-locking hook drive command and a spray gun locking command are output to perform mechanical locking and cut off the paint supply, including:

[0138] In response to the three-level redundant trigger signal, a drive command to pop out and lock is sent to the drive motor of the mechanical self-locking hook, so that the self-locking hook is hooked to the attachment point on the wall.

[0139] It should be noted that the mechanical self-locking hook is a purely physical safety device independent of pneumatic and electromagnetic adsorption. It is usually made of high-strength alloy steel and has a hook structure driven by a spring or an electric push rod. The drive command is an electrical signal that controls the forward and reverse rotation of the motor or the action of the solenoid valve. After the command is issued, the self-locking hook will quickly pop out and use barbs or ratchet mechanisms to firmly hook onto the angle steel, bolt holes or other structural features of the wall, providing final physical support and preventing the robot from falling vertically. For example, similar to the rope grabber or climbing axe on a high-altitude work safety belt, when the system determines that a fall is imminent, it sends an extension command to the servo motor of the self-locking hook. The hook pops out and inserts into the gap of the angle steel below. Even if the negative pressure and magnetic force are completely eliminated, the robot is still suspended on the wall by the mechanical hook.

[0140] Send a closing command to the paint valve of the explosion-proof spraying linkage unit to cut off the paint supply;

[0141] It should be noted that the explosion-proof spraying linkage unit refers to a paint supply system specifically designed to prevent paint solvent evaporation from exploding upon contact with sparks. Its motor and circuit meet explosion-proof standards. The paint valve is usually a pneumatic or electric ball valve, installed on the pipeline between the paint pump and the spray gun. The shut-off command is used to forcibly cut off the physical path of the paint to prevent paint from being sprayed out at high pressure due to pipeline rupture or uncontrolled spray gun during the robot's fall, causing environmental pollution or secondary slippage risks caused by paint leakage. For example, after receiving a level 3 signal, the system sends a power-off shut-off signal to the explosion-proof solenoid valve installed on the main paint pipeline. The valve closes within 1 second, the paint pump stops working, and ensures that even if the spray gun falls, no paint will leak out and contaminate the substation equipment below.

[0142] Send a locking command to the robotic arm locking mechanism of the spray gun to lock the robotic arm in its current position;

[0143] It should be noted that the robotic arm locking mechanism refers to the electromagnetic brake or mechanical pin device installed at the joints of the robotic arm, used to lock the joint rotation when power is lost or when a command is received; the locking command aims to freeze the degrees of freedom of the robotic arm, preventing it from shifting its center of gravity and accelerating the fall due to gravity swing during the fall, or preventing the spray gun from hitting the wall due to inertial swing and causing equipment damage; for example, the system sends a brake command to the servo drivers of the six joints of the robotic arm, and the electromagnetic brake inside the motor locks instantly, fixing the robotic arm at the current angle, preventing it from swinging like a pendulum during the fall and causing the robot to fall off the wall;

[0144] An alarm signal is generated and the audible and visual alarm device is triggered.

[0145] It should be noted that the alarm signal is a warning message issued by the system to the external environment. The audible and visual alarm device usually includes a high-decibel siren and a high-brightness flashing light, which are installed in a conspicuous position on the robot. The purpose of this action is to remind on-site personnel to take precautions when the robot performs the final mechanical locking and cutting actions, so as to prevent personnel from entering the fall radius or accidentally touching the danger zone.

[0146] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention.

Claims

1. A safety redundancy protection system for adsorption-type spray painting robots in power substations, characterized in that, include: The data acquisition module is used to acquire multi-source sensor data of the robot; The reliability calculation fusion module is used to calculate the negative pressure adsorption reliability and magnetic adsorption reliability of each zone based on multi-source sensing data; and to fuse the negative pressure adsorption reliability and magnetic adsorption reliability to obtain the overall adsorption safety margin. The first-level redundancy compensation module is used to compare the overall adsorption safety margin with the first safety threshold of the corresponding roughness level. If it is lower than the first safety threshold, a first-level redundancy trigger signal is generated. Based on the first-level redundancy trigger signal, the leakage over-limit zone is closed and the negative pressure setting value of the adjacent zone is increased. At the same time, the power supply current of the magnetic adsorption unit is increased, and a first-level compensation control command is output. The secondary redundancy switching module is used to reacquire multi-source sensing data and update the overall adsorption safety margin after the execution of the primary compensation control command. If the updated overall adsorption safety margin is lower than the second safety threshold of the corresponding roughness level, a secondary redundancy trigger signal is generated. Based on the secondary redundancy trigger signal, the negative pressure supply source is switched to the emergency gas storage device, and a deceleration control command for the spraying device is generated. The three-level redundancy locking module is used to update the overall machine adsorption safety margin again after generating the two-level redundancy trigger signal. If the updated overall machine adsorption safety margin is lower than the third safety threshold of the corresponding roughness level, a three-level redundancy trigger signal is generated. Based on the three-level redundancy trigger signal, the mechanical self-locking hook drive command and the spray gun locking command are output to perform mechanical locking and cut off the paint supply.

2. The safety redundancy protection system for adsorption-type spray painting robot in power substations according to claim 1, characterized in that, Multi-source sensing data includes the real-time negative pressure value of each independent negative pressure adsorption zone, the real-time current value of the magnetic adsorption unit, the tilt angle of the machine body, the air leakage of the sealing cavity of each zone, and the roughness level of the current working wall surface. The reliability of negative pressure adsorption in each zone is calculated based on multi-source sensing data, including: Obtain the roughness level of the current working wall surface from the multi-source sensing data, and find the reference negative pressure value of each zone corresponding to the roughness level from the preset roughness-reference negative pressure mapping table; The negative pressure deviation value of each partition is obtained by subtracting the real-time negative pressure value of each partition from the corresponding baseline negative pressure value. The leakage of the sealed cavity in each partition is obtained from the multi-source sensing data. The absolute value of the negative pressure deviation value is weighted and summed with the leakage of the sealed cavity to obtain the negative pressure attenuation of each partition. Based on the negative pressure attenuation, the negative pressure adsorption reliability of each partition is calculated through a preset attenuation-reliability mapping function; whereby the negative pressure adsorption reliability is negatively correlated with the negative pressure attenuation.

3. The safety redundancy protection system for adsorption-type spray painting robot in power substations according to claim 2, characterized in that, The reliability of magnetic adsorption in each partition is calculated based on multi-source sensing data, including: The rated operating current of the magnetic adsorption unit in the vertical adsorption state on a flat wall is obtained as the reference current; The current sustaining ratio is obtained by comparing the real-time current value in the multi-source sensing data with the reference current. Obtain the fuselage tilt angle from multi-source sensing data, and calculate the cosine value of the fuselage tilt angle as the normal component coefficient of the adsorption force; The reliability of magnetic adsorption is obtained by multiplying the current maintenance ratio by the normal component coefficient of the adsorption force.

4. The safety redundancy protection system for adsorption-type spray painting robot in power substations according to claim 3, characterized in that, By combining the reliability of negative pressure adsorption and the reliability of magnetic adsorption, the overall adsorption safety margin of the machine is obtained, including: The minimum value of the negative pressure adsorption reliability in all partitions is taken as the worst reliability of the negative pressure system. The weighted fusion of the worst-case reliability of the negative pressure system and the reliability of magnetic adsorption is used as the overall adsorption safety margin output. The sum of the weights of the negative pressure system and the magnetic system is 1.

5. The safety redundancy protection system for adsorption-type spray painting robot in power substations according to claim 4, characterized in that, The overall adsorption safety margin is compared with the first safety threshold corresponding to the roughness level. If it is lower than the first safety threshold, a first-level redundant trigger signal is generated, including: From the preset roughness-safety threshold mapping table, obtain the first safety threshold, the second safety threshold, and the third safety threshold corresponding to the roughness level, respectively; wherein the first safety threshold, the second safety threshold, and the third safety threshold decrease sequentially. The overall adsorption safety margin is numerically compared with the first safety threshold. When the overall adsorption safety margin is less than the first safety threshold, a first-level redundant trigger signal is generated.

6. The safety redundancy protection system for adsorption-type spray painting robot in power substations according to claim 5, characterized in that, Based on the primary redundancy trigger signal, the leakage-over-limit zone is closed and the negative pressure setpoint of the adjacent zone is increased. Simultaneously, the power supply current of the magnetic adsorption unit is increased, and a primary compensation control command is output, including: In response to the first-level redundancy trigger signal, the leakage of the sealing cavity of each zone is compared, and the zone whose sealing cavity leakage exceeds the preset leakage threshold is marked as the leakage over-limit zone. Send a shut-off command to the solenoid valve corresponding to the zone where leakage exceeds the limit; Identify several zones that are spatially adjacent to the zone with excessive leakage, and increase the negative pressure setting value of the adjacent zones by a preset compensation ratio based on the original baseline negative pressure value. Send a current boost command to the power supply module of the magnetic adsorption unit to increase the power supply current to a preset multiple of the rated current; The above instructions are summarized into a first-level compensation control instruction and output.

7. A safety redundancy protection system for adsorption-type painting robot loss in power substations according to claim 6, characterized in that, After the first-level compensation control command is executed, multi-source sensing data is reacquired and the overall adsorption safety margin is updated. If the updated overall adsorption safety margin is lower than the second safety threshold for the corresponding roughness level, a second-level redundancy trigger signal is generated, including: After a preset waiting period following the execution of the first-level compensation control command, the real-time negative pressure value of each independent negative pressure adsorption zone, the real-time current value of the magnetic adsorption unit, the body tilt angle, and the air leakage of the sealing cavity of each zone are re-acquired to generate new multi-source sensing data. Based on the new multi-source sensing data, the overall adsorption safety margin is recalculated as the updated overall adsorption safety margin; The updated overall adsorption safety margin is numerically compared with the second safety threshold. When the updated overall adsorption safety margin is less than the second safety threshold, a secondary redundancy trigger signal is generated.

8. The safety redundancy protection system for adsorption-type painting robot loss in power substations according to claim 7, characterized in that, Based on the secondary redundancy trigger signal, the negative pressure supply source is switched to the emergency gas storage device, and a deceleration control command for the spraying device is generated, including: In response to the secondary redundancy trigger signal, a switching command is sent to the gas supply switching valve of the explosion-proof vacuum supply unit to switch the negative pressure supply source from the main vacuum pump to the emergency gas storage device. The deceleration ratio of the spraying device is determined based on the difference between the updated overall adsorption safety margin and the second safety threshold. The larger the difference, the higher the deceleration ratio. Based on the deceleration ratio, a deceleration control command for the spraying device is generated and sent to the adaptive spraying execution module to reduce the travel speed of the spraying operation and the paint output flow rate.

9. A safety redundancy protection system for adsorption-type spray painting robot in power substations according to claim 8, characterized in that, After generating the secondary redundancy trigger signal, the overall adsorption safety margin is updated again. If the updated overall adsorption safety margin is lower than the third safety threshold for the corresponding roughness level, a tertiary redundancy trigger signal is generated, including: After a preset waiting period following the generation of the secondary redundancy trigger signal, multi-source sensing data is collected again. Based on the multi-source sensing data that was re-collected, the overall adsorption safety margin was recalculated again, which became the updated overall adsorption safety margin. The updated overall adsorption safety margin is compared numerically with the third safety threshold. When the overall adsorption safety margin of the updated unit is less than the third safety threshold, a level 3 redundancy trigger signal is generated.

10. A safety redundancy protection system for adsorption-type spray painting robot in power substations according to claim 9, characterized in that, Based on the three-level redundant trigger signal, the mechanical self-locking hook drive command and the spray gun locking command are output to perform mechanical locking and cut off the paint supply, including: In response to the three-level redundant trigger signal, a drive command to pop out and lock is sent to the drive motor of the mechanical self-locking hook, so that the self-locking hook is hooked to the attachment point on the wall. Send a closing command to the paint valve of the explosion-proof spraying linkage unit to cut off the paint supply; Send a locking command to the robotic arm locking mechanism of the spray gun to lock the robotic arm in its current position; An alarm signal is generated and the audible and visual alarm device is triggered.

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