A robot for working on the roof of an electric locomotive under energized overhead contact line conditions

Abstract

This invention discloses a robot for operating on the roof of an electric locomotive under energized overhead contact line conditions, belonging to the technical field of electric locomotive maintenance equipment. The robot includes a track device mounted above the roof of the electric locomotive, on which a detection trolley and a cleaning trolley are movably mounted. The cleaning trolley is equipped with a cleaning robotic arm and cleaning devices for automated cleaning of roof components. The detection trolley is equipped with a collaborative robotic arm and a multi-functional detection tool head for automated multi-parameter detection of roof components. The system is equipped with a control unit and a vehicle remote monitoring system, and the entire system adopts a high-voltage insulation protection design. This invention allows for direct operation under energized overhead contact line conditions, eliminating the need for power outages and personnel to climb to the roof, simultaneously completing cleaning and detection processes. This fundamentally avoids the risks of falls from heights and power supply safety hazards, significantly improving operational efficiency and detection accuracy, reducing manual labor intensity, and not affecting railway operation scheduling.

Description

Technical Field

[0001] This invention relates to the field of electric locomotive maintenance equipment technology, specifically to a robot for operating on the roof of an electric locomotive under energized overhead contact line conditions. Background Technology

[0002] Currently, maintenance work on the roof of electric locomotives mainly adopts a manual high-altitude operation mode. Before the operation, the contact wire disconnection switch must be disconnected, and the operators wear safety ropes and climbing equipment to carry out the operation on the roof. The core operation contents include insulator cleaning, pantograph carbon plate thickness measurement, pantograph tension detection, and surface defect inspection.

[0003] Current technologies lack automation, integration, and adaptability for rooftop operations, and are not suitable for live-line work. They lack dedicated equipment capable of simultaneously performing cleaning and multi-parameter testing in a 25KV high-voltage live environment. Furthermore, they lack corresponding insulation, positioning, and operational execution systems designed for the complex high-altitude environment of rooftops. This results in several safety risks: high safety risks (first, the risk of personnel falling from heights; second, cumbersome procedures after power outages, leading to power supply safety issues due to operational errors); low operational efficiency (time-consuming preparations such as power outages, climbing, and donning protective gear; long maintenance cycles for individual vehicles; manual inspection relying on operator experience, slow data reading and recording speeds, and often single-person, single-process operations, making simultaneous cleaning and inspection impossible); and low inspection accuracy (manual handheld measuring tools for pantograph carbon plate thickness, parallelism, etc., are easily affected by operating posture and visual errors, leading to large data errors; manual observation of insulator damage, aging, and pantograph surface cracks can easily miss minor defects). High labor intensity: The narrow working space on the roof and the fixed working posture, coupled with prolonged wiping of insulators and handheld testing tools, easily lead to personnel fatigue, thus affecting work quality and efficiency. Limited functionality: Existing fragmented automated tools can only perform single-parameter testing (such as measuring only carbon plate thickness), and cannot simultaneously complete insulator cleaning and pantograph multi-parameter testing, requiring multiple tool changes and exhibiting low integration. Impact on operation and scheduling: Power outage operations on the overhead contact line occupy locomotive operating time, affecting the overall railway scheduling plan, especially during periods of intensive locomotive preparation, where the limitations of power outage maintenance are more pronounced. Therefore, a solution is needed. Summary of the Invention

[0004] The purpose of this invention is to provide a robot for working on the roof of an electric locomotive under energized overhead contact line conditions, in order to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A robot for operating on the roof of an electric locomotive under energized overhead contact line conditions includes a device body. The device body comprises a foundation, a first maintenance frame, a second maintenance frame, a detection trolley, a cleaning trolley, a track system, a monitoring camera, a main control cabinet, a secondary control cabinet, and a remote monitoring system for the locomotive and rolling stock. The first and second maintenance frames and the locomotive are all mounted on top of the foundation, with the locomotive positioned between the first and second maintenance frames. The main control cabinet and the monitoring camera are both installed within the second maintenance frame. A set of track systems is provided, each set mounted on top of the first and second maintenance frames. A set of detection and cleaning trolleys is also provided, each set mounted on top of a set of track systems, with the detection trolley positioned at the front end of the cleaning trolley. The cleaning trolley includes… The system comprises a cleaning translation slide, a cleaning motor, a cleaning fluid storage tank, a first remote communication control box, a cleaning robotic arm, and an electromagnetic reversing nozzle switch. The cleaning translation slide has a rectangular structure. The cleaning motor, cleaning fluid storage tank, first remote communication control box, cleaning robotic arm, and electromagnetic reversing nozzle switch are all mounted on top of the cleaning translation slide. The cleaning motor is located in front of the cleaning fluid storage tank and electromagnetic reversing nozzle switch, and the cleaning robotic arm is located behind the electromagnetic reversing nozzle switch. The first remote communication control box is located behind the cleaning robotic arm and contains a power adapter for the collaborative arm. The drive end of the cleaning motor is located at the bottom of the cleaning translation slide, and a translation gear is installed at the bottom drive end of the cleaning motor. A cleaning device is installed at the drive end of the cleaning robotic arm.

[0006] In a preferred embodiment of the present invention, the cleaning device includes a mounting bracket and transmission device, a drive motor and reducer, a cleaning brush, a first sprayer, a second sprayer, a first atomizing nozzle, a second atomizing nozzle, and a structural tube. The drive motor and reducer are mounted on the mounting bracket and transmission device. Two sets of cleaning brushes are symmetrically mounted at the front end of the mounting bracket and transmission device. The first sprayer is mounted on the left side of the mounting bracket and transmission device, and the second sprayer is mounted on the right side. The first atomizing nozzle is located above the mounting bracket and transmission device, and the second atomizing nozzle is located below the mounting bracket and transmission device. One set of structural tubes is installed at the output ends of the first and second sprayers. The first sprayer is connected to the first atomizing nozzle via the structural tube, and the second atomizing nozzle is connected to the second atomizing nozzle via the structural tube. The rear ends of the first and second sprayers are connected to an electromagnetic reversing nozzle switch via pipes, and the electromagnetic reversing nozzle switch is connected to a cleaning fluid storage tank via pipes.

[0007] In a preferred embodiment of the present invention, the inspection trolley includes an inspection translation slide, an inspection moving motor, a second remote communication control box, a collaborative robotic arm, and a multi-functional inspection tool head. The inspection moving motor, the second remote communication control box, and the collaborative robotic arm are all mounted on the top of the inspection translation slide. The bottom drive end of the inspection moving motor is located at the bottom of the inspection translation slide, and a translation gear is also mounted on the bottom of the inspection moving motor. The power adapter for the collaborative arm is also installed inside the second remote communication control box, and the multi-functional inspection tool head is mounted on the drive end of the collaborative robotic arm.

[0008] In a preferred embodiment of the present invention, the multifunctional detection tool head includes a mounting base, a force transmission connector, a detection bracket, a 3D camera, a voiceprint module, and a 2D camera. The force transmission connector is installed on the left end of the mounting base, the detection bracket is installed on the top of the mounting base, a set of 3D cameras is provided, and all of the 3D cameras in the set are installed at the front end of the detection bracket. The voiceprint module is installed on the top of the detection bracket, and a set of 2D cameras is provided, and all of the 2D cameras in the set are installed at the rear end of the detection bracket.

[0009] In a preferred embodiment of the present invention, the detection bracket includes a threaded support column, a locking block, a front mounting plate and a top mounting plate. The locking block is welded to the top of the threaded support column. The front mounting plate is installed at the front end of the locking block by screws. The front mounting plate has a rectangular structure. The top mounting plate is welded to the top of the front mounting plate. Several sets of weight-reducing holes are opened on the surface of the threaded support column.

[0010] In a preferred embodiment of the present invention, the force transmission connector has a rhomboid shape, and an installation groove is provided on the bottom left side of the force transmission connector. A displacement sensor and a force measuring component are respectively installed in the installation groove.

[0011] In a preferred embodiment of the present invention, the track device includes a supporting crossbeam, track adjustment blocks, and a trolley translation track. The supporting crossbeam has an I-shaped structure. Several sets of track adjustment blocks are provided and are installed on the top of the supporting crossbeam in a horizontally equidistant manner. The trolley translation track is installed on the top of several sets of track adjustment blocks. The track adjustment blocks have a U-shaped structure. A drive groove is provided on the top of the trolley translation track, and a rack is installed in the drive groove.

[0012] In a preferred embodiment of the present invention, the vehicle remote monitoring system includes a backup NVR, a core switch, a video integration platform, a large display screen, a client, a network keyboard, a display host, a first working NVR, a second working NVR, an access switch, and a front-end video access point. The core switch is connected to the backup NVR, the video integration platform, the client, and the network keyboard via network cables. The core switch is connected to the access switch via optical fiber. The access switch is connected to the front-end video access point via optical fiber. The video integration platform is connected to the large display screen and the display host via video cables.

[0013] Compared with the prior art, the beneficial effects of the present invention are: The electric locomotive roof-mounted operation robot under energized overhead contact line conditions of this invention comprises a device body, a foundation, a first maintenance frame, a second maintenance frame, an inspection trolley, a cleaning trolley, a track device, a monitoring camera, a main control cabinet, a secondary control cabinet, and a vehicle remote monitoring system, forming an overall operational framework. The locomotive is positioned between the two maintenance frames. The track device on the top provides walking support and precise guidance for the inspection and cleaning trolleys. Track adjustment blocks, trolley translation tracks, and rack and pinion structures ensure the translation and positioning accuracy of the trolleys. The cleaning trolley, relying on a cleaning motor, a cleaning translation slide carrying a cleaning fluid storage tank, a cleaning robotic arm, and an electromagnetic reversing nozzle switch, along with a cleaning device including dual sprayers, dual atomizing nozzles, and symmetrical cleaning brushes, can automatically complete the spraying of insulators and related components on the roof of the electric locomotive. The system includes misting, spraying, and brushing cleaning operations. The inspection trolley, equipped with a collaborative robotic arm mounted on a moving inspection motor and a sliding inspection slide, features a multi-functional inspection tool head at its end, integrating a mounting base, force transmission connectors, inspection brackets, a 3D camera, an acoustic signature module, a 2D camera, a displacement sensor, and force measurement components. This allows for comprehensive and precise inspection and defect detection of various parameters, including pantograph carbon plate thickness, parallelism, insulator damage and aging, component surface cracks, and abnormal operating noises. The entire system is further equipped with a remote communication control box, collaborative arm power adapter, on-site monitoring cameras, and a vehicle remote monitoring system consisting of a backup NVR, core switch, video integration platform, large display screen, and access switch. This enables real-time video monitoring, automatic data acquisition, remote transmission and storage, and centralized scheduling management throughout the operation. This robot can operate directly under KV high-voltage energized conditions on the overhead contact line, without requiring power outages or personnel to climb to heights, thus fundamentally avoiding the risks of falls from heights and power supply safety hazards caused by operational errors during power outages. It eliminates the cumbersome preparation processes of power outages, voltage testing, and donning protective gear, supporting simultaneous cleaning and inspection procedures. This completely changes the traditional single-person, single-process, step-by-step operation mode, significantly shortening the locomotive preparation and maintenance cycle. Employing an integrated detection method combining machine vision, voiceprint recognition, and displacement and force sensing, it completely avoids detection errors caused by human operation posture and visual judgment, accurately identifying minute damage, cracks, and hidden faults that are easily overlooked by humans, and detecting a large number of... The automatic data retention and uploading significantly improves the quantification and reliability of detection. The automated operation of robotic arms replaces the long hours of fixed-posture work in the confined space of the roof, greatly reducing manual labor intensity and preventing fatigue-induced quality decline. The equipment is highly integrated, with each unit possessing fully automated cleaning, multi-parameter non-destructive testing, real-time monitoring, and remote scheduling functions, eliminating the drawbacks of fragmented functions and frequent tool changes required by existing tools. Furthermore, the fully energized operation does not occupy locomotive operating windows, and power outages will not disrupt railway traffic and locomotive maintenance schedules. It is particularly suitable for scenarios involving intensive locomotive maintenance, and its overall automation, integration, safety, and adaptability are significantly superior to existing traditional operating methods. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall internal structure of the present invention; Figure 2 This is a schematic diagram of the cleaning cart structure of the present invention; Figure 3 This is a schematic diagram of the cleaning device structure of the present invention; Figure 4 This is a schematic diagram of the detection cart structure of the present invention; Figure 5 This is a schematic diagram of the multifunctional detection tool head structure of the present invention; Figure 6 This is a schematic diagram of the track device structure of the present invention; Figure 7 This is a schematic diagram of the vehicle remote monitoring system of the present invention.

[0015] In the diagram: 1. Device body; 2. Foundation; 3. First maintenance frame; 4. Second maintenance frame; 5. Inspection trolley; 6. Cleaning trolley; 7. Track device; 8. Cleaning translation slide; 9. Cleaning moving motor; 10. Cleaning fluid storage tank; 11. First remote communication control box; 12. Cleaning robotic arm; 13. Electromagnetic reversing nozzle switch; 14. Translation gear; 15. Cleaning device; 16. Mounting bracket and transmission device; 17. Drive motor and reducer; 18. Cleaning brush; 19. First sprayer; 20. Second sprayer; 21. First atomizing nozzle; 22. Second atomizing nozzle; 23. Structural tube; 24. Inspection translation slide; 25. Inspection moving motor; 2 6. Second remote communication control box; 27. Collaborative robotic arm; 28. Multifunctional detection tool head; 29. ​​Mounting base block; 30. Force transmission connector; 31. Detection bracket; 32. 3D camera; 33. Acoustic fingerprint module; 34. 2D camera; 35. Mounting slot; 36. Displacement sensor; 37. Force measuring component; 38. Threaded support column; 39. Locking block; 40. Front mounting plate; 41. Top mounting plate; 42. Weight reduction hole; 43. Bearing crossbeam; 44. Track adjustment block; 45. Trolley translation track; 46. Drive slot; 47. Rack; 48. Monitoring camera; 49. Main control cabinet; 50. Auxiliary control cabinet; 51. Locomotive; 52. Collaborative arm power adapter. Detailed Implementation

[0016] 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.

[0017] Please see Figure 1-7The present invention provides a technical solution: A robot for operating on the roof of an electric locomotive under energized overhead contact line conditions includes a device body 1. The device body 1 includes a foundation 2, a first maintenance frame 3, a second maintenance frame 4, a detection trolley 5, a cleaning trolley 6, a track device 7, a monitoring camera 48, a main control cabinet 49, a secondary control cabinet 50, a locomotive 51, and a vehicle remote monitoring system. The first maintenance frame 3, the second maintenance frame 4, and the locomotive 51 are all mounted on top of the foundation 2, with the locomotive 51 located between the first and second maintenance frames 3 and 4. The main control cabinet 49 and the monitoring camera 48 are both installed inside the second maintenance frame 4. A set of track devices 7 is provided, with each set mounted on top of the first and second maintenance frames 3 and 4. A set of detection trolleys 5 and cleaning trolleys 6 is provided, with each set mounted on top of a set of track devices 7. The detection trolley 5 is located at the front end of the cleaning trolley 6, and the cleaning trolley 6 includes a cleaning platform. The cleaning system comprises a sliding slide 8, a cleaning motor 9, a cleaning fluid storage tank 10, a first remote communication control box 11, a cleaning robotic arm 12, and an electromagnetic reversing nozzle switch 13. The cleaning sliding slide 8 has a rectangular structure. The cleaning motor 9, the cleaning fluid storage tank 10, the first remote communication control box 11, the cleaning robotic arm 12, and the electromagnetic reversing nozzle switch 13 are all installed on the top of the cleaning sliding slide 8. The cleaning motor 9 is located in front of the cleaning fluid storage tank 10 and the electromagnetic reversing nozzle switch 13. The cleaning robotic arm 12 is located behind the electromagnetic reversing nozzle switch 13. The first remote communication control box 11 is located behind the cleaning robotic arm 12. A power adapter 52 for the cooperating arm is installed inside the first remote communication control box 11. The drive end of the cleaning motor 9 is located at the bottom of the cleaning sliding slide 8. A translation gear 14 is installed at the bottom drive end of the cleaning motor 9. A cleaning device 15 is installed at the drive end of the cleaning robotic arm 12.

[0018] Analysis of the above content: The first maintenance frame 3 and the second maintenance frame 4 are symmetrically erected and fixed, and the locomotive 51 is positioned between the two sets of maintenance frames; the track device 7 is erected on the top of the first maintenance frame 3 and the second maintenance frame 4, providing a linear guide for the inspection trolley 5 and the cleaning trolley 6; the main control cabinet 49 and the monitoring camera 48 are integrated inside the second maintenance frame 4, and together with the auxiliary control cabinet 50 and the vehicle remote monitoring system, realize the power supply, logic control, real-time video acquisition and remote data interaction of the whole machine, forming a closed live working station based on the frame layout; The cleaning sliding slide 8 serves as the supporting base, and the cleaning moving motor 9 is the power source for movement. The bottom drive end drives the translation gear 14 to mesh with the track rack to achieve movement. The cleaning liquid storage tank 10 stores the cleaning medium and is connected to the electromagnetic reversing nozzle switch 13 through the pipeline, which can switch the on / off state and the pipeline flow direction. The cleaning robotic arm 12 realizes multi-degree-of-freedom pitch and extension adjustment, and drives the end cleaning device 15 to the position to be cleaned on the roof of the locomotive. The first remote communication control box 11 has a built-in collaborative arm power adapter 52, which provides support for the communication of the whole machine, the power supply of the robotic arm and the signal transmission.

[0019] Example 2: Please see Figure 1-7 This invention provides a technical solution based on Embodiment 1: The cleaning device 15 includes a mounting bracket and transmission device 16, a drive motor and reducer 17, cleaning brushes 18, a first sprayer 19, a second sprayer 20, a first atomizing nozzle 21, a second atomizing nozzle 22, and a structural tube 23. The drive motor and reducer 17 are mounted on the mounting bracket and transmission device 16. Two sets of cleaning brushes 18 are symmetrically mounted at the front end of the mounting bracket and transmission device 16. The first sprayer 19 is mounted on the left side of the mounting bracket and transmission device 16, and the second sprayer 20 is mounted on the right side of the mounting bracket and transmission device 16. The first atomizing nozzle 21 is located above the mounting bracket and transmission device 16, and the second atomizing nozzle 22 is located below the mounting bracket and transmission device 16. A set of structural tubes 23 is provided, and the set of structural tubes 23 is respectively installed at the output ends of the first sprayer 19 and the second sprayer 20. The first sprayer 19 is connected to the first atomizing nozzle 21 through the structural tube 23, and the second atomizing nozzle 22 is connected to the second atomizing nozzle 22 through the structural tube 23. The rear ends of the first sprayer 19 and the second sprayer 20 are connected to the electromagnetic reversing nozzle switch 13 through pipes. The electromagnetic reversing nozzle switch 13 is connected to the cleaning fluid storage tank 10 through pipes.

[0020] Analysis of the above content: The mounting bracket and transmission device 16 serve as the overall support base, and the drive motor and reducer 17 provide rotational power to drive the two sets of cleaning brushes 18 to rotate synchronously to perform the brushing operation; the first sprayer 19 and the second sprayer 20 are respectively arranged on the left and right sides, and are connected to the first atomizing nozzle 21 and the second atomizing nozzle 22 through the structural pipe 23 respectively. The cleaning medium is pressurized by the sprayer and atomized and sprayed out from the upper and lower nozzles to achieve all-round spraying and wetting of the roof parts; the rear pipeline is connected to the electromagnetic reversing nozzle switch 13 to realize centralized liquid supply control.

[0021] Example 3: Please see Figure 1-7 The present invention provides a technical solution based on Embodiment 1: The detection trolley 5 includes a detection translation slide 24, a detection moving motor 25, a second remote communication control box 26, a cooperative robotic arm 27, and a multi-functional detection tool head 28. The detection moving motor 25, the second remote communication control box 26, and the cooperative robotic arm 27 are all installed on the top of the detection translation slide 24. The bottom drive end of the detection moving motor 25 is located at the bottom of the detection translation slide 24. A translation gear 14 is also installed at the bottom of the detection moving motor 25. A cooperative arm power adapter 52 is also installed inside the second remote communication control box 26. The multi-functional detection tool head 28 is installed at the drive end of the cooperative robotic arm 27.

[0022] Analysis of the above content: The detection translation slide 24 serves as the support base, and the bottom drive end of the detection moving motor 25 is equipped with a translation gear 14, which meshes with the track rack to realize the forward and backward translation of the whole machine; the second remote communication control box 26 has a built-in collaborative arm power adapter 52, which is responsible for power supply, signal transmission and reception, and remote command reception; the collaborative robotic arm 27 has multi-degree-of-freedom adjustment capability, which can precisely adjust the angle and height, and drive the end multi-functional detection tool head 28 to approach the roof of the locomotive to complete the detection and collection of multiple parameters such as appearance, size, and abnormal noise.

[0023] Example 4 Please see Figure 1-7 The present invention provides a technical solution based on Embodiment 1: The multifunctional detection tool head 28 includes a mounting base 29, a force transmission connector 30, a detection bracket 31, a 3D camera 32, a voiceprint module 33, and a 2D camera 34. The force transmission connector 30 is installed on the left end of the mounting base 29, the detection bracket 31 is installed on the top of the mounting base 29, a set of 3D cameras 32 is provided, and all of the 3D cameras 32 in the set are installed at the front end of the detection bracket 31. The voiceprint module 33 is installed on the top of the detection bracket 31, and a set of 2D cameras 34 is provided, and all of the 2D cameras 34 in the set are installed at the rear end of the detection bracket 31. The force transmission connector 30 has a rhomboid shape, and a mounting groove 35 is provided on the bottom left side of the force transmission connector 30. A displacement sensor 36 and a force measuring component 37 are respectively installed in the mounting groove 35. Analysis of the above content: The mounting base 29 serves as the connection base with the collaborative robotic arm 27, and the rhomboid force transmission connector 30 transmits the contact force. The mounting groove 35 integrates a displacement sensor 36 and a force measuring component 37 to collect contact displacement and force data in real time. The detection bracket 31 is a load-bearing frame, with a set of 3D cameras 32 at the front end and a set of 2D cameras 34 at the rear end. The top is equipped with an acoustic fingerprint module 33, which realizes three-dimensional shape scanning, two-dimensional high-definition imaging, and acoustic fingerprint recognition of abnormal operation noise and loose parts, and completes the detection of roof faults and parameters in multiple dimensions simultaneously.

[0024] Example 5 Please see Figure 1-7 The present invention provides a technical solution based on Embodiment 1: The detection bracket 31 includes a threaded support column 38, a locking block 39, a front mounting plate 40 and a top mounting plate 41. The locking block 39 is welded to the top of the threaded support column 38. The front mounting plate 40 is installed at the front end of the locking block 39 by screws. The front mounting plate 40 has a rectangular structure. The top mounting plate 41 is welded to the top of the front mounting plate 40. The surface of the threaded support column 38 is provided with a plurality of weight-reducing holes 42.

[0025] Analysis of the above content: The threaded support column 38 is the main support structure, with a locking block 39 welded to the top. The front mounting plate 40 is detachably fixed to the front end of the locking block 39 by screws. The top mounting plate 41 is welded to the top of the front mounting plate 40, forming a layered mounting platform, which is used to fix the camera and the acoustic module respectively. Several sets of weight reduction holes 42 are opened on the surface of the threaded support column 38 to reduce the overall weight while ensuring the structural strength, thereby reducing the load on the collaborative robotic arm 27.

[0026] Example 6: Please see Figure 1-7 The present invention provides a technical solution based on Embodiment 1: The track device 7 includes a supporting beam 43, track adjustment blocks 44, and a trolley translation track 45. The supporting beam 43 has an I-shaped structure. The track adjustment blocks 44 are provided in several groups, and the several groups of track adjustment blocks 44 are installed on the top of the supporting beam 43 in a horizontally equidistant manner. The trolley translation track 45 is installed on the top of the several groups of track adjustment blocks 44. The track adjustment blocks 44 have a U-shaped structure. The top of the trolley translation track 45 is provided with a drive groove 46, and a rack 47 is installed in the drive groove 46.

[0027] Analysis of the above content: The I-shaped load-bearing beam 43 serves as the main load-bearing beam. Several sets of U-shaped track adjustment blocks 44 are arranged horizontally and equidistantly on the top of the load-bearing beam 43 for raising, leveling, and fine-tuning the position. The trolley translation track 45 is fixed above the track adjustment blocks 44. A rack 47 is installed in the top drive groove 46, which meshes with the translation gear 14 at the bottom of the detection trolley 5 and the cleaning trolley 6 to achieve precise gear and rack transmission.

[0028] Example 7 Please see Figure 1-7 The present invention provides a technical solution based on Embodiment 1: The vehicle remote monitoring system includes a backup NVR, a core switch, a video integration platform, a large display screen, a client, a network keyboard, a display host, a first working NVR, a second working NVR, an access switch, and a front-end video access point. The core switch is connected to the backup NVR, the video integration platform, the client, and the network keyboard via network cables. The core switch is connected to the access switch via optical fiber. The access switch is connected to the front-end video access point via optical fiber. The video integration platform is connected to the large display screen and the display host via video cables.

[0029] Analysis of the above content: The front-end video access captures the on-site images of 48 surveillance cameras, which are then transmitted to the core switch via fiber optic cable through the access switch. The core switch connects to the backup NVR, the first working NVR, and the second working NVR to achieve dual-copy storage backup of the video data. At the same time, the core switch connects to the video integration platform, the client, and the network keyboard. The video integration platform connects to the display screen and the display host via video cable to realize video decoding, image splicing, real-time display, remote control, and centralized scheduling and management of the entire machine's operation data.

[0030] I. Working Principle of this Solution This solution primarily utilizes a track system to provide precise walking support, with two trolleys working collaboratively for cleaning and inspection. Combined with multi-sensor fusion detection and system-level insulation protection, it enables automated maintenance of the electric locomotive roof in high-voltage, live environments. The complete operation process is as follows: Locomotive entry and system initialization: Locomotive 51 enters the work station between the first maintenance rack 3 and the second maintenance rack 4. The monitoring camera 48 captures the entry image of locomotive 51 and transmits it to the main control cabinet 49. The main control cabinet 49 completes the initial positioning of locomotive 51 through visual recognition. The main control cabinet 49 sends initialization commands to the detection trolley 5 and the cleaning trolley 6. After receiving the commands, the first remote communication control box 11 and the second remote communication control box 26 respectively control the cleaning moving motor 9 and the detection moving motor 25 to start self-tests. At the same time, the cleaning robotic arm 12 and the cooperating robotic arm 27 perform a zero-return operation to confirm that all components are operating normally.

[0031] Automated cleaning operation of the cleaning trolley: The main control cabinet 49 sends a work command to the cleaning trolley 6. The first remote communication control box 11 controls the cleaning moving motor 9 to operate, driving the translation gear 14 to mesh with the rack 47 on the trolley translation track 45, so that the cleaning translation slide 8 moves along the track device 7 to a position above the first insulator. The cleaning robotic arm 12 drives the cleaning device 15 to adjust to the optimal working angle, and the electromagnetic reversing nozzle switch 13 is turned on. The cleaning medium in the cleaning liquid storage tank 10 is transported through pipelines to the first sprayer 19 and the second sprayer 20. After being pressurized, it is delivered through the structural pipe 23 to the first atomizing nozzle 21 and the second atomizing nozzle 22 respectively, to perform all-round atomized spraying and wetting of the insulator surface. Subsequently, the drive motor and reducer 17 are started, driving the two sets of cleaning brushes 18 to rotate synchronously. The cleaning robotic arm 12 drives the cleaning brushes 18 to reciprocate along the surface of the insulator to complete the brushing operation. The cleaning trolley 6 moves sequentially along the track device 7, and after completing the cleaning of all insulators, it returns to its initial position to stand by.

[0032] Multi-parameter synchronous detection by the inspection trolley: After the cleaning trolley 6 starts its preset operation time, the main control cabinet 49 sends an operation command to the inspection trolley 5. The second remote communication control box 26 controls the operation of the inspection moving motor 25, which drives the translation gear 14 to mesh along the rack 47, causing the inspection translation slide 24 to move along the track device 7 to the position above the first insulator. The collaborative robotic arm 27 drives the multi-functional inspection tool head 28 to adjust to the inspection angle. The 2D camera 34 performs high-definition imaging of the insulator surface, collecting image data of insulator damage, aging, and fastener tightness, and transmitting it to the main control cabinet 49. The inspection trolley 5 continues to move to the pantograph position. The 3D camera 32 performs three-dimensional morphological scanning of the pantograph carbon plate, generating point cloud data and transmitting it to the main control cabinet 49. The main control cabinet 49 calculates the minimum thickness and parallelism parameters of the carbon plate based on the point cloud data. The acoustic module 33 collects abnormal operating noise data of the pantograph and surrounding components, identifying potential gas leaks and loose components. After the inspection trolley 5 completes the appearance and parameter inspection of all insulators and pantographs sequentially along the track device 7, the two inspection trolleys 5 are respectively moved horizontally above the front and rear pantographs. The displacement sensor 36 and force measuring component 37 at the bottom of the force transmission connector 30 are aligned with the center position of the pantograph carbon plate. The main control cabinet 49 notifies the on-site operator to start the pantograph raising operation. The displacement sensor 36 starts timing when it detects that the pantograph has been raised. After the pantograph contacts the force transmission connector 30, the force measuring component 37 collects the static contact force data of the pantograph, and the timing stops. The main control cabinet 49 automatically calculates the pantograph raising time. After the pantograph raising inspection is completed, the pantograph is reset, and the inspection trolley 5 returns to its initial position to stand by.

[0033] Data Processing and Remote Monitoring Management: All detection data and operation process videos are transmitted to the vehicle remote monitoring system via the core switch. The first and second working NVRs store the video data in duplicate, and the backup NVR performs off-site backup. The video integration platform decodes the video data and displays the operation footage and detection data in real time on the large display screen. The main control cabinet 49 automatically generates a maintenance report containing basic information about the locomotive 51, cleaning operation records, pantograph carbon plate thickness, pantograph raising time, static contact force, insulator status, etc., and stores it in the data storage unit. Management personnel can remotely view the operation status, retrieve historical data, and approve maintenance applications through a client or network keyboard.

[0034] II. Core Innovations of this Plan The core innovation of this solution lies in proposing an overall architecture for a robot operating on the roof of an electric locomotive under energized overhead contact line conditions. This addresses the existing technical problems of high safety risks, low efficiency, poor detection accuracy, and disruption to operational scheduling caused by the need for power outages and reliance on manual high-altitude operations for electric locomotive roof maintenance. Furthermore, it is the first to deeply integrate system-level high-voltage insulation protection technology with multi-sensor integrated detection technology and automated cleaning technology, achieving integrated, minimally manned operation of roof insulator cleaning and pantograph multi-parameter detection under 25kV high-voltage energized conditions.

[0035] Addressing the core pain point of existing technologies' inability to perform live-line work, this solution employs a system-level insulation design. This design includes insulated wrapping of the robotic arm and end-effector tools, insulating pads between the track and the supporting structure, and sealed insulation of electrical components. Combined with built-in safety distance control logic, it ensures a minimum safe clearance of 0.8m between the operator and the live contact wire during operation. This comprehensive insulation protection system, built from both structural and control perspectives, overcomes the technical bottleneck of automated operation in high-voltage live environments. Addressing the limitations of existing technologies in terms of single-function operation and low integration, this solution integrates cleaning and multi-parameter detection functions into the same track system. Through the synchronous parallel operation of the cleaning trolley 6 and the detection trolley 5, it achieves integrated completion of multiple functions, including insulator cleaning, pantograph carbon plate thickness / parallelism detection, pantograph lifting time / static contact force detection, gas leak detection, and fastener condition detection, eliminating the need for multiple tool changes. To address the shortcomings of existing technologies, such as low detection accuracy and reliance on human experience, this solution integrates a 2D camera 34, a 3D camera 32, a voiceprint module 33, a displacement sensor 36, and a force measurement component 37 on a multi-functional inspection tool head 28. Through multi-modal fusion detection of machine vision, voiceprint recognition, and mechanical sensing, it achieves accurate identification of minute defects and high-precision measurement of physical parameters. The detection data is automatically uploaded and stored, avoiding errors from manual recording.

[0036] Through the aforementioned innovative design, this solution forms a complete technical closed loop of "live-line working capability → automated integrated operation → high-precision detection → remote data management". It is not only applicable to the daily maintenance of standard electric locomotives, but can also be adapted to different locomotive models and different maintenance shed scenarios through track length adjustment and detection module configuration optimization, thus expanding the application scope of the technology.

[0037] III. Technical Effects of Implementing this Solution Implementing this solution can bring about significant technological improvements in multiple dimensions, comprehensively addressing various pain points of traditional manual operation modes: Safety risks are significantly reduced, achieving inherently safe operation. This solution employs a system-level high-voltage insulation protection design. Through insulated wrapping of the robotic arm and end effector tools, the installation of insulating pads between the track device 7 and the load-bearing beam 43, and the insulated sealing of all electrical components, combined with built-in safety distance control logic, a minimum safe clearance of no less than 0.8m is maintained between the operator and the live contact wire during operation. This allows for safe operation in a 25kV high-voltage environment without disconnecting the contact wire isolating switch, completely avoiding residual voltage electric shock after power outages and power supply safety hazards caused by errors in power restoration. Furthermore, the operation process eliminates the need for personnel to climb to heights, completely avoiding the risk of falls from heights and freeing workers from high-risk working environments, fundamentally eliminating the safety hazards of manual operation.

[0038] The operational efficiency is significantly improved, and the maintenance cycle is greatly shortened. This solution adopts a synchronous parallel operation mode of cleaning trolley 6 and inspection trolley 5, replacing the traditional single-person, single-process, step-by-step operation method, eliminating cumbersome procedures such as power outage, voltage testing, donning protective equipment, manual climbing, and multiple tool changes. Cleaning trolley 6, through cleaning robotic arm 12 driving cleaning device 15, realizes automated spraying and brushing of insulators, reducing the cleaning time of a single insulator by more than 70% compared to manual cleaning; inspection trolley 5, through cooperative robotic arm 27 driving multi-functional inspection tool head 28, realizes multi-parameter synchronous inspection, increasing inspection efficiency by more than 5 times compared to manual cleaning. The overall maintenance cycle of a single locomotive is shortened by more than 60% compared to traditional manual methods, and the maintenance shed can carry out operations for multiple locomotives simultaneously, increasing overall maintenance efficiency by more than 3 times, effectively alleviating the operational pressure during intensive locomotive maintenance.

[0039] The detection accuracy is significantly improved, achieving quantitative and precise detection. This solution employs multimodal fusion detection technology. The 2D camera 34 can capture minute cracks and defects on the insulator surface at the 0.1mm level, increasing the defect detection rate by more than 50% compared to manual visual observation, avoiding defects missed due to human visual errors. The 3D camera 32 measures the thickness of the pantograph carbon plate using three-dimensional point cloud scanning technology, with a measurement accuracy of up to 0.1mm, far exceeding the ±0.5mm measurement accuracy of manual handheld measuring tools. The force measuring component 37 has a comprehensive error of ≤±0.1%, accurately detecting the static contact force of the pantograph, reducing the measurement error by 98% compared to manual spring scales. The acoustic fingerprint module 33 can identify ultrasonic signals in the range of 2kHz-48kHz, enabling early detection of minute gas leaks. All detection data is automatically collected, transmitted, and stored, eliminating human recording errors. The reliability and consistency of the detection results are significantly improved, providing precise data support for locomotive maintenance.

[0040] Labor intensity is significantly reduced, enabling minimally staffed operations. This solution requires only 1-2 on-site operators to complete simple operations such as locomotive guidance and system startup. It eliminates the need for personnel to maintain a fixed posture for extended periods in the confined space of the roof for wiping and inspection work, completely resolving the problems of high labor intensity and fatigue leading to decreased work quality in manual high-altitude operations. Simultaneously, the remote monitoring system enables full-process visual management of the operation. Managers can remotely monitor the operating status of multiple devices from a monitoring center without on-site supervision. The number of personnel required for a single vehicle operation is reduced from 4 to 1, lowering labor costs by over 75%.

[0041] With a high degree of integration, this solution offers more flexible operation and scheduling. It integrates cleaning, inspection, monitoring, and management functions into a single unit, allowing a single device to perform the tasks that would typically require multiple units, thus reducing equipment investment costs and floor space. The fully energized operation does not interrupt locomotive operating windows, ensuring that power outages do not disrupt railway traffic and locomotive maintenance schedules. This makes it particularly suitable for the locomotive maintenance needs of high-speed rail and bullet train lines with high operating density, thereby improving overall railway operational efficiency.

[0042] Modular design ensures high adaptability and maintainability. The track device 7 in this solution adopts a modular design; the length of the trolley translation track 45 can be flexibly adjusted according to site requirements, adapting to electric locomotives of different lengths. Consumable parts such as the cleaning brush 18, 2D camera 34, and 3D camera 32 all feature quick-change designs, allowing for rapid disassembly and replacement, reducing equipment maintenance costs and time. Each module operates independently; a failure in one module does not affect the normal operation of other modules. The average mean time between failures (MTBF) of the equipment can reach 100,000 hours, significantly improving reliability and availability.

[0043] IV. Comparative Examples and Research Data (I) Core technologies of traditional solutions Traditional electric locomotive roof maintenance employs a manual, high-altitude power-off operation mode. The core technical process is as follows: Before work begins, the contact network isolating switch is disconnected and a grounding wire is installed. Workers, wearing safety ropes and helmets, ascend to the locomotive roof via a ladder. They manually wipe away dust and oil from the insulator surfaces using cloths and cleaning brushes. They manually measure the thickness and parallelism of the pantograph's carbon plate using calipers and rulers, measure the static contact force of the pantograph using a spring scale, and record the pantograph raising / lowering time using a stopwatch. They manually observe insulator damage, aging, and pantograph surface cracks, and manually record the inspection data. After the work is completed, the workers leave the roof, remove the grounding wire, and restore power to the contact network. This traditional approach relies on manual operation, with only simple cleaning tools and handheld measuring instruments. There is no automated integrated operation equipment, and all work must be completed manually, and it must be carried out under conditions of contact network power outage.

[0044] (ii) Distinguishing technical features The core differences between this application and traditional solutions are as follows: In terms of the working environment, traditional solutions require power outage operation, while this application can operate directly in a 25kV high-voltage energized environment; in terms of the working method, traditional solutions rely on manual high-altitude work, while this application uses automated robotic operation, eliminating the need for personnel to climb to the top; in terms of the working mode, traditional solutions involve single-person, single-process, step-by-step operation, while this application uses dual trolleys for simultaneous parallel operation of cleaning and inspection; in terms of the inspection method, traditional solutions rely on manual handheld measuring tools and visual observation, while this application uses multi-modal sensor fusion detection; in terms of data management, traditional solutions rely on manual recording, while this application achieves automated data acquisition and electronic archiving; and in terms of safety protection, traditional solutions rely on personal protective equipment and power-off operation, while this application employs a three-level protection system of system-level insulation + safety distance control + leakage protection.

[0045] (III) Comparison of R&D data Average maintenance time per vehicle 120 minutes 45 minutes Pantograph carbon plate thickness measurement accuracy ±0.5mm ±0.1mm Pantograph static contact force measurement error ±5% ±0.1% Insulator micro-defect detection rate 65% 98% Number of personnel required for operation of a single vehicle 4 people 1 person Overhead contact network power outage time 120 minutes / unit 0 minutes / unit Average annual accident rate (per 10,000 vehicles) Starting from 2.3 Starting from 0 Mean Time Between Failures (MTBF) - 100,000 hours Data Validity Statement: All data above are from on-site measurements at the Hefei Locomotive Depot's maintenance shed, conducted from October 2025 to February 2026. The test sample consisted of 100 HXD3 electric locomotives, including 50 tested using the traditional manual operation method and 50 tested using the robotic operation method described in this application. The test environment was a normal maintenance operation environment with a 25kV rated voltage for the overhead contact line, a temperature of 0℃-40℃, and a relative humidity of 30%-80%. All test data were calculated by averaging three times, ensuring data accuracy and reliability, and objectively reflecting the technical performance differences between the two methods.

[0046] V. Application Examples of this Solution Regarding the application embodiment 1 of this solution: Another embodiment of the present invention has the same basic structure as the basic embodiment, but the difference is that: the trolley translation track 45 adopts a multi-segment splicing structure, each segment of the track is 6m long, and is spliced ​​and fixed by track adjustment blocks 44. The total length can be flexibly adjusted within the range of 12m-36m according to the length of the locomotive 51; the load-bearing crossbeam 43 adopts segmented I-beams, which are connected and fixed by flanges, and are adapted to maintenance platforms of different spans. The above-mentioned modified solutions can all achieve precise translation of the detection trolley 5 and the cleaning trolley 6 along the track device 7, covering the entire roof working area, and fall within the protection scope of the present invention.

[0047] Application Example 2 of this solution: Another embodiment of the present invention has the same basic structure as the basic embodiment, except that: the cleaning brush 18 uses horsehair instead of nylon, suitable for work scenarios with slight contamination of the insulator surface; the cleaning medium stored in the cleaning liquid storage tank 10 uses deionized water instead of special cleaning agent, suitable for work scenarios in maintenance sheds with high environmental protection requirements; the first atomizing nozzle 21 and the second atomizing nozzle 22 use fan-shaped nozzles instead of conical nozzles, and the spraying angle is adjusted to 120° to achieve a larger area of ​​atomized spraying. All of the above modifications can effectively clean the insulator surface and fall within the protection scope of this invention.

[0048] Regarding the application embodiment 3 of this solution: Another embodiment of the present invention has the same basic structure as the basic embodiment, except that: an infrared thermal imaging camera is added to the multi-functional detection tool head 28 and installed on the right side of the top mounting plate 41 to detect abnormal temperatures of electrical components on the roof and identify overheating faults; the acoustic signature module 33 uses a 64-channel microphone array instead of a 128-channel microphone array, which is suitable for ordinary maintenance operation scenarios with lower requirements for gas leak detection accuracy; the range of the force measuring component 37 is adjusted to 0-1T, which is suitable for pantograph tension detection of light electric locomotives such as light rail and subway. All of the above variations can achieve automated multi-parameter detection of roof components and fall within the protection scope of this invention.

[0049] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A robot for operating on the roof of an electric locomotive under energized overhead contact line conditions, characterized in that: The device includes a main body (1), which includes a track device (7), a detection trolley (5), a cleaning trolley (6), a monitoring unit, a control unit, and a vehicle remote monitoring system. The track device (7) is mounted on the roof of the electric locomotive (51). The detection trolley (5) and the cleaning trolley (6) can be movably mounted on the track device (7). The cleaning trolley (6) is equipped with a cleaning robotic arm (12) and a cleaning device (15) for automated cleaning of the roof components of the electric locomotive. The detection trolley (5) is equipped with a collaborative robotic arm (27) and a multi-functional detection tool head (28) for automated multi-parameter detection of the roof components of the electric locomotive. The control unit is electrically connected to the detection trolley (5) and the cleaning trolley (6), and the vehicle remote monitoring system is communicatively connected to the control unit. The robot as a whole adopts a high-voltage insulation protection design and can carry out operations directly under the condition that the contact network is energized. The track device (7) includes a bearing beam (43), track adjustment blocks (44) and a trolley translation track (45). The track adjustment blocks (44) have a U-shaped structure. Several sets of track adjustment blocks (44) are installed horizontally at equal intervals on the top of the bearing beam (43) for raising, leveling and fine-tuning the position. The trolley translation track (45) is installed on the top of several sets of track adjustment blocks (44). The top of the trolley translation track (45) is provided with a drive groove (46). A rack (47) is installed in the drive groove (46). The bottom of the detection trolley (5) and the cleaning trolley (6) are provided with translation gears (14) that mesh with the rack (47). Precise movement along the track is achieved through gear and rack transmission. The cleaning trolley (6) also includes a cleaning translation slide (8), a cleaning motor (9), a cleaning fluid storage tank (10), and a first remote communication control box (11); the cleaning motor (9) drives the translation gear (14) to rotate, the cleaning fluid storage tank (10) is connected to the cleaning device (15) through a pipe, and the first remote communication control box (11) is connected to the control unit to receive work instructions and transmit equipment status data; the cleaning device (15) includes a mounting bracket and transmission device (16), a drive motor and reducer (17), two sets of symmetrically arranged cleaning brushes (18), and a first sprayer (19). The system includes a second sprayer (20), a first atomizing nozzle (21), and a second atomizing nozzle (22). The drive motor and reducer (17) drive two sets of cleaning brushes (18) to rotate synchronously to perform the brushing operation. The first atomizing nozzle (21) is located above the mounting bracket and transmission device (16), and the second atomizing nozzle (22) is located below the mounting bracket and transmission device (16). The first sprayer (19) is connected to the first atomizing nozzle (21) through the structural tube (23), and the second sprayer (20) is connected to the second atomizing nozzle (22) through the structural tube (23), so as to realize the all-round atomizing spraying of the parts to be cleaned. The inspection trolley (5) also includes an inspection translation slide (24), an inspection moving motor (25), and a second remote communication control box (26); the inspection moving motor (25) drives the translation gear (14) to rotate, and the second remote communication control box (26) is connected to the control unit to receive work instructions and transmit inspection data; the multi-functional inspection tool head (28) integrates a vision inspection module and a sensor inspection module; the vision inspection module includes at least one set of 2D cameras (34) and at least one set of 3D cameras (32), the 2D cameras (34) are used for two-dimensional defect identification of the roof components, and the 3D cameras (32) are used for three-dimensional morphological scanning and dimensional parameter measurement of the roof components; the sensor inspection module includes an acoustic sensor, a displacement sensor (36), and a force measuring component (37), the acoustic sensor is used for abnormal noise detection of the roof components, the displacement sensor (36) is used for displacement parameter measurement, and the force measuring component (37) is used for force parameter measurement; The high-voltage insulation protection design includes: the robotic arm and end effector are covered with insulating material, insulating pads are installed between the track and the load-bearing structure, and electrical components are treated with insulation and sealing; and the system has built-in safety distance control logic to ensure that a minimum safety gap of not less than 0.8m is maintained between the robotic arm and the live parts of the contact network during operation. After the control unit controls the cleaning trolley (6) to start the operation for a preset time, the inspection trolley (5) starts the operation simultaneously, so that the cleaning process and the inspection process can be carried out in parallel.

2. The electric locomotive roof-operating robot under energized overhead contact line conditions as described in claim 1, characterized in that: The cleaning device (15) also includes an electromagnetic reversing nozzle switch (13), which is installed on the pipeline between the cleaning liquid storage tank (10) and the first sprayer (19) and the second sprayer (20) for switching on / off and pipeline flow direction.

3. The electric locomotive roof-operating robot under energized overhead contact line conditions as described in claim 1, characterized in that: The multi-functional testing tool head (28) includes a mounting base (29), a force transmission connector (30), and a testing bracket (31). The force transmission connector (30) is mounted on the left end of the mounting base (29), the testing bracket (31) is mounted on the top of the mounting base (29), the 3D camera (32) is mounted on the front end of the testing bracket (31), the acoustic sensor is mounted on the top of the testing bracket (31), the 2D camera (34) is mounted on the rear end of the testing bracket (31), and the displacement sensor (36) and the force measuring component (37) are mounted in the mounting groove (35) at the bottom of the force transmission connector (30).

4. The electric locomotive roof-operating robot under energized overhead contact line conditions as described in claim 3, characterized in that: The detection bracket (31) includes a threaded support column (38), a locking block (39), a front mounting plate (40), and a top mounting plate (41). The locking block (39) is welded to the top of the threaded support column (38). The front mounting plate (40) is installed at the front end of the locking block (39) by screws. The top mounting plate (41) is welded to the top of the front mounting plate (40). The surface of the threaded support column (38) is provided with several sets of weight-reducing holes (42).

5. The electric locomotive roof-operating robot under energized overhead contact line conditions as described in claim 1, characterized in that: The vehicle remote monitoring system includes a video monitoring unit, a data storage unit, and a remote control unit. The video monitoring unit is used to collect operation footage in real time. The data storage unit includes a first working NVR, a second working NVR, and a backup NVR, used to store detection data and operation videos in duplicate and perform off-site backup. The remote control unit is used to remotely issue operation instructions and monitor the operating status of the equipment.

Images