An automatic crawling scanning vehicle based on full-focus detection for rust removal

Abstract

The application is suitable for the field of nondestructive testing equipment, and provides an automatic crawling scanning vehicle for rust removal based on full-focus detection, which comprises a scanning vehicle body, magnetic force wheels located at the bottom of the scanning vehicle body, an angle adjusting device located at the front end of the scanning vehicle body, a buffer device located at the output end in front of the angle adjusting device, a polishing device installed at the front end of the buffer device, a rust removal wheel body on the polishing device, a scanning device at the tail end of the scanning vehicle body, and a visual guiding unit installed at the top of the scanning vehicle body; the angle adjusting device is used for adjusting the buffer stroke of the buffer device, so that the buffer stroke direction and the ground form an acute angle; the scanning device comprises a scanner which can scan back and forth along the width direction of the scanning vehicle body, and the scanner is internally provided with a 3D full-focus ultrasonic imaging assembly and a visual detection unit. Therefore, the device realizes integrated operation of rust removal, ultrasonic full-focus detection and magnetic powder detection, completes the detection operation in a restricted space, and meets the nondestructive testing requirements of metal structure welds.

Description

Technical Field

[0001] This invention is applicable to the field of non-destructive testing equipment and provides an automatic crawling sweeping vehicle based on full-focus rust removal. Background Technology

[0002] The automated crawling inspection vehicle is an automated device integrating mobile operation and non-destructive testing functions. It is primarily used for weld flaw detection in metal structures such as hydropower station spiral casings and pressure steel pipes, and can also be extended to defect detection in large steel structures such as petrochemical pipelines, storage tanks, and wind power equipment. Its core function is to replace manual labor in high-altitude and confined space ultrasonic and magnetic particle testing operations, automating the inspection process and data acquisition, reducing the risks of manual operation, and improving inspection efficiency and data standardization.

[0003] Currently, most existing automated crawling inspection vehicles adopt a conventional modular structure, mainly including a vehicle frame, a driving mechanism, a fixing mechanism, and a basic inspection module. Among them, the vehicle frame serves as the load-bearing base, housing various functional components; the driving mechanism is mostly composed of a motor, wheels, or tracks, providing power for movement on a plane or wall; the basic inspection module simply integrates an ultrasonic probe or magnetic particle inspection components to complete basic flaw detection signal acquisition.

[0004] However, existing automated crawling inspection vehicles are difficult to integrate rust removal and inspection in the complex working conditions of metal structures in hydropower stations, and cannot meet the high-precision flaw detection requirements of the entire process. Summary of the Invention

[0005] To address the aforementioned deficiencies, the present invention aims to provide an automatic crawling inspection vehicle based on full-focus detection for rust removal, in order to solve the problems mentioned in the background art. The device includes a scanning vehicle body, a magnetic wheel located at the bottom of the scanning vehicle body, an angle adjustment device located at the forward end of the scanning vehicle body, a buffer device located at the output end in front of the angle adjustment device, a grinding device installed at the front end of the buffer device, a rust removal wheel on the grinding device, a scanning device at the rear end of the scanning vehicle body, and a visual guidance unit installed on the top of the scanning vehicle body.

[0006] The angle adjustment device is used to adjust the buffer stroke of the buffer device so that the buffer stroke direction forms an acute angle with the ground.

[0007] The scanning device includes a scanner that can scan back and forth along the width of the scanning vehicle body. The scanner has a built-in 3D full-focus ultrasonic imaging component and a vision inspection unit, which can perform high-resolution real-time 3D full-focus imaging scanning and inspection of the weld seams of the metal structure on the walking surface.

[0008] Furthermore, the main body of the scanning vehicle is equipped with a crawling guide device and a visual guide unit;

[0009] The crawling guidance device is an obstacle avoidance radar that detects the direction in which the probe is facing the main body of the scanning vehicle;

[0010] The visual guidance unit is equipped with a visual camera and an LED ring light source.

[0011] Furthermore, the angle adjustment device includes a mounting front seat and a front mounting base plate on which angle adjustment can be performed, the angle adjustment function being realized by an angle adjustment locking mechanism; it also includes a locking base mounted on the mounting front seat;

[0012] The angle adjustment locking mechanism includes a hinge base mounted on the front mount, and a hinge sub-mount is hinged to one end of the hinge base away from the mount body. The hinge sub-mount is mounted on the front mount base plate.

[0013] The locking base is provided with an arc-shaped slide rail, and the front mounting plate is fixedly connected with a locking body that cooperates with the arc-shaped slide rail; the locking body is provided with a reserved hole through which the arc-shaped slide rail can pass, and the locking body is provided with a locking knob that can fix the locking base.

[0014] Furthermore, the arc-shaped slide rail is provided with a number of locking holes, which are evenly arranged along the length of the arc-shaped slide rail, and the locking knob can be screwed into the locking holes.

[0015] Furthermore, a front mounting plate is installed on the side of the front mounting base away from the angle adjustment locking mechanism via a lifting adjustment mechanism;

[0016] Furthermore, the lifting adjustment mechanism includes a first slide rail vertically mounted on the front mounting plate and a first slide block thereon, the first slide block being fixedly connected to the front mounting plate;

[0017] A stepper motor is mounted on the front mounting base plate, and its output end is connected to a rotating arm through the front mounting base plate. The other end of the rotating arm is rotatably connected to a roller.

[0018] The front mounting plate is provided with an elongated hole with a horizontal length, and the roller is disposed inside the elongated hole, with the outer circumferential surface of the roller rolling and abutting against the inner sidewall of the elongated hole.

[0019] Furthermore, the buffer device includes a carrier that is fixedly connected at one end to the angle adjustment device;

[0020] The hanging carrier is provided with a second vertical slide rail, and a second slide block is slidably mounted on the second slide rail. A first spring is provided between the hanging carrier and the second slide block.

[0021] The lifting buffer seat is provided with a second limiting part on both sides, and a wheel cover base is rotatably connected to the middle of the lifting buffer seat; the two second limiting parts and the top of the bottom wheel cover base are each provided with a second spring part, which is responsible for the offset buffer at both ends of the wheel cover base.

[0022] Furthermore, a wheel cover bracket is fixedly connected to the front end of the wheel cover base. A rust-removing wheel and a wheel cover are installed on the wheel cover bracket. An adjustment groove extending circumferentially along the rust-removing wheel is provided on the wheel cover bracket, and an adjustment bolt is fitted on the adjustment groove.

[0023] Furthermore, the scanning device includes a scanning base fixedly connected to the main body of the scanning vehicle, a third slide rail mounted on the scanning base, a third slide block slidably connected to the third slide rail, and a scanner mounted on the third slide block;

[0024] A drive motor is installed at one end of the third slide rail, and a screw is installed on the output end of the drive motor. The third slide block is provided with a threaded part that cooperates with the screw. The third slide block can move laterally on the third slide rail under the drive of the drive motor.

[0025] Furthermore, the scanning device also includes: a fourth slide rail mounted on the third slide block, a fourth slide block slidably connected to the fourth slide rail, and a tension spring provided between the fourth slide block and the third slide block; a mounting bracket is fixedly connected to the bottom of the fourth slide block, and a scanner is fixedly connected to the mounting bracket; a ground support device is fixedly connected to the bottom of the mounting bracket.

[0026] This invention realizes the integrated automation of rust removal, ultrasonic full-focusing inspection, and magnetic particle inspection, replacing manual labor in high-altitude and confined space inspection operations, significantly reducing operational risks, improving inspection efficiency and accuracy, and simultaneously enabling digital archiving and intelligent analysis of inspection data. It balances inspection efficiency, cost, and reliability, and fully meets the industrial application requirements for non-destructive testing of welds in metal structures of hydropower stations. Attached Figure Description

[0027] Figure 1 This is a three-dimensional schematic diagram of the overall structure of the device;

[0028] Figure 2 A schematic diagram of the installation structure of the vehicle body and the angle adjustment device;

[0029] Figure 3 This is a schematic diagram of the three-dimensional structure of the angle adjustment device;

[0030] Figure 4 A three-dimensional structural diagram of the angle adjustment device, omitting the underside of the front mounting housing;

[0031] Figure 5 This is a schematic diagram of the cooperation structure between the rotating arm and the roller;

[0032] Figure 6 This is a three-dimensional structural diagram of the buffer device.

[0033] Figure 7 This is a side view of the buffer device;

[0034] Figure 8 A three-dimensional schematic diagram of the cooperation structure between the buffer device and the rust removal wheel;

[0035] Figure 9 This is a schematic diagram of the three-dimensional structure of the scanning device;

[0036] In the diagram: 01-Scanning vehicle body; 011-Main base plate; 012-Mounting base; 02-Magnetic wheel; 021-Wheel frame; 03-Angle adjustment device; 031-Front mounting frame; 04-Buffer device; 05-Grinding device; 06-Rust removal visual recognition device; 07-Crawling guide device; 08-Scanning device;

[0037] 1-Mount front mount; 11-Hinged base; 12-Hinged sub-mount; 13-Locking base; 131-Locking hole;

[0038] 2-Front mounting plate; 201-Front mounting housing; 21-Locking body; 22-Locking knob; 23-First slide rail; 24-First slide block; 25-Front mounting plate; 251-Elongated hole;

[0039] 3-Stepper motor; 31-Reducer; 32-Reducer output end; 33-Rotating arm; 34-Roller;

[0040] 4-Hanging carrier; 41-Second slide rail; 42-Second slide block; 43-First spring part;

[0041] 5-Lifting buffer seat; 501-Arc groove; 51-Rotating shaft; 52-Wheel cover base; 521-Limit bolt; 53-Second limit part; 54-Second spring part; 55-Wheel cover bracket; 551-Adjusting groove; 552-Adjusting bolt; 56-Wheel cover; 57-Rust removal wheel body; 58-Pulley; 59-Shielding body;

[0042] 6-Scanning mount; 61-Third slide rail; 62-Third slide block; 63-Fourth slide rail; 64-Fourth slide block; 65-Tension spring;

[0043] 7-Mounting bracket; 71-Wheel caster; 8-Scanner. Detailed Implementation

[0044] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0045] It should be noted that, in the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0046] Furthermore, in the description of this invention, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0047] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0048] See appendix Figure 1 Appendix Figure 2 and attached Figure 8 This invention discloses an automatic crawling scanning vehicle based on full-focus detection for rust removal, including a scanning vehicle body 01, four magnetic wheels 02 located at the bottom of the scanning vehicle body 01, an angle adjustment device 03 located at the forward end of the scanning vehicle body 01, a buffer device 04 located at the output end in front of the angle adjustment device 03, a grinding device 05 installed at the front end of the buffer device 04, a rust removal wheel 57 on the grinding device 05, a scanning device 08 at the rear end of the scanning vehicle body 01, and a visual guidance unit installed on the top of the scanning vehicle body 01.

[0049] Preferably, the grinding device 05 is provided with multiple units in front of the buffer device 04.

[0050] The main body 01 of the scanning vehicle serves as the load-bearing base for the entire scanning vehicle. It includes the main base plate 011 on the top and is the mounting carrier for various functional components. The overall structure is a flat frame structure, which is suitable for crawling inspection operations on straight or inclined walls of metal structures such as hydropower station spiral casings and pressure steel pipes.

[0051] Specifically, in this solution, the magnetic wheels 02 are located at the four corners of the bottom of the scanning vehicle body 01. The bottom of the scanning vehicle body 01 is provided with a wheel frame 021, and each set of magnetic wheels 02 is matched and installed on the wheel frame 021. That is to say, the top of the wheel frame 021 is fixedly installed on the lower surface of the scanning vehicle body 01, and the bottom side is rotatably connected to the magnetic wheel 02, so as to realize the stable support and free rotation of the magnetic wheel 02.

[0052] The magnetic wheel 02 in this design uses a strong magnetic adsorption component with a diameter of D=80mm. Each wheel weighs 0.85KG, and the vertical adsorption force is set to 15~20KG. It magnetically adheres to the surface of the metal structure being tested, providing stable wall adhesion for the sweeping vehicle and enabling its movement. More specifically, the magnetic wheel 02 is a four-wheel drive structure, working in conjunction with an electric drive unit to achieve forward, backward, and turning movements. It possesses both strong load-bearing capacity and walking stability, and the magnetic wheel 02 has a power-off self-locking function to ensure the safety and stability of the sweeping vehicle during operation and parking.

[0053] Angle adjustment device 03 is fixedly installed at the front end of the scanning vehicle body 01 and is detachably connected to the scanning vehicle body 01. It serves as an adjustment carrier for the functional execution components, enabling manual adjustment of the angle of the rust removal and inspection components. The front end of the angle adjustment device 03 is sequentially connected to the buffer device 04 and the rust removal wheel 57.

[0054] One end of the buffer device 04 is connected to the angle adjustment device 03, and the other end is fixedly fitted with the rust removal wheel body 57; that is, the buffer device 04 is located between the angle adjustment device 03 and the rust removal wheel body 57, and plays an elastic buffering role, so that the rust removal wheel body 57 can fit against the surface of the metal structure to carry out rust removal operations, avoiding component damage caused by rigid contact.

[0055] The scanning device 08 is installed at the rear end of the scanning vehicle body 01 and is fixedly connected to the scanning vehicle body 01. The scanning device 08 has a built-in 3D full-focus ultrasonic imaging component and a visual inspection unit. Specifically, it integrates a CTS-PA322T phased array full-focus inspection module with 64 fully parallel phased array hardware channels, which can realize real-time 3D full-focus imaging and 4D continuous scanning imaging of the weld area.

[0056] Meanwhile, a crawling guide device 07, which is an obstacle avoidance radar, is installed at the front end of the top of the scanning vehicle body 01. The obstacle avoidance radar is fixed to one side of the front end of the scanning vehicle body 01, and its detection probe is set facing the direction of travel of the scanning vehicle. It detects obstacles and the edges of workpieces in front to achieve collision avoidance.

[0057] The obstacle avoidance radar transmits and receives radar detection signals to collect environmental data in real time, such as the distance to obstacles and the position of workpiece edges ahead of the sweeping vehicle. After converting the collected analog signals into digital signals, the data is transmitted to the sweeping vehicle's onboard control system. The control system analyzes and processes the data, and when it detects an obstacle within a preset distance ahead or when the sweeping vehicle approaches the edge of a workpiece, it immediately issues a stop command, cuts off the power to the walking drive mechanism, and achieves automatic shutdown, thereby achieving the protection effect of collision prevention and fall prevention. At the same time, the obstacle avoidance radar can synchronously upload the real-time detected environmental data and stop signal to a remote control terminal to achieve remote synchronization and monitoring of the detection data.

[0058] The obstacle detection, signal transmission, and data uploading technologies of the aforementioned obstacle avoidance radar are all conventional existing technologies in the field of industrial automation. Their specific circuit structures, signal transmission principles, and control logic are all mature existing technologies, so they will not be elaborated here.

[0059] The vision guidance unit is fixedly suspended on the top of the scanning vehicle body 01 via a fixed rod frame and is fixedly connected to the scanning vehicle body 01. The vision guidance unit is equipped with a high-pixel vision camera and an LED ring light source. The camera has a pixel count of no less than 5 million, and the light source can make the surface illumination of the inspected workpiece ≥1000Lx. It can automatically identify the weld seam line, acquire weld seam images in real time, adjust the vehicle body posture, and control the scanning vehicle to move precisely along the weld seam, realizing automatic weld seam tracking and autonomous navigation.

[0060] Furthermore, the main body 01 of the scanning vehicle also integrates two battery packs. One is a drive battery pack that powers the magnetic wheel 02, the vision guidance unit, the obstacle avoidance radar, and the control system. It uses a lithium battery with a voltage of no more than 36V and has an operating time of no less than two hours. The other is a detection battery pack that powers the rust removal wheel 57, the scanning device 08, and the magnetic particle inspection components. It integrates a DC / AC conversion circuit to realize the inverter AC output and has overvoltage, undervoltage, overcurrent, short circuit, and temperature protection functions.

[0061] The magnetic wheel 02 of this device drives the scanning vehicle body 01 to adhere to and move on the metal structure surface. The vision guidance unit identifies weld seams in real time and corrects the walking path. The angle adjustment device 03, in conjunction with the buffer device 04, drives the rust removal wheel 57 to adhere to the metal surface to complete the rust removal operation. The scanning device 08 simultaneously performs 3D full-focus ultrasonic testing and visual data acquisition. The obstacle avoidance radar monitors the working environment in real time to ensure the safe and stable operation of the scanning vehicle throughout the process. Therefore, this device can realize the integrated operation of automated rust removal and full-focus non-destructive testing of weld seams in the metal structure of hydropower stations.

[0062] See appendix Figure 1 - Appendix Figure 5The automatic crawling inspection vehicle based on full-focus detection for rust removal of the present invention includes, for the angle adjustment device 03, a front mounting frame 031 installed at the forward end of the scanning vehicle body 01;

[0063] The front mounting bracket 031 is integrally assembled at the front end of the vehicle body. The front mounting bracket 031 serves as a load-bearing base for the buffer device 04 and for mounting the grinding device 05 via the buffer device 04. It also allows adjustment of the stress-bearing angle of the grinding device 05. Specifically, a flat mounting base 012 is pre-installed at the front end of the vehicle body. The mounting base 012 is an installation mating surface, located in the middle of the front end of the vehicle body, specifically for aligning and fitting with the front mounting seat 1. The vehicle body not only bears the functions of its own movement and overall counterweight but also serves as the installation reference for the front mounting bracket 031.

[0064] Combined with appendix Figure 2 Appendix Figure 3 As shown, the front mount 031 is detachably and fixedly connected to the vehicle body via fasteners; it is arranged vertically and its tilt angle is adjustable; the front mount 1 is a plate-like structure, mounted on the mount base 012, and an angle adjustment locking mechanism is installed on its end face away from the vehicle body; a front mount base plate 2 is installed on the side of the angle adjustment locking mechanism away from the mount base 012. In other words, the front mount 031 includes the front mount 1 and the front mount base plate 2 on which the angle can be adjusted, and its angle adjustment function is realized by the angle adjustment locking mechanism.

[0065] The following is a preferred embodiment of the angle adjustment locking mechanism:

[0066] The angle adjustment locking mechanism includes a hinge base 11 mounted on the front mounting base 1. A hinge sub-base 12 is hinged to one end of the hinge base 11 away from the mounting base 012. The end of the hinge sub-base 12 away from the hinge base 11 is fixedly connected to the front mounting base 2. The angle adjustment locking mechanism also includes a locking base 13 mounted on the mounting base 012. The locking base 13 is provided with an arc-shaped slide rail. The arc shape of the arc-shaped slide rail is arranged in an arc shape with the hinge point of the hinge base 11 and the hinge sub-base 12 as the center. A locking body 21 that cooperates with the arc-shaped slide rail is fixedly connected to the front mounting base 2.

[0067] Specifically, the locking body 21 is provided with a reserved hole through which the arc-shaped slide rail can pass, so that when the front mounting plate 2 rotates, the arc-shaped slide rail always slides within the reserved hole of the locking body 21.

[0068] More specifically, the angle adjustment locking mechanism also includes a locking knob 22 rotatably connected to the locking body 21. When the locking knob 22 is tightened, one end of the locking knob 22 screwed into the locking body 21 can abut against the arc-shaped slide rail of the locking base 13, thereby locking the angle adjustment.

[0069] In another preferred embodiment, the arc-shaped slide rail of the locking base 13 is provided with a plurality of locking holes 131, which are evenly arranged along the length of the arc-shaped slide rail. Thus, when the front mounting plate 2 is adjusted to a certain angle and the locking knob 22 is screwed in, the front mounting plate 2 can be precisely locked at a certain preset height, thereby achieving better locking and precise locking angle.

[0070] A front mounting plate 25 is installed on the side of the front mounting base plate 2 away from the angle adjustment locking mechanism via a lifting adjustment mechanism; specifically, the front mounting plate 25 is used to mount the buffer device 04; that is, a lifting adjustment mechanism is installed between the front mounting plate 25 and the front mounting base plate 2.

[0071] The lifting and adjusting mechanism includes a first slide rail 23 vertically mounted on the front mounting plate 2, a first slide block 24 slidably connected to the first slide rail 23, and the first slide block 24 fixedly connected to the front mounting plate 25; a stepper motor 3 and a reducer 31 connected to the stepper motor 3 are mounted on the front mounting plate 2, the output end of the reducer 31 passes through the front mounting plate 2, and a rotating arm 33 is fixedly connected to the end of the reducer 31 that protrudes from the front mounting plate 2, the rotating arm 33 can rotate under the drive of the reducer 31, and a roller 34 is rotatably connected to the other end of the rotating arm 33. The roller 34 adopts a wear-resistant engineering plastic or metal wheel structure; the front mounting plate 25 is provided with an elongated hole 251 with a horizontal length, the roller 34 is disposed inside the elongated hole 251, and the outer circumferential surface of the roller 34 rolls and abuts against the inner wall of the elongated hole 251.

[0072] Therefore, when the rotating arm 33 is driven to rotate, the roller 34 at the end of the rotating arm 33 is also driven to move in a circle around the output end of the reducer 31. Under the limitation of the elongated hole 251, the first slide rail 23, and the first slide block 24, when the roller 34 is displaced in the vertical direction, the front mounting plate 25 is driven to move up and down.

[0073] See appendix Figure 1 Appendix Figure 2 Appendix Figure 6 - Appendix Figure 8 The automatic crawling sweeping vehicle based on full-focus detection for rust removal of the present invention, with regard to the buffer device 04, includes a mounting carrier 4, a lifting buffer seat 5, a wheel cover base 52, a wheel cover 56, a rust removal wheel body 57, and a pulley 58. One end of the mounting carrier 4 is fixedly connected to the front mounting plate 25 of the angle adjustment device 03. A second vertical slide rail 41 is provided on the mounting carrier 4, and a second slide block 42 is slidably mounted on the second slide rail 41. The second slide block 42 can slide up and down along the second slide rail 41 to achieve position adjustment in the height direction.

[0074] In one embodiment, a first spring part 43 is provided between the hanging carrier 4 and the second slide block 42. The first spring part 43 is arranged along the direction of the second slide rail 41, and its two ends abut against the stop block on the top of the hanging carrier 4 and the second slide block 42 respectively, providing elastic buffering force and restoring force for the up and down sliding of the second slide block 42, so that the second slide block 42 can achieve vertical elastic floating in a passive state.

[0075] In another embodiment, the lifting buffer seat 5 is fixedly installed on the outside of the second slide 42 and can move up and down synchronously with the second slide 42 along the second slide rail 41. A limit rod is installed on the top of the lifting buffer seat 5. The limit rod passes through the stop block on the top of the carrier 4. The first spring part 43 is sleeved on the outside of the limit rod, so that the limit rod plays a limiting role on the first spring part 43.

[0076] A second limiting part 53 is provided on both sides of the lifting buffer seat 5, and the second limiting parts 53 are symmetrically arranged on the left and right sides of the lifting buffer seat 5. A rod is provided at the bottom of the second limiting part 53, and a second spring part 54 is sleeved on the outside of the rod. That is, the second spring part 54 is sleeved on the rod of the second limiting part 53, and its two ends abut against the lifting buffer seat 5 and the wheel cover base 52 respectively, to provide vertical elastic support for the wheel cover base 52. Together with the first spring part 43, it forms a double buffer structure, further improving the passive attitude adjustment capability of the device.

[0077] Specifically, for the second spring part 54, each of the two second spring parts 54 is responsible for the offset buffer at both ends of the wheel cover base 52.

[0078] More specifically, a pivot 51 is provided in the middle of the lifting buffer seat 5. The pivot 51 extends horizontally and is used to achieve a hinged connection between the wheel cover base 52 and the lifting buffer seat 5. The wheel cover base 52 is hinged to the lifting buffer seat 5 via the pivot 51. The wheel cover base 52 can rotate around the pivot 51 at a certain angle to adapt to working surfaces with different curvatures. That is to say, the wheel cover base 52 can rotate on the lifting buffer seat 5. When rotating, one side of the wheel cover base 52 will rise or fall, and the other side will fall or rise. At this time, the second spring part 54 can push the rising side to generate a restoring force.

[0079] In one embodiment, the lifting buffer seat 5 is further provided with an arc-shaped groove 501, which is distributed in an arc shape with the rotating shaft 51 as the center. The wheel cover base 52 is provided with a limiting bolt 521 corresponding to the position of the arc-shaped groove 501. The arc-shaped groove 501 is used to cooperate with the limiting bolt 521 on the wheel cover base 52 to realize the limiting control of the rotation angle of the wheel cover base 52 around the rotating shaft 51. That is, the wheel cover base 52 is provided with a limiting bolt 521, which passes through the arc-shaped groove 501 and can slide along the trajectory of the arc-shaped groove 501. The sliding range of the limiting bolt 521 is limited by the two end walls of the arc-shaped groove 501, thereby controlling the rotation angle of the wheel cover base 52.

[0080] The front end of the wheel cover base 52 is fixedly connected to the wheel cover bracket 55. The wheel cover bracket 55 has an adjustment groove 551 extending circumferentially along the rust removal wheel body 57. The adjustment groove 551 is used to cooperate with the adjustment bolt 552 to achieve fine adjustment of the position of the wheel cover 56.

[0081] Specifically, the wheel cover 56 is installed between two wheel cover brackets 55, and the wheel cover 56 is fixedly connected by adjusting bolts 552 and adjusting grooves 551. The adjusting bolts 552 pass through the adjusting grooves 551. When the adjusting bolts 552 are loosened, the wheel cover 56 can rotate along the direction of the adjusting grooves 551, thereby adjusting the rotational position of the wheel cover 56. After adjustment, tightening the adjusting bolts 552 will fix the wheel cover 56 in the desired position.

[0082] The lower end of the wheel cover 56 is provided with a shield 59, which extends toward the working surface of the rust removal wheel 57 to block the flying debris generated during the rust removal operation and improve the safety of the operation.

[0083] The rust-removing wheel 57 is the core component for rust removal operations. It is installed inside the wheel cover 56, and its outer circumferential surface serves as the rust-removing working surface. Rotation allows for grinding and rust removal of the metal structure surface. A pulley 58 is fixedly installed at one end of the rust-removing wheel 57 and is used to connect to the transmission belt of an external drive device to receive power and drive the rust-removing wheel 57 to rotate.

[0084] See appendix Figure 1 and attached Figure 9 The automatic crawling inspection vehicle based on full-focus detection for rust removal of the present invention, for the scanning device 08, includes a scanning base 6, a third slide rail 61, a third slide block 62, a fourth slide rail 63, a fourth slide block 64, a tension spring 65, and a scanner 8;

[0085] The scanning base 6 is fixedly mounted at the rear end of the scanning carriage body 01. The scanning base 6 serves as the mounting reference and bearing base for the entire scanning device 08 and is detachably connected to the scanning carriage body 01 using fasteners. A third slide rail 61 is horizontally arranged on the scanning base 6. The third slide rail 61 extends horizontally and a third slide block 62 is slidably mounted on it. The third slide block 62 can slide smoothly laterally along the third slide rail 61. A drive motor is installed at one end of the third slide rail 61, and a screw is installed at the output end of the drive motor. The third slide block 62 has a threaded part that mates with the screw, thus forming a threaded screw transmission pair. Under the drive of the drive motor, the third slide block 62 can move laterally on the third slide rail 61.

[0086] A vertically arranged fourth slide rail 63 is fixedly installed on the upper end of the third slide block 62. A fourth slide block 64 is slidably mounted on the fourth slide rail 63. The fourth slide block 64 can slide vertically up and down along the fourth slide rail 63, thereby realizing the position adjustment of the scanner 8 in the height direction.

[0087] A tension spring 65 is provided between the fourth slide block 64 and the third slide block 62. The tension spring 65 is installed vertically along the layout direction of the fourth slide rail 63. The two ends of the tension spring 65 are respectively connected to the third slide block 62 and the fourth slide block 64, so that the fourth slide block 64 has an elastic preload after sliding upward.

[0088] A mounting bracket 7 is fixedly connected to the bottom of the fourth slide 64, and a scanner 8 is fixedly connected to the mounting bracket 7. The scanner 8 can be adjusted horizontally and vertically synchronously with the fourth slide 64 and the third slide 62. The scanner 8 has a built-in 3D full-focus ultrasonic imaging component and a vision inspection unit. Specifically, it is equipped with a CTS-PA322T phased array full-focus inspection module, which has 64 fully parallel phased array hardware channels. It can acquire up to 4096 raw full matrix data of A-type waves in real time, and can perform high-resolution real-time 3D full-focus imaging inspection of welds in the metal structure of hydropower stations. It can also combine encoder continuous scanning to form a three-dimensional and intuitive 4D inspection image. The continuous scanning speed can reach up to 100mm / s.

[0089] The bottom of the mounting bracket 7 is fixedly connected to a ground support device, which in one embodiment is a caster wheel 71.

[0090] Therefore, under normal conditions, due to the weight of the mounting bracket 7, the scanner 8 and mounting bracket 7 naturally sag. Simultaneously, the force transmitted from the ground to the mounting bracket 7, then to the fourth slide 64, and finally to the tension spring 65 causes the tension spring to be slightly stretched. In other words, the tension spring always applies a certain force, ensuring that the ground support device remains in contact with the ground. Furthermore, when the vehicle body bumps due to uneven surfaces or foreign objects, the scanner 8 maintains a consistent distance from the surface due to the tension of the tension spring 65. This adaptively conforms to the surface of the metal structure being measured, while simultaneously providing sliding reset and shock absorption, preventing vertical swaying during operation.

[0091] In a preferred embodiment, the scanner 8 integrates visual acquisition function and works in conjunction with the vision guidance unit of the whole machine. It can automatically collect and store flaw detection image data, mark the defect location, match the grid scale, and accurately measure the size, which facilitates the later traceability of defect location and the generation of customized inspection reports.

[0092] At the same time, with the combined action of the angle adjustment device 03 and the buffer device 04, this device can perform predetermined attitude adjustment of the carrier mounted on the front of the vehicle body through manual adjustment.

[0093] In one embodiment, the overall tilt of the buffer device 04 and the matching degree between the wheel cover 56 and the ground can be adjusted by adjusting the locking knob 22 and the adjusting bolt 552 to deal with situations where there are too many impurities on the walking surface and the unevenness causes the rust removal wheel body 57 to need more cushioning.

[0094] Specifically, after loosening the locking knob 22, the pitch angle of the front mounting plate 2 inside the angle adjustment device 03 can be manually fine-tuned, thereby driving the connected mounting carrier 4 and the entire buffer device 04 to synchronously change their overall tilt posture. At the same time, loosening the adjusting bolt 552 allows for circumferential adjustment of the installation angle and blocking position of the wheel cover 56 along the adjusting groove 551, ensuring that the wheel cover 56 maintains the optimal fit angle with the ground. When encountering conditions with excessive impurities or uneven surfaces on the running surface, the adjustment allows for a larger parallel buffer stroke for the rust-removing wheel 57, providing more adaptive space and grinding force for the rust-removing wheel 57 when contacting convex surfaces.

[0095] During the above process, when the rust removal wheel 57 is on a crawling surface with large undulations, it can apply grinding pressure in an oblique downward direction, conform to the working surface of the metal structure, meet the need for greater buffer compensation under complex working conditions, ensure that the rust removal operation is carried out continuously and smoothly, and ensure the grinding effect.

[0096] This automatic crawling inspection vehicle, based on full-focus ultrasonic rust removal, integrates mechanical walking, automatic rust removal, 3D full-focus ultrasonic inspection, magnetic particle inspection, intelligent control, and human-machine interaction into a complete automated inspection system for weld seams of hydropower unit metal structures. The entire machine weighs ≤10kg, balancing lightweight design with a sensor load capacity of ≥3kg. It has overcome the technical challenges of integrating precision mechanics, intelligent algorithms, and industrial adaptation, and is suitable for automated inspection operations in spaces without GPS constraints, such as hydropower station spiral casings and pressure steel pipes.

[0097] In a preferred embodiment, the automatic crawling sweeper based on full-focus detection for rust removal according to the present invention also has the following detailed configuration:

[0098] The automatic crawling sweeping vehicle based on full-focus rust removal utilizes a four-wheel drive magnetic wheel 02 as its walking mechanism. The magnetic wheel 02 employs strong magnetic adsorption components, with a single wheel diameter of 80mm and a weight of 0.85KG. The vertical adsorption force is controlled between 15~20KG, ensuring stable adsorption on the wall surface and self-locking in the event of power failure while reducing walking resistance caused by redundant magnetic force and lowering the overall operating power consumption. Simultaneously, the magnetic wheel 02 meets the environmental adaptability requirements of IP67 dust and water resistance and 50Hz power frequency electromagnetic interference suppression in industrial environments, enabling stable operation under complex industrial conditions.

[0099] The vehicle's movement is divided into two modes: automatic vision-guided driving and manual remote control.

[0100] In automatic mode, relying on the front vision guidance unit and line laser tracking technology, the machine automatically identifies the weld seam trajectory, collects weld seam images in real time and adjusts the vehicle body posture. The deviation between the walking trajectory and the weld seam direction is ≤1mm, and the control system response time is <100ms, achieving precise autonomous crawling along the weld seam. With the front obstacle avoidance radar, the machine monitors the environment and automatically stops when it encounters obstacles or the edge of the workpiece, achieving anti-collision and anti-fall protection.

[0101] In manual mode, operators can control the vehicle to move forward, backward, and steer via a remote terminal. With the help of AR-assisted human-machine collaboration, the detection data is overlaid onto the operator's field of view in real time, enabling precise remote control.

[0102] The vehicle operation adopts a modular and convenient design, and the vehicle body is equipped with a quick-release assembly structure, which can quickly complete the switching and assembly of 3D full-focus inspection device, automatic rust removal device and magnetic particle flaw detection device without complicated disassembly and assembly steps.

[0103] Before operation, the working posture and fit of the rust removal wheel 57 and the scanner 8 are pre-adjusted using the locking knob 22 of the angle adjustment device 03 and the adjusting bolt 552 of the buffer device 04. After startup, the automatic rust removal device operates first, with the rust removal wheel 57 rotating at high speed to polish the metal surface, achieving a cleaning level of St2 or above according to GB / T 8923.1-2011 standard, meeting the requirements for subsequent surface inspection. Subsequently, the scanner 8 moves synchronously with the trolley, relying on the built-in CTS-PA322T phased array full-focusing module, and through 64 fully parallel phased array hardware channels, it collects full matrix data in real time, realizing 3D full-focusing imaging and 4D continuous scanning. With the force feedback adjustment mechanism, the probe pressure is adaptively adjusted to ensure the detection coupling effect of surfaces with different roughness, and the beam focusing error for curved surface detection is ≤0.1mm.

[0104] Furthermore, the vehicle system is equipped with a lightweight AI model based on edge computing, which can process detection data in real time, accurately distinguish between pseudo-defects such as surface scratches and stains and real cracks, and realize real-time defect alarms; relying on UWB and IMU fusion positioning technology, it can achieve precise positioning of ±1mm in the absence of GPS, ensuring the accuracy of repeated positioning under complex paths.

[0105] During the inspection process, the system automatically collects and stores ultrasonic and magnetic particle inspection image data, supports defect location marking, precise dimensional measurement, and customized inspection report generation. The inspection results comply with domestic and international standards such as ASME B31.3 and GB / T 12604. The energy system uses dual battery packs for independent power supply, optimizing the energy consumption of high-power inspection modules to ensure continuous and stable operation of the entire machine. It is also compatible with wireless charging and fast battery swapping to meet the needs of long-term operation.

[0106] Of course, the present invention may have other various embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and modifications according to the present invention, but these corresponding changes and modifications should all fall within the protection scope of the appended claims.

Claims

1. An automatic crawling sweeping vehicle based on full-focus detection for rust removal, characterized in that, It includes a scanning vehicle body (01), a magnetic wheel (02) located at the bottom of the scanning vehicle body (01), an angle adjustment device (03) located at the forward end of the scanning vehicle body (01), a buffer device (04) located at the output end in front of the angle adjustment device (03), a grinding device (05) installed at the front end of the buffer device (04), a rust removal wheel (57) on the grinding device (05), a scanning device (08) at the rear end of the scanning vehicle body (01), and a visual guidance unit installed on the top of the scanning vehicle body (01); The angle adjustment device (03) is used to adjust the buffer stroke of the buffer device (04) so ​​that the buffer stroke direction forms an acute angle with the ground. The scanning device (08) includes a scanner (8) that can scan back and forth along the width direction of the scanning vehicle body (01). The scanner (8) has a built-in 3D full-focus ultrasonic imaging component and a visual inspection unit to perform high-resolution real-time 3D full-focus imaging scanning and inspection of the weld seams of the metal structure on the walking surface.

2. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to claim 1, characterized in that, The main body (01) of the scanning vehicle is equipped with a crawling guide device (07) and a visual guide unit; The crawling guidance device (07) is an obstacle avoidance radar that detects the probe's direction of travel toward the scanning vehicle body (01); The visual guidance unit is equipped with a visual camera and an LED ring light source.

3. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to any one of claims 1 or 2, characterized in that, The angle adjustment device (03) includes a mounting front seat (1) and a front mounting base plate (2) on which the angle can be adjusted, and the angle adjustment function is realized by the angle adjustment locking mechanism; it also includes a locking base (13) installed on the mounting front seat (1). The angle adjustment locking mechanism includes a hinge base (11) mounted on the front mount (1), and a hinge sub-mount (12) is hinged to one end of the hinge base (11) away from the mount base (012). The hinge sub-mount (12) is mounted on the front mount base (2). The locking base (13) is provided with an arc-shaped slide rail, and the front mounting plate (2) is fixedly connected with a locking body (21) that cooperates with the arc-shaped slide rail; the locking body (21) is provided with a reserved hole through which the arc-shaped slide rail can pass, and the locking body (21) is provided with a locking knob (22) that can fix the locking base (13).

4. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to claim 3, characterized in that, The arc-shaped slide rail is provided with a number of locking holes (131), and the number of locking holes (131) are evenly arranged along the length of the arc-shaped slide rail. The locking knob (22) can be screwed into the locking hole (131).

5. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to claim 3, characterized in that, The front mounting plate (25) is mounted on the side away from the angle adjustment locking mechanism via a lifting adjustment mechanism.

6. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to claim 5, characterized in that, The lifting adjustment mechanism includes a first slide rail (23) vertically mounted on the front mounting plate (2) and a first slide block (24) thereon, the first slide block (24) being fixedly connected to the front mounting plate (25); A stepper motor (3) is installed on the front mounting base plate (2), and its output end is connected to a rotating arm (33) through the front mounting base plate (2). The other end of the rotating arm (33) is rotatably connected to a roller (34). The front mounting plate (25) is provided with a long hole (251) with a horizontal length. The roller (34) is located inside the long hole (251), and the outer circumferential surface of the roller (34) rolls and abuts against the inner wall of the long hole (251).

7. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to any one of claims 1 or 2, characterized in that, The buffer device (04) includes a carrier (4) that is fixedly connected to the angle adjustment device (03) at one end; The hanging carrier (4) is provided with a vertical second slide rail (41), and a second slide block (42) is slidably installed on the second slide rail (41). A first spring part (43) is provided between the hanging carrier (4) and the second slide block (42). The lifting buffer seat (5) is provided with a second limiting part (53) on both sides, and the middle part of the lifting buffer seat (5) is rotatably connected to the wheel cover base (52); the two second limiting parts (53) and the top of the bottom wheel cover base (52) are each provided with a second spring part (54) which is responsible for the offset buffer at both ends of the wheel cover base (52).

8. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to claim 7, characterized in that, The front end of the wheel cover base (52) is fixedly connected to the wheel cover bracket (55). The wheel cover bracket (55) is equipped with a rust removal wheel body (57) and a wheel cover (56). The wheel cover bracket (55) has an adjustment groove (551) extending circumferentially along the rust removal wheel body (57). The adjustment groove (551) is fitted with an adjustment bolt (552).

9. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to any one of claims 1 or 2, characterized in that, The scanning device (08) includes a scanning base (6) fixedly connected to the scanning vehicle body (01), a third slide rail (61) mounted on the scanning base (6), a third slide block (62) slidably connected to the third slide rail (61), and a scanner (8) mounted on the third slide block (62). A drive motor is installed at one end of the third slide rail (61), and a screw is installed on the output end of the drive motor. The third slide block (62) is provided with a threaded part that cooperates with the screw. The third slide block (62) can move laterally on the third slide rail (61) under the drive of the drive motor.

10. The automatic crawling sweeping vehicle based on full-focus detection for rust removal according to claim 9, characterized in that, The scanning device (08) further includes: a fourth slide rail (63) mounted on the third slide (62), a fourth slide (64) slidably connected to the fourth slide rail (63), and a tension spring (65) provided between the fourth slide (64) and the third slide (62); a mounting bracket (7) is fixedly connected to the bottom of the fourth slide (64), and a scanner (8) is fixedly connected to the mounting bracket (7); The bottom of the mounting bracket (7) is fixedly connected to a ground support device.

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