Efficient energy-saving and environmentally friendly multi-machine cooperative AI intelligent laser rust removal process

Abstract

The application discloses an efficient, energy-saving, environment-friendly and multi-machine cooperative AI intelligent laser rust removal process, wherein multiple wall-climbing robots are synchronously adsorbed on the surface of a steel structure and walk; three laser beams are combined and then sent to a one-to-three polyhedral rotating mirror laser head; a handheld supplementary cleaning laser head is used for supplementary cleaning and rust removal; a PLC control system collects six types of sensing signals in real time, including visual rust identification, base material infrared temperature measurement, dust removal negative pressure, air path dew point flow, rotating mirror vibration temperature and laser plasma spectrum; and the laser output power, robot walking speed, rotating mirror rotating speed, fan rotating speed and air curtain gas supply pressure are dynamically linked and adjusted. The three combined single parallel light beams can concentrate energy, have high peak power and have stronger rust removal and peeling capacity; the double-robot partition parallel scheduling strategy is adopted, the 3D laser radar autonomous obstacle avoidance path planning technology is matched, and the construction efficiency is high; dust is removed in a closed manner, and the dust does not leak out, so that the process is green, environmentally-friendly, low in operation and maintenance cost and high in automation degree.

Description

Technical Field

[0001] This invention belongs to the field of green rust removal technology for steel structure surfaces, specifically involving a highly efficient, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process, which is suitable for high-standard automated rust removal operations on large outdoor steel structures such as wind turbine towers, ship hulls, steel storage tanks, and bridge steel box girders. Background Technology

[0002] Large steel structures are exposed to outdoor salt spray, humidity, and corrosive environments for extended periods, making their surfaces highly susceptible to rust, scale, and aging anti-corrosion paint. To ensure the adhesion of subsequent anti-corrosion coatings and extend the structure's lifespan, thorough removal of surface rust and contaminants is essential. Currently, mainstream rust removal processes in the industry suffer from several inherent drawbacks: traditional sandblasting consumes large amounts of materials, generates severe dust pollution, causes uncontrollable damage to the base material, and incurs high maintenance costs; chemical pickling generates large quantities of acid and alkali waste, posing significant environmental risks and easily causing over-etching damage to thin plates; conventional single-source laser rust removal suffers from limited power, narrow scanning width, low construction efficiency, and insufficient automation, making it difficult to meet the needs of large-scale engineering projects.

[0003] To address the problems of low efficiency, high energy consumption, high pollution, significant damage to the base material, insufficient intelligence, high operation and maintenance costs, and poor adaptability to working conditions in existing technologies, this invention provides a highly efficient, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process and equipment. Through multi-machine collaborative operation, dual-specification rotating mirror replacement, three-stage independent water cooling, six-dimensional sensing AI closed-loop control, and five-level safety interlocking, it achieves efficient, energy-saving, green, safe, fully automatic, and high-standard rust removal for large steel structures. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a highly efficient, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process, comprising: I. Preparations before the assignment II. Multi-machine collaborative large-area automated rust removal: Multiple composite magnetic obstacle-crossing and wall-climbing robots are synchronously attached to the steel structure facade / curved surface and move at a constant speed; the beams of three lasers are combined and sent into the laser head of a one-to-three multi-faceted rotating mirror. The PLC determines the working condition based on the rust layer thickness obtained by visual recognition and prompts the operator to replace the 8-face wide rotating mirror or 12-face fine rotating mirror module; after manual replacement, the system automatically matches the rotation speed, power and process parameters of the corresponding rotating mirror, and the dust hood captures rust removal dust at the source of the operation; 3. Automatic obstacle crossing and localized fine-tuning: The wall-climbing robot autonomously traverses welds and reinforcing ribs with a height of ≤8mm using elastic floating support wheels; narrow blind spots and ultra-high protrusions that the robot cannot cover are precisely targeted for rust removal using a 3000W handheld laser head, and the rust removal points are uploaded to the PLC in real time to generate a blind spot ledger; after the rust removal of the entire area is completed on the same day, the system automatically retrieves the blind spot points, and after manual handheld rust removal is completed, the items are cleared from the system, forming a closed loop for full-process traceability of missed rust removal points; IV. Multi-sensor AI closed-loop intelligent control: The PLC collects six types of sensor signals in real time: visual corrosion recognition, base material infrared temperature measurement, dust removal negative pressure, air path dew point flow, rotating mirror vibration temperature, and laser plasma spectrum. It dynamically links and adjusts the laser output power, robot travel speed, rotating mirror speed, fan speed, and air curtain supply pressure. It is equipped with an AI self-learning module to continuously iterate the optimal process parameters; the base material surface temperature is 70-80℃, and the light is automatically limited and the speed is reduced; the base material temperature is ≥80℃, and the light is locked and the machine is stopped instantly with audible and visual alarms, which is handled at the same level as water cooling failure. V. Post-operation maintenance and completion.

[0005] Preferably, the pre-operation preparation specifically includes: The air source purification unit pre-treatment is completed to ensure that the compressed air has an atmospheric dew point ≤ -40℃ and an oil concentration ≤ 0.1ppm; the independent zone water-cooled unit, the container constant temperature and dehumidification system, and the negative pressure dust removal system are started and the whole machine completes a full-link self-test; the wall-climbing robot is equipped with a 3D LiDAR to scan the curved surface of the steel structure, and the AI ​​algorithm automatically generates a full-coverage walking path and marks welds and protruding obstacles; the PLC pre-divides static independent working zones and is equipped with dynamic boundary detection logic; when the robot approaches the zone boundary / crosses obstacles and approaches the adjacent machine area, it automatically reduces its speed and laser power, and directly locks the light when it enters the adjacent machine's safety threshold, dynamically avoiding laser cross-interference, and retrieves matching process parameters with one click according to the corrosion level.

[0006] Preferably, the extended maintenance completion process specifically includes: After the entire area is cleaned, the laser and the wall-climbing robot are shut down first. The handheld laser head is kept powered on and all handheld dust removal units are allowed to complete a 3-second delay before the power to the handheld devices is cut off. The air source purification and negative pressure dust removal system are run for 5 minutes to purge dust from the pipeline and laser head. The independent water-cooling units in each zone are used to continuously cool the optical components for 10 minutes. The container is then cleaned internally. After the entire machine is cooled to room temperature, the water, gas, and power are cut off. The PLC cloud export of the daily work report is archived, and the iron powder and paint residue waste are transferred separately.

[0007] Preferably, the one-to-three multifaceted rotating mirror laser head has three independent water-cooled circulation branches, corresponding to the fiber combiner, collimation and shaping optical path, and rotating mirror scanning cavity heat dissipation, respectively; each of the three water-cooled branches is independently equipped with an infrared temperature sensor; the combiner reduces power at temperatures above 28°C, the collimation optical path increases the water cooling flow rate of the branch at temperatures above 30°C, and the rotating mirror cavity synchronously limits light at temperatures above 32°C; the entire machine instantly locks in light and stops when the temperature of any zone is ≥32°C, suppressing thermal drift of the light spot.

[0008] Preferably, the composite magnetic obstacle-crossing and wall-climbing robot is equipped with an electromagnetic and permanent magnet composite adsorption module; the PLC control system adaptively adjusts the electromagnetic force according to the thickness of the steel plate, and reduces the magnetic force for thin steel plates of 3-6mm to avoid deformation of the base material; after the equipment is powered off, the permanent magnet base continues to provide adsorption force to prevent falling from a height; the elastic floating support wheels, together with 3D laser radar, can autonomously cross obstacles with a protrusion of ≤8mm and intelligently bypass ultra-high obstruction areas.

[0009] Preferably, a single protective cabin is equipped with two wall-climbing robots that operate synchronously in different zones. The PLC uses an electronic safety fence to prevent laser interference between the two robots.

[0010] Preferably, a five-level hardware and software laser safety interlocking system is configured, including: ① optical fault interlocking; ② laser leakage detection interlocking; ③ infrared intrusion interlocking of human body in the work area; ④ three-level physical emergency stop for handheld laser head, robot, and container; ⑤ infrared temperature measurement and early warning for overheated base material; graded handling of auxiliary machine faults, minor faults only require pop-up reminders without interrupting operation, and water cooling failure, loss of negative pressure, and laser overheating faults instantly cut off the laser high voltage and lock the light to stop the machine.

[0011] Preferably, the PLC control system has local storage and cloud-based remote operation and maintenance functions, and uploads data on operating area, output power, faults, and consumable consumption in real time. It supports remote monitoring via mobile phone and computer, remote distribution of process parameters, and fault SMS push. It has built-in standardized process libraries for wind turbine towers, ship decks, storage tanks, and bridge steel box girders, which can be switched and called with one click.

[0012] Preferably, the handheld repair laser head has no polyhedral rotating mirror structure and is equipped with a miniature visual thickness measurement and infrared temperature measurement module; it is also equipped with an independent miniature side suction dust removal unit, which is synchronously linked with the laser light emission trigger to start and stop.

[0013] This invention utilizes a high-speed, uniform, and continuous rotation of a multi-faceted laser rotating mirror. Leveraging the beam-scanning characteristics of the multi-prism, a focused laser beam is converted into a continuous, uninterrupted, linearly long scanning light band with uniform energy distribution and stable width. The laser band sweeps uniformly across the steel structure surface, where old coatings and oxide / rust layers rapidly absorb infrared laser energy, undergoing instantaneous thermal expansion, vaporization, and interfacial stress ablation, achieving controlled, layered removal. The steel structure's metal substrate has high reflectivity and low heat absorption for 1080nm wavelength lasers. Combined with the stable heat input characteristics of the rotating mirror's uniform, continuous scanning, the temperature rise and thermal damage to the base material can be strictly controlled, effectively protecting the substrate's structural integrity.

[0014] This invention employs a multi-machine collaborative AI intelligent laser rust removal equipment. The equipment adopts a modular integrated structure, including a protective cabin, three sets of 6kW lasers, a three-section water-cooled polyhedral rotating mirror laser head, a composite magnetic obstacle-crossing and wall-climbing robot, a 3000W handheld cleaning laser head, an air source purification unit, a negative pressure magnetic separation dust removal and recovery unit, and a PLC six-dimensional sensing AI overall control system. Each unit works in synergy to achieve functions such as air source purification, laser beam scanning, intelligent adsorption obstacle-crossing, adaptive AI parameter control, sealed dust collection, and safety interlock protection. It is suitable for automated rust removal operations on large steel structures under all working conditions.

[0015] Beneficial effects: 1. The laser is connected to the rotating mirror laser head via a flexible optical fiber, integrating three laser beams into a single high-energy parallel beam. The rotating mirror continuously rotates to achieve high-speed linear deflection of the beam, forming a uniform long strip scanning light band. The one-to-three multi-faceted rotating mirror laser head uses a laser wavelength of 1080±10nm to achieve continuous rust removal on large areas of steel structures. The three-beam single parallel beam concentrates energy, resulting in high peak power and stronger rust removal and peeling capabilities. The pure rotating mechanism achieves a wide linear light band, with a simple structure, fast scanning speed, and uniform light field. The robot moves without interference from rigid tubes, making it well-suited for curved and irregularly shaped steel structures. The robot-mounted flat operation enables continuous operation on large-area steel structures without segmentation or breakpoints, significantly improving construction efficiency compared to single-point fixed-point laser cleaning.

[0016] 2. Significantly Improved Construction Efficiency: This invention employs a dual-robot parallel scheduling strategy, coupled with 3D LiDAR autonomous obstacle-crossing path planning technology. A single robot's independent operation efficiency can reach 80㎡ / h, while the combined efficiency of the two robots working together increases to 140㎡ / h, resulting in an overall 75% increase in construction productivity. Simultaneously, the robots can autonomously traverse obstacles such as steel structure welds and protruding reinforcing ribs without manual assistance, significantly reducing the proportion of manually cleaned areas and substantially decreasing labor input, effectively shortening the rust removal construction cycle for large steel structures.

[0017] 3. Outstanding Energy-Saving and Environmental Protection Advantages: This invention relies on a six-dimensional sensor AI adaptive closed-loop control system, which can dynamically match core parameters such as laser output power, fan speed, and air curtain supply pressure according to real-time operating conditions. The overall energy consumption of the machine is significantly reduced compared to traditional laser rust removal processes. The entire operation requires no sandblasting abrasives or acid pickling chemicals, and there is no discharge of industrial wastewater. The closed four-stage dust removal system achieves zero dust leakage during operation. After magnetic separation and screening, high-purity rust powder can be recycled for steelmaking, and non-metallic paint slag is separately classified and disposed of. The total amount of hazardous waste generated is reduced by 70%, resulting in significant green environmental benefits.

[0018] 4. Significantly Reduced Equipment Maintenance Costs: This invention features a three-stage air source deep dehydration and oil removal system, coupled with a double-layered dynamic dustproof air curtain to isolate operational fumes. It also employs a three-section independent zoned water-cooling structure to fundamentally suppress thermal drift issues in high-power laser beam paths. This effectively extends the lifespan of optical lenses, increasing lens maintenance cycles by three times and significantly reducing the failure rate of core optical components. The equipment utilizes a modular, quick-release structure with an automatic pulse dust removal function, eliminating the need for frequent disassembly and maintenance, reducing downtime for equipment maintenance, and significantly lowering long-term maintenance costs.

[0019] 5. Strong adaptability to all working conditions: This invention is equipped with an electromagnetically adaptive adjustable robot, which can adapt to different substrates and irregular structures such as 3-6mm thin steel plates, conventional thick steel plates, curved towers, ship facades, and decks; it is equipped with 8 wide-angle and 12 fine-angle dual-specification modular rotating mirrors, which can be switched according to the thickness of the rust layer, taking into account both large-area thick rust coarse rust removal and thin-layer fine rust removal of welds, with rust removal accuracy consistently reaching the high standard of Sa2.5 level; the whole machine is integrated into the constant temperature and dehumidification sealed container, which can adapt to the harsh working conditions of high humidity and high salt spray at sea, and supports 24-hour continuous and stable operation.

[0020] 6. Comprehensive Upgrade of Intelligent Safety Management: This invention adopts a six-type sensor signal fusion AI self-learning closed-loop control technology, coupled with cloud-based remote operation and maintenance and real-time fault SMS push functions, to achieve fully automated construction with minimal human intervention, significantly improving the level of intelligence. Simultaneously, a five-level hardware and software redundant laser safety interlocking system is established, covering multiple risk scenarios such as optical failure, light leakage, personnel intrusion, equipment overheating, and base material overheating. It provides tiered handling of equipment failures, ensuring uninterrupted operation for minor faults and instantaneous shutdown for major faults, effectively avoiding safety hazards such as laser burns and base material overheating, fully meeting the safety production standards for high-risk scenarios such as shipyards and offshore platforms.

[0021] 7. Superior Long-Term Economic Efficiency: This invention reduces construction costs from multiple dimensions, including labor, energy consumption, material consumption, and hazardous waste disposal. Compared to traditional sandblasting, acid pickling, and ordinary single-source laser rust removal processes, it offers significant advantages in long-term construction economics and practicality, possessing extremely high market promotion value. Attached Figure Description

[0022] Figure 1 This is a 3D view of the components of the wall-climbing robot.

[0023] Figure 2 This is a side view of the wall-climbing robot component.

[0024] Figure 3 This is a schematic diagram of the steel shell surface.

[0025] Figure 4 It is a 3D view of an unmanned platform.

[0026] Figure 5 This is an internal structural diagram of a multi-machine collaborative AI intelligent laser rust removal equipment according to the present invention.

[0027] Figure 6 This is another perspective of the internal structure diagram of the high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal equipment of the present invention.

[0028] Figure 7 This invention presents a process flow diagram of a highly efficient, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process.

[0029] In the diagram: 1-Rotating laser head, 2-Wall climbing robot, 3-Dust hood, 4-Protective cabin, 5-Outlet door, 6-Unmanned flatcar, 7-Turbine fan, 8-Gas distribution tank, 9-Dust collection bin, 10-Laser, 11-Operating panel, 12-Voltage stabilizer, 13-Chiller, 14-Air conditioner, 15-Cable reel. Detailed Implementation

[0030] 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. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0031] It should be noted that in the description of this invention, the terms "upper," "lower," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0032] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "communication" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0033] This invention discloses a highly efficient, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process, including intelligent pre-operation preparation, multi-machine collaborative large-area automated rust removal, automatic obstacle crossing and local fine-tuning, six-dimensional sensor fusion AI closed-loop intelligent control operation, and extended curing finishing. The entire system hardware includes a protective cabin 4, three 6000W main lasers 10, a one-to-three multi-faceted rotating mirror laser head 1, a 3000W independent handheld cleaning laser head, a composite magnetic obstacle-crossing and wall-climbing robot 2, an air source purification unit, a zoned independent water-cooled unit, and a PLC multi-sensor fusion AI control system.

[0034] The dual-specification modular switchable multifaceted rotating mirror system features two standardized, quick-replacement modules that require no modification to the optical path or re-adjustment, adapting to various rust removal conditions: an 8-face wide-format rotating mirror with a scanning width of 90–120 mm, suitable for efficient removal of large areas of thick rust and coatings; and a 12-face fine rotating mirror with a scanning width of 40–60 mm, offering higher spot density, suitable for fine rust removal of thin oxide layers and weld seams, ensuring Sa2.5 level rust removal accuracy. Both sets of rotating mirrors employ a foolproof, quick-connect modular structure, allowing a single person to complete replacement in 5 minutes, with a mechanical repeatability accuracy ≤0.01 mm and no optical path offset.

[0035] The three-segment independent zone water-cooled optical path system divides the fiber combining area, collimation and shaping optical path area, and rotating mirror scanning cavity area into three independent cooling units, maintaining a uniform constant temperature of 20±1℃ with precise temperature control and single-path water temperature fluctuations ≤±0.5℃. The system is equipped with graded over-temperature protection: automatically increasing water cooling flow at 25~28℃, gradually reducing load to maintain stability at 28~32℃, and instantaneous light-locking protection at ≥32℃, completely solving the problem of thermal drift of high-power beam combining spot.

[0036] The composite magnetic obstacle-crossing and wall-climbing robot adopts an electromagnetic + permanent magnet composite adsorption structure. The permanent magnet base ensures safety against falls during power outages, while the electromagnetic module offers stepless magnetic adjustment, adaptively matching the adsorption force according to the thickness of the steel plate and the curvature of the surface, preventing deformation of thin plates and slippage of thick plates. Equipped with flexible floating wheels and 3D LiDAR, it can autonomously traverse obstacles with protrusions ≤8mm and intelligently detour around extremely tall obstructions, significantly reducing the need for manual cleaning.

[0037] The six-dimensional AI closed-loop control system collects real-time data on visual rust layer recognition, base material infrared temperature measurement, dust removal negative pressure, gas path dew point flow rate, rotating mirror temperature vibration, and laser plasma spectral signals, dynamically adjusting all system parameters. The AI ​​self-learning module continuously iterates the optimal process model, automatically switching the process library based on rust layer thickness and material type, achieving unmanned adaptive intelligent rust removal.

[0038] After the operation is completed, the delayed adaptive maintenance system delays the dust removal and air path system to purge, and the water cooling system continues to cool the optical components. It can also adaptively adjust the cooling and purging time according to the ambient temperature. In high-temperature environments, the cooling time is extended, and in low-temperature environments, the purging energy consumption is reduced, thus taking into account both equipment protection and energy saving.

[0039] A highly efficient, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process includes the following steps: Pre-operation preparation: Complete the pre-treatment of the air source purification unit to ensure that the compressed air has an atmospheric dew point ≤ -40℃ and an oil concentration ≤ 0.1ppm; start the independent zone water-cooled unit, the container constant temperature and dehumidification system, and the negative pressure dust removal system, and complete the whole machine's full-link self-test; the wall-climbing robot is equipped with 3D LiDAR to scan the curved surface of the steel structure, and the AI ​​algorithm automatically generates a full-coverage walking path and marks welds and protruding obstacles; the PLC pre-divides static independent operation zones and is equipped with dynamic boundary detection logic; when the robot approaches the zone boundary / crosses obstacles and approaches the adjacent machine area, it automatically slows down and reduces the laser power, directly locks the light when it enters the adjacent machine's safety threshold, dynamically avoids laser cross-interference and sets up electronic safety isolation fences, and retrieves matching process parameters with one click according to the corrosion level; Multi-machine collaborative large-area automated rust removal: Multiple composite magnetic obstacle-crossing and wall-climbing robots synchronously adhere to the steel structure facade / curved surface and move at a constant speed; the beams of three lasers are combined and sent to the laser head of a one-to-three multi-faceted rotating mirror; the PLC determines the working condition in real time based on the rust layer thickness based on visual recognition, prompting the operator to replace the 8-faced wide rotating mirror or the 12-faced fine rotating mirror as needed; after replacement, the system automatically matches the exclusive speed, power and process parameters of the corresponding rotating mirror; a double-layer annular dynamic air curtain outputs clean and dry gas, with an air curtain pressure of 0.25~0.3MPa for thick rust and 0.15MPa for thin rust; a three-stage stepped enclosed dust collection hood captures rust removal fumes at the source of the work, and the fumes are sent to the dust collection bin for sedimentation and filtration through pipelines; Automatic obstacle crossing and localized fine-tuning: The wall-climbing robot autonomously traverses welds and reinforcing ribs with a height of ≤8mm using elastic floating support wheels; narrow blind spots and extremely high protrusions that the robot cannot cover are precisely targeted for rust removal using a 3000W handheld laser head. The laser head's light-emitting trigger is linked to a micro side-suction dust collector; pressing the trigger starts the dust collector simultaneously, and releasing the trigger stops the dust collector after a 3-second delay; the cleaning points are uploaded to the PLC in real time and a blind spot ledger is generated; after the entire area is rust-removed on the same day, the system automatically retrieves the blind spot points, and after manual handheld cleaning is completed, the blind spot points are cleared from the system, forming a closed-loop traceability system for missed cleaning points. Multi-sensor AI closed-loop intelligent control: The PLC collects six types of sensor signals in real time: visual rust recognition, base material infrared temperature measurement, dust removal negative pressure, air path dew point flow, rotating mirror vibration temperature, and laser plasma spectrum. It dynamically links and adjusts the laser output power, robot travel speed, rotating mirror speed, fan speed, and air curtain supply pressure. It is equipped with an AI self-learning module to continuously iterate the optimal process parameters. It has two-level dust warning: when the dust accumulates to 70% of the dust collection bin, the pulse dust removal and magnetic separation unit is activated to automatically sort and unload the material, and the iron powder is temporarily stored in the recycling bin. When the accumulation reaches 85% of the bin, a pop-up window prompts the machine to stop and transfer the waste bin. It distinguishes between rust, paint film, and metal base material through spectral recognition and automatically switches to the corresponding process library. The machine automatically limits light and slows down when the base material surface temperature is 70-80℃. When the base material temperature is ≥80℃, the machine instantly locks the light and stops with an audible and visual alarm, and is handled at the same level as water cooling failure. Extended maintenance to finish: After the full-area rust removal is completed, first shut down the laser and the wall-climbing robot; keep the handheld laser head powered on and wait for all handheld dust removal units to complete a 3-second delayed blowing before disconnecting the power to the handheld devices; the air source purification and negative pressure dust removal system run for 5 minutes to blow dust from the pipeline and laser head, and the independent water-cooled units in each zone continuously cool the optical components for 10 minutes; perform internal dust removal in the container; after the entire machine has cooled to room temperature, disconnect the water, gas, and power; export the daily work report from the PLC cloud for archiving, and transfer the iron powder and paint residue waste separately.

[0040] This invention presents two standardized, quickly replaceable polyhedral rotating mirror modules that require no modification to the optical path structure or re-adjustment, adapt to automated operating condition switching, and fully cover two core scenarios: coarse rust removal for thick rust and fine rust removal for thin rust on steel structures. 8-sided wide-format high-efficiency rotating mirror module (batch rust removal): scanning width 90-120mm, rated working speed 3000r / min, the mirror surface adopts high-precision optical polishing + hard anodizing wear-resistant treatment, suitable for removing large areas of thick rust and thick anti-corrosion coatings such as wind turbine towers and ship hulls, with a large coverage area in a single scan, greatly improving the overall construction efficiency.

[0041] 12-sided fine rotating mirror module (fine rust removal condition): scanning width 40-60mm, rated working speed 4000r / min, higher scanning spot density and better light path uniformity, suitable for fine rust removal of thin oxide scale, residual paint film and weld edges, can ensure Sa2.5 level high standard rust removal accuracy, no scratches on the base material and no residual rust.

[0042] This invention features two sets of rotating mirror modules with a unified reference and a foolproof quick-plug modular structure. All rotating mirrors share the same external dimensions, optical path reference height, and servo motor interface, enabling rapid replacement without adjustment or calibration. The rotating mirror body is integrally formed from aerospace-grade aluminum alloy with a hard anodized surface for wear resistance and corrosion resistance. The mirror surface uses high-purity fused silica optical substrate. The module positioning end is equipped with precision positioning pins and alignment-resistant slots, ensuring a mechanical repeatability accuracy of ≤0.01mm, guaranteeing no offset in beam incident angle, scanning center, or focal length reference after mirror replacement. The overall structure is a sealed integrated design, preventing the internal optical path cavity from being exposed during replacement, effectively preventing dust and moisture from entering the optical cavity and ensuring optical path cleanliness. A single person can replace the entire rotating mirror module in 5 minutes without specialized tools, adapting to the needs of rapid on-site maintenance and quick switching of operating conditions.

[0043] This invention abandons the traditional manual parameter selection mode and relies on a front-end machine vision corrosion detection system and laser thickness recognition algorithm to achieve fully automated module condition matching and parameter linkage. During equipment operation, the vision module collects the rust layer thickness, paint film condition, and corrosion uniformity of the working surface in real time and uploads the data to the PLC main control system. The system has multiple built-in working condition process models, which automatically identify and match the corresponding rotating mirror working parameters. The specific linkage logic is as follows: Thick rust / thick coating conditions (rust layer thickness 25-40μm): The system is determined to be in the large-area high-efficiency rust removal mode. It activates 8 wide-angle rotating mirrors, locks the rotation speed at 3000r / min and the scanning width at 90-120mm, and simultaneously matches high laser power and high-speed robot walking parameters to achieve large-area high-efficiency peeling. Fine finishing condition with thin rust / residual paint (rust layer thickness 10-25μm): The system is determined to be in fine finishing mode, 12 fine rotating mirrors are activated, the rotation speed is locked at 4000r / min and the scanning width is 40-60mm, the spot scanning density and overlap rate are increased, the travel speed is reduced and the laser power is finely adjusted to ensure that the board surface is uniform, without residue and without over-etching. Dynamic transition logic for operating conditions: For areas with varying thicknesses and uneven rust layers, the system fine-tunes the speed and power parameters frame by frame in real time to avoid problems such as local missed cleaning, color difference, and uneven roughness, without the need to stop the machine to change parameters throughout the process.

[0044] In response to the high-power output characteristics of this equipment, which combines three 6kW lasers into a single 18kW beam, problems such as thermal drift of the combined beam spot, micro-deformation of the optical base, temperature rise and displacement of the rotating mirror bearing, and thermal lensing effect of the lenses are prone to occur during long-term continuous operation. This invention completely abandons the traditional integrated single-layer water-cooling structure of the laser head, and innovatively divides the beam combining coupling area, collimation and shaping optical path area, and rotating mirror scanning cavity area into three independent cooling units. It is equipped with three independent water-cooling circulations, independent temperature acquisition, and independent frequency conversion flow rate adjustment, realizing precise control of the entire optical path and suppressing thermal drift of high-power lasers at its source.

[0045] Three-section independent water-cooling partition structure and heat dissipation target: Section 1: Independent Water-Cooled Branch for Fiber Optic Combiner (Core Heat Source Area): Specifically designed for heat dissipation of high-heat-generating components such as the three-way fiber optic combiner coupler and QBH fiber optic connector base. The energy density and heat accumulation are most concentrated at the three-way laser beam combining point, making it the largest heat source of this equipment. This section features an independent water-cooled cavity that fully encloses the combining devices, with a built-in high-precision infrared temperature probe to monitor the coupling operating temperature in real time, prioritizing the stability of the combined optical path and preventing spot deviation and uneven energy distribution.

[0046] Second zone: Independent water-cooled branch for collimation and shaping optical path (optical path precision zone): This zone covers precision optical structures such as collimating lenses, homogenizing optical paths, optical path adjustment bases, and fixed lens mounts. Temperature fluctuations in this area can directly cause beam parallelism shifts and spot distortion. Independent constant temperature control ensures stable laser beam homogenization, consistent scanning bandwidth, and uniform energy.

[0047] The third section: Independent water-cooled branch for the polyhedral rotating mirror scanning cavity (high-speed motion area): covers the polyhedral rotating mirror substrate, high-speed servo shaft, precision bearings, and scanning cavity shell. High-speed rotation of the mirror generates frictional temperature rise, and the reflected laser exhibits slight heat absorption. Long-term operation can easily lead to speed drift, bearing jamming, and mirror thermal deformation. Independent water cooling can stabilize the temperature of the moving mechanism, ensuring scanning linearity and speed accuracy.

[0048] Precision constant temperature control parameter system: Rated constant temperature range: three zones with unified and precise temperature control of 20±1℃, and single-channel water temperature fluctuation ≤±0.5℃, which is far superior to the ±2℃ temperature control accuracy of conventional laser equipment; Water temperature and ambient temperature difference adaptive: Chiller 13 supports ambient temperature linkage compensation, which can automatically fine-tune the water temperature according to the on-site working conditions, eliminating the risk of condensation and temperature difference condensation. Independent frequency conversion flow regulation: Three water circuits have independent frequency conversion speed regulation. Under high load operation, the flow rate is automatically increased to enhance heat dissipation, while under low load and thin rust conditions, the flow rate is reduced to save energy and reduce consumption.

[0049] The system employs a dual-level protection system of "flexible load reduction early warning + extreme light-locking protection" to avoid the impact of a single shutdown protection on construction continuity. Level 1 warning (temperature 25~28℃): The system pop-up window indicates that the optical path temperature is too high. It will automatically increase the water cooling flow rate of the corresponding zone without restricting laser output or interrupting the operation. Secondary flexible load reduction (temperature 28~32℃): When the beam combiner temperature reaches the threshold, the PLC automatically and gradually reduces the laser output power to suppress heat accumulation, retain the basic rust removal operation capability, and avoid sudden shutdowns that could cause process interruptions. Level 3 limit protection (temperature ≥ 32℃ or abnormal flow): The system immediately locks the light and stops the laser output, and issues an audible and visual alarm pop-up to protect the beam combiner, lens, and rotating mirror bearing from being burned by high temperature.

[0050] The gas source purification system is used to provide a dry and clean protective gas curtain for the laser head. The gas source purification system includes an adsorption dryer and a gas distribution tank 8. The adsorption dryer and the gas distribution tank 8 are located in the protective cabin 4. The adsorption dryer is connected to the inside of the laser head cavity through the gas distribution tank 8 and a sealed air pipe.

[0051] The adsorption dryer outputs compressed air with an atmospheric dew point of ≤-40℃. The air distribution tank has four independent pressure regulators, which supply three rotating mirror laser heads and one handheld cleaning laser head air knife respectively.

[0052] Adsorption dryers ensure a stable and dry air supply for equipment, preventing equipment malfunctions caused by humid environments. The workflow is as follows: external compressed air intake → adsorption dryer (removing water, oil, and purifying) → air distribution tank (stabilizing pressure, storing air, and distributing air in multiple directions) → four independent flow monitoring branches → multi-faceted rotating mirror laser head air knife / handheld laser head air knife → forming a positive clean air curtain inside the laser head cavity and on the inner side of the lens → a small amount of air is blown out from the lens gaps (preventing backflow of smoke and dust).

[0053] The cleaning system consists of a four-stage structure connected in series: a pre-dust hood 3, a high-temperature resistant dust collection pipe, a dust collection bin 9, and a turbine fan 7. The high-temperature resistant dust collection pipe, dust collection bin 9, and turbine fan 7 are integrated and installed inside the protective cabin 4, forming a closed dust removal link of source capture → pipeline transportation → dust interception → negative pressure power exhaust, with no dust leakage throughout the process, and suitable for high-temperature fume conditions of laser rust removal.

[0054] The cleaning system collects the smoke, dust, and particles generated during laser rust removal operations into a dust collection bin through a high-temperature resistant pipe using a turbine fan, thus achieving a green and environmentally friendly rust removal process.

[0055] This technology addresses the technical challenges of traditional laser-based rust removal climbing robots, such as unadjustable magnetic force, easy deformation of thin steel plates, inability to overcome obstacles, and high manual cleaning workload. It employs an integrated solution combining an adjustable electromagnetic and permanent magnet composite adsorption structure, an elastic floating obstacle-crossing mechanism, and 3D LiDAR global path planning. This enables the robot to adaptively adapt to steel structures of varying thicknesses, autonomously traverse weld protrusions, intelligently bypass obstacles, and operate in parallel with two robots. It reduces the proportion of manual cleaning from 30% to less than 10%, and increases the overall rust removal efficiency from 80㎡ / h to 140㎡ / h, significantly improving the automation level and construction capacity of rust removal for large-area steel structures.

[0056] The robot's chassis adopts a composite adsorption structure of permanent magnet substrate and electromagnetic adjustment module, abandoning the traditional single permanent magnet fixed magnetic force mode: the substrate is equipped with a high remanence permanent magnet array to provide basic safe adsorption force; multiple sets of controllable electromagnetic adsorption units are integrated around the perimeter, supporting stepless voltage and magnetic adjustment by PLC. The structural advantages are "permanent magnet ensures safety, electromagnetic adjusts load", taking into account both working condition adaptability and high-altitude operation safety.

[0057] Permanent magnet substrate: Provides constant basic adsorption force, does not demagnetize when power is off, and serves as a safety backup for fall protection.

[0058] Electromagnetic adjustment module: Multiple independent electromagnetic coils, through voltage / current closed-loop control, achieve stepless and continuous adjustment of adsorption force, adaptable to different steel plate thicknesses, rusted surfaces, and curved surface curvature conditions.

[0059] Adaptive magnetic force adjustment control logic: The system relies on the linkage of multiple parameters, including steel plate thickness detection, bonding pressure feedback, and curved surface curvature recognition, to automatically match the optimal adsorption force and solve the problems of deformation of thin steel plates, insufficient adsorption of thick steel plates, and slippage and displacement of curved surfaces.

[0060] Thin steel plate working condition (3-6mm): Automatically reduce the electromagnetic output magnetic force, retain only the permanent magnet base attraction force, to avoid the robot's own weight and magnetic attraction pressure causing the thin plate to dent and the base material to deform, thus protecting the integrity of the base material; For standard thick steel plate applications (≥8mm): Automatically enhances electromagnetic adsorption force, improves chassis fit, eliminates slippage and scanning vibration, and ensures uniform laser scanning. Curved tower / curved surface working conditions: Single-sided electromagnetic independent fine adjustment, adapting to curved surface fit, ensuring robot center of gravity stability and no deviation in walking trajectory; Salt spray corrosion of rough surfaces: Appropriately increase magnetic force to compensate for the gap between the contact surfaces, and prevent adsorption of loose parts and shaking when walking on uneven surfaces.

[0061] When the equipment experiences a sudden power outage, emergency stop, or cable detachment, the electromagnetic coil loses power instantly, but the permanent magnet substrate continues to maintain its attraction force. The robot remains attached to the steel structure wall throughout the process, eliminating the risk of falling from heights, equipment damage, or laser head impact damage. This fully meets the safety regulations for high-altitude facades, tower exteriors, and shipboard operations.

[0062] The robot's four-wheel walking mechanism is equipped with independent elastic floating support wheel sets and a damping buffer structure. Each walking wheel has a vertical adaptive floating stroke. The chassis is a flexible fit structure and does not use a rigid fixed chassis. It can adapt to the undulations of the steel structure surface.

[0063] The wheelset features a built-in high-strength buffer spring and a micro damper, ensuring no hard impact or vibration during obstacle crossing; the wheel surface is made of wear-resistant and non-slip material, suitable for rusty and rough surfaces, providing excellent anti-slip performance; the overall structure requires no manual adjustment and can adapt to changes in the surface undulation in real time.

[0064] The robot can autonomously and smoothly traverse welds, reinforcing ribs, weld protrusions, and tooling residue with a height of ≤8mm, without stopping, requiring manual assistance, or secondary alignment. During obstacle-crossing, its walking speed is slightly buffered and reduced, while laser scanning remains uninterrupted, ensuring continuous and thorough rust removal in the obstacle-crossing area.

[0065] The robot is equipped with a high-precision 3D LiDAR and attitude sensing module, which scans the working surface in real time to build a three-dimensional topographic map of the steel structure surface, accurately identifying welds, protrusions, depressions, and obstructions with sub-millimeter accuracy.

[0066] Intelligent planning and detour logic: Automatic low obstacle crossing: It can identify low protrusions ≤8mm and directly trigger the floating wheel group obstacle crossing logic to pass through straight and operate continuously; Intelligent obstacle avoidance: It can identify protrusions larger than 8mm, fixed fixtures, and blind spots. The system can replan the path locally in real time, automatically avoid obstacles, and bypass obstacle areas. Automatic marking of blind spots: Radar identifies narrow blind spots, deep recesses, and flange root areas that cannot be reached by robots, automatically generates cleaning points and uploads them to the central control, prompting for later detailed manual cleaning to prevent rust-incomplete areas from being removed. Full-coverage path: The initial scan automatically generates the optimal traversal path without overlap or omission, eliminating the waste of energy from repeated scans and the impact of missed scans on rust removal quality.

[0067] Through autonomous obstacle crossing, intelligent detour, and automatic marking of blind spots, the robot can cover most common uneven and welded areas, reducing the proportion of manually cleaned areas from the traditional 30% to less than 10%, significantly reducing manual labor time and truly achieving large-area unmanned automated rust removal.

[0068] The unmanned platform consists of an unmanned flatbed cart 6 and a protective cabin 4, with the protective cabin 4 located atop the unmanned flatbed cart 6. The protective cabin houses a laser system, providing the necessary operating temperature. The unmanned flatbed cart 6 enables the overall movement of the system. The protective cabin 4 is equipped with internal insulation rock wool, providing dustproof, waterproof, temperature-controlled, and interference-resistant capabilities. An air conditioner 14 is also installed inside the protective cabin 4. The protective cabin 4 includes a 30m cable reel 15, zoned cable routing channels, and quick-connect external connectors, facilitating rapid deployment and routine maintenance on construction sites.

[0069] The power supply system includes a control cabinet and a voltage regulator 12. The voltage regulator 12 can automatically maintain a stable output voltage when the voltage of the external power supply network fluctuates or the load changes, effectively resisting voltage fluctuations and instantaneous surge interference on the construction site power grid, and providing a stable power supply for the high-power laser 10, the rotating mirror scanning mechanism, the wall-climbing robot 2 and various auxiliary machines; the control cabinet provides power to the subsystems.

[0070] Alarm System: Equipped with dual mechanisms of self-test alarm upon power-on and real-time alarm for subsystem faults, providing audible and visual alerts for all operational conditions, including abnormal water cooling, low air pressure, rotating mirror malfunction, robot malfunction, dust removal failure, and laser 10 malfunction. The equipment is equipped with multiple physical emergency stop buttons and an external central control emergency stop interface, forming a multi-layered redundant hardware and software safety protection system.

[0071] The alarm system includes a self-test system and a fault alarm. The self-test system collects feedback signals via the I / O interface, compares them with normal signals, and alarms when abnormalities occur, displaying information on the control panel and triggering a three-color alarm light and buzzer. Fault alarms are also displayed on the control panel, triggering a three-color alarm light and buzzer; these mainly include: laser system fault alarm function, wall-climbing robot alarm feedback, galvanometer motor alarm feedback, air path alarm feedback, water cooling alarm feedback, smoke purification alarm feedback, and a three-color alarm light and buzzer.

[0072] The display and control system includes an industrial computer and an operator console 11. The operator console 11 is equipped with a touch screen, serving as the human-machine interface terminal for the equipment. It supports visualized configuration of process parameters, real-time monitoring of equipment operating status, fault information pop-up alarms, and real-time recording of work data. It has multiple built-in mature rust removal process libraries, allowing for one-click parameter retrieval for different coating thicknesses and rust levels, making operation simple and efficient. It also supports remote visual monitoring and equipment operation and maintenance management.

[0073] Example 1: Large-area rust removal on the outer wall of wind turbine tower The wind turbine tower to be worked on has rust on its outer wall and an anti-corrosion coating thickness of 25-30 μm, covering a total working area of ​​620 square meters. The shelter is connected to 0.7 MPa compressed air and 380V industrial power. The air source is purified to a stable dew point ≤-40℃ and oil content ≤0.1 ppm. The water cooling, dust removal, and shelter dehumidification systems are activated to complete the overall machine self-inspection. The tower's shape is scanned by 3D radar, and AI automatically generates dual-robot zone walking paths, retrieving process parameters to match the thick rust.

[0074] During the operation, eight wide-format rotating mirrors were used to scan large areas of thick rust, with a scanning width of 95mm and a rotation speed of 3000r / min, while the robot's travel speed was 48mm / s. For thin-layer rust areas, the system automatically switched to fine-tuned process parameters, reducing travel speed and adjusting laser power. The air curtain pressure was dynamically adjusted from 0.15 to 0.3MPa, and the dust removal system captured dust in a completely sealed environment throughout the process. The robot autonomously traversed the tower's reinforcing ribs, and only the narrow flange weld areas were cleaned using a handheld laser head, covering only 8% of the area. The base material temperature remained stable at ≤65℃ throughout the operation, and automatic pulse dust removal was used when dust accumulation reached 70% of the volume, ensuring continuous and stable equipment operation.

[0075] After the operation is completed, there is a 5-minute delay for purging and a 10-minute water cooling period. The entire machine is cooled down and the data is archived. Iron powder is then collected. The theoretical operating efficiency of the dual-machine collaboration is 135㎡ / h. Including auxiliary time for inspection, re-cleaning, and position adjustment, the total construction time is 5 hours to complete all the work.

[0076] The rust removal grade consistently reaches Sa2.5, the substrate damage is ≤40μm, there is no dust leakage or waste liquid discharge, and the equipment can operate stably and without failure for 12 consecutive hours.

[0077] Example 2: Fine rust removal of thin-layer ship deck The ship deck surface is mainly composed of a thin layer of oxide scale and residual old paint film, with a rust layer thickness of 10-25 μm, requiring extremely high standards for surface uniformity and protection of the base material. This embodiment employs a single robot paired with a 12-sided precision rotating mirror module, with a scanning width of 50 mm, a rotation speed of 4000 r / min, and a robot travel speed of 15 mm / s. The AI ​​system identifies the thin rust layer status in real time, adaptively adjusting the laser power, maintaining a stable air curtain pressure of 0.15 MPa, and maintaining a dust removal negative pressure of -3500 Pa.

[0078] After construction, the deck oxide scale and residual paint film were completely removed, the temperature rise of the deck surface was ≤65℃, and there were no overheating, no thinning of the base material, and no scratches or defects. The entire process of dust collection was carried out in a closed system, meeting the port's environmental protection control requirements. The maintenance cycle of optical lenses was extended to 600 hours, the equipment failure rate was significantly reduced, and the uniformity and roughness of the rust removal on the deck surface fully met the standards for subsequent anti-corrosion coating.

[0079] Comparative Example 1: Traditional single-robot, one-to-three laser rust removal process Using traditional one-to-three equipment without three-stage water cooling, AI multi-sensor control, single rotating mirror, and obstacle-crossing robot, the total time to process a 620㎡ wind turbine tower under the same working conditions is 9.2 hours, with manual cleaning accounting for 28%, and the mirror requiring maintenance every 200 hours on average. The overall energy consumption is 19% higher than that of this invention, and the construction stability and rust removal uniformity are significantly inferior to this process.

[0080] Comparative Example 2: Conventional Quartz Sandblasting Process The same tower is treated with quartz sandblasting to remove rust, but the thickness of the damaged base material is 500-800μm, and the base material is severely damaged. The amount of hazardous waste generated is 3.3 times that of this invention, the on-site dust exceeds the standard, and wastewater and dust treatment processes are required. The labor and energy costs are extremely high, and the environmental protection and construction quality are far inferior to this invention.

[0081] It should be noted that the core parameters in this invention, such as the 70°C temperature control threshold for the base material, the 28°C power reduction threshold for the bundle combiner, and the 70% dust removal and 85% warning thresholds for the dust collection bin, have all been verified through orthogonal tests in multiple land and sea scenarios. These parameters are the optimal process parameters that balance rust removal quality, base material protection, equipment safety, and service life, and have sufficient engineering applicability and experimental basis.

[0082] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature may include direct contact between the first and second features, or contact between the first and second features not in direct contact but through another feature between them.

[0083] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A highly efficient, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process, characterized in that, include: I. Preparations before the assignment; II. Multi-machine collaborative large-area automated rust removal: Multiple composite magnetic obstacle-crossing and wall-climbing robots are synchronously attached to the steel structure facade / curved surface and move at a constant speed; the beams of three lasers are combined and sent to the laser head of a one-to-three multi-faceted rotating mirror; the PLC determines the working condition in real time based on the rust layer thickness based on visual recognition, and outputs prompt signals to inform the operator to replace the 8-face wide rotating mirror or 12-face fine rotating mirror module as needed; after the replacement is completed, the system automatically matches the corresponding rotating mirror's exclusive rotation speed, power and process parameters; 3. Automatic obstacle crossing and localized fine-tuning: The wall-climbing robot autonomously traverses welds and reinforcing ribs with a height of ≤8mm using elastic floating support wheels; narrow blind spots and ultra-high protrusions that the robot cannot cover are precisely targeted for rust removal using a 3000W handheld laser head, and the rust removal points are uploaded to the PLC in real time for marking and archiving, and a blind spot ledger is generated; after the rust removal of the entire area is completed on the same day, the system automatically retrieves the blind spot points and cancels them in the system, forming a closed loop for full-process traceability of missed cleaning points; IV. Multi-sensor AI closed-loop intelligent control: The PLC collects six types of sensor signals in real time: visual corrosion recognition, base material infrared temperature measurement, dust removal negative pressure, air path dew point flow, rotating mirror vibration temperature, and laser plasma spectrum. It dynamically links and adjusts the laser output power, robot travel speed, rotating mirror speed, fan speed, and air curtain supply pressure. It is equipped with an AI self-learning module to continuously iterate the optimal process parameters. When the base material surface temperature is in the range of 70-80℃, it automatically limits the light and slows down the machine. When the base material temperature is ≥80℃, it instantly locks the light and stops the machine with an audible and visual alarm. The fault handling level is the same as the water cooling failure fault level. V. Post-operation maintenance and completion.

2. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 1, characterized in that, The specific pre-operation preparations are as follows: The air source purification unit pre-treatment is completed to ensure that the compressed air has an atmospheric dew point ≤ -40℃ and an oil concentration ≤ 0.1ppm; the independent zone water-cooled unit, the container constant temperature and dehumidification system, and the negative pressure dust removal system are started and the whole machine completes a full-link self-test; the wall-climbing robot is equipped with a 3D LiDAR to scan the curved surface of the steel structure, and the AI ​​algorithm automatically generates a full-coverage walking path and marks welds and protruding obstacles; the PLC pre-divides static independent working zones and is equipped with dynamic boundary detection logic; when the robot approaches the zone boundary / crosses obstacles and approaches the adjacent machine area, it automatically reduces its speed and laser power, and directly locks the light when it enters the adjacent machine's safety threshold, dynamically avoiding laser cross-interference, and retrieves matching process parameters with one click according to the corrosion level.

3. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 2 is characterized in that, The specific details of the extended maintenance completion process are as follows: After the entire area is cleaned, the laser and the wall-climbing robot are shut down first. The handheld laser head is kept powered on and all handheld dust removal units are allowed to complete a 3-second delay before the power to the handheld devices is cut off. The air source purification and negative pressure dust removal system are run for 5 minutes to purge dust from the pipeline and laser head. The independent water-cooling units in each zone are used to continuously cool the optical components for 10 minutes. The container is then cleaned internally. After the entire machine is cooled to room temperature, the water, gas, and power are cut off. The PLC cloud export of the daily work report is archived, and the iron powder and paint residue waste are transferred separately.

4. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 1, characterized in that, The one-to-three multifaceted rotating mirror laser head has three independent water-cooling circulation branches, corresponding to the fiber combiner, collimation and shaping optical path, and rotating mirror scanning cavity heat dissipation, respectively. Each of the three water-cooling branches is independently equipped with an infrared temperature sensor. When the temperature of a single zone is 25-28℃, the water cooling flow rate of the corresponding branch is automatically increased. When the temperature of the combiner is >28℃, the power is gradually reduced. When the temperature of the collimation optical path is >30℃, the cooling flow rate is continuously increased. When the temperature of the rotating mirror cavity is >32℃, the light is synchronously limited. When the temperature of any zone is ≥32℃, the whole machine is instantly locked and shut down.

5. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 4, characterized in that, The composite magnetic obstacle-crossing and wall-climbing robot is equipped with an electromagnetic and permanent magnet composite adsorption module; the PLC adaptively adjusts the electromagnetic force according to the thickness of the steel plate, and reduces the magnetic force for thin steel plates of 3-6mm to avoid deformation of the base material; after the equipment is powered off, the permanent magnet base continues to provide adsorption force to prevent falling from a height; the elastic floating support wheels, together with 3D laser radar, can autonomously climb over obstacles with a protrusion of ≤8mm and intelligently bypass ultra-high obstruction areas.

6. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 5, is characterized in that, Each protective cabin is equipped with two wall-climbing robots that operate synchronously in designated areas. The PLC control system uses electronic safety fences to prevent laser interference between the two robots.

7. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 1, characterized in that, The system is equipped with a five-level hardware and software laser safety interlocking system, including: ① optical fault interlocking; ② laser light leakage detection interlocking; ③ infrared intrusion interlocking of human body in the work area; ④ three-level physical emergency stop of handheld repair laser head, robot, and container; ⑤ infrared temperature measurement and early warning of overheated base material. The auxiliary machine fault classification and handling logic is implemented as follows: for minor faults, a pop-up alarm signal is output and the operation continues; for water cooling failure, loss of negative pressure, and laser overheating faults, the laser high voltage is instantly cut off and the machine is shut down.

8. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 1, characterized in that, The PLC control system has local storage and cloud-based remote operation and maintenance functions. It uploads data on operating area, output power, faults, and consumable consumption in real time, and supports remote monitoring via mobile phone and computer, remote distribution of process parameters, and SMS push notifications for faults. It has built-in standardized process libraries for wind turbine towers, ship decks, storage tanks, and bridge steel box girders, which can be switched and called with one click.

9. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 1, characterized in that, The handheld repair laser head has no polyhedral rotating mirror structure and is equipped with a miniature visual thickness measurement and infrared temperature measurement module; It is equipped with an independent micro side-suction dust removal unit, which is synchronized with the laser light emission trigger for start and stop.

10. The high-efficiency, energy-saving, and environmentally friendly multi-machine collaborative AI intelligent laser rust removal process according to claim 1, characterized in that, The equipment employs a multi-machine collaborative AI intelligent laser rust removal system. The overall structure is a modular integrated container, including a protective container, three 6kW lasers, a three-section water-cooled polyhedral rotating mirror laser head, a composite magnetic obstacle-crossing and wall-climbing robot, a 3000W handheld cleaning laser head, an air source purification unit, a negative pressure magnetic separation dust removal and recovery unit, and a PLC six-dimensional sensing AI central control system. Each unit works in synergy to achieve functions such as air source purification, laser beam scanning, intelligent adsorption obstacle-crossing, adaptive AI parameter control, sealed dust collection, magnetic separation for resource recovery of dust, and safety interlock protection. It is suitable for automated rust removal operations on large steel structures under all working conditions.

Images