Large transformer on-line intelligent operation and maintenance robot

Abstract

The present application relates to the technical field of large transformer cleaning, and discloses an online intelligent operation and maintenance robot for large transformer, which comprises a whole cover, a supporting frame installed inside the whole cover, a sliding block fixedly arranged outside the supporting frame, a baffle slidingly connected with a sliding groove inside the supporting frame, a brush and an auger shaft rotatably connected with the inside of the baffle, and a sleeve fixedly connected with the inside of the baffle. The online intelligent operation and maintenance robot for large transformer adopts a large-gap deep V-shaped brush layout, is matched with 45mm lengthened brush hair and 0.4mm optimized wire diameter, solves the problem of willow catkin wrapping the rolling brush, is suitable for the working conditions of collapsed and uneven radiator protective net, and can completely clean. The rotating direction of the brush is matched with the collecting hopper to guide the directional collection of sundries and avoid secondary pollution.

Description

Technical Field

[0001] This invention relates to the field of cleaning technology for large transformers, specifically to an online intelligent operation and maintenance robot for large transformers. Background Technology

[0002] In northern China, spring is dry and windy with a lot of willow catkins flying around. When the transformer cooling fan is running, a large amount of willow catkins will be drawn into the radiator and adhere to the heat dissipation surface, directly reducing the transformer's heat dissipation and ventilation efficiency. In severe cases, it can cause the transformer to overheat and threaten the safe operation of power equipment.

[0003] Currently, the mainstream cleaning methods in the industry are divided into three categories: First, manual cleaning while the transformer is electrified, relying on extended brooms and high-pressure water guns. Transformers are high-voltage electrical equipment, making manual cleaning highly risky. The operation requires multiple people to cooperate and supervise, and the difficulty and safety hazards are further increased in adverse weather conditions such as night, rain, snow, and strong winds. The timeliness and effectiveness of cleaning are difficult to guarantee. Second, modifying the cooling fan control cabinet to use fans to periodically back-blown clean the willow catkins. However, the willow catkins have strong adhesion inside the radiator, and back-blowing is difficult to completely remove them. In addition, the willow catkins blown out in the opposite direction are easily sucked back into adjacent fans. At the same time, the bidirectional air intake of the fans can introduce new operational hazards. Third, traditional roller brush sweepers, which have several structural and performance defects. 1. The roller brush uses closely spaced bristles in a straight row, which are easily trapped by willow catkins. The bristles are also short and cannot be used to clean the radiator mesh when it is collapsed or uneven. 2. The equipment frame is made of thin steel plate by cold bending, which has low structural strength and is easy to deform. Deformation will cause the lifting mechanism to be out of sync and jam. 3. The overall width of the equipment is too small, which limits the adjustment stroke of the roller brush and further reduces the cleaning effect; 4. The control system uses relays paired with single-phase thyristor speed-regulating motors, which has weak anti-interference capabilities. It uses mechanical contact limit switches for commutation, which is prone to impact and slippage problems. The overall protection level of the equipment is low and it cannot adapt to harsh outdoor environments for a long time. 5. There is no dedicated debris collection device, and the swept willow catkins accumulate on the surface of the roller brush, resulting in significant secondary pollution.

[0004] Therefore, there is an urgent need for a large-scale transformer online intelligent operation and maintenance robot to solve the problems of easy tangling of brush bristles, insufficient structural strength, poor transmission reliability, and small adjustment range. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an online intelligent operation and maintenance robot for large transformers, which has the advantages of convenient cleaning and reliable safety, and solves the problems of easy tangling of brush bristles, insufficient structural strength, poor transmission reliability, and small adjustment range.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a large transformer online intelligent operation and maintenance robot, comprising an overall cover, a support frame installed inside the overall cover, a slider fixedly installed on the outside of the support frame, a baffle slidably connected to a groove on the inside of the support frame, a brush and an auger shaft rotatably connected to the inside of the baffle, and a sleeve fixedly connected to the inside of the baffle. Two single-machine connection seats are installed on the plate inside the support frame. A three-phase variable frequency motor is installed inside the single-machine connection seat. A gear four is fixedly connected to the output end of one of the three-phase variable frequency motors. Gear four meshes with gear two. Gear two meshes with gear three. Gear two is installed on a shaft at one end of the auger shaft. Gear three is installed on a shaft at one end of the brush. The brush surface is provided with a large-gap deep V-shaped bristle structure.

[0007] The brush features a large-gap, deep V-shaped bristle layout, with 45mm extended bristles and an optimized 0.4mm bristle diameter. This not only solves the problem of willow catkins clogging the roller brush but also adapts to the working conditions of collapsed or uneven radiator mesh, ensuring thorough cleaning. The brush rotation direction, combined with the collection hopper, guides the debris for directional collection, avoiding secondary pollution.

[0008] Preferably, another three-phase variable frequency motor output terminal is fixedly connected to a gear, the gear meshing with a traveling gear, the two traveling gears are fixedly mounted on a connecting rod, and the connecting rod is rotatably connected to the plates on both sides of the overall cover.

[0009] Preferably, the auger shaft is located inside the sleeve.

[0010] Preferably, a bearing seat two is rotatably connected to the shaft of the auger shaft, and the bearing seat two is fixedly connected to the outside of the baffle by bolts.

[0011] Preferably, the brush shaft is rotatably connected to a bearing seat, and the bearing seat is fixedly connected to the inside of the baffle by bolts.

[0012] Preferably, a slot is provided on the front of the support frame at the position corresponding to the baffle, and the slot is used to install long bolts.

[0013] Preferably, the brush bristles are 45mm long and the bristle diameter is 0.4mm.

[0014] Preferably, the support frame is formed by splicing hard aluminum alloy thick plates and aluminum alloy profiles, and the surfaces of the support frame, baffle and sleeve are all anodized; the three-phase frequency conversion motor is covered with a 304 stainless steel waterproof protective cover.

[0015] Preferably, it also includes an intelligent control component, which includes a PLC controller, a touch screen, a host computer, a temperature sensor, a wind speed sensor, and a contactless proximity switch; the proximity switch is installed on the upper and lower sides of the support frame cover, and the proximity switch sensing distance is 4~8mm; the temperature sensor and the wind speed sensor are electrically connected to the PLC controller, and the PLC controller is communicatively connected to the touch screen and the host computer.

[0016] In summary, the present invention has at least one of the following beneficial effects: 1. This large transformer online intelligent operation and maintenance robot features a brush with a large-gap deep V-shaped bristle layout, combined with 45mm extended bristles and 0.4mm optimized filament diameter. This not only solves the problem of willow catkins covering the roller brush, but also adapts to the working conditions of collapsed and uneven radiator guards, ensuring thorough cleaning. The rotation direction of the brush, in conjunction with the collection hopper, guides the debris for directional collection, avoiding secondary pollution.

[0017] 2. The main frame of this large transformer online intelligent operation and maintenance robot is made of hard aluminum alloy thick plate, which is not easy to deform and eliminates the problem of jamming of the lifting mechanism; the aluminum alloy gears are embedded with gear steel sleeves, which greatly improves the hardness and wear resistance of the gear shaft connection position and prevents the failure of the rolling key; with outdoor maintenance-free aluminum alloy guide rail slider, the transmission and lifting stability are greatly improved.

[0018] 3. This large-scale transformer online intelligent operation and maintenance robot, with baffles and long bolts and screw holes, enables a wide range of continuous adjustment of the brush gap, and can be adapted to transformer radiators of different models and different aging levels, making it more versatile.

[0019] 4. This large transformer online intelligent operation and maintenance robot adopts a three-phase frequency conversion motor combined with brake logic control, and the control system has strong anti-interference ability; the contactless proximity switch realizes smooth commutation and completely solves the commutation impact and slippage faults; the whole machine uses waterproof electrical components and stainless steel shell, and can operate stably in harsh outdoor environments such as wind, sand, rain, snow, high and low temperatures for a long time.

[0020] 5. This large transformer online intelligent operation and maintenance robot integrates temperature and wind speed sensors, PLC, touch screen and host computer, which can monitor the environment and equipment status in real time, and has the functions of fault self-diagnosis and overload protection; it supports local operation and remote centralized management and control, and completes cleaning operations automatically without the need for on-site human supervision, which greatly reduces the labor cost and safety risks of high voltage equipment operation and maintenance. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the intelligent operation and maintenance robot of the present invention; Figure 2 This is a schematic diagram of the connection structure between the brush and the support frame of the present invention; Figure 3This is a schematic diagram of the connection structure of the sleeve, auger shaft, collecting hopper and support frame of the present invention; Figure 4 This is a schematic diagram of the auger shaft structure of the present invention.

[0022] The components include: 1. Overall cover; 2. Support frame; 3. Slider; 4. Baffle; 5. Brush; 6. Bearing seat one; 7. Single machine connecting seat; 8. Three-phase frequency conversion motor; 9. Gear one; 10. Travel gear; 11. Sleeve; 12. Screw shaft; 13. Bearing seat two; 14. Collection hopper; 15. Slot; 16. Gear two; 17. Gear three; 18. Proximity switch; 19. Gear four. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figure 1-4 The large transformer online intelligent operation and maintenance robot includes an overall cover 1, a support frame 2 installed inside the overall cover 1, a slider 3 fixedly set on the outside of the support frame 2, a baffle 4 slidably connected to the inner groove of the support frame 2, a brush 5 rotatably connected to the inner side of the baffle 4, an auger shaft 12, and a sleeve 11 fixedly connected to the inner side of the baffle 4. The overall cover 1 protects the internal structure, and the slider 3 is installed on the track on the outside of the large transformer, so that the online intelligent operation and maintenance robot can move on the outside of the large transformer to clean the outside of the large transformer. The bristle length of brush 5 is 45mm, the bristle diameter is 0.4mm, and the surface of brush 5 is provided with a deep V-shaped bristle structure with large gaps. Brush 5 cleans the outside of the large transformer as it rotates; The auger shaft 12 is located inside the sleeve 11. Two single-unit connecting seats 7 are installed on the plate inside the support frame 2. A three-phase variable frequency motor 8 is installed inside the single-unit connecting seat 7. A gear 4 19 is fixedly connected to the output end of one of the three-phase variable frequency motors 8. Gear 4 19 is meshed with gear 2 16. Gear 2 16 is meshed with gear 3 17. Gear 2 16 is installed on the shaft at one end of the auger shaft 12. Gear 3 17 is installed on the shaft at one end of the brush 5. A collection hopper 14 is installed on the plate at the bottom of the support frame 2 at the position corresponding to the brush 5 and the auger shaft 12. After the three-phase variable frequency motor 8 starts, it drives gear 4 19 to rotate. When gear 4 19 rotates, it drives gear 2 16 and gear 3 17 to rotate. Gear 2 16 drives auger shaft 12 to rotate, and gear 3 17 drives brush 5 to rotate. When brush 5 rotates, it cleans the outside of the large transformer. The cleaned debris enters the inside of sleeve 11. Gear 2 16 drives auger shaft 12 to rotate. When auger shaft 12 rotates, it pushes the debris. The debris falls from the slot on the outside of sleeve 11 onto collection hopper 14, thereby guiding the debris to be collected in a specific direction and avoiding secondary pollution. Specifically, another three-phase variable frequency motor 8 has a gear 9 fixedly connected to its output end. The gear 9 meshes with a traveling gear 10. The two traveling gears 10 are fixedly installed on the connecting rod. The connecting rod is rotatably connected to the plates on both sides of the overall cover 1. The shaft of the auger shaft 12 is rotatably connected to a bearing seat 13. The bearing seat 13 is fixedly connected to the outside of the baffle 4 by bolts.

[0025] With the above technical solution, when another three-phase variable frequency motor 8 starts, the three-phase variable frequency motor 8 drives gear 9 and walking gear 10 to rotate. When the walking gear 10 rotates, it drives the online intelligent operation and maintenance robot to move up and down through the teeth on the outside of the large transformer, so as to clean the online intelligent operation and maintenance robot.

[0026] Specifically, the shaft of the brush 5 is rotatably connected to a bearing seat 6, which is fixedly connected to the inside of the baffle 4 by bolts. A slot 15 is provided on the front of the support frame 2 at the position corresponding to the baffle 4. The slot 15 is used to install long bolts.

[0027] Through the above technical solution, the long screw is rotatably connected to the outside of the support frame 2. The long screw passes through the slot 15 on the front of the support frame 2 and is threaded to the baffle 4. When the long screw is rotated, the long screw drives the baffle 4 to move inside the support frame 2, thereby changing the position of the brush 5, the sleeve 11 and the auger shaft 12.

[0028] Specifically, the large transformer online intelligent operation and maintenance robot also includes intelligent control components, which include a PLC controller, a touch screen, a host computer, a temperature sensor, a wind speed sensor, and a contactless proximity switch 18. The proximity switch 18 is installed on the upper and lower sides of the overall cover 1, and the sensing distance of the proximity switch 18 is 4~8mm. The temperature sensor and the wind speed sensor are electrically connected to the PLC controller, and the PLC controller is communicatively connected to the touch screen and the host computer.

[0029] Through the above technical solution, contactless proximity switches 18 are installed at the upper and lower limit positions of the lifting stroke of the overall cover 1. The proximity switches 18 are selected as outdoor waterproof models with a sensing distance range of 4~8mm: when the equipment is lifting and reversing normally, the sensing distance is controlled at 8mm; when the mechanism runs to the limit position, the 4mm sensing distance triggers the limit protection and forces the machine to stop, effectively preventing the mechanism from colliding or slipping. The entire machine is equipped with intelligent control components. Temperature and wind speed sensors are deployed around the transformer radiator to collect ambient temperature and wind speed data in real time. The sensor signal output terminals are electrically connected to the signal input terminals of the PLC controller. The PLC controller is communicatively connected to the field touchscreen and the remote host computer, and is also electrically connected to the frequency converter of the three-phase variable frequency motor 8. The frequency converter integrates short-circuit and overload protection functions. Combined with the PLC's internal logic program, it can realize automatic alarm for equipment faults, shutdown protection, and recording and uploading of operating data. When in use, first assemble the robot onto the matching vertical track on the outside of the large transformer radiator using slider 3 to complete the overall positioning and installation; the operator rotates the long bolt passing through the slot 15 to drive the baffle 4 to slide vertically along the inner groove of the support frame 2, thereby adjusting the cleaning gap between the brush 5 and the transformer radiator guard, adapting to the actual working conditions of the radiator guard collapsing and uneven. After adjustment, tighten the long bolt to fix the position of the baffle 4. After mechanical debugging is completed, the power supply line of the whole machine and the remote communication line are connected, and the intelligent control components are powered on and initialized. Temperature sensors and wind speed sensors arranged around the radiator collect on-site environmental data in real time and transmit it to the PLC controller. The staff can set the operating parameters through the on-site touch screen or remote host computer, including the reciprocating speed of the whole machine, the rotation speed of the brush 5, the automatic cleaning cycle, the limit protection sensing threshold and other parameters. After the cleaning start command is issued, the two three-phase variable frequency motors 8 start synchronously: one is the cleaning drive motor, which drives the gear 4 19 to rotate at the output end. The gear 4 19 drives the gear 3 17 to rotate through the gear 2 16. The gear 2 16 drives the auger shaft 12 to rotate continuously inside the sleeve 11. The gear 3 17 drives the brush 5 to rotate. The large gap deep V-shaped bristles on the surface of the brush 5 roll and clean the radiator guard. The willow catkins and accumulated dirt attached to the heat dissipation surface are brushed off and collected into the sleeve 11 under the guidance of the rotating bristles. The auger shaft 12 continuously pushes the debris to the discharge port of the sleeve 11. The debris falls directly into the collection hopper 14 below for centralized collection, avoiding the willow catkins from scattering and causing secondary pollution. Another three-phase variable frequency motor 8 serves as a walking drive motor. The output drive gear 9 meshes with the walking gears 10 on both sides. The walking gears 10 rotate synchronously with the connecting rod and mesh with the outer teeth of the transformer track, driving the overall cover 1 and support frame 2 to move vertically along the track and perform reciprocating cleaning operations on the entire height area of ​​the radiator. When the machine travels to the upper and lower limit positions of the track, the non-contact proximity switches 18 on the upper and lower sides of the overall cover 1 sense and trigger the signal. When the sensing distance reaches 8mm, the equipment will change direction normally and smoothly. If the mechanism deviates or overtravel tends to occur, the 4mm limit sensing distance will immediately trigger the stop protection. In conjunction with the brake logic locking transmission mechanism of the three-phase variable frequency motor 8, the equipment impact and slippage faults are prevented. During the entire operation of the equipment, the PLC controller collects data on motor current, ambient temperature, wind speed, and mechanism position in real time and uploads it to the touch screen and host computer simultaneously. If faults such as motor overload, short circuit, or overheating occur, the frequency converter and PLC will work together to execute shutdown protection and push fault alarm information to the host computer to prompt maintenance personnel to perform maintenance. After the equipment reaches the preset cleaning time, it automatically stops cleaning and returns to the initial standby position on the track, waiting for the next round of timed cleaning instructions. Once the debris inside the collection bucket 14 accumulates to the threshold, maintenance personnel only need to disconnect the power and disassemble the collection bucket 14 to empty the accumulated willow catkins and dirt. There is no need to carry out high-voltage live cleaning operations at close range, realizing unattended online intelligent operation and maintenance of large transformer radiators around the clock.

[0030] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A large transformer online intelligent operation and maintenance robot, comprising an overall cover (1), a support frame (2) installed inside the overall cover (1), a slider (3) fixedly disposed on the outside of the support frame (2), a baffle (4) slidably connected to the inner groove of the support frame (2), a brush (5) and an auger shaft (12) rotatably connected to the inner side of the baffle (4), and a sleeve (11) fixedly connected to the inner side of the baffle (4), characterized in that: Two single-unit connecting seats (7) are installed on the plate inside the support frame (2). A three-phase variable frequency motor (8) is provided inside the single-unit connecting seat (7). A gear four (19) is fixedly connected to the output end of one of the three-phase variable frequency motors (8). The gear four (19) is meshed with a gear two (16). The gear two (16) is meshed with a gear three (17). The gear two (16) is installed on the shaft at one end of the auger shaft (12). The gear three (17) is installed on the shaft at one end of the brush (5). The brush (5) has a large-gap deep V-shaped bristle structure on its surface.

2. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: Another three-phase variable frequency motor (8) has a gear 1 (9) fixedly connected to its output end. The gear 1 (9) is meshed with a walking gear (10). The two walking gears (10) are fixedly installed on the connecting rod, and the connecting rod is rotatably connected to the plates on both sides of the overall cover (1).

3. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: The auger shaft (12) is located inside the sleeve (11).

4. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: A collection hopper (14) is installed on the bottom plate of the support frame (2) at a position corresponding to the brush (5) and the auger shaft (12).

5. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: The auger shaft (12) is rotatably connected to a bearing seat (13), which is fixedly connected to the outside of the baffle (4) by bolts.

6. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: The shaft of the brush (5) is rotatably connected to a bearing seat (6), which is fixedly connected to the inside of the baffle (4) by bolts.

7. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: The support frame (2) has a slot (15) on the front corresponding to the baffle (4), and the slot (15) is used to install long bolts.

8. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: The brush (5) has a bristle length of 45 mm and a bristle diameter of 0.4 mm.

9. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: The support frame (2) is formed by splicing hard aluminum alloy thick plate and aluminum alloy profile. The surfaces of the support frame (2), baffle (4) and sleeve (11) are all anodized. The three-phase frequency converter motor (8) is covered with a 304 stainless steel waterproof protective cover.

10. The large transformer online intelligent operation and maintenance robot according to claim 1, characterized in that: It also includes intelligent control components, which include a PLC controller, a touch screen, a host computer, a temperature sensor, a wind speed sensor, and a contactless proximity switch (18); the proximity switch (18) is installed on the upper and lower sides of the overall cover (1), and the sensing distance of the proximity switch (18) is 4~8mm; the temperature sensor and the wind speed sensor are electrically connected to the PLC controller, and the PLC controller is communicatively connected to the touch screen and the host computer.

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