A laser cleaning and ultrasonic flaw detection integrated intelligent robot

Abstract

The application discloses a kind of laser cleaning and ultrasonic flaw detection integrated intelligent robot, robot includes Mecanum wheel mobile chassis, laser cleaning head, ultrasonic flaw detection component, coupling agent supply device and machine vision module;The laser cleaning component is set to the front end of robot;Ultrasonic flaw detection component is integrated in the inside of robot car body, it is arranged in the rear side of laser cleaning component along the direction of travel, forms the continuous operation layout of front-end cleaning, internal detection.The robot realizes omnidirectional movement by Mecanum wheel, and the ultrasonic probe completes multidimensional position adjustment by the help of transverse scanning mechanism and screw lifting mechanism, and the stable adhesion of probe and workpiece is guaranteed by cooperating spring pressing structure;Machine vision module can identify weld and automatically plan walking and scanning path.The application can realize cleaning, detection continuous automatic operation, mobile flexible, detection stable, and the modular structure is convenient for maintenance, suitable for ship, pressure vessel, rail transit and other metal component weld detection scene.

Description

Technical Field

[0001] This invention relates to the field of robots for inspecting weld seams on metal walls, and specifically to an intelligent robot that integrates laser cleaning and ultrasonic inspection. Background Technology

[0002] In industrial sectors such as energy equipment, rail transportation, shipbuilding, and pressure vessels, quality inspection of large metal components and welds is a crucial aspect of production and maintenance. Currently, the mainstream operating mode in the industry is manual operation: first, rust, oil, and oxide layers on the workpiece surface are cleaned by mechanical grinding, high-pressure water washing, and chemical cleaning, and then defect detection is carried out using handheld ultrasonic flaw detection equipment.

[0003] This operational mode has several drawbacks: it involves high manual labor intensity, and workpiece inspection often takes place in high-altitude, enclosed, and other high-risk conditions, posing significant safety risks. Furthermore, the separation of cleaning and flaw detection processes necessitates multiple transfers and repositioning of the workpiece, resulting in low efficiency and introducing positioning errors, leading to inconsistent inspection results. Existing automated equipment is mostly designed as separate units, with laser cleaning and ultrasonic flaw detection equipment operating independently, failing to achieve continuous operation of the two processes and thus failing to meet the demands of modern industrial intelligent and high-efficiency inspection. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an intelligent robot that integrates laser cleaning and ultrasonic flaw detection. It integrates surface cleaning and ultrasonic flaw detection functions on the same mobile platform, realizes continuous operation, improves work efficiency, detection accuracy and work safety, and the equipment has a modular structure, which facilitates maintenance and functional expansion.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an intelligent robot integrating laser cleaning and ultrasonic flaw detection, comprising a robot body and a Mecanum wheel chassis located at the bottom of the robot body. A laser cleaning head is installed at the front end of the robot body, and a transverse scanning mechanism, a lead screw lifting mechanism, and an ultrasonic flaw detection scanning frame are arranged inside the robot body. The ultrasonic flaw detection scanning frame is drivenly connected to the transverse scanning mechanism and the lead screw lifting mechanism, and an ultrasonic probe is mounted on the ultrasonic flaw detection scanning frame. Along the robot's travel direction, the laser cleaning head is located in front of the ultrasonic flaw detection scanning frame. After the workpiece surface is cleaned by the laser cleaning head, the ultrasonic probe performs flaw detection, realizing continuous cleaning and flaw detection operations.

[0006] Furthermore, the Mecanum wheel mobile chassis includes four Mecanum wheels, which are respectively installed at the four corners of the bottom of the robot body, and each Mecanum wheel is equipped with an independent drive mechanism.

[0007] Furthermore, the position of the laser cleaning head is adjustable, and it maintains a fixed distance from the workpiece surface during operation.

[0008] Furthermore, the transverse scanning mechanism includes a guide rail, a slider, and a gear and rack transmission assembly. The slider is slidably mounted on the guide rail, the ultrasonic flaw detection scanning frame is fixedly connected to the slider, and the gear and rack transmission assembly drives the slider to perform transverse reciprocating motion along the guide rail.

[0009] Furthermore, the lead screw lifting mechanism is arranged vertically, and the movable end of the lead screw lifting mechanism is connected to the ultrasonic flaw detection scanning frame, which is used to drive the ultrasonic flaw detection scanning frame and the ultrasonic probe to lift as a whole.

[0010] Furthermore, the ultrasonic flaw detection scanning frame is equipped with a probe clamping mechanism, and the ultrasonic probe is fixedly installed on the probe clamping mechanism.

[0011] Furthermore, the probe clamping mechanism is equipped with a spring clamping mechanism, which applies a preload force to the ultrasonic probe, so that the ultrasonic probe flexibly fits against the surface of the workpiece.

[0012] Furthermore, the robot body is also equipped with a coupling agent supply device, with the liquid outlet of the coupling agent supply device facing the detection area of ​​the ultrasonic probe, for coating the cleaned workpiece surface with ultrasonic coupling agent.

[0013] Furthermore, the laser cleaning head, the lateral scanning mechanism, the lead screw lifting mechanism, the ultrasonic flaw detection scanning frame, and the Mecanum wheel mobile chassis all adopt a detachable modular assembly structure.

[0014] Furthermore, the front end of the robot body is also equipped with a weld seam recognition camera, which is electrically connected to a machine vision processing module. The machine vision processing module generates a walking path and a scanning path based on the collected weld seam images.

[0015] Compared with the prior art, the present invention has the following advantages: 1. This invention integrates laser cleaning and ultrasonic flaw detection on the same mobile platform, enabling continuous operation of the two processes, eliminating the need for secondary workpiece transfer and repeated positioning steps, and effectively improving work efficiency and detection accuracy; 2. Adopting a Mecanum wheel omnidirectional mobile chassis, it can adapt to complex sites, irregular weld seams and narrow working spaces, making the equipment flexible to move and applicable to a wider range of scenarios; 3. Equipped with a transverse scanning mechanism, a lead screw lifting mechanism, and a spring clamping structure, the ultrasonic probe can be adjusted in multiple dimensions and flexibly fitted, ensuring a stable testing process and good consistency of test results; 4. Equipped with a machine vision module, it enables automatic weld seam recognition and path planning, reducing manual intervention and achieving unmanned intelligent operation, while avoiding the risks of high-risk manual operations; 5. The whole machine adopts a modular design, with each functional module assembled independently, making disassembly, maintenance, and functional expansion convenient, and enhancing the equipment's versatility and practicality. Attached Figure Description

[0016] Figure 1 is a schematic diagram of the overall three-dimensional structure of the robot of the present invention.

[0017] Figure 2 is a schematic diagram of the three-dimensional structure of the robot from the rear view of the present invention.

[0018] Figure 3 is a schematic diagram of the Mecanum wheel mobile chassis structure.

[0019] Figure 4 is a schematic diagram of the laser cleaning head assembly structure.

[0020] Figure 5 is a schematic diagram of the transverse scanning mechanism (gear and rack mechanism).

[0021] Figure 6 is a schematic diagram of the screw lifting mechanism.

[0022] Figure 7 is a schematic diagram of the ultrasonic flaw detection scanning frame structure.

[0023] Figure 8 is a schematic diagram of the ultrasonic probe clamping mechanism.

[0024] Figure 9 is a schematic diagram of the probe spring clamping mechanism.

[0025] In the picture: 1-Aluminum profile frame, 2-Laser cleaning head, 3-Gear and rack mechanism, 4-Screw module, 5-Gate frame scanning frame, 6-Ultrasonic probe clamp, 7-Ultrasonic probe, 8-Mecanum wheel, 9-Nut seat, 10-Chassis drive motor, 11-Horizontal sweep drive motor, 12-Lifting motor. Detailed Implementation

[0026] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The following embodiments are only preferred embodiments of the present invention and are not intended to limit the present invention. Equivalent substitutions and improvements made by those skilled in the art based on the concept of the present invention are all within the protection scope of the present invention.

[0027] like Figures 1-9 As shown, this embodiment provides an integrated intelligent robot for laser cleaning and ultrasonic flaw detection. The main body uses an aluminum profile frame 1 as the load-bearing structure, and a Mecanum wheel mobile chassis is mounted at the bottom of the frame. A Mecanum wheel 8 is installed at each of the four corners of the chassis, and each Mecanum wheel 8 is driven by an independent chassis drive motor 10. In this embodiment, the Mecanum wheel preferably has a diameter of 142mm, and the chassis drive motor is preferably an XD-57BL60-2430 type DC brushless geared motor, with an output torque of approximately 1.15 N·m and a speed of approximately 26.9 r / min. This selection can meet the requirements of omnidirectional movement and path tracking of the equipment.

[0028] The laser cleaning head 2 is fixedly mounted on the front mounting bracket of the aluminum profile frame 1. The installation position can be slightly adjusted left and right, and a constant distance is maintained from the workpiece surface during operation to ensure uniform laser cleaning effect. During the robot's movement, the laser cleaning head 2 first cleans the rust, oil, oxide layer, and residual coating on the workpiece surface, providing a clean base surface for subsequent flaw detection operations.

[0029] An aluminum profile frame 1 houses a support plate, on which a gear and rack mechanism 3, a lead screw module 4, and a gate-type scanning frame 5 are mounted. The gear and rack mechanism 3 consists of a rack, gears, guide rails, a slider, and a horizontal sweeping drive motor 11. The rack is fixed to the support plate, the gears are connected to the output shaft of the horizontal sweeping drive motor 11 and mesh with the rack, and the slider is fixedly connected to the gate-type scanning frame 5. In this embodiment, the gear pitch circle radius is 13mm, and both the gear and rack are made of 45 steel. The horizontal sweeping drive motor is preferably a 42BYGH48-4170 stepper motor with an output torque of approximately 0.36 N·m and a speed of approximately 36.75 r / min. During operation, the horizontal sweeping drive motor 11 drives the gears to rotate, driving the slider and the gate-type scanning frame 5 to reciprocate laterally along the guide rail, completing the horizontal sweeping action.

[0030] The lead screw module 4 is vertically arranged and includes a lifting drive motor 12, a lead screw, a nut seat 9, and a guide structure. The lead screw has a lead of 2mm and a shaft diameter of 10mm, and is made of alloy steel. The lifting drive motor is preferably a 57AI76-4204YS2 type brake stepper motor, with an output torque of approximately 0.52 N·m and a speed of approximately 150 r / min. The nut seat 9 is connected to the gantry-type scanning frame 5. The lifting drive motor 12 drives the lead screw to rotate, thereby driving the entire gantry-type scanning frame 5 to lift and lower, thus adjusting the working height of the ultrasonic probe 7 to accommodate workpieces of different sizes.

[0031] An ultrasonic probe clamp 6 is installed on the gantry-type scanning frame 5, and the ultrasonic probe 7 is fixed inside the ultrasonic probe clamp 6. The ultrasonic probe clamp 6 integrates a spring clamping mechanism, which can apply a stable pre-tightening force to the ultrasonic probe 7, so that the probe is always in close contact with the workpiece surface during the scanning process, ensuring the stability of the ultrasonic detection signal.

[0032] In this embodiment, a coupling agent supply device is also installed inside the robot body. This device includes a liquid storage container, a delivery pipeline, a liquid supply control valve, and a liquid outlet, with the liquid outlet positioned in front of the ultrasonic probe 7. During operation, the coupling agent supply device can continuously or intermittently apply ultrasonic coupling agent to the cleaned workpiece surface according to the travel speed, thereby establishing a stable acoustic coupling interface.

[0033] The robot's front end is also equipped with a weld seam recognition camera, which is electrically connected to the machine vision processing module. The camera acquires weld seam images in real time, and after the machine vision processing module analyzes the image information, it automatically generates the robot's travel path and the ultrasonic probe's scanning path, enabling fully autonomous operation. The control system controls the movement of the Mecanum wheel 8 based on the weld seam path information, enabling the robot to move automatically along the weld seam direction and assisting the gear and rack mechanism 3 in adjusting the scanning position, thereby further improving the positioning accuracy of the robot during cleaning, coupling, and flaw detection processes.

[0034] The equipment adopts modular assembly. The laser cleaning head 2, gear and rack mechanism 3, lead screw module 4, ultrasonic flaw detection component, and Mecanum wheel chassis are all assembled with standard connectors and can be disassembled, replaced and upgraded individually.

[0035] The workflow of this invention is as follows: (1) After the equipment is in place, the machine vision module identifies the weld seam or the area to be inspected on the workpiece through the front-end camera and plans the travel and scanning path; (2) The Mecanum wheel chassis drives the robot to move along a preset path, and the front laser cleaning head 2 cleans the surface of the workpiece. (3) The cleaned area moves into the internal flaw detection station of the robot body, and the coupling agent supply device automatically applies ultrasonic coupling agent; (4) The lead screw module 4 adjusts the ultrasonic probe 7 to a suitable height, the spring clamping mechanism ensures that the probe is in contact with the workpiece, and the gear and rack mechanism 3 drives the probe to scan laterally to complete the ultrasonic flaw detection. (5) The robot continues to move and cycles through the entire process of “cleaning-coating coupling agent-flaw detection” until the entire workpiece is inspected.

[0036] This equipment is suitable for automated cleaning and non-destructive testing of planar metal workpieces and straight / curved welds, and can be widely used in industrial scenarios such as shipbuilding, pressure vessels, rail transportation, and energy equipment.

[0037] Through the above structure, this embodiment arranges the ultrasonic flaw detection-related structures inside the robot body, allowing the cleaned inspection area to directly enter the scanning range inside the vehicle, realizing integrated continuous operation of "front-end cleaning followed by in-vehicle ultrasonic flaw detection". Compared with the traditional method of separating manual cleaning and manual inspection, this embodiment can reduce repeated positioning errors, improve work efficiency and inspection consistency, and reduce the risk of manual operation in complex or dangerous environments.

Claims

1. An intelligent robot integrating laser cleaning and ultrasonic flaw detection, comprising a robot body and a Mecanum wheel chassis located at the bottom of the robot body, characterized in that: The robot body is equipped with a laser cleaning head at its front end. Inside the robot body, there is a lateral scanning mechanism, a lead screw lifting mechanism, and an ultrasonic flaw detection scanning frame. The ultrasonic flaw detection scanning frame is connected to the lateral scanning mechanism and the lead screw lifting mechanism, and an ultrasonic probe is mounted on the ultrasonic flaw detection scanning frame. Along the robot's direction of travel, the laser cleaning head is located in front of the ultrasonic flaw detection scanning frame. After the workpiece surface is cleaned by the laser cleaning head, the ultrasonic probe performs flaw detection, realizing continuous cleaning and flaw detection operations.

2. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 1, characterized in that: The Mecanum wheel mobile chassis includes four Mecanum wheels, which are respectively installed at the four corners of the bottom of the robot body, and each Mecanum wheel is equipped with an independent drive mechanism.

3. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 1, characterized in that: The position of the laser cleaning head is adjustable, and it maintains a fixed distance from the workpiece surface during operation.

4. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 1, characterized in that: The transverse scanning mechanism includes a guide rail, a slider, and a gear and rack transmission assembly. The slider is slidably mounted on the guide rail, and the ultrasonic flaw detection scanning frame is fixedly connected to the slider. The gear and rack transmission assembly drives the slider to perform transverse reciprocating motion along the guide rail.

5. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 1, characterized in that: The lead screw lifting mechanism is arranged vertically, and the movable end of the lead screw lifting mechanism is connected to the ultrasonic flaw detection scanning frame, which is used to drive the ultrasonic flaw detection scanning frame and ultrasonic probe to lift as a whole.

6. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 1, characterized in that: The ultrasonic flaw detection scanning frame is equipped with a probe clamping mechanism, and the ultrasonic probe is fixedly installed on the probe clamping mechanism.

7. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 6, characterized in that: The probe clamping mechanism is equipped with a spring clamping mechanism, which applies a preload force to the ultrasonic probe, so that the ultrasonic probe flexibly fits against the surface of the workpiece.

8. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 1, characterized in that: The robot body is also equipped with a coupling agent supply device, with the outlet end of the coupling agent supply device facing the detection area of ​​the ultrasonic probe, for coating the cleaned workpiece surface with ultrasonic coupling agent.

9. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to claim 1, characterized in that: The laser cleaning head, lateral scanning mechanism, lead screw lifting mechanism, ultrasonic flaw detection scanning frame, and Mecanum wheel mobile chassis all adopt a detachable modular assembly structure.

10. The intelligent robot integrating laser cleaning and ultrasonic flaw detection according to any one of claims 1-7, characterized in that: The robot's main body is also equipped with a weld seam recognition camera at its front end. The weld seam recognition camera is electrically connected to a machine vision processing module, which generates a walking path and a scanning path based on the collected weld seam images.

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