A tracing device and method of a wall-climbing robot for detecting defects of a leakage prevention ring of a runner of a hydraulic turbine

Abstract

A kind of tracing device and method of leakage stop ring defect in situ detection wall-climbing robot of hydraulic turbine runner, including magnetic adsorption crawler, X-R adjusting mechanism, guide module, visual positioning module;X-R adjusting mechanism is installed on magnetic adsorption crawler;Guide module is connected with the lower end of X-R adjusting mechanism;Visual positioning module is installed on X-R adjusting mechanism;Guide module includes guide module device base, guide column spacing adjustment mechanism, guide column insertion mechanism, guide column;Guide column spacing adjustment mechanism is installed on guide module device base;Guide column insertion mechanism is connected with guide column spacing adjustment mechanism;Guide column is connected with guide column insertion mechanism;Three-axis force sensor is installed on guide column.It solves the problem that wall-climbing robot cannot accurately move along the gap of leakage stop ring due to magnetic wheel slip, improves the precision of wall-climbing robot along the gap of leakage stop ring, avoids probe damage, reduces the difficulty of wall-climbing robot control, and improves the defect detection efficiency of leakage stop ring.

Description

Technical Field

[0001] This invention belongs to the field of in-situ detection technology of turbine runner leak-proof ring, and specifically relates to a tracking device and method for a wall-climbing robot for in-situ detection of defects in turbine runner leak-proof ring. Background Technology

[0002] As the core equipment of a hydroelectric generating unit, the operating condition of the turbine directly affects the unit's efficiency and operational safety. The sealing ring, installed between the upper crown and lower ring of the runner, is a sealing structure used to reduce leakage between rotating and stationary components. Its structural condition significantly impacts key performance characteristics of the turbine, such as efficiency, thrust, and pressure pulsation. During long-term operation, the sealing ring is susceptible to damage from water flow impact, cavitation wear, and stress concentration, leading to defects such as wear, cavitation, and even cracks. These defects not only increase the turbine's volumetric losses and reduce operating efficiency but can also, in severe cases, cause the sealing ring to crack, damage the runner, and trigger major equipment accidents. Therefore, regular in-situ inspections and condition assessments of the sealing ring are of significant engineering importance.

[0003] Because there is a height difference of about 3 meters from the bottom ring of the turbine runner to the top cover, and the gap of the leak-stop ring is small (3-6mm) and the longitudinal depth is large (300-500mm), it is necessary to use a wall-climbing robot to carry the detection equipment to the vicinity of the leak-stop ring gap, insert the sheet sensor into the gap, and rely on the wall-climbing robot to drive the sheet sensor to move along the leak-stop ring gap to complete the in-situ detection of surface defects of the leak-stop ring.

[0004] However, since the turbine runner top cover is made of carbon steel and the bottom ring is made of martensitic stainless steel, both of which are magnetic materials, the magnetic crawler will slip during the crawling process on the surface. If not properly controlled, the sheet probe inserted into the gap of the leak-proof ring can easily be damaged.

[0005] Therefore, there is an urgent need to propose a method and device for in-situ detection of defects in the sealing ring of a water turbine runner, which can be used to track the wall-climbing robot, ensure that the wall-climbing robot can move accurately along the gap of the sealing ring, reduce the control difficulty of the wall-climbing robot, avoid probe damage, and improve detection efficiency. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a tracking device and method for a wall-climbing robot for in-situ detection of defects in the sealing ring of a water turbine runner. It is applicable to in-situ detection of defects in the sealing ring of a water turbine runner and in-situ measurement of the gap width. Using this method can ensure that the wall-climbing robot crawls along the gap of the sealing ring, reduce the control difficulty of the wall-climbing robot, and improve the detection efficiency.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A tracking device for a wall-climbing robot for in-situ detection of defects in the leak-proof ring of a water turbine runner includes a magnetic adsorption crawler, an XR adjustment mechanism, a guide module, and a vision positioning module. The XR adjustment mechanism is mounted on the magnetic adsorption crawler. The guide module is connected to the lower end of the XR adjustment mechanism. The vision positioning module is mounted on the XR adjustment mechanism. The guide module includes a guide module base, a guide column spacing adjustment mechanism, a guide column insertion mechanism, and guide columns. The guide column spacing adjustment mechanism is mounted on the guide module base. The guide column insertion mechanism is connected to the guide column spacing adjustment mechanism. The guide columns are connected to the guide column insertion mechanism. A triaxial force sensor is mounted on the guide column.

[0008] As a preferred embodiment, the guide column spacing adjustment mechanism includes a second drive motor, left and right rotating lead screws, a first guide rail, and a T-shaped slider; the first guide rail is fixed on the base of the guide module device; the T-shaped slider is slidably engaged with the first guide rail; the left and right rotating lead screws are connected to the second drive motor; the T-shaped slider and the left and right rotating lead screws form a helical transmission pair.

[0009] As a preferred embodiment, the guide post insertion mechanism includes a second electric rod; the second electric rod is mounted on the T-shaped slider; the guide post is connected to the moving end of the second electric rod.

[0010] As a preferred embodiment, the XR adjustment mechanism includes an XR mechanism horizontal drive motor, a first lead screw, a first slider, a horizontal rod, a first electric rod, and a column; the XR mechanism horizontal drive motor is mounted on the magnetic adsorption crawler; the first lead screw is connected to the XR mechanism horizontal drive motor; the first slider cooperates with the first lead screw; the horizontal rod is connected to the first slider; one end of the first electric rod is hinged to the horizontal rod, and the other end is hinged to the column; the lower end of the column is connected to the base of the guide module device.

[0011] As a preferred embodiment, the visual positioning module includes a CCD visual sensor and a visual sensor mounting bracket; the visual sensor mounting bracket is installed on a column; and the CCD visual sensor is installed on the visual sensor mounting bracket.

[0012] As a preferred embodiment, a miniature bearing is fitted at the bottom end of the guide post; the miniature bearing is a radial thrust bearing.

[0013] As a preferred embodiment, there are two guide columns, symmetrically arranged below the base of the guide module device.

[0014] A method for in-situ detection and tracing of defects in the sealing ring of a water turbine runner includes the following steps: S1. Adjust the guide post spacing adjustment mechanism to adjust the spacing between the two guide posts; S2. Control the magnetic adsorption crawler to move to the vicinity of the leak-stopping ring, perform coarse positioning through the visual positioning module, and adjust the XR adjustment mechanism to align the guide post with the gap of the leak-stopping ring. S3. Control the guide post insertion mechanism to push the guide post into the gap of the leak-stopping ring; S4. Control the magnetic adsorption crawler to crawl along the gap of the leak-proof ring. During the crawling process, adjust the movement of the magnetic adsorption crawler according to the feedback signal of the triaxial force sensor.

[0015] In step S1, the corresponding chord length is calculated based on the diameter of the leak-stopping ring to be tested, and the spacing between the two guide posts is adjusted to the calculated chord length value through the guide post spacing adjustment mechanism.

[0016] In step S4, when the magnetic adsorption crawler crawls, the guide post contacts the side wall of the gap between the leak-proof ring and the triaxial force sensor collects the lateral force on the guide post in real time, and dynamically adjusts the traveling direction of the magnetic adsorption crawler according to the change of the lateral force.

[0017] This method is applicable to both upper and lower leak-proof ring inspections. When inspecting the upper leak-proof ring, the magnetic adsorption crawler is lifted to the turbine top cover by a lifting mechanism. When inspecting the lower leak-proof ring, the magnetic adsorption crawler operates on the bottom ring surface near the movable guide vane.

[0018] The present invention can achieve the following beneficial effects: 1. This method solves the problem of detecting defects and gaps in the water turbine sealing ring and controlling the movement of the wall-climbing robot along the sealing ring gap. It can be used in both upper and lower sealing ring tracking scenarios. 2. The device involved in this method has a simple structure and can automatically adjust the distance between the left and right guide columns according to the diameter of the leak-proof ring of different specifications to adapt to different specifications of units; 3. This method utilizes guide posts for guidance, transforming the magnetic crawler's tracking control into crawling along a track. The feedback control using a triaxial force sensor installed on the guide posts improves guidance accuracy and avoids damage to the guide posts.

[0019] 4. This method helps improve the accuracy of the magnetic crawler in tracking along the turbine's leak-proof ring, reduces the risk of sensor damage, lowers the control difficulty of the wall-climbing robot's tracking, and improves the in-situ detection efficiency of leak-proof ring defects. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is the front view of the present invention; Figure 2 This is a side view of the present invention; Figure 3 This is a diagram illustrating the effect of using the present invention.

[0021] In the diagram: 1-Magnetic adsorption crawler; 2-Horizontal drive motor of XR mechanism; 3-First slider; 4-First lead screw; 5-First electric rod; 6-Column; 7-CCD vision sensor; 8-Horizontal rod; 9-Second electric rod; 10-T-shaped slider; 11-Guide column; 12-Miniature bearing; 13-Guide module device base; 14-Vision sensor fixing support; 15-Second drive motor; 16-Left and right rotating lead screw; 17-First guide rail; 18-Triaxial force sensor; 19-Leak-proof ring. Detailed Implementation

[0022] The structure of this device is as follows: Figure 1 , 2 As shown, its main structure includes a magnetic adsorption crawler, a guidance module, an XR adjustment mechanism, and a visual positioning module. Among them: (1) The guide module consists of a device base, a guide column spacing adjustment mechanism, a guide column fixing block, a guide column insertion mechanism, guide columns, and miniature bearings (outer diameter 3mm, inner diameter 1mm, thickness 2mm). Radial thrust bearings are recommended.

[0023] (2) The guide column spacing adjustment mechanism adopts differential screw transmission, with screws 2 with different screw directions at both ends, a guide rail fixed on the base of the guide module device, a T-shaped slider for fixing the guide column, and a nut machined in the middle of the T-shaped slider to form a screw transmission pair with the screw 2; by controlling the second drive motor to drive the screw nut to move, the left and right guide columns can be brought together and opened.

[0024] (3) The guide post insertion mechanism consists of an electric push rod, which is fixed on the T-shaped slider. The guide post and the moving parts of the electric push rod are fixed together. A miniature bearing is installed at the bottom of the guide post. In addition to electric push rods, the guide post insertion mechanism can also use lead screws or guide rod mechanisms. (4) The guide module is fixed at the bottom of the column; a CCD vision sensor mounting base and a CCD vision sensor are installed on the column for coarse positioning.

[0025] (5) The XR adjustment mechanism consists of an XR horizontal drive motor, a first lead screw, a first slider, a horizontal rod fixed on the first slider, and an electric push rod hinged to one end of the horizontal rod. The column is hinged to the electric push rod and the horizontal rod respectively. It realizes the positioning of the guide module; R is mainly used because there is usually a certain curvature between the magnetic crawler's travel plane and the gap of the leak-proof ring, which needs to be adjusted by the R mechanism.

[0026] The XR adjustment mechanism is mounted on the magnetic adsorption crawler 1; the guide module is connected to the lower end of the XR adjustment mechanism; the visual positioning module is mounted on the XR adjustment mechanism; the guide module includes a guide module device base 13, a guide column spacing adjustment mechanism, a guide column insertion mechanism, and a guide column 11; the guide column spacing adjustment mechanism is mounted on the guide module device base 13; the guide column insertion mechanism is connected to the guide column spacing adjustment mechanism; the guide column 11 is connected to the guide column insertion mechanism; a triaxial force sensor 18 is mounted on the guide column 11. The guide column spacing adjustment mechanism includes a second drive motor 15, a left and right rotating lead screw 16, a first guide rail 17, and a T-shaped slider 10; the first guide rail 17 is fixed on the guide module device base 13; the T-shaped slider 10 slides with the first guide rail 17; the left and right rotating lead screw 16 is connected to the second drive motor 15; the T-shaped slider 10 and the left and right rotating lead screw 16 form a helical transmission pair. The XR adjustment mechanism includes an XR mechanism horizontal drive motor 2, a first lead screw 4, a first slider 3, a horizontal rod 8, a first electric rod 5, and a column 6. The XR mechanism horizontal drive motor 2 is mounted on the magnetic adsorption crawler 1. The first lead screw 4 is connected to the XR mechanism horizontal drive motor 2. The first slider 3 cooperates with the first lead screw 4. The horizontal rod 8 is connected to the first slider 3. One end of the first electric rod 5 is hinged to the horizontal rod 8, and the other end is hinged to the column 6. The lower end of the column 6 is connected to the guide module device base 13. The visual positioning module includes a CCD visual sensor 7 and a visual sensor fixing support 14. The visual sensor fixing support 14 is mounted on the column 6. The CCD visual sensor 7 is mounted on the visual sensor fixing support 14.

[0027] The tracking method of this device is as follows: ①For example Figure 3 As shown, the chord length is calculated using a formula based on the diameter of the leak-stopping ring to be tested, and the spacing between the left and right guide columns is adjusted to the calculated chord length using the guide column spacing adjustment mechanism.

[0028] ② Control the magnetic crawler to approach the leak-stopping ring, use the vision module for coarse positioning, control the XR platform to move the guide post above the leak-stopping ring gap, and control the insertion mechanism to push the guide post into the leak-stopping ring gap.

[0029] ③ Control the magnetic crawler to crawl along the gap of the leak-proof ring. During the crawling process, the system uses the feedback signal from the triaxial force sensor installed on the guide column to dynamically adjust the movement of the magnetic crawler.

[0030] Embodiments of the present invention (1) Tracing the upper leak-stopping ring: Before maintenance, the diameter of the leak-stopping ring to be inspected is input into the robot control system. The system automatically calculates the chord length and adjusts the distance between the left and right guide columns through the guide column adjustment mechanism.

[0031] Then, using a lifting mechanism, the magnetic crawler is lifted to the vicinity of the turbine's top cover. The robot is then controlled to adhere to and move onto the top cover. Next, the wall-climbing robot is controlled to move to the leak-stop ring gap. Using feedback signals from a vision sensor, the robot is controlled to move the guide column above the leak-stop ring gap via an XR platform. Finally, the insertion mechanism is controlled to push the guide column into the leak-stop ring gap.

[0032] The system controls the magnetic crawler to crawl along the gap of the leak-proof ring. During the crawling process, the system uses the feedback signal from the triaxial force sensor installed on the guide column to adjust the movement of the magnetic crawler, thereby improving the robot's tracking accuracy and efficiency.

[0033] (2) Tracing the lower stop-leak ring: Before maintenance, the diameter of the leak-stopping ring to be inspected is input into the robot control system. The system automatically calculates the chord length and adjusts the distance between the left and right guide columns through the guide column adjustment mechanism.

[0034] Then, near the movable guide vane, control the wall-climbing robot to move to the leak-stop ring gap. Using feedback signals from the vision sensor, control the robot to adjust the XR adjustment mechanism so that the left and right guide pillars are above the leak-stop ring gap. Control the insertion mechanism to push the guide pillars into the leak-stop ring gap.

[0035] The magnetic crawler is controlled to crawl along the gap of the leak-proof ring. During the crawling process, the system uses the feedback signal from the triaxial force sensor installed on the guide column to adjust the movement of the magnetic crawler.

[0036] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A tracking device for a wall-climbing robot for in-situ detection of defects in the leak-proof ring of a water turbine runner, characterized in that, It includes a magnetic adsorption crawler (1), an XR adjustment mechanism, a guide module, and a visual positioning module; the XR adjustment mechanism is installed on the magnetic adsorption crawler (1); the guide module is connected to the lower end of the XR adjustment mechanism; the visual positioning module is installed on the XR adjustment mechanism; the guide module includes a guide module device base (13), a guide column spacing adjustment mechanism, a guide column insertion mechanism, and a guide column (11); the guide column spacing adjustment mechanism is installed on the guide module device base (13); the guide column insertion mechanism is connected to the guide column spacing adjustment mechanism; the guide column (11) is connected to the guide column insertion mechanism; a triaxial force sensor (18) is installed on the guide column (11).

2. The tracking device for a wall-climbing robot for in-situ detection of defects in the turbine runner leak-proof ring according to claim 1, characterized in that, The guide column spacing adjustment mechanism includes a second drive motor (15), a left and right rotating screw (16), a first guide rail (17), and a T-shaped slider (10); the first guide rail (17) is fixed on the base (13) of the guide module device; the T-shaped slider (10) is slidably engaged with the first guide rail (17); the left and right rotating screw (16) is connected to the second drive motor (15); the T-shaped slider (10) and the left and right rotating screw (16) form a helical transmission pair.

3. The tracking device for a wall-climbing robot for in-situ detection of defects in the turbine runner leak-proof ring according to claim 2, characterized in that, The guide post insertion mechanism includes a second electric rod (9); the second electric rod (9) is mounted on a T-shaped slider (10); the guide post (11) is connected to the moving end of the second electric rod (9).

4. The tracking device for a wall-climbing robot for in-situ detection of defects in the turbine runner leak-proof ring according to claim 1, characterized in that, The XR adjustment mechanism includes an XR mechanism horizontal drive motor (2), a first lead screw (4), a first slider (3), a horizontal rod (8), a first electric rod (5), and a column (6); the XR mechanism horizontal drive motor (2) is mounted on the magnetic adsorption crawler (1); the first lead screw (4) is connected to the XR mechanism horizontal drive motor (2); the first slider (3) cooperates with the first lead screw (4); the horizontal rod (8) is connected to the first slider (3); one end of the first electric rod (5) is hinged to the horizontal rod (8), and the other end is hinged to the column (6); the lower end of the column (6) is connected to the base (13) of the guide module device.

5. The tracking device for a wall-climbing robot for in-situ detection of defects in the turbine runner leak-proof ring according to claim 4, characterized in that, The visual positioning module includes a CCD visual sensor (7) and a visual sensor mounting bracket (14); the visual sensor mounting bracket (14) is mounted on the column (6); the CCD visual sensor (7) is mounted on the visual sensor mounting bracket (14).

6. The tracking device for a wall-climbing robot for in-situ detection of defects in the turbine runner leak-proof ring according to claim 1, characterized in that, The bottom end of the guide post (11) is fitted with a miniature bearing (12); the miniature bearing (12) is a radial push bearing.

7. The tracking device for a wall-climbing robot for in-situ detection of defects in the turbine runner leak-proof ring according to claim 1, characterized in that, There are two guide columns (11), which are symmetrically arranged below the base (13) of the guide module device.

8. A method for in-situ detection and tracing of defects in the sealing ring of a water turbine runner, characterized in that, The tracking device for a wall-climbing robot for in-situ detection of defects in the sealing ring of a water turbine runner, as described in any one of claims 1-7, includes the following steps: S1. Adjust the guide column spacing adjustment mechanism to adjust the spacing between the two guide columns (11); S2. Control the magnetic adsorption crawler (1) to move to the vicinity of the leak-stop ring, perform coarse positioning through the visual positioning module, and adjust the XR adjustment mechanism to align the guide column (11) with the gap of the leak-stop ring. S3. Control the guide post insertion mechanism to push the guide post (11) into the leak-stopping ring gap; S4. Control the magnetic adsorption crawler (1) to crawl along the gap of the leak-proof ring. During the crawling process, adjust the movement of the magnetic adsorption crawler (1) according to the feedback signal of the triaxial force sensor (18).

9. The method for in-situ detection and tracing of defects in the turbine runner sealing ring according to claim 8, characterized in that, In step S1, the corresponding chord length is calculated based on the diameter of the leak-proof ring to be tested, and the spacing between the two guide posts (11) is adjusted to the calculated chord length value through the guide post spacing adjustment mechanism.

10. The method for in-situ detection and tracing of defects in the turbine runner sealing ring according to claim 8, characterized in that, In step S4, when the magnetic adsorption crawler (1) crawls, the guide post (11) contacts the side wall of the gap between the leak-proof ring and the triaxial force sensor (18) collects the lateral force on the guide post (11) in real time and dynamically adjusts the direction of travel of the magnetic adsorption crawler (1) according to the change of the lateral force.

11. The method for in-situ detection and tracing of defects in the turbine runner leak-proof ring according to claim 8, characterized in that, This method is applicable to the detection of the upper and lower sealing rings. When the upper sealing ring is detected, the magnetic adsorption crawler (1) is lifted to the top cover of the turbine by the lifting mechanism. When the lower sealing ring is detected, the magnetic adsorption crawler (1) operates on the bottom ring surface near the movable guide vane.

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