Integrated Fillet Welding Device and Method for Wall-Climbing Robots of Large Pressure Equipment

Abstract

This invention discloses an integrated operation device and method for fillet weld seams of large pressure equipment using a wall-climbing robot. The device includes a wall-climbing robot and an automatic tracking platform. The wall-climbing robot comprises a magnetically adsorbed wall-climbing body and a grinding robotic arm, a magnetic particle inspection robotic arm, and a magnetic suspension supply mechanism. The magnetic particle inspection robotic arm is equipped with a three-pole three-dimensional combined magnetic yoke and a visual inspection mechanism. The three magnetic poles are triangularly distributed, and the winding method involves the same current being divided into two equal paths: one path is full-wave rectified, and the other is AC current. Within one AC current cycle, longitudinal and circumferential magnetization are alternately generated. This invention employs a three-pole right-angled isosceles triangular combined magnetic yoke structure and utilizes AC / DC composite magnetization to achieve rapid alternation between longitudinal and circumferential magnetization, ensuring the detection of defects in different directions. This invention achieves integrated operation of grinding, inspection, repair, and re-inspection of the inner and outer surfaces of fillet weld seams in large pressure equipment pipes, significantly improving inspection efficiency and safety.

Description

Technical Field

[0001] This invention relates to the technical field of safety inspection of special equipment, and in particular to an integrated operation device and method for corner weld seams of wall-climbing robots for large pressure equipment. Background Technology

[0002] Large pressure equipment is prone to various defects during use, thus requiring comprehensive and regular inspections. Taking large spherical tanks as an example, according to relevant Chinese regulations, they must be inspected every 3-6 years. Before inspection, the tank must be shut down, toxic gases and liquids replaced, and scaffolding erected inside and outside the tank. Maintenance personnel then climb the scaffolding to carry inspection equipment. For instance, when using widely adopted magnetic particle inspection technology for surface or near-surface inspection, a suitable magnetic suspension solution must be sprayed, and the equipment must be handheld for inspection, with defects observed and identified using the naked eye and a black light. Currently, for the maintenance of large pressure equipment, wall-climbing robots are available that can perform magnetic particle inspection on surface defects. If all magnetic particle inspections are satisfactory, fully automated robotic operation and inspection can be achieved, eliminating the need for scaffolding, significantly reducing operating time and costs, and ensuring personnel safety during the operation.

[0003] Prior to this invention, domestic inventions had addressed the grinding and magnetic particle inspection of butt welds without obstacles. Currently, wall-climbing robots exist in China capable of grinding and magnetic particle inspection of inner surface defects in butt welds without obstacles. However, existing robots have the following technical problems during inspection: They can only inspect butt welds without obstacles; they cannot inspect butt welds on inner and outer surfaces, or those near obstacles (such as spray pipes). Furthermore, for fillet welds on large pressure equipment, magnetic particle inspection of inner and outer surfaces is... This process is still necessary, so inspections still require scaffolding to be erected, and workers climbing the scaffolding to manually grind the welds before re-inspection. This renders the previously omitted scaffolding step meaningless, making it difficult to significantly reduce working time and costs while ensuring personal safety during the operation. Furthermore, for some large pressure equipment pipe fillet welds, magnetic particle testing often detects surface defects on both the inner and outer surfaces. This leads to the problem that even after discovering surface defects, manual weld repair is still required, necessitating scaffolding to be erected, and workers climbing the scaffolding to manually grind the defects before re-inspection. Therefore, to achieve automation in the field of pressure equipment safety assurance, create a completely new operating model, and change the industry's long-standing reliance on manual labor, it is essential to solve the problem of completing the integrated operation of grinding, magnetic particle testing, defect repair, and re-inspection of the inner and outer surfaces of large pressure equipment pipe fillet welds without entering the tank. Summary of the Invention

[0004] The purpose of this invention is to solve the problems in the prior art and to propose an integrated operation device and method for fillet welds of large pressure equipment using a wall-climbing robot. By using a wall-climbing robot equipped with a grinding robotic arm and a magnetic particle inspection robotic arm, and setting a three-yoke right-angled triangle composite magnetization device at the front end of the magnetic particle inspection robotic arm, the integrated operation of grinding, inspection, repair and re-inspection of the inner and outer surfaces of fillet welds of large pressure equipment pipes can be realized. There is no need to build scaffolding or enter the tank, thus improving inspection efficiency and safety.

[0005] To achieve the above objectives, this invention proposes an integrated wall-climbing robot for large pressure equipment, comprising a wall-climbing robot and an automatic tracking gimbal. The automatic tracking gimbal is used to monitor the walking and working posture of the wall-climbing robot in real time and transmit signals to an external operating platform. The wall-climbing robot includes a magnetically adsorbed wall-climbing vehicle body that is magnetically attached to the inner and outer walls of the pressure equipment and can move along the wall surface, and a grinding robotic arm, a magnetic particle inspection robotic arm, and a magnetic suspension liquid supply mechanism mounted on the magnetically adsorbed wall-climbing vehicle body. The magnetically adsorbed wall-climbing vehicle body is equipped with nozzles that cooperate with the magnetic suspension liquid supply mechanism to spray magnetic suspension liquid onto the surface of the pressure equipment. The magnetic particle inspection robotic arm is equipped with a three-dimensional combined magnetic yoke for applying an AC / DC composite magnetization field to the area to be inspected and a visual inspection mechanism. The three-dimensional combined magnetic yoke is a three-pole iron core structure, including three triangularly distributed magnetic poles A, B, and C. Magnetic poles A, B, and C form a detection position for the pressure equipment to enter through the pipe. The winding method of magnetic poles A, B, and C is such that the same current is divided into two paths: one is unidirectional full-wave rectified, and the other is alternating current. Both have the same peak value and frequency. The two paths are connected to different magnetic poles, so that longitudinal magnetization and circumferential magnetization are alternately generated within one alternating current cycle.

[0006] Preferably, the automatic tracking gimbal has a built-in high-resolution camera and an infrared positioning module, and the wall-climbing robot is equipped with an infrared light source target that works in conjunction with the infrared positioning module.

[0007] Preferably, the visual inspection mechanism includes a black light, a video inspection system, and a white light, with the black light and the video inspection system installed at the lower front end of the three-dimensional combined magnetic yoke.

[0008] Preferably, the magnetic poles A, B, and C are arranged in a right-angled isosceles triangle. The magnetic poles B and C overlap on one side near the fillet weld, and the magnetic pole A is arranged on the other side, forming a triangular arrangement that tapers towards the center of the pressure equipment nozzle. The magnetic poles A, B, and C form a detection position for the pressure equipment nozzle to enter, and the opening of the detection position is located between the magnetic poles B and C.

[0009] Preferably, the magnetic flux area of ​​magnetic pole B is equal to that of magnetic pole C, and the effective magnetic flux area of ​​magnetic pole A is twice that of magnetic pole B or magnetic pole C.

[0010] As a preferred option, one of the two current paths is rectified by a full-wave current and supplied to magnetic poles A and B, so that magnetic pole A is always the S pole and magnetic pole B is always the N pole; the other path is directly supplied to magnetic poles A and C, with magnetic pole C connected to AC current.

[0011] Preferably, the grinding robotic arm includes a grinding component, a forward and backward moving component for driving the grinding component to move forward and backward, and a left and right moving component for driving the grinding component to move left and right. The grinding component includes a grinding motor, a grinding head connected to the driving shaft of the grinding motor via a chuck, and a movable lifting plate. The grinding motor is fixed on the movable lifting plate, and the movable lifting plate is connected to the left and right moving component or the forward and backward moving component via the lifting motor. A laser automatic navigator is provided next to the grinding head.

[0012] Preferably, the movable lifting plate is also provided with a suspension spring system, which is fixedly installed on the movable lifting plate and its lower end passes through the movable lifting plate and is connected to the grinding motor to provide downward pressure for the grinding head.

[0013] Preferably, the grinding head includes a flat grinding head for grinding flat surfaces, an arc grinding head for grinding arc surfaces, and a pit grinding head for grinding pits.

[0014] Another object of the present invention is to provide a method for operating the integrated fillet weld work device for climbing walls of large pressure equipment as described in any of the above-mentioned claims, comprising the following steps:

[0015] Step S1: Verify the sensitivity of the magnetic particle inspection robot arm on a simulated pipe fillet weld test block to determine the effective length L of a single inspection.

[0016] Step S2: The wall-climbing robot travels to the vicinity of the fillet weld of the pipe and positions itself. The grinding robot arm extends to grind the weld and heat-affected zone to meet the inspection requirements.

[0017] Step S3: After polishing is completed, retract the polishing robotic arm and extend the magnetic particle detection robotic arm to perform magnetic particle detection.

[0018] Step S4: If a defect is found, determine whether the grinding head on the grinding robot arm meets the grinding requirements based on the depth of the defect. If it does, grind directly. If it does not, move the wall-climbing robot to the lower manhole position and replace the grinding head on the grinding robot arm with a special defect-eliminating grinding head.

[0019] In step S5, the wall-climbing robot moves back to the defect location and manipulates the special defect-removing grinding head to perform local defect removal and grinding.

[0020] The beneficial effects of the present invention, a wall-climbing robot integrated fillet weld operation device and method for large pressure equipment, are as follows:

[0021] 1. This invention enables integrated operation of grinding, magnetic particle testing, defect repair and re-exploration of the inner and outer surfaces of fillet welds of large pressure equipment pipes without scaffolding or entering the tank, thus improving work efficiency.

[0022] 2. Based on the principle of three points determining a plane, this invention adopts a three-dimensional structure with three magnetic poles to ensure that the magnetic poles are in close contact with the container wall.

[0023] 3. Compared to the shape and structure of the fillet weld of the pipe seat, the combined magnetic yoke core is not a typical square but a right-angled isosceles triangle that contracts towards the center of the pipe, so that it can achieve a better magnetization effect in the middle section of the weld; the hypotenuse has an inward concave structure, which can get closer to the pipe.

[0024] 4. This invention adopts a three-dimensional structure of combined magnetic yoke iron core. By utilizing the spatial arrangement of three magnetic poles and different current states, longitudinal magnetization and circumferential magnetization are achieved simultaneously through instantaneously changing magnetic poles. This enables rapid switching between longitudinal and circumferential magnetization, which is equivalent to two magnetic circuits acting simultaneously, forming a superposition of magnetic fields to ensure the magnetization effect.

[0025] 5. By designing the optimal arc surface structure for the fillet weld stress state (minimum stress concentration) through stress analysis, a custom grinding head is used to ensure that the shape of the weld after grinding matches the optimal arc surface structure, thereby removing defects and reducing stress concentration in the fillet weld.

[0026] 6. This invention enables operators to inspect uneven areas (such as inner and outer fillet welds, and butt welds near spray pipes) without having to get close to the inspection site or areas inaccessible to the robot body. It utilizes a flexible and mobile robotic arm to reach these areas, eliminating the need for scaffolding and climbing. This allows for better completion of tasks involving fillet welds on large pressure equipment pipes and other areas difficult for conventional robots to access.

[0027] The features and advantages of the present invention will be described in detail through embodiments and in conjunction with the accompanying drawings. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the working state of the integrated fillet weld operation device for climbing walls of large pressure equipment of the present invention;

[0029] Figure 2 This is a three-dimensional view of the overall structure of the wall-climbing robot of the present invention;

[0030] Figure 3 This is a schematic diagram of the structure of the grinding robotic arm of the present invention;

[0031] Figure 4 This is a logic block diagram of the constant force grinding control system of the present invention;

[0032] Figure 5 This is a diagram illustrating the grinding process under three different working conditions for defect elimination in this invention.

[0033] Figure 6 This is a schematic diagram of the structure of the magnetic particle inspection robotic arm of the present invention;

[0034] Figure 7 This is a schematic diagram of the three-dimensional combined magnetic yoke of the present invention;

[0035] Figure 8 This is a schematic diagram of the winding principle of the three-dimensional combined magnetic yoke of the present invention;

[0036] Figure 9 This is a schematic diagram of the longitudinal magnetization magnetic field distribution during the positive half-cycle of alternating current.

[0037] Figure 10 This is a schematic diagram of the circumferential magnetization magnetic field distribution during the negative half-cycle of alternating current.

[0038] In the diagram: 1. Wall-climbing robot; 1-1. Magnetic wall-climbing vehicle body; 1-2. Grinding robotic arm; 1-3. Control box; 1-4. Safety rope suspension device; 1-5. Power supply box; 1-6. Magnetic particle inspection robotic arm; 1-7. Magnetic suspension tank; 1-2-1. Grinding motor; 1-2-2. Grinding head; 1-2-3. Laser automatic navigator; 1-2-4. Moving lifting plate; 1-2-5. Pressure sensor; 1-2-6. Suspension spring system; 1-2-7. Grinding lifting motor; 1-2-8. Fixed mounting plate; 1-2-9. Left and right movement drive motor; 1-2-10. Left and right movement slide; 1-2-11. Left and right movement slide mounting block; 1-2-12. First stiffener; 1-2-13. Motor mounting plate. 1. Mounting block; 1-2-14. Front and rear moving slide; 1-2-15. Front and rear moving slide mounting block; 1-2-16. Front and rear moving drive motor; 1-6-1. Nozzle; 1-6-2. Three-dimensional combined magnetic yoke; 1-6-3. Black light; 1-6-4. Video detection system; 1-6-5. White light; 1-6-6. First mounting block; 1-6-7. Mounting plate; 1-6-8. Second stiffening plate; 1-6-9. Second mounting block; 1-6-10. Waterproof light shield; Magnetic pole A, 1-6-2-1; Magnetic pole B, 1-6-2-2; Magnetic pole C, 1-6-2-3; 2. Safety rope device; 3. Automatic tracking pan-tilt unit; 4. Wireless signal repeater; 5. Pan-tilt unit frame; 6. External operating console; 7. Large pressure-bearing equipment. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0040] In the description of this invention, it should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to or indirectly connected to the other element.

[0041] In the description of this invention, it should be noted that the terms "center," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use. They are used only for the convenience of describing the 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 the invention. Furthermore, the terms "first," "second," and "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. "Several" means one or more, unless otherwise explicitly specified.

[0042] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" 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 connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0043] Example 1:

[0044] See Figure 1This invention provides an integrated working device for corner welds of wall-climbing robots in large pressure equipment, including a wall-climbing robot 1, a safety rope device 2, an automatic tracking gimbal 3, a wireless signal repeater 4, a gimbal frame 5, and an external operating platform 6. It is used for integrated operations of grinding, magnetic particle inspection, defect repair and re-inspection of the inner and outer surfaces of the corner welds of the pipes in large pressure equipment 7 (taking a spherical tank as an example in this embodiment).

[0045] When the wall-climbing robot 1 operates inside the spherical tank, its top is connected to the connecting flange via a safety rope device 2. The safety rope device 2 uses a flexible steel wire rope and a spring buffer to prevent the robot from accidentally falling. An automatic tracking gimbal 3 is fixedly installed at the bottom of the spherical tank via a gimbal frame 5. The automatic tracking gimbal 3 has a built-in high-resolution camera and infrared positioning module for real-time monitoring of the wall-climbing robot 1's walking and working posture, and transmits the video signal to an external control console 6 via a transmission cable. The external control console 6 includes a display screen, a control handle, and an industrial computer. It sends motion commands to the control box 1-3 on the wall-climbing robot 1 via a wireless signal repeater 4, enabling remote control.

[0046] like Figure 2 As shown, the magnetically attached wall-climbing robot 1's body 1-1 includes a drive wheel, a driven wheel, a drive shaft mounting component, and a DC servo drive motor. Infrared light source targets are positioned at opposite locations on both sides of the magnetically attached wall-climbing body 1-1 to facilitate the automatic tracking gimbal 3 in identifying the robot's position.

[0047] A control box 1-3, a power supply box 1-5, and a magnetic suspension supply mechanism are fixedly installed on the top of the magnetic adsorption climbing vehicle body 1-1. In this embodiment, the magnetic suspension supply mechanism is a magnetic suspension tank 1-7. The control box 1-3 controls the entire detection operation and can control operations such as magnetization, magnetic suspension spraying, and movement of the magnetic adsorption climbing vehicle body. The power supply box 1-5 is a lithium battery pack that powers the entire vehicle. The magnetic suspension tank 1-7 is a sealed pressure tank containing magnetic suspension (fluorescent magnetic powder and water-based carrier liquid mixed in proportion). The bottom of the tank is equipped with a stirring motor and a pressure pump. The outlet is connected to the nozzle 1-6-1 at the front end of the magnetic powder detection robotic arm 1-6 through a solenoid valve and a pipeline.

[0048] A grinding robotic arm 1-2 is installed on the left side of the magnetic adsorption wall-climbing vehicle body 1-1, and a magnetic particle inspection robotic arm 1-6 is installed on the right side. The magnetic adsorption wall-climbing vehicle body 1-1 is equipped with a safety rope suspension device 1-4.

[0049] Example 2:

[0050] like Figure 3 As shown, the grinding robotic arm 1-2 consists of a forward and backward movement component, a left and right movement component, and a grinding component.

[0051] The forward and backward moving assembly includes a forward and backward moving slide mounting block 1-2-15, a forward and backward moving slide 1-2-14, and a forward and backward moving drive motor 1-2-16. The slide uses a precision ball screw guide rail, and the drive motor is a stepper motor with a maximum stroke of 100mm. The left and right moving assembly includes a left and right moving slide mounting block 1-2-11, a left and right moving slide 1-2-10, a left and right moving drive motor 1-2-9, a motor mounting block 1-2-13, and a first stiffening plate 1-2-12, with a maximum stroke of 80mm. The forward and backward moving slide mounting block 1-2-15 is fixed to the magnetic adsorption climbing vehicle body 1-1 by bolts.

[0052] The grinding assembly is mounted on the slider of the left and right moving slides 1-2-10 and includes a constant force device, a laser automatic navigator 1-2-3, a grinding motor 1-2-1, and a grinding head 1-2-2. The constant force device consists of a fixed mounting plate 1-2-8, a grinding lifting motor 1-2-7, a suspension spring system 1-2-6, a pressure sensor 1-2-5, and a moving lifting plate 1-2-4. The fixed mounting plate 1-2-8 is fixedly connected to the left and right moving slides 1-2-10. The grinding lifting motor 1-2-7 (a linear stepper motor) drives the moving lifting plate 1-2-4 to move up and down, with a maximum lifting stroke of 40mm. The suspension spring system 1-2-6 is mounted on the moving lifting plate 1-2-4, with its upper end extending above the moving lifting plate 1-2-4 and its lower end penetrating through the moving lifting plate 1-2-4 and connecting to the grinding motor 1-2-1, thereby providing downward pressure to the grinding motor 1-2-1 and the grinding head 1-2-2. Specifically, the suspension spring system 1-2-6 includes a lifting mechanism, a compression spring, and a guide rod, used to transmit downward pressure and buffer impact. The pressure sensor 1-2-5 (piezoresistive type) is installed between the grinding motor 1-2-1 and the suspension spring system 1-2-6 to detect the grinding downward pressure in real time.

[0053] The grinding motor 1-2-1 is fixed to the lower end face of the movable lifting plate 1-2-4, and the grinding head 1-2-2 is mounted on its output shaft. The laser automatic navigator 1-2-3 is fixed to the movable lifting plate 1-2-4, and emits a laser beam to irradiate the weld surface in front of the grinding head to measure the distance.

[0054] The logic of the constant force grinding control system is as follows: Figure 4As shown. The main control center (located inside control box 1-3) receives pressure signals from pressure sensor 1-2-5 and distance signals from laser auto-navigator 1-2-3. The grinding force monitoring unit compares the force signal with a preset force value; the deviation is adjusted via a PID controller to the lifting mechanism in the suspension spring system 1-2-6, thereby adjusting the spring compression and downward pressure. The grinding position monitoring unit compares the distance signal with a preset grinding allowance (e.g., 0.2mm); the deviation is also adjusted via a PID controller to regulate the grinding lifting motor 1-2-7, ensuring that the grinding head 1-2-2 always maintains a set allowance close to the wall surface. The two PID loops employ a two-degree-of-freedom control strategy, operating independently to achieve dual closed-loop control of force and position. The main control center also includes an adaptive calculation module that automatically adjusts the PID parameters based on real-time deviations to adapt to changes in wall curvature and hardness.

[0055] The grinding lifting motor 1-2-7 drives the movable lifting plate 1-2-4 to descend, bringing the grinding head 1-2-2 close to the workpiece surface and reaching a set height (at this point, the suspension spring system 1-2-6 may be in a natural or slightly pre-compressed state). When the grinding head 1-2-2 contacts the workpiece and continues to press down slightly, the workpiece exerts an upward reaction force on the grinding head 1-2-2. This reaction force is transmitted to the suspension spring system 1-2-6, compressing the springs to absorb the impact and provide flexible grinding pressure. The pressure sensor 1-2-5 receives the pressure signal and transmits it to the central control center (located in the control box 1-3). At this time, the grinding lifting motor 1-2-7 maintains its current extension length (locked or fine-tuned), and the "average distance" between the two plates is maintained by the motor, but the slight deformation of the springs allows the movable lifting plate 1-2-4 to float slightly around this average position.

[0056] During the grinding process, the forward and backward moving components and the left and right moving components drive the grinding head 1-2-2 to reciprocate along the weld direction according to the planned path. At the same time, the lifting mechanism in the grinding lifting motor 1-2-7 or the suspension spring system 1-2-6 is dynamically adjusted according to feedback until the surface roughness of the entire grinding area meets the magnetic particle testing requirements (Ra≤3.2μm) and the grinding depth reaches the preset allowance. At this time, the grinding is terminated.

[0057] In this embodiment, the grinding heads are divided into three categories: flat grinding heads, curved grinding heads, and pit grinding heads. Specifically, as shown... Figure 5As shown, the following three working conditions are applied according to the defect depth: Condition 1: When the defect depth is shallow, a flat grinding head is used to remove the defect. Grinding is performed at a uniform speed along the weld length, removing only the surface defect layer. After grinding, the weld surface has a planar structure. Condition 2: When the defect depth is large, an arc-shaped grinding head is used to ensure that the weld shape after grinding matches the optimal arc structure, ensuring that the defect is completely removed while the weld transition zone is smooth and the stress concentration factor is minimized. Condition 3: If the defect depth cannot be removed using an arc-shaped grinding head, a pit grinding head is used to grind a local pit at the defect location. The pit depth and width are determined according to the actual size of the defect. After grinding, the dimensionless parameter G is used for evaluation. Only when the G value does not exceed the allowable range is the pit considered acceptable; otherwise, other repair measures such as welding must be adopted.

[0058] Example 3:

[0059] like Figure 6 As shown, the magnetic particle inspection robotic arm 1-6 includes a nozzle 1-6-1, a three-dimensional combined magnetic yoke 1-6-2, a black light 1-6-3, a video inspection system 1-6-4, a white light 1-6-5, a first mounting block 1-6-6, a mounting plate 1-6-7, a second stiffening plate 1-6-8, and a second mounting block 1-6-9. The mounting plate 1-6-7 is connected to the robotic arm joint on the side of the wall-climbing robot 1 via the first mounting block 1-6-6 and the second mounting block 1-6-9. Through the robotic arm, the magnetic particle inspection device can approach the fillet weld, and the second stiffening plate 1-6-8 enhances rigidity.

[0060] The three-dimensional combined magnetic yoke 1-6-2 has a three-pole iron core structure, such as... Figure 7 As shown, the three iron cores are labeled as magnetic poles A1-6-2-1, B1-6-2-2, and C1-6-2-3 (hereinafter referred to as magnetic poles A, B, and C, or A, B, C). The three magnetic poles are fixed together by a bracket, with B and C overlapping on one side near the fillet weld, and A positioned on the other side, forming a triangle to concentrate the magnetic lines of force through the fillet weld area. The center distance between B and C is 200mm. The cross-sectional areas of magnetic poles B1-6-2-2 and C1-6-2-3 are 10×10, and the cross-sectional area of ​​magnetic pole A is 14×14. The area within 25mm of the magnetic poles is considered an invalid region; therefore, the effective magnetization range of the weld is 100mm, which meets the magnetization range specified in the standard.

[0061] Winding method as follows Figure 8 As shown. The same AC power supply is split into two paths after being isolated by a transformer: one path is rectified by a full-wave rectifier and supplies coils A and B, so that pole A is always the S pole and pole B is always the N pole; the other path directly supplies coils A and C (note that pole A is connected to both the rectifier and AC), and pole C is connected to AC. The peak value and frequency of the two currents are the same.

[0062] When the alternating current is in the positive half-cycle, C is the N pole (relative to A), and A is the S pole, B is the N pole, and C is the N pole. Therefore, the two pairs of magnetic yokes AB and AC act simultaneously, forming two magnetic fields in the weld area, whose resultant direction is perpendicular to the weld (longitudinal magnetization), as shown below. Figure 9 As shown. During the negative half-cycle of the alternating current, A is the source and north pole, B is the north pole, and C is the source pole, thus forming two pairs of magnetic yokes, A and B, and A and C. The magnetic fields formed by these two pairs of magnetic yokes in the weld area of ​​the workpiece overlap. According to the principle of vector superposition, their combined magnetic field is a circumferential magnetic field that is basically parallel to the weld, as shown. Figure 10 As shown. Therefore, longitudinal magnetization and circumferential magnetization are achieved respectively within one AC cycle (0.2 seconds at power frequency). During the application time of the magnetic suspension, there are dozens of alternating longitudinal and circumferential magnetizations, ensuring that defects in different directions are detected simultaneously.

[0063] The magnetic suspension is sprayed through nozzle 1-6-1, whose spraying time and flow rate are controlled by a solenoid valve. A black light 1-6-3 and a video detection system 1-6-4 are installed at the lower front end of the three-dimensional combined magnetic yoke 1-6-2, forming a certain intersection angle to enhance the visibility of the defect fluorescence display. A white light 1-6-5 is used for illumination assistance. Video images are transmitted in real time to an external control panel, allowing operators to observe the magnetic trace display and determine defects.

[0064] The visual inspection mechanism also includes a waterproof light shield 1-6-10 covering the black light 1-6-3, the video inspection system 1-6-4, and the white light 1-6-5. This shield provides waterproofing and light protection, preventing interference with the operation of the visual inspection mechanism and also preventing damage from impacts, thus providing a certain degree of protection.

[0065] Example 4:

[0066] This embodiment proposes a method for operating a wall-climbing robot corner weld integrated operation device for large pressure equipment as described in any of the above embodiments:

[0067] S1. Preparation: In the laboratory, use a simulated test block with the same material and welding process as the equipment under test, adjust the magnetization current, magnetic suspension concentration and spraying time, verify the detection sensitivity with a standard test piece, and determine the effective coverage length L of a single magnetization test.

[0068] S2. Send the wall-climbing robot 1 into the spherical tank through the manhole, connect the safety rope, activate the automatic tracking gimbal 3, and establish wireless communication. The operator starts the wall-climbing robot 1 on the external control panel 6, allowing it to move along the tank wall to the vicinity of the weld seam of the connecting pipe, and accurately locate the center line of the weld seam using the laser automatic navigator 1-2-3 on the grinding robotic arm 1-2.

[0069] S3. Extend the grinding robotic arm 1-2 so that the grinding head 1-2-2 contacts the weld surface. Activate the constant force grinding control system and grind along a preset path (segmented along the weld circumference, each segment no longer than 100mm), covering the weld and the heat-affected zones on both sides. Monitor the grinding force and distance in real time during the grinding process until the surface roughness and allowance meet the standards. After grinding is complete, retract the grinding robotic arm 1-2.

[0070] S4. Extend the magnetic particle inspection robotic arm 1-6 and place the three-dimensional combined magnetic yoke 1-6-2 in the polishing area, with the magnetic end face pressed against the wall. Start the magnetization program through the control box, and simultaneously open the magnetic suspension solenoid valve to spray the magnetic suspension for 2-3 seconds, during which the magnetic yoke completes dozens of alternating longitudinal / circumferential magnetizations. After spraying, turn off the magnetization, turn on the black light and camera, collect magnetic trace images, and upload them.

[0071] S5. The operator observes the image. If magnetic traces (defects such as cracks or porosity) are found, the operator uses the scale of the video inspection system to measure the coordinate position of the defect on the weld. The defect information is recorded.

[0072] S6. Move the wall-climbing robot 1 to the vicinity of the lower manhole (within the reach of the safety rope), and the operator opens the manhole cover and manually replaces the flat grinding head at the front end of the grinding robotic arm 1-2 with an arc-shaped grinding head.

[0073] S7. The wall-climbing robot 1 returns to the defect location. After precise positioning, it extends the grinding robotic arm 1-2 and uses spot grinding to locally remove the defect.

[0074] S8. After the defect elimination is completed, extend the magnetic particle inspection robot arm 1-6 again to perform magnetic particle re-inspection on the repair area to confirm that there are no new defects and the original defects have been completely eliminated.

[0075] S9. After the re-inspection is deemed satisfactory, retract all robotic arms, shut down the equipment, and allow the robot to move along the wall to the manhole for manual removal. Operation complete.

[0076] Example 5:

[0077] The automatic tracking gimbal 3, equipped with an automatic zoom lens and an infrared rangefinder, can lock onto the light source target on the wall-climbing robot 1 via magnetic adhesion, enabling real-time tracking of the robot's posture and transmitting coordinate data to an external control panel. The external control panel can then plan the walking path and avoid obstacles. The wireless signal repeater 4 is installed on the bracket inside the tank to enhance signal transmission stability.

[0078] All standard parts used in this application can be purchased from the market. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the existing technology. The internal components of the electric slide rail, cylinder, welding machine, electric telescopic rod and controller all adopt conventional models in the existing technology, and their internal structure belongs to the existing technology structure. Workers can complete the normal operation of them according to the existing technical manual. In addition, the circuit connection adopts the conventional connection method in the existing technology, and will not be described in detail here.

[0079] It should be noted that although the above embodiments have been described herein, this does not limit the scope of patent protection for this invention. Therefore, any changes and modifications made to the embodiments described herein based on the innovative concept of this invention, or equivalent structural or procedural transformations made using the description and drawings of this invention, directly or indirectly applying the above technical solutions to other related technical fields, are all included within the scope of protection of this invention.

Claims

1. A wall-climbing robot integrated fillet weld operation device for large pressure equipment, comprising a wall-climbing robot (1), characterized in that: The wall-climbing robot (1) includes a magnetically adsorbed wall-climbing vehicle (1-1) that is magnetically adsorbed onto the inner and outer walls of the pressure-bearing equipment and can move along the wall surface, and a grinding robotic arm (1-2), a magnetic powder detection robotic arm (1-6), and a magnetic suspension liquid supply mechanism provided on the magnetically adsorbed wall-climbing vehicle (1-1). The magnetically adsorbed wall-climbing vehicle (1-1) is provided with a nozzle (1-6-1) that cooperates with the magnetic suspension liquid supply mechanism to spray the magnetic suspension liquid onto the surface of the pressure-bearing equipment. The magnetic powder detection robotic arm (1-6) is provided with a three-dimensional combined magnetic yoke (1-6-2) for applying an AC / DC composite magnetization field to the area to be detected and a vision detection mechanism. The three-dimensional combined magnetic yoke (1-6-2) is a three-pole iron core structure, including three triangularly distributed magnetic poles A (1-6-2-1), B (1-6-2-2), and C (1-6-2-3). The magnetic poles A (1-6-2-1), B (1-6-2-2), and C (1-6-2-3) form a detection position for the pressure equipment pipe to enter, allowing the three-dimensional combined magnetic yoke (1-6-2) to straddle both sides of the pipe to magnetize the fillet weld of the connecting pipe. The winding method of the magnetic poles A (1-6-2-1), B (1-6-2-2), and C (1-6-2-3) is such that the same current is divided into two paths, one is unidirectional full-wave rectified, and the other is alternating current. The peak values ​​and frequencies of the two paths are the same, and the two paths are connected to different magnetic poles, so that longitudinal magnetization and circumferential magnetization are alternately generated within one alternating current cycle.

2. The integrated corner weld operation device for climbing walls of large pressure equipment as described in claim 1, characterized in that: It also includes an automatic tracking gimbal (3), which is used to monitor the walking and working posture of the wall-climbing robot (1) in real time and transmit the signal to the external operating console (6). The automatic tracking gimbal (3) has a built-in high-resolution camera and an infrared positioning module. The wall-climbing robot (1) is equipped with an infrared light source target that works in conjunction with the infrared positioning module.

3. The integrated fillet weld operation device for wall-climbing robots of large pressure equipment as described in claim 1, characterized in that: The visual inspection mechanism includes a black light (1-6-3), a video inspection system (1-6-4), and a white light (1-6-5). The black light (1-6-3) and the video inspection system (1-6-4) are installed at the lower front end of the three-dimensional combined magnetic yoke (1-6-2).

4. The integrated corner weld operation device for climbing walls of large pressure equipment as described in claim 1, characterized in that: The magnetic poles A (1-6-2-1), B (1-6-2-2), and C (1-6-2-3) are arranged in a right-angled equilateral triangle. The magnetic poles B (1-6-2-2) and C (1-6-2-3) overlap on one side near the fillet weld, and the magnetic pole A (1-6-2-1) is arranged on the other side, forming a triangular arrangement that tapers towards the center of the pressure equipment pipe. The magnetic poles A (1-6-2-1), B (1-6-2-2), and C (1-6-2-3) together form a detection position for the pressure equipment pipe to enter, and the opening of the detection position is located between the magnetic poles B (1-6-2-2) and C (1-6-2-3).

5. The integrated fillet weld operation device for wall-climbing robots of large pressure equipment as described in claim 4, characterized in that: The magnetic flux area of ​​magnetic pole B (1-6-2-2) is equal to that of magnetic pole C (1-6-2-3), and the effective magnetic flux area of ​​magnetic pole A (1-6-2-1) is twice that of magnetic pole B (1-6-2-2) or magnetic pole C (1-6-2-3).

6. The integrated corner weld operation device for climbing walls of large pressure equipment as described in claim 1, characterized in that: One of the two currents is rectified by a full-wave rectifier and supplied to magnetic poles A (1-6-2-1) and B (1-6-2-2), so that magnetic pole A (1-6-2-1) is always the S pole and magnetic pole B (1-6-2-2) is always the N pole; the other current is directly supplied to magnetic poles A (1-6-2-1) and C (1-6-2-3), and magnetic pole C (1-6-2-3) is connected to AC power.

7. The integrated fillet weld operation device for wall-climbing robots of large pressure equipment as described in claim 1, characterized in that: The grinding robotic arm (1-2) includes a grinding component, a forward and backward moving component for driving the grinding component to move forward and backward, and a left and right moving component for driving the grinding component to move left and right. The grinding component includes a grinding motor (1-2-1), a grinding head (1-2-2) connected to the drive shaft of the grinding motor (1-2-1) via a chuck, and a movable lifting plate (1-2-4). The grinding motor (1-2-1) is fixed on the movable lifting plate (1-2-4). The movable lifting plate (1-2-4) is connected to the left and right moving component or the forward and backward moving component via a grinding lifting motor (1-2-7). A laser automatic navigator (1-2-3) is provided next to the grinding head (1-2-2).

8. The integrated fillet weld operation device for wall-climbing robots of large pressure equipment as described in claim 7, characterized in that: The movable lifting plate (1-2-4) is also equipped with a suspension spring system (1-2-6). The suspension spring system (1-2-6) is fixedly installed on the movable lifting plate (1-2-4), and its lower end passes through the movable lifting plate (1-2-4) and is connected to the grinding motor (1-2-1) to provide downward pressure to the grinding head. A pressure sensor (1-2-5) is provided between the grinding motor (1-2-1) and the suspension spring system (1-2-6).

9. The integrated fillet weld operation device for wall-climbing robots of large pressure equipment as described in claim 7, characterized in that: The grinding head (1-2-2) includes a flat grinding head for grinding flat surfaces, an arc grinding head for grinding arc surfaces, and a pit grinding head for grinding pits.

10. A method for operating a wall-climbing robot with integrated fillet weld seam working device for large pressure equipment as described in any one of claims 1-9, characterized in that, Includes the following steps: Step S1: Verify the sensitivity of the magnetic particle inspection robot arm (1-6) on the simulated pipe fillet weld test block to determine the effective length L of one inspection. Step S2: The wall-climbing robot (1) travels to the vicinity of the fillet weld of the pipe and positions itself. The grinding robot arm (1-2) extends to grind the weld and heat-affected zone to meet the inspection requirements. Step S3: After polishing is completed, retract the polishing robotic arm (1-2) and extend the magnetic particle detection robotic arm (1-6) to perform magnetic particle detection; Step S4: If a defect is found, determine whether the grinding head on the grinding robot arm (1-2) meets the grinding requirements based on the depth of the defect. If it meets the requirements, grind directly. If it does not meet the requirements, move the wall-climbing robot (1) to the lower manhole position and replace the grinding head on the grinding robot arm (1-2) with a special defect-eliminating grinding head. Step S5, the wall-climbing robot (1) walks to the defect location again and operates the special defect-eliminating grinding head to perform local defect elimination and grinding.

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