Intelligent threading robot for pre-stressed tendon in micro-tube and canopy bundle structure

Abstract

The application discloses a micro-tube curtain bundle structure inner pre-stressed tendon intelligent threading robot, and relates to the technical field of robots, and the technical scheme points comprise the following: the mobile chassis moves along the axial direction of the rectangular steel pipe joint; the lifting support seat is arranged on the mobile chassis, and the lifting support seat is used for adjusting the spatial pose of the multi-degree-of-freedom mechanical arm; the multi-degree-of-freedom mechanical arm is installed on the lifting support seat, and a clamping chuck device is arranged at the tail end of the multi-degree-of-freedom mechanical arm, so that the clamping chuck device is driven to approach the reserved hole position of one side wall of the rectangular steel pipe joint; the clamping chuck device is used for clamping the pre-stressed tendon to be threaded; the illumination camera system is used for collecting the working environment image; after the clamping chuck device clamps the pre-stressed tendon, the multi-degree-of-freedom mechanical arm drives the pre-stressed tendon to be threaded along the connecting line direction of the reserved hole positions of the two side walls of the rectangular steel pipe joint, and the effect is that continuous and automatic threading construction can be realized.

Description

Technical Field

[0001] This invention relates to the field of robotics, and more specifically, to an intelligent threading robot for prestressed tendons within a micro-tube curtain structure. Background Technology

[0002] The UBIT (Unified Backdrop Injection) method typically involves jacking in multiple rectangular steel pipe sections one by one, with corrugated pipes and prestressed tendons inserted between adjacent sections. Subsequent concrete filling and prestressing tensioning then transform the dispersed rectangular steel pipe sections into a unified load-bearing structure. This method can be used for tunneling projects beneath existing stations, roads, or underground spaces. In actual construction, the internal space of a single rectangular steel pipe section is relatively small, with a typical cross-section of approximately 1.2 meters × 1.2 meters. After robots or personnel enter this space, the distance between the left and right pipe walls is limited. Furthermore, the top, bottom, and side walls may contain interference factors such as steel plate edges, bolts, partitions, stiffening ribs, pre-drilled holes, welds, and localized water accumulation and corrosion. This environment makes it significantly inconvenient for manual drilling, clamping, and tensioning of prestressed tendons.

[0003] After entering a UBIT rectangular steel pipe section, the robot can typically only move forward or backward along the longitudinal direction of the pipe section, making lateral movement or turning around difficult. Furthermore, the insertion direction of the prestressing tendons is not along the robot's forward direction, but rather requires them to pass through pre-drilled holes on the left and right sides of the same pipe section. In other words, the robot's movable direction is not consistent with the insertion direction of the prestressing tendons. Existing bridge duct tendon insertion equipment mostly pushes or pulls along the duct direction, making it difficult to adapt to this narrow pipe section operation mode involving longitudinal robot movement and lateral insertion of prestressing tendons. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide an intelligent prestressing tendon threading robot for micro-tube curtain bundle structures.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] The intelligent prestressing tendon threading robot for the micro-tube curtain bundled structure includes a mobile chassis, a lifting support, a multi-degree-of-freedom robotic arm, a clamping gripper, a lighting and camera system, and a control system.

[0007] The mobile chassis moves axially along the rectangular steel pipe section; the lifting support is mounted on the mobile chassis and is used to adjust the spatial posture of the multi-degree-of-freedom robotic arm; the multi-degree-of-freedom robotic arm is mounted on the lifting support, and its end is equipped with a clamping chuck device to drive the clamping chuck device close to the reserved hole on one side of the rectangular steel pipe section wall; the clamping chuck device is used to clamp the prestressed tendon to be installed; the lighting and camera system is used to collect images of the working environment.

[0008] The control system is connected to the mobile chassis, lifting support, multi-degree-of-freedom robotic arm, clamping gripper and lighting camera system respectively.

[0009] In operation, the moving direction of the mobile chassis intersects with the insertion direction of the prestressing tendon. After the clamping chuck device clamps the prestressing tendon, the multi-degree-of-freedom robotic arm drives the prestressing tendon to be inserted along the line connecting the reserved holes on both sides of the rectangular steel pipe section.

[0010] Preferably, the mobile chassis is a tracked chassis, and the width and height of the mobile chassis are both smaller than the internal passage space of the rectangular steel pipe section, so that the mobile chassis can move forward or backward along the axial direction within the rectangular steel pipe section;

[0011] The lifting support base adjusts the installation height of the multi-degree-of-freedom robotic arm through the lifting drive unit to adapt to the reserved holes at different heights on both sides of the rectangular steel pipe section.

[0012] Preferably, the multi-degree-of-freedom robotic arm includes one or more of rotation, pitch, telescopic, or wrist rotation structures, so that the clamping gripper can reach the reserved hole area on one side of the rectangular steel pipe section without changing the lateral position of the moving chassis, and adjust to the posture suitable for the prestressed tendons to enter.

[0013] Preferably, the clamping chuck device includes a chuck mounting base, a first clamping member, a second clamping member, a drive mechanism, and a clamping force sensor;

[0014] The first clamping member and the second clamping member are movably connected to the chuck mounting base, and a clamping channel for the prestressing tendon to enter is formed between the first clamping member and the second clamping member.

[0015] The driving mechanism is used to drive the first clamping member and / or the second clamping member to move relative to each other, so as to open or close the clamping channel;

[0016] The clamping force sensor is installed on the clamping chuck device. The clamping force sensor is used to detect the clamping force of the clamping chuck device on the prestressing tendon and to feed the detection data back to the control system.

[0017] Preferably, the opposite inner surfaces of the first clamping member and the second clamping member are provided with one or more of the following: an arc-shaped clamping groove, an anti-slip pad, or a shallow semi-arc-shaped anti-slip pad.

[0018] Preferably, the lighting and camera system includes one or more of a front-view camera, a side camera, a supplementary light, or an auxiliary locator, and the observation direction of at least one camera is toward the reserved holes on both sides of the rectangular steel pipe section and the clamping area of ​​the clamping chuck device;

[0019] The robot includes a power supply and communication system, which is connected to the mobile chassis, lifting support, multi-degree-of-freedom robotic arm, gripping gripper, lighting and camera system, and control system, respectively.

[0020] The control system collects image data from the lighting and camera system, and determines the stopping position of the mobile chassis, the relative position of the clamping device and the reserved hole, and the path of the prestressing tendon based on the image data.

[0021] Preferably, after the clamping chuck device clamps the prestressed tendon, the multi-degree-of-freedom robotic arm drives the clamping chuck device to pull laterally along the line connecting the reserved holes on both sides of the rectangular steel pipe section.

[0022] When a single pulling stroke is insufficient to complete the lateral insertion, the clamping gripper device performs a segmented pulling action, specifically including:

[0023] The clamping chuck device clamps the prestressing tendon and pulls it out, then releases it. The multi-degree-of-freedom robotic arm returns to its original position, and the clamping chuck device clamps the prestressing tendon again and continues to pull it towards the right side of the pipe wall until the prestressing tendon reaches the reserved hole position on the right side of the pipe wall.

[0024] The control system adjusts the posture of the multi-degree-of-freedom robotic arm using image data from the lighting and camera system to assist the prestressed tendons in inserting into the pre-drilled holes in the right-side pipe wall.

[0025] The mobile chassis moves forward or backward along the longitudinal direction of the pipe section to the next target section, so as to achieve continuous operation at multiple holes.

[0026] Preferably, the control system adjusts the posture of the multi-degree-of-freedom robotic arm using image data from the lighting and camera system to assist the prestressed tendon in inserting into the pre-drilled hole in the right-side pipe wall, specifically:

[0027] The control system extracts the orifice contour through the image data of the lighting camera system, and determines the reference points of the orifice center and one side edge based on the orifice contour;

[0028] The attitude of the multi-degree-of-freedom robotic arm is adjusted based on the reference point so that the end of the prestressed tendon is aligned with the reference point. The prestressed tendon is then advanced along the direction of the reference point so that the end of the prestressed tendon contacts the edge of the hole and drives the end of the prestressed tendon to move along the edge of the hole toward the center of the hole.

[0029] When the end of the prestressed tendon moves to the center position of the orifice, the advancing direction of the multi-degree-of-freedom robotic arm is kept consistent with the axis of the orifice.

[0030] Continue advancing the prestressed tendons along the axis of the borehole until they penetrate the reserved hole in the right side of the pipe wall.

[0031] Preferably, the posture of the multi-degree-of-freedom robotic arm is adjusted based on a reference point so that the end of the prestressed tendon is aligned with the reference point, specifically as follows:

[0032] Extract edge contour data around the reference point, and obtain gradient direction data for each point on the edge based on the edge contour data;

[0033] By associating gradient direction data with the current position data of the prestressed tendon end, the edge gradient direction corresponding to the end position is determined;

[0034] The edge gradient is mapped to the main degree of freedom adjustment channel of the robotic arm to generate the main adjustment direction data;

[0035] The adjustment margin of the main adjustment direction channel is obtained based on the main adjustment direction data, and the deviation component of the main adjustment direction data is extracted based on the adjustment margin.

[0036] The deviation components are mapped to the secondary degree of freedom adjustment channels to generate corresponding secondary adjustment direction data;

[0037] The attitude adjustment direction data of the multi-degree-of-freedom robotic arm is obtained based on the primary adjustment direction data and the secondary adjustment direction data.

[0038] Adjust the posture of the multi-degree-of-freedom robotic arm according to the posture adjustment direction data, so that the end of the prestressed tendon is aligned with the reference point.

[0039] Preferably, the gradient direction data is correlated with the current position data of the prestressed tendon end to determine the edge gradient direction corresponding to the end position, specifically:

[0040] A gradient diffusion field extending from the edge inward is formed based on the gradient direction data;

[0041] The gradient diffusion field extends inward until it covers the area at the end of the prestressed tendon.

[0042] Gradient diffusion field data at the current position of the prestressed tendon end is extracted from the gradient diffusion field in the covered end region to obtain gradient direction information;

[0043] The gradient direction information is determined as the edge gradient direction corresponding to the current position of the prestressed tendon end.

[0044] Compared with the prior art, the present invention has the following beneficial effects:

[0045] This invention enables a mobile chassis to move axially along a rectangular steel pipe section. A lifting support is mounted on the mobile chassis to adjust the spatial posture of a multi-degree-of-freedom robotic arm. A clamping chuck is mounted at the end of the multi-degree-of-freedom robotic arm to move it closer to a pre-drilled hole. The clamping chuck is used to clamp the prestressed tendon to be inserted. A lighting and camera system is used to collect images of the working environment. The control system is connected to each component via signals. In the working state, the moving direction of the mobile chassis intersects with the insertion direction of the prestressed tendon. The multi-degree-of-freedom robotic arm drives the prestressed tendon to be inserted along the line connecting the pre-drilled holes on both sides of the pipe wall.

[0046] This robot is specifically designed for pipe section construction conditions involving longitudinal robot movement and lateral insertion of prestressed tendons, making it well-suited for the construction characteristics of micro-tube curtain structures. The robot does not need to turn around laterally or make large lateral movements within the pipe section; it only needs to move longitudinally along the pipe section to the target section to perform its work, simplifying motion control within narrow pipes and improving work efficiency. By extending its robotic arm and using a gripper to clamp near the holes on the left side of the pipe wall, it effectively reduces the difficulty of clamping and pulling prestressed tendons within narrow pipe sections, alleviating worker fatigue and avoiding the safety hazards of manual operation in confined spaces.

[0047] By observing the left and right hole positions and clamping areas through a lighting and camera system, the accuracy of hole alignment and clamping in the dark environment inside the pipe can be significantly improved, ensuring that the prestressed tendons can be accurately inserted into the reserved holes, reducing rework and time waste caused by misalignment. The robot repeatedly performs longitudinal movement positioning, clamping, lateral pulling and releasing actions at multiple hole positions, making it suitable for multi-hole tendon insertion operations in pipe section bundling structures. It can achieve continuous and automated tendon insertion construction, improving overall construction efficiency and quality. Attached Figure Description

[0048] Figure 1 This is a schematic diagram of the intelligent tendon threading robot for the prestressed tendons in the micro-tube curtain bundle structure proposed in this invention.

[0049] Figure 2 This invention presents a schematic diagram of the intelligent tendon-threading robot for prestressing tendons in a micro-tube curtain structure, demonstrating its transverse tendon-threading operation within a rectangular steel tube section.

[0050] Figure 3 A partial structural diagram of the clamping gripper device for the intelligent threading robot of the prestressed tendons in the micro-tube curtain bundle structure proposed in this invention.

[0051] Figure 4 This is a schematic diagram of the control system connection relationship of the intelligent tendon threading robot for the prestressed tendons in the micro-tube curtain bundle structure proposed in this invention.

[0052] Figure 5 This invention presents a schematic diagram of the transverse threading process of prestressed tendons in a micro-tube curtain bundle structure using an intelligent threading robot.

[0053] 1. Mobile chassis; 2. Lifting support; 3. Multi-degree-of-freedom robotic arm; 4. Clamping chuck device; 5. Lighting and camera system; 6. Control system; 7. Power supply and communication system; 8. Chuck mounting base; 9. First clamping component; 10. Second clamping component; 11. Drive mechanism; 12. Clamping channel; 13. Anti-slip pad; 14. Clamping force sensor. Detailed Implementation

[0054] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0055] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0056] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places throughout this specification does not necessarily refer to the same embodiment, nor is it a single embodiment or an embodiment selectively excluded from other embodiments.

[0057] Reference Figures 1-5 As shown.

[0058] The embodiments further illustrate the intelligent threading robot for prestressed tendons in the micro-tube curtain bundle structure proposed in this invention.

[0059] The intelligent tendon threading robot for the prestressed tendons in the micro-tube curtain bundle structure includes a mobile chassis 1, a lifting support 2, a multi-degree-of-freedom robotic arm 3, a clamping gripper 4, a lighting and camera system 5, and a control system 6.

[0060] The mobile chassis 1 moves axially along the rectangular steel pipe section; the lifting support 2 is set on the mobile chassis 1 and is used to adjust the spatial posture of the multi-degree-of-freedom robotic arm 3; the multi-degree-of-freedom robotic arm 3 is installed on the lifting support 2, and its end is equipped with a clamping chuck device 4 to drive the clamping chuck device 4 close to the reserved hole on the pipe wall of the rectangular steel pipe section; the clamping chuck device 4 is used to clamp the prestressed tendon to be installed; the lighting and camera system 5 is used to collect images of the working environment.

[0061] The control system 6 is connected to the mobile chassis 1, the lifting support 2, the multi-degree-of-freedom robotic arm 3, the clamping gripper 4, and the lighting and camera system 5 respectively.

[0062] In operation, the moving direction of the mobile chassis 1 intersects with the direction of the prestressing tendon insertion. After the clamping chuck device 4 clamps the prestressing tendon, the multi-degree-of-freedom robotic arm 3 drives the prestressing tendon to be inserted along the line connecting the reserved holes on both sides of the rectangular steel pipe section.

[0063] The mobile chassis 1 is a tracked chassis. The width and height of the mobile chassis 1 are both smaller than the internal passage space of the rectangular steel pipe section, so that the mobile chassis 1 can move forward or backward along the axial direction within the rectangular steel pipe section.

[0064] The mobile chassis 1 is a tracked chassis, and its tracked walking structure provides good ground adaptability and stable walking performance. The width and height of the mobile chassis 1 are both smaller than the internal passage space of the rectangular steel tube section, allowing the mobile chassis 1 to smoothly enter the interior of the rectangular steel tube section and move forward or backward axially within it. Moving the mobile chassis 1 along the axial direction of the rectangular steel tube section enables the entire robot to be transported to different working section positions, providing mobility and basic support for the threading operation.

[0065] The lifting support 2 adjusts the installation height of the multi-degree-of-freedom robotic arm 3 through the lifting drive unit to adapt to the reserved holes at different heights on both sides of the rectangular steel pipe section.

[0066] The lifting support 2 is mounted on the mobile chassis 1. The lifting support 2 adjusts the installation height of the multi-degree-of-freedom robotic arm 3 via a lifting drive unit. The lifting drive unit provides lifting power, causing the multi-degree-of-freedom robotic arm 3 to rise or fall as a whole to accommodate the pre-drilled holes at different heights on both sides of the rectangular steel pipe section. The lifting support 2 is used to adjust the spatial posture of the multi-degree-of-freedom robotic arm 3, enabling it to adaptively adjust according to the actual height of the pre-drilled holes. This ensures that the working height of the multi-degree-of-freedom robotic arm 3 matches the height of the pre-drilled holes, providing height-direction position adjustment capability for prestressed tendon installation.

[0067] The multi-degree-of-freedom robotic arm 3 includes one or more of rotation, pitch, telescopic or wrist rotation structures, so that the clamping gripper 4 can reach the reserved hole area on one side of the rectangular steel pipe section without changing the lateral position of the moving chassis 1, and adjust to the posture suitable for the prestressed tendons to enter.

[0068] A multi-degree-of-freedom robotic arm 3 is mounted on a lifting support 2. A clamping chuck 4 is installed at the end of the multi-degree-of-freedom robotic arm 3 to move the clamping chuck 4 close to a pre-drilled hole in the wall of the rectangular steel pipe section. The multi-degree-of-freedom robotic arm 3 includes one or more rotation, pitch, telescopic, or wrist rotation structures. Through a combination of various motion structures, the end-effector clamping chuck 4 achieves multi-degree-of-freedom movement in space.

[0069] The rotary structure of the multi-degree-of-freedom robotic arm 3 enables the entire robotic arm to rotate, adjusting its horizontal angle. The pitch structure enables the robotic arm to swing up and down, adjusting its vertical angle. The telescopic structure enables the robotic arm to extend or retract, adjusting its working radius. The wrist rotation structure enables the end-effector gripper 4 to rotate, adjusting its attitude angle.

[0070] The multi-degree-of-freedom robotic arm 3 can bring the clamping chuck 4 to the reserved hole area on one side of the rectangular steel pipe section without changing the lateral position of the mobile chassis 1, and adjust it to the posture suitable for the prestressing tendons. The multi-degree-of-freedom robotic arm 3 realizes the spatial positioning and posture adjustment of the clamping chuck 4 through motion control.

[0071] The clamping chuck device 4 includes a chuck mounting base 8, a first clamping member 9, a second clamping member 10, a drive mechanism 11, and a clamping force sensor 14;

[0072] The first clamping member 9 and the second clamping member 10 are movably connected to the clamp mounting base 8, and a clamping channel 12 for the prestressing tendons to enter is formed between the first clamping member 9 and the second clamping member 10.

[0073] The drive mechanism 11 is used to drive the first clamping member 9 and / or the second clamping member 10 to move relative to each other, so as to open or close the clamping channel 12;

[0074] The clamping force sensor 14 is installed on the clamping chuck device 4. The clamping force sensor 14 is used to detect the clamping force of the clamping chuck device 4 on the prestressing tendon and feed the detection data back to the control system 6.

[0075] The first clamping member 9 and the second clamping member 10 are movably connected to the clamp mounting base 8, forming a clamping channel 12 between them for the prestressing tendon to enter. The first clamping member 9 and the second clamping member 10 can move relative to the clamp mounting base 8, thereby changing the size of the clamping channel 12. The opposing inner surfaces of the first clamping member 9 and the second clamping member 10 are provided with one or more of the following: an arc-shaped clamping groove, an anti-slip pad 13, or a shallow semi-arc-shaped anti-slip pad, to increase the contact area and friction with the prestressing tendon, improve the stability and reliability of the clamping, and prevent the prestressing tendon from slipping out during installation.

[0076] The driving mechanism 11 is used to drive the first clamping member 9 or the second clamping member 10 to move relative to each other, so as to open or close the clamping channel 12. When the driving mechanism 11 drives the first clamping member 9 and the second clamping member 10 away from each other, the clamping channel 12 opens, and the prestressing tendon can enter the clamping channel 12. When the driving mechanism 11 drives the first clamping member 9 and the second clamping member 10 closer to each other, the clamping channel 12 closes, and the first clamping member 9 and the second clamping member 10 work together to clamp the prestressing tendon, thereby fixing and clamping the prestressing tendon.

[0077] A clamping force sensor 14 is installed in the clamping chuck device 4. The clamping force sensor 14 detects the clamping force of the clamping chuck device 4 on the prestressing tendons and feeds the detection data back to the control system 6. The clamping force sensor 14 can monitor the magnitude of the clamping force in real time, ensuring that the clamping force is appropriate. Insufficient clamping force will prevent the prestressing tendons from slipping during installation, while excessive clamping force will not damage the surface structure of the prestressing tendons. The control system 6 adjusts the output force of the drive mechanism 11 based on the data fed back by the clamping force sensor 14.

[0078] The lighting and camera system 5 includes one or more of a front-view camera, a side camera, a supplementary light, or an auxiliary locator, with at least one camera's observation direction facing the reserved holes on both sides of the rectangular steel pipe section and the clamping area of ​​the clamping chuck device 4.

[0079] The robot includes a power supply and communication system 7, which is connected to a mobile chassis 1, a lifting support 2, a multi-degree-of-freedom robotic arm 3, a gripping gripper 4, a lighting and camera system 5, and a control system 6.

[0080] The control system 6 uses the image data collected by the lighting and camera system 5 to determine the stopping position of the mobile chassis 1, the relative position of the clamping device 4 and the reserved hole, and the path of the prestressing tendon.

[0081] The forward-facing camera captures environmental images in front of the robot, observing road conditions and obstacles in its direction of travel. The side-facing camera captures environmental images from the robot's sides, observing the sidewalls of the rectangular steel pipe section. A supplementary light provides illumination in low-light conditions inside the pipe, ensuring the camera can capture clear images. An auxiliary locator provides auxiliary positioning, helping the robot determine its own position. At least one camera's observation direction is towards the pre-drilled holes on both sides of the rectangular steel pipe section and the clamping area of ​​the gripper 4, enabling real-time monitoring of the position of the pre-drilled holes and the state of the clamping area, providing visual feedback information to the control system 6.

[0082] The robot includes a power supply and communication system 7, which is connected to the mobile chassis 1, the lifting support 2, the multi-degree-of-freedom robotic arm 3, the gripper 4, the lighting and camera system 5, and the control system 6. The power supply and communication system 7 provides power to all components of the robot, ensuring their normal operation. It also provides communication links between these components, enabling the control system 6 to transmit data and exchange signals with the mobile chassis 1, the lifting support 2, the multi-degree-of-freedom robotic arm 3, the gripper 4, and the lighting and camera system 5, thus achieving coordinated control and management of the entire robot.

[0083] The control system 6 is connected to the mobile chassis 1, the lifting support 2, the multi-degree-of-freedom robotic arm 3, the clamping chuck device 4, and the lighting and camera system 5. Based on the image data collected by the lighting and camera system 5, the control system 6 determines the stopping position of the mobile chassis 1, ensuring it remains in the appropriate working position. The control system 6 also determines the relative position of the clamping chuck device 4 to the pre-drilled holes based on the image data, providing a basis for adjusting the posture of the multi-degree-of-freedom robotic arm 3. Furthermore, the control system 6 determines the path for the prestressed tendons and plans their installation trajectory, ensuring they are accurately inserted into the pre-drilled holes. Through visual feedback, the control system 6 achieves intelligent control of the entire tendon insertion process, improving the accuracy and efficiency of the operation.

[0084] After the clamping chuck device 4 clamps the prestressed tendon, the multi-degree-of-freedom robotic arm 3 drives the clamping chuck device 4 to pull laterally along the line connecting the reserved holes on both sides of the rectangular steel pipe section.

[0085] When a single pulling stroke is insufficient to complete the lateral insertion, the clamping gripper 4 performs a segmented pulling action, specifically including:

[0086] After clamping the prestressing tendon and pulling it out, the multi-degree-of-freedom robotic arm 3 returns to its original position. The clamping chuck 4 clamps the prestressing tendon again and continues to pull it towards the right side of the pipe wall until the prestressing tendon reaches the reserved hole position on the right side of the pipe wall.

[0087] The control system 6 adjusts the posture of the multi-degree-of-freedom robotic arm 3 through the image data of the lighting and camera system 5 to assist the prestressed tendons in passing through the reserved holes in the right side of the pipe wall;

[0088] The mobile chassis 1 moves forward or backward along the longitudinal direction of the pipe section to the next target section to achieve continuous operation at multiple holes.

[0089] After the clamping chuck device 4 clamps the prestressing tendon, the multi-degree-of-freedom robotic arm 3 drives the clamping chuck device 4 to pull laterally along the line connecting the reserved holes on both sides of the rectangular steel pipe section. Through its own movement, the multi-degree-of-freedom robotic arm 3 pulls the clamped prestressing tendon from one side of the pipe wall to the other side, realizing the lateral insertion of the prestressing tendon.

[0090] When a single pulling stroke is insufficient to complete the lateral threading, the clamping chuck device 4 performs a segmented pulling action. After clamping the prestressing tendon and pulling it a certain distance, the clamping chuck device 4 releases, and the multi-degree-of-freedom robotic arm 3 returns to its initial position. The clamping chuck device 4 then clamps the prestressing tendon again and continues pulling it towards the right side of the pipe wall. This cycle repeats until the prestressing tendon reaches the pre-drilled hole on the right side of the pipe wall. By using segmented pulling, a longer distance of prestressing tendon threading can be completed within the limited stroke range of the multi-degree-of-freedom robotic arm 3, overcoming the limitations of the robotic arm's own stroke.

[0091] The control system 6 adjusts the posture of the multi-degree-of-freedom robotic arm 3 based on the image data from the lighting and camera system 5 to assist the prestressed tendon in passing through the pre-drilled hole in the right-side pipe wall. The lighting and camera system 5 acquires images of the pre-drilled hole and the end of the prestressed tendon in real time. Based on the image data, the control system 6 determines the relative position of the end of the prestressed tendon and the pre-drilled hole, and adjusts the posture of the multi-degree-of-freedom robotic arm 3 to ensure that the end of the prestressed tendon is accurately aligned with the pre-drilled hole, thus ensuring that the prestressed tendon can be smoothly passed through the pre-drilled hole in the right-side pipe wall.

[0092] After completing the prestressing tendon installation at the current section, the mobile chassis 1 moves longitudinally forward or backward along the pipe section to the next target section, enabling continuous multi-position operation. The mobile chassis 1 drives the entire robot to move axially along the rectangular steel pipe section, stopping at the next section where prestressing tendons need to be installed, and then repeating the tendon installation process. Through the longitudinal movement of the mobile chassis 1 and the repeated tendon installation, the robot can continuously complete the prestressing tendon installation work at multiple positions within the rectangular steel pipe section, improving overall construction efficiency.

[0093] The control system 6 adjusts the posture of the multi-degree-of-freedom robotic arm 3 based on the image data from the lighting and camera system 5 to assist the prestressed tendons in inserting into the pre-drilled holes in the right-side pipe wall. Specifically:

[0094] The control system 6 extracts the orifice contour through the image data of the lighting camera system 5, and determines the reference points of the orifice center and one side edge based on the orifice contour;

[0095] The posture of the multi-degree-of-freedom robotic arm 3 is adjusted based on a reference point so that the end of the prestressed tendon is aligned with the reference point, specifically as follows:

[0096] Extract edge contour data around the reference point, and obtain gradient direction data for each point on the edge based on the edge contour data;

[0097] The control system 6 extracts the orifice contour from the image data of the lighting camera system 5. The lighting camera system 5 acquires images of the pre-reserved hole positions on the wall of the rectangular steel pipe section. The image resolution can be 1920×1080 pixels. The control system 6 performs edge detection processing on the image to identify the edge contour information of the orifice. The control system 6 determines the reference points for the center of the orifice and one side edge based on the orifice contour. For example, the diameter of a circular orifice is 50 mm. The coordinates of the orifice center can be obtained by calculating the average coordinates of all points on the contour. The calculation formula is: Orifice center x-coordinate = sum of x-coordinates of all points on the contour ÷ total number of points on the contour; Orifice center y-coordinate = sum of y-coordinates of all points on the contour ÷ total number of points on the contour. The reference point for one side edge can be selected as the midpoint of the left edge of the orifice. The reference point serves as the initial alignment reference position for the prestressing tendon end. By guiding the prestressing tendon along the edge of the orifice towards the center, the success rate and accuracy of insertion are improved.

[0098] The control system 6 adjusts the posture of the multi-degree-of-freedom robotic arm 3 based on a reference point, aligning the end of the prestressing tendon with the reference point. The multi-degree-of-freedom robotic arm 3 adjusts its posture according to the instructions of the control system 6, driving the end-effector gripper 4 and the gripped prestressing tendon to move, so that the end position of the prestressing tendon corresponds to the reference point position. For example, if the coordinates of the reference point are 100 mm x 100 mm x 200 mm, and the current coordinates of the prestressing tendon end are 80 mm x 80 mm x 190 mm, then the lateral adjustment distance = 100 mm - 80 mm = 20 mm, and the longitudinal adjustment distance = 200 mm - 190 mm = 10 mm. The multi-degree-of-freedom robotic arm 3 moves according to this adjustment amount, moving the end of the prestressing tendon to the reference point position.

[0099] Control system 6 extracts edge contour data around the reference point and obtains gradient direction data for each point on the edge based on the edge contour data. The gradient direction data reflects the normal direction of each point on the orifice edge, that is, the direction information from the edge towards the inside of the orifice. For example, for a point on the edge, if the grayscale value of the pixel to its left is 50 and the grayscale value of the pixel to its right is 150, then the horizontal gradient value = 150 - 50 = 100, and the gradient direction points in the direction of increasing grayscale value, that is, from left to right. By calculating the gradient direction of each point on the edge contour, control system 6 can obtain the geometric feature information of the orifice edge, providing a data basis for attitude adjustment and path planning. The gradient direction data can indicate the direction in which the prestressed tendon end moves from the edge towards the center of the orifice, providing directional guidance for the insertion movement of the prestressed tendon.

[0100] The gradient direction data is correlated with the current position data of the prestressed tendon end to determine the edge gradient direction corresponding to the end position, specifically:

[0101] A gradient diffusion field extending from the edge inward is formed based on the gradient direction data;

[0102] The gradient diffusion field extends inward until it covers the area at the end of the prestressed tendon.

[0103] Gradient diffusion field data at the current position of the prestressed tendon end is extracted from the gradient diffusion field in the covered end region to obtain gradient direction information;

[0104] The gradient direction information is determined as the edge gradient direction corresponding to the current position of the prestressed tendon end;

[0105] The edge gradient is mapped to the main degree of freedom adjustment channel of the three-degree-of-freedom robotic arm 3 to generate the main adjustment direction data;

[0106] The adjustment margin of the main adjustment direction channel is obtained based on the main adjustment direction data, and the deviation component of the main adjustment direction data is extracted based on the adjustment margin.

[0107] The deviation components are mapped to the secondary degree of freedom adjustment channels to generate corresponding secondary adjustment direction data;

[0108] The attitude adjustment direction data of the multi-degree-of-freedom robotic arm 3 is obtained based on the main adjustment direction data and the secondary adjustment direction data.

[0109] Adjust the posture of the multi-degree-of-freedom robotic arm 3 according to the posture adjustment direction data, so that the end of the prestressed tendon is aligned with the reference point;

[0110] The control system 6 generates a gradient diffusion field extending inward from the edge based on gradient direction data. Starting from the edge of the orifice, the gradient diffusion field gradually diffuses inward, propagating the gradient direction information from the edge to various locations within the orifice. For example, if the gradient direction vector at the orifice edge has a horizontal component of 0.8 and a vertical component of 0.6, and the diffusion step size is 5 mm, then the gradient direction information is propagated to a new location every 5 mm of inward diffusion. The gradient diffusion field expands inward until it covers the area at the end of the prestressing tendon, ensuring that the end of the prestressing tendon also receives gradient direction information. For example, if the end of the prestressing tendon is 20 mm from the edge of the orifice, the diffusion field needs to diffuse through 20 mm ÷ 5 mm = 4 steps to cover the end area. The gradient diffusion field data at the current position of the prestressing tendon end is extracted from the gradient diffusion field covering the end area, thus obtaining the gradient direction information. This gradient direction information is then determined as the edge gradient direction corresponding to the current position of the prestressing tendon end. The control system 6 can extend the gradient direction information of the orifice edge to any position inside the orifice, so that the prestressing tendon end can obtain the corresponding edge gradient direction no matter where it is inside the orifice, providing directional guidance for the movement of the prestressing tendon.

[0111] The master degree of freedom adjustment channel is the channel responsible for the main motion direction of the multi-degree-of-freedom robotic arm 3. For example, the extension and retraction degree of freedom of the robotic arm serves as the master degree of freedom adjustment channel, with a stroke range of 0 to 500 mm. The angle between the direction vector pointing to the edge gradient and the motion direction of the master degree of freedom is 15 degrees. Therefore, the magnitude of the master adjustment direction data = gradient magnitude × cos15 degrees. The control system 6 obtains the adjustment margin of the master degree of freedom adjustment channel based on the master adjustment direction data. The adjustment margin represents the range within which the master degree of freedom adjustment channel can continue to adjust. For example, if the current position of the master degree of freedom is 200 mm and the maximum stroke is 500 mm, then the adjustment margin = 500 mm - 200 mm = 300 mm. The control system 6 extracts the deviation component of the master adjustment direction data based on the adjustment margin. The deviation component represents the portion where the adjustment requirements cannot be fully met by adjusting only the master degree of freedom. For example, if the main adjustment direction data needs to be adjusted by 350 mm, but the adjustment margin is only 300 mm, then the deviation component = 350 mm - 300 mm = 50 mm. The 50 mm adjustment amount needs to be supplemented by other degrees of freedom.

[0112] The control system 6 maps the deviation component to the secondary degree of freedom adjustment channel, generating corresponding secondary adjustment direction data. The secondary degree of freedom adjustment channel is the degree of freedom channel for auxiliary adjustment by the multi-degree-of-freedom robotic arm 3. For example, the pitch degree of freedom of the robotic arm serves as the secondary degree of freedom adjustment channel, supplementing the deficiencies of the primary degree of freedom adjustment to achieve attitude adjustment. For example, if the deviation component is 50 mm and the lever arm length of the secondary degree of freedom is 200 mm, then the secondary degree of freedom adjustment angle = arctan(50 mm ÷ 200 mm) ≈ 14 degrees. The control system 6 obtains the attitude adjustment direction data of the multi-degree-of-freedom robotic arm 3 based on the primary and secondary adjustment direction data, and synthesizes the direction information of the primary and secondary adjustments to form an attitude adjustment scheme. For example, if the displacement vector of the primary adjustment direction is 300 mm x 0 mm and 0 mm y, and the displacement vector of the secondary adjustment direction is 0 mm x 0 mm and 50 mm y, then the x-coordinate component of the attitude adjustment direction data = 300 mm + 0 mm = 300 mm, and the y-coordinate component = 0 mm + 50 mm = 50 mm. The control system 6 adjusts the posture of the multi-degree-of-freedom robotic arm 3 according to the posture adjustment direction data, so that the end of the prestressed tendon is aligned with the reference point. Through the coordinated adjustment of the main and secondary degrees of freedom, the control system 6 can realize the posture control of the multi-degree-of-freedom robotic arm 3, ensuring that the end of the prestressed tendon can be accurately aligned with the reference point, providing a positional basis for the insertion operation.

[0113] The prestressing tendon is advanced along the reference point until the end of the prestressing tendon contacts the edge of the hole, and the end of the prestressing tendon moves along the edge of the hole toward the center of the hole.

[0114] When the end of the prestressed tendon moves to the center position of the orifice, the advancing direction of the multi-degree-of-freedom robotic arm 3 is kept consistent with the axis of the orifice.

[0115] Continue advancing the prestressed tendons along the axis of the borehole until they penetrate the reserved hole in the right side of the pipe wall.

[0116] The control system 6 advances the prestressing tendon along the reference point, causing the tendon tip to contact the edge of the borehole. This movement then propels the tendon tip towards the center of the borehole. For example, if the reference point is located on the left edge of the borehole, the tendon tip, starting from the reference point, advances towards the borehole along a gradient direction at a speed of 10 mm per second. If the radius of curvature of the borehole edge is 25 mm, the tendon tip slides along the curved edge towards the center of the borehole. This gradual movement of the tendon tip from the edge to the center of the borehole avoids insertion failure due to alignment errors.

[0117] When the end of the prestressing tendon moves to the center position of the borehole, the control system 6 aligns the advancing direction of the multi-degree-of-freedom robotic arm 3 with the borehole axis. The borehole axis is the direction of the central axis of the reserved hole. For example, if the direction vector of the borehole axis is 1 in the horizontal direction and 0 in the vertical direction, and the direction vector of the current advancing direction of the multi-degree-of-freedom robotic arm 3 is 0.98 in the horizontal direction and 0.2 in the vertical direction, then the required angle difference = arctan(0.2÷0.98)≈11.5 degrees. By adjusting its own posture, the multi-degree-of-freedom robotic arm 3 ensures that the advancing direction is completely aligned with the borehole axis, ensuring that the advancing action can proceed along the axis of the hole and avoiding friction or jamming between the prestressing tendon and the hole wall.

[0118] The control system 6 continues to advance the prestressing tendon along the borehole axis until it passes through the pre-drilled hole in the right-side pipe wall. The multi-degree-of-freedom robotic arm 3 drives the clamping chuck device 4 and the clamped prestressing tendon forward along the borehole axis. For example, if the thickness of the right-side pipe wall is 8 mm, the prestressing tendon needs to pass through 8 mm, and the advancing speed is 15 mm per second, then the time required for penetration = 8 mm ÷ 15 mm per second ≈ 0.53 seconds. During the advancement process, the lighting and camera system 5 monitors the penetration status of the prestressing tendon in real time to ensure that it can smoothly pass through the pre-drilled hole in the right-side pipe wall. Once the prestressing tendon is completely inserted into the pre-drilled hole in the right-side pipe wall, the tendon insertion operation is complete, and the clamping chuck device 4 can release the prestressing tendon, preparing for the next borehole operation.

[0119] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An intelligent robot for threading prestressed tendons into a micro-tube curtain structure, characterized in that, It includes a mobile chassis (1), a lifting support (2), a multi-degree-of-freedom robotic arm (3), a clamping gripper (4), a lighting and camera system (5), and a control system (6); The mobile chassis (1) moves axially along the rectangular steel pipe section; the lifting support (2) is set on the mobile chassis (1), and the lifting support (2) is used to adjust the spatial posture of the multi-degree-of-freedom robotic arm (3); the multi-degree-of-freedom robotic arm (3) is installed on the lifting support (2), and the clamping chuck device (4) is set at its end to drive the clamping chuck device (4) to approach the reserved hole on one side of the pipe wall of the rectangular steel pipe section; the clamping chuck device (4) is used to clamp the prestressed tendon to be installed; the lighting and camera system (5) is used to collect images of the working environment; The control system (6) is connected to the mobile chassis (1), the lifting support (2), the multi-degree-of-freedom robotic arm (3), the clamping gripper (4), and the lighting and camera system (5) respectively. In operation, the moving direction of the mobile chassis (1) intersects with the insertion direction of the prestressing tendon. After the clamping chuck device (4) clamps the prestressing tendon, the multi-degree-of-freedom robotic arm (3) drives the prestressing tendon to be inserted along the line connecting the reserved holes on both sides of the rectangular steel pipe section.

2. The intelligent threading robot for prestressed tendons in the micro-tube curtain bundled structure according to claim 1, characterized in that, The mobile chassis (1) is a tracked chassis. The width and height of the mobile chassis (1) are both smaller than the internal passage space of the rectangular steel pipe section, so that the mobile chassis (1) can move forward or backward along the axial direction within the rectangular steel pipe section. The lifting support (2) adjusts the installation height of the multi-degree-of-freedom robotic arm (3) through the lifting drive unit to adapt to the reserved holes at different heights on both sides of the rectangular steel pipe section.

3. The intelligent threading robot for prestressed tendons in the micro-tube curtain bundled structure according to claim 1, characterized in that, The multi-degree-of-freedom robotic arm (3) includes one or more of rotation, pitch, telescopic or wrist rotation structures, so that the clamping gripper (4) can reach the reserved hole area on one side of the rectangular steel pipe section without changing the lateral position of the moving chassis (1), and adjust it to the posture of the prestressed tendon.

4. The intelligent threading robot for prestressed tendons in the micro-tube curtain bundled structure according to claim 1, characterized in that, The clamping chuck device (4) includes a chuck mounting base (8), a first clamping member (9), a second clamping member (10), a drive mechanism (11), and a clamping force sensor (14); The first clamping member (9) and the second clamping member (10) are movably connected to the clamp mounting base (8), and a clamping channel (12) for the prestressing tendon to enter is formed between the first clamping member (9) and the second clamping member (10); The driving mechanism (11) is used to drive the first clamping member (9) and / or the second clamping member (10) to move relative to each other, so as to open or close the clamping channel (12); The clamping force sensor (14) is disposed on the clamping chuck device (4). The clamping force sensor (14) is used to detect the clamping force of the clamping chuck device (4) on the prestressing tendon and to feed back the detection data to the control system (6).

5. The intelligent prestressed tendon threading robot in the micro-tube curtain bundled structure according to claim 4, characterized in that, The first clamping member (9) and the second clamping member (10) are provided with one or more of the following on their opposite inner surfaces: an arc-shaped clamping groove, an anti-slip pad (13), or a shallow semi-arc anti-slip pad.

6. The intelligent threading robot for prestressed tendons in the micro-tube curtain bundled structure according to claim 1, characterized in that, The lighting and camera system (5) includes one or more of a front-view camera, a side camera, a supplementary light or an auxiliary locator, and the observation direction of at least one camera is toward the reserved holes on both sides of the rectangular steel pipe section and the clamping area of ​​the clamping chuck device (4). The robot includes a power supply and communication system (7), which is connected to the mobile chassis (1), the lifting support (2), the multi-degree-of-freedom robotic arm (3), the clamping gripper (4), the lighting and camera system (5), and the control system (6), respectively. The control system (6) collects image data from the lighting and camera system (5) and determines the stopping position of the mobile chassis (1), the relative position of the clamping device (4) and the reserved hole, and the path of the prestressed tendon based on the image data.

7. The intelligent prestressed tendon threading robot for the micro-tube curtain bundled structure according to claim 6, characterized in that, After the clamping chuck device (4) clamps the prestressed tendon, the multi-degree-of-freedom robotic arm (3) drives the clamping chuck device (4) to be pulled laterally along the line connecting the reserved holes on both sides of the rectangular steel pipe section. When a single pulling stroke is insufficient to complete the lateral insertion, the clamping chuck device (4) performs a segmented pulling action, specifically including: The clamping chuck device (4) clamps the prestressed tendon and pulls it out, then releases it. The multi-degree-of-freedom robotic arm (3) returns to its original position. The clamping chuck device (4) clamps the prestressed tendon again and continues to pull it towards the right side of the pipe wall until the prestressed tendon reaches the reserved hole position on the right side of the pipe wall. The control system (6) adjusts the posture of the multi-degree-of-freedom robotic arm (3) through the image data of the lighting and camera system (5) to assist the prestressed tendon in passing through the reserved hole in the right side of the pipe wall; The mobile chassis (1) moves forward or backward along the longitudinal direction of the pipe section to the next target section to achieve continuous operation at multiple holes.

8. The intelligent threading robot for prestressed tendons in the micro-tube curtain bundled structure according to claim 7, characterized in that, The control system (6) adjusts the posture of the multi-degree-of-freedom robotic arm (3) using image data from the lighting and camera system (5) to assist the prestressed tendons in passing through the pre-drilled holes in the right-side pipe wall, specifically: The control system (6) extracts the orifice contour through the image data of the lighting camera system (5), and determines the reference point of the orifice center and one side edge based on the orifice contour; Adjust the posture of the multi-degree-of-freedom robotic arm (3) based on the reference point, so that the end of the prestressed tendon is aligned with the reference point, and the prestressed tendon is advanced along the reference point direction, so that the end of the prestressed tendon contacts the edge of the hole, and drives the end of the prestressed tendon to move along the edge of the hole towards the center of the hole. When the end of the prestressed tendon moves to the center position of the orifice, the advancing direction of the multi-degree-of-freedom robotic arm (3) is kept consistent with the axis of the orifice; Continue advancing the prestressed tendons along the axis of the borehole until they penetrate the reserved hole in the right side of the pipe wall.

9. The intelligent threading robot for prestressed tendons in the micro-tube curtain bundled structure according to claim 8, characterized in that, The posture of the multi-degree-of-freedom robotic arm (3) is adjusted based on the reference point so that the end of the prestressed tendon is aligned with the reference point, specifically as follows: Extract edge contour data around the reference point, and obtain gradient direction data for each point on the edge based on the edge contour data; By associating gradient direction data with the current position data of the prestressed tendon end, the edge gradient direction corresponding to the end position is determined; The edge gradient is mapped to the main degree of freedom adjustment channel of the manipulator (3) to generate the main adjustment direction data; The adjustment margin of the main adjustment direction channel is obtained based on the main adjustment direction data, and the deviation component of the main adjustment direction data is extracted based on the adjustment margin. The deviation components are mapped to the secondary degree of freedom adjustment channels to generate corresponding secondary adjustment direction data; The attitude adjustment direction data of the multi-degree-of-freedom robotic arm (3) is obtained based on the main adjustment direction data and the secondary adjustment direction data. Adjust the posture of the multi-degree-of-freedom robotic arm (3) according to the posture adjustment direction data, so that the end of the prestressed tendon is aligned with the reference point.

10. The intelligent threading robot for prestressed tendons in the micro-tube curtain bundled structure according to claim 9, characterized in that, The gradient direction data is correlated with the current position data of the prestressed tendon end to determine the edge gradient direction corresponding to the end position, specifically: A gradient diffusion field extending from the edge inward is formed based on the gradient direction data; The gradient diffusion field extends inward until it covers the area at the end of the prestressed tendon. Gradient diffusion field data at the current position of the prestressed tendon end is extracted from the gradient diffusion field in the covered end region to obtain gradient direction information; The gradient direction information is determined as the edge gradient direction corresponding to the current position of the prestressed tendon end.

Images