Pipe welding repair robot suitable for limited space and repair method

Abstract

The present application relates to the field of nuclear power maintenance, especially to a pipeline welding maintenance robot suitable for limited space and a maintenance method. The robot comprises a small multi-direction displacement robot, an execution mechanism connected to the small multi-direction displacement robot, an industrial computer and an execution mechanism control cabinet; the industrial computer is connected to an on-site control module of the small multi-direction displacement robot through a network cable outside the limited space; the execution mechanism comprises a pipeline clamping tool, a cutting tool, a polishing tool, an automatic welding tool and a non-destructive testing tool; the execution mechanism is connected to the execution mechanism control cabinet through a cable, and the execution tools are controlled by the execution mechanism control cabinet to realize remote control of the execution tools; each tool of the execution mechanism has a single function and can independently enter a round hole with an inner diameter not less than 220 mm. The present application improves the accessibility and accuracy of pipeline maintenance and completes automatic replacement and maintenance of pipelines in complex environments of nuclear power stations.

Description

Technical Field

[0001] This invention relates to the field of nuclear power plant maintenance, and more particularly to a pipe welding and maintenance robot and method suitable for confined spaces. Background Technology

[0002] Nuclear power pipelines are crucial components of nuclear power plants, and their safety and reliability determine the normal operation of the entire plant. Although nuclear power equipment is designed, constructed, and operated in accordance with standards and specifications, some pipelines inevitably fail due to external environmental factors such as stress, vibration, wear, temperature, corrosion, and radiation during long-term service. Repairing these failed pipelines is therefore essential. Domestic nuclear power pipeline maintenance primarily relies on manual labor. Repairing pipelines in confined spaces is limited by space and visibility constraints, requiring highly skilled welders, and ensuring welding quality is difficult. Furthermore, maintenance work is challenging in areas inaccessible to manual labor.

[0003] A search of relevant patents revealed that China Fifth Metallurgical Construction Group Co., Ltd. designed a pipe repair device for confined spaces, primarily for adhesive spraying repair of chemical pipelines, but it cannot be used for repairing defects in metal pipelines. Jinan Femtosecond Laser Technology Co., Ltd. designed a pipe welding equipment and method, which can be used for all-position welding of round and square pipes of different sizes, but it cannot perform automatic positioning and installation for welding operations, lacks pipe cutting and non-destructive testing of welds, and its large size makes it unsuitable for confined spaces. Due to the complexity of pipelines in nuclear power plants, most pipelines are restricted by space constraints, making them inaccessible to maintenance personnel; existing welding equipment cannot meet the size and functionality requirements for maintenance. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a pipe welding and repair device and method suitable for confined spaces, so as to realize automated pipe cutting, grinding, welding and non-destructive testing operations in areas inaccessible to personnel.

[0005] This invention provides a pipe welding and repair robot and method suitable for confined spaces, which improves the accessibility and accuracy of pipe repair and enables automatic pipe replacement and repair operations in the complex environment of nuclear power plants.

[0006] This invention provides a pipe welding and repair robot suitable for confined spaces, comprising: a small multi-directional displacement robot, an actuator connected thereto, an industrial control computer, and an actuator control cabinet;

[0007] The small multi-directional displacement robot includes:

[0008] Local control module;

[0009] The chassis module is the main structure of the transport robot, providing an installation platform and support for other structures; the wheel hubs are located at the bottom of the chassis module, and the wheel hub drive motor drives the wheel hubs.

[0010] The lifting module is located in the middle of the chassis module, and the lifting screws are located on the front and rear sides of the lifting module. The lifting module moves up and down by rotating the lifting screws. The lifting module is connected to the trolley connection module. A planar floating mechanism is set at the bottom of the trolley connection module.

[0011] The chassis module is also equipped with a video monitoring module;

[0012] The industrial computer is connected to the local control module of a small multi-directional displacement robot via a network cable outside a confined space.

[0013] The actuators include: pipe clamping tools, cutting tools, grinding tools, automatic welding tools, and non-destructive testing tools;

[0014] The actuator is connected to the actuator control cabinet via a cable, and the actuator control cabinet controls the actuator, enabling remote operation of the actuator;

[0015] The pipe clamping tool includes:

[0016] Clamping main body;

[0017] Two grippers are set horizontally and perpendicular to the side of the gripping body;

[0018] The grippers are designed with a coaxial shape.

[0019] The clamping tool connection mechanism is located at the bottom of the gripper, and the clamping connection mechanism can be connected to the trolley connection module and other execution tool connection modules respectively;

[0020] Each tool of the actuator has a single function and can individually enter a circular hole with an inner diameter of not less than 220 mm.

[0021] In one specific embodiment of the present invention, the structure of the cutting tool is as follows:

[0022] Both the cutting tool base and the cutting module are U-shaped structures. The cutting module and the cutting blade holder are installed and fixed, driving the cutting blade holder to move in a circle around the center of the cutting tool base. The cutting tool base and the cutting tool connecting module are installed vertically and connected by a connecting plate. There is a positioning pin between the cutting tool base and the cutting tool connecting module.

[0023] After the airlock at the upper end of the cutting tool connection module is connected to the clamping tool connection mechanism, the pipe to be repaired passes through the U-shaped structure, and the center of the pipe is concentric with the center of the cutting tool base.

[0024] The electrical control equipment controls the rotation of the motor reducer shaft, which in turn drives the cutting module and the cutting blade holder to rotate, thus achieving the function of cutting pipes.

[0025] The structure of the polishing tool is as follows:

[0026] The grinding tool head and the cutting tool holder are replaced. The grinding tool head is installed on the cutting module, and the cutting module drives the grinding tool head to rotate, so that the grinding brush can grind the pipe opening.

[0027] In one specific embodiment of the present invention, the automatic welding tool can realize automatic self-fusion welding of pipe joints, and its structure is as follows:

[0028] The L-shaped welding torch is the main structure of the automatic welding tool. The welding torch cover opening and closing motor is located above the L-shaped welding torch handle and is connected to the welding torch cover through gears. The motor drives the gears on the welding torch cover to rotate, thereby opening and closing the welding torch cover.

[0029] The connecting structure is located on the side of the L-shaped welding torch handle and is installed perpendicular to the side of the handle.

[0030] To meet the requirement of the equipment entering confined spaces, the L-shaped welding torch and the welding torch connecting module are assembled after entering the confined space. The welding torch connecting module and the L-shaped welding torch are connected by a dual-axis hole positioning method, with one axis positioned by a spring pin. The spring pin controls the locking and unlocking of the L-shaped welding torch and the welding torch connecting module, enabling quick assembly and disassembly of the two structures.

[0031] In one specific embodiment of the present invention, the non-destructive testing tool includes a radiographic non-destructive testing tool and a penetrant non-destructive testing tool;

[0032] The structure of the X-ray nondestructive testing tool is as follows:

[0033] The bottom is a connecting structure, the upper part of which is equipped with a base structure. The upper part of the base structure is connected to a support rod, the top plate of which is connected to a tray. Limiting rods are connected to both sides of the tray, and the limiting rods are equipped with source fixing holes and video monitoring devices.

[0034] The structure of the penetrant nondestructive testing tool is as follows:

[0035] The bottom of the penetrant testing tool is a connecting structure, and a base structure is installed on the upper part of the connecting structure. A double-HALF structure is connected to the base structure. A flaw detection medium input port is arranged horizontally on one side of the double-HALF structure, and an ultrasonic cleaning probe is arranged at the bottom on the other side. A video monitoring device is arranged at the top, and a penetrant nozzle is arranged inside.

[0036] This invention provides a method for welding and repairing pipes in a confined space, comprising the following steps:

[0037] Step 1: A small multi-directional displacement robot is used as a transport platform to transport the pipe clamping tool to the location of the pipe to be repaired and fix it in place through remote control operation;

[0038] Step 2: A small multi-directional displacement robot transports the cutting tool to the bottom of the pipe clamping tool. Under video monitoring, the airlock of the cutting tool and the airlock of the pipe clamping tool are installed and aligned. The cutting tool is remotely controlled to cut the pipe to be repaired and grind the pipe end.

[0039] Step 3: The small multi-directional displacement robot transports the cutting tool out of the limited space and the grinding tool under the pipe clamping tool. Under video monitoring, the air lock of the grinding tool is installed and aligned with the air lock of the pipe clamping tool, and the grinding tool is remotely controlled to grind and clean the cut pipe opening.

[0040] Step 4: Under remote monitoring, the new pipe is manually replaced. The small multi-directional displacement robot loads the automatic welding tool under the pipe clamping tool. Under video monitoring, the air lock of the automatic welding tool and the air lock of the pipe clamping tool are installed and aligned. The automatic welding tool is remotely controlled to weld the pipe. After welding, the automatic welding tool and the pipe clamping tool are transported out of the confined space in sequence.

[0041] Step 5: A small multi-directional displacement robot transports the penetrant nondestructive testing tool to the pipe welding position below the X-ray nondestructive testing tool. Under monitoring, the pipe weld is lowered and stuck in the HALF structure, and penetrant nondestructive testing is performed remotely. Then, the X-ray nondestructive testing tool is replaced to perform remote X-ray nondestructive testing on the pipe welding position.

[0042] In a specific embodiment of the present invention, step 1 specifically includes:

[0043] Step 1-1: Place the small multi-directional displacement robot and the pipe clamping tool into the confined space, and connect the two tools with an airlock;

[0044] Steps 1-2: The remote control operation controls the small multi-directional displacement robot to transport the pipe clamping tool to the location of the pipe to be repaired. The video monitoring module is used to position the pipe clamping tool to ensure that the center line of the two clamps coincides with the center line of the pipe.

[0045] Steps 1-3: Use a small multi-directional displacement robot lifting mechanism to lift the pipe clamping tool so that the clamping center is at the same height as the pipe center;

[0046] Steps 1-4: Remotely control the pipe clamping tool, reduce the clamping distance, and clamp the pipe clamping tool onto the pipe to complete the installation and positioning of the pipe clamping tool.

[0047] In a specific embodiment of the present invention, step 2 specifically includes:

[0048] Step 2-1: Install the cutting tool onto the small multi-directional displacement robot, which will then transport the cutting tool to the bottom of the pipe clamping tool. Use a video monitoring module to align the airlock of the cutting tool with the airlock of the pipe clamping tool.

[0049] Step 2-2: The main control cabinet remotely controls the cutting tool to cut the pipe to be repaired;

[0050] Steps 2-3: After the pipe cutting is completed, the pipe clamping tool releases the jaws on the side holding the defective pipe, and the maintenance personnel remove the cut defective pipe.

[0051] Step 3 specifically includes:

[0052] Step 3-1: A small multi-directional displacement robot transports the cutting tool to the entrance of the confined space, where maintenance personnel replace the grinding tool with the cutting tool;

[0053] Step 3-2: The small multi-directional displacement robot carries the grinding tool to the bottom of the pipe clamping tool, aligns the air lock of the grinding tool with the air lock of the pipe clamping tool, lifts it up, and connects the air lock of the grinding tool with the air lock of the pipe clamping tool.

[0054] Step 3-3: The tool control cabinet remotely controls the grinding tool to grind the pipe opening to be repaired.

[0055] In one specific embodiment of the present invention, step 4 specifically includes:

[0056] Step 4-1: The maintenance personnel pass the new pipe through the loosened jaws of the pipe clamping tool and align the pipe end with the ground pipe end;

[0057] Step 4-2: After alignment, the pipe clamping tool slowly clamps the new pipe. During the clamping process, observe the gap and misalignment of the pipe installation. If necessary, loosen the side clamps of the new pipe and adjust the pipe installation position to ensure that the gap and misalignment of the two pipes meet the welding process requirements after installation.

[0058] Step 4-3: A small multi-directional displacement robot carries the pipe welding tool onto the pipe clamping tool for installation and positioning;

[0059] Step 4-4: Remotely control the automatic welding tool to weld the pipe. After welding is completed, remove the automatic welding tool from the pipe clamping tool, transport it to the entrance of the narrow space, and have maintenance personnel take out the automatic welding tool.

[0060] Steps 4-5: The small multi-directional displacement robot removes the pipe clamping tool from the pipe and transports it to the entrance of the narrow space to retrieve the pipe clamping tool.

[0061] In one specific embodiment of the present invention, step 5 specifically includes:

[0062] Step 5-1: The small multi-directional displacement robot moves to the entrance of the narrow space and the penetration testing tool is installed on the small multi-directional displacement robot using an airlock;

[0063] Step 5-2: The small multi-directional displacement robot transports the penetrant non-destructive testing tool to the area below the pipe welding position. Using a video monitoring module, the installation port of the penetrant non-destructive testing tool is positioned directly below and parallel to the pipe. The penetrant non-destructive testing tool is then raised and the weld seam of the pipe to be inspected is clamped in the double HALF structure.

[0064] Step 5-3: The main control cabinet remotely operates the penetrant non-destructive testing tool to spray liquid from the flaw detection medium input port to rinse the weld area, spray penetrant, clean, spray colorant, and then clean again;

[0065] Step 5-4: Use a video monitoring module to observe the location of the pipe weld and determine the results of the weld penetration test;

[0066] Step 5-5: Use a small multi-directional displacement robot to transport the penetrant non-destructive testing tool to the entrance of the confined space, replace it with the radiographic non-destructive testing tool, and enter the weld seam for radiographic testing;

[0067] Steps 5-6: Fix the dark box and radiation source in the X-ray tray and the source fixing hole respectively. Connect the connection structure of the X-ray device to the connection module of the small multi-directional displacement robot. Transport the device to the vicinity of the designated location through the small multi-directional displacement robot. Then, complete the fine-tuning and positioning of the X-ray device through the video monitoring device. After that, start the first exposure.

[0068] Steps 5-7: The small multi-directional displacement robot transports the X-ray inspection tool to the entrance of the confined space, where maintenance personnel take out the X-ray inspection tool and install the X-ray device with different angles onto the small multi-directional displacement robot.

[0069] Steps 5-8: Repeat steps 5-6 and 5-7 until the final radiographic inspection is completed.

[0070] Compared with the prior art, the pipe welding and repair robot and repair method of the present invention, which are suitable for confined spaces, have the following beneficial effects:

[0071] (1) The pipeline welding and repair equipment adopts a modular design. Each module has a single function and can enter a round hole with an inner diameter of not less than 220mm. It can be quickly disassembled and assembled in a narrow space, solving the problem of personnel being unable to enter the environment for pipeline repair.

[0072] (2) The pipe clamping tool is designed as a positioning reference. The relative position of the pipe clamping tool and the pipe to be repaired remains unchanged during the maintenance process. The positioning and installation of each execution tool and the pipe clamping tool can ensure the accuracy of the working position and welding position of each execution tool, which effectively improves the efficiency and quality of pipe maintenance.

[0073] (3) The pipe welding robot is designed as a multi-modal tool to reduce the size of each module and ensure that the corresponding module has a single function. It performs the work alternately for each process of pipe replacement and maintenance until the maintenance work is completed.

[0074] (4) A floating device is designed below the lifting mechanism of the transport robot, which has the ability to float in the XY plane while the connecting tool is rising, so as to avoid the torque generated by the tool alignment and installation causing the trolley to deviate or overturn, thus improving the stability of the trolley.

[0075] (5) The pipe clamping tool has a concentric design with two clamps and a rigid base design. When the two clamps are clamped at the same time, it can assist in the alignment and installation of the assembled pipe and improve the accuracy of pipe assembly.

[0076] (6) The penetrant testing tool is designed with a double HALF structure, which is easy to install with the pipeline to be tested. It can prevent liquid from flowing out during the penetrant testing process and flows to the external waste liquid collection box through the conduit at the bottom of the structure, thus avoiding the pollution of surrounding pipelines or environment by the penetrant testing waste liquid.

[0077] (7) The positioning and installation direction of each tool is unified, and the spatial positioning of each tool is achieved by combining visual monitoring and mechanical guidance positioning, which improves the accuracy and efficiency of tool positioning and installation, and ensures the accuracy and stability of equipment installation. Attached Figure Description

[0078] Figure 1 A schematic diagram showing the structure of a small multi-directional displacement robot;

[0079] Figure 2 This diagram shows the structure of a pipe clamping tool.

[0080] Figure 3 A schematic diagram showing the structure of cutting and grinding tools;

[0081] Figure 4 This diagram shows the structure of an automatic welding tool.

[0082] Figure 5 This is a schematic diagram of the structure of a radiographic nondestructive testing tool.

[0083] Figure 6 This diagram shows the structure of a penetrant nondestructive testing tool.

[0084] In the diagram, 1-local control module, 2-lifting screw, 3-hub drive motor, 4-lifting module, 5-cart connection module, 6-video monitoring module, 7-hub, 8-chassis module, 9-clamping body, 10-gripper, 11-clamping tool connection mechanism, 12-cutting tool base, 13-cutting tool connection module, 14-connecting plate, 15-cutting module, 16-cutting tool holder, 17-grinding tool head, 18-grinding brush, 19-L-shaped welding torch, 20-welding torch cover opening and closing motor, 21-welding torch connection module, 22-welding torch cover, 23-radiation tray, 24-video monitoring device (shared by non-destructive testing and radiographic testing tools), 25-ultrasonic cleaning probe, 26-penetrating fluid nozzle, 27-flaw detection medium input port, 28-double HALF structure, 29-penetrating fluid connection module, 30-radiation tool connection module. Detailed Implementation

[0085] To further understand the present invention, embodiments of the present invention are described below in conjunction with examples. However, it should be understood that these descriptions are only for further illustrating the features and advantages of the present invention, and not for limiting the present invention.

[0086] An embodiment of the present invention discloses a pipe welding and repair robot suitable for confined spaces, comprising: a small multi-directional displacement robot, an actuator connected thereto, an industrial control computer, and an actuator control cabinet;

[0087] The small multi-directional displacement robot and the actuator are both connected by airlocks.

[0088] Outside the confined space, the industrial control computer is connected to the local control module 1 of the small multi-directional displacement robot via a network cable. As the host computer system of the entire small multi-directional displacement robot, the industrial control computer collects signals from the cameras and sensors transmitted back by the local control module 1, processes them accordingly, and feeds them back to the host computer software. It can also send a series of instructions to the local control module 1 through the software to control the movement of the small multi-directional displacement robot.

[0089] The small multi-directional displacement robot includes the following components: a local control module 1, which includes a main control PLC and a switch. This module is connected to the industrial control computer via a network cable, can receive control signals from the industrial control computer, drive the transport robot to work, and send the image signals from the video monitoring module 6 back to the industrial control computer.

[0090] Chassis module 8 is the main structure of the transport robot, providing an installation platform and support for other structures;

[0091] The hub 7 is located at the bottom of the chassis module 8, and the hub drive motor 3 drives the hub 7 to realize the full-position movement of the transport robot;

[0092] The lifting module 4 is located in the middle of the chassis module 8, and the lifting screw 2 is located on both the front and rear sides of the lifting module 4. The lifting module 4 moves up and down by rotating the lifting screw 2. The lifting module 4 is connected to the trolley connection module 5 and can move up and down together with the trolley connection module 5. The bottom of the trolley connection module 5 is equipped with a planar floating mechanism, which enables the trolley connection module 5 to float in the XY plane (horizontal plane), avoiding the torque caused by the misalignment of the tool airlock, which could cause the trolley to tilt or even tip over.

[0093] Preferably, a connecting module is installed inside the lifting module 4, with a first airlock installed at the top and a floating mechanism installed at the bottom. A video monitoring module 6 is also provided on the chassis module 8. The video monitoring module 6 provides video-assisted positioning for the installation of the actuator, working together with the mechanical guiding device to achieve precise alignment and installation of the equipment.

[0094] The actuators include: pipe clamping tools, cutting tools, grinding tools, automatic welding tools, radiographic non-destructive testing tools, and penetrant non-destructive testing tools;

[0095] The actuator control system and the small multi-directional displacement robot control system are set up separately. After each tool enters the confined space, it is connected to the actuator control cabinet through cables. The actuator control cabinet controls the actuator tool, realizing remote operation of the actuator tool.

[0096] The structure of the pipe clamping tool is as follows:

[0097] The clamping body 9 is the main support structure of the pipe clamping tool, which bears the reaction force of other tools during installation and operation.

[0098] Two grippers 10 are set horizontally and perpendicular to the side of the gripping body 9;

[0099] The 10 clamps are coaxially designed. When the two clamps hold the pipe at the same time, they can help the pipe installation and centering, so that the center line deviation of the two pipes after assembly meets the welding process requirements.

[0100] The clamping tool connecting mechanism 11 is located at the bottom of the gripper 10. The clamping connecting mechanism 11 can be connected to the trolley connecting module 5 and other execution tool connecting modules respectively, providing an installation positioning reference for other execution tools.

[0101] Preferably, a main gripper and a secondary gripper are vertically mounted at both ends of the clamping body, and a second airlock is connected to the lower end of the main gripper. The structure of the cutting tool is as follows:

[0102] Both the cutting tool base 12 and the cutting module 15 are U-shaped structures, connected in parallel. The cutting module 15 is fixedly installed with the cutting blade holder 16, causing the cutting blade holder 16 to rotate around the center of the cutting tool base 12. The cutting tool base 12 and the cutting tool connecting module 13 are installed vertically and connected by a connecting plate 14. A positioning pin is located between the cutting tool base 12 and the cutting tool connecting module 13 to ensure that they are perpendicular. After the air lock at the upper end of the cutting tool connecting module 13 is connected to the clamping tool connecting mechanism 11, the pipe to be repaired passes through the U-shaped structure, with the center of the pipe concentric with the center of the cutting tool base 12. A third air lock is installed at the lower part of the cutting tool connecting module 13, and a fourth air lock is installed at the upper part. The electrical control equipment controls the rotation of the motor reducer shaft, which drives the cutting module 15 and the cutting blade holder 16 to rotate, thus realizing the function of cutting the pipe. The radial movement of the cutting tool is achieved by the needle-pulling cylinder on the side of the cutting module 15. The rotation of the cutting module 15 drives the cylinder to extend and retract, thereby achieving the radial movement of the tool. The radial advance or retraction of the cutting tool is controlled by the rotation direction of the cutting module 15.

[0103] The structure of the grinding tool is as follows:

[0104] The grinding tool head 17 is replaced with the cutting tool holder 16. The grinding tool head 17 is installed on the cutting module 15, and the cutting module 15 drives the grinding tool head 17 to rotate, so that the grinding brush 18 can grind the pipe opening.

[0105] The automatic welding tool can realize automatic self-fusion welding of pipe joints, and its structure is as follows:

[0106] The L-shaped welding torch 19 is the main structure of the automatic welding tool. The torch cover opening and closing motor 20 is located above the handle of the L-shaped welding torch 19 and is connected to the torch cover 22 via gears. The motor drives the gears on the torch cover 22 to rotate, thus opening and closing the torch cover 22. The connecting structure is located on the side of the handle of the L-shaped welding torch 19 and is installed perpendicular to the side of the handle. To meet the requirement of the equipment entering a narrow space (an inner diameter hole of 220mm), the L-shaped welding torch 19 and the welding torch connecting module 21 are assembled after entering the narrow space respectively. The welding torch connecting module 21 has a fifth air lock installed at the bottom and a sixth air lock installed at the top.

[0107] The welding torch connection module 21 and the L-shaped welding torch 19 are connected by a dual-axis hole positioning method. One of the axes is positioned by a spring pin. The spring pin controls the locking and unlocking of the L-shaped welding torch 19 and the welding torch connection module 21, enabling quick assembly and disassembly of the two structures.

[0108] The structure of the X-ray nondestructive testing tool is as follows:

[0109] The bottom is a connecting structure. A seventh airlock is installed at the bottom of the X-ray tool connecting module 30, and a base structure is installed at the top. A support rod is connected to the top of the base structure, and the top of the support rod is connected to the X-ray tray 23. Limiting rods are connected to both sides of the X-ray tray 23. The limiting rods are respectively provided with source fixing holes and video monitoring devices 24. The limiting rods can achieve preliminary positioning of the pipeline to be inspected. The source fixing holes are located on the limiting rods on the side of the X-ray tray 23 and are parallel to the upper surface of the tray. The video monitoring device 24 is installed on the other side of the X-ray tray 23 for observing the positioning between the X-ray tray 23 and the pipeline to be inspected.

[0110] The structure of a penetrant nondestructive testing tool is as follows:

[0111] The penetration tool connection module 29 is located at the bottom of the tool and is a component that connects the non-destructive testing tool base to the small multi-directional displacement robot. The penetration tool connection module 29 has a base structure installed on the upper part and an eighth airlock installed on the lower part. The base structure is connected to a double HALF structure 28. The double HALF structure 28 has a flaw detection medium input port 27 arranged horizontally on one side and an ultrasonic cleaning probe 25 arranged at the bottom on the other side. A video monitoring device 24 is arranged at the top, and a penetration liquid nozzle 26 is arranged inside.

[0112] The pipeline to be inspected passes through the double-half structure 28 and is sealed with double-layer silicone to prevent liquid leakage at the pipeline installation location. A video monitoring device 24 is located above the double-half structure. An ultrasonic cleaning probe 25 is installed behind the double-half structure 28, mounted on the same component as the penetrant nozzle 26. The flaw detection medium inlet 27 is located in front of the double-half structure 28, arranged in a straight line. Liquid generated during the penetrant testing process can be extracted through the suction pipe at the bottom of the double-half structure 28, preventing damage to adjacent pipelines or the environment during the penetrant testing process.

[0113] An embodiment of the present invention discloses a method for replacing and repairing defects in confined space pipelines, comprising the following steps:

[0114] Step 1: A small multi-directional displacement robot is used as a transport platform to deliver the pipe clamping tool to the location of the pipe to be repaired and fix it in place;

[0115] Specifically, it includes:

[0116] Step 1-1: Place the small multi-directional displacement robot and the pipe clamping tool into the confined space, and connect the two tools with an airlock.

[0117] Steps 1-2: The remote control operation controls the small multi-directional displacement robot to transport the pipe clamping tool to the location of the pipe to be repaired. The video monitoring module 6 is used to position the pipe clamping tool to ensure that the center line of the two clamps coincides with the center line of the pipe.

[0118] Steps 1-3: The pipe clamping tool is lifted by the small multi-directional displacement robot lifting mechanism 4, so that the center of the clamp 10 is at the same height as the center of the pipe.

[0119] Steps 1-4: Remotely control the pipe clamping tool, reduce the clamping distance, and clamp the pipe clamping tool onto the pipe to complete the installation and positioning of the pipe clamping tool.

[0120] Step 2: Cutting the pipe to be repaired and grinding the pipe ends;

[0121] Specifically, it includes:

[0122] Step 2-1: Install the cutting tool onto the small multi-directional displacement robot, which will then transport the cutting tool to the bottom of the pipe clamping tool. Use video monitoring module 6 to align the airlock of the cutting tool with the airlock of the pipe clamping tool.

[0123] Step 2-2: The main control cabinet remotely controls the cutting tool to cut the pipe to be repaired;

[0124] Steps 2-3: After the pipe cutting is completed, the pipe clamping tool releases the jaws on the side holding the defective pipe, and the maintenance personnel remove the cut defective pipe.

[0125] Step 3: Cut the pipe opening and grind / clean it;

[0126] Specifically, it includes:

[0127] Step 3-1: A small multi-directional displacement robot transports the cutting tool to the entrance of the confined space, where maintenance personnel replace the grinding tool with the cutting tool;

[0128] Step 3-2: The small multi-directional displacement robot carries the grinding tool to the bottom of the pipe clamping tool, aligns the air lock of the grinding tool with the air lock of the pipe clamping tool, lifts it up, and connects the air lock of the grinding tool with the air lock of the pipe clamping tool.

[0129] Step 3-3: Use the remote-controlled grinding tool from the tool control cabinet to grind the pipe opening to be repaired;

[0130] Step 4: New pipe installation and welding;

[0131] Step 4-1: The maintenance personnel pass the new pipe through the loosened jaws of the pipe clamping tool and align the pipe end with the ground pipe end;

[0132] Step 4-2: After alignment, the pipe clamping tool slowly clamps the new pipe. During the clamping process, observe the gap and misalignment of the pipe installation. If necessary, loosen the side clamps of the new pipe and adjust the pipe installation position to ensure that the gap and misalignment of the two pipes meet the welding process requirements after installation.

[0133] Step 4-3: A small multi-directional displacement robot carries the pipe welding tool onto the pipe clamping tool for installation and positioning;

[0134] Step 4-4: Remotely control the automatic welding tool to weld the pipe. After welding is completed, remove the automatic welding tool from the pipe clamping tool, transport it to the entrance of the narrow space, and have maintenance personnel take out the automatic welding tool.

[0135] Steps 4-5: The small multi-directional displacement robot removes the pipe clamping tool from the pipe and transports it to the entrance of the narrow space to retrieve the pipe clamping tool.

[0136] Step 5: Use non-destructive testing tools to perform penetrant and radiographic testing on the weld seams of the pipeline.

[0137] Specifically, it includes:

[0138] Step 5-1: The small multi-directional displacement robot moves to the entrance of the narrow space and the penetration testing tool is installed on the small multi-directional displacement robot using an airlock;

[0139] Step 5-2: The small multi-directional displacement robot transports the penetrant non-destructive testing tool to the area below the pipe welding position. Using the video monitoring module 6, the installation port of the penetrant non-destructive testing tool is positioned directly below the pipe and parallel to the pipe. The penetrant non-destructive testing tool is then raised and the weld seam of the pipe to be inspected is clamped in the double HALF structure 28.

[0140] Step 5-3: The main control cabinet remotely operates the penetrant non-destructive testing tool to spray liquid from the flaw detection medium input port 27 to rinse the weld area, spray penetrant, clean, spray colorant and clean again;

[0141] Step 5-4: Use video monitoring module 24 to observe the location of the pipe weld and judge the results of the weld penetration test;

[0142] Step 5-5: Use a small multi-directional displacement robot to transport the penetrant non-destructive testing tool to the entrance of the confined space, replace it with the radiographic non-destructive testing tool, and enter the weld seam for radiographic testing;

[0143] Steps 5-6: Fix the cassette and radiation source in the X-ray tray 22 and the source fixing hole 23 respectively. Connect the X-ray device connection structure 30 to the connection module 5 of the small multi-directional displacement robot. Transport the device to the vicinity of the designated location by the small multi-directional displacement robot. Then, the video monitoring device 24 completes the fine-tuning and positioning of the X-ray device before the first exposure is carried out.

[0144] Steps 5-7: The small multi-directional displacement robot transports the X-ray inspection tool to the entrance of the confined space, where maintenance personnel take out the X-ray inspection tool and install the X-ray device with different angles onto the small multi-directional displacement robot.

[0145] Steps 5-8: Repeat steps 6 / 7 until the final radiographic inspection is completed.

[0146] The above description of the embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A pipe welding and repair robot suitable for confined spaces, characterized in that, include: A small multi-directional displacement robot, connected to an actuator, an industrial computer, and an actuator control cabinet; The small multi-directional displacement robot includes: Local control module; The chassis module is the main structure of the transport robot, providing an installation platform and support for other structures; the wheel hubs are located at the bottom of the chassis module, and the wheel hub drive motor drives the wheel hubs. The lifting module is located in the middle of the chassis module, and the lifting screws are located on the front and rear sides of the lifting module. The lifting module moves up and down by rotating the lifting screws. The lifting module is connected to the trolley connection module. A planar floating mechanism is set at the bottom of the trolley connection module. The chassis module is also equipped with a video monitoring module; The industrial computer is connected to the local control module of a small multi-directional displacement robot via a network cable outside a confined space. The actuators include: pipe clamping tools, cutting tools, grinding tools, automatic welding tools, and non-destructive testing tools; The actuator is connected to the actuator control cabinet via a cable, and the actuator control cabinet controls the actuator, enabling remote operation of the actuator; The pipe clamping tool includes: Clamping main body; Two grippers are set horizontally and perpendicular to the side of the gripping body; The grippers are designed with a coaxial shape. The clamping tool connection mechanism is located at the bottom of the gripper, and the clamping connection mechanism can be connected to the trolley connection module and other execution tool connection modules respectively; Each tool of the actuator has a single function and can individually enter a circular hole with an inner diameter of not less than 220 mm.

2. The pipe welding and repair robot suitable for confined spaces according to claim 1, characterized in that, The cutting tool has the following structure: Both the cutting tool base and the cutting module are U-shaped structures. The cutting module and the cutting blade holder are installed and fixed, driving the cutting blade holder to move in a circle around the center of the cutting tool base. The cutting tool base and the cutting tool connecting module are installed vertically and connected by a connecting plate. There is a positioning pin between the cutting tool base and the cutting tool connecting module. After the airlock at the upper end of the cutting tool connection module is connected to the clamping tool connection mechanism, the pipe to be repaired passes through the U-shaped structure, and the center of the pipe is concentric with the center of the cutting tool base. The electrical control equipment controls the rotation of the motor reducer shaft, which in turn drives the cutting module and the cutting blade holder to rotate, thus achieving the function of cutting pipes. The structure of the polishing tool is as follows: The grinding tool head and the cutting tool holder are replaced. The grinding tool head is installed on the cutting module, and the cutting module drives the grinding tool head to rotate, so that the grinding brush can grind the pipe opening.

3. The pipe welding and repair robot suitable for confined spaces according to claim 1, characterized in that, The automatic welding tool can realize automatic self-fusion welding of pipe joints, and its structure is as follows: The L-shaped welding torch is the main structure of the automatic welding tool. The welding torch cover opening and closing motor is located above the L-shaped welding torch handle and is connected to the welding torch cover through gears. The motor drives the gears on the welding torch cover to rotate, thereby opening and closing the welding torch cover. The connecting structure is located on the side of the L-shaped welding torch handle and is installed perpendicular to the side of the handle. To meet the requirement of the equipment entering confined spaces, the L-shaped welding torch and the welding torch connecting module are assembled after entering the confined space. The welding torch connecting module and the L-shaped welding torch are connected by a dual-axis hole positioning method, with one axis positioned by a spring pin. The spring pin controls the locking and unlocking of the L-shaped welding torch and the welding torch connecting module, enabling quick assembly and disassembly of the two structures.

4. The pipe welding and repair robot suitable for confined spaces according to claim 1, characterized in that, The non-destructive testing tools include radiographic non-destructive testing tools and penetrant non-destructive testing tools.

5. The pipe welding and repair robot suitable for confined spaces according to claim 4, characterized in that, The structure of the radiographic nondestructive testing tool is as follows: The bottom is a connecting structure, the upper part of which is equipped with a base structure, the upper part of which is connected to a support rod, the top plate of which is connected to a tray, and the two sides of which are connected to limiting rods. The limiting rods are equipped with source fixing holes and video monitoring devices. The structure of the penetrant nondestructive testing tool is as follows: The bottom of the penetrant testing tool is a connecting structure, and a base structure is installed on the upper part of the connecting structure. A double-HALF structure is connected to the base structure. A flaw detection medium input port is arranged horizontally on one side of the double-HALF structure, and an ultrasonic cleaning probe is arranged at the bottom on the other side. A video monitoring device is arranged at the top, and a penetrant nozzle is arranged inside.

6. A method for welding and repairing pipes in a confined space, characterized in that, Includes the following steps: Step 1: A small multi-directional displacement robot is used as a transport platform to transport the pipe clamping tool to the location of the pipe to be repaired and fix it in place through remote control operation; Step 2: A small multi-directional displacement robot transports the cutting tool to the bottom of the pipe clamping tool. Under video monitoring, the airlock of the cutting tool and the airlock of the pipe clamping tool are installed and aligned. The cutting tool is remotely controlled to cut the pipe to be repaired and grind the pipe end. Step 3: The small multi-directional displacement robot transports the cutting tool out of the limited space and the grinding tool under the pipe clamping tool. Under video monitoring, the air lock of the grinding tool is installed and aligned with the air lock of the pipe clamping tool, and the grinding tool is remotely controlled to grind and clean the cut pipe opening. Step 4: Under remote monitoring, the new pipe is manually replaced. The small multi-directional displacement robot loads the automatic welding tool under the pipe clamping tool. Under video monitoring, the air lock of the automatic welding tool and the air lock of the pipe clamping tool are installed and aligned. The automatic welding tool is remotely controlled to weld the pipe. After welding, the automatic welding tool and the pipe clamping tool are transported out of the confined space in sequence. Step 5: A small multi-directional displacement robot transports the penetrant nondestructive testing tool to the pipe welding position below the X-ray nondestructive testing tool. Under monitoring, the pipe weld is lowered and stuck in the HALF structure, and penetrant nondestructive testing is performed remotely. Then, the X-ray nondestructive testing tool is replaced to perform remote X-ray nondestructive testing on the pipe welding position.

7. The confined space pipeline welding and repair method according to claim 6, characterized in that, Step 1 specifically includes: Step 1-1: Place the small multi-directional displacement robot and the pipe clamping tool into the confined space, and connect the two tools with an airlock; Steps 1-2: The remote control operation controls the small multi-directional displacement robot to transport the pipe clamping tool to the location of the pipe to be repaired. The video monitoring module is used to position the pipe clamping tool to ensure that the center line of the two clamps coincides with the center line of the pipe. Steps 1-3: Use a small multi-directional displacement robot lifting mechanism to lift the pipe clamping tool so that the clamping center is at the same height as the pipe center; Steps 1-4: Remotely control the pipe clamping tool, reduce the clamping distance, and clamp the pipe clamping tool onto the pipe to complete the installation and positioning of the pipe clamping tool.

8. The confined space pipeline welding and repair method according to claim 6, characterized in that, Step 2 specifically includes: Step 2-1: Install the cutting tool onto the small multi-directional displacement robot, which will then transport the cutting tool to the bottom of the pipe clamping tool. Use a video monitoring module to align the airlock of the cutting tool with the airlock of the pipe clamping tool. Step 2-2: The main control cabinet remotely controls the cutting tool to cut the pipe to be repaired; Steps 2-3: After the pipe cutting is completed, the pipe clamping tool releases the jaws on the side holding the defective pipe, and the maintenance personnel remove the cut defective pipe. Step 3 specifically includes: Step 3-1: A small multi-directional displacement robot transports the cutting tool to the entrance of the confined space, where maintenance personnel replace the grinding tool with the cutting tool; Step 3-2: The small multi-directional displacement robot carries the grinding tool to the bottom of the pipe clamping tool, aligns the air lock of the grinding tool with the air lock of the pipe clamping tool, lifts it up, and connects the air lock of the grinding tool with the air lock of the pipe clamping tool. Step 3-3: The tool control cabinet remotely controls the grinding tool to grind the pipe opening to be repaired.

9. The confined space pipeline welding and repair method according to claim 6, characterized in that, Step 4 specifically includes: Step 4-1: The maintenance personnel pass the new pipe through the loosened jaws of the pipe clamping tool and align the pipe end with the ground pipe end; Step 4-2: After alignment, the pipe clamping tool slowly clamps the new pipe. During the clamping process, observe the gap and misalignment of the pipe installation. If necessary, loosen the side clamps of the new pipe and adjust the pipe installation position to ensure that the gap and misalignment of the two pipes meet the welding process requirements after installation. Step 4-3: A small multi-directional displacement robot carries the pipe welding tool onto the pipe clamping tool for installation and positioning; Step 4-4: Remotely control the automatic welding tool to weld the pipe. After welding is completed, remove the automatic welding tool from the pipe clamping tool, transport it to the entrance of the narrow space, and have maintenance personnel take out the automatic welding tool. Steps 4-5: The small multi-directional displacement robot removes the pipe clamping tool from the pipe and transports it to the entrance of the narrow space to retrieve the pipe clamping tool.

10. The confined space pipeline welding and repair method according to claim 6, characterized in that, Step 5 specifically includes: Step 5-1: The small multi-directional displacement robot moves to the entrance of the narrow space and the penetration testing tool is installed on the small multi-directional displacement robot using an airlock; Step 5-2: The small multi-directional displacement robot transports the penetrant non-destructive testing tool to the area below the pipe welding position. Using a video monitoring module, the installation port of the penetrant non-destructive testing tool is positioned directly below and parallel to the pipe. The penetrant non-destructive testing tool is then raised and the weld seam of the pipe to be inspected is clamped in the double HALF structure. Step 5-3: The main control cabinet remotely operates the penetrant non-destructive testing tool to spray liquid from the flaw detection medium input port to rinse the weld area, spray penetrant, clean, spray colorant, and then clean again; Step 5-4: Use a video monitoring module to observe the location of the pipe weld and determine the results of the weld penetration test; Step 5-5: Use a small multi-directional displacement robot to transport the penetrant non-destructive testing tool to the entrance of the confined space, replace it with the radiographic non-destructive testing tool, and enter the weld seam for radiographic testing; Steps 5-6: Fix the dark box and radiation source in the X-ray tray and the source fixing hole respectively. Connect the connection structure of the X-ray device to the connection module of the small multi-directional displacement robot. Transport the device to the vicinity of the designated location through the small multi-directional displacement robot. Then, complete the fine-tuning and positioning of the X-ray device through the video monitoring device. After that, start the first exposure. Steps 5-7: The small multi-directional displacement robot transports the X-ray inspection tool to the entrance of the confined space, where maintenance personnel take out the X-ray inspection tool and install the X-ray device with different angles onto the small multi-directional displacement robot. Steps 5-8: Repeat steps 5-6 and 5-7 until the final radiographic inspection is completed.

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