Wall-climbing weld seam inspection robot and autonomous weld seam inspection method

Abstract

The present application relates to a wall-climbing weld detection robot and a weld autonomous detection method. The wall-climbing weld detection robot comprises a control module, a wall-climbing moving platform, a visual laser positioning device fixedly connected with the wall-climbing moving platform through a connecting plate, the visual laser positioning device comprising a camera and at least one laser, the laser being capable of emitting laser to the weld to be detected, the camera collecting laser reflection information and / or image data of the weld generated thereby and transmitting the laser reflection information and / or the image data to the control module, the control module calculating position deviation and / or attitude deviation of the weld relative to the wall-climbing moving platform, a detection following device comprising at least one detection probe for detecting the weld and a driving mechanism, the control module outputting the position deviation and / or the attitude deviation to the driving mechanism, and the driving mechanism moving the detection probe according to the position deviation and / or the attitude deviation, and an odometer moving in left-right and / or height directions.

Description

Technical Field

[0001] This invention relates to the field of weld inspection technology, and in particular to a wall-climbing weld inspection robot and an autonomous weld inspection method. Background Technology

[0002] Large steel structures such as wind turbine towers, spherical storage tanks, and ship hulls operate under conditions of high load, corrosion, and temperature fluctuations. Circumferential and longitudinal welds are structurally weak points, requiring regular non-destructive testing to detect internal cracks, incomplete penetration, and other defects. Currently, weld inspection is mostly conducted manually using scaffolding and suspended platforms, with inspectors manually inspecting using handheld ultrasonic probes. This method carries high safety risks and labor costs, and the poor repeatability of manual walking trajectories and unstable probe coupling pressure easily lead to missed detections and inconsistent test data.

[0003] While existing magnetically adsorbed wall-climbing weld inspection robots can climb steel walls using magnetic adsorption, in practical engineering applications, the weld tracking and probe position adjustment mechanisms are controlled independently, lacking closed-loop linkage control. When the robot deflects along the weld, the detection probe cannot synchronously compensate for positional deviations, failing to meet the process requirements for relative position and scanning spacing of weld inspection probes. Furthermore, existing magnetically adsorbed wall-climbing weld inspection robot probes are mostly rigidly fixed; fluctuations in weld reinforcement and localized unevenness in the plate material can cause probe decoupling, sudden pressure changes, and signal distortion. Moreover, the lack of a matching mileage measurement structure makes it impossible to synchronously calibrate the weld mileage position corresponding to defects, resulting in significant difficulties in defect location, retesting, and tracing in subsequent inspection reports.

[0004] For example, CN119000890A discloses a magnetic crawling inspection device with laser tracking, which adopts an integrated frame design and uses time-of-flight diffraction ultrasonic testing (TOFD) to inspect welds. However, its inspection probe lacks a buffer structure, has poor coupling stability, lacks an odometer, cannot accurately calibrate the defect location, and the vision only controls the vehicle's movement, unable to link the probe for multi-dimensional compensation. Summary of the Invention

[0005] Therefore, the present invention aims to provide a wall-climbing weld inspection robot and an autonomous weld inspection method to overcome the problems in the prior art, such as the lack of closed-loop linkage control in the weld tracking and probe position adjustment mechanism and the difficulty in accurately recording the weld inspection length.

[0006] To achieve the above objectives, the present invention provides a wall-climbing weld inspection robot, comprising: a control module, a wall-climbing mobile platform, and a visual laser positioning device. The visual laser positioning device is connected to the wall-climbing mobile platform. The visual laser positioning device includes a camera and at least one laser. The camera and laser are oriented towards the weld to be inspected. The laser is capable of emitting laser light towards the weld. The camera is capable of acquiring the resulting laser reflection information and / or image data of the weld and transmitting the laser reflection information and / or image data to the control module. The control module calculates the positional deviation and / or attitude deviation of the weld relative to the wall-climbing mobile platform.

[0007] The wall-climbing weld inspection machine also includes an inspection following device, which comprises at least one inspection probe for inspecting the weld and a drive mechanism. The control module is capable of outputting positional deviation and / or attitude deviation to the drive mechanism, and the drive mechanism is capable of moving the inspection probe according to the positional deviation and / or attitude deviation.

[0008] In addition, the wall-climbing weld inspection machine also includes an odometer that can move in the left-right and / or height directions.

[0009] In one embodiment of the invention, the wall-climbing mobile platform includes a front vehicle and a rear vehicle, which are connected by a torsion mechanism, enabling the front vehicle and the rear vehicle to rotate relative to each other about a longitudinal central axis AA.

[0010] In one embodiment of the invention, at least one passive adapting spring is provided on each side of the torsion mechanism. One end of the passive adapting spring is connected to or in contact with a connecting plate extending from the underside of the front vehicle, and the other end of the passive adapting spring is connected to or in contact with a connecting plate extending from the upper side of the rear vehicle. The passive adapting spring allows the corresponding connecting plates to move closer to or further away from each other. Alternatively, one end of the passive adapting spring is connected to or in contact with a connecting plate extending from the upper side of the front vehicle, and the other end of the passive adapting spring is connected to or in contact with a connecting plate extending from the underside of the rear vehicle. The passive adapting spring allows the corresponding connecting plates to move closer to or further away from each other.

[0011] In one embodiment of the present invention, the laser reflection information is a laser feature line or a laser feature point, and the image data includes the weld center line, edge line, or weld outline.

[0012] In one embodiment of the present invention, the driving mechanism includes a detection probe support mechanism for supporting the detection probe, a left-right actuator for moving the detection probe support mechanism in the left-right direction, and a height actuator for moving the detection probe support mechanism in the height direction.

[0013] In one embodiment of the invention, the visual laser positioning device is connected to a wall-climbing mobile platform via a connecting frame. A left-right actuator is arranged on the connecting frame for actuating a first slider along a first guide rail arranged on the connecting frame. The first slider is slidably arranged on the first guide rail. A second guide rail is arranged on the first slider. A height-direction actuator is arranged at one end of the second guide rail for actuating a second slider along the second guide rail. The second slider is slidably arranged on the second guide rail, and a detection probe support mechanism is arranged on the second slider.

[0014] In one embodiment of the present invention, the detection probe support mechanism includes a third guide rail. The third guide rail is arranged on a second slider in a left-right direction W, and a detection probe actuator is arranged at one end of the third guide rail. The detection probe actuator is used to actuate at least one third slider along the third guide rail, the third slider being slidably arranged on the third guide rail. A fourth guide rail extending in a height direction H is arranged on each of the at least one third slider, and a fourth slider is arranged on the fourth guide rail, the fourth slider being slidably arranged on the fourth guide rail. The detection probe support mechanism further includes a first bias spring, one end of which is connected to the lower part of the fourth guide rail, and the other end of which is connected to the fourth slider, applying a downward force to the fourth slider.

[0015] In one embodiment of the present invention, the fourth slider is connected to a pivoting link, which extends obliquely relative to the height direction H and is pivotable relative to the fourth slider. The pivoting link is connected to a detection probe bracket for supporting the detection probe, and the front and rear ends of the detection probe bracket are pivotable relative to the pivoting link.

[0016] In one embodiment of the present invention, a torsion spring is provided at the pivot point between the pivot link and the fourth slider, the torsion spring causing one end of the pivot link connected to the detection probe to pivot downward.

[0017] In one embodiment of the invention, a fifth guide rail extending along the height direction H is arranged at the third guide rail, and a fifth slider is arranged on the fifth guide rail, the fifth slider being slidable along the fifth guide rail. A second biasing spring is provided between the fifth guide rail and the fifth slider, one end of the second biasing spring being connected to the lower part of the fifth guide rail and the other end being connected to the fifth slider, applying a downward force to the fifth slider. An odometer is arranged on the fifth slider.

[0018] In one embodiment of the present invention, the odometer is capable of recording the weld inspection length and the mileage of the weld defect location and transmitting the weld inspection length and the mileage of the weld defect location to the control module, which is capable of corresponding the data collected or detected by the camera and / or the detection probe with the spatial location of the weld.

[0019] In one embodiment of the invention, two third sliders are slidably arranged on a third guide rail. The third guide rail includes a lead screw, which is driven to rotate by a detection probe actuator. The two third sliders are configured as two threaded pairs having threads with opposite directions of rotation.

[0020] The present invention also provides an autonomous weld inspection method, which uses a wall-climbing weld inspection robot according to the present invention. Attached Figure Description

[0021] Figure 1 A perspective view of one embodiment of the wall-climbing weld inspection robot according to the present invention is shown.

[0022] Figure 2 A perspective view of one embodiment of the wall-climbing mobile platform according to the present invention is shown.

[0023] Figure 3 An exploded view of one embodiment of the wall-climbing mobile platform according to the present invention is shown.

[0024] Figure 4 A front view of one embodiment of the detection and tracking device and odometer according to the present invention is shown.

[0025] Figure 5 A rear view of one embodiment of the detection and tracking device and odometer according to the present invention is shown.

[0026] Figure 6 Detailed diagrams of one embodiment of the detection and tracking device and odometer according to the present invention are shown.

[0027] Explanation of reference numerals in the attached figures

[0028] 1. Wall-climbing weld inspection robot 2. Wall-climbing mobile platform 21. Front vehicle 22. Rear vehicle 23. Torsion mechanism 231. Pivot sleeve 232. Pivot shaft 24. Passive adaptive spring 25. Connecting plate 26. Pivot sleeve mounting plate 27. Pivot shaft mounting plate 3. Visual laser positioning device 31. Connecting frame 32. Camera 33. Laser 4. Detection following device 41. Detection probe 5. Odometer 51. Fifth guide rail 52. Fifth slider 53. Odometer mounting plate 54. Odometer bracket 6. Drive mechanism 61. Detection probe support mechanism 611. Third guide rail 612. Detection probe actuator 613. Third slider 614. Fourth guide rail 615. Fourth slider 616. First bias spring 617. Pivot linkage 618. Detection probe bracket 62. Left and right direction actuator 63. Height direction actuator 64. First guide rail 65. First slider 66. Second guide rail 67. Second slider Detailed Implementation

[0029] Various exemplary embodiments, features, and aspects of this application will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0030] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0031] Furthermore, to better illustrate this application, numerous specific details are provided in the following detailed embodiments. Those skilled in the art should understand that this application can be implemented even without certain specific details. In some instances, methods, means, and elements well-known to those skilled in the art have not been described in detail in order to highlight the main points of this application.

[0032] It is understood that the directions of height, left and right, upward, and downward mentioned in this application all refer to the corresponding directions of the wall-climbing weld inspection robot 1, and are based on the wall-climbing weld inspection robot 1 being placed on a horizontal plane. Of course, the wall-climbing weld inspection robot 1 of this application can travel on horizontal planes, vertical planes, various inclined planes, and curved surfaces. For example, when the wall-climbing weld inspection robot 1 is moving in a vertical plane, the lower side of the wall-climbing weld inspection robot 1 points towards the inspection surface, which is the horizontal direction in natural space.

[0033] Figure 1 A perspective view of one embodiment of the wall-climbing weld inspection robot 1 according to the present invention is shown.

[0034] A wall-climbing weld inspection robot 1 according to an embodiment of the present invention may include a control module, a wall-climbing mobile platform 2, and a visual laser positioning device 3. The visual laser positioning device 3 is signal-connected to the control module and fixedly connected to the wall-climbing mobile platform 2 via a connecting frame 31. The visual laser positioning device 3 includes a camera 32 and at least one (e.g., two) lasers 33. The camera 32 and lasers 33 are oriented towards the weld to be inspected. The lasers 33 are capable of emitting laser light towards the weld to be inspected. The camera 32 is capable of acquiring the resulting laser reflection information and / or image data of the weld and transmitting the laser reflection information and / or image data to the control module. The control module can calculate the positional deviation and / or attitude deviation of the weld relative to the wall-climbing mobile platform 2, for controlling the wall-climbing mobile platform to automatically move along the weld. For example, the laser reflection information is a laser feature line or laser feature point. The image data includes the weld centerline, edge line, or weld contour.

[0035] Specifically, lasers 33 are positioned on both sides of the weld seam or at a predetermined geometric position corresponding to the camera's field of view, so as to more accurately form identifiable laser feature lines or feature points.

[0036] Preferably, the visual laser positioning device 3 further includes a light shield, which is disposed outside the camera 32 and at least part of the laser 33, for shielding the image quality and laser reflection information from interference by sunlight or other strong ambient light.

[0037] The wall-climbing weld inspection robot 1 also includes an inspection following device 4, which is signal-connected to the control module and includes at least one inspection probe 41 for inspecting the weld and a drive mechanism 6. The control module can output position deviation and / or attitude deviation to the drive mechanism 6, and the drive mechanism 6 can move the inspection probe 41 according to the position deviation and / or attitude deviation, thereby controlling the inspection following device 4 to complete cooperative positioning when the wall-climbing mobile platform automatically moves along the weld. For example, differential speed control is performed on the left and right drive devices of the wall-climbing mobile platform 2 according to the position deviation and / or attitude deviation of the weld relative to the wall-climbing mobile platform 2 to achieve the walking correction of the wall-climbing mobile platform 2. At the same time, the inspection following device 4 moves the inspection probe 41 in the left-right direction W and the height direction H, so that the inspection probe 41 is always kept in the process-specified position relative to the weld.

[0038] In addition, the wall-climbing weld inspection robot 1 also includes an odometer 5. The odometer 5 is connected to the control module and can move in the left-right direction W and / or the height direction H to record weld inspection length, travel displacement, inspection position mileage information, etc., so as to facilitate length calibration of the inspection report and defect location backtracking.

[0039] Through the coordinated operation of the wall-climbing mobile platform 2, the visual laser positioning device 3, the detection and following device 4, and the odometer 5, the system can simultaneously achieve autonomous movement along the weld seam, stable probe following, multi-degree-of-freedom detection of the weld seam, and positioning and calibration of the detection data. At the same time, it can accurately record the detection length and / or the spatial position of the weld seam, facilitating subsequent processing steps such as reviewing detection results and verifying weld quality.

[0040] Specifically, the detection probe can be a time-of-flight diffraction (TOFD) ultrasound probe, a phased array ultrasound (PAUT) probe, or an electromagnetic ultrasound (EMAT) probe.

[0041] Specifically, the odometer can record the weld inspection length and the mileage of the weld defect location and transmit the weld inspection length and the mileage of the weld defect location to the control module, which can correlate the data collected or detected by the camera 32 and / or the detection probe 41 with the spatial location of the weld.

[0042] Specifically, the relative distance, relative orientation, and / or scanning trajectory between the detection probe 41 and the weld seam meet the process requirements of diffraction time-of-flight ultrasonic testing, phased array ultrasonic testing, or electromagnetic ultrasonic testing.

[0043] Figure 2 A perspective view of one embodiment of the wall-climbing mobile platform according to the present invention is shown. Figure 3 An exploded view of one embodiment of the wall-climbing mobile platform according to the present invention is shown.

[0044] like Figure 2 As shown, the wall-climbing mobile platform includes a front vehicle 21 and a rear vehicle 22. The front vehicle 21 and the rear vehicle 22 are connected by a torsion mechanism 23, allowing them to rotate relative to each other about the longitudinal central axis AA. Figure 2 In the illustrated embodiment, at least one passive adapting spring 24 is provided on each side of the torsion mechanism 23. One end of the passive adapting spring 24 is connected to or in contact with a connecting plate 25 extending from the lower side of the front vehicle 21, and the other end of the passive adapting spring 24 is connected to or in contact with a connecting plate 25 extending from the upper side of the rear vehicle 22. Optionally, one end of the passive adapting spring 24 is connected to or in contact with a connecting plate extending from the upper side of the front vehicle 21, and the other end of the passive adapting spring 24 is connected to or in contact with a connecting plate extending from the lower side of the rear vehicle 22. The passive adapting spring 24 allows the corresponding connecting plates (i.e., the vertically opposite connecting plates) to move closer to or further away from each other. In a non-limiting example, the passive adapting spring 24 can be a compression spring, sleeved on two vertically separated connecting posts connected to the two corresponding connecting plates 25. In this way, in addition to being compressed or extended, the passive adapting spring 24 can also be torsion to a certain extent, facilitating relative rotation (torsion) of the front vehicle 21 and the rear vehicle 22.

[0045] like Figure 3 As shown, the pivoting mechanism 23 includes a pivot sleeve 231 and a pivot shaft 232. The pivot shaft 232 is pivotally arranged in the pivot sleeve 231 via a support assembly such as a ball bearing. The pivot sleeve 231 is connected to the front vehicle 21 via a pivot sleeve mounting plate 26, and the pivot shaft 232 is connected to the rear vehicle 22 via a pivot shaft mounting plate 27. In particular, one or more spring mounting plates 25 are detachably connected to the pivot sleeve mounting plate 26 and / or the pivot shaft mounting plate 27, or one or more spring mounting plates 25 are integrally formed with the pivot sleeve mounting plate 26 and / or the pivot shaft mounting plate 27.

[0046] Through the pivoting mechanism 23, the front vehicle 21 and the rear vehicle 22 can maintain multiple wheels on the ground simultaneously on curved surfaces, locally undulating surfaces, and corner areas, improving adsorption reliability and motion stability. For example, the front vehicle 21 and the rear vehicle 22 can pivot relative to each other around the pivot axis 232, thereby maintaining four wheels on the ground simultaneously on curved steel plate walls such as wind turbine towers.

[0047] Both the front vehicle 21 and the rear vehicle 22 are equipped with magnetic adsorption walking modules. The magnetic adsorption walking modules preferably adopt a semi-enclosed structure, where magnetic components are arranged only on the semi-circle where the wheels contact the wall surface to be inspected; no magnetic components are placed in the areas not in contact with the wall surface. This optimizes weight and allows the wall-climbing platform to maintain its adsorption force while traversing both inner and outer bends. The wall-climbing platform 2 can be powered by either a cable or a lithium battery.

[0048] Figure 4 A front view of one embodiment of the detection and tracking device and odometer according to the present invention is shown. Figure 5 A rear view of one embodiment of the detection and tracking device and odometer according to the present invention is shown, and Figure 6 Detailed diagrams of one embodiment of the detection and tracking device and odometer according to the present invention are shown.

[0049] like Figure 4 As shown, the drive mechanism 6 includes a detection probe support mechanism 61 for supporting the detection probe 41, a left-right direction actuator 62 for moving the detection probe support mechanism 61 in the left-right direction W, and a height direction actuator 63 for moving the detection probe support mechanism 61 in the height direction H.

[0050] exist Figure 4 In the illustrated embodiment, a left-right actuator 62 is arranged on a connecting frame 31 for actuating a first slider 65 along a first guide rail 64 arranged on the connecting frame 31. The first slider 65 is slidably arranged on the first guide rail 64. A second guide rail 66 is arranged on the first slider 65. A height-direction actuator 63 is arranged at one end of the second guide rail 66 for actuating a second slider 67 along the second guide rail 66 (see [link to figure]). Figure 5 The second slider 67 is slidably arranged on the second guide rail 66. The detection probe support mechanism 61 is arranged on the second slider 67. Therefore, the left-right actuator 62 can adjust the lateral position of the detection probe 41 arranged on the detection probe support mechanism 61 relative to the wall-climbing moving platform 2, and the height actuator 63 can adjust the height position or clamping state of the detection probe 41 arranged on the detection probe support mechanism 61 relative to the wall surface or weld to be detected.

[0051] In addition, such as Figure 4 and Figure 5As shown, the detection probe support mechanism 61 includes a third guide rail 611, which is arranged on the second slider 67 in a left-right direction W. A detection probe actuator 612 is arranged at one end of the third guide rail 611. The detection probe actuator 612 is used to actuate at least one third slider 613 along the third guide rail 611, and the third slider 613 is slidably arranged on the third guide rail 611. Therefore, the detection probe actuator 612 can be used to adjust the spacing between at least two detection probes 41 to meet the requirements of different detection processes for probe arrangement.

[0052] exist Figure 4 and Figure 5 In the illustrated embodiment, two third sliders 613 are slidably arranged on a third guide rail 611. The third guide rail 611 includes a lead screw, which is driven to rotate by a detection probe actuator 612. The two third sliders are configured as two threaded auxiliary sliders having threads with opposite directions of rotation. When the detection probe actuator 612 drives the lead screw to rotate, the two threaded auxiliary sliders with opposite directions of rotation move symmetrically along the width direction W toward both ends of the third guide rail 611, causing the detection probes 41, respectively connected to the two threaded auxiliary sliders, to also move symmetrically along the width direction W toward both ends of the third guide rail 611, i.e., moving closer to or further away from each other, thereby adjusting the distance between the two detection probes 41 and the target weld at equal intervals.

[0053] In particular, such as Figure 6 As shown, the odometer 5 can be fixed to the third guide rail 611 by, for example, an odometer mounting plate 53 extending along the height direction H. Thus, the odometer 5 can move synchronously with the third guide rail 611 in the left-right direction W and / or the height direction H by means of a left-right actuator 62 and a height direction actuator 63. Preferably, a fifth guide rail 51 is provided on the odometer mounting plate 53, extending thereal. A fifth slider 52 is slidably provided on the fifth guide rail 51. The odometer 5 is connected to the fifth slider 52 by, for example, an odometer bracket 54 extending along the height direction H, allowing the odometer 5 to move in the height direction H.

[0054] Specifically, the wall-climbing mobile platform 2 is connected to the control module and can be configured to correct its movement based on positional and / or posture deviations. Preferably, the left-right actuator 62, the height actuator 63, the detection probe actuator 612, and the wall-climbing mobile platform 2 can be configured to achieve coordinated adjustment under the control of the control module, so that the relative distance, relative posture, and scanning trajectory between the detection probe and the target weld meet the requirements of the adopted weld inspection process. Thus, the visual laser positioning device 3 and the detection following device 4 form a coordinated closed-loop control, which not only enables the wall-climbing weld inspection robot 1 to move automatically along the weld, but also meets the process requirements of the ultrasonic probe for relative positional accuracy.

[0055] exist Figure 5 In the illustrated embodiment, at least one third slider 613 is provided with a fourth guide rail 614 extending along the height direction H, and a fourth slider 615 is provided on the fourth guide rail 614, the fourth slider 615 being slidably arranged on the fourth guide rail 614. The detection probe support mechanism 61 further includes a first bias spring 616, one end of which is connected to the lower part of the fourth guide rail 614, and the other end is connected to the fourth slider 615, applying a downward force to the fourth slider 615, and subsequently to the detection probe 41. For example, the first bias spring 616 can be a tension coil spring.

[0056] like Figure 6 As shown, the fourth slider is connected to a pivot link 617. The pivot link 617 extends obliquely relative to the height direction H and is capable of pivoting relative to the fourth slider 615. The pivot link 617 is connected to a detection probe bracket 618 for supporting the detection probe 41. The detection probe bracket 618 is pivotally connected to the pivot link 617 at its midpoint in the front-rear direction, so that the front and rear ends of the detection probe bracket 618 can pivot relative to the pivot link 617.

[0057] Specifically, the pivot link 617 can be tilted relative to the height direction H and the left-right direction W. The pivot axis of the pivot link 617 and the pivot axis of the detection probe holder 618 can be parallel to each other. The pivot link 617 can be pivoted relative to the fourth slider 615 by a force-applying component such as a torsion spring, thereby causing the detection probe 41 to move downward, i.e., toward the weld.

[0058] Through the first bias spring 616, after contacting a locally uneven wall surface or weld, the detection probe 41 can adaptively adjust its position in the height direction H, so that the detection probe 41 can always maintain contact with the wall surface or weld. The inclined pivot link 617 makes the adaptive height adjustment of the detection probe 41 smoother and less prone to jamming.

[0059] With the adoption of a two-stage buffer and damping structure of torsion spring and tension spring, the detection probe 41 can maintain a stable coupling state under complex wall surface and attitude disturbance conditions, thereby improving the quality of detection data.

[0060] For example, when using detection processes such as TOFD and PAUT, the detection probe can use water as a coupling agent. In other embodiments, gel, oil-based, or composite coupling media can also be selected as coupling agents according to process requirements.

[0061] like Figure 4As shown, a fifth guide rail 51 extending along the height direction H is arranged at the third guide rail. A fifth slider 52 is arranged on the fifth guide rail 51 and can slide along the fifth guide rail 51. A second bias spring (not shown) is provided between the fifth guide rail 51 and the fifth slider 52. One end of the second bias spring is connected to the lower part of the fifth guide rail 51, and the other end is connected to the fifth slider, applying a downward force to the fifth slider 52 and then to the odometer 5. For example, the second bias spring can be a tension coil spring. The odometer 5 is arranged on the fifth slider 52.

[0062] Alternatively, one end of the second bias spring is connected to the underside of the odometer mounting plate 53, and the other end is connected to the unconnected end of the odometer 5 on the odometer bracket 54, so that the odometer 5 can adaptively roll into contact with the detected wall surface.

[0063] With the second bias spring, the odometer 5 can stably roll and contact the wall to be inspected under complex wall surface and attitude disturbance conditions, so as to more accurately record the weld inspection length, travel displacement or inspection position mileage information, thereby improving the accuracy of weld length calibration and defect location information.

[0064] The embodiments of this application also provide an autonomous weld inspection method, which is implemented using a wall-climbing weld inspection robot 1 according to this application.

[0065] Specifically, the self-inspection method for welds may include the following steps:

[0066] The wall-climbing weld inspection robot 1 adheres to the magnetic wall surface where the weld to be inspected is located, especially adhering to the vicinity of the weld to be inspected, and completes the initial positioning of the weld to be inspected.

[0067] The laser 33 of the visual laser positioning device 3 emits a laser towards the weld to be inspected, and the camera 32 acquires the laser reflection information and / or image data of the weld generated therefrom and transmits the laser reflection information and / or the image data to the control module.

[0068] The control module calculates the positional deviation and / or attitude deviation of the weld relative to the wall-climbing moving platform 2, and outputs the positional deviation and / or attitude deviation to the drive mechanism 6, so that the drive mechanism 6 moves the detection probe 41 according to the positional deviation and / or attitude deviation.

[0069] The odometer 5 records the detection length and defect location mileage, realizing the correspondence between the detection data and the spatial location of the weld.

[0070] Specifically, the wall-climbing mobile platform 2 corrects its movement based on positional and / or posture deviations.

[0071] Preferably, the left-right actuator 62, the height actuator 63, the detection probe actuator 612, and the wall-climbing moving platform 2 are coordinated and adjusted under the control of the control module, thereby adjusting the relative distance, relative posture, and scanning trajectory between the detection probe and the target weld. Thus, the visual laser positioning device 3 and the detection following device 4 form a coordinated closed-loop control, enabling the wall-climbing weld inspection robot 1 to automatically move along the weld and meeting the process requirements for relative position accuracy of the ultrasonic probe. For example, differential speed control is applied to the left-right drive device of the wall-climbing moving platform 2 based on the positional deviation and / or posture deviation of the weld relative to the wall-climbing moving platform 2 to correct the movement of the platform. Simultaneously, the detection following device 4 moves the detection probe 41 in the left-right direction W and the height direction H, ensuring that the detection probe 41 remains in the process-specified position relative to the weld.

[0072] Preferably, the two detection probes 41 are moved symmetrically along the width direction W, either away from or close to each other, so as to adjust the distance between the two detection probes 41 and the target weld at equal intervals.

[0073] Preferably, after completing the automatic inspection of the weld, the wall-climbing weld inspection robot 1 can output the spatial position of the weld corresponding to the data detected by the visual laser positioning device 3 and / or the detection following device 4.

[0074] It should be understood that at least some aspects or features of the above-described implementation methods, embodiments, or examples can be appropriately combined.

[0075] It should be understood that the above-described embodiments, examples, or examples are merely exemplary and are not intended to limit this application. Those skilled in the art can make various modifications and changes to the above-described embodiments, examples, or examples under the teachings of this application without departing from the scope of this application.

Claims

1. A wall-climbing weld inspection robot, characterized in that, include: Control module; Wall-climbing mobile platform (2); A visual laser positioning device (3) is connected to the wall-climbing mobile platform (2). The visual laser positioning device (3) includes a camera (32) and at least one laser (33). The camera (32) and the laser (33) are oriented toward the weld to be inspected. The laser (33) is capable of emitting laser light toward the weld to be inspected. The camera (32) is capable of acquiring the laser reflection information and / or image data of the weld generated therefrom and transmitting the laser reflection information and / or the image data to the control module. The control module calculates the positional deviation and / or attitude deviation of the weld relative to the wall-climbing mobile platform (2). A detection following device (4) includes at least one detection probe (41) for detecting weld seams and a drive mechanism (6). The control module is capable of outputting the position deviation and / or the attitude deviation to the drive mechanism (6), and the drive mechanism (6) is capable of moving the detection probe (41) according to the position deviation and / or the attitude deviation. Odometer (5), which is movable in the left-right direction (W) and / or the height direction (H).

2. The wall-climbing weld inspection robot according to claim 1, characterized in that, The wall-climbing mobile platform includes a front vehicle (21) and a rear vehicle (22), which are connected by a torsion mechanism (23) so that the front vehicle (21) and the rear vehicle (22) can rotate relative to each other about the longitudinal central axis (AA).

3. The wall-climbing weld inspection robot according to claim 2, characterized in that, At least one passive adaptation spring (24) is provided on each side of the torsion mechanism (23). One end of the passive adapting spring (24) is connected to or in contact with a connecting plate (25) extending from the underside of the front vehicle (21), and the other end of the passive adapting spring (24) is connected to or in contact with a connecting plate (25) extending from the upper side of the rear vehicle (22). The passive adapting spring (24) allows the corresponding connecting plates (25) to move closer to or further away from each other. One end of the passive adaptation spring (24) is connected to or in contact with a connecting plate extending from the upper side of the front vehicle (21), and the other end of the passive adaptation spring (24) is connected to or in contact with a connecting plate extending from the lower side of the rear vehicle (22). The passive adaptation spring (24) allows the corresponding connecting plates to move closer to or further away from each other.

4. The wall-climbing weld inspection robot according to claim 1, characterized in that, The laser reflection information is a laser feature line or laser feature point, and the image data includes the weld center line, edge line, or weld outline.

5. The wall-climbing weld inspection robot according to claim 1, characterized in that, The drive mechanism (6) includes a detection probe support mechanism (61) for supporting the detection probe (41), a left-right direction actuator (62) for moving the detection probe support mechanism (61) in the left-right direction (W), and a height direction actuator (63) for moving the detection probe support mechanism (61) in the height direction (H).

6. The wall-climbing weld inspection robot according to claim 5, characterized in that, The visual laser positioning device (3) is connected to the wall-climbing moving platform (2) via a connecting frame (31). The left-right actuator (62) is arranged on the connecting frame (31) and is used to actuate the first slider (65) along the first guide rail (64) arranged on the connecting frame (31). The first slider (65) is slidably arranged on the first guide rail (64). A second guide rail (66) is arranged on the first slider (65), and a height-direction actuator (63) is arranged at one end of the second guide rail (66) for actuating a second slider (67) along the second guide rail (66). The second slider (67) is slidably arranged on the second guide rail (66). The detection probe support mechanism (61) is arranged on the second slider (67).

7. The wall-climbing weld inspection robot according to claim 6, characterized in that, The detection probe support mechanism (61) includes a third guide rail (611), which is arranged along the left-right direction (W) on the second slider (67). A detection probe actuator (612) is arranged at one end of the third guide rail (611). The detection probe actuator (612) is used to actuate at least one third slider (613) along the third guide rail (611). The third slider (613) is slidably arranged on the third guide rail (611). A fourth guide rail (614) extending along the height direction (H) is arranged on at least one of the third sliders (613), and a fourth slider (615) is arranged on the fourth guide rail (614), the fourth slider (615) being slidably arranged on the fourth guide rail (614). The detection probe support mechanism (61) further includes a first bias spring (616), one end of which is connected to the lower part of the fourth guide rail (614), and the other end is connected to the fourth slider (615), applying downward force to the fourth slider (615).

8. The wall-climbing weld inspection robot according to claim 7, characterized in that, The fourth slider is connected to a pivot link (617), which extends at an angle relative to the height direction (H) and is able to pivot relative to the fourth slider (615). The pivot link (617) is connected to a detection probe bracket (618) for supporting the detection probe (41), and the front and rear ends of the detection probe bracket (618) are able to pivot relative to the pivot link (617).

9. The wall-climbing weld inspection robot according to claim 8, characterized in that, A torsion spring is provided at the pivot point between the pivot link (617) and the fourth slider (615), the torsion spring causing the end of the pivot link (617) connected to the detection probe (41) to pivot downward.

10. The wall-climbing weld inspection robot according to claim 7, characterized in that, A fifth guide rail (51) extending along the height direction (H) is arranged at the third guide rail, and a fifth slider (52) is arranged on the fifth guide rail (51), the fifth slider (52) being able to slide along the fifth guide rail (51). A second biasing spring is provided between the fifth guide rail (51) and the fifth slider (52). One end of the second biasing spring is connected to the lower part of the fifth guide rail (51), and the other end is connected to the fifth slider (52), applying downward force to the fifth slider (52). The odometer (5) is connected to the fifth slider (52).

11. The wall-climbing weld inspection robot according to claim 1, characterized in that, The odometer can record the weld inspection length and the mileage of the weld defect location and transmit the weld inspection length and the mileage of the weld defect location to the control module. The control module can correspond the data collected or detected by the camera (32) and / or the detection probe (41) with the spatial location of the weld.

12. The wall-climbing weld inspection robot according to claim 7, characterized in that, Two third sliders (613) are slidably arranged on the third guide rail (611). The third guide rail (611) includes a lead screw, and the detection probe actuator (612) is capable of driving the lead screw to rotate. The two third sliders are configured as two threaded pairs sliders with threads having opposite directions of rotation.

13. A method for autonomous weld inspection, wherein the method uses the wall-climbing weld inspection robot (1) as described in any of the preceding claims.

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