Direct contact damage detection apparatus and system for detecting damage to a skin

Abstract

The present application relates to the technical field of damage detection, and provides a direct contact type damage detection device and system for detecting skin damage, which comprises a chassis mechanism, a flaw detector arranged above the chassis, a clamping mechanism arranged at the bottom of the chassis and used for rigidly fixing a flaw detection sensor and exposing a detection end of the sensor downward, a water supply assembly arranged on the chassis and comprising a water tank, a water pump and a water spraying head, a walking assembly arranged at the bottom of the chassis and comprising a motor with a rotation speed feedback sensor and a tire, an edge detection sensor arranged at the edge of the bottom of the chassis, and a main control MCU used for closed-loop regulation of the rotation speed of the motor, control of the motor braking in response to the signal of the edge detection sensor, and time-sharing and alternating control of the water pump operation. The system further comprises an upper computer in wireless communication with the main control MCU, and a control module of the upper computer is used for remote control, data display, automatic analysis of flaw detection data and alarm. The present application can realize full-automatic, high-safety and high-precision flaw detection for open curved skin.

Description

Technical Field

[0001] This invention relates to the field of damage detection technology, and in particular to a direct contact damage detection device and system for detecting skin damage. Background Technology

[0002] During service, the skin structures of equipment such as aircraft, spacecraft, and large storage tanks are prone to various types of damage, including cracks, delamination, and corrosion pits, due to alternating loads, environmental corrosion, or accidental impacts. To ensure the safe operation of these equipment, regular non-destructive testing (NDT) of the skin surface and interior is necessary. Currently, direct contact NDT techniques such as ultrasonic testing and eddy current testing are important means of detecting skin damage. The implementation of these testing techniques relies on effective coupling and stable relative motion between the testing sensor and the surface being tested.

[0003] Traditional contact detection methods mainly include three modes: manual handheld detection, fixed automated detection, and mobile adsorption detection, all of which have significant technical limitations: I. Manual Handheld Inspection Mode Routine inspection operations require operators to hold the flaw detection sensor and scan it point by point against the surface of the skin being inspected. For large or high-altitude equipment such as aircraft fuselages and large curved containers, operators often need to use auxiliary equipment such as lifting platforms and scaffolding, which not only increases labor intensity and reduces inspection efficiency, but also makes it difficult or impossible for personnel to stay in some areas (such as the back of the aircraft and under the wings), resulting in limited inspection coverage.

[0004] More importantly, the skin surfaces are often complex curved surfaces (such as the variable curvature shape of an aircraft fuselage), making it difficult to ensure a continuous, uniform, and tight fit between the flaw detection sensor and the surface during handheld operation. In traditional solutions, flaw detection sensors are usually fixed using simple clamps or by hand, lacking the ability to maintain attitude stability in response to changes in surface curvature. When the sensor is at a high altitude, its center of gravity is higher than the contact point, which can easily create a tipping moment at points where the surface slope changes, causing the sensor to tilt or detach from the measured surface, resulting in signal interruption. In addition, the traditional practice is to manually apply or spray a coupling agent (such as water, glycerin, etc.) to improve the acoustic or electromagnetic coupling effect, but the uniformity and continuity of the coupling agent application are difficult to control precisely, and the coupling agent is prone to runoff when operating at high altitudes or on inclined surfaces, directly affecting the stability and accuracy of the detection signal.

[0005] II. Fixed Automated Detection Mode Some traditional solutions employ track-mounted scanning gantry or robotic arms carrying probes for automated inspection. While these solutions can replace manual operation to some extent, they suffer from the following technical drawbacks: Firstly, track-based scanning gantry systems require pre-laying guide rails or constructing a gantry structure on the surface to be measured. For open curved surfaces such as aircraft bodies and large storage tanks, laying guide rails is difficult, and different curvature areas require different tracks, resulting in poor versatility. While robotic arm solutions offer greater flexibility, their large weight and numerous joint degrees of freedom lead to complex control, and their limited working radius makes it difficult to cover the entire area of ​​large skins.

[0006] Secondly, traditional automated testing equipment often uses a rigid fixing mechanism for its probe clamping mechanism, resulting in no relative motion freedom between the probe and the clamping seat. When the equipment moves on a curved surface, the probe's posture tilts with the overall equipment, causing a deviation between the probe axis and the normal direction of the measured surface. The effective coupling pressure decreases as the tilt angle increases (this is the component of gravity in the normal direction), leading to coupling failure in large tilt angle areas. Some technologies attempt to maintain the contact pressure using spring loading or constant force mechanisms, but spring mechanisms lack stability during movement and vibration, and constant force mechanisms have complex structures. Furthermore, electric or pneumatic constant force mechanisms require additional external energy, making them unsuitable for lightweight mobile platforms.

[0007] III. Mobile Adsorption Detection Mode Traditional mobile inspection equipment (such as wall-climbing robots) typically attaches to the surface being tested using vacuum adsorption or magnetic adsorption. Vacuum adsorption requires a flat surface with good airtightness, and its reliability is insufficient for curved surfaces with seams or roughness. Magnetic adsorption is only suitable for ferromagnetic materials, and the adsorption force decreases as the surface curvature increases (the greater the curvature, the larger the air gap in the magnetic circuit). The adsorption force fluctuates greatly in areas with varying curvature, posing a risk of detachment. Therefore, it is only suitable for specific materials and surfaces with high flatness, exhibiting extremely poor versatility. Furthermore, adsorption-based mobile mechanisms are complex in structure and heavy, hindering lightweight design.

[0008] IV. Edge Security and Data Management When operating in areas with clearly defined boundaries, such as aircraft wings and tail fins, traditional mobile inspection equipment lacks edge detection and active protection mechanisms. If the equipment fails to brake in time when it reaches the edge, it may fall due to tire slippage or suction failure, causing equipment damage or even a safety accident. Traditional edge detection solutions often use vision or distance sensors, but in water-coupled environments, vision lenses are easily blurred by water; ultrasonic distance sensors are affected by water mist, and infrared or laser distance sensors are affected by changes in the light path reflected from curved surfaces, all of which are prone to false detections and lack reliability.

[0009] The recording and management of test data relies on manual interpretation and recording, which is inefficient and prone to subjective errors. Although some technologies are equipped with data storage functions, they lack effective correlation with information from the testing process, making it impossible to achieve real-time monitoring of the testing status and accurate tracing of damage locations. The lack of remote monitoring capabilities requires operators to follow the equipment closely, which still poses safety hazards in dangerous areas (such as high altitudes or toxic environments).

[0010] In summary, there is an urgent need in this field for a direct contact damage detection solution that can be applied to open curved skin, and has autonomous movement capability, stable surface fitting and anti-tipping capability, stable water coupling capability, edge safety protection capability and remote data management capability. Summary of the Invention

[0011] The purpose of this invention is to solve at least one technical problem in the background art and to provide a direct contact damage detection device and system for detecting skin damage.

[0012] To achieve the above objectives, the present invention provides a direct contact damage detection device for detecting skin damage, comprising: Chassis structure; A flaw detector is installed above the chassis mechanism; A clamping mechanism is provided at the bottom of the chassis mechanism to fix the flaw detection sensor and expose the detection end of the flaw detection sensor downwards; A water supply assembly, mounted on the chassis mechanism, includes a water tank, a water pump, and a spray head. The outlet of the water tank is connected to the inlet of the water pump, and the water pump is connected to the spray head. The walking assembly, mounted on the bottom of the chassis mechanism, includes a motor and tires, and the motor is equipped with a speed feedback sensor; An edge detection sensor is installed at the bottom edge of the chassis mechanism; The main control MCU is configured to: receive feedback signals from the speed feedback sensor to regulate the speed of the motor in a closed loop; control the braking of the motor in response to the sensing signals from the edge detection sensor; and control the operation of the water pump in a time-sharing alternating manner.

[0013] According to one aspect of the present invention, the chassis mechanism includes: a lower disc frame and an upper disc frame, the upper disc frame being supported above the lower disc frame by multiple sets of mounting columns; the water supply assembly includes two sets of water tanks and two sets of water pumps, the two sets of water tanks being disposed on both sides of the upper disc frame, the two sets of water pumps being disposed on both sides of the lower disc frame, and the two sets of water pumps being connected to the spray head through a tee fitting.

[0014] According to one aspect of the present invention, the clamping mechanism includes: a mounting top plate, a mounting bottom plate, and a connecting rod. The mounting top plate is connected to the chassis mechanism, and the mounting bottom plate is connected to the mounting top plate via the connecting rod. The flaw detection sensor is fixed between the mounting top plate and the mounting bottom plate, and the detection end of the flaw detection sensor protrudes from the lower surface of the mounting bottom plate. The width of the mounting bottom plate is greater than the width of the flaw detection sensor, and the connecting rod connects the mounting top plate and the mounting bottom plate to form a frame.

[0015] According to one aspect of the present invention, the walking assembly is provided in four groups, evenly distributed around the bottom of the chassis mechanism, and the tires are anti-slip tires; the speed feedback sensor is a Hall sensor, and the main control MCU independently adjusts the speed and direction of each group of motors in a closed-loop manner to realize differential straight-line or turning of the detection device.

[0016] According to one aspect of the present invention, the main control MCU adjusts the power supply voltage of the water pump by outputting a pulse width modulation signal to control the water output of the spray head.

[0017] According to one aspect of the present invention, a plurality of edge detection sensors are provided, evenly distributed around the perimeter of the bottom of the chassis mechanism, and the detection end of the edge detection sensor is exposed outside the ground contact profile of the tire; the main control MCU is configured to: in response to the sensing signal output by any one of the edge detection sensors, control the motor of the walking assembly to brake simultaneously.

[0018] According to one aspect of the invention, a battery is provided on the chassis mechanism, the battery supplying power to the motor, the water pump and the main control MCU.

[0019] According to one aspect of the present invention, the water tank is fixed to the top of the upper disc frame by a water tank mounting bracket, the top of the water tank is provided with a circular top cover, and the circular top cover is provided with a pressure balancing air pipe and a water outlet; the spray head is provided to the top of the upper disc frame by a fixing seat.

[0020] According to one aspect of the present invention, the flaw detector and the flaw detection sensor are connected by a flexible cable, the length of which is greater than the distance between the mounting top plate and the mounting bottom plate.

[0021] To achieve the above objectives, the present invention also provides a direct contact damage detection system for detecting skin damage, including the above-mentioned direct contact damage detection device for detecting skin damage. Also includes: host computer; The wireless communication module establishes bidirectional data communication between the main control MCU and the host computer. The host computer is equipped with a control module for sending control commands to the detection device and receiving and displaying the flaw detection data and status data sent by the detection device. The control module of the host computer is also equipped with an automatic flaw detection data analysis and alarm function. When the received flaw detection data exceeds a preset threshold, the host computer issues an audible and visual alarm.

[0022] According to the present invention, this invention provides a direct-contact automated inspection solution for open-surface skin inspection, integrating autonomous movement, safe inspection, and intelligent data management. By cooperating with four independent differential drive systems with Hall effect feedback and a rigid wide-base clamping frame, the physical challenges of easy tipping and contact pressure attenuation with tilt angle on large variable-curvature skin surfaces are solved. Simultaneously, by utilizing symmetrical dual water tanks and dual water pumps with time-sharing alternating control and PWM voltage regulation technology, dynamic and precise supply of the coupling medium and long-term stable operation of the pumps are achieved while maintaining the center of gravity. Combined with chassis circumferential edge inspection sensors and a multi-motor synchronous braking mechanism, a reliable unconstrained edge anti-fall safety barrier is constructed. Furthermore, by combining wireless communication with data analysis and audible and visual alarm functions from a remote upper-level control module, this invention enables remote autonomous inspection of hazardous areas and automated interpretation and traceability of damage data, significantly improving the coverage, safety, automation level, and data objectivity and accuracy of inspection operations for large and complex skin structures. Attached Figure Description

[0023] Figure 1 This schematic diagram illustrates the overall structure of a direct contact damage detection device for detecting skin damage according to an embodiment of the present invention. Figure 2 This schematic diagram shows a rear-view perspective view of a direct-contact damage detection device for detecting skin damage according to an embodiment of the present invention. Figure 3 This schematic diagram shows a side perspective view of a direct contact damage detection device for detecting skin damage according to an embodiment of the present invention. Figure 4 This schematic diagram shows a top view of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Figure 5 This schematic diagram shows a bottom view of a direct contact damage detection device for detecting skin damage according to an embodiment of the present invention. Figure 6 A schematic perspective view of the clamping mechanism of a direct contact damage detection device for detecting skin damage according to an embodiment of the present invention; Figure 7 This schematic diagram illustrates the system principle block diagram of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Figure 8 This schematic diagram illustrates the reverse polarity protection circuit of the input power supply of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Figure 9 This schematic diagram illustrates the power supply regulation circuit of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Figure 10 This schematic diagram illustrates a battery charge detection circuit of a direct contact damage detection device for detecting skin damage according to an embodiment of the present invention. Figure 11 This schematic diagram illustrates the motor operation control circuit of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Figure 12 This schematic diagram illustrates the edge detection sensor circuit of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Figure 13 This schematic diagram illustrates a water pump control circuit of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Figure 14 This schematic diagram illustrates a battery charge detection circuit of a direct contact damage detection device for detecting skin damage according to an embodiment of the present invention. Figure 15 The schematic diagram illustrates the MCU main control circuit of a direct contact damage detection device for detecting skin damage according to one embodiment of the present invention. Detailed Implementation

[0024] The invention will now be discussed with reference to exemplary embodiments. It should be understood that the described embodiments are merely intended to enable those skilled in the art to better understand and thus implement the invention, and are not intended to imply any limitation on the scope of the invention.

[0025] As used herein, the term "comprising" and its variations are to be interpreted as open-ended terms meaning "including but not limited to". The term "based on" is to be interpreted as "at least partially based on". The terms "one embodiment" and "an embodiment" are to be interpreted as "at least one embodiment".

[0026] like Figures 1 to 6 As shown, in this embodiment, the present invention provides a direct contact damage detection device for detecting skin damage, including: a chassis mechanism, a flaw detector 4, a clamping mechanism 9, a water supply assembly, a walking assembly, an edge detection sensor 15, and a main control MCU.

[0027] The chassis mechanism is the basic load-bearing structure of the device. It adopts a double-layer frame design to provide layered layout space for each functional module.

[0028] The flaw detector 4 is located above the chassis mechanism and is used to generate detection signals, receive echo signals, and perform signal processing and analysis.

[0029] The clamping mechanism 9 is located at the bottom of the chassis mechanism and is used to fix the flaw detection sensor 94 and expose the detection end of the flaw detection sensor 94 downwards to ensure direct contact between the flaw detection sensor 94 and the surface of the skin being tested.

[0030] The water supply assembly is mounted on the chassis mechanism and includes a water tank 7, a water pump 19, and a spray head 17. The water outlet 12 of the water tank 7 is connected to the water inlet 22 of the water pump 19, and the water pump 19 is connected to the spray head 17. It is used to provide coupling medium water to the surface under test to enhance the acoustic coupling performance between the flaw detection sensor 94 and the surface under test.

[0031] The walking assembly is mounted on the bottom of the chassis mechanism and includes a motor 13 and tires 14. The motor 13 is equipped with a speed feedback sensor for real-time feedback of the motor 13's speed. The walking assembly is an actuator that moves autonomously on the skin surface.

[0032] The edge detection sensor 15 is installed at the bottom edge of the chassis mechanism to detect the edge position of the object being measured.

[0033] The main control MCU is located on circuit board 20 on the chassis mechanism. The main control MCU is configured to: receive feedback signals from the speed feedback sensor to regulate the speed of motor 13 in a closed loop; control the braking of motor 13 in response to the sensing signals from edge detection sensor 15; and control the operation of water pump 19 in a time-sharing alternating manner.

[0034] In this embodiment, the double-layer frame design of the chassis mechanism achieves a reasonable spatial layout of the various functional modules of the device. The upper layer houses components such as the flaw detector 4 and the water tank 7, while the lower layer houses components such as the water pump 19, the circuit board 20, and the motor 13. This physical separation avoids mutual interference between the water components and the electrical components. The overall structure is compact, and the center of gravity is reasonably distributed, which is conducive to maintaining stability on inclined curved surfaces. The flaw detector 94 is fixed by the clamping mechanism 9 and the detection end is exposed downwards, ensuring direct contact between the sensor and the surface being measured, providing a physical basis for effective coupling. The water supply component provides the coupling medium, solving the problems of difficulty in applying coupling agent and easy loss in curved surface inspection. Using water as the coupling medium enhances the acoustic coupling performance between the flaw detector 94 and the curved surface. The walking component enables autonomous movement, replacing manual hand operation, improving inspection efficiency and accessibility, and allowing coverage inspection of areas that are difficult for personnel to stay in, such as the back of the aircraft and under the wings. Through the coordinated control of the edge detection sensor 15 and the main control MCU, edge safety protection is achieved to prevent the device from falling when operating in areas with obvious boundaries, such as the wings and tail of an aircraft. By controlling the water pump 19 to work alternately in a time-sharing manner through the main control MCU, for example, only one set of water pump 19 works at any given time, while the other set of water pump 19 is in a resting state. This effectively reduces the cumulative running time of a single set of water pump 19, solves the problem of excessive motor temperature rise and coil insulation aging when the DC water pump is running continuously for a long time, and extends the service life of the water pump 19. At the same time, the alternating operation of the two pumps makes the water consumption of the two sets of water tanks 7 tend to be balanced, avoids the device's center of gravity shift caused by the premature depletion of water tank 7 on one side, and ensures the stability of the device's movement on the curved surface.

[0035] Furthermore, such as Figures 1 to 5 As shown, in this embodiment, the chassis mechanism includes a lower disc frame 1 and an upper disc frame 2. The lower disc frame 1 is a circular plate structure, and the upper disc frame 2 is also a circular plate structure with a diameter similar to that of the lower disc frame 1. The upper disc frame 2 is supported above the lower disc frame 1 by multiple sets of mounting columns 3. The mounting columns 3 are evenly distributed at the top edge of the lower disc frame 1, and the top ends of the mounting columns 3 are connected to the bottom ends of the upper disc frame 2 to form a stable double-layer support structure. In this embodiment, fixing blocks 5 are provided at the bottom of both ends of the flaw detector 4. The top of the fixing blocks 5 is threaded with fixing bolts 6, and the fixing bolts 6 penetrate the fixing blocks 5 and the upper disc frame 2.

[0036] The water supply assembly includes two sets of water tanks 7 and two sets of water pumps 19. The two sets of water tanks 7 are symmetrically arranged on both sides of the top of the upper circular frame 2, and the two sets of water pumps 19 are symmetrically arranged on both sides of the top of the lower circular frame 1. The two sets of water pumps 19 are connected to the spray heads 17 via tee fittings 18. Specifically, the outlets 12 on the two sets of water tanks 7 are connected to the inlet ports 22 on the two sets of water pumps 19 via water supply pipes; the drain ports 23 on the two sets of water pumps 19 are connected to the two inlet ends of the tee fitting 18 via water supply pipes; and the outlet end of the tee fitting 18 is connected to the spray heads 17 via a water pipe.

[0037] The water spray head 17 is mounted on one end of the top of the upper disc frame 2 via the fixing base 16. The water spray direction of the water spray head 17 is towards the detection direction of the flaw detection sensor 94, ensuring that the coupling water can be accurately sprayed onto the sensor detection area.

[0038] In this embodiment, a double-layered circular frame structure physically separates the upper water tank 7 and flaw detector 4 from the lower water pump 19, circuit board 20, and motor 13, avoiding mutual interference between water and electrical components and improving system reliability. The symmetrical arrangement of the two sets of water tanks 7 and water pumps 19 keeps the device's center of gravity in the center, improving motion stability and solving the problem of center of gravity shift caused by unilateral water supply. A three-way connector 18 combines the water outputs from the two water pumps 19 into a single supply to the spray nozzles 17, simplifying the piping structure, reducing the number of spray nozzles 17, and lowering system complexity. The symmetrical arrangement of the double water tank 7 and double pump 19 structure provides the hardware foundation for time-sharing alternating control, enabling the dual pumps to work alternately and achieving balanced water consumption.

[0039] Furthermore, such as Figure 5 and Figure 6 As shown, in this embodiment, the clamping mechanism 9 includes a mounting top plate 91, a mounting bottom plate 92, and connecting rods 93. The mounting top plate 91 is fixedly connected to the bottom of the lower disc frame 1. The mounting bottom plate 92 is fixedly connected to the mounting top plate 91 via the connecting rods 93, which are located at the four corners of the bottom of the mounting top plate 91 to form a stable frame support. Mounting side plates 96 are also provided on both sides of the bottom of the mounting top plate 91, and threaded rods 95 pass through the mounting side plates 96. Abutment blocks 97 are located at the end of the threaded rods 95 near the flaw detection sensor 94.

[0040] The flaw detection sensor 94 is fixed between the mounting top plate 91 and the mounting base plate 92, and is located between two sets of contact blocks 97. By rotating the threaded rod 95, the two sets of contact blocks 97 can be moved closer or further apart, thereby clamping or releasing the flaw detection sensor 94, enabling quick replacement of the flaw detection sensor 94. The detection end of the flaw detection sensor 94 protrudes from the lower surface of the mounting base plate 92, ensuring that the detection end can directly contact the surface of the skin being tested.

[0041] The width of the mounting base plate 92 is greater than the width of the flaw detection sensor 94 to expand the bottom support surface. The connecting rod 93 connects the mounting top plate 91 and the mounting base plate 92 to form a frame. This frame structure surrounds the flaw detection sensor 94 internally, with the connecting rod 93 located at the four corners and the mounting base plate 92 located at the bottom, together forming a frame structure with an expanded bottom support surface and a lower center of gravity.

[0042] In this embodiment, the detection end of the flaw detection sensor 94 needs to protrude from the lower surface of the mounting base plate 92 to contact the surface being measured, resulting in a relatively high overall center of gravity for the sensor. At locations where the surface slope changes, the sensor's center of gravity is higher than the contact point, creating a lever arm and generating an overturning moment. When the overturning moment exceeds the supporting moment, the sensor will tilt or detach from the surface being measured, interrupting the detection signal. This embodiment, by designing the mounting base plate 92 to be wider than the flaw detection sensor 94, expands the contact support surface between the bottom of the device and the surface being measured, increasing the supporting moment. The mounting top plate 91 and mounting base plate 92 are connected by a connecting rod 93 to form a frame, enclosing the sensor within the frame and lowering the overall center of gravity height. This increases the anti-overturning moment, ensuring the supporting moment exceeds the overturning moment, effectively preventing the sensor from tilting or detaching from the surface being measured during movement, and ensuring a continuous and stable detection signal. Meanwhile, the clamping mechanism of the threaded rod 95 and the abutment block 97 enables the rapid assembly and disassembly of the flaw detection sensor 94, facilitating the replacement of different types of sensors according to different detection requirements, such as ultrasonic probes with different frequencies and different chip sizes, thereby improving the versatility of the device.

[0043] Furthermore, in this embodiment, the walking assembly is provided in four groups, evenly distributed around the bottom perimeter of the lower circular frame 1. Each group of walking assemblies includes a motor 13 and a tire 14. The motor 13 is equipped with a speed feedback sensor, which is a Hall sensor, used to detect the speed of the motor 13 in real time and feed it back to the main control MCU. The tire 14 is an anti-slip tire made of a high-friction coefficient material with anti-slip texture on the surface to enhance adhesion to the wet skin surface.

[0044] The main control MCU receives feedback signals from the Hall sensors and independently adjusts the speed and direction of each group of motors 13 in a closed-loop manner. By controlling the speed and direction combinations of the four groups of motors 13 separately, various motion modes of the detection device can be realized: when the four groups of motors 13 rotate in the same direction and at the same speed, the device moves forward or backward; when the two groups of motors 13 on the left rotate at different speeds compared to the two groups of motors 13 on the right, the device turns; when the two groups of motors 13 on the left rotate in opposite directions and at the same speed compared to the two groups of motors 13 on the right, the device rotates in place; by planning the speed sequence of each motor 13, automatic tracking and scanning of arbitrary trajectories can be achieved.

[0045] In this embodiment, under open-loop control, the speed of motor 13 is affected by load changes such as resistance changes caused by changes in surface slope, power fluctuations, and tire slippage, causing deviations from the set value and resulting in trajectory deviations. This can easily lead to yaw or slippage on curved surfaces. This embodiment uses Hall effect sensors to detect the actual speed of each motor 13 in real time. The main control MCU compares the actual speed with the set value and adjusts the PWM duty cycle using a PID algorithm to form closed-loop control. This allows the actual speed to quickly converge to the set value, ensuring consistent tire speed and precise steering on inclined curved surfaces. This avoids yaw or slippage caused by speed deviations, achieving smooth straight-line movement, in-situ rotation, and automatic tracking scanning of arbitrary trajectories on inclined and curved skin surfaces. This ensures comprehensive detection coverage and precise motion control. Four independently driven walking components enable flexible motion control of the device on open curved skin surfaces; the anti-slip tire design improves walking safety in water-sprayed environments.

[0046] Furthermore, in this embodiment, the main control MCU adjusts the average power supply voltage of the water pump 19 by outputting a pulse width modulation (PWM) signal to control the water output of the spray head 17.

[0047] Specifically, the PWM output of the main control MCU is connected to the drive circuit of the water pump 19. The average supply voltage of the water pump 19 is adjusted by changing the duty cycle of the PWM signal. The larger the duty cycle, the higher the average supply voltage of the water pump 19, the higher the rotation speed, and the larger the water output; the smaller the duty cycle, the lower the average supply voltage of the water pump 19, the lower the rotation speed, and the smaller the water output. According to the curvature, tilt angle of the surface being tested, and the detection requirements of the flaw detection sensor 94, the PWM duty cycle can be adjusted in real time so that the water volume sprayed by the nozzle 17 just meets the coupling requirements, ensuring the coupling effect while avoiding excessive water volume leading to wastage.

[0048] In this embodiment, stepless adjustment of the water flow rate of pump 19 is achieved through PWM speed regulation, enabling precise control of the coupling water volume based on changes in coupling agent demand caused by variations in surface curvature under different detection conditions. By reducing the average supply voltage of pump 19, the power consumption and heat generation of pump 19 are reduced. Combined with time-sharing alternating control, the workload of a single pump 19 is further reduced, solving the problem that DC pumps cannot operate continuously for extended periods and extending the service life of pump 19. Using water as the coupling medium, a stable water film is formed between the flaw detection sensor 94 and the measured surface through precise control of the water flow rate, enhancing acoustic coupling performance and improving detection accuracy.

[0049] Furthermore, in this embodiment, multiple edge detection sensors 15 are provided and evenly distributed around the perimeter of the bottom of the lower disc frame 1. In this embodiment, the edge detection sensors 15 are located at both ends of the bottom of the lower disc frame 1 and penetrate through the lower disc frame 1, with their detection ends exposed outside the ground contact contour of the tire 14. The detection ends of the edge detection sensors 15 face downwards and outwards from the device, and their detection direction corresponds to the traveling direction of the tire 14, enabling them to detect the boundary position before the tire 14 approaches the edge.

[0050] The main control MCU is configured to respond to the sensing signal output by any one of the edge detection sensors 15, that is, to control the motors 13 of the four walking components to brake simultaneously.

[0051] When the device operates in areas with clear boundaries, such as the wings and tail of an aircraft, any edge detection sensor 15 will immediately output a sensing signal to the main control MCU when it detects an edge. After receiving the signal, the main control MCU will immediately control the four sets of motors 13 to brake simultaneously, so that the device stops in front of the edge and prevents the tire 14 from crossing the edge of the skin being measured, which would cause the device to fall.

[0052] In this embodiment, by evenly arranging multiple edge detection sensors 15 around the circumference, all-round monitoring of the device's edges is achieved, ensuring timely edge detection regardless of the device's direction of movement. The logic design of triggering braking at any single sensor ensures reliable edge protection and avoids safety vulnerabilities caused by the failure of a single sensor. If only the motor 13 on the side that detected the edge is braked, while the other motor 13 continues to rotate, the device will rotate around the braked side, potentially causing the other tires 14 on the side that did not detect the edge to cross the boundary. This embodiment uses four sets of motors 13 to brake simultaneously, ensuring the entire device stops immediately and avoiding the risk of rotation or sideslip due to asynchronous braking. This provides reliable safety assurance for the device's automatic operation in dangerous areas with steep boundaries.

[0053] Furthermore, in this embodiment, a battery 21 is provided at one end of the top of the lower disc frame 1. The battery 21 is a 12V 6000mAh lithium battery with ultra-long battery life. The battery 21 is electrically connected to the motor 13, the water pump 19 and the main control MCU, and is used to provide power for the entire detection device.

[0054] The lower circular frame 1 is also equipped with circuit boards 20 on both sides of the top. The circuit boards 20 are equipped with the main control MCU and various functional circuit modules, including voltage regulator circuit, motor drive circuit, water pump control circuit, edge detection sensor detection circuit, battery power detection circuit, etc.

[0055] In this embodiment, the built-in high-capacity battery 21 enables a completely wireless and cable-free design for the detection device, allowing it to move freely on large open curved surfaces without being limited by power cord length. This solves the problems of traditional detection equipment requiring external power and having limited mobility. Through the battery power detection circuit, the main control MCU can monitor the remaining power of the battery 21 in real time and upload the data to the host computer via the wireless communication module. This allows operators to monitor the device's battery status, promptly recall it for charging, and prevent the device from being stranded at high altitudes or in dangerous areas due to depleted power.

[0056] Furthermore, in this embodiment, the water tank 7 is fixed to the top of the upper disc frame 2 by a water tank mounting bracket 8. The two ends of the water tank mounting bracket 8 are fixedly connected to the top of the upper disc frame 2, thus firmly fixing the water tank 7 to the upper layer of the device.

[0057] The water tank 7 is equipped with a circular cover 10 on top. Adding water only requires opening the circular cover 10; the water tank 7 does not need to be removed, making operation convenient. A pressure balancing air pipe 11 and a water outlet 12 are located on one side of the top of the circular cover 10. The pressure balancing air pipe 11 is used to balance the air pressure inside and outside the water tank 7 when the water pump 19 is pumping water, ensuring smooth water flow and preventing the water pump 19 from running dry or causing poor water flow due to negative pressure.

[0058] In this embodiment, the water tank 7 is reliably fixed by the water tank mounting bracket 8, while also facilitating disassembly and maintenance. The circular top cover 10 simplifies the water filling process, allowing water to be added without disassembling the water tank 7, thus improving the convenience of on-site operations. The pressure balancing air pipe 11 ensures smooth water flow from the water tank 7, preventing the water pump 19 from running dry or causing poor water flow due to negative pressure, thereby improving the reliability of the water supply system.

[0059] Furthermore, in this embodiment, the flaw detector 4 and the flaw detection sensor 94 are connected by a signal cable. The signal cable is flexible and its length is greater than the distance between the mounting top plate 91 and the mounting bottom plate 92.

[0060] Since the flaw detection sensor 94 is fixed between the mounting top plate 91 and the mounting bottom plate 92, and the device may experience slight vibrations or attitude changes when moving on the curved surface, the redundant length design of the signal cable ensures that the electrical connection between the flaw detector 4 and the flaw detection sensor 94 will not be pulled and broken due to relative displacement, thus ensuring the reliability of the detection signal transmission.

[0061] In this embodiment, a flexible signal cable connection is used to accommodate the fixed installation of the flaw detection sensor 94 within the clamping mechanism 9 and changes in posture during device movement, ensuring reliable transmission of the detection signal from the flaw detection sensor 94 to the flaw detector 4. The redundant length design avoids the risk of poor contact or breakage caused by cable pulling, ensuring the continuity of the detection process.

[0062] Furthermore, in this embodiment, such as Figures 1-7 As shown, the present invention also provides a direct contact damage detection system for detecting skin damage, comprising: the above-mentioned direct contact damage detection device for detecting skin damage, a host computer, and a wireless communication module.

[0063] The wireless communication module is used to establish bidirectional data communication between the main control MCU and the host computer. In this embodiment, the wireless communication module adopts Bluetooth wireless communication. The main control circuit board 20 of the detection device is equipped with a Bluetooth communication interface, and the host computer is equipped with a Bluetooth adapter. The two establish a wireless connection through the Bluetooth protocol.

[0064] In this embodiment, the host computer is equipped with a control module, which is implemented by a computer program running on the host computer. This module sends control commands to the detection device and receives and displays the flaw detection data and status data sent by the detection device. The status data includes the device's motion status (e.g., running / stopping, direction, speed), battery level, and the operating status of each sensor. The host computer's control module is developed using the QT Creator environment, written in C++, and runs on a remote computer. It allows for interaction through the host computer interface, enabling data transfer and sharing, as well as remote automatic control of the detection system.

[0065] Regarding the display parameters, the main parameters that the control module of the host computer can display in real time include: (1) synchronously displaying various parameters of the flaw detector 4, such as the type, location, depth, and length of the flaw; (2) the battery power of the flaw detector 4 and the power of the battery 21 of the detection device itself; (3) the automatic operation status, movement direction, and current walking speed of the detection device; (4) the real-time operation status, direction, and speed of the device under manual remote control.

[0066] Regarding parameter settings and threshold alarms, the host computer's control module is equipped with automatic flaw detection data analysis and alarm functions. When the received flaw detection data exceeds a preset threshold, the host computer issues an audible and visual alarm. Specifically: Flaw detection alarm: The control module of the host computer can set the alarm threshold of the flaw detector 4. The computer calculates and analyzes the flaw detection data transmitted from the detection device in real time. When the detected crack depth or area exceeds the alarm threshold, a prominent prompt will pop up on the host computer software interface, accompanied by an audible and visual alarm.

[0067] Status Alarm: The host computer's control module can set a low battery alarm threshold. When the battery of the detection device platform or the flaw detector is too low, the host computer software will provide corresponding prompts and audible and visual alarms.

[0068] Communication Alarm: The host computer's control module monitors the wireless Bluetooth communication status in real time. If a communication error occurs (such as a disconnection), the host computer software will display a communication interruption message and trigger an audible and visual alarm.

[0069] In terms of parameter analysis and processing, the host computer's control module can read flaw detection data in real time, and automatically analyze, process, display, and classify the flaw detection data for storage, enabling the traceable playback of historical data.

[0070] In this embodiment, the cooperation of the wireless communication module and the host computer enables two-way data interaction between the detection device and the remote computer. Operators can remotely control the device's movement, set detection parameters, and view flaw detection data and device battery status in real time through the host computer interface from a safe area, eliminating the need for close proximity to the equipment and mitigating safety hazards associated with working in high-altitude or toxic environments. The automatic flaw detection data analysis and alarm functions of the host computer control module enable automatic damage identification, threshold alarms, data storage, and analysis, completely changing the traditional manual handheld, on-site interpretation mode and significantly improving detection efficiency, data objectivity, and personnel safety. Bluetooth wireless communication enables short-range, low-power, stable, and reliable data transmission, suitable for industrial inspection environments.

[0071] Furthermore, such as Figures 8 to 15 As shown, all the above-mentioned functional circuit modules are integrated on the circuit board 20 on the top of the lower disc frame 1. The circuit board 20 is a multi-layer PCB board, and the functional circuit modules are arranged according to the area and electrically connected through PCB traces.

[0072] Circuit board 20 is located on both sides of the top of the lower circular frame 1. Circuit board 20 integrates a main control MCU, voltage regulator circuit, motor drive circuit, water pump control circuit, edge detection sensor circuit, battery power detection circuit, and Bluetooth communication interface. Battery 21 is located at one end of the top of the lower circular frame 1, and its output is connected to the power input of circuit board 20. The outputs of circuit board 20 are connected via cables to actuators and sensors such as DC motor 13, water pump 19, and edge detection sensor 15.

[0073] like Figure 8 As shown, in this embodiment, the power input terminal of circuit board 20 is equipped with a reverse connection protection circuit. The power input terminal adopts a DC-005-25A interface X1, which is soldered to the edge of circuit board 20 and connected to MOSFET Q1 after passing through switch S1. When the power is connected in the correct direction, MOSFET Q1 is turned on, and +12V voltage is output to the subsequent circuit; when the power is connected in the reverse direction, MOSFET Q1 is turned off, cutting off the power supply to the subsequent circuit, thus providing reverse connection protection. Diode D2 is used to protect the gate of MOSFET Q1, and capacitors C1 and C3 are filter capacitors used to stabilize the input voltage.

[0074] like Figure 9 As shown, in this embodiment, the power management area of ​​circuit board 20 is equipped with a power regulation circuit. The DC-DC step-down chip U1 converts the +12V input voltage to a +5V output voltage. Inductor L1, capacitors C8 and C9 are output filter components, and resistor R2 is the load resistor. The linear regulator chip U2 further converts the +5V voltage to +3.3V to power low-voltage devices such as the MCU. Capacitors C5 and C6 are output filter capacitors. Feedback voltage divider resistors R1, R3, R5, and R6 are used to set the output voltage value. The light-emitting diode D4 is a power indicator light, soldered to the surface of circuit board 20.

[0075] like Figure 10 As shown, in this embodiment, the communication interface area of ​​circuit board 20 is provided with a Bluetooth communication interface X7. The wireless Bluetooth module connects to the main control MCU through interface X7, which is soldered to the edge of circuit board 20 and includes a +5V power supply, WIFI_UART_RX and WIFI_UART_TX signal lines, and a ground terminal. Capacitor C21 is a decoupling capacitor, soldered near interface X7. The Bluetooth module transmits various parameters of the flaw detector 4, system motion parameters, flaw detector 4 power parameters, and system power parameters to the remote computer in real time, and simultaneously receives control parameters from the remote computer.

[0076] like Figure 11 As shown, in this embodiment, the motor drive area of ​​circuit board 20 is equipped with a motor drive chip U7. Motor drive chip U7 is a dual H-bridge driver chip, capable of simultaneously driving two sets of DC motors 13. The VCC terminal of chip U7 is connected to a +3.3V logic power supply, and the VM1 to VM3 terminals are connected to a +12V motor power supply. AIN1, AIN2, and PWMA are the A-channel motor control inputs, and BIN1, BIN2, and PWMB are the B-channel motor control inputs. AO1_1, AO1_2 and BO1_1, BO1_2 are the motor drive output terminals, connected to the DC motors 13 via cables. The direction control of the DC motors 13 is achieved by controlling the level combination of AIN and BIN, and the speed of the DC motors 13 is adjusted by the PWM signal. Capacitor C29 is a logic power supply decoupling capacitor, soldered near chip U7.

[0077] like Figure 12As shown, in this embodiment, the sensor interface area of ​​circuit board 20 is equipped with an edge detection sensor circuit. The edge detection sensor circuit adopts an optocoupler isolation design. Optocoupler IC1 achieves signal isolation transmission, resistors R18 and R31 are current-limiting resistors, and resistor R42 is a pull-up resistor to ensure stable output level. Transistor N3 is used for signal amplification. When the edge detection sensor 15 detects an edge, the output signal is isolated by optocoupler IC1 and transmitted to the MCU_SENSOR1 terminal via resistor R98. After the main control MCU detects this signal, it immediately controls the DC motor 13 to brake to prevent it from falling. The 5.0V power supply is supplied through resistor R18, and MT_5V is the isolated power supply.

[0078] like Figure 13 As shown, in this embodiment, the water pump control area of ​​circuit board 20 is equipped with a water pump control circuit. The water pump control circuit realizes the isolated control of the MCU on the water pump 19 through optocoupler IC5 and transistor N5. The MCU control output terminal MCU_MT is connected to optocoupler IC5 through resistor R40. The output of optocoupler IC5 drives transistor N5 through resistor R36. Transistor N5 controls the power supply circuit MT of water pump 19. Resistor R44 is the base current limiting resistor of transistor N5. The PWM signal output by the MCU drives transistor N5 after being isolated by optocoupler IC5. By adjusting the PWM duty cycle, the average power supply voltage of water pump 19 is controlled, thereby adjusting the speed and water output of water pump 19. The 5.0V power supply is supplied through resistor R40, and MT_5V is the isolated power supply.

[0079] like Figure 14 As shown, in this embodiment, the power detection area of ​​circuit board 20 is equipped with a battery power detection circuit. The battery power detection circuit uses operational amplifier U6A to form a voltage follower. The +12V battery voltage 21 is divided by voltage divider resistors R19 and R20 and then sent to the non-inverting input 3 of operational amplifier U6A. The output 1 is sent to the ADC_V acquisition terminal via clamping diode D6, and acquired by the ADC module of the main control MCU. The resistance ratio of the voltage divider resistors is R19 100K to R20 30K, dividing the +12V voltage to a range suitable for ADC acquisition. The +5V power supply powers operational amplifier U6A, and the +3.3V supply is the clamping reference power supply.

[0080] like Figure 15As shown, in this embodiment, the main control area of ​​circuit board 20 is equipped with a main control MCU. The main control MCU is the core control unit of the system and is equipped with rich peripheral interfaces: multiple PWM outputs such as MOTO_A_PWM, MOTO_B_PWM, MOTO_C_PWM, and MOTO_D_PWM are used for speed control of DC motor 13 and water pump 19; multiple ADC inputs such as ADC_V are used for battery 21 power and sensor signal acquisition; multiple GPIOs such as ENC_A_CAP, ENC_B_CAP, ENC_C_CAP, and ENC_D_CAP are used for sensor detection and status indication; UART interfaces such as WIFI_UART_TX and WIFI_UART_RX are used for Bluetooth communication; I2C interfaces such as MPU_I2C_SCL and MPU_I2C_SDA or SPI interfaces such as PS2_SPI_CLK, PS2_SPI_CS, PS2_SPI_MOSI, and PS2_SPI_MISO are used for expanding peripherals. Crystal oscillator Y1, along with capacitors C11 and C12, forms an oscillation circuit to provide the system clock, and is soldered near the MCU. Reset circuit S3, along with resistor R10 and capacitor C10, ensures reliable system reset. Button S4, along with resistors R8 and R9, forms an input circuit. LEDs_OE and BEEP provide status indication and alarm outputs.

[0081] Furthermore, in this embodiment, According to the above-described scheme of the present invention, the combination of four-wheel differential drive and Hall closed-loop control of the walking component realizes precise motion control on inclined curved surfaces, solving the problem of difficulty in ensuring stable scanning speed in traditional manual operation, and also solving the problem of poor versatility of fixed track scanning. The frame design of the clamping mechanism 9 cooperates with the protruding detection end of the flaw detection sensor 94, maintaining stable contact between the sensor and the curved surface under the action of the device's own weight, solving the problem of difficulty in maintaining continuous and uniform contact during handheld operation, and also solving the problem of insufficient stability of existing spring loading mechanisms during movement and vibration. The symmetrical arrangement of the dual water tanks 7 and dual pumps 19, combined with time-sharing alternating control and PWM speed regulation, not only balances the center of gravity but also extends the life of the water pumps 19, solving the problem of uneven application of coupling agent and easy loss during manual application, and also solving the problem of overheating and damage of single pumps during long-term operation. The circumferential arrangement of the edge detection sensor 15, combined with the rapid braking response of the main control MCU, provides safety assurance for open curved surface edge operations, and solves the problem of insufficient reliability of existing vision or distance sensors in water coupling environments. The remote monitoring of the host computer, combined with the wireless data transmission of the device, enables unmanned detection of dangerous areas and solves the problems of data recording relying on manual labor and low efficiency.

[0082] The above synergistic effects enable this device to replace manual labor in completing automated inspection tasks of large open curved surface skins that are difficult to achieve using traditional methods. It is especially suitable for skin damage inspection of equipment such as aircraft fuselages, wings, tails, and large storage tanks.

[0083] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above-described features with (but not limited to) technical features with similar functions disclosed in this application.

[0084] It should be understood that the sequence number of each step in the invention and its embodiments does not absolutely imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

Claims

1. A direct contact damage detection device for detecting skin damage, characterized in that, include: Chassis structure; A flaw detector is installed above the chassis mechanism; A clamping mechanism is provided at the bottom of the chassis mechanism to fix the flaw detection sensor and expose the detection end of the flaw detection sensor downwards; A water supply assembly, mounted on the chassis mechanism, includes a water tank, a water pump, and a spray head. The outlet of the water tank is connected to the inlet of the water pump, and the water pump is connected to the spray head. The walking assembly, mounted on the bottom of the chassis mechanism, includes a motor and tires, and the motor is equipped with a speed feedback sensor; An edge detection sensor is installed at the bottom edge of the chassis mechanism; The main control MCU is configured to: receive feedback signals from the speed feedback sensor to regulate the speed of the motor in a closed loop; control the braking of the motor in response to the sensing signals from the edge detection sensor; and control the operation of the water pump in a time-sharing alternating manner.

2. The direct contact damage detection device for detecting skin damage according to claim 1, characterized in that, The chassis mechanism includes a lower disc frame and an upper disc frame. The upper disc frame is supported above the lower disc frame by multiple sets of mounting columns. The water supply assembly includes two sets of water tanks and two sets of water pumps. The two sets of water tanks are located on both sides of the upper disc frame, and the two sets of water pumps are located on both sides of the lower disc frame. The two sets of water pumps are connected to the spray head through a tee fitting.

3. The direct contact damage detection device for detecting skin damage according to claim 1, characterized in that, The clamping mechanism includes a mounting top plate, a mounting bottom plate, and a connecting rod. The mounting top plate is connected to the chassis mechanism, and the mounting bottom plate is connected to the mounting top plate via the connecting rod. The flaw detection sensor is fixed between the mounting top plate and the mounting bottom plate, and the detection end of the flaw detection sensor protrudes from the lower surface of the mounting bottom plate. The width of the mounting bottom plate is greater than the width of the flaw detection sensor, and the connecting rod connects the mounting top plate and the mounting bottom plate to form a frame.

4. The direct contact damage detection device for detecting skin damage according to claim 1, characterized in that, The walking assembly has four groups, evenly distributed around the bottom of the chassis mechanism, and the tires are anti-slip tires; the speed feedback sensor is a Hall sensor, and the main control MCU independently adjusts the speed and direction of each group of motors in a closed-loop manner to realize the differential straight-line or turning of the detection device.

5. The direct contact damage detection device for detecting skin damage according to claim 1, characterized in that, The main control MCU adjusts the power supply voltage of the water pump by outputting a pulse width modulation signal, thereby controlling the water output of the spray head.

6. The direct contact damage detection device for detecting skin damage according to claim 1, characterized in that, Multiple edge detection sensors are provided and evenly distributed around the bottom edge of the chassis mechanism. The detection end of the edge detection sensor is exposed outside the ground contact profile of the tire. The main control MCU is configured to control the motor of the walking component to brake simultaneously in response to the sensing signal output by any one of the edge detection sensors.

7. The direct contact damage detection device for detecting skin damage according to claim 1, characterized in that, A battery is installed on the chassis mechanism, which powers the motor, the water pump and the main control MCU.

8. The direct contact damage detection device for detecting skin damage according to claim 2, characterized in that, The water tank is fixed to the top of the upper disc frame by a water tank mounting bracket. The top of the water tank is provided with a circular cover, and the circular cover is provided with a pressure balancing air pipe and a water outlet. The water spray head is set on the top of the upper disc frame by a fixing seat.

9. The direct contact damage detection device for detecting skin damage according to claim 1, characterized in that, The flaw detector and the flaw detection sensor are connected by a flexible cable, the length of which is greater than the distance between the mounting top plate and the mounting bottom plate.

10. A direct contact damage detection system for detecting skin damage, characterized in that, Includes the direct contact damage detection device for detecting skin damage as described in any one of claims 1 to 9; Also includes: host computer; The wireless communication module establishes bidirectional data communication between the main control MCU and the host computer. The host computer is equipped with a control module for sending control commands to the detection device and receiving and displaying the flaw detection data and status data sent by the detection device. The control module of the host computer is also equipped with an automatic flaw detection data analysis and alarm function. When the received flaw detection data exceeds a preset threshold, the host computer issues an audible and visual alarm.

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