A multi-process coupled GIS detection robot body precision forming machining process

Abstract

The application provides a multi-process coupled GIS detection robot body precision forming process, which verifies and corrects FDM size through SLA, carries out FDM partition filling, carries out CNC processing and post-processing, solves problems such as multi-process tolerance accumulation, difficulty in balancing lightweight and precision strength, and easy interference, wear and dust accumulation of printed parts, and improves assembly precision, environmental adaptability and operation stability; the process steps comprise: dividing the body components into FDM parts, SLA verification parts and CNC metal parts according to the function and design boundary size of the body components; first, the SLA verification part is photocured, the measured deviation is returned to the three-dimensional model, and the FDM part assembly opening and reference size are corrected; the FDM part bearing area is filled with honeycomb, and the reference area is solid printed; the CNC part is machined and hard anodized; the FDM part is polished, epoxy immersion coated and cured, and anti-static electromagnetic shielding sprayed; finally, the whole machine is assembled, and after normal operation in the simulated GIS cavity working condition, it is used as the final whole machine.

Description

Technical Field

[0001] This invention relates to the field of machining technology, specifically to a precision forming process for the body of a GIS inspection robot with multiple coupled processes. Background Technology

[0002] As a core sealed device in high-voltage power systems, GIS (Gas Insulated Switchgear) is prone to potential faults such as poor conductor contact, insulation layer cracking, and accumulation of free metal particles during long-term operation. Due to the narrow internal space, complex piping structure, and multiple bends and flange steps within the GIS cavity, manual inspection is impossible. Therefore, the industry commonly uses miniature wheeled inspection robots equipped with imaging modules, ultra-wideband (UWB) positioning modules, and dual communication systems to achieve non-destructive testing inside the cavity.

[0003] GIS sealed cavities present complex operating conditions, including narrow gap passage restrictions, multi-diameter adaptation requirements, strong electromagnetic radiation, static electricity accumulation, and metal dust adhesion. These conditions place stringent demands on the structure of inspection robots, requiring them to simultaneously meet comprehensive performance requirements such as small size and lightweight design, high molding precision, high obstacle-crossing structural strength, electromagnetic interference resistance, and dust and static electricity prevention. Currently, GIS inspection robot manufacturing often employs single or simple combined processing techniques, resulting in significant technical shortcomings and making it difficult to adapt to extreme cavity conditions.

[0004] Existing single processing technologies have inherent limitations: the self-weight of a pure aluminum alloy integral CNC (Computer Numerical Control) milling machine body is large, resulting in high power consumption and poor endurance for robot movement; the single FDM (Fused Deposition Modeling) process has low forming accuracy and loose component structure, which easily leads to module vibration and imaging misalignment after assembly, and the structure has insufficient impact resistance; the single SLA (Stereolithography) process produces components with high brittleness and weak load-bearing capacity, and can only produce micro-parts, which cannot meet the requirements of the main body structure and obstacle crossing load-bearing.

[0005] Currently, the limited number of composite processing methods in the industry only involve the mechanical assembly of different parts, failing to form a systematic and interconnected composite molding system. This results in three major defects: First, various processing techniques are formed independently without a dimensional linkage calibration mechanism, leading to severe accumulation of tolerances in the assembly of components prepared by different processes and poor stability in the assembly of precision modules. Second, it is impossible to simultaneously achieve lightweight, high precision, and high strength. Third, general 3D printing post-processing only involves simple polishing and painting, which can easily cause signal interference, component wear, and dust accumulation in pores during long-term operation of the robot inside the cavity.

[0006] In summary, there is an urgent need to develop a composite molding process for the fuselage of GIS inspection robots that can balance lightweight, high precision, high strength, and environmental adaptability, in order to address the aforementioned shortcomings of existing processing technologies, specifically for the unique service conditions of GIS inspection robots. Summary of the Invention

[0007] This invention aims to address the technical deficiencies of existing technologies by providing a precision forming process for the body of a GIS inspection robot that involves multiple coupled processes. Through SLA verification and correction of FDM dimensions, FDM partition filling, CNC machining, and post-processing, it solves problems such as the accumulation of tolerances across multiple processes, the difficulty in balancing lightweight design with precision and strength, and the ease with which printed parts are susceptible to interference, wear, and dust accumulation. This improves assembly accuracy, environmental adaptability, and operational stability.

[0008] This invention provides the following technical solution: a precision forming process for the body of a GIS inspection robot involving multiple coupled processes, comprising:

[0009] Based on the functions of the machine's body components and the design boundary dimensional constraints of the machine, the machine's body components are divided into FDM molded parts, SLA photopolymerization verification parts, and CNC machined metal parts.

[0010] The SLA photocurable calibration part is photocured and molded. The actual size of the calibrated part is detected. The measured deviation data is sent back to the robot's three-dimensional design model to correct the assembly opening and reference size of the FDM molded part, thus obtaining the corrected FDM molded part.

[0011] The load-bearing area of ​​the modified FDM molded part is filled with a honeycomb structure, and the assembly reference area of ​​the FDM molded part is filled with solid material for printing, thus obtaining the printed FDM molded part.

[0012] The CNC metal part is subjected to machining and hard anodizing treatment in sequence to obtain the treated CNC metal part;

[0013] The printed FDM molded parts are sequentially subjected to sanding and deburring, epoxy resin impregnation and curing, and anti-static electromagnetic shielding spraying to obtain the processed FDM molded parts.

[0014] The machined CNC metal parts and the processed FDM molded parts are then assembled to obtain the finished machine.

[0015] When the processed complete machine operates normally under the pre-constructed simulated GIS cavity conditions, the processed complete machine is regarded as the final complete machine.

[0016] The following are further optimizations and / or improvements to the above-mentioned technical solution:

[0017] In the above processing technology:

[0018] The FDM molded part includes the main body shell, the circuit compartment shell, and the battery support shell;

[0019] The SLA photocurable calibration kit includes an infrared camera mounting base, a UWB antenna mounting bracket, and a supplementary light assembly support.

[0020] The CNC machined metal parts include a motor mounting flange, a wheel assembly hinge support base, and a drive shaft limit bracket.

[0021] In the above processing technology:

[0022] The SLA photocurable calibration component is formed by photocuring with radio frequency compatible photosensitive resin. The thickness of the molded layer of the SLA photocurable calibration component is 0.02 mm, the exposure time of the bottom layer is 35 s, and the exposure time of the single layer is 3.5 s.

[0023] In the above processing technology:

[0024] The actual dimensions of the formed verification piece are measured using a digital micrometer and dial indicator on a marble precision testing platform; the actual dimensions include the coaxiality of the mounting holes and the flatness of the reference surface.

[0025] In the above processing technology:

[0026] The printing parameters for the printed FDM molded parts are as follows: layer thickness is 0.18mm, global dimensional tolerance is within ±0.8mm, and the printing stacking direction is the robot pipeline travel axis; after printing, the parts are naturally cooled in a constant temperature chamber for 4 hours.

[0027] In the above processing technology:

[0028] The steps of sequentially machining and hard anodizing the CNC metal part to obtain the treated CNC metal part include:

[0029] The CNC metal workpiece is subjected to rough milling to remove excess material, semi-finish milling to form the shape, and finish milling to refine the shape, thereby obtaining a pre-machined CNC metal workpiece. The rough milling to remove excess material is 1.0-1.5mm on one side, with a machining feed rate of 800-1000mm / min and a spindle speed of 3500-4000r / min. The flatness of the workpiece after rough milling is controlled to be ≤0.2mm. The semi-finish milling to form the shape is to leave a finishing allowance of 0.25-0.25mm on one side. 4mm, feed rate 500-600mm / min, spindle speed 4500-5000r / min, flatness after semi-finish milling ≤0.10mm, parallelism ≤0.08mm; the single-sided cutting allowance for finish milling is 0.04-0.08mm, feed rate 250-300mm / min, spindle speed 6000-6500r / min, flatness of the reference surface after finish milling ≤0.06mm, and the contour dimensional tolerance is IT7 grade;

[0030] The bearing holes and shaft holes of the pre-processed CNC metal parts are precision bored and then mirror-polished using a surface grinder to obtain the machined CNC metal parts.

[0031] The CNC machined part is subjected to hard anodizing treatment to obtain the treated CNC machined part; wherein the oxide layer thickness of the hard anodizing treatment is 20 μm.

[0032] In the above processing technology:

[0033] The epoxy resin impregnation and curing process uses a two-component transparent epoxy resin with a dynamic viscosity of 120–180 mPa·s, a constant immersion temperature of 25°C, an immersion time of 30 min, and a curing time of 24 h.

[0034] In the above processing technology:

[0035] The antistatic electromagnetic shielding spraying treatment adopts a low-pressure cross-spraying process with an atomization pressure of 0.18-0.22MPa, a spraying distance of 180-220mm, and a spray gun moving speed of 200mm / s. The antistatic electromagnetic shielding coating is sprayed in two layers, with a single layer thickness of 12μm and a total coating thickness of 24μm. It is cured in a dust-free environment at room temperature for 12 hours.

[0036] In the above processing technology:

[0037] The assembly of the entire machine uses high-temperature resistant insulating rubber flat pads as isolation auxiliary materials, and the assembly bolts are fixed by a diagonal symmetrical torque tightening method.

[0038] In the above processing technology:

[0039] The processed machine can continuously traverse a 25mm flange step 20 times, smoothly pass through an 80mm narrow gap channel, and operate continuously at full load for 8 hours with key assembly reference dimension changes ≤0.05mm; infrared imaging offset ≤2 pixels, UWB steady-state positioning error ≤2cm, and communication system packet loss rate ≤0.2%; the surface resistance of the machine body is maintained at 10 Ω·cm. 6 -10 9 Ω.

[0040] This invention effectively eliminates the tolerance accumulation problem of multi-process molding by using reverse correction before photopolymerization molding and multi-process dimensional linkage calibration, significantly improving the assembly accuracy of robot precision modules and avoiding faults such as motor vibration, imaging offset, and positioning distortion. While ensuring the narrow clearance size requirements of the robot body and significantly reducing the overall weight, it effectively improves obstacle crossing and impact resistance, solving the problem that traditional processes cannot balance lightweight and structural strength. Through epoxy resin deep penetration curing and anti-static electromagnetic shielding spraying, it effectively improves the defects of 3D printed components that are loose and easy to wear, while significantly improving the adaptability of the robot body in the strong electromagnetic, electrostatic, and dusty environment of GIS, greatly improving the stability and service life of the robot during long-term continuous operation. It can be adapted to the molding and manufacturing of GIS cavity inspection robots with different pipe diameters and clearance sizes, with strong process versatility, effectively shortening the prototype iteration cycle and reducing R&D and production costs. Attached Figure Description

[0041] Figure 1 This is a process flow diagram of an embodiment of the present invention;

[0042] Figure 2 This is a schematic cross-sectional view of a honeycomb filling structure provided in an embodiment of the present invention;

[0043] Figure 3 This is a schematic diagram of a solid filling provided in an embodiment of the present invention. Detailed Implementation

[0044] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0045] like Figures 1-3 As shown, the purpose of this invention is to provide a precision forming process for the body of a GIS inspection robot with multi-process coupling, the process steps of which include:

[0046] S101. Based on the functions of the machine body components and the design boundary dimension constraints of the machine, the machine body components are divided into FDM molded parts, SLA photopolymerization verification parts, and CNC metal processing parts.

[0047] Furthermore, the FDM molded parts include the main body shell, the circuit compartment shell, and the battery support shell; the SLA photopolymerization calibration parts include the infrared camera mounting base, the UWB antenna mounting bracket, and the supplementary lighting assembly bracket; and the CNC machined metal parts include the motor mounting flange, the wheel assembly hinge support base, and the drive shaft limit bracket.

[0048] It is understood that this embodiment uses 3D software to complete the 3D modeling of the GIS inspection robot, constrains the maximum external dimensions of the whole machine according to the narrow gap passage conditions of the equipment, and completes the partitioning and process matching according to the component functions and stress characteristics.

[0049] Specifically, large-sized, complex curved surface components such as the left and right main body shells, circuit compartment shells, battery support shells, and travel mechanism protective shells are classified as FDM molded parts. These components are large in size, have complex curved structures, and do not require ultra-high precision fitting, making them suitable for FDM rapid integrated molding technology. Miniature precision components such as the infrared camera mounting base, UWB antenna mounting bracket, and supplementary lighting component support are classified as SLA photopolymerization calibration parts for overall assembly benchmark accuracy calibration. RF adapter photosensitive resin with a dielectric constant of 4.4 and a thickness of 1.2mm is selected for molding to ensure the operational stability of the RF module. Dynamically stressed components such as the motor mounting flange, wheel assembly hinge support base, and drive shaft limit bracket are classified as CNC machined metal parts, using 6061-T6 aerospace aluminum alloy as the raw material, to withstand instantaneous impact loads and dynamic loads during robot obstacle crossing and travel.

[0050] S102. The SLA photocurable calibration part is photocured and molded. The actual size of the calibrated part is detected. The measured deviation data is sent back to the robot's three-dimensional design model to correct the assembly opening and reference size of the FDM molded part, and the corrected FDM molded part is obtained.

[0051] The measured deviation data are obtained based on the actual dimensions and the theoretical design dimensions.

[0052] Furthermore, the SLA photocurable calibration component is photocured using radio frequency compatible photosensitive resin. The thickness of the molded layer of the SLA photocurable calibration component is 0.02 mm, the exposure time of the bottom layer is 35 s, and the exposure time of the single layer is 3.5 s.

[0053] Furthermore, the actual dimensions of the molded verification part are obtained through the following methods:

[0054] The actual dimensions of the calibrated parts after molding are measured using a digital micrometer and dial indicator on a marble precision inspection platform; the actual dimensions include the coaxiality of the mounting holes and the flatness of the reference surface.

[0055] In one implementation, an industrial-grade SLA photopolymer printer is used to form SLA photopolymer calibration parts. The forming layer thickness is set to 0.02 mm, the bottom layer exposure time to 35 s, and the standard single-layer exposure time to 3.5 s, completing the forming of all precision small parts in one pass. After forming, the workpiece is ultrasonically cleaned in anhydrous ethanol for 15 minutes to thoroughly remove residual resin from the gaps; then it is placed in a UV curing chamber for 40 minutes to complete the structural curing. On a marble precision inspection platform, a digital micrometer and dial indicator are used to inspect the coaxiality of the mounting holes and the flatness of the reference surface. In this embodiment, the center deviation of the antenna bracket mounting holes is 0.07 mm, and the flatness of the mounting surface is 0.04 mm, meeting the assembly requirements. The measured hole positions and flatness data are transmitted back to the 3D model, and the coordinates of the corresponding assembly openings on the FDM fuselage are slightly corrected to achieve closed-loop matching of multiple process dimensions, avoiding assembly misalignment problems from the source.

[0056] S103. The bearing area of ​​the modified FDM molded part is filled with a honeycomb structure, and the assembly reference area of ​​the FDM molded part is filled with solid material for printing to obtain the printed FDM molded part.

[0057] Furthermore, the printing parameters for the printed FDM molded parts are as follows: layer thickness is 0.18mm, global dimensional tolerance is within ±0.8mm, and the printing stacking direction is the robot pipeline travel axis; after printing, the parts are naturally cooled in a constant temperature chamber for 4 hours.

[0058] In one embodiment, this example uses an industrial-grade FDM printer and high-strength ABS engineering consumables, with finely set molding parameters: layer thickness is set to 0.18mm, and global dimensional tolerance is controlled within ±0.8mm; the robot's pipeline travel axis is uniformly used as the printing stacking direction to minimize interlayer internal stress and suppress shell warping deformation. An integrated, zoned, differentiated filling process is adopted. Figure 2 This is a schematic cross-sectional view of a honeycomb filling structure provided in an embodiment of the present invention, as shown below. Figure 2 As shown, the load-bearing areas such as the fuselage shell and main control compartment adopt a hexagonal topological honeycomb structure with a wall thickness of 0.8mm and a fill rate of 30%. Figure 3 This is a schematic diagram of a solid filling provided by an embodiment of the present invention, such as... Figure 3 As shown, the lens mounting platform and motor mounting platform areas are 100% solid-filled. After printing, the workpiece is naturally cooled in the constant temperature chamber of the equipment for 4 hours to completely release the molding internal stress before demolding and removal, avoiding component distortion caused by sudden temperature changes.

[0059] S104. The CNC metal part is subjected to machining and hard anodizing treatment in sequence to obtain the treated CNC metal part.

[0060] Furthermore, the CNC metal workpiece is subjected to rough milling to remove excess material, semi-finish milling to form the workpiece, and finish milling to refine the workpiece shape, thereby obtaining a pre-machined CNC metal workpiece. The rough milling removal involves removing 1.0-1.5mm of material on one side, with a feed rate of 800-1000mm / min and a spindle speed of 3500-4000r / min. The flatness of the workpiece after rough milling is controlled to be ≤0.2mm. The semi-finish milling involves leaving a finishing allowance of 0.25mm on one side. -0.4mm, feed rate 500-600mm / min, spindle speed 4500-5000r / min, flatness after semi-finish milling ≤0.10mm, parallelism ≤0.08mm; the single-sided cutting allowance for finish milling is 0.04-0.08mm, feed rate 250-300mm / min, spindle speed 6000-6500r / min, flatness of the reference surface after finish milling ≤0.06mm, and the contour dimensional tolerance is IT7 grade;

[0061] After the initial machining of the CNC metal parts, the bearing holes and shaft holes are precision bored and then mirror polished by a surface grinder to obtain the machined CNC metal parts.

[0062] The CNC machined metal parts are subjected to hard anodizing treatment to obtain the treated CNC metal parts; wherein the oxide layer thickness of the hard anodizing treatment is 20 μm.

[0063] In one embodiment, a 6061-T6 aluminum alloy blank is used as the CNC machined part. Three cutting processes are performed sequentially: rough milling to remove excess material, semi-finish milling to form the shape, and finish milling to refine the shape. The motor flange bearing hole and the hinge seat shaft hole are machined using precision boring. A 0.1mm grinding allowance is reserved on the assembly reference end face. After milling, mirror grinding is performed using a surface grinder, resulting in a final assembly end face flatness ≤0.05mm and a mounting hole coaxiality error <0.1mm, meeting the requirements for precision rotation and assembly. After complete deburring, a 20μm thick hard anodizing treatment is performed to improve the surface hardness and wear resistance of the aluminum alloy. Simultaneously, the insulating oxide layer weakens the electromagnetic reflection effect of the metal, reducing multipath electromagnetic interference in the GIS cavity and ensuring stable operation of surrounding RF and imaging modules, resulting in the processed CNC machined part.

[0064] S105. The printed FDM molded part is subjected to grinding and deburring, epoxy resin impregnation and curing, and anti-static electromagnetic shielding spraying treatment in sequence to obtain the treated FDM molded part.

[0065] Furthermore, the epoxy resin impregnation and curing process uses a two-component transparent epoxy resin with a dynamic viscosity of 120–180 mPa·s, a constant immersion temperature of 25°C, an immersion time of 30 min, and a curing time of 24 h.

[0066] The antistatic electromagnetic shielding coating treatment adopts a low-pressure cross-spraying process with an atomization pressure of 0.18-0.22MPa, a spraying distance of 180-220mm, and a spray gun moving speed of 200mm / s. The antistatic electromagnetic shielding coating is sprayed in two layers, with a single layer thickness of 12μm and a total coating thickness of 24μm. It is cured in a dust-free environment at room temperature for 12 hours.

[0067] In one implementation, all FDM printed components undergo multi-stage sanding to remove burrs and high-pressure dust and oil stains. Specifically, all printing supports are removed, and the inner and outer surfaces of the components are sanded layer by layer with 400-grit, 800-grit, and 1200-grit sandpaper to eliminate FDM layer lines and burrs; sanding dust and surface oil stains are thoroughly cleaned using a high-pressure air gun in conjunction with anhydrous alcohol.

[0068] A two-component transparent epoxy resin was formulated, using a low-viscosity system with a dynamic viscosity of 120–180 mPa·s. The immersion temperature was controlled at 25°C, and the printed component was completely immersed for 30 minutes to allow the resin to fully penetrate and fill the micro-pores between the printed layers. This viscosity range ensures that the resin, through capillary action, completely penetrates the micron-level pores between the FDM molding layers, avoiding localized porosity defects caused by incomplete penetration. After removal, the component was placed in a dust-free, temperature-controlled environment for 24 hours to fully cure, significantly improving the component's structural density, resistance to delamination and cracking, and wear resistance. A low-pressure cross-spraying process was employed, using an atomizing air pressure of 0.18–0.22 MPa, a spraying distance of 180–220 mm, and a spray gun movement speed of 200 mm / s. The spraying path used a horizontal and vertical cross-spraying method, applying a special anti-static electromagnetic shielding coating in two coats. Each coat had a thickness of 12 μm, resulting in a total coating thickness of 24 μm. The coating was cured for 12 hours in a dust-free environment at room temperature. After curing, the surface resistance of the component meets the anti-static specifications for high-voltage power equipment, which can effectively suppress static electricity accumulation, shield electromagnetic interference, reduce metal dust adsorption, and prevent blockage of module holes.

[0069] S106. The machine is assembled from the processed CNC metal parts and the processed FDM molded parts to obtain the machined complete machine.

[0070] Furthermore, the assembly of the whole machine uses high-temperature resistant insulating rubber flat pads as isolation auxiliary materials, and the assembly bolts are fixed by a diagonal symmetrical torque fastening method.

[0071] In one embodiment, high-temperature resistant insulating rubber flat pads are used as isolation materials during assembly to achieve insulation isolation between the metal load-bearing components and the printer body, buffering operational vibrations and blocking electromagnetic conduction. All assembly bolts are fixed using a diagonal symmetrical torque tightening method to ensure tight fit and uniform stress distribution of components. The assembly gaps and overall dimensions of the machine are measured using precision feeler gauges and high-precision calipers. The maximum width of the machine body is re-measured to be 76mm, providing a 4mm safety margin compared to the 80mm narrow gap passage boundary, fully meeting the requirement for friction-free passage in narrow gaps. All assembly gaps, component verticality, and horizontality meet design tolerance standards.

[0072] S107. When the processed complete machine is operating normally under the pre-constructed simulated GIS cavity working conditions, the processed complete machine is taken as the final complete machine.

[0073] The machine is considered to be operating normally if all of the following quantitative judgment conditions are met simultaneously: It can continuously traverse a 25mm flange step 20 times without cracks in the machine body or loose bolts; it can smoothly pass through an 80mm narrow gap channel without scraping or jamming; the machine can operate continuously at full load for 8 hours with key assembly reference dimension changes ≤0.05mm; infrared imaging offset ≤2 pixels, UWB steady-state positioning error ≤2cm, and communication system packet loss rate ≤0.2%; the surface resistance of the machine body is maintained at 10 Ω·cm. 6 -10 9 Ω; After the test, there was no obvious dust accumulation in the pores or blockage of the transmission holes in the components.

[0074] This invention completed prototype prototyping and simultaneously set up multiple control prototypes to conduct comparative tests simulating the GIS cavity. The tests strictly controlled variables: the external contour dimensions of the four prototypes were uniformly 76mm, and the drive motor, battery capacity, imaging unit, UWB positioning module, communication module, and load were completely identical, differing only in the body molding process. Test items included static assembly accuracy, no-load performance, GIS simulated full-load 8-hour continuous operation, 20 cycles of 25mm flange obstacle crossing fatigue, and strong electromagnetic environment adaptability tests. Experimental group A was the prototype using the multi-process coupling closed-loop molding process of this invention; control group B was pure FDM molding (directly ground and assembled after molding, without closed-loop dimension correction, epoxy resin penetration, or electromagnetic shielding spraying); control group C was pure SLA whole-machine molding, with conventional post-processing without metal reinforcement of load-bearing components; control group D was the entire machine formed by CNC integrated milling of 6061-T6 aluminum alloy, with conventional hard anodizing and no insulation structure. Table 1 shows the performance comparison of prototypes using different molding processes.

[0075] Table 1:

[0076]

[0077] The results of the comparative tests show that, in terms of structural static strength, the complete aluminum alloy CNC chassis possesses the highest theoretical structural strength; however, it is heavy, consumes a lot of power, has a short full-load endurance, and the metal surface is prone to electromagnetic wave reflection, causing multipath electromagnetic interference inside the GIS cavity, resulting in a relatively high packet loss rate. The pure SLA chassis is the lightest and has excellent no-load endurance; however, the material is brittle and has poor fatigue impact resistance, making it unsuitable for long-term obstacle crossing operations and limiting its engineering practicality. The pure FDM process has low cost, but poor forming precision, porous internal components, and dust infiltration into pores during long-term operation can cause vibration and imaging shift in precision modules, failing to meet the requirements for long-term stable inspection.

[0078] This invention achieves optimal overall engineering results through a multi-process coupled molding scheme: key load-bearing components retain aluminum alloy CNC machining to ensure strength; SLA pre-loop calibration effectively reduces assembly cumulative tolerances; additive components employ partitioned molding and integrated dense-shielded post-processing, effectively controlling the overall weight; and combined with an insulating assembly process, significantly improves electromagnetic compatibility, antistatic properties, and dustproof performance. While this invention does not achieve perfection in every single indicator, it achieves a balanced and synergistic improvement in multiple performance aspects, including lightweight design, molding accuracy, impact resistance, and adaptability to harsh working conditions, resulting in comprehensive technical effects that cannot be achieved by any single existing process.

[0079] Understandably, this process can customize the machine body forming size based on standard GIS pipe diameters of 150mm, 200mm, and 285mm. The forming machine body's external dimensions are adapted to an 8cm narrow gap passage space, and can be matched with multi-diameter bends and turning conditions. The differentiated forming of load-bearing components and lightweight shell ensures that the structural strength can be adapted to the 25mm flange step obstacle crossing load, avoiding operational deformation and jamming defects.

[0080] The integrated post-processing of this technology produces a body with anti-static and electromagnetic shielding properties. Its high-precision assembly structure is compatible with imaging, UWB positioning, and dual communication modules, ensuring stable operation of the power module and sensor communication module, and meeting the requirements of long-term inspection of GIS sealed cavities.

[0081] In the above technical solution, this invention effectively eliminates the tolerance accumulation problem of multi-process molding by using photopolymerization molding pre-verification reverse correction and multi-process dimensional linkage calibration, significantly improving the assembly accuracy of robot precision modules and avoiding faults such as motor vibration, imaging offset, and positioning distortion. While ensuring the narrow gap passage size requirements of the machine body and significantly reducing the overall weight, it effectively improves obstacle crossing and impact resistance, solving the problem that traditional processes cannot balance lightweight and structural strength. Through epoxy resin deep penetration curing and anti-static electromagnetic shielding spraying treatment, the defects of 3D printed components being loose and easily worn are effectively improved, while significantly enhancing the adaptability of the machine body in GIS strong electromagnetic, electrostatic, and dusty environments, greatly improving the stability and service life of the robot during long-term continuous operation. It can be adapted to the molding and manufacturing of GIS cavity inspection robots with different pipe diameters and gap sizes, with strong process versatility, effectively shortening the prototype iteration cycle and reducing R&D and production costs.

[0082] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention. These changes involve related technologies well known to those skilled in the art, and all of them fall within the protection scope of the present invention.

[0083] Many other changes and modifications can be made without departing from the concept and scope of this invention. It should be understood that this invention is not limited to the specific embodiments, and the scope of this invention is defined by the appended claims.

Claims

1. A precision forming process for the body of a GIS inspection robot involving multi-process coupling, characterized in that, include: Based on the functions of the machine's body components and the design boundary dimensional constraints of the machine, the machine's body components are divided into FDM molded parts, SLA photopolymerization verification parts, and CNC machined metal parts. The SLA photocurable calibration part is photocured and molded. The actual size of the calibrated part is detected. The measured deviation data is sent back to the robot's three-dimensional design model to correct the assembly opening and reference size of the FDM molded part, thus obtaining the corrected FDM molded part. The load-bearing area of ​​the modified FDM molded part is filled with a honeycomb structure, and the assembly reference area of ​​the FDM molded part is filled with solid material for printing, thus obtaining the printed FDM molded part. The CNC metal part is subjected to machining and hard anodizing treatment in sequence to obtain the treated CNC metal part; The printed FDM molded parts are sequentially subjected to sanding and deburring, epoxy resin impregnation and curing, and anti-static electromagnetic shielding spraying to obtain the processed FDM molded parts. The machined CNC metal parts and the processed FDM molded parts are then assembled to obtain the finished machine. When the processed complete machine operates normally under the pre-constructed simulated GIS cavity conditions, the processed complete machine is regarded as the final complete machine.

2. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The FDM molded part includes the main body shell, the circuit compartment shell, and the battery support shell; The SLA photocurable calibration kit includes an infrared camera mounting base, a UWB antenna mounting bracket, and a supplementary light assembly support. The CNC machined metal parts include a motor mounting flange, a wheel assembly hinge support base, and a drive shaft limit bracket.

3. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The SLA photocurable calibration component is formed by photocuring with radio frequency compatible photosensitive resin. The thickness of the molded layer of the SLA photocurable calibration component is 0.02mm, the exposure time of the bottom layer is 35s, and the exposure time of the single layer is 3.5s.

4. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The actual dimensions of the formed verification piece are measured using a digital micrometer and dial indicator on a marble precision testing platform; the actual dimensions include the coaxiality of the mounting holes and the flatness of the reference surface.

5. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The printing parameters for the printed FDM molded parts are as follows: layer thickness is 0.18mm, global dimensional tolerance is within ±0.8mm, and the printing stacking direction is the robot pipeline travel axis; after printing, the parts are naturally cooled in a constant temperature chamber for 4 hours.

6. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The steps of sequentially machining and hard anodizing the CNC metal part to obtain the treated CNC metal part include: The CNC metal workpiece is subjected to rough milling to remove excess material, semi-finish milling to form the shape, and finish milling to refine the shape, thereby obtaining a pre-machined CNC metal workpiece. The rough milling to remove excess material is 1.0-1.5mm on one side, with a machining feed rate of 800-1000mm / min and a spindle speed of 3500-4000r / min. The flatness of the workpiece after rough milling is controlled to be ≤0.2mm. The semi-finish milling to form the shape is to leave a finishing allowance of 0.25-0.25mm on one side. 4mm, feed rate 500-600mm / min, spindle speed 4500-5000r / min, flatness after semi-finish milling ≤0.10mm, parallelism ≤0.08mm; the single-sided cutting allowance for finish milling is 0.04-0.08mm, feed rate 250-300mm / min, spindle speed 6000-6500r / min, flatness of the reference surface after finish milling ≤0.06mm, and the contour dimensional tolerance is IT7 grade; The bearing holes and shaft holes of the pre-processed CNC metal parts are precision bored and then mirror-polished using a surface grinder to obtain the machined CNC metal parts. The CNC machined part is subjected to hard anodizing treatment to obtain the treated CNC machined part; wherein the oxide layer thickness of the hard anodizing treatment is 20 μm.

7. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The epoxy resin impregnation and curing process uses a two-component transparent epoxy resin with a dynamic viscosity of 120–180 mPa·s, a constant immersion temperature of 25°C, an immersion time of 30 min, and a curing time of 24 h.

8. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The antistatic electromagnetic shielding spraying treatment adopts a low-pressure cross-spraying process with an atomization pressure of 0.18-0.22MPa, a spraying distance of 180-220mm, and a spray gun moving speed of 200mm / s. The antistatic electromagnetic shielding coating is sprayed in two layers, with a single layer thickness of 12μm and a total coating thickness of 24μm. It is cured in a dust-free environment at room temperature for 12 hours.

9. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The assembly of the entire machine uses high-temperature resistant insulating rubber flat pads as isolation auxiliary materials, and the assembly bolts are fixed by a diagonal symmetrical torque tightening method.

10. The precision forming process for the body of a GIS inspection robot with multi-process coupling according to claim 1, characterized in that, The normal operation criteria are as follows: the machined unit can continuously traverse a 25mm flange step 20 times, smoothly pass through an 80mm narrow gap channel, operate continuously at full load for 8 hours, and the change in key assembly reference dimensions is ≤0.05mm; infrared imaging offset is ≤2 pixels, UWB steady-state positioning error is ≤2cm, and the packet loss rate of the communication system is ≤0.2%; the surface resistance of the machine body is maintained at 10 Ω·cm. 6 -10 9 Ω.

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