Intelligent inspection system for valve hall

Abstract

The utility model relates to an intelligent inspection system for a valve hall, which comprises a plurality of inspection devices, and the inspection devices have the same structure and are uniformly distributed in the valve hall; each inspection device comprises a robot, a holder, visible light equipment, a thermal infrared imager and a vertical guide rail; the robot comprises a robot shell, a synchronizing wheel, a worm and gear speed reducer and a motor. The worm and gear speed reducer and the motor are arranged in the robot shell; an input shaft of the worm and gear speed reducer is connected with the motor, and an output shaft of the worm and gear speed reducer is connected with the synchronizing wheel; one part of the synchronizing wheel is located in the shell, and the other part of the synchronizing wheel is exposed out of the shell through an opening in the rear wall of the robot shell; a synchronous belt is arranged in the vertical guide rail, and the synchronous wheel is engaged with the synchronous belt, so that the robot moves up and down on the vertical guide rail; the holder is arranged on the top of the robot shell, and the thermal infrared imager and the visible light equipment are installed on the left side and the right side of the holder.

Description

Technical Field

[0001] The utility model relates to the technical field of intelligent inspection of valve halls, and particularly relates to an intelligent inspection system for valve halls. Background Art

[0002] Robots have basic characteristics such as perception, decision-making, and execution, and can assist or even replace humans in completing dangerous, heavy, and complex tasks, improve work efficiency and quality, serve human life, and expand or extend the scope of human activities and capabilities.

[0003] There are multiple voltage levels inside the valve hall converter station, the electrical connections are complex, and there are numerous liquid level meters, digital meters, and pointer meters. The manual inspection workload is large and it is easy to miss, so it is necessary to use intelligent robots to replace manual inspection. At the same time, if a short circuit occurs at a certain circuit node in the valve hall, it will cause great harm and it is not easy to troubleshoot.

[0004] Because the heights of various meters from the ground are different, a robot relying solely on flat movement or erected at a certain height cannot complete the task and needs to move back and forth at different heights; various meters are not only distributed at different heights, but also at different angles from the robot's visual window. In the inspection of the valve hall, the values of the meters in each corner need to be clearly read, and at the same time, it is necessary to detect whether there is a short circuit at each welding point in the valve hall. Therefore, it is necessary to design an intelligent inspection robot system for valve halls that can clearly read the values of all meters in the valve hall and detect whether there is a short circuit at each welding point, so as to solve the problems of large workload, high error rate, and difficulty in locating short circuit points caused by manual inspection. Summary of the Utility Model

[0005] In view of the above analysis, the utility model aims to provide an intelligent inspection robot system for valve halls to solve the problems of large workload, high error rate, and difficulty in locating short circuit points caused by manual inspection in the prior art.

[0006] The purpose of the utility model is mainly achieved through the following technical solutions:

[0007] An intelligent inspection system for a valve hall, the system includes a plurality of inspection devices, each inspection device has the same structure, and each inspection device is evenly arranged in the valve hall; each inspection device includes a robot, a pan-tilt, a visible light device, an infrared thermal imager, and a vertical guide rail; the robot includes a robot housing, a synchronous pulley, a worm and worm gear reducer, and a motor; the worm and worm gear reducer and the motor are arranged inside the robot housing; the input shaft of the worm and worm gear reducer is connected to the motor, and the output shaft of the worm and worm gear reducer is connected to the synchronous pulley; a part of the synchronous pulley is located inside the housing, and the other part leaks out of the housing through an opening in the rear wall of the robot housing; a synchronous belt is arranged inside the vertical guide rail, and the synchronous pulley engages with the synchronous belt to realize the up and down movement of the robot on the vertical guide rail; the pan-tilt is arranged on the top of the robot housing, and the infrared thermal imager and the visible light device are installed on the left and right sides of the pan-tilt.

[0008] Furthermore, the vertical guide rails of each inspection device are fixed on the wall; the distance between adjacent two vertical guide rails is 10m - 20m.

[0009] Furthermore, the pan-tilt includes a pan-tilt bottom fixed housing and a pan-tilt rotation assembly; the pan-tilt rotation assembly is installed above the pan-tilt bottom fixed housing; the visible light device and the infrared thermal imager are installed on the left and right sides of the pan-tilt rotation assembly.

[0010] Furthermore, the outer shell of the pan-tilt rotation assembly is of a cuboid structure; inside the outer shell, there are a horizontal rotation shaft, a horizontal shaft, a worm wheel, a worm, a gear, a conveyor belt, and a pitching motor; the horizontal rotation shaft is located at the center of the bottom surface of the pan-tilt rotation assembly outer shell, and the horizontal rotation shaft drives the pan-tilt rotation assembly to rotate horizontally; the horizontal shaft is located between the left and right side walls of the pan-tilt rotation assembly, one end of the horizontal shaft is provided with a worm wheel, the worm wheel is connected to the gear through a worm, and the gear is connected to the rotation shaft of the pitching motor through a conveyor belt.

[0011] Furthermore, the pan-tilt rotation assembly also includes a servo motor control board and a power board; the horizontal shaft is of a hollow structure, and a slip ring is arranged inside; the cables of the visible light device and the infrared thermal imager are installed into the slip ring; an opening is arranged in the middle of the horizontal shaft, and the cables of the visible light device and the infrared thermal imager are led out from the opening and connected to the servo motor control board and the power board.

[0012] Furthermore, an aviation plug connector is arranged on the right side wall of the robot housing, and the cables on the aviation plug connector include a power cable, a network cable, and a serial communication cable; the cables adopt fire-resistant shielded cables and optical cables, and are laid on the wall through metal pipes or metal cable trays.

[0013] Furthermore, the system includes a host computer; the robot includes a power board and a main control board; the power cable of the aviation plug connector is connected to the power board internally and to the power supply externally; the network cable and the serial communication cable of the aviation plug connector are connected to the main control board internally and to the host computer externally.

[0014] Furthermore, a single-chip microcomputer and a serial port to network port interface circuit are provided on the main control board. The serial port to network port interface circuit uses an iport conversion chip. One end of the iport conversion chip is connected to the serial communication pin of the single-chip microcomputer, and the other end of the iport conversion chip is connected to the network cable.

[0015] Furthermore, the visible light device has a resolution of 4 million pixels, and the lens focal length is 4.5 mm - 135 mm.

[0016] Furthermore, a pickup is also provided on the robot housing, and the pickup is signal-connected to the main control board.

[0017] Compared with the prior art, the present utility model can at least achieve one of the following beneficial effects:

[0018] 1. The intelligent inspection robot system for valve halls of the present invention is provided with a pan-tilt, a visible light device, and an infrared thermal imager. A second aviation head connector is provided on the side of the fixed housing at the bottom of the pan-tilt. After the cable of the second aviation head connector enters the fixed housing at the bottom of the pan-tilt, it then enters the pan-tilt rotating assembly. A slip ring is provided in the pan-tilt rotating assembly to connect the power line, network cable with the visible light device and infrared thermal imager above the pan-tilt rotating assembly. The second aviation head connector transmits the video signals collected by the visible light device and infrared thermal imager to the upper computer through the network cable, and the upper computer can detect the readings of each meter and the short-circuit condition of the circuit nodes according to the collected videos.

[0019] 2. The intelligent inspection robot system for valve halls of the present invention can move up and down driven by the visible light device and infrared thermal imager under the drive of the robot, expand the horizontal field of view angle driven by the horizontal rotation assembly of the pan-tilt, and expand the vertical field of view angle driven by the pitch rotation assembly of the pan-tilt. At the same time, clear imaging is achieved under the drive of its own focusing motor and field-of-view zoom motor, and then the images of each meter captured are transmitted to the upper computer through the network cable, realizing an intelligent inspection robot system for valve halls.

[0020] 3. A photoelectric sensor is provided on the left or right side wall of the robot housing of the present invention. During the movement of the robot, the soft limit of the robot movement control is realized through the induction of the photoelectric sensor to surrounding objects or people; a limit switch is provided on the upper part of the rear wall of the robot housing, and the limit switch is electrically connected to the main control board and the motor control board. When the limit switch touches an obstacle, the change of the signal state of the limit switch is transmitted to the main control board and the motor control board, and the main control board and the motor control board control the motor to cut off the power or rotate in the opposite direction, driving the robot to leave the limit area to avoid collision damage to the robot or surrounding objects.

[0021] 4. A synchronous belt is provided on the vertical guide rail of the present invention, and I-beams are provided on both sides of the synchronous belt; the robot includes a worm and worm gear reducer, a motor, and a synchronous pulley; the synchronous pulley engages with the synchronous belt, and the worm and worm gear reducer reduces the running speed of the robot while increasing the output torque. The synchronous pulley engaging with the synchronous belt can bear a maximum weight of 50 kg; the robot also includes a mounting plate. The rear wall of the robot housing is fixed on the mounting plate. An L-shaped hook is provided on the rear wall of the robot housing, and through holes are provided at positions on the mounting plate corresponding to the L-shaped hook. The robot housing is hung on the through holes of the mounting plate through the L-shaped hook, making the disassembly and assembly of the robot very convenient; pulleys are provided on the left and right sides of the mounting plate; when the robot moves up and down on the vertical guide rail, the pulleys on the mounting plate slide up and down inside the I-beam of the vertical guide rail, making the robot move smoothly on the guide rail.

[0022] 5. An aviation connector is provided on the right side wall of the robot housing of the present invention. The cables on the aviation connector include a power cable, a network cable, and a serial communication cable; the robot communicates with the host computer through the network cable and the serial port. The single-chip microcomputer on the main control board receives the commands of the host computer to control the motion state of the robot, the operation states of the visible light device and the infrared thermal imager, and the data reading situation, realizing the remote control of the robot system through the host computer.

[0023] In the present utility model, the above technical solutions can also be combined with each other to achieve more preferred combination schemes. Other features and advantages of the present utility model will be described in the following content. Moreover, some advantages can be made obvious from the specification or understood by implementing the present utility model. The purpose and other advantages of the present utility model can be realized and obtained through the content specifically pointed out in the text and the drawings. Description of the Drawings

[0024] The drawings are only for the purpose of showing specific embodiments and are not considered as limitations to the present utility model. Throughout the drawings, the same reference signs represent the same components.

[0025] Figure 1 It is a schematic diagram of the overall structure of an intelligent inspection system for a valve hall.

[0026] Figure 2 It is a schematic diagram of the internal structure of the pan-tilt rotation assembly of an intelligent inspection system for a valve hall and the positional relationship between the pan-tilt, the visible light device, and the infrared thermal imager.

[0027] Figure 3 It is a schematic diagram of the structure of the robot of an intelligent inspection system for a valve hall.

[0028] Figure 4 It is a schematic diagram of the installation of the robot of an intelligent inspection system for a valve hall on the vertical guide rail and the installation position of the internal circuit board of the robot.

[0029] Figure 5 It is a flow chart of a smart inspection system for a valve hall that controls the motor power supply through a limit switch.

[0030] Reference numerals:

[0031] 1 - Visible light device;

[0032] 2 - Vertical guide rail;

[0033] 3 - Pan - tilt rotation assembly;

[0034] 4 - Robot;

[0035] 5 - Photoelectric sensor induction plate;

[0036] 6 - Hard limit switch stop block;

[0037] 7 - Shock - absorbing plate;

[0038] 8 - Shock - absorbing seat;

[0039] 9 - Screw;

[0040] 10 - Fixed housing at the bottom of the pan - tilt;

[0041] 11 - High - precision magnetic - encoding servo motor;

[0042] 12 - Horizontal rotating conveyor belt;

[0043] 13 - Gear assembly;

[0044] 14 - Horizontal rotating shaft;

[0045] 15 - Photoelectric sensor;

[0046] 16 - Aviation - plug connector;

[0047] 17 - L - shaped hook;

[0048] 18 - Synchronous pulley;

[0049] 19 - Limit switch;

[0050] 20 - U - shaped protective baffle;

[0051] 21 - First aviation - plug connector;

[0052] 22 - Power management board;

[0053] 23 - Acousto - optic alarm;

[0054] 24 - Main control board;

[0055] 25 - Motor control board;

[0056] 26 - I - beam;

[0057] 27 - Mounting plate;

[0058] 28 - Infrared thermal imager;

[0059] 29 - Horizontal axis;

[0060] 30 - Gear;

[0061] 31 - Conveyor belt;

[0062] 32 - Pitch motor rotating shaft. Specific embodiments

[0063] The preferred embodiments of the present utility model will be specifically described below with reference to the accompanying drawings. The accompanying drawings form a part of this application and are used together with the embodiments of the present utility model to explain the principles of the present utility model, rather than to limit the scope of the present utility model.

[0064] A specific embodiment of the present utility model discloses an intelligent inspection system for a valve hall, as Figure 1 shown. The system includes a plurality of inspection devices, each inspection device having the same structure, and the inspection devices are evenly arranged in the valve hall; each inspection device includes a robot 4, a pan-tilt head, a visible light device 1, an infrared thermal imager 28, and a vertical guide rail 2; the robot 4 includes a robot housing, a synchronous pulley 18, a worm and worm gear reducer, and a motor; the worm and worm gear reducer and the motor are arranged inside the robot housing; the input shaft of the worm and worm gear reducer is connected to the motor, and the output shaft of the worm and worm gear reducer is connected to the synchronous pulley 18; a part of the synchronous pulley 18 is located inside the housing, and the other part leaks out of the housing through an opening in the rear wall of the robot housing; a synchronous belt is arranged inside the vertical guide rail 2, and the synchronous pulley 18 engages with the synchronous belt to realize the up and down movement of the robot 4 on the vertical guide rail 2; the pan-tilt head is arranged on the top of the robot housing, and the infrared thermal imager 28 and the visible light device 1 are installed on the left and right sides of the pan-tilt head.

[0065] Specifically, the worm and worm gear reducer reduces the running speed of the robot 4 while increasing the output torque, and the synchronous pulley 18 engaging with the synchronous belt can bear a maximum weight of 50 kg; the robot 4 further includes a mounting plate 27, the rear wall of the robot housing is fixed on the mounting plate 27, an L-shaped hook 17 is arranged on the rear wall of the robot housing, through holes are arranged at positions corresponding to the L-shaped hook 17 on the mounting plate 27, and the robot housing is hung on the through holes of the mounting plate 27 through the L-shaped hook 17, making the disassembly and assembly of the robot 4 very convenient; pulleys are arranged on the left and right sides of the mounting plate 27; when the robot 4 moves up and down on the vertical guide rail 2, the pulleys on the mounting plate 27 slide up and down inside the I-beam 26 of the vertical guide rail 2, making the robot 4 move smoothly on the guide rail.

[0066] The vertical guide rail 2 further includes I-beams 26 arranged in parallel on both sides of the synchronous belt; the robot 4 further includes a mounting plate 27, and the rear wall of the robot housing is fixed on the mounting plate 27; pulleys are arranged on the left and right sides of the mounting plate 27; when the robot 4 moves up and down along the vertical guide rail 2, the pulleys on the mounting plate 27 slide up and down inside the I-beams 26 of the vertical guide rail 2.

[0067] A detachable shock-absorbing device is provided at the bottom of the vertical guide rail 2; the shock-absorbing device includes a shock-absorbing plate 7 and a shock-absorbing seat 8; the shock-absorbing plate 7 is mounted on the shock-absorbing seat 8; the shock-absorbing device is mounted directly below the vertical guide rail 2.

[0068] Specifically, when the robot 4 needs to be installed on the vertical guide rail 2, first remove the shock-absorbing device, push the pulleys of the mounting plate 27 of the robot 4 from the bottom of the vertical guide rail 2 upward into the I-beams 26, and then install the shock-absorbing device on the bottom of the vertical guide rail 2. The shock-absorbing device prevents the robot 4 from being damaged due to out-of-control.

[0069] A plurality of screws 9 are provided below the shock-absorbing plate 7, and springs are provided on each screw 9. The screws 9 are fixed on the shock-absorbing seat 8.

[0070] The vertical guide rails 2 of each inspection device are fixed on the wall; the distance between two adjacent vertical guide rails 2 is 10m - 20m.

[0071] Specifically, the vertical guide rails 2 of the system are arranged at intervals of 10m - 20m, and each guide rail has the same robot 4, pan-tilt head, visible light device 1, and infrared thermal imager 28; it can realize the inspection of equipment in all corners of the valve hall without dead angles.

[0072] The pan-tilt head includes a fixed housing 10 at the bottom of the pan-tilt head and a pan-tilt rotation assembly 3; the pan-tilt rotation assembly 3 is installed above the fixed housing 10 at the bottom of the pan-tilt head; the visible light device 1 and the infrared thermal imager 28 are installed on the left and right sides of the pan-tilt rotation assembly 3.

[0073] Specifically, during installation, the visible light device 1 and the infrared thermal imager 28 can not only pitch and rotate along the horizontal axis 29, but also horizontally rotate along the horizontal rotation axis 14, or can horizontally rotate and pitch and rotate simultaneously.

[0074] The housing of the pan-tilt rotation assembly 3 is of a cuboid structure; a horizontal rotation axis 14, a horizontal axis 29, a worm gear, a worm, a gear 30, a conveyor belt 31, and a pitching motor are arranged inside the housing; the horizontal rotation axis 14 is located at the center of the bottom surface of the housing of the pan-tilt rotation assembly 3, and the horizontal rotation axis 14 drives the pan-tilt rotation assembly 3 to rotate horizontally; the horizontal axis 29 is located between the left and right side walls of the pan-tilt rotation assembly 3, a worm gear is provided at one end of the horizontal axis 29, the worm gear is connected to the gear 30 through a worm, and the gear 30 is connected to the rotation axis 32 of the pitching motor through the conveyor belt 31.

[0075] Specifically, the pan-tilt head includes a fixed housing 10 at the bottom of the pan-tilt head and a pan-tilt rotation assembly 3. The bottom of the fixed housing is fixed on the mounting base plate at the top of the robot housing. The fixed housing is surrounded by a U-shaped protective baffle 20. The pan-tilt rotation assembly 3 is arranged above the fixed housing.

[0076] Specifically, the fixed housing 10 at the bottom of the pan-tilt head is fixedly connected to the robot 4 and cannot rotate. When the horizontal rotation shaft 14 rotates, the pan-tilt rotation assembly 3 rotates accordingly.

[0077] A first aviation connector 21 is also arranged at the top of the robot 4 housing. A through hole is arranged on the side of the fixed housing 10 at the bottom of the pan-tilt head for installing a second aviation connector. The external cable of the first aviation connector 21 is connected to the second aviation connector.

[0078] The pan-tilt rotation assembly 3 includes a housing, an internal mounting plate arranged inside the housing, a high-precision magnetic encoding servo motor 11, a gear assembly 13, a horizontal rotation conveyor belt 12, and a horizontal rotation shaft 14. The high-precision magnetic encoding servo motor 11 and the gear assembly 13 are fixed on the internal mounting plate. The rotating shaft of the high-precision magnetic encoding servo motor 11 and one end of the gear assembly 13 are connected by the horizontal rotation conveyor belt 12, and the other end of the gear assembly 13 is connected to the horizontal rotation shaft 14 for driving the horizontal rotation shaft to rotate.

[0079] The internal structure of the system pan-tilt rotation assembly 3 is as Figure 2 shown.

[0080] Specifically, the gear assembly 13 includes a first gear, a first worm, and a first worm gear. The center of the first gear is sleeved on one end of the first worm, and a first worm gear is arranged at the other end of the first worm. A second gear is sleeved on the pan-tilt rotation shaft 14, and the first worm gear is connected to the second gear on the horizontal rotation shaft 14. Therefore, when the rotating shaft of the high-precision magnetic encoding servo motor 11 drives the first gear at one end of the gear assembly 13 to rotate through the horizontal rotation conveyor belt 12, the first gear drives the first worm of the gear assembly 13 to rotate, thereby driving the first worm gear to rotate. The rotation of the first worm gear drives the second gear on the horizontal rotation shaft 14 to rotate, thereby driving the horizontal rotation shaft 14 to rotate.

[0081] The pan-tilt rotation assembly 3 further includes a servo motor control board and a power supply board. The horizontal shaft 29 is of a hollow structure, and a slip ring is arranged inside. The cables of the visible light device 1 and the infrared thermal imager 28 are installed in the slip ring. An opening is arranged in the middle of the horizontal shaft 29, and the cables of the visible light device 1 and the infrared thermal imager 28 are led out from the opening and connected to the servo motor control board and the power supply board.

[0082] Specifically, the center of the horizontal rotation axis 14 is also a hollow structure. A first slip ring is arranged inside the hollow structure. Part of the cables inside the first slip ring are connected to the servo motor control board and the power supply board; another part of the cables inside the first slip ring are connected to the slip ring arranged inside the horizontal shaft 29 through the opening inside the horizontal shaft 29, thereby providing power and network cables for the visible light devices 1 and the infrared thermal imager 28 on the left and right sides.

[0083] An aviation plug connector 16 is provided on the right side wall of the robot housing. The cables on the aviation plug connector 16 include a power cable, a network cable, and a serial communication cable; the cables are made of fire-resistant shielded cables and optical cables, and are laid on the wall through metal pipes or metal trough boxes.

[0084] Specifically, the cables on the aviation plug connector 16 are externally connected to a power supply and a host computer.

[0085] The system includes a host computer; the robot 4 includes a power supply board and a main control board 24; the power cable of the aviation plug connector 16 is internally connected to the power supply board and externally connected to a power supply; the network cable and the serial communication cable of the aviation plug connector 16 are internally connected to the main control board 24 and externally connected to the host computer.

[0086] Specifically, the host computer can realize remote control of the robot 4, the visible light device 1, the infrared thermal imager 28, and the pan-tilt head.

[0087] A single-chip microcomputer and a serial-to-Ethernet interface circuit are provided on the main control board 24. The serial-to-Ethernet interface circuit uses an iport conversion chip. One end of the iport conversion chip is connected to the serial communication pin of the single-chip microcomputer, and the other end of the iport conversion chip is connected to the network cable.

[0088] Specifically, the iport conversion chip realizes the conversion of data from the external network port to the serial port of the single-chip microcomputer, and also realizes the conversion of data from the serial port of the single-chip microcomputer to the network port provided to the outside.

[0089] The visible light device 1 has a resolution of 4 million pixels and a lens focal length of 4.5 mm - 135 mm.

[0090] Specifically, the visible light device 1 uses a high-resolution detector. The visible light lens has focusing and zooming functions, which are realized by adjusting the visible light lens through the internal focusing motor and zooming motor of the visible light device. The infrared thermal imager 28 uses an uncooled detector with a resolution of not less than 640×480. The lens of the infrared thermal imager 28 also has focusing and zooming functions, which are realized by adjusting the lens of the infrared thermal imager 28 through the internal focusing motor and zooming motor of the infrared thermal imager 28.

[0091] A pickup is also provided on the robot housing, and the signal of the pickup is connected to the main control board 24.

[0092] Specifically, the pick-up signal is connected to the main control board 24, and the main control board 24 transmits the pick-up signal to the upper computer through the network port. An audio analysis software is installed on the upper computer to judge the collected sound. If the sound is abnormal, power-off and other processing are carried out in a timely manner.

[0093] The robot 4 further includes a main control board 24, and the main control board 24 is arranged inside the housing; a photoelectric sensor 15 is arranged on the left or right side wall of the housing of the robot 4; a photoelectric sensor induction plate 5 is arranged on the left or right side at the upper and lower ends of the vertical guide rail 2; the photoelectric sensor 15 is electrically connected to the main control board 24, and the control signal output end of the main control board 24 is connected to the control signal input end of the motor.

[0094] Specifically, the photoelectric sensor 15 and the photoelectric sensor induction plate 5 are arranged on the same side. There is one photoelectric sensor 15 on the robot 4, and a total of two photoelectric sensor induction plates 5 are arranged at the upper and lower ends of the vertical guide rail 2. When the robot 4 moves near the photoelectric sensor induction plate 5, the photoelectric sensor 15 on the robot 4 emits an induction signal when blocked by the photoelectric sensor induction plate 5. After receiving the induction signal, the main control board 24 sends a command through the single-chip microcomputer to control the motor of the robot 4 to stop running. If the photoelectric sensor 15 does not detect the induction signal, or the command sent by the main control board 24 is missing, or the software is out of control, and the robot 4 continues to run in one direction, the hard limit switch 19 power-off protection device will be triggered to force the motor to power off, so as to protect the motor from being damaged due to jamming. Subsequently, the device can be reset manually through the background for restoration operation.

[0095] Specifically, the robot 4 includes a dual-limit protection function of the photoelectric sensor 15 and the limit switch 19. The side wall of the housing of the robot 4 is provided with the photoelectric sensor 15, and the soft limit of the movement position of the robot 4 is realized by the induction of the surrounding objects by the photoelectric sensor 15 during the movement of the robot 4; the limit switch 19 is arranged on the side walls around the housing of the robot 4 to realize the hard limit of the movement position of the robot 4; the robot 4 is also provided with a motor control board 25, and the limit switch 19 is electrically connected to the main control board 24 and the motor control board 25. When the limit switch 19 touches an obstacle, the change of the signal state of the limit switch 19 is transmitted to the main control board 24 and the motor control board 25, and the main control board 24 and the motor control board 25 control the motor to power off or rotate in the opposite direction to drive the robot 4 to leave the limit area; to avoid collision damage to the robot 4 or surrounding objects.

[0096] The robot 4 further includes a motor control board 25, which is arranged inside the housing; above the photoelectric sensor induction plate 5 on the upper part of the vertical guide rail 2 and below the photoelectric sensor induction plate 5 on the lower part of the vertical guide rail 2, a hard limit switch stopper 6 is provided respectively; on the upper part of the rear wall of the housing of the robot 4, a limit switch 19 is provided, and the limit switch 19 is electrically connected to the main control board 24 and the motor control board 25.

[0097] Schematic diagram of the installation position of the internal circuit board of the robot 4 is as Figure 4 shown.

[0098] Below the main control board 24 of the robot 4, a power management board 22 is provided, and on the right side of the main control board 24, a motor control board 25 is provided.

[0099] Schematic diagram of the installation of the robot 4 and the vertical guide rail 2 is as Figure 4 shown.

[0100] Specifically, pulleys are provided on the left and right sides of the mounting plate 27; when the robot 4 moves up and down on the vertical guide rail 2, the pulleys on the mounting plate 27 slide up and down inside the I-beam 26 of the vertical guide rail 2, so that the robot 4 moves smoothly on the guide rail.

[0101] On the rear wall of the housing of the robot 4, an L-shaped hook 17 is provided; at a position corresponding to the L-shaped hook 17 on the mounting plate 27, a through hole is provided; the housing of the robot 4 is hung on the through hole of the mounting plate 27 through the L-shaped hook 17.

[0102] Specifically, the housing of the robot 4 is hung on the through hole of the mounting plate 27 through the L-shaped hook 17, so that the disassembly and assembly of the robot 4 are very convenient.

[0103] Schematic diagram of the structure of the robot 4 is as Figure 3 shown.

[0104] The motor control board 25 includes an OR gate, an AND gate logic chip, and a relay; the signal output end of the limit switch 19 is simultaneously connected to the first input pin of the OR gate and the signal input pin of the main control board 24, the first logic output pin of the main control board 24 is connected to the second input pin of the OR gate, the output pin of the OR gate is connected to the first input pin of the AND gate, and the second logic output pin of the main control board 24 is connected to the second input pin of the AND gate; the output pin of the AND gate is connected to the relay, and the relay is connected in series with the power supply line of the motor driver.

[0105] Flow chart of controlling the motor power supply through the limit switch 19 is as Figure 5 shown.

[0106] Specifically, the switch signal cable of the limit switch 19 located at the upper part of the rear wall of the housing is simultaneously connected to the signal input pin of the single-chip microcomputer of the main control board 24 and the first input pin of the OR gate of the motor control board 25. When the limit switch 19 is not triggered, the limit switch 19 is closed, and the switch signal is at a high level, that is, the first input pin of the OR gate is at a high level. The first logic output pin of the main control board 24 outputs a logic low to the OR gate; the OR gate outputs a high level to the first input pin of the AND gate; the second logic output pin of the main control board 24 outputs a logic high to the second input pin of the AND gate; the output pin of the AND gate outputs a high level to control the relay to close. The relay is connected in series with the motor power supply line, and the motor is normally powered. When the limit switch 19 of the robot 4 device is triggered, the limit switch 19 opens, and the switch signal cable emits a low level; the first input pin of the OR gate is at a low level, and the first logic output pin of the main control board 24 still outputs a logic low to the OR gate; the OR gate outputs a low level to the first input pin of the AND gate, and the output pin of the AND gate outputs a low level to control the relay to disconnect; the motor is powered off. When the single-chip microcomputer of the main control board 24 captures the low level of the switch quantity of the limit switch 19, it sends an abnormal message to the upper computer through the network. Relevant personnel can remotely control the main control board 24 to output a logic high to the OR gate. At this time, the OR gate outputs a logic high to the AND gate, and the AND gate outputs a logic high to control the relay to close, and the motor driver is normally powered. The background uses manual means to reset the device and perform a restoration operation.

[0107] An audible and visual alarm 23 is also provided on the housing of the robot 4, and the audible and visual alarm 23 is connected to the single-chip microcomputer of the main control board 24.

[0108] Specifically, when the robot 4 detects abnormal information, the single-chip microcomputer controls the audible and visual alarm 23 to give an alarm and reports the abnormal information to the upper computer.

[0109] Compared with the prior art, the intelligent inspection robot system for valve halls in this embodiment is provided with a pan-tilt, a visible light device 1, and an infrared thermal imager 28. A second aviation connector is provided on the side of the fixed housing 10 at the bottom of the pan-tilt. After the cable of the second aviation connector enters the fixed housing 10 at the bottom of the pan-tilt, it then enters the pan-tilt rotating assembly 3. A slip ring is arranged in the pan-tilt rotating assembly 3 to connect the power line and network cable to the visible light device 1 and the infrared thermal imager 28 above the pan-tilt rotating assembly 3. The second aviation connector transmits the video signals collected by the visible light device 1 and the infrared thermal imager 28 to the upper computer through the network cable. The upper computer can inspect the readings of various meters and the short-circuit conditions of circuit nodes based on the collected videos. The intelligent inspection robot system for valve halls in this embodiment can move up and down driven by the visible light device 1 and the infrared thermal imager 28 under the drive of the robot, expand the horizontal field of view angle under the drive of the horizontal rotating assembly of the pan-tilt, and expand the vertical field of view angle under the drive of the pitching rotating assembly of the pan-tilt. At the same time, clear imaging is achieved under the drive of its own focusing motor and field-of-view zoom motor, and then the images of various meters captured are transmitted to the upper computer through the network cable, realizing an intelligent inspection robot system for valve halls. A photoelectric sensor 15 is provided on the left or right side wall of the robot housing in this embodiment. During the movement of the robot, the soft limit of the robot movement control is realized through the induction of the photoelectric sensor 15 to surrounding objects or people; an end limit switch 19 is provided on the upper part of the rear wall of the robot housing. The end limit switch 19 is electrically connected to the main control board 24 and the motor control board 25. When the end limit switch 19 touches an obstacle, the change in the signal state of the end limit switch 19 is transmitted to the main control board 24 and the motor control board 25. The main control board 24 and the motor control board 25 control the motor to cut off power or rotate in the opposite direction, driving the robot to leave the limit area to avoid collision damage to the robot or surrounding objects. A synchronous belt is provided on the vertical guide rail in this embodiment, and I-beams 26 are provided on both sides of the synchronous belt; the robot includes a worm and worm gear reducer, a motor, and a synchronous pulley 18; the synchronous pulley 18 engages with the synchronous belt. The worm and worm gear reducer reduces the running speed of the robot while increasing the output torque. The synchronous pulley engaging with the synchronous belt can bear a maximum weight of 50 kg; the robot 4 also includes a mounting plate 27. The rear wall of the robot housing is fixed on the mounting plate 27. An L-shaped hook 17 is provided on the rear wall of the robot housing. Through holes are provided at positions on the mounting plate 27 corresponding to the L-shaped hook 17. The robot housing is hung on the through holes of the mounting plate 27 through the L-shaped hook 17, making the disassembly and assembly of the robot 4 very convenient; pulleys are provided on the left and right sides of the mounting plate 27; when the robot 4 moves up and down on the vertical guide rail, the pulleys on the mounting plate 27 slide up and down inside the I-beams 26 of the vertical guide rail, enabling the robot 4 to move smoothly on the guide rail.On the right side wall of the robot housing in this embodiment, an aviation connector 16 is provided. The cables on the aviation connector 16 include a power cable, a network cable, and a serial communication cable. The robot 4 communicates with the host computer through the network cable and the serial port. The single-chip microcomputer on the main control board 24 receives the commands from the host computer to control the motion state of the robot 4, the operation states of the visible light device 1 and the infrared thermal imager 28, and the data reading situation, realizing the remote control of the robot system through the host computer.

[0110] Those skilled in the art can understand that the programs / software involved in the above embodiments are common methods in the prior art, and the present invention does not involve any improvement in software. The present invention only needs to connect the devices with corresponding functions through the connection relationships given in the embodiments of the present invention, and does not involve any improvement in program software. As for the connection methods between the hardware devices with corresponding functions, those skilled in the art can all implement them using the prior art and will not be elaborated here.

[0111] The above is only the preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered by the protection scope of the present invention.

Claims

1. An intelligent inspection system for a valve hall, characterized in that: The system includes multiple inspection devices, each of which has the same structure and is evenly arranged in the valve hall; each inspection device includes a robot, a pan-tilt platform, a visible light device, an infrared thermal imager, and a vertical guide rail; the robot includes a robot housing, a synchronous wheel, a worm gear reducer, and a motor; the worm gear reducer and the motor are arranged inside the robot housing; the input shaft of the worm gear reducer is connected to the motor, and the output shaft of the worm gear reducer is connected to the synchronous wheel; a part of the synchronous wheel is located in the housing, and the other part leaks out of the housing through an opening in the rear wall of the robot housing; a synchronous belt is arranged in the vertical guide rail, and the synchronous wheel is engaged with the synchronous belt to realize the up and down movement of the robot on the vertical guide rail; the pan-tilt platform is arranged on the top of the robot housing, and the infrared thermal imager and the visible light device are installed on the left and right sides of the pan-tilt platform.

2. The intelligent inspection system according to claim 1, characterized in that: The vertical guide rails of each inspection device are fixed on the wall; the distance between two adjacent vertical guide rails is 10m-20m.

3. The intelligent inspection system according to claim 2, characterized in that: The gimbal comprises a fixed shell at the bottom of the gimbal and a gimbal rotating assembly; the gimbal rotating assembly is installed above the fixed shell at the bottom of the gimbal; the visible light device and the infrared thermal imager are installed on the left and right sides of the gimbal rotating assembly.

4. The intelligent inspection system according to claim 3, characterized in that: The outer shell of the gimbal rotation assembly is a rectangular structure; a horizontal rotation axis, a horizontal axis, a worm wheel, a worm, a gear, a conveyor belt, and a pitch motor are arranged inside the outer shell; the horizontal rotation axis is located at the center of the bottom surface of the outer shell of the gimbal rotation assembly, and the horizontal rotation axis drives the gimbal rotation assembly to rotate horizontally; the horizontal axis is located between the left and right side walls of the gimbal rotation assembly, a worm wheel is arranged at one end of the horizontal axis, the worm wheel is connected to the gear through a worm, and the gear is connected to the rotation axis of the pitch motor through a conveyor belt.

5. The intelligent inspection system according to claim 4, characterized in that: The pan / tilt rotation assembly also includes a servo motor control board and a power board; the horizontal axis is a hollow structure with a slip ring inside; the visible light device cable and the infrared thermal imager cable are installed in the slip ring; an opening is provided in the middle of the horizontal axis, and the visible light device cable and the infrared thermal imager cable are led out from the opening and connected to the servo motor control board and the power board.

6. The intelligent inspection system according to claim 5, characterized in that: An aviation head connector is provided on the right side wall of the robot shell. The cables on the aviation head connector include power cables, network cables, and serial communication cables. The cables are made of fire-resistant shielded cables and optical cables, and are laid on the wall through metal pipes or metal trough boxes.

7. The intelligent inspection system according to claim 6, characterized in that: The system includes a host computer; the robot includes a power board and a main control board; the aviation head connector power line is internally connected to the power board and externally connected to the power supply; the aviation head connector network cable and the serial port communication cable are internally connected to the main control board and externally connected to the host computer.

8. The intelligent inspection system according to claim 7, characterized in that: The main control board is provided with a single-chip microcomputer and a serial port to network port interface circuit. The serial port to network port interface circuit adopts an iport conversion chip. One end of the iport conversion chip is connected to the serial port communication pin of the single-chip microcomputer, and the other end of the iport conversion chip is connected to the network cable.

9. The intelligent inspection system according to claim 1, characterized in that: The visible light device has a resolution of 4 megapixels and a lens focal length of 4.5mm-135mm.

10. The intelligent inspection system according to claim 1, characterized in that: The robot shell is also provided with a microphone, and the microphone signal is connected to the main control board.

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