Robot for intelligent detection of pressure vessel

Abstract

A robot for intelligent detection of a pressure container comprises a control system, a multi-sensor fusion detection module, a mechanical arm module and a trolley integration module. The multi-sensor fusion detection module is mounted on a tail end bracket of the mechanical arm module; the front end of the mechanical arm module is mounted on the trolley integration module through a rotary steering engine and a telescopic steering engine; the trolley integration module comprises a trolley body, the front end is provided with a laser radar, and the center is provided with a visual identification module; a lithium battery is arranged in the trolley body, a control system is installed in the position, behind the lithium battery, of the trolley body, and the multi-sensor fusion detection module, the rotary steering engine, the telescopic steering engine, the laser radar and the visual recognition module are all electrically connected with the control system. And the lithium battery supplies power to the control system, the multi-sensor fusion detection module, the rotary steering engine, the telescopic steering engine, the laser radar and the visual identification module. According to the utility model, real-time acquisition and positioning of various corrosion and defect conditions in remote transmission are realized, the labor intensity of technicians is reduced, and the working environment is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of non-destructive testing of pressure vessels, and particularly refers to a robot for intelligent detection of pressure vessels. Background Art

[0002] After decades of great development in China's chemical industry, pressure vessels have been widely used in various industries, especially in the chemical industry. Different from other ordinary containers, pressure vessels usually have special functions in use.

[0003] Most of the existing pressure vessel inspection equipment is only a simple visual appearance detector, and there are certain environmental requirements for the pressure vessels to be inspected. For example, when there is a certain medium in the container, the staff needs to drain the medium first before a comprehensive inspection can be carried out. As the service life of pressure vessels increases, due to some physical factors or chemical reactions, the insecurity of the containers increases, which requires inspection, maintenance and repair of the containers. Currently, the commonly used inspections are mostly carried out manually through ultrasonic testing technology, magnetic flux leakage, penetration, endoscopy and ray detection technology. Among them, contact-type conventional ultrasonic inspection requires the ultrasonic probe to be in close contact with the surface of the pressure vessel, and the ultrasonic waves of the probes at various angles are respectively transmitted from both sides to the weld. Since the surface area of pressure vessels in the chemical and petroleum fields is relatively large, the efficiency and reliability of inspection equipment are crucial. The inspection equipment in the prior art generally cannot achieve full coverage of all inspection parts. Coupled with waterproof and explosion-proof technologies, it is difficult to achieve a comprehensive inspection of containers containing toxic, corrosive and explosive media.

[0004] In the existing automated pressure vessel inspection technology, the mobile technology, automatic operation technology, automatic positioning and tracking flaw detection technology, data processing, signal recognition and automatic evaluation technology of robots are not utilized. As a result, it cannot provide a reference for formulating internal and external maintenance plans for pressure vessels, the inspection information is not comprehensive, and it cannot locate and display the position to be repaired. Summary of the Utility Model

[0005] The utility model provides a robot for intelligent detection of pressure vessels, which can achieve a comprehensive inspection of pressure vessels in a confined space containing media.

[0006] The technical solution adopted by the utility model is as follows:

[0007] A robot for intelligent detection of pressure vessels, including a control system, a multi-sensor fusion detection module, a robotic arm module and a trolley integration module; the multi-sensor fusion detection module is installed on the end bracket of the robotic arm module; the front end of the robotic arm module is installed on the trolley integration module through a rotary servo and a telescopic servo; the trolley integration module includes a trolley body, on both sides of the front end of the trolley body, lidar is installed, and a visual recognition module is installed in the center of the front end; a lithium battery is arranged in the center of the trolley body, and a control system is installed in the vehicle body behind the lithium battery. The multi-sensor fusion detection module, the rotary servo, the telescopic servo, the lidar and the visual recognition module are all electrically connected to the control system, and the lithium battery supplies power to the control system, the multi-sensor fusion detection module, the rotary servo, the telescopic servo, the lidar and the visual recognition module.

[0008] It includes an inkjet system, and the inkjet system includes a nozzle, a DC brushless water pump and an ink cartridge; the nozzle is arranged on the end bracket behind the multi-sensor fusion detection module, the inlet of the nozzle is communicated with the outlet of the DC brushless water pump through a pipeline, the inlet of the DC brushless water pump is communicated with the ink cartridge through a pipeline, and the DC brushless water pump is electrically connected to the control system.

[0009] The robotic arm module is a truss parallelogram structure.

[0010] The truss parallelogram structure includes a main arm, a secondary arm, a connecting rod I, a connecting rod II and a triangular bracket; the two angles of the triangular bracket are respectively hinged to the connecting rod I and the connecting rod II, the other angle of the triangular bracket is simultaneously hinged to one end of the main arm and the secondary arm, the other end of the secondary arm and the other end of the connecting rod I are respectively hinged to the end bracket, the other end of the main arm is hinged to the telescopic servo through one end of a reinforcing rod, and the other end of the connecting rod II is hinged to the other end of the reinforcing rod through the telescopic servo on its side; the telescopic servo is installed on a support, the support is installed on the rotary servo, and the rotary servo is installed on the trolley integration module.

[0011] Permanent magnetic wheels are installed at the four corners of the trolley body.

[0012] A fan is installed in the trolley body behind the lidar.

[0013] The overall protection level of the trolley body is IP68.

[0014] An LED screen is arranged above the control system, and the LED screen is electrically connected to the control system.

[0015] The control system includes an intelligent mode and a remote operation mode; the remote control of the remote operation mode is electrically connected to a wireless transmission module arranged at the rear end of the trolley body, the remote control and the wireless transmission module are both electrically connected to the control system, and the lithium battery supplies power to the wireless transmission module.

[0016] This utility model adopts multi-sensor fusion to detect various types of corrosion inside and outside pressure vessels and weld structure defects, can accurately measure the corrosion situation and the size of weld defects, and transmits the images through a high-definition camera to the control system. In addition, it is equipped with a built-in positioning transmitter and an inkjet system at the end of the manipulator, which can accurately determine the positions of the screened defects and mark them, facilitating subsequent manual inspection and repair. It can remotely transmit and collect and locate various corrosion and defect conditions in places that are inaccessible to the naked eye in real time. This robot greatly reduces the labor intensity of professional technicians and improves the working environment. Brief Description of the Drawings

[0017] Figure 1 is a schematic diagram of the external structure of this utility model;

[0018] Figure 2 is a schematic diagram of the integrated module structure of the trolley of this utility model;

[0019] Figure 3 is a schematic diagram of the manipulator arm module of this utility model;

[0020] In the figure: 1. Multi-sensor fusion detection module, 2. Inkjet system, 3. Manipulator arm module, 4. Integrated module of the trolley, 5. Permanent magnet wheel, 6. Lidar, 7. Fan, 8. Visual recognition module, 9. DC brushless water pump, 10. Rotary servo, 11. Ink cartridge, 12. Lithium battery, 13. Control module, 14. LED screen, 15. Trolley body, 16. Wireless transmission module, 17. End bracket, 18. Auxiliary arm, 19. Link I, 20. Triangular bracket, 21. Main arm, 22. Link II, 23. Telescopic servo, 24. Support, 25. Reinforcing bar. Detailed Description of the Preferred Embodiment

[0021] The following further describes this utility model in detail with reference to the drawings.

[0022] Refer to Figure 1 、 Figure 2 、 Figure 3, A robot for intelligent inspection of pressure vessels, including a control system, a multi-sensor fusion detection module 1, a robotic arm module and a trolley integration module; the multi-sensor fusion detection module 1 is installed on the end bracket 17 of the robotic arm module; the front end of the robotic arm module is installed on the trolley integration module through a rotary servo 10 and a telescopic servo 23; the trolley integration module includes a trolley body 15, on both sides of the front end of the trolley body 15, lidar 6 is installed, and a visual recognition module 8 is installed in the center of the front end; a lithium battery 12 is arranged in the center of the trolley body 15, and a control system 13 is installed in the vehicle body behind the lithium battery 12. The multi-sensor fusion detection module 1, the rotary servo 10, the telescopic servo 23, the lidar 6, and the visual recognition module 8 are all electrically connected to the control system 13, and the lithium battery 12 supplies power to the control system 13, the multi-sensor fusion detection module 1, the rotary servo 10, the telescopic servo 23, the lidar 6, and the visual recognition module 8.

[0023] The utility model uses the robot's mobile technology, automatic operation technology, automatic positioning and tracking flaw detection technology, data processing, signal recognition and automatic evaluation technology to cooperate with the hardware structure to provide a reference for the internal and external maintenance plans of pressure vessels, and the detected information is comprehensive, and it can locate and display the maintenance position.

[0024] The above multi-sensor fusion detection module 1 is an existing robot control technology, which is briefly introduced as follows: It is mainly composed of a lidar emission and reception device, an ultrasonic emission and reception device, a high-definition camera device, and an LED lamp lighting device. The multi-sensor fusion detection module 1 is the main component for realizing the intelligent detection of corrosion and weld defects of the robot. During the process, according to the corrosion and defects of the pressure vessel to be detected, the condition of the detected surface is judged by combining the control system based on the duration and reflectivity of laser and ultrasonic waves in a reflection cycle. At the specified sampling interval and at the variation of the weld defect, the probe should stop moving and collect data at a fixed point, and the pause time should be greater than one scanning cycle. Since the information obtained by a single lidar sensor is limited and may be affected by external environmental factors, intelligent robots are usually equipped with sensors such as lidar and ultrasonic waves to meet feature-level fusion. First, representative features are extracted from the observation data provided by each sensor, and these features are fused into a single feature vector, and then processed by using pattern recognition methods, which can accurately measure the defect size and track flaw detection technology. It mainly scans the wall surface by emitting lidar and ultrasonic wavelengths, and combines the model in the software to judge the corrosion and defect conditions of the detected container wall. Such multi-fusion sensors are used to inspect the corrosion of the entire area of the inner and outer walls of the pressure vessel, and various surface defects (surface cracks, surface pores, surface slag inclusions, undercut and misalignment) of the circumferential and longitudinal welds inside and outside the pressure vessel. Its advantages lie in continuous detection, abnormal situation analysis, and real-time transmission. The lidar and ultrasonic wave technologies have the characteristics of high sensitivity, strong penetration, flexible flaw detection, and high efficiency.

[0025] The control system 13 is also an existing robot control technology, and its main control chip uses iMX8MPlus. It mainly consists of the following aspects:

[0026] 1. Robot platform: It includes the robot body, drive system and control system, and is responsible for the movement and navigation of the robot.

[0027] 2. Sensing system: It includes cameras, lidar, ultrasonic probes, etc., and is used to collect images and data of the inner and outer walls of the container.

[0028] 3. Data acquisition and processing system: It is responsible for collecting, storing and processing the data transmitted back by the robot, and performing image stitching, data analysis and visualization.

[0029] 4. Control system: It is responsible for the control and task planning of the robot, and adjusts the movement trajectory and detection plan of the robot according to the real-time data.

[0030] 5. Sensing technology is the sensing technology used in the in-container detection of the robot, mainly including:

[0031] A. Visual sensing: Using a camera to collect high-definition images of the inner wall of the container for the identification of defects such as cracks, corrosion, and scaling.

[0032] B. LiDAR: Scanning the inner wall of the pipeline with laser beams to generate three-dimensional point cloud data for precise measurement and modeling of the pipeline interior.

[0033] C. Ultrasonic probe: Detecting defects such as the wall thickness, corrosion, and cracks of the container through ultrasonic waves, and positioning and imaging the container wall.

[0034] 6. Data processing technology. The data collected in robot detection is huge and complex, and needs to be analyzed, processed, and visualized through data processing technology. The main technologies include:

[0035] A. Image processing: Processing the collected images to enhance the image quality, eliminate noise and interference, and improve the recognition rate of defects in the images.

[0036] B. Point cloud processing: Processing the point cloud data generated by LiDAR scanning, removing noise points, performing point cloud matching and reconstruction, and generating a three-dimensional model of the inner wall of the container.

[0037] C. Defect recognition: Using artificial intelligence algorithms to analyze the processed images and point cloud data, identify the types and locations of defects inside the container, and inkjet mark them.

[0038] D. Data visualization: Displaying the detection results through visualization technology to generate defect location maps, three-dimensional models of the container, and defect assessment reports, facilitating users to intuitively understand the internal situation of the container.

[0039] The visual recognition module 8 and the LiDAR 6 are also existing robot control technologies. They are electrically connected to the GPS module of the control system 13. The LiDAR 6 and the visual recognition module 8 cooperate with the GPS to achieve their own precise positioning, effectively solving the problem of poor signal shielding due to metal in the restricted space, and can automatically plan the walking route of the robot in the tank and control it. At the same time, through rapid GPS positioning, corrosion pits and weld defects of the pressure vessel can be detected.

[0040] The utility model further includes an inkjet system 2, and the inkjet system 2 includes a nozzle, a DC brushless water pump 9, and an ink cartridge 11; the nozzle is arranged on the end bracket 17 behind the multi-sensor fusion detection module 1. The inlet of the nozzle is communicated with the outlet of the DC brushless water pump 9 through a pipeline, the inlet of the DC brushless water pump 9 is communicated with the ink cartridge 11 through a pipeline, and the DC brushless water pump 9 is electrically connected to the control system 13.

[0041] The robot trolley signal recognition and automatic evaluation technology in the control system 13 is used for detection and inkjet marking of the defect positions. The signal recognition and automatic evaluation module transmits the information collected by the lidar and camera to the upper computer, and the evaluation software evaluates the collected information and marks the data suspicious points. The image information and position information collected by the robot trolley can be transmitted to the upper computer screen at any time.

[0042] The robotic arm module 3 is of a truss parallelogram structure, which is compact, light and convenient; at the same time, during the attitude change of the robotic arm, the parallelogram structure can always keep the lidar beam center perpendicular to the detection surface.

[0043] The truss parallelogram structure includes a main arm 21, a secondary arm 18, a connecting rod I 19, a connecting rod II 22, and a triangular bracket 20; the two angles of the triangular bracket 20 are respectively hinged to the connecting rod I 19 and the connecting rod II 22, and the other angle of the triangular bracket 20 is simultaneously hinged to one end of the main arm 21 and the secondary arm 18. The other ends of the secondary arm 18 and the connecting rod I 19 are respectively hinged to the end bracket 17. The other end of the main arm 21 is hinged to the telescopic servo 23 through one end of a reinforcing rod 25, and the other end of the connecting rod II 22 is hinged to the other end of the reinforcing rod 25 through the telescopic servo 23 on its side; the telescopic servo 23 is installed on the support 24, and the support 24 is installed on the rotary servo 10, and the rotary servo 10 is installed on the trolley integration module.

[0044] The rotary servo 10 and the telescopic servo 23 can enable the robotic arm module to perform slewing and telescoping actions, aiming to effectively increase the one-way detection area through slewing and telescoping movements while maintaining the small size of the robot trolley, and improve the relative endurance of the trolley.

[0045] Permanent magnet wheels 5 are installed at the four corners of the trolley body 15. The permanent magnet wheels 5 move fast, turn flexibly, and can firmly climb in the limited space inside the tank.

[0046] A fan 7 is installed inside the trolley body 15 behind the lidar 6 to cool each component in the trolley integration module.

[0047] The overall protection level of the trolley body 15 is IP68, which can prevent component fouling in complex situations inside the tank and effectively increase the service life of the whole machine.

[0048] An LED screen 14 is arranged above the control system 13, and the LED screen 14 is electrically connected to the control system 13. It is used for warning inspection and fault inspection of the machine itself.

[0049] The control system 13 includes an intelligent mode and a remote operation mode. The remote controller in the remote operation mode is electrically connected to a wireless transmission module 16 provided at the rear end of the trolley body 15. Both the remote controller and the wireless transmission module 16 are electrically connected to the control system. The lithium battery 12 supplies power to the wireless transmission module 16.

[0050] In the intelligent mode, the trolley completely plans the path by itself. In the remote operation mode, the staff needs to operate with the remote controller, which can realize rapid inspection of specified positions.

[0051] The working process of the present utility model:

[0052] The trolley turns on the power and self-checks the program, and then enters the tank from the equipment manhole to start running;

[0053] After the trolley enters the container, it scans the container space through the lidar and visual recognition module at the front end of the body, and establishes a map of the internal space of the container, and transmits the collected data to the upper computer.

[0054] According to the established three-dimensional model space, the robot will automatically select the best points on the three-dimensional map, the manipulator adjusts its posture, and the multi-sensor fusion detection module at the end of the manipulator starts to work. The preliminary detection is mainly aimed at the corrosion and welding defects of the welds in the container. If the corrosion at the weld is serious, the inspection range of its part will be expanded.

[0055] By the telescopic and rotary motion of the robotic arm, the detection radius is increased, thereby increasing the effective detection area per trip. The laser beam in the multi-sensor fusion detection module scans the inner wall of the tank to generate three-dimensional point cloud data for precise measurement and modeling of the inside of the tank. The ultrasonic probe detects defects such as the wall thickness, corrosion and cracks of the container through ultrasonic waves, and locates and images the container wall. Using intelligent algorithms, the images and point cloud data are analyzed to identify the types and positions of the defects inside the container, and inkjet marking is performed. The detection results are uploaded to the upper computer to generate a defect position map, a three-dimensional model of the container and a defect assessment report, which is convenient for users to intuitively understand the internal situation of the container. When the power of the power supply is less than 5%, the device body and the upper computer issue an alarm prompt and mark the last detection position for subsequent work handover.

Claims

1. A robot for intelligent detection of pressure vessels, including a control system, characterized in that, There are also a multi-sensor fusion detection module (1), a robotic arm module and a trolley integration module; the multi-sensor fusion detection module (1) is installed on the end bracket (17) of the robotic arm module; the front end of the robotic arm module is installed on the trolley integration module through a rotary servo (10) and a telescopic servo (23); the trolley integration module includes a trolley body (15), and lidar (6) is installed on both sides of the front end of the trolley body (15), and a visual recognition module (8) is installed in the center of the front end; a lithium battery (12) is arranged in the center of the trolley body (15), and a control system (13) is installed in the vehicle body behind the lithium battery (12). The multi-sensor fusion detection module (1), the rotary servo (10), the telescopic servo (23), the lidar (6), and the visual recognition module (8) are all electrically connected to the control system (13), and the lithium battery (12) supplies power to the control system (13), the multi-sensor fusion detection module (1), the rotary servo (10), the telescopic servo (23), the lidar (6), and the visual recognition module (8).

2. The robot for intelligent inspection of a pressure vessel according to claim 1, wherein, It includes an inkjet system (2), and the inkjet system (2) includes a print head, a DC brushless water pump (9), and an ink cartridge (11); the print head is arranged on the end bracket (17) behind the multi-sensor fusion detection module (1), the inlet of the print head is connected to the outlet of the DC brushless water pump (9) through a pipeline, the inlet of the DC brushless water pump (9) is connected to the ink cartridge (11) through a pipeline, and the DC brushless water pump (9) is electrically connected to the control system (13).

3. The robot for intelligent inspection of a pressure vessel according to claim 1, characterized in that, The robotic arm module (3) is a truss parallelogram structure.

4. The robot for intelligent detection of a pressure vessel according to claim 3, characterized in that, The truss parallelogram structure includes a main arm (21), an auxiliary arm (18), a connecting rod I (19), a connecting rod II (22), and a triangular bracket (20); the two corners of the triangular bracket (20) are respectively hinged to the connecting rod I (19) and the connecting rod II (22), the other corner of the triangular bracket (20) is simultaneously hinged to one end of the main arm (21) and the auxiliary arm (18), the other ends of the auxiliary arm (18) and the connecting rod I (19) are respectively hinged to the end bracket (17), the other end of the main arm (21) is hinged to one end of a reinforcing rod (25) and the telescopic servo (23), and the other end of the connecting rod II (22) is hinged to the other end of the reinforcing rod (25) through the telescopic servo (23) on its side; the telescopic servo (23) is installed on a support (24), the support (24) is installed on the rotary servo (10), and the rotary servo (10) is installed on the trolley integration module.

5. A robot for intelligent inspection of pressure vessels according to any one of claims 1-4, characterized in that, Permanent magnet wheels (5) are installed at the four corners of the trolley body (15).

6. The robot for intelligent inspection of a pressure vessel according to claim 5, wherein, A fan (7) is installed in the trolley body (15) behind the lidar (6).

7. The robot for intelligent inspection of a pressure vessel according to claim 6, characterized in that, The overall protection level of the trolley body (15) is IP68.

8. The robot for intelligent inspection of a pressure vessel according to claim 1, characterized in that, An LED screen (14) is arranged above the control system (13), and the LED screen (14) is electrically connected to the control system (13).

9. The robot for intelligent inspection of a pressure vessel according to claim 1, characterized in that, The control system (13) includes an intelligent mode and a remote operation mode; a remote controller in the remote operation mode is electrically connected to a wireless transmission module (16) provided at the rear end of the vehicle body (15) of the trolley, and both the remote controller and the wireless transmission module (16) are electrically connected to the control system. The lithium battery (12) supplies power to the wireless transmission module (16).

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