Calcium carbide furnace inspection robot

Abstract

The utility model belongs to the technical field of calcium carbide furnace auxiliary equipment, and relates to a calcium carbide furnace inspection robot which comprises a robot body, a visible light camera, a thermal infrared imager, a binocular camera, a pod and a mechanical arm. The binocular camera and the mechanical arm are arranged on the robot body; the binocular camera is located in front of the mechanical arm. The pod is located at the top of the mechanical arm, the visible light camera and the thermal infrared imager are both arranged on the pod, and the mechanical arm is used for driving the pod to extend into and out of the calcium carbide furnace to inspect the calcium carbide furnace. According to the inspection robot for the calcium carbide furnace, all-weather inspection of the calcium carbide furnace can be achieved, the inspection safety is improved, and the inspection efficiency and the inspection quality are improved.

Description

Technical Field

[0001] This utility model belongs to the technical field of auxiliary equipment for calcium carbide furnaces, and relates to a calcium carbide furnace inspection robot. Background Technology

[0002] The calcium carbide furnace is the main equipment for producing calcium carbide. Inside the furnace, the high temperature generated by the electric arc melts the furnace charge, producing calcium carbide. In actual production, to promptly detect equipment abnormalities, eliminate operational defects and potential hazards, and ensure normal equipment operation, production safety, and stable production, regular inspections of the calcium carbide furnace are necessary. Currently, these inspections are conducted manually at regular intervals. However, this method has the following problems:

[0003] 1. The second floor of the calcium carbide furnace is a safety red zone control area. The production process is highly dangerous, and the risk of burns to personnel during inspection is high. There are many water supply devices above the furnace cover, and the temperature is high, which poses a risk of water leakage and explosion to the staff on duty, posing a great safety hazard to the staff on duty.

[0004] 2. Due to the high temperature inside the calcium carbide furnace, combustible gases such as carbon monoxide are prone to flash explosion when exposed to air in the high-temperature environment. The electric furnace is at risk of water leakage and explosion. Explosions and burns are likely to occur during manual inspections, which has a great impact on the personal safety of personnel.

[0005] 3. Because the staff work in high-dust and carbon monoxide environments for long periods of time, the safety risks to the staff are increased, and their lives are not adequately protected.

[0006] 4. Due to the large number of equipment and operation points that need to be inspected, the inspection work is labor-intensive and time-consuming; moreover, the inspection personnel conduct inspections on a regular basis and rely on visual or olfactory methods, resulting in low inspection efficiency and poor inspection quality.

[0007] In summary, the existing manual inspection of calcium carbide furnaces has technical defects such as poor safety, low inspection efficiency, and poor inspection quality. Utility Model Content

[0008] In view of the technical problems of poor safety, low inspection efficiency and poor inspection quality in the existing manual inspection of calcium carbide furnaces, this utility model provides a calcium carbide furnace inspection robot.

[0009] The calcium carbide furnace inspection robot provided by this utility model can realize all-weather inspection of calcium carbide furnaces, improve the safety of inspection, and enhance the efficiency and quality of inspection.

[0010] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0011] A calcium carbide furnace inspection robot includes a robot body, a visible light camera, an infrared thermal imager, a binocular camera, a pod, and a robotic arm; the binocular camera and the robotic arm are both mounted on the robot body; the binocular camera is located in front of the robotic arm; the pod is located on top of the robotic arm, and the visible light camera and the infrared thermal imager are both mounted on the pod; the robotic arm is used to drive the pod to extend into and out of the calcium carbide furnace to inspect the furnace.

[0012] Furthermore, the calcium carbide furnace inspection robot also includes a three-dimensional lidar mounted on the robot body, located between the robotic arm and the binocular camera.

[0013] Furthermore, the calcium carbide furnace inspection robot also includes a laser obstacle avoidance sensor mounted on the front end of the robot body.

[0014] The calcium carbide furnace inspection robot also includes an ultrasonic obstacle avoidance sensor mounted on the front end of the robot body; the ultrasonic obstacle avoidance sensor is located above the laser obstacle avoidance sensor.

[0015] Furthermore, the calcium carbide furnace inspection robot also includes a collision avoidance strip installed on the front end of the robot body.

[0016] Furthermore, the calcium carbide furnace inspection robot also includes supplementary lighting lights installed on the pods.

[0017] Furthermore, the calcium carbide furnace inspection robot also includes an antenna mounted on the robot body.

[0018] Furthermore, the calcium carbide furnace inspection robot also includes a front status indicator light, a rear status indicator light, and an emergency stop button, all of which are respectively installed on the robot body.

[0019] Furthermore, the calcium carbide furnace inspection robot also includes power switches respectively installed on the robot body; the power switches are respectively connected to the robot body, front status indicator, rear status indicator, supplementary light, visible light camera, infrared thermal imager, binocular camera and robotic arm.

[0020] Furthermore, the calcium carbide furnace inspection robot also includes a charging device disposed on the underside of the robot body; the charging device is connected to the robot body.

[0021] Compared with the prior art, the beneficial effects of this utility model are:

[0022] 1. The calcium carbide furnace inspection robot provided by this utility model has a robotic arm used to drive the pod to extend into and out of the calcium carbide furnace, so that the optical camera and infrared thermal imager on the pod can inspect the corresponding positions of the calcium carbide furnace. This enables all-weather inspection in harsh environments such as high temperature and high dust in calcium carbide furnaces, reducing the risk of personnel exposure to harsh environments, lowering the incidence of safety accidents, and improving the safety of inspection.

[0023] 2. The calcium carbide furnace inspection robot provided by this utility model can conduct 24-hour uninterrupted inspections. Compared with manual timed inspections, it can check the equipment more frequently and improve inspection efficiency.

[0024] 3. In this utility model, intelligent inspection is carried out by visible light camera, infrared thermal imager, binocular camera, etc., which can effectively detect the temperature of electrodes and material surface in calcium carbide furnace, detect water leakage in calcium carbide furnace equipment and electrode condition. The inspection is not only accurate and high-precision, but can also replace manual visual or olfactory inspection methods, improving the efficiency and quality of inspection.

[0025] 4. This utility model improves the safety and reliability of inspection by setting up laser obstacle avoidance sensors and ultrasonic obstacle avoidance sensors, and through the obstacle avoidance function of the double arms.

[0026] 5. The calcium carbide furnace inspection robot provided by this utility model can monitor and inspect the operation of the calcium carbide furnace in real time, which facilitates the timely detection and handling of minor faults, thereby improving the operational stability of the calcium carbide furnace. Attached Figure Description

[0027] Figure 1 A schematic diagram of the front side of the structure of the calcium carbide furnace inspection robot provided by this utility model;

[0028] Figure 2 A schematic diagram of the structure of the calcium carbide furnace inspection robot provided by this utility model on the right side;

[0029] Figure 3 A top view schematic diagram of the calcium carbide furnace inspection robot provided by this utility model;

[0030] in:

[0031] 1-Visible light camera; 2-Supplemental light; 3-Infrared thermal imager; 4-3D LiDAR; 5-Binocular camera; 6-Front status indicator; 7-Ultrasonic obstacle avoidance sensor; 8-Laser obstacle avoidance sensor; 9-Pod; 10-Robotic arm; 11-Antenna; 12-Handle; 13-Maintenance interface; 14-Rear status indicator; 15-Power switch; 16-Emergency stop button; 17-Anti-collision strip; 18-Charging device. Detailed Implementation

[0032] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the scope of protection of the present invention.

[0033] Example

[0034] See Figure 1 and Figure 2 The calcium carbide furnace inspection robot provided in this embodiment includes a robot body, a visible light camera 1, an infrared thermal imager 3, a binocular camera 5, a pod 9, and a robotic arm 10. The binocular camera 5 and the robotic arm 10 are both placed on the robot body. The binocular camera 5 is located in front of the robotic arm 10. The pod 9 is located on top of the robotic arm 10. The visible light camera 1 and the infrared thermal imager 3 are both placed on the pod 9. The robotic arm is used to drive the pod to extend into and out of the calcium carbide furnace to inspect the calcium carbide furnace.

[0035] Preferably, the robot body is a self-driving mobile robot with an overall rectangular structure.

[0036] In this embodiment, the visible light camera 1 is used to collect images of the calcium carbide furnace site in real time during inspections, and to monitor the calcium carbide furnace site in real time based on the collected images, so as to determine whether there are any abnormalities at the calcium carbide furnace site and facilitate timely handling.

[0037] In this embodiment, due to the high reaction temperature inside the calcium carbide furnace, the infrared thermal imager 3 can clearly capture the reaction scene (i.e., thermal image) under the high-temperature environment inside the calcium carbide furnace during inspection. Simultaneously, the infrared thermal imager 3 can also measure the temperature of the reaction system inside the calcium carbide furnace and display the highest and lowest temperatures in real time on the thermal image, facilitating timely detection of any abnormalities in the reaction temperature inside the calcium carbide furnace based on the displayed results. The infrared thermal imager 3 can also capture thermal images of water leakage from the furnace cover and top, enabling water leakage monitoring of the calcium carbide furnace equipment.

[0038] In this embodiment, the binocular camera 5 is used to monitor the status of the electrode cylinder ribs, electrode cylinder guard plates, electrodes, external furnace cover, furnace charge, and charging nozzle from all angles and directions. This is because the smoke and fire inside the calcium carbide furnace are too intense. The binocular camera 5 collects images of the electrode cylinder ribs, electrode cylinder guard plates, electrodes, external furnace cover, furnace top, and charging nozzle. Using the built-in video image enhancement technology of the binocular camera 5, the collected images are processed to transmit light and fog, resulting in a clear view of their actual operating status. Ultimately, through smoke and dust, the camera can clearly capture water leakage within the calcium carbide furnace and the operating conditions at various points. This not only allows for real-time monitoring of the operation of the electrode cylinder ribs, electrode cylinder guard plates, electrodes, internal and external furnace covers, furnace top, and charging nozzle, facilitating the determination of whether these components are operating normally, but also provides clear images that accurately reflect the operation of the calcium carbide furnace, improving the quality of inspections.

[0039] In this embodiment, in order to ensure the stability of the robotic arm 10 installed on the robot body, a mounting block is set on the robot body. One end (fixed end) of the robotic arm 10 is placed on the mounting block, and the other end (moving end) of the robotic arm 10 is facing upward away from the robot body. The pod 9 is placed on the other end of the robotic arm 10. The moving end of the robotic arm 10 drives the pod 9 to move. When the robotic arm (10) extends into and out of the calcium carbide furnace, it drives the pod 9 to also extend into and out of the calcium carbide furnace, thereby driving the optical camera 1 and infrared thermal imager 3 on the pod 9 to inspect the corresponding position of the calcium carbide furnace.

[0040] Preferably, the robotic arm 10 is a multi-joint six-axis robotic arm. This type of robotic arm has a very high degree of freedom and is suitable for various different trajectories or multi-angle movements. At this time, a visible light camera 1 and an infrared thermal imager 3 are installed on the pod 9. When the robotic arm 10 drives the pod 9 to move, the visible light camera 1 and the infrared thermal imager 3 can conduct a comprehensive inspection of the operation of the equipment inside and outside the calcium carbide furnace.

[0041] In use, the robot body is equipped with a robotic arm 10, and a pod 9 at the end of the robotic arm 10 (the moving end). A visible light camera 1 mounted on the pod 9 can inspect all equipment within 30cm to 150cm above the ground of the calcium carbide furnace. An infrared thermal imager 3 mounted on the pod 9 can effectively detect the temperature of the electrodes and material surface inside the calcium carbide furnace, and monitor for leaks in the furnace equipment. Therefore, this invention enables automatic inspection of the equipment and interior of the calcium carbide furnace, saving time and avoiding the safety hazards to inspection personnel caused by the high temperature of the furnace. The visible light camera 1 and the infrared thermal imager 3 improve the accuracy of the calcium carbide furnace inspection.

[0042] In this embodiment, the calcium carbide furnace inspection robot also includes a three-dimensional lidar 4 mounted on the robot body, which is located between the robotic arm 10 and the binocular camera 5.

[0043] With the robot's direction of travel as the front, the 3D LiDAR 4 is located in front of the robotic arm 10, and the binocular camera 5 is located in front of the 3D LiDAR 4. Initially, the installation height of the 3D LiDAR 4 is higher than that of the binocular camera 5. The binocular camera 5 is movably connected to the robot body via a vertical telescopic rod. The vertical height of the binocular camera 5 can be adjusted according to the inspection requirements of the calcium carbide furnace to meet the inspection requirements.

[0044] The 3D LiDAR 4 is used to control whether the robot body reaches the designated monitoring position according to the walking route. When the robot body is inspecting according to the set walking route, the 3D LiDAR 4 monitors whether the robot body has reached the designated monitoring position. When the position is reached, the robot body stops walking, completing the monitoring and inspection of the calcium carbide furnace at that monitoring position. Then the robot body continues to walk according to the set walking route to complete the inspection of calcium carbide furnaces at different monitoring positions.

[0045] In this embodiment, the calcium carbide furnace inspection robot also includes a laser obstacle avoidance sensor 8 disposed on the front end of the robot body. The calcium carbide furnace inspection robot also includes an ultrasonic obstacle avoidance sensor 7 disposed on the front end of the robot body; the ultrasonic obstacle avoidance sensor 7 is located above the laser obstacle avoidance sensor 8.

[0046] To ensure the safety of the robot during inspection, a laser obstacle avoidance sensor 8 is installed at the front of the robot, using the forward and backward direction as a reference. During movement, the laser obstacle avoidance sensor 8 detects obstacles using the reflective properties of a laser beam, allowing the robot to automatically avoid them. Simultaneously, an ultrasonic obstacle avoidance sensor 7 is installed below the laser obstacle avoidance sensor 8. During movement, the ultrasonic obstacle avoidance sensor 7 detects obstacles using the reflective properties of ultrasonic waves, allowing the robot to automatically avoid them as well. Through the dual obstacle avoidance functions of the ultrasonic obstacle avoidance sensor 7 and the laser obstacle avoidance sensor 8, obstacles at different heights and in different areas at the calcium carbide furnace site can be detected, improving the safety and reliability of the robot's inspection work.

[0047] Preferably, there are two ultrasonic obstacle avoidance sensors 7, which are symmetrically distributed on the front end of the robot body about the central axis of the robot body.

[0048] See Figure 1 In this embodiment, the calcium carbide furnace inspection robot also includes supplementary lighting 2 installed on the pod 9. The supplementary lighting 2 ensures that the images captured by the visible light camera 1, the infrared thermal imager 3, and the binocular camera 5 are clear, thus ensuring reliable and accurate inspection results.

[0049] See Figure 3In this embodiment, the calcium carbide furnace inspection robot also includes an antenna 11 mounted on the robot body. The antenna 11 is connected to the robot body, preferably using a known wireless communication connection, to achieve precise positioning of the robot body and ensure that the robot body performs inspections according to a predetermined walking route.

[0050] In this embodiment, handles 12 are provided at the middle positions of the left and right sides of the robot body, so that the operator can hold the robot body by pulling the handles 12.

[0051] In this embodiment, a maintenance interface 13 is also provided on the robot body. The maintenance interface 13 is mainly used to realize the data interaction, remote monitoring and control between the robot body and external devices, that is, the communication interface.

[0052] See Figure 1 and Figure 3 In this embodiment, the calcium carbide furnace inspection robot also includes a front status indicator light 6, a rear status indicator light 14, and an emergency stop button 16, which are respectively installed on the robot body.

[0053] Preferably, the front status indicator 6 is located on the front end of the robot body and around the ultrasonic obstacle avoidance sensor 7, while the rear status indicator 14 is located on the rear end of the robot body. Both the front and rear status indicator lights 6 and 14 are normally open during robot body movement and inspection, indicating that the robot body is working normally. The emergency stop button 16 is located on one of the left or right sides of the robot body, used for manual control to stop the robot body during movement or in case of an emergency.

[0054] See Figure 3 In this embodiment, the calcium carbide furnace inspection robot also includes a collision protection strip 17 set on the front end of the robot body; if the robot body cannot stop in time in an emergency while moving forward, the collision protection strip 17 will protect the robot body and improve the safety of use.

[0055] In this embodiment, the calcium carbide furnace inspection robot also includes power switches 15 respectively installed on the robot body; the power switches 15 are connected to the robot body, the front status indicator 6, the rear status indicator 14, the supplementary light 2, the visible light camera 1, the infrared thermal imager 3, and the binocular camera 5 respectively. The operation of the above devices and the connection and disconnection of the external power supply can be controlled by a single button press of the power switch 15. The robotic arm 10 is started and stopped by a separate robotic arm controller.

[0056] See Figure 1The calcium carbide furnace inspection robot also includes a charging device 18 disposed on the underside of the robot body; the charging device 18 is connected to the robot body and is used to charge the robot body. Preferably, the charging device 18 is a conventional charging device such as a storage battery.

[0057] It should be noted that the robot body, visible light camera 1, supplementary light 2, infrared thermal imager 3, three-dimensional lidar 4, binocular camera 5, ultrasonic obstacle avoidance sensor 7, laser obstacle avoidance sensor 8, robotic arm 10 (including matching robotic arm controller), antenna 11, maintenance interface 13, etc. disclosed in this utility model are all existing known products in the field purchased from the market.

[0058] It should be noted that in this utility model, the robot body's inspection according to the set walking route and the multi-angle extension and retraction of the robotic arm 10 are all prior art known in the art. The processing of images or pictures acquired by the visible light camera 1, infrared thermal imager 3, and binocular camera 5 are all prior art known in the art; the working principles of the three-dimensional lidar 4, ultrasonic obstacle avoidance sensor 7, and laser obstacle avoidance sensor 8 are all prior art known in the art.

[0059] The calcium carbide furnace inspection robot provided in this embodiment is used to circulate the calcium carbide furnace on the second-floor platform, thereby replacing manual inspections on the periphery of the calcium carbide furnace. It can effectively avoid the safety problems caused by manual inspections in the high-risk working environment of the calcium carbide furnace, realize intelligent and unmanned inspection of the calcium carbide furnace, and improve inspection efficiency and quality.

[0060] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the description and drawings of this utility model, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A calcium carbide furnace inspection robot, characterized in that, The system includes a robot body, a visible light camera (1), an infrared thermal imager (3), a binocular camera (5), a pod (9), and a robotic arm (10); the binocular camera (5) and the robotic arm (10) are both placed on the robot body; the binocular camera (5) is located in front of the robotic arm (10); the pod (9) is located on top of the robotic arm (10), and the visible light camera (1) and the infrared thermal imager (3) are both placed on the pod (9); the robotic arm (10) is used to drive the pod (9) to extend into and outside the calcium carbide furnace to inspect the calcium carbide furnace.

2. The calcium carbide furnace inspection robot according to claim 1, characterized in that, The calcium carbide furnace inspection robot also includes a three-dimensional laser radar (4) mounted on the robot body, which is located between the robotic arm (10) and the binocular camera (5).

3. The calcium carbide furnace inspection robot according to claim 2, characterized in that, The calcium carbide furnace inspection robot also includes a laser obstacle avoidance sensor (8) installed on the front end of the robot body.

4. The calcium carbide furnace inspection robot according to claim 3, characterized in that, The calcium carbide furnace inspection robot also includes an ultrasonic obstacle avoidance sensor (7) installed on the front end of the robot body; the ultrasonic obstacle avoidance sensor (7) is located above the laser obstacle avoidance sensor (8).

5. The calcium carbide furnace inspection robot according to claim 4, characterized in that, The calcium carbide furnace inspection robot also includes a collision protection strip (17) installed on the front end of the robot body.

6. The calcium carbide furnace inspection robot according to claim 5, characterized in that, The calcium carbide furnace inspection robot also includes supplementary lights (2) installed on the pod (9).

7. The calcium carbide furnace inspection robot according to claim 6, characterized in that, The calcium carbide furnace inspection robot also includes an antenna (11) mounted on the robot body.

8. The calcium carbide furnace inspection robot according to claim 7, characterized in that, The calcium carbide furnace inspection robot also includes a front status indicator (6), a rear status indicator (14), and an emergency stop button (16) respectively installed on the robot body.

9. The calcium carbide furnace inspection robot according to claim 8, characterized in that, The calcium carbide furnace inspection robot also includes power switches (15) respectively installed on the robot body; the power switches (15) are respectively connected to the robot body, the front status indicator (6), the rear status indicator (14), the fill light (2), the visible light camera (1), the infrared thermal imager (3) and the binocular camera (5).

10. The calcium carbide furnace inspection robot according to any one of claims 1-9, characterized in that, The calcium carbide furnace inspection robot also includes a charging device (18) installed on the bottom surface of the robot body; the charging device (18) is connected to the robot body.

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