Multi-sensor fusion welding seam defect detection industrial robot

Abstract

The utility model relates to the field of detection equipment, and discloses a multi-sensor fusion welding seam defect detection industrial robot, which comprises a rack, a plurality of ultrasonic detectors, a plurality of bottom cameras and a plurality of rollers, a top camera is rotatably arranged at the top of the rack, and in a working state, the bottom camera is rotatably arranged at the bottom of the rack. The top camera rotates along the periphery of the rack; the ultrasonic detector is connected to the bottom of the rack, and a probe of the ultrasonic detector faces the end away from the rack; the bottom cameras are connected to the two ends of the bottom of the rack, and probes of the bottom cameras face the middle of the bottom of the rack; and the rollers are rotatably connected to four corners of the bottom of the rack. The welding seam detection device has the beneficial effects that a signal is sent out when the welding seam of the storage tank is detected to have defects, and at the moment, the camera at the bottom also shoots the specific form, distribution, size and position characteristics of the welding seam.

Description

Technical Field

[0001] This utility model relates to the field of testing equipment, specifically to an industrial robot for weld defect detection using multi-sensor fusion. Background Technology

[0002] With rapid industrialization, large storage tanks, as important industrial equipment, are widely used in petroleum, chemical, and storage and transportation fields. Welds, as crucial connection points in storage tanks, directly affect their safety and service life. Traditional weld defect detection methods primarily rely on handheld ultrasonic flaw detectors, but this approach depends heavily on the operator's experience, resulting in low efficiency and limited accuracy. Furthermore, while automated testing methods such as magnetic particle testing and eddy current testing have been introduced in recent years, these technologies still present numerous challenges in inspecting welds in large storage tanks.

[0003] Currently, ultrasonic detectors are generally used to inspect internal defects in the welds of storage tanks. They can only send signals when defects are found in the welds, and cannot visualize the weld defects in three dimensions, making it difficult to intuitively show the shape, distribution, size, and location characteristics of the defects. Utility Model Content

[0004] The technical problem this invention aims to solve is that current ultrasonic detectors can only emit signals when weld defects are detected, and cannot visualize weld defects in three dimensions. It is difficult to intuitively display the shape, distribution, size, and location characteristics of defects. The purpose is to provide an industrial robot for weld defect detection using multi-sensor fusion. The robot adjusts its detection angle and position based on the shape and location characteristics of the weld over a large area of ​​the structure being inspected, obtained by the top camera. When a defect is detected in the weld of a storage tank, a signal is emitted. At this time, the bottom camera also captures the specific shape, distribution, size, and location characteristics of the weld, making it easier for workers to accurately locate the defect.

[0005] This utility model is achieved through the following technical solution:

[0006] An industrial robot for weld defect detection using multi-sensor fusion includes a frame, several ultrasonic detectors, several bottom cameras, and several rollers. A top camera is rotatably mounted on the top of the frame, and in operation, the top camera rotates along the outer perimeter of the frame. The ultrasonic detectors are connected to the bottom of the frame, with their probes facing away from the frame. The bottom cameras are connected to both ends of the bottom of the frame, with their probes facing the center of the bottom of the frame. The rollers are rotatably connected to the four corners of the bottom of the frame.

[0007] The beneficial effects of this utility model are as follows: By rotatably mounting a top camera on the top of the frame, it is convenient to obtain the shape and position characteristics of a large area of ​​weld seams in large storage tanks or other inspected structures by rotating the top camera along the outer periphery of the frame during operation. This allows for flexible adjustment of the robot's detection angle and position according to the weld seam location. An ultrasonic detector is set at the bottom of the frame to detect the internal characteristics of the weld seam and emit a signal when a defect is found. At the same time, a bottom camera at the bottom of the frame captures close-up images of the welding process, obtaining the shape, distribution, and size of the weld seam at that moment. The control terminal can store and mark the captured and ultrasonic data, making it easier for operators to accurately locate the defect location later. This enables the integration of multiple detection technologies, thereby achieving automated, intelligent detection and three-dimensional visualization of weld seam defects. Rollers are also provided at the bottom of the frame to facilitate the robot's movement on the inspected surface.

[0008] In some embodiments, the system further includes a turntable and a drive structure. The drive structure is connected to the top of the frame, and its output end is connected to the bottom of the turntable. The top of the turntable is connected to the top camera via a movable joint. By setting the drive structure to drive the turntable to rotate, which in turn drives the top camera to rotate, the system can acquire the external shape and positional features of welds over a large area of ​​large storage tanks or other structures.

[0009] In some embodiments, the drive structure includes a drive motor and a reduction mechanism. The output shaft of the drive motor is connected to the input shaft of the reduction mechanism, and the turntable is connected to the output shaft of the reduction mechanism. By providing power to the turntable's rotation with a drive motor and adjusting the output torque of the motor through the reduction mechanism, the rotation speed of the turntable is controlled.

[0010] In some embodiments, the movable joint includes a first joint assembly and a second joint assembly. Both the first and second joint assemblies consist of several joints hinged end-to-end. One end of each joint assembly is fixedly connected to the turntable, and the other end of the first joint assembly is hinged to the middle of the second joint assembly. The top camera is hinged to the other end of the second joint assembly, and the vertical projection of the top camera is located outside the frame. By using a joint assembly with several joints hinged end-to-end to connect the top camera, it is convenient to adjust the height of the top camera and its distance from the frame according to the requirements of the component being inspected.

[0011] In some embodiments, an ultrasonic mounting shaft is further included, on which several ultrasonic detectors are mounted. Lugs are provided at the center of both sides of the frame, extending from the end away from the bottom of the frame. Both ends of the ultrasonic mounting shaft are connected to the corresponding lugs. The ultrasonic detectors are supported and positioned by the lugs and the ultrasonic mounting shaft.

[0012] In some embodiments, the ultrasonic detector includes a large housing, a small housing, an ultrasonic mounting shaft, and several ultrasonic probes. Both the small and large housings have two coaxial through holes. Each ultrasonic probe is connected to the ultrasonic mounting shaft, with the end of the ultrasonic probe furthest from the detection head fixedly connected to the ultrasonic mounting shaft. The detection head of the ultrasonic probe faces away from the bottom of the frame. Both ends of the ultrasonic mounting shaft are sealed to the two through holes of the small housing via a first sealing ring. An ultrasonic coupling fluid is provided inside the small housing. The ultrasonic probes are located inside the small housing to form a detection assembly. The detection assembly is located inside the large housing. The large housing is rotatably connected to the ultrasonic mounting shaft. Both the large and small housings are made of silicone. By pointing the ultrasonic probe away from the base plate (towards the outer surface of the storage tank), defects in the weld seams on the outer surface of the storage tank can be easily detected. Furthermore, by installing a coupling fluid inside the small housing instead of applying the coupling fluid to the outer surface of the storage tank during inspection, the detection efficiency is improved and the contamination of the workpiece by the coupling fluid is prevented. The large housing is rotatably connected to the ultrasonic mounting shaft, so that only the large housing rolls when the inspection robot moves. Moreover, by using silicone as the material for both the large and small housings, the silicone forms the outer coupling layer of the ultrasonic probe, eliminating the need to apply a coupling agent separately to the outer surface of the storage tank during measurement, thus enabling the ultrasonic detector to detect defects on the outer surface of the storage tank.

[0013] In some embodiments, the ultrasonic detector further includes two ultrasonic mounting bearings and two second sealing rings. The two ends of the ultrasonic mounting shaft are respectively located within two through holes of the large housing. The ultrasonic mounting shaft and the large housing are sealed together by the second sealing rings. The inner rings of the ultrasonic mounting bearings mate with the shaft holes at both ends of the ultrasonic mounting shaft, and the outer rings of the ultrasonic mounting bearings mate with the through holes of the large housing. By providing bearings, the large housing is rotatably connected to the outside of the detection assembly, thus protecting the detection assembly.

[0014] In some embodiments, roller mounting structures are provided at both ends of the bottom of the frame. Each roller mounting structure has through holes, and a wheel drive motor is mounted at both ends of each through hole. The output shaft of the wheel drive motor is connected to the mounting shaft of the roller, and the roller is rotatably mounted on the mounting shaft. By providing the roller mounting structures to support and position the drive motors, and by using the drive motors to provide driving force to the rollers, the robot can move on the component being inspected.

[0015] In some embodiments, the hub of the roller is made of magnet, and the tread of the roller is made of rubber. By making the hub a magnetic material and the tread of the roller a rubber material, the tread is compressed by the magnetic force formed between the hub and the workpiece being inspected when the robot moves, thereby enabling the ultrasonic detector to adhere to the surface of the workpiece being inspected and improving the accuracy of the inspection data.

[0016] In some embodiments, the bottom camera is mounted on the roller mounting structure.

[0017] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0018] 1. The robot's detection angle and position are adjusted based on the shape and position characteristics of the weld seam within a large range of the structure being inspected, as obtained by the top camera. When a defect is detected in the weld seam of the storage tank, a signal is sent. At this time, the bottom camera also captures the specific shape, distribution, size, and position characteristics of the weld seam, which helps the staff to accurately locate the defect later.

[0019] 2. By setting the hub to a magnetic material and the tread of the roller to rubber, the tread is compressed by the magnetic force between the hub and the workpiece being inspected when the robot moves, thereby enabling the ultrasonic detector to fit closely to the surface of the workpiece and improving the accuracy of the inspection data. Attached Figure Description

[0020] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present invention and form part of this application, do not constitute a limitation thereof. In the drawings:

[0021] Figure 1 This is a structural diagram of the present utility model;

[0022] Figure 2 This is a structural diagram from another perspective of the present invention;

[0023] Figure 3 This is the front view of the present invention;

[0024] Figure 4 This is a partial structural diagram of the present invention;

[0025] Figure 5 This is an exploded view of the ultrasonic detector in this utility model;

[0026] Figure 6 This is a structural diagram of the ultrasonic detector in this utility model.

[0027] The attached diagram shows the markings and corresponding component names:

[0028] Drive structure 10, frame 11, turntable 12, battery 13, first joint assembly 141, second joint assembly 142, top camera 15, wheel drive motor 20, roller 21, wheel hub 22, bottom camera 23, ultrasonic mounting bearing 25, ultrasonic detector 30, ultrasonic probe 31, ultrasonic mounting shaft 32, small shell 33, first sealing ring 35, second sealing ring 36, large shell 38, roller mounting structure 40. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of this utility model are only used to explain this utility model and are not intended to limit this utility model.

[0030] Throughout this specification, references to "an embodiment," "an example," or "an example" mean that a particular feature, structure, or characteristic described in connection with that embodiment or example is included in at least one embodiment of the present invention. Therefore, the phrases "an embodiment," "an example," "an example," or "an example" appearing in various places throughout the specification do not necessarily refer to the same embodiment or example. Furthermore, specific features, structures, or characteristics can be combined in one or more embodiments or examples in any suitable combination and / or sub-combination. Moreover, those skilled in the art will understand that the illustrations provided herein are for illustrative purposes and are not necessarily drawn to scale. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] In the description of this utility model, the terms "front", "rear", "left", "right", "up", "down", "vertical", "horizontal", "high", "low", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of this utility model.

[0032] The terms "first," "second," etc., used in this utility model are merely for clarity of description and are not intended to limit any order or emphasize importance. Furthermore, the term "connection" as used herein, unless otherwise specified, can refer to a direct connection or an indirect connection via other components.

[0033] Example

[0034] like Figures 1-6 As shown, this embodiment provides a multi-sensor fusion weld defect detection industrial robot, including a frame 11, several ultrasonic detectors 30, several bottom cameras 23, and several rollers 21. A top camera 15 is rotatably mounted on the top of the frame 11, and in the working state, the top camera 15 rotates along the outer periphery of the frame 11. The ultrasonic detectors 30 are connected to the bottom of the frame 11, and the ultrasonic probes 31 of the ultrasonic detectors 30 face the end away from the frame 11. The bottom cameras 23 are connected to both ends of the bottom of the frame 11, and the probes of the bottom cameras 23 face the middle of the bottom of the frame 11. The rollers 21 are rotatably connected to the four corners of the bottom of the frame 11.

[0035] See Figures 1-6 It also includes a turntable 12 and a drive structure 10. The drive structure 10 is connected to the top of the frame 11, and its output end is connected to the bottom of the turntable 12. The top of the turntable 12 is connected to the top camera 15 via a movable joint. By setting the drive structure 10 to drive the turntable 12 to rotate, which in turn drives the top camera 15 to rotate, the external shape and positional features of welds over a large area of ​​large storage tanks or other structures can be obtained.

[0036] Specifically, the drive structure 10 includes a drive motor and a reduction mechanism. The output shaft of the drive motor is connected to the input shaft of the reduction mechanism, and the turntable 12 is connected to the output shaft of the reduction mechanism. The drive motor provides power for the rotation of the turntable 12, and the reduction mechanism adjusts the output torque of the motor, thereby controlling the rotation speed of the turntable 12. The reduction mechanism is a single-stage gear reduction mechanism, mainly composed of a driving pinion and a driven gear. The driving pinion is connected to the input shaft, and the driven gear is connected to the output shaft; the driving pinion and driven gear mesh with each other.

[0037] See Figures 1-3The movable joint includes a first joint assembly 141 and a second joint assembly 142. Both the first joint assembly 141 and the second joint assembly 142 are composed of several joints hinged end-to-end. One end of both the first joint assembly 141 and the second joint assembly 142 is fixedly connected to the turntable 12, and the other end of the first joint assembly 141 is hinged to the middle of the second joint assembly 142. The top camera 15 is hinged to the other end of the second joint assembly 142, and the vertical projection of the top camera 15 is located on the outside of the frame 11. By setting a joint assembly composed of several joints hinged end-to-end to connect the top camera 15, it is convenient to adjust the height of the top camera 15 and its distance from the frame 11 according to the needs of the component being inspected.

[0038] See Figures 4-6 It also includes an ultrasonic mounting shaft 32, on which several ultrasonic detectors 30 are mounted. Lugs are provided at the center of both sides of the frame 11, extending from the end away from the bottom of the frame 11. Both ends of the ultrasonic mounting shaft 32 are connected to the corresponding lugs. The ultrasonic detectors are supported and positioned by the lugs and the ultrasonic mounting shaft 32.

[0039] See Figures 4-6The ultrasonic detector 30 includes a large shell 38, a small shell 33, an ultrasonic mounting shaft 32, and several ultrasonic probes 31. Both the small shell 33 and the large shell 38 have two coaxial through holes. The ultrasonic probes 31 are all connected to the ultrasonic mounting shaft 32. The end of each ultrasonic probe 31 away from the detection head is fixedly connected to the ultrasonic mounting shaft 32, with the detection head of the ultrasonic probe 31 facing away from the bottom of the frame 11. Both ends of the ultrasonic mounting shaft 32 are sealed to the two through holes of the small shell 33 through a first sealing ring 35. An ultrasonic coupling fluid is disposed inside the small shell 33. The ultrasonic probes 31 are located inside the small shell 33, forming a detection assembly. The detection assembly is located inside the large shell 38. The large shell 38 is rotatably connected to the ultrasonic mounting shaft 32. Both the large shell 38 and the small shell 33 are made of silicone. By orienting the ultrasonic probe 31 toward the end away from the base plate (towards the outer surface of the storage tank), it is convenient to detect defects in the weld seam on the outer surface of the storage tank. Furthermore, by installing a coupling fluid inside the small shell 33 instead of applying the coupling fluid to the outer surface of the storage tank during inspection, the inspection efficiency is improved and the workpiece is prevented from being contaminated by the coupling fluid. The large shell 38 is rotatably connected to the ultrasonic mounting shaft 32, so that only the large shell 38 rolls when the inspection robot moves. Moreover, by making both the large shell 38 and the small shell 33 the material of silicone, which constitutes the outer coupling of the ultrasonic probe, it is not necessary to apply a coupling agent separately to the outer surface of the storage tank during measurement, so that the ultrasonic detector 30 can detect defects on the outer surface of the storage tank.

[0040] See Figures 4-6 The ultrasonic detector 30 further includes two ultrasonic mounting bearings 25 and two second sealing rings 36. The two ends of the ultrasonic mounting shaft 32 are respectively located within two through holes in the large housing 38. The ultrasonic mounting shaft 32 and the large housing 38 are sealed together by the second sealing rings 36. The inner rings of the ultrasonic mounting bearings 25 are respectively engaged with the shaft holes at both ends of the ultrasonic mounting shaft 32, and the outer rings of the ultrasonic mounting bearings 25 are engaged with the through holes in the large housing 38. By using bearings, the large housing 38 is rotatably connected to the outside of the detection assembly, thus protecting the detection assembly.

[0041] See Figures 1-3 The bottom of the frame 11 is provided with roller mounting structures 40 at both ends. Each roller mounting structure 40 has through holes, and a wheel drive motor 20 is mounted at both ends of each through hole. The output shaft of the wheel drive motor 20 is connected to the mounting shaft of the roller 21, and the roller 21 is rotatably mounted on the mounting shaft. By providing support and positioning for the drive motors through the roller mounting structures 40, and by providing driving force to the rollers 21 through the drive motors, the robot can move on the component being inspected.

[0042] See Figures 1-3 The hub 22 of the roller 21 is made of magnet, and the tread of the roller 21 is made of rubber. By making the hub 22 a magnetic material and the tread of the roller 21 a rubber material, the tread is compressed by the magnetic force formed between the hub 22 and the workpiece being tested when the robot moves, thereby enabling the ultrasonic detector 30 to adhere to the surface of the workpiece being tested and improving the accuracy of the test data.

[0043] Specifically, it also includes a controller, the control area being electrically connected to the ultrasonic detector 30, the wheel drive motor 20, and the drive motor, and the bottom camera 23, the top camera 15, and the ultrasonic detector 30 being electrically connected to the control terminal. A battery 13 is also provided on the frame 11, and the battery 13 is electrically connected to the controller, the ultrasonic detector 30, the wheel drive motor 20, the drive motor, the top camera 15, and the ultrasonic detector 30, respectively.

[0044] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above description is only a specific embodiment of this utility model and is not intended to limit the scope of protection of this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.

Claims

1. A multi-sensor fusion based weld seam defect detection industrial robot, characterized in that, The utility model relates to a kind of ultrasonic detection device, including: Rack, the top of the rack is rotatably mounted with top camera, in working condition, the top camera rotates along the outer periphery of the rack; Several ultrasonic detectors, the ultrasonic detector is connected at the bottom of the rack, the ultrasonic probe of the ultrasonic detector is directed away from the end of the rack; Several bottom cameras, the bottom camera is connected at the bottom of the rack both ends, the probe of the bottom camera is directed to the middle of the rack bottom; Several rollers, the roller is rotatably connected at the bottom of the rack four corners.

2. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 1, wherein, It also includes a turntable and a drive structure, the output end of the drive structure is connected with the bottom of the turntable, the top of the turntable is connected with the top camera through a movable joint.

3. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 2, wherein, The drive structure includes a drive motor and a speed reducer, the output shaft of the drive motor is connected with the input shaft of the speed reducer, and the turntable is connected with the output shaft of the speed reducer.

4. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 2, wherein, The movable joint includes a first joint assembly and a second joint assembly, the first joint assembly and the second joint assembly are both composed of several joints connected head to tail, one end of the first joint assembly and the second joint assembly is fixedly connected to the turntable, the other end of the first joint assembly is hinged to the middle of the second joint assembly, and the top camera is hinged to the other end of the second joint assembly, and the vertical projection of the top camera is located on the outside of the rack.

5. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 1, wherein, It also includes an ultrasonic mounting shaft, the ultrasonic detector is mounted on the ultrasonic mounting shaft, the middle of the two sides of the rack is provided with a lug, the lug extends away from the end of the bottom of the rack, and the two ends of the ultrasonic mounting shaft are respectively connected with the corresponding lug.

6. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 5, wherein, The ultrasonic detector includes a large shell, a small shell, an ultrasonic mounting shaft and several ultrasonic probes, two coaxial through holes are formed in the small shell and the large shell, the ultrasonic probe is connected to the ultrasonic mounting shaft, the end of the ultrasonic probe away from the detection head is fixedly connected to the ultrasonic mounting shaft, the detection head of the ultrasonic probe is directed away from the end of the bottom of the rack, the two ends of the ultrasonic mounting shaft are respectively sealed and connected with the two through holes of the small shell through a first sealing ring, ultrasonic coupling liquid is arranged in the small shell, the detection assembly is formed in the small shell, the detection assembly is located in the large shell, the large shell is rotatably connected with the ultrasonic mounting shaft, and the material of the large shell and the small shell is silica gel.

7. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 6, wherein, The ultrasonic detector also includes two ultrasonic mounting bearings and two second sealing rings, the two ends of the ultrasonic mounting shaft are respectively located in the two through holes of the large shell, the ultrasonic mounting shaft is sealed and connected with the large shell through the second sealing ring, the inner ring of the ultrasonic mounting bearing is respectively matched with the two ends of the ultrasonic mounting shaft, and the outer ring of the ultrasonic mounting bearing is matched with the through hole of the large shell.

8. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 1, wherein, The bottom of the rack is provided with a roller mounting structure at both ends, a through hole is arranged on the roller mounting structure, a wheel driving motor is mounted at both ends of the through hole, the output shaft of the wheel driving motor is connected with the mounting shaft of the roller, and the roller is rotatably mounted on the mounting shaft.

9. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 8, wherein, The material of the hub of the roller is a magnet, and the tread of the roller is rubber.

10. The multi-sensor fusion based weld seam defect detection industrial robot as claimed in claim 8, wherein, The bottom camera is arranged on the roller mounting structure.

Images