Rail-Mounted Inspection Robot Barcode Positioning
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Solution Overview
Problem
Existing rail-mounted inspection robots face challenges in achieving accurate positioning and high detection efficiency within substation environments, which are crucial for reliable and efficient inspection operations.
Innovation Solution
A rail-mounted intelligent inspection robot equipped with a translation mechanism using barcodes for precise positioning, a lifting mechanism with a synchronous pulley and ball spline system for vertical movement, and integrated camera and sensor modules for data collection, allowing for accurate and efficient data analysis and decision support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional positioning methods are used in rail-mounted inspection robots, then the device complexity is reduced, but the positioning accuracy deteriorates
Solution Approach 1:
The patent introduces barcodes as an intermediary positioning medium attached to the guide rail. The barcode reader on the robot body reads these barcodes to determine position, thereby achieving high positioning accuracy without complex positioning systems. The barcode serves as a simple yet effective mediator between the robot and the positioning requirement.
2Productivity
If manual inspection methods are used in substations, then the device complexity is low, but the productivity and detection efficiency deteriorate
Solution Approach 1:
The inspection robot is designed to autonomously perform inspection tasks along the guide rail without continuous human intervention. It automatically reads barcodes for positioning, operates detection instruments, and collects data, thereby achieving high productivity while maintaining relatively simple device structure through automation of routine operations.
Solution Approach 2:
The robot body integrates multiple functions including positioning (barcode reading), movement control (translation mechanism), lifting (lifting mechanism), and various detection capabilities (electrical, thermal, acoustic sensors). This multi-functionality allows a single device to replace multiple specialized tools and manual operations, improving productivity without proportionally increasing complexity.
3Measurement precision
If fixed sensors and instruments are extensively installed for intelligent substation monitoring, then the measurement precision is improved, but the ease of manufacture and retrofitting deteriorates
Solution Approach 1:
The patent extracts the sensing and detection functions from fixed installations and consolidates them into a mobile robot platform. Instead of installing extensive fixed sensors throughout the substation, the robot carries necessary detection instruments and moves to perform inspections, thereby maintaining detection accuracy while dramatically simplifying installation and retrofitting requirements.
Solution Approach 2:
The system transitions from static fixed sensor installations to a dynamic mobile inspection robot. The robot can move to different positions along the guide rail to perform detections, providing the same measurement capabilities as fixed sensors but with the flexibility and ease of deployment characteristic of mobile systems, thus improving ease of manufacture and retrofitting.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The robot achieves high measurement accuracy of ±1 mm, enables continuous 24/7 operation, and enhances the reliability and automation of substation inspections by providing real-time data analysis and timely fault detection.
Implementation Method 1
one side of the guide rail facing the robot body is affixed with a plurality of barcodes, and the translation mechanism is provided with a barcode reader that is opposite to the barcodes
Implementation Method 2
The lifting mechanism includes a lifting rope, a cylinder and a lifting motor that drives the cylinder to rotate, wherein the lifting rope has one end wound on the cylinder
Implementation Method 3
The synchronous pulley is connected to the lifting motor through a conveyor belt, the synchronous pulley is mounted on the ball spline shaft
Implementation Method 4
a ball spline shaft and a ball spline sleeve that are matched with each other
Implementation Method 5
The trapezoidal screw has one end fixedly mounted on the roller wheels, and one other end rotatably cooperated with the trapezoidal nut
Implementation Method 6
an infrared camera module and a visible light camera module that are disposed on both sides of the body
Implementation Method 7
The intelligent holder includes a body, an infrared camera module and a visible light camera module that are disposed on both sides of the body
Implementation Method 8
a ground electric wave sensor and an ultrasonic sensor are disposed on the insulation measurement probe
Implementation Method 9
roller wheels are disposed on an internal top surface of the translation mechanism, and auxiliary wheels are disposed on a side surface of the translation mechanism, wherein the roller wheels abut an upper surface of the guide rail
Implementation Method 10
A sliding contact wire that connects a power supply is disposed on the guide rail, and an electric contact that is electrically connected to the sliding contact wire is disposed within the translation mechanism
Data Source
AI summary
A rail-mounted intelligent inspection robot includes a robot body and a guide rail, the robot body being hung on the guide rail and moving along the guide rail. One side of the guide rail facing the robot body is affixed with a plurality of barcodes, and the translation mechanism is provided with a barcode reader. A control module and a translation motor are disposed within the control platform. The lifting mechanism is connected to the control platform and the detection platform, and an intelligent holder is disposed below the detection platform. The rail-mounted inspection robot of the present invention may perform continuous inspection operations, and may meet the 7*24 hours of uninterrupted work through the power supply of the sliding contact wire. The recognized dial data is more accurate, and the read information may be transmitted to the background and processed in time.