Wall-Climbing Tank Robot With Bendable Ruler and Rust Removal
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Solution Overview
Problem
The existing methods for measuring the capacity of large vertical metal tanks are labor-intensive, risky, and suffer from insufficient accuracy due to manual operation and difficulties in controlling the magnetic block, with existing wall-climbing robots facing issues like indentation, height restrictions, and rust interference.
Innovation Solution
A wall-climbing robot equipped with a mesh structure of magnets for attraction, a bendable ruler for precise measurements, a rust removal unit, and a control system including a microcontroller, posture detector, and communication device to adjust attraction force, maintain posture, and avoid obstacles, allowing for accurate and efficient capacity measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual operation is used to lift and position the magnetic block, then measurement can be performed, but labor intensity is high, risk is high, and measurement accuracy is insufficient
Solution Approach 1:
The wall-climbing robot is equipped with a rust removal device that automatically detects and removes rust from the tank wall surface before measurement. The system performs self-service by autonomously preparing the measurement surface without requiring manual intervention for rust removal, thereby reducing labor intensity and operation time.
Solution Approach 2:
The patent replaces the manual mechanical lifting and positioning system with an automated wall-climbing robot that uses magnetic attraction and mechanical climbing mechanisms. The robot autonomously navigates the tank wall, positions itself at measurement points, and performs measurements, eliminating the need for manual aloft work and significantly reducing labor intensity and time loss.
2Reliability
If fixed attraction force is applied by the wall-climbing robot, then the robot can climb, but it leaves indentations on the metal tank surface
Solution Approach 1:
The patent implements a dynamic attraction force adjustment mechanism that continuously adapts the magnetic attraction strength based on the robot's climbing state and tank wall conditions. The system reduces attraction force when climbing over smooth sections to prevent indentations, while maintaining sufficient force for stable climbing on rougher sections, thereby resolving the contradiction between climbing stability and surface protection.
Solution Approach 2:
The patent changes the attraction force parameter dynamically during the climbing process. The control system adjusts the magnetic attraction force based on real-time feedback from sensors that detect wall surface conditions, robot position, and climbing velocity. This parameter adjustment prevents excessive force that causes indentations while maintaining enough force for reliable climbing.
3Adaptability or versatility
If a rigid ruler is used for measurement, then structural simplicity is maintained, but it cannot pass through fire protection pipelines
Solution Approach 1:
The patent employs a flexible ruler that can dynamically change its shape from straight to bent configurations. The ruler is designed with sufficient flexibility to bend around fire protection pipelines and other obstacles on the tank wall, while maintaining measurement accuracy. This dynamic adaptability allows the robot to navigate complex wall surfaces without requiring complex bypass mechanisms.
Solution Approach 2:
The patent uses a flexible ruler constructed from thin, bendable material that can conform to the contours of the tank wall and wrap around obstacles such as fire protection pipelines. The flexible ruler maintains its measurement marking capabilities while adapting its shape to pass through restricted areas, thereby providing adaptability without significantly increasing device complexity.
4Measurement precision
If the wall-climbing robot operates on rusty surfaces, then it can perform measurement, but measurement accuracy is affected by rust interference
Solution Approach 1:
The patent implements a preliminary rust removal action before measurement. The robot is equipped with a rust removal device that actively detects rust on the tank wall surface and removes it before the measurement process begins. This preliminary action ensures that the measurement is performed on a clean, rust-free surface, thereby eliminating rust interference and improving measurement precision.
Solution Approach 2:
The patent converts the harmful effect of rust into a beneficial detection opportunity. The rust detection sensors identify rusted areas, and the robot automatically navigates to these locations to perform rust removal before measurement. By detecting and addressing the rust problem proactively, the system transforms the potential measurement error source into a trigger for corrective action, ensuring accurate measurements.
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 overcomes labor intensity, risk, and accuracy issues by providing real-time attraction force adjustment, passing through height-restricted areas, and mitigating rust effects, enhancing measurement precision and efficiency.
Implementation Method 1
an attraction unit, comprising a plurality of magnets for attracting a wall of the metal tank
Data Source
AI summary
A wall-climbing robot for measuring capacity of vertical metal tanks includes a robot body including a chassis, a casing, and wheels. The robot body further includes: an attraction unit including a plurality of magnets; a measurement unit including a bendable ruler provided on the chassis and protruding from a top of the casing; the rust removal unit including a rust removing bucket provided at a front side of the robot body, and a driver for the lifting and lowering of the rust removing bucket; and a control unit including a microcontroller, a posture detector, an obstacle detector, an attraction detector, and a distance sensor. The wall-climbing robot of the present invention leaves no indentation on a surface of the metal tank, and is not affected by the rusts formed on the surface.