CN104858167A - Safety protection system and method for electrified water washing robot for substation - Google Patents
Safety protection system and method for electrified water washing robot for substation Download PDFInfo
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- CN104858167A CN104858167A CN201510209413.5A CN201510209413A CN104858167A CN 104858167 A CN104858167 A CN 104858167A CN 201510209413 A CN201510209413 A CN 201510209413A CN 104858167 A CN104858167 A CN 104858167A
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 229
- 238000005406 washing Methods 0.000 title claims abstract description 51
- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000011010 flushing procedure Methods 0.000 claims abstract description 31
- 238000009413 insulation Methods 0.000 claims abstract description 26
- 230000008569 process Effects 0.000 claims abstract description 14
- 230000007246 mechanism Effects 0.000 claims description 38
- 239000012212 insulator Substances 0.000 claims description 14
- 230000033001 locomotion Effects 0.000 claims description 11
- 239000007921 spray Substances 0.000 claims description 11
- 238000005259 measurement Methods 0.000 claims description 10
- 238000004422 calculation algorithm Methods 0.000 claims description 9
- 238000002360 preparation method Methods 0.000 claims description 7
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- 238000002474 experimental method Methods 0.000 claims description 4
- 238000011897 real-time detection Methods 0.000 claims description 4
- 239000012498 ultrapure water Substances 0.000 claims description 3
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- 230000007935 neutral effect Effects 0.000 claims 3
- 238000012544 monitoring process Methods 0.000 abstract description 3
- 230000003993 interaction Effects 0.000 abstract description 2
- 238000004140 cleaning Methods 0.000 description 7
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- 238000005516 engineering process Methods 0.000 description 5
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/02—Cleaning by the force of jets or sprays
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B13/00—Accessories or details of general applicability for machines or apparatus for cleaning
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Abstract
本发明公开了一种变电站带电水冲洗机器人用安全防护系统及方法,系统包括行走控制系统和安全控制系统,行走控制系统包括遥控模块、车载控制器和信息采集模块;所述遥控模块与车载控制器之间及车载控制器和信息采集模块之间均采用无线设备,构建WIFI网络,实现三模块间的数据交互;安全控制系统利用云台上安装的超声传感器、磁场测距传感器、水阻率传感器及水压传感器,实现机器人运行过程的实时监控。本发明实现水阻率、水压、水柱长度的实时在线监测,保证水冲洗过程中机器人本体及变电站带电设备的绝缘性能,有效提高了水冲洗作业的安全性。
The invention discloses a safety protection system and method for a substation charged water washing robot. The system includes a walking control system and a safety control system. The walking control system includes a remote control module, a vehicle-mounted controller and an information collection module; the remote control module and the vehicle-mounted control Wireless devices are used between the controllers and between the on-board controller and the information acquisition module to build a WIFI network to realize data interaction between the three modules; the safety control system uses the ultrasonic sensor, magnetic field ranging sensor, water resistivity Sensors and water pressure sensors realize real-time monitoring of the robot's running process. The invention realizes the real-time on-line monitoring of the water resistivity, water pressure and water column length, ensures the insulation performance of the robot body and the live equipment of the substation during the water flushing process, and effectively improves the safety of the water flushing operation.
Description
技术领域technical field
本发明涉及一种变电站带电水冲洗机器人用安全防护系统及方法。The invention relates to a safety protection system and method for a substation charged water washing robot.
背景技术Background technique
随着大气环境污染日趋严重,电网设备污闪事故增加,严重影响电网设备安全运行。变电站绝缘子长时间暴露在外界环境中,表面易沉积污垢,这些污垢受恶劣天气侵害容易发生污闪事故。据统计,由污秽引起的绝缘闪络事故目前在电网事故总数中已占到第2位,仅1971-1994年全国35-500kV发、变电站就污闪1768座次。绝缘子带电水冲洗作业可以提高供电的可靠性,减少停电损失,保证变电站及输电线路的安全。在现阶段的变电站绝缘子冲洗作业主要存在以下缺点:With the increasing pollution of the air environment, pollution flashover accidents of power grid equipment have increased, seriously affecting the safe operation of power grid equipment. Substation insulators are exposed to the external environment for a long time, and dirt is easy to deposit on the surface. These dirt are prone to pollution flashover accidents when they are damaged by bad weather. According to statistics, insulation flashover accidents caused by pollution have now taken the second place in the total number of power grid accidents. From 1971 to 1994, there were 1,768 pollution flashovers in 35-500kV power generation and substations nationwide. The washing operation of insulators with live water can improve the reliability of power supply, reduce power failure losses, and ensure the safety of substations and transmission lines. At the present stage, the washing operation of substation insulators mainly has the following shortcomings:
1、冲洗方式大多是由清洗技术人员手持冲洗设备进入现场进行作业,人工冲洗不仅依赖于天气情况,还需要清洗人员具备较高技术水平及熟练的操作流程,对绝缘子进行带电水冲洗时需要高规格的安全防护,以避免短路电流造成的安全事故,引发人员伤亡,这类作业方式存在安全隐患;1. Most of the cleaning methods are carried out by cleaning technicians who enter the site with hand-held cleaning equipment. Manual cleaning not only depends on the weather conditions, but also requires cleaning personnel to have a high technical level and skilled operation procedures. Standardized safety protection to avoid safety accidents caused by short-circuit current, causing casualties. This type of operation method has potential safety hazards;
2、人工作业面临着劳动强度大,效率低,自动化水平低等诸多问题;2. Manual operations are faced with many problems such as high labor intensity, low efficiency, and low level of automation;
3、无法对水阻率、水压、水柱长度的实时在线监测,无法实时修改机器人运行状态,不能保证水冲洗过程中机器人本体及变电站带电设备的绝缘性能;3. It is impossible to monitor the water resistance rate, water pressure, and water column length in real time, to modify the operating status of the robot in real time, and to guarantee the insulation performance of the robot body and live equipment in the substation during the water flushing process;
4、无自动化的控制系统,保持供电的连续性和水冲洗机器人一直与绝缘子保持安全距离;4. There is no automatic control system to maintain the continuity of power supply and the water washing robot to keep a safe distance from the insulator;
因此研发能够实现用于水冲洗机器人的安全防护系统是非常有必要的,是符合时代发展要求的。Therefore, it is very necessary to develop a safety protection system that can be used for water washing robots, and it is in line with the development requirements of the times.
发明内容Contents of the invention
本发明为了解决上述问题,提出了一种变电站带电水冲洗机器人用安全防护系统及方法,该系统可代替操作人员,在不停电的情况下对变电站设备进行机器人带电水冲洗作业,其可有效减轻人工清洗工作的繁重体力劳动,保证操作人员的人身安全,保证电网的安全运行。In order to solve the above problems, the present invention proposes a safety protection system and method for a substation charged water washing robot. The heavy physical labor of manual cleaning work ensures the personal safety of operators and the safe operation of the power grid.
为了实现上述目的,本发明采用如下技术方案:In order to achieve the above object, the present invention adopts the following technical solutions:
一种变电站带电水冲洗机器人用安全防护系统,包括行走控制系统和安全控制系统,行走控制系统包括遥控模块、车载控制器和信息采集模块,所述遥控模块与车载控制器之间通过无线方式连接,用于控制水洗机器人的垂直升降机构和行走机构;所述信息采集模块采集装设于水冲洗机器人上的各个传感器测得的信号,安全控制系统基于对绝缘安全造成影响的因素,控制机器人与绝缘子串之间的距离保持在安全距离之内,安全控制系统包括超声传感器、激光测距仪、水电阻率传感器、水压传感器及磁场测距传感器,超声传感器和磁场测距传感器安装在机械臂末端的四个面上,用于检测机械臂末端与带电设备间的距离,激光测距仪与水枪平行安装,实时检测水冲洗过程中水柱的长度,水电阻率传感器及水压传感器安装在高压纯水制备设备之上,用于实时检测冲洗过程中水的压力和水的导电性能。A safety protection system for a substation charged water washing robot, including a walking control system and a safety control system. The walking control system includes a remote control module, a vehicle-mounted controller, and an information collection module. The remote control module and the vehicle-mounted controller are connected wirelessly , used to control the vertical lifting mechanism and the walking mechanism of the water washing robot; the information collection module collects the signals measured by each sensor installed on the water washing robot, and the safety control system controls the robot and the The distance between the insulator strings is kept within a safe distance. The safety control system includes ultrasonic sensors, laser rangefinders, water resistivity sensors, water pressure sensors and magnetic field distance sensors. The ultrasonic sensors and magnetic field distance sensors are installed on the mechanical arm. The four surfaces of the end are used to detect the distance between the end of the mechanical arm and the live equipment. The laser range finder is installed in parallel with the water gun to detect the length of the water column in real time during the water flushing process. The water resistivity sensor and the water pressure sensor are installed on the high pressure On pure water preparation equipment, it is used to detect the pressure of water and the conductivity of water in the flushing process in real time.
所述车载控制器布置在水冲洗机器人移动底盘之上,电控开关是车载控制器的末端执行机构,当电控开关位于中位,此时电控开关控制电动机停止运动;当输入电压大于中位电压时,控制电动机正向旋转,当输入电压小于中位电压时,控制电动机反向旋转,通过TRIO控制器(为英国生产的翠欧运动控制器)IO输出口与垂直升降机构的电控开关输入口连接,通过控制TRIO控制器输出口的输出电压,实现机器人电气执行机构的运动方向及运动速度的控制。The on-board controller is arranged on the mobile chassis of the water washing robot, and the electric control switch is the terminal actuator of the on-board controller. When the electric control switch is in the middle position, the electric control switch controls the motor to stop moving; when the input voltage is greater than the middle When the input voltage is lower than the median voltage, the motor is controlled to rotate in the forward direction. When the input voltage is lower than the median voltage, the motor is controlled to rotate in the opposite direction. The switch input port is connected, and by controlling the output voltage of the TRIO controller output port, the control of the motion direction and motion speed of the robot's electrical actuator is realized.
所述遥控模块包括由工控机、触摸屏、遥控手柄和按键,在控制系统中,一方面,遥控手柄、触摸屏和按键均与工控机连接,通过无线WIFI向TRIO控制器下发垂直升降机构的控制命令,实现机开环控制;另一方面,工控机、TRIO控制器、电控开关及云台的角度传感器又组成闭环控制系统,实现对垂直升降机构的二级机械臂的闭环伺服控制。The remote control module includes an industrial computer, a touch screen, a remote control handle and buttons. In the control system, on the one hand, the remote control handle, touch screen and buttons are all connected to the industrial computer, and the control of the vertical lifting mechanism is issued to the TRIO controller through wireless WIFI. On the other hand, the industrial computer, TRIO controller, electric control switch and the angle sensor of the pan/tilt form a closed-loop control system to realize the closed-loop servo control of the secondary mechanical arm of the vertical lifting mechanism.
所述信息采集模块及车载控制器的角度传感器采集垂直升降机构的升降高度及云台的角度信息,通过串口服务器将RS485协议数据转换为TCP协议数据,并通过HUB将数据发送至无线AP模块,进而实现与遥控端工控机的实时通讯。The angle sensor of the information collection module and the on-board controller collects the lifting height of the vertical lifting mechanism and the angle information of the cloud platform, converts the RS485 protocol data into TCP protocol data through the serial port server, and sends the data to the wireless AP module through the HUB, And then realize the real-time communication with the industrial computer at the remote control end.
所述信息采集模块布置在水冲洗机器人水枪云台之上,信息采集模块通过无线CLIENT与主控模块中的无线AP模块建立WIFI通讯连接,信息采集模块通过串口服务器采集绝对值角度编码器获取的云台俯仰、云台倾角数据,并通过WIFI网络上传至遥控模块的工控机中,实现从而水枪云台上传感器信息的实时采集。The information collection module is arranged on the water washing robot water gun platform, the information collection module establishes a WIFI communication connection with the wireless AP module in the main control module through the wireless CLIENT, and the information collection module collects the absolute value angle encoder through the serial port server. The gimbal pitch and gimbal inclination data are uploaded to the industrial computer of the remote control module through the WIFI network to realize real-time collection of sensor information on the water gun gimbal.
所述信息采集模块通过串口服务器采集绝对值角度编码器获取的云台俯仰及云台倾角数据,并通过WIFI网络上传至遥控模块的工控机中;The information collection module collects the pan-tilt pitch and pan-tilt inclination data obtained by the absolute value angle encoder through the serial port server, and uploads to the industrial computer of the remote control module through the WIFI network;
所述遥控模块包括工控机,工控机收集信息采集模块采集的传感器信息,通过TRIO控制器实现垂直升降机构及车体的控制。The remote control module includes an industrial computer, and the industrial computer collects the sensor information collected by the information acquisition module, and realizes the control of the vertical lifting mechanism and the car body through the TRIO controller.
所述无线方式为采用无线AP模块和无线CLIENT设备。The wireless way is to use wireless AP module and wireless CLIENT equipment.
所述超声传感器、磁场测距传感器及激光测距仪均通过HUB及无线AP模块将数据上传至工控机。The ultrasonic sensor, the magnetic field ranging sensor and the laser rangefinder all upload data to the industrial computer through the HUB and the wireless AP module.
所述垂直升降机构与带电设备间的距离大于变电站规定的安全工作距离。The distance between the vertical lifting mechanism and the live equipment is greater than the safe working distance specified by the substation.
所述激光测距仪采用红色激光,其光源光斑为1mm*1mm,测量距离1.5m至8m,测量时间为1至5毫秒。The laser range finder adopts red laser, the light source spot is 1mm*1mm, the measurement distance is 1.5m to 8m, and the measurement time is 1 to 5 milliseconds.
一种基于上述安全防护系统的工作方法,具体为:A working method based on the above-mentioned safety protection system, specifically:
遥控系统控制工控机,使动力总成驱动车体行走机构运动,安全控制系统基于对绝缘安全造成影响的因素,控制机器人与绝缘子串之间的距离保持在安全距离之内,当水枪架上的激光测距仪,检测到水枪与需要冲洗的绝缘子的水平距离满足安全距离后,车载控制器控制垂直升降机构进行竖直方向上的伸缩运动,以使水枪与绝缘子之间的距离满足冲洗距离,进行冲洗;跟踪摄像机实时观察水枪的状态,遥控系统控制云台的旋转,使水枪进行水平和俯仰运动,不断调整水枪的喷射角度,以使冲洗效果达到最好;水电阻率及水压传感器安装在高压纯水制备设备之上,用于实时检测冲洗过程中水的压力和水的导电性能;通过改变水柱的长度来改变绝缘水柱的绝缘性能。The remote control system controls the industrial computer to make the powertrain drive the movement of the car body walking mechanism. The safety control system controls the distance between the robot and the insulator string to keep within a safe distance based on the factors that affect the insulation safety. The laser rangefinder detects that the horizontal distance between the water gun and the insulator that needs to be flushed meets the safety distance, and the on-board controller controls the vertical lifting mechanism to perform vertical telescopic movement so that the distance between the water gun and the insulator meets the flushing distance. Rinse; track the camera to observe the state of the water gun in real time, and the remote control system controls the rotation of the pan/tilt to make the water gun perform horizontal and pitch movements, and constantly adjust the spray angle of the water gun to achieve the best flushing effect; install water resistivity and water pressure sensors On top of high-pressure pure water preparation equipment, it is used to detect the pressure of water and the conductivity of water in the flushing process in real time; the insulation performance of the insulating water column can be changed by changing the length of the water column.
所述对绝缘安全造成影响的因素包括水的电阻率、水柱的长度和机械臂与带电设备间的距离,其中水电阻率应大于500千欧每厘米;水柱长度应不小于2米,机械臂与带电设备间的距离应大于变电站规定的安全工作距离。The factors that affect the insulation safety include the resistivity of water, the length of the water column and the distance between the mechanical arm and the live equipment, wherein the resistivity of the water should be greater than 500 kohms per centimeter; The distance from live equipment should be greater than the safe working distance specified by the substation.
所述水柱的电阻与水柱的横截面积成反比,与水柱长度成正比,绝缘水柱的电阻的计算公式如下:The resistance of the water column is inversely proportional to the cross-sectional area of the water column and proportional to the length of the water column. The formula for calculating the resistance of the insulating water column is as follows:
R=r×L/AR=r×L/A
其中r为水的电阻率,其含义为截面面积为一平方厘米,长度为一厘米的水柱的电阻值,L为水柱的长度,A为水柱的截面面积,R为水柱的电阻值;Wherein r is the resistivity of water, and its implication is that the cross-sectional area is one square centimeter, the resistance value of the water column that is one centimeter in length, L is the length of the water column, A is the cross-sectional area of the water column, and R is the resistance value of the water column;
在喷枪喷嘴口径一定的情况下,水柱的截面面积为一常数,在水的电阻率r变化时,可以通过改变水冲洗机器人喷嘴与设备间的距离,改变绝缘水柱的长度L,从而实现水柱绝缘性能的调节。When the nozzle diameter of the spray gun is constant, the cross-sectional area of the water column is a constant. When the resistivity r of the water changes, the length L of the insulating water column can be changed by changing the distance between the nozzle of the water washing robot and the equipment, so as to realize the insulation of the water column. performance tuning.
所述水柱的长度的自动控制算法为一双闭环控制算法,内环为作业距离和压力环,外环为水阻率环,当高纯水水阻率发生变化时,在线式水阻率传感器检测到该变化,通过事先通过实验建立好的水阻率与作业距离、喷水压力的专家系统得到与之对应的理想作业距离和喷水压力信息,由此进入内环系统,一方面通过激光测距仪的实时反馈信息,实现对作业距离的闭环控制,另一方面通过压力传感器返回的压力信息,实现对压力装置的输出压力的控制,进而实现对水冲洗机器人绝缘水柱绝缘性能的自动控制。The automatic control algorithm of the length of the water column is a double closed-loop control algorithm, the inner ring is the working distance and pressure ring, and the outer ring is the water resistivity ring. When the water resistivity of high-purity water changes, the online water resistivity sensor detects the Change, through the expert system of water resistivity, working distance and water spray pressure established through experiments in advance, the corresponding ideal working distance and water spray pressure information is obtained, and then enter the inner ring system, on the one hand, through the laser rangefinder The real-time feedback information realizes the closed-loop control of the working distance. On the other hand, the pressure information returned by the pressure sensor realizes the control of the output pressure of the pressure device, and then realizes the automatic control of the insulation performance of the water washing robot insulation water column.
本发明的有益效果为:The beneficial effects of the present invention are:
(1)本发明代替操作人员,在不停电的情况下对变电站设备进行带电水冲洗作业,其可有效减轻人工清洗工作的繁重体力劳动,保证操作人员的人身安全,同时通过对设备污秽的清洗,防止设备污闪事故、保证电网的安全运行;(1) The present invention replaces the operator, and performs the charged water flushing operation on the substation equipment without power failure, which can effectively reduce the heavy physical labor of manual cleaning work, ensure the personal safety of the operator, and at the same time clean the dirty equipment , to prevent equipment pollution flashover accidents and ensure the safe operation of the power grid;
(2)本发明采用多传感器融合技术,实现水冲洗过程的自动实现,提高水冲洗作业的自动化和智能化水平;(2) The present invention adopts multi-sensor fusion technology to realize the automatic realization of the water flushing process and improve the automation and intelligence level of the water flushing operation;
(3)本发明可实现水阻率、水压、水柱长度的实时在线监测,保证水冲洗过程中机器人本体及变电站带电设备的绝缘性能,有效提高了水冲洗作业的安全性。(3) The present invention can realize real-time on-line monitoring of water resistivity, water pressure, and water column length, ensure the insulation performance of the robot body and the live equipment of the substation during the water flushing process, and effectively improve the safety of the water flushing operation.
附图说明Description of drawings
图1为本发明的整体方框图;Fig. 1 is an overall block diagram of the present invention;
图2为本发明的机器人控制系统车载控制器与遥控模块方框图;Fig. 2 is a block diagram of a robot control system vehicle-mounted controller and a remote control module of the present invention;
图3为本发明的控制系统框图;Fig. 3 is a control system block diagram of the present invention;
图4为本发明的安全控制系统示意图;Fig. 4 is a schematic diagram of the safety control system of the present invention;
图5为本发明的自动控制算法流程图。Fig. 5 is a flowchart of the automatic control algorithm of the present invention.
具体实施方式:Detailed ways:
下面结合附图与实施例对本发明作进一步说明。The present invention will be further described below in conjunction with the accompanying drawings and embodiments.
如图1-3所示,一种变电站带电水冲洗机器人包括机器人本体和机器人控制系统。As shown in Figure 1-3, a substation live water washing robot includes a robot body and a robot control system.
一种变电站带电水冲洗机器人包括:车体行走机构、动力总成、垂直升降机构、水枪冲洗机构、电气控制系统等组成;其中,车体行走机构为履带式移动底盘结构,动力总成采用柴油机提供动力,安装于移动底盘上,垂直升降机构连接在车体移动机构前端,垂直升降机构安装有两级伸缩臂,两级伸缩臂的上臂通过绝缘支柱与水枪冲洗机构的工作云台相连;电气控制系统包括车载子系统和遥控子系统,遥控子系统与车载子系统相配合,通过无线方式远程完成对机器人垂直升降机构及水枪冲洗机构的控制。A substation electrified water washing robot includes: a car body traveling mechanism, a power assembly, a vertical lifting mechanism, a water gun washing mechanism, an electrical control system, etc.; wherein, the car body traveling mechanism is a crawler-type mobile chassis structure, and the power assembly adopts a diesel engine It provides power and is installed on the mobile chassis. The vertical lifting mechanism is connected to the front end of the moving mechanism of the car body. The vertical lifting mechanism is equipped with two-stage telescopic arms. The control system includes a vehicle-mounted subsystem and a remote control subsystem. The remote control subsystem cooperates with the vehicle-mounted subsystem to remotely complete the control of the robot's vertical lifting mechanism and water gun flushing mechanism through wireless means.
车体行走机构主要由履带底盘、左行走马达、右行走马达、驱动轮、从动轮、承重轮、履带、张紧缓冲装置组成,左行走马达和右行走马达通过螺栓连接在履带底盘支架上,驱动轮通过驱动轴与行走马达联接,从动轮、承重轮与张紧缓冲装置分别通过旋转轴与履带底盘支架联接,履带套在驱动轮、从动轮、承重轮与张紧缓冲装置的外侧,底盘左边为液压油箱,右边为柴油箱。The traveling mechanism of the car body is mainly composed of a crawler chassis, a left traveling motor, a right traveling motor, a driving wheel, a driven wheel, a load-bearing wheel, a crawler belt, and a tension buffer device. The left traveling motor and the right traveling motor are connected to the crawler chassis bracket by bolts. The driving wheel is connected with the travel motor through the drive shaft, and the driven wheel, load-bearing wheel and tension buffer device are respectively connected with the track chassis bracket through the rotating shaft. The hydraulic oil tank is on the left and the diesel tank is on the right.
一种变电站带电水冲洗机器人用安全防护系统,包括行走控制系统和安全控制系统,行走控制系统包括遥控模块、车载控制器和信息采集模块,所述遥控模块与车载控制器之间通过无线方式连接,用于控制水洗机器人的垂直升降机构和行走机构;所述信息采集模块采集装设于水冲洗机器人上的各个传感器测得的信号,安全控制系统基于对绝缘安全造成影响的因素,控制机器人与绝缘子串之间的距离保持在安全距离之内,安全控制系统包括超声传感器、激光测距仪、水电阻率传感器、水压传感器及磁场测距传感器,超声传感器和磁场测距传感器安装在机械臂末端的四个面上,用于检测机械臂末端与带电设备间的距离,激光测距仪与水枪平行安装,实时检测水冲洗过程中水柱的长度,水电阻率传感器及水压传感器安装在高压纯水制备设备之上,用于实时检测冲洗过程中水的压力和水的导电性能。A safety protection system for a substation charged water washing robot, including a walking control system and a safety control system. The walking control system includes a remote control module, a vehicle-mounted controller, and an information collection module. The remote control module and the vehicle-mounted controller are connected wirelessly , used to control the vertical lifting mechanism and the walking mechanism of the water washing robot; the information collection module collects the signals measured by each sensor installed on the water washing robot, and the safety control system controls the robot and the The distance between the insulator strings is kept within a safe distance. The safety control system includes ultrasonic sensors, laser rangefinders, water resistivity sensors, water pressure sensors and magnetic field distance sensors. The ultrasonic sensors and magnetic field distance sensors are installed on the mechanical arm. The four surfaces of the end are used to detect the distance between the end of the mechanical arm and the live equipment. The laser range finder is installed in parallel with the water gun to detect the length of the water column in real time during the water flushing process. The water resistivity sensor and the water pressure sensor are installed on the high pressure On pure water preparation equipment, it is used to detect the pressure of water and the conductivity of water in the flushing process in real time.
车载控制器布置在水冲洗机器人移动底盘之上,电控开关是车载控制器的末端执行机构,当电控开关位于中位,此时电控开关控制电动机停止运动;当输入电压大于中位电压时,控制电动机正向旋转,当输入电压小于中位电压时,控制电动机反向旋转,通过TRIO控制器IO输出口与垂直升降机构的电控开关输入口连接,通过控制TRIO控制器输出口的输出电压,实现机器人电气执行机构的运动方向及运动速度的控制。The on-board controller is arranged on the mobile chassis of the water washing robot. The electric control switch is the terminal actuator of the on-board controller. When the electric control switch is in the middle position, the electric control switch controls the motor to stop moving; when the input voltage is greater than the middle voltage When the input voltage is lower than the median voltage, the motor is controlled to rotate in the reverse direction. The IO output port of the TRIO controller is connected to the input port of the electric control switch of the vertical lifting mechanism, and the output port of the TRIO controller is controlled. The output voltage realizes the control of the movement direction and movement speed of the electric actuator of the robot.
遥控模块包括由工控机、触摸屏、遥控手柄和按键,在控制系统中,一方面,遥控手柄、触摸屏和按键均与工控机连接,通过无线WIFI向TRIO控制器下发垂直升降机构的控制命令,实现机开环控制;另一方面,工控机、TRIO控制器、电控开关及云台的角度传感器又组成闭环控制系统,实现对垂直升降机构的二级机械臂的闭环伺服控制。The remote control module includes an industrial computer, a touch screen, a remote control handle and buttons. In the control system, on the one hand, the remote control handle, touch screen and buttons are all connected to the industrial computer, and the control command of the vertical lifting mechanism is sent to the TRIO controller through wireless WIFI. Realize the open-loop control of the machine; on the other hand, the industrial computer, TRIO controller, electric control switch and the angle sensor of the pan-tilt form a closed-loop control system to realize the closed-loop servo control of the secondary mechanical arm of the vertical lifting mechanism.
信息采集模块及车载控制器的角度传感器采集垂直升降机构的升降高度及云台的角度信息,通过串口服务器将RS485协议数据转换为TCP协议数据,并通过HUB将数据发送至无线AP模块,进而实现与遥控端工控机的实时通讯。The information acquisition module and the angle sensor of the on-board controller collect the lifting height of the vertical lifting mechanism and the angle information of the pan-tilt, convert the RS485 protocol data into TCP protocol data through the serial port server, and send the data to the wireless AP module through the HUB, and then realize Real-time communication with the remote industrial computer.
信息采集模块布置在水冲洗机器人水枪云台之上,信息采集模块通过无线CLIENT与主控模块中的无线AP模块建立WIFI通讯连接,信息采集模块通过串口服务器采集绝对值角度编码器获取的云台俯仰、云台倾角数据,并通过WIFI网络上传至遥控模块的工控机中,实现从而水枪云台上传感器信息的实时采集。The information collection module is arranged on the water gun pan/tilt of the water washing robot. The information collection module establishes a WIFI communication connection with the wireless AP module in the main control module through the wireless CLIENT. The information collection module collects the pan/tilt obtained by the absolute value angle encoder through the serial port server. The pitch and tilt angle data of the gimbal are uploaded to the industrial computer of the remote control module through the WIFI network, so as to realize the real-time collection of sensor information on the gimbal of the water gun.
信息采集模块通过串口服务器采集绝对值角度编码器获取的云台俯仰及云台倾角数据,并通过WIFI网络上传至遥控模块的工控机中;The information collection module collects the pan-tilt pitch and pan-tilt inclination data obtained by the absolute value angle encoder through the serial port server, and uploads them to the industrial computer of the remote control module through the WIFI network;
遥控模块包括工控机,工控机收集信息采集模块采集的传感器信息,通过TRIO控制器实现垂直升降机构及车体的控制。The remote control module includes an industrial computer, and the industrial computer collects the sensor information collected by the information acquisition module, and realizes the control of the vertical lifting mechanism and the car body through the TRIO controller.
无线方式为采用无线AP模块和无线CLIENT设备。The wireless way is to use wireless AP module and wireless CLIENT equipment.
超声传感器、磁场测距传感器及激光测距仪均通过HUB及无线AP模块将数据上传至工控机。Ultrasonic sensors, magnetic field ranging sensors and laser rangefinders all upload data to the industrial computer through the HUB and wireless AP module.
垂直升降机构与带电设备间的距离应大于变电站规定的安全工作距离。The distance between the vertical lifting mechanism and the live equipment should be greater than the safe working distance specified by the substation.
激光测距仪采用红色激光,其光源光斑为1mm*1mm,测量距离1.5m至8m,测量时间为1至5毫秒,测量结果通过RS232信号传输,其与水枪平行安装,可以实时检测水冲洗过程中水柱的长度;水电阻率及水压传感器安装在高压纯水制备设备之上,用于实时检测冲洗过程中水的压力和水的导电性能。The laser rangefinder uses a red laser, its light source spot is 1mm*1mm, the measurement distance is 1.5m to 8m, and the measurement time is 1 to 5 milliseconds. The measurement results are transmitted through RS232 signals. It is installed in parallel with the water gun, which can detect the water washing process in real time. The length of the water column; the water resistivity and water pressure sensors are installed on the high-pressure pure water preparation equipment for real-time detection of water pressure and water conductivity during the flushing process.
本发明设计了一套变电站带电水冲洗辅冲机器人安全控制系统,如图4所示。该安全控制系统主要包括:超声传感器、磁场测距传感器、激光测距仪、水阻率传感器、水压传感器、串口服务器、工控机及无线AP和无线CLIENT组成。其中无线AP和无线CLIENT模块用于构建WIFI网络,实现各模块间数据的交互。The present invention designs a set of substation electrified water flushing auxiliary flushing robot safety control system, as shown in Figure 4. The safety control system mainly includes: ultrasonic sensor, magnetic field distance sensor, laser distance meter, water resistivity sensor, water pressure sensor, serial port server, industrial computer, wireless AP and wireless CLIENT. Among them, the wireless AP and wireless CLIENT modules are used to build a WIFI network to realize data interaction between modules.
超声测距传感器和磁场测距传感器安装在机械臂末端的四个面上,用于检测机械臂末端与带电设备间的距离,其中磁场测距传感器利用带电设备周围磁场强度的分布,实现机械臂与带电设备间距离的实时检测,解决在潮湿天气条件下带电设备绝缘距离缩小的问题;当系统检测到机械臂与设备间的距离小于安全工作距离时,可以及时向操作人员反馈危险信息,并在必要时停止机器人的作业。The ultrasonic ranging sensor and the magnetic field ranging sensor are installed on the four surfaces of the end of the manipulator to detect the distance between the end of the manipulator and the charged equipment. The magnetic field ranging sensor utilizes the distribution of the magnetic field strength around the live equipment to realize the The real-time detection of the distance between the live equipment and the live equipment solves the problem of shrinking the insulation distance of the live equipment under wet weather conditions; when the system detects that the distance between the mechanical arm and the equipment is less than the safe working distance, it can promptly feed back danger information to the operator, and Stop the robot's work when necessary.
激光测距仪采用红色激光,其光源光斑为1mm*1mm,测量距离1.5m至8m,测量时间为1至5毫秒,测量结果通过RS232信号传输,其与水枪平行安装,可以实时检测水冲洗过程中水柱的长度;水电阻率及水压传感器安装在高压纯水制备设备之上,用于实时检测冲洗过程中水的压力和水的导电性能。The laser rangefinder uses a red laser, its light source spot is 1mm*1mm, the measurement distance is 1.5m to 8m, and the measurement time is 1 to 5 milliseconds. The measurement results are transmitted through RS232 signals. It is installed in parallel with the water gun, which can detect the water washing process in real time. The length of the water column; the water resistivity and water pressure sensors are installed on the high-pressure pure water preparation equipment for real-time detection of water pressure and water conductivity during the flushing process.
变电站水冲洗机器人喷射的高阻率水柱是其绝缘方式的一种,而水柱的绝缘性能受水的电阻率、水柱的长度,喷嘴的口径等因素的影响,其中任何一个因素发生变化时,都可能导致系统的绝缘性能下降,此时必须通过相应措施来弥补该绝缘性能的损失。实验证明,通过改变水柱的长度来改变绝缘水柱的绝缘性能是最可行,也是最有效的方法。The high-resistivity water column sprayed by the substation water washing robot is one of its insulation methods, and the insulation performance of the water column is affected by factors such as the resistivity of the water, the length of the water column, and the diameter of the nozzle. When any of these factors change, the It may lead to a decrease in the insulation performance of the system. At this time, corresponding measures must be taken to compensate for the loss of insulation performance. Experiments have proved that it is the most feasible and effective method to change the insulation performance of the insulating water column by changing the length of the water column.
理论上,水柱的电阻与水柱的横截面积成反比,与水柱长度成正比。绝缘水柱的电阻的计算也是如此,其公式如下:In theory, the resistance of the water column is inversely proportional to the cross-sectional area of the water column and directly proportional to the length of the water column. The same is true for the calculation of the resistance of the insulating water column, the formula is as follows:
R=r×L/AR=r×L/A
其中r为水的电阻率,其含义为截面面积为一平方厘米,长度为一厘米的水柱的电阻值,L为水柱的长度,A为水柱的截面面积,R为水柱的电阻值。Where r is the resistivity of water, which means the resistance value of a water column with a cross-sectional area of one square centimeter and a length of one centimeter, L is the length of the water column, A is the cross-sectional area of the water column, and R is the resistance value of the water column.
在喷枪喷嘴口径一定的情况下,水柱的截面面积为一常数,从绝缘水柱的电阻值的公式可以看出,在水的电阻率r变化时,可以通过改变水冲洗机器人喷嘴与设备间的距离,改变绝缘水柱的长度L,从而实现水柱绝缘性能的调节。本发明采用一种变电站水冲洗机器人绝缘水柱自动控制算法,实现机械臂和压力装置的智能调节,改变水冲洗机器人喷嘴与设备间的距离,从而改变绝缘水柱的长度,保证足够的绝缘性能。When the nozzle diameter of the spray gun is constant, the cross-sectional area of the water column is a constant. From the formula of the resistance value of the insulating water column, it can be seen that when the resistivity r of the water changes, the distance between the nozzle of the water flushing robot and the equipment can be changed. , to change the length L of the insulating water column, so as to realize the adjustment of the insulating performance of the water column. The invention adopts an automatic control algorithm of the insulating water column of the substation water washing robot, realizes the intelligent adjustment of the mechanical arm and the pressure device, changes the distance between the nozzle of the water washing robot and the equipment, thereby changes the length of the insulating water column, and ensures sufficient insulation performance.
如图5所示,为变电站水冲洗机器人绝缘水柱自动控制算法的原理图,由原理图可知,该算法为一双闭环控制算法,内环为作业距离和压力环,外环为水阻率环。当高纯水由于某种原因水阻率发生变化时,在线式水阻率传感器检测到该变化,通过查找专家系统中事先通过大量实验建立的水阻率与作业距离、喷水压力的数据关系表,得到与之对应的理想作业距离和喷水压力信息,由此进入内环系统,一方面通过激光测距仪的实时反馈信息,实现对作业距离的闭环控制,另一方面通过压力传感器返回的压力信息,实现对压力装置的输出压力的控制,进而实现对水冲洗机器人绝缘水柱绝缘性能的自动控制。As shown in Figure 5, it is the schematic diagram of the automatic control algorithm of the insulating water column of the substation water washing robot. From the schematic diagram, it can be seen that the algorithm is a double closed-loop control algorithm, the inner loop is the working distance and pressure loop, and the outer loop is the water resistance loop. When the water resistivity of high-purity water changes due to some reason, the online water resistivity sensor detects the change. By searching the data relationship table of water resistivity, working distance and spray pressure established in the expert system in advance through a large number of experiments, Get the corresponding ideal working distance and water spray pressure information, and then enter the inner loop system. On the one hand, through the real-time feedback information of the laser rangefinder, the closed-loop control of the working distance is realized; on the other hand, the pressure returned by the pressure sensor Information, to realize the control of the output pressure of the pressure device, and then realize the automatic control of the insulation performance of the water washing robot insulation water column.
本发明所述水冲洗机器人样机已经研制成功。其顺利通过了实验室内220KV等级高压、及电磁环境测试,并已顺利在220KV实验变电站内得到试验性应用,试验性应用表明,该控制系统能满足变电站带电水冲洗辅冲机器人的控制需求,并保证水冲洗机器人和被冲设备的运行安全。The water washing robot prototype of the present invention has been successfully developed. It has successfully passed the 220KV level high-voltage and electromagnetic environment tests in the laboratory, and has been successfully applied in the 220KV experimental substation. The experimental application shows that the control system can meet the control requirements of the auxiliary flushing robot for live water washing in the substation. And ensure the safe operation of the water washing robot and the equipment being washed.
本发明提供了一种变电站水冲洗机器人智能控制系统,该系统基于物联网技术和多传感器融合技术,构建变电站水冲洗机器人智能控制系统,采用该控制系统可以使变电站巡检机器人代替人的完成220kV变电站带电作业频率高的绝缘子水冲洗任务,一方面可减轻作业人员的劳动强度,另一方面也为作业人员的安全提供了保证的变电站水冲洗机器人无线遥控系统。后续将机器视觉技术引入该系统,利用图像处理、模式识别等功能,实现冲洗设备的自动识别,并利用视觉伺服技术进一步提高系统的智能型和自主性,随着系统的性能的不断提高,相信系统将会有相当大的应用空间。The invention provides an intelligent control system for a substation water flushing robot. The system is based on the Internet of Things technology and multi-sensor fusion technology to build an intelligent control system for a substation water flushing robot. Using the control system, the substation inspection robot can replace humans to complete 220kV The insulator water washing task with high frequency of live work in substations can reduce the labor intensity of operators on the one hand, and provide a wireless remote control system for water washing robots in substations that guarantees the safety of operators on the other hand. In the future, machine vision technology will be introduced into the system, image processing, pattern recognition and other functions will be used to realize automatic recognition of washing equipment, and visual servo technology will be used to further improve the intelligence and autonomy of the system. With the continuous improvement of system performance, it is believed that The system will have a considerable application space.
上述虽然结合附图对本发明的具体实施方式进行了描述,但并非对本发明保护范围的限制,所属领域技术人员应该明白,在本发明的技术方案的基础上,本领域技术人员不需要付出创造性劳动即可做出的各种修改或变形仍在本发明的保护范围以内。Although the specific implementation of the present invention has been described above in conjunction with the accompanying drawings, it does not limit the protection scope of the present invention. Those skilled in the art should understand that on the basis of the technical solution of the present invention, those skilled in the art do not need to pay creative work Various modifications or variations that can be made are still within the protection scope of the present invention.
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