CN108680647B - Ultrasonic flaw detection robot for large spherical tank steel container - Google Patents
Ultrasonic flaw detection robot for large spherical tank steel container Download PDFInfo
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
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- G—PHYSICS
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- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
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- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/265—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
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- G—PHYSICS
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Abstract
The invention discloses an ultrasonic flaw detection robot for a large spherical tank steel container, which comprises a robot body, an image acquisition device, an adsorption device, a flaw detection device and a control system, wherein the robot body comprises a machine body frame and an elastic connection structure; the image acquisition device acquires the weld joint characteristics and transmits the acquired image to the control system for processing; the control system receives the image acquired by the image acquisition device, extracts a central line by identifying a welding line on the wall surface of the container, and realizes the functions of moving and detecting the robot according to the central line; the robot can automatically search the wall surface welding line to move, and detect the welding line, can replace manual work to carry out high-altitude operation, avoids the danger of manual operation, and has flexible action on the metal wall surface and high working efficiency.
Description
Technical Field
The invention belongs to the technical field of industrial special robots, and particularly relates to an ultrasonic flaw detection robot for a large spherical tank steel container.
Background
With the development of the industrial level, especially in the petrochemical industry, more and more large steel spherical tanks are used for industrial production, and the spherical tanks are used for storing various flammable and combustible liquid and gas raw materials. Therefore, the requirement on the safety of the large spherical tank container is higher and higher, the large spherical tank container is produced by welding all parts, a plurality of welding seams can appear, and because a plurality of accidents are caused by the welding seams, in order to ensure the safety of the production process, the welding seams of the spherical tank container need to be detected to check whether the interior of the spherical tank container has defects. The detection workload is large, the manual detection efficiency is low, the operation is required to be carried out at a high place, and certain dangerousness is realized.
Along with the development of the robot technology, the robot is applied to various fields, the wall-climbing robot can be adsorbed on a wall surface to move, and the robot is used for replacing manpower to complete high-altitude operation and is the current trend which cannot be blocked.
Nondestructive testing detects a material to be tested by means of not damaging the object to be tested, and evaluates the material through corresponding detection indexes. The ultrasonic nondestructive testing method is widely applied due to good safety and high testing precision, ultrasonic waves emitted by the ultrasonic probe are transmitted into a tested object through the coupling agent, and the internal state of the tested object is analyzed through reflected echoes.
Disclosure of Invention
Aiming at the detection work of welding seams of steel containers of spherical tanks in the current industrial production, the invention provides an ultrasonic flaw detection robot for large steel containers of spherical tanks, which can realize tracing navigation of welding seams on wall surfaces and ultrasonic flaw detection of the welding seams.
In order to achieve the purpose, the invention adopts the technical scheme that: an ultrasonic flaw detection robot for a large spherical tank steel container comprises a robot body, an image acquisition device, an adsorption device, a flaw detection device and a control system;
the image acquisition device is an industrial camera, is arranged on the robot body and is used for shooting the weld seam on the wall surface of the steel container of the spherical tank and transmitting the shot image to the control system for processing, so that the function of tracing the weld seam is realized.
The control system receives the wall surface image of the spherical tank steel container sent by the image acquisition device and performs the following processing:
(1) anisotropic filtering processing is carried out on the wall surface image of the steel container of the spherical tank, and the method specifically comprises the following steps:
firstly, calculating gradient values of an image at (m, n) points, and setting I (m, n) as gray values, wherein the gray gradients of the (m, n) points in four directions are as follows:
calculating a diffusion function corresponding to the point (m, n) according to the gradient value of the point (m, n):
the filtering of the image is carried out and,
the pixel value I of the m +1 th point is a constant of the diffusion intensitym+1Comprises the following steps:
(2) binarization processing of an image: determining a segmentation threshold, converting the gray value of the point higher than the threshold into 255, and setting the gray value of the point lower than the threshold as 0;
(3) performing edge detection by using a Sobel operator in image processing, and extracting edge information of an image;
i (M, n) is the gray scale value of the (M, n) point on the image, then the 3 x 3 neighborhood M of point (M, n) is:
performing convolution operation on the Sobel operator through two 3 × 3 matrix operators and 3 × 3 neighborhoods to respectively obtain a transverse gradient value Gx and a longitudinal gradient value Gy:
the gradient value G at point (m, n) is:
setting a threshold value A, wherein when G is greater than A, the pixel is 0, and when G is less than A, the pixel is 255;
(4) and extracting the center line of the welding line from the processed image, and automatically adjusting the running condition of the motor according to the position of the center line.
The robot body comprises a body frame and an elastic connection structure, the body frame comprises a front part, a middle part and a rear part, the three parts are connected through the elastic connection structure in sequence, each part is provided with two wheels, the wheels mounted on the rear part are driving wheels, the wheels mounted on the front part and the middle part are driven wheels, and the robot body is driven to move through the rotation of the driving wheels in the moving process.
The adsorption device is a permanent magnet, five pieces of aluminum-nickel-cobalt permanent magnet alloy are arranged at the bottom of the machine body frame, and two pieces, two pieces and one piece are respectively arranged at the front part, the middle part and the rear part, so that the robot body can be stably adsorbed on the magnetic conduction wall surface of the steel container.
The flaw detection device is arranged at the front part of the machine body frame through a support and comprises a couplant smearing device and an ultrasonic flaw detector probe, the couplant smearing device is arranged at the foremost end, the ultrasonic flaw detector probe is arranged at the second end, and in the working process, the couplant smearing device is used for smearing the couplant on the wall surface, and then the ultrasonic flaw detector probe is used for detecting and detecting the flaw of the wall surface; furthermore, the support is installed in the front of the frame of the machine body through a steering engine, and the position of flaw detection is changed through rotation of the steering engine.
The control system comprises a single chip microcomputer control system and an upper computer control system, the single chip microcomputer control system comprises a control chip, a motor driver, a motor, a power supply and a wireless communication module, the control chip and the motor driver are installed in the middle of the machine body frame, the power supply is installed in the front of the machine body frame, and the motor is installed in the rear of the machine body frame and connected with the driving wheel; the power supply supplies power to each part, the control chip sends a control signal to the motor driver, and the motor driver drives the motor to operate according to the received control signal, so that the overall advancing, retreating and steering functions of the robot are realized; the upper computer control system is built by C # software, and communication between the upper computer and the single chip microcomputer control system is realized through a TCP communication protocol.
The invention has the following advantages:
1. the invention can replace manual work to carry out high-altitude operation, thereby avoiding the danger of manual operation.
2. The invention has flexible action on the metal wall surface and high working efficiency.
3. The invention can carry out communication control through a remote computer, and the control is simple and convenient.
4. The invention can be used for detecting large spherical tank steel containers and other fields, such as search and rescue, exploration and the like.
Drawings
FIG. 1 is a schematic view of the overall structure of an ultrasonic inspection robot according to the present invention;
FIG. 2 is a schematic view showing the mounting of the wheels, motors and permanent magnets of the ultrasonic inspection robot of the present invention;
FIG. 3 is a schematic view showing the installation of a control chip, a power supply and a motor driver of the ultrasonic inspection robot according to the present invention;
FIG. 4 is a hardware block diagram of a control unit according to the present invention;
FIG. 5 is a circuit diagram of a hardware portion of the present invention;
FIG. 6 is a block diagram of an upper computer interface of the control unit of the present invention;
FIG. 7 is a schematic diagram of the obstacle crossing process of the ultrasonic inspection robot of the present invention;
FIG. 8 is a schematic view of a cross-sectional structure of an ultrasonic inspection robot according to the present invention.
Detailed Description
The invention is described in further detail below with reference to the figures and specific examples.
Referring to fig. 1, the ultrasonic flaw detection robot for the large-scale spherical tank steel container provided by the invention comprises a robot body, an image acquisition device, an adsorption device, a flaw detection device and a control system; the robot body comprises a body frame and an elastic connection structure, the adsorption device is arranged at the lower part of the body, the flaw detection device is arranged at the front part of the body, and the control system is arranged in the body; the image acquisition device is an industrial camera, is installed on the robot body and is used for shooting the weld seam on the wall surface of the steel container of the spherical tank and transmitting the shot image to the control system for processing, so that the function of tracing the weld seam is realized. The control system receives the wall surface image of the spherical tank steel container sent by the image acquisition device and performs the following processing:
(1) anisotropic filtering processing is carried out on the wall surface image of the steel container of the spherical tank, and the method specifically comprises the following steps:
firstly, calculating gradient values of an image at (m, n) points, and setting I (m, n) as gray values, wherein the gray gradients of the (m, n) points in four directions are as follows:
calculating a diffusion function corresponding to the point (m, n) according to the gradient value of the point (m, n):
the filtering of the image is carried out and,
the pixel value I of the m +1 th point is a constant of the diffusion intensitym+1Comprises the following steps:
(2) binarization processing of an image: determining a segmentation threshold, converting the gray value of the point higher than the threshold into 255, and setting the gray value of the point lower than the threshold as 0;
(3) performing edge detection by using a Sobel operator in image processing, and extracting edge information of an image;
i (M, n) is the gray scale value of the (M, n) point on the image, then the 3 x 3 neighborhood M of point (M, n) is:
performing convolution operation on the Sobel operator through two 3 × 3 matrix operators and 3 × 3 neighborhoods to respectively obtain a transverse gradient value Gx and a longitudinal gradient value Gy:
the gradient value G at point (m, n) is:
setting a threshold value A, wherein when G is greater than A, the pixel is 0, and when G is less than A, the pixel is 255;
(4) and extracting the center line of the welding line from the processed image, and automatically adjusting the running condition of the motor according to the position of the center line.
Referring to fig. 2, the robot body comprises a body frame 1 and an elastic connection structure 2, the body frame 1 comprises a front part, a middle part and a rear part, the three parts are sequentially connected through the elastic connection structure 2, each part is provided with two wheels, the wheels arranged at the rear part are driving wheels 1-1, the wheels arranged at the front part and the middle part are driven wheels 1-2, and the robot body is driven to move through the rotation of the driving wheels 1-1 in the moving process.
The adsorption device is permanent magnets 1-4, five pieces of aluminum-nickel-cobalt permanent magnet alloy are arranged at the bottom of the machine body frame 1, and two pieces, two pieces and one piece are respectively arranged at the front part, the middle part and the rear part, so that the robot body can be stably adsorbed on the magnetic conduction wall surface of the steel container.
The flaw detection device is arranged at the front part of the machine body frame 1 through a support and comprises a couplant smearing device 4 and an ultrasonic flaw detector probe 3, the couplant smearing device 4 is arranged at the foremost end, and the ultrasonic flaw detector probe 3 is arranged at the second end; further, the support is installed in the front of the fuselage frame 1 through a 180-degree steering engine, and the position of flaw detection can be changed through rotation of the steering engine.
Referring to fig. 3 and 4, the control system comprises a single chip microcomputer control system and an upper computer control system, the single chip microcomputer control system comprises a control chip 2-1, a motor driver 2-3, a motor 1-3, a power supply 2-2 and a wireless communication module, the control chip 2-1 and the motor driver 2-3 are installed in the middle of the machine body frame 1, the power supply 2-2 is installed in the front of the machine body frame 1, and the motor 1-3 is installed in the rear of the machine body frame 1 and connected with the driving wheel 1-1; the power supply 2-2 supplies power to each part, the control chip 2-1 sends a control signal to the motor driver 2-3, and the motor driver 2-3 drives the motor 1-3 to operate according to the received control signal, so that the overall forward, backward and steering functions of the robot are realized; one specific implementation is as follows, but is not limited to:
referring to fig. 5, a control chip 2-1 is an STM32F103, a motor driver 2-3 is an L298N chip, a power supply 2-2 is a 12V direct-current power supply, the direct-current power supply respectively supplies power to the STM32F103 and the L298N chip, when the power supply is supplied to the STM32F103, voltage needs to be converted into 3.3V through a direct-current voltage stabilizing chip, the motor 1-3 is a 12V direct-current speed reducing motor, the STM32F103 sends a PWM signal to the L298N chip, the 12V direct-current speed reducing motor is connected with the L298N chip, and the operation condition of the 12V direct-current speed reducing motor is controlled through the L298.
Referring to fig. 6, which is a block diagram of an interface of an upper computer, the upper computer control system is built by using C # software, and communication between the upper computer and the single chip microcomputer control system is realized through a TCP communication protocol.
Referring to fig. 7 and 8, which are schematic diagrams of obstacle crossing of the robot, a body frame 1 of a robot body is divided into three sections, the three sections are connected through a spring structure, when encountering an obstacle 3-2, the whole structure imitates a centipede movement mode, the body frame 1 encountering the obstacle 3-2 is protruded upwards, the body frame 1 not encountering the obstacle 3-2 is kept in an original state, the whole process can be realized through stretching of the spring structure, and stable operation of the robot body on a steel container wall surface 3-1 is ensured.
The above-described embodiments are intended to illustrate rather than to limit the invention, and any modifications and variations of the present invention are within the spirit of the invention and the scope of the appended claims.
Claims (4)
1. An ultrasonic flaw detection robot for a large spherical tank steel container is characterized by comprising a robot body, an image acquisition device, an adsorption device, a flaw detection device and a control system;
the robot body comprises a body frame (1) and an elastic connecting structure (2), the body frame (1) comprises a front part, a middle part and a rear part, the three parts are sequentially connected through the elastic connecting structure (2), each part is provided with two wheels, the wheel mounted at the rear part is a driving wheel (1-1), the wheels mounted at the front part and the middle part are driven wheels (1-2), and the robot body is driven to move by the rotation of the driving wheels (1-1) in the moving process;
the image acquisition device is arranged on the machine body frame (1) and is used for shooting the weld joint on the wall surface of the steel container of the spherical tank and transmitting the shot image to the control system;
the adsorption device is a permanent magnet (1-4), five pieces of aluminum-nickel-cobalt permanent magnet alloy are arranged at the bottom of the machine body frame (1), and two pieces, two pieces and one piece are respectively arranged at the front part, the middle part and the rear part, so that the robot body can be stably adsorbed on the magnetic conduction wall surface of the steel container;
the flaw detection device is arranged at the front part of the machine body frame (1) through a support and comprises a couplant smearing device (4) and an ultrasonic flaw detector probe (3), the couplant smearing device (4) is arranged at the foremost end, the ultrasonic flaw detector probe (3) is arranged at the second end, and in the working process, the couplant smearing device (4) is firstly used for smearing the couplant on the wall surface, and then the ultrasonic flaw detector probe (3) is used for detecting and detecting the wall surface;
the control system receives the image of the wall surface of the steel container of the spherical tank sent by the image acquisition device, extracts the central line of the welding line according to the image, and automatically adjusts the motion of the robot body according to the position of the central line to realize the tracking function of the welding line; the control system comprises a single chip microcomputer control system and an upper computer control system; the single chip microcomputer control system comprises a control chip (2-1), a motor driver (2-3), a motor (1-3), a power supply (2-2) and a wireless communication module, wherein the control chip (2-1) and the motor driver (2-3) are installed in the middle of the machine body frame (1), the power supply (2-2) is installed in the front of the machine body frame (1), and the motor (1-3) is installed in the rear of the machine body frame (1) and connected with a driving wheel (1-1); the power supply (2-2) supplies power to each part, the control chip (2-1) sends a control signal to the motor driver (2-3), and the motor driver (2-3) drives the motor (1-3) to operate according to the received control signal, so that the overall forward, backward and steering functions of the robot are realized; the upper computer control system realizes the communication between the upper computer and the singlechip control system through a TCP communication protocol;
the control system receives the wall surface image of the spherical tank steel container sent by the image acquisition device and performs the following processing:
(1) anisotropic filtering processing is carried out on the wall surface image of the steel container of the spherical tank, and the method specifically comprises the following steps:
firstly, calculating gradient values of an image at (m, n) points, and setting I (m, n) as gray values, wherein the gray gradients of the (m, n) points in four directions are as follows:
calculating a diffusion function corresponding to the point (m, n) according to the gradient value of the point (m, n):
the filtering of the image is carried out and,
as a constant of the diffusion intensity, the pixel value Im +1 at the m +1 th point is:
(2) binarization processing of an image: determining a segmentation threshold, converting the gray value of the point higher than the threshold into 255, and setting the gray value of the point lower than the threshold as 0;
(3) performing edge detection by using a Sobel operator in image processing, and extracting edge information of an image;
i (M, n) is the gray scale value of the (M, n) point on the image, then the 3 x 3 neighborhood M of point (M, n) is:
performing convolution operation on the Sobel operator through two 3 × 3 matrix operators and 3 × 3 neighborhoods to respectively obtain a transverse gradient value Gx and a longitudinal gradient value Gy:
the gradient value G at point (m, n) is:
a threshold a is set, with a pixel being 0 when G > a and 255 when G < a.
2. The ultrasonic flaw detection robot for the large-scale spherical tank steel container is characterized in that the support is mounted at the front part of the machine body frame (1) through a 180-degree steering engine, and the flaw detection position is changed through the rotation of the steering engine.
3. The ultrasonic inspection robot for the large-scale spherical tank steel container according to claim 1, it is characterized in that the control chip (2-1) adopts STM32F103, the motor driver (2-3) adopts an L298N chip, the power supply (2-2) adopts a 12V direct current power supply, the power supply (2-2) supplies power for the control chip (2-1) and the motor driver (2-3), when supplying power for the control chip (2-1), the voltage is converted into 3.3V through a direct current voltage stabilizing chip, the motor (1-3) adopts a 12V direct current speed reducing motor, the control chip (2-1) sends PWM signals to the motor driver (2-3), the motor (1-3) is connected with the motor driver (2-3), the running conditions of the motors (1-3) are controlled by the motor drivers (2-3).
4. The ultrasonic inspection robot for the large-scale spherical tank steel container as claimed in claim 1, wherein three parts of the body frame (1) of the robot body are connected through spring structures, when an obstacle is encountered, the whole structure imitates the way of centipede movement, the body frame (1) encountering the obstacle protrudes upwards, the body frame (1) not encountering the obstacle keeps the original state, and the whole process is realized through the stretching of the spring structures, so that the stable operation of the robot body is ensured.
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| CN107328859A (en) * | 2017-06-30 | 2017-11-07 | 林幸东 | A kind of cable quality detection means and its method of work |
| CN107336763A (en) * | 2017-07-10 | 2017-11-10 | 上海理工大学 | A kind of comprehensive multi-joint simulating crawling robot |
| CN207336443U (en) * | 2017-10-27 | 2018-05-08 | 河南双发石油装备制造股份有限公司 | Ultrasonic wave metal wall weld seam detection climbs wall device |
| CN207516309U (en) * | 2017-11-16 | 2018-06-19 | 西安石油大学 | One kind is from tracking seam inspection robot |
| CN108100068A (en) * | 2017-12-19 | 2018-06-01 | 北京航空航天大学 | A kind of climbing robot of marmem driving |
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