CN113305864A - Intelligent sand blasting robot for wind power rotor - Google Patents
Intelligent sand blasting robot for wind power rotor Download PDFInfo
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- CN113305864A CN113305864A CN202110867469.5A CN202110867469A CN113305864A CN 113305864 A CN113305864 A CN 113305864A CN 202110867469 A CN202110867469 A CN 202110867469A CN 113305864 A CN113305864 A CN 113305864A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
- B25J11/0075—Manipulators for painting or coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J19/00—Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
- B25J19/02—Sensing devices
- B25J19/021—Optical sensing devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1602—Programme controls characterised by the control system, structure, architecture
- B25J9/161—Hardware, e.g. neural networks, fuzzy logic, interfaces, processor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
- B25J9/1661—Programme controls characterised by programming, planning systems for manipulators characterised by task planning, object-oriented languages
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
Abstract
The invention provides an intelligent sand blasting robot for a wind power rotor. The scheme comprises a control system, a telescopic mechanical arm, a spray gun, an image recognition system, a memory, an online laser speckle roughness measuring instrument and an automatic abrasive switching device, wherein the telescopic mechanical arm comprises a first mechanical arm and a second mechanical arm; the spray gun is arranged at the end part of the first mechanical arm; the first mechanical arm is used for driving the spray gun to move up and down and rotate; the spray gun is used for spraying sand to the surface of a position to be processed on the wind power rotor; the image recognition system is used for scanning the wind power rotor for a circle before the sand blasting work is started, recognizing the information of the wind power rotor and performing the sand blasting work. This scheme is through the rotor of the different models of automatic adaptation when the sandblast to carry out sandblast working method according to the severity of rotor yoke surface burr, corrosion, greasy dirt and select.
Description
Technical Field
The invention relates to the technical field of wind power equipment detection, in particular to an intelligent sand blasting robot for a wind power rotor.
Background
Among the prior art, wind generating set workshop is mainly used the manual work to wind-powered electricity generation rotor sandblast, stands in the rotor inside in the sandblast room by a mill during the operation, holds the spray gun head and carries out the sandblast to the rotor inner wall. The process mainly depends on the experience (for example, visual inspection) of workers in work to judge whether the sand blasting is finished, and then detection personnel detect whether the sand blasting is finished, if the detection is unqualified, the sand blasting equipment needs to be restarted to perform the sand blasting again, and the process is long in time consumption. Meanwhile, when performing the sand blasting operation, the worker wears the whole body protective clothing to avoid the influence of the high-density dust on the body, and even then, the dust is still sucked into the body by the worker. In summer hot weather, the operation mode can cause the workers to feel more uncomfortable.
The follow-up magnetic steel piece that will bond in yoke surface that the sandblast was operated, the roughness yoke of unclean, unsatisfied technological requirement can influence the firmness that the magnetic steel piece bonded, and the firmness is not good can lead to the magnetic steel piece to drop. Once the magnetic steel falls off, foreign matters are clamped between the stator and the rotor of the wind driven generator, the wind driven generator must be disassembled and returned to a factory for maintenance, and only the lifting and transportation cost loss is up to more than 50 ten thousand yuan. The wind driven generator runs in a natural environment, sunlight is directly irradiated in summer, the north in winter is extremely cold, and the expansion with heat and contraction with cold also put forward more strict requirements on the magnetic pole bonding process.
Therefore, the sand blasting process is a critical process in the production process of the wind generating set, and if a robot is adopted to carry out standardized sand blasting operation, the failure risk of magnetic steel bonding can be reduced.
The rotor support of the wind generating set is mostly annular, and the structure is relatively fixed. But the diameters and the heights of the magnetic yokes of the rotor supports of different types of wind generating sets are different. The fixed structural characteristics provide a foundation for the implementation of the universal operation of the robot.
Disclosure of Invention
The invention provides an intelligent sand blasting robot for a wind power rotor, which solves the technical problems that at least the robot can be automatically adapted to rotors of different models during sand blasting, the focus point during sand blasting is selected according to the severity of burrs, corrosion and oil stains on the surface of a magnetic yoke of the rotor, the sand blasting operation efficiency of the rotor is improved, and the operation intensity of workers is reduced.
In one or more embodiments, preferably, the intelligent sand blasting robot for the wind power rotor comprises: the automatic abrasive material spraying device comprises a control system, a telescopic mechanical arm, a spray gun, an image recognition system, a memory, an online laser speckle roughness measuring instrument and an automatic abrasive material switching device, wherein the telescopic mechanical arm comprises a first mechanical arm and a second mechanical arm; the spray gun is arranged at the end part of the first mechanical arm;
the first mechanical arm is used for driving the spray gun to move up and down and rotate;
the spray gun is used for spraying sand to the surface of a position to be processed on the wind power rotor;
the image recognition system is used for scanning the wind power rotor for one circle before the sand blasting work is started, recognizing the information of the wind power rotor, comparing and determining the model of the wind power rotor from the control system, and calling a sand blasting control program corresponding to the model of the wind power rotor to perform the sand blasting work;
the online laser speckle roughness measuring instrument is arranged on the second mechanical arm and used for monitoring the surface roughness of the magnet yoke in real time and meeting the required process, and automatically switching the grinding materials through the automatic grinding material switching device under the condition of deviation;
the online laser speckle roughness measuring instrument is characterized in that a dust cover and an air draft device are further arranged on the online laser speckle roughness measuring instrument, an opening area is arranged on one surface, facing the wind power rotor, of the dust cover, and soft rubber is arranged on the edge of the opening area and used for being attached to the inner wall of the wind power rotor, so that the online laser speckle roughness measuring instrument works in a closed environment;
and the air draft device is arranged in the dust cover and used for quickly pumping out dust in a closed environment formed by the dust cover and the inner wall of the wind power rotor in a laminating way so as to ensure that the online laser speckle roughness measuring instrument is not interfered by the dust during working.
In one or more embodiments, preferably, the method for determining the model of the wind power rotor by the image recognition system specifically includes:
before the image recognition system starts the sand blasting work, scanning the wind power rotor for one circle, and measuring the inner diameter and the height of a magnetic yoke of the wind power rotor;
transmitting to the control system a signal based on the yoke inside diameter and the yoke height;
the control system compares the inner diameter and the height of the magnetic yoke with the inner diameter and the height of the magnetic yoke of a preset model in the process;
when the deviation between the inner diameter of the magnetic yoke of the preset model and the inner diameter of the magnetic yoke is lower than 5%, and the deviation between the height of the magnetic yoke of the preset model and the height of the magnetic yoke is also lower than 5%, the model of the wind power rotor, which is measured at this time, corresponding to the preset model at this time is fed back.
In one or more embodiments, preferably, the method for measuring the inner diameter of the yoke of the wind power rotor specifically includes:
measuring the inner diameter of the wind power rotor in the direction from 12 points to 6 points, and storing the inner diameter as a first inner diameter;
measuring the inner diameter of the wind power rotor in the direction from 3 points to 9 points, and storing the inner diameter as a second inner diameter;
and taking the average value of the first inner diameter and the second inner diameter as the inner diameter of the magnetic yoke of the wind power rotor.
In one or more embodiments, preferably, during the sand blasting operation, the first mechanical arm drives the spray gun to move so that a nozzle of the spray gun is kept at a distance of 15cm from the wind power rotor and at an included angle of 30-45 degrees with an upper surface of a processing position of the wind power rotor.
In one or more embodiments, preferably, the blasting control program is configured to automatically control the telescopic arm length of the telescopic robot arm and the range of the up-down stroke of the blasting gun during the blasting operation.
In one or more embodiments, preferably, the image recognition system is further configured to recognize a state of a circle of an inner surface of the wind turbine rotor, determine whether there is any burr, rust and/or oil stain at each position, judge the severity, and record information of the severity in the memory.
In one or more embodiments, preferably, the recognition algorithm for recognizing three cleaning states of burrs, rust and oil stains around the yoke region of the wind turbine rotor by the image recognition system includes:
setting a preset observation distance, and extracting all pairs of sub-regions to be measured in the wind power rotor, which meet the preset observation distance, according to the preset observation distance;
calculating all surface normal direction differences in the yoke region by using a first calculation formula according to the sub-region pair to be measured;
calculating all distance change intensities in the yoke region by using a second calculation formula according to the pair of sub-regions to be measured;
calculating all the gray scale change intensities in the yoke region by using a third calculation formula according to the pair of sub-regions to be measured;
calculating all average gray level differences in the yoke region by using a fourth calculation formula according to the pair of sub-regions to be measured;
acquiring a preset surface normal direction difference unqualified range and a preset distance change strength unqualified range, and outputting burrs in a magnet yoke area of the wind power rotor when the surface normal direction difference meets the surface normal direction difference unqualified range and the distance change strength unqualified range;
acquiring a preset unqualified gray-scale change strength range, and outputting that the magnet yoke area of the wind power rotor is corroded when the gray-scale change strength is within the unqualified gray-scale change strength range;
acquiring a preset unqualified range of average gray scale difference, and outputting that oil stains exist in a magnet yoke area of the wind power rotor when the average gray scale difference is within the unqualified range of the average gray scale difference;
the first calculation formula is:
Ang(i,j)=arcos(Ni·Nj)
where Ang (i, j) is the surface normal direction difference, NiIs the surface unit normal vector, N, of the first sub-area ijThe surface unit normal vector of a second sub-area j which is separated from the first sub-area i by the preset observation distance is obtained;
the second calculation formula is:
wherein the content of the first and second substances,
n is the number of boundary pixels of a first sub-area i and a second sub-area j spaced from the first sub-area i by a predetermined distance, Δ Z (x) for the intensity of the distance variationm，ym) Is a pixel (x) on the boundarym，ym) Absolute value of change in z-value of distance of neighborhood, xmIs the m-th pixel abscissa, ymIs the mth pixel ordinate;
the third calculation formula is:
wherein the content of the first and second substances,
n is the number of boundary pixels of the first sub-area i and the second sub-area j spaced apart from the first sub-area i by a predetermined distance, Δ G (x) for the intensity of the gray variationm，ym) Is a pixel (x) on the boundarym，ym) The amount of change in gray value within a neighborhood;
the fourth calculation formula is:
Gmd(i,j) =|Gmi-Gmj|
where Gmd (i, j) is the average gray scale difference, Gmi is the average gray scale of the first sub-region i, and Gmj is the average gray scale of the second sub-region j separated from the first sub-region i by a predetermined distance.
In one or more embodiments, preferably, the intelligent blasting robot for the wind power rotor further comprises a blasting machine airflow pressure adjusting device, and the blasting machine airflow pressure adjusting device adjusts the size of the blasting machine airflow pressure according to the size of burrs on the wind power rotor.
In one or more embodiments, preferably, a degreaser nozzle is further disposed on the telescopic mechanical arm, and the degreaser nozzle sprays degreaser to a portion where the oil contamination is detected by the image recognition system.
In one or more embodiments, preferably, the image recognition system is further configured to monitor the cleanliness of the surface of a magnet yoke of the wind turbine rotor in real time, after the cleanliness of the surface of the magnet yoke meets a preset cleanliness margin, determine whether the online laser speckle roughness measurement instrument detects that the roughness of the surface of the magnet yoke of the wind turbine rotor is lower than a preset roughness limit value, and notify the control system to exit the sand blasting control program and stop the sand blasting operation when the cleanliness margin is met and the roughness limit value is lower than the roughness limit value.
The technical scheme provided by the embodiment of the invention can have the following beneficial effects:
the intelligent sand blasting robot for the wind power rotor is provided with a telescopic mechanical arm, a spray gun is arranged on the mechanical arm, and the spray gun is driven to move up and down through the mechanical arm. The nozzle of the spray gun and the wind power rotor keep a distance of 15cm and face the surface of a position to be processed on the wind power rotor at an angle of 30-45 degrees, so that the abrasive material achieves the best effect with the least abrasion.
The intelligent sand blasting robot for the wind power rotor can be adaptive to rotors of different models without manual adjustment. Scanning wind-powered electricity generation rotor a week through image recognition system before the work, discernment wind-powered electricity generation rotor's information is compared from the system and is confirmed the wind-powered electricity generation rotor of which type of operation object to come the sandblast control program of calling correspondence, if: the required arm length and the range of up and down stroke of the nozzle.
When the intelligent sand blasting robot for the wind power rotor performs sand blasting work, the state of the inner surface (magnet yoke) of the wind power rotor in a circle can be identified, whether burrs, corrosion and oil stains exist at each position or not is determined, and the severity is judged. The information of the severity degree is recorded into a memory, and the sand blasting operation is performed with more than one spraying in a side-focusing manner.
In the sand blasting process, the intelligent sand blasting robot for the wind power rotor is provided with an online laser speckle roughness measuring instrument, and the surface roughness of the magnet yoke can be monitored in real time to meet the required process. If deviation occurs, the abrasive is automatically switched.
The intelligent sand blasting robot for the wind power rotor can complete sand blasting at one time. In the prior art, after the sand blasting worker finishes spraying, quality testing personnel detect the sand blasting worker, and the sand blasting worker consumes time and labor after being unqualified.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
Fig. 1 is a schematic structural diagram of an intelligent sand blasting robot for a wind power rotor according to an embodiment of the invention.
Fig. 2 is a flowchart of a method for determining the model of a wind rotor in an intelligent sand blasting robot for the wind rotor according to an embodiment of the invention.
Fig. 3 is a flowchart of a method for measuring an inner diameter of a magnetic yoke of a wind power rotor in an intelligent sand blasting robot for the wind power rotor according to an embodiment of the invention.
Fig. 4 is a flowchart of an algorithm for identifying three cleaning states of burrs, rust and oil stains at each magnetic yoke region in an intelligent sand blasting robot for a wind power rotor according to an embodiment of the present invention.
Detailed Description
In some of the flows described in the present specification and claims and in the above figures, a number of operations are included that occur in a particular order, but it should be clearly understood that these operations may be performed out of order or in parallel as they occur herein, with the order of the operations being indicated as 101, 102, etc. merely to distinguish between the various operations, and the order of the operations by themselves does not represent any order of performance. Additionally, the flows may include more or fewer operations, and the operations may be performed sequentially or in parallel. It should be noted that, the descriptions of "first", "second", etc. in this document are used for distinguishing different messages, devices, modules, etc., and do not represent a sequential order, nor limit the types of "first" and "second" to be different.
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Wind energy is used as a clean renewable energy source, the cumulative installation of the wind driven generator at home exceeds 200GW, and the installation speed of the wind driven generator at home is further accelerated in future. The hub of the wind power generator is an important part for converting the kinetic energy of wind into mechanical energy and consists of a plurality of blades. When wind blows to the blades, aerodynamic force is generated on the blades to drive the hub to rotate. The hub drives a rotor bracket of the wind generating set to rotate. The inner diameter of a rotor support of the permanent magnet direct-drive wind generating set is more than 5 meters, and the inner diameter of a rotor support of the large offshore unit is more than 16 meters.
The inner wall of the rotor bracket of the permanent magnet direct-drive wind generating set is provided with a magnetic steel block, and the inner wall is also called as a magnetic yoke. And carrying out sand blasting treatment on the magnetic yoke of the rotor bracket before assembling the magnetic steel block. The sand blasting treatment process has the advantages that stains on the surface of the magnetic yoke are removed (cleanliness is guaranteed), certain roughness is kept, the magnetic steel blocks are bonded with the magnetic yoke through potting resin more firmly, and meanwhile, tiny burrs on the surface of the magnetic yoke can be cleaned through sand blasting to reduce damage of the magnetic steel blocks in the process of pushing the magnetic yoke into the surface.
The principle of the sand blasting process is a process of cleaning and coarsening the surface of a matrix by using the impact action of high-speed sand flow.
Among the prior art, wind generating set workshop is mainly used the manual work to wind-powered electricity generation rotor sandblast, stands in the rotor inside in the sandblast room by a mill during the operation, holds the spray gun head and carries out the sandblast to the rotor inner wall. The process mainly depends on the experience (visual inspection) of workers in work to judge whether the sand blasting is finished or not, then detection personnel detect the sand blasting, if the detection is unqualified, the sand blasting equipment needs to be restarted to perform the sand blasting again, and the process is long in time consumption. Meanwhile, when performing the sand blasting operation, the worker wears the whole body protective clothing to avoid the influence of the high-density dust on the body, and even then, the dust is still sucked into the body by the worker. In summer hot weather, the operation mode can cause the workers to feel more uncomfortable.
The follow-up magnetic steel piece that will bond in yoke surface that the sandblast was operated, the roughness yoke of unclean, unsatisfied technological requirement can influence the firmness that the magnetic steel piece bonded, and the firmness is not good can lead to the magnetic steel piece to drop. Once the magnetic steel falls off, foreign matters are clamped between the stator and the rotor of the wind driven generator, the wind driven generator must be disassembled and returned to a factory for maintenance, and only the lifting and transportation cost loss is up to more than 50 ten thousand yuan. The wind driven generator runs in a natural environment, sunlight is directly irradiated in summer, the north in winter is extremely cold, and the expansion with heat and contraction with cold also put forward more strict requirements on the magnetic pole bonding process.
Therefore, the sand blasting process is a critical process in the production process of the wind generating set, and if a robot is adopted to carry out standardized sand blasting operation, the failure risk of magnetic steel bonding can be reduced.
The rotor support of the wind generating set is mostly annular, and the structure is relatively fixed. But the diameters and the heights of the magnetic yokes of the rotor supports of different types of wind generating sets are different. The fixed structural characteristics provide a foundation for the implementation of the universal operation of the robot.
The embodiment of the invention provides an intelligent sand blasting robot for a wind power rotor. This scheme is the rotor of the different models of automatic adaptation when the sandblast to select the sandblast work according to the severity of rotor yoke surface burr, corrosion, greasy dirt, promote rotor sandblast operating efficiency.
Fig. 1 is a schematic structural diagram of an intelligent sand blasting robot for a wind power rotor according to an embodiment of the invention.
As shown in fig. 1, in one or more embodiments, preferably, the intelligent sand blasting robot for the wind power rotor comprises: the automatic abrasive material distribution system comprises a control system 101, a telescopic mechanical arm 102, a spray gun 103, an image recognition system 104, a memory 105, an online laser speckle roughness measuring instrument 106 and an automatic abrasive material switching device 107, wherein the telescopic mechanical arm comprises a first mechanical arm and a second mechanical arm; the spray gun is arranged at the end part of the first mechanical arm;
the first mechanical arm is used for driving the spray gun to move up and down and rotate;
the spray gun is used for spraying sand to the surface of a position to be processed on the wind power rotor;
the image recognition system is used for scanning the wind power rotor for one circle before the sand blasting work is started, recognizing the information of the wind power rotor, comparing and determining the model of the wind power rotor from the control system, and calling a sand blasting control program corresponding to the model of the wind power rotor to perform the sand blasting work;
the online laser speckle roughness measuring instrument is arranged on the second mechanical arm and used for monitoring the surface roughness of the magnet yoke in real time and meeting the required process, and automatically switching the grinding materials through the automatic grinding material switching device under the condition of deviation;
the online laser speckle roughness measuring instrument is characterized in that a dust cover and an air draft device are further arranged on the online laser speckle roughness measuring instrument, an opening area is arranged on one surface, facing the wind power rotor, of the dust cover, and soft rubber is arranged on the edge of the opening area and used for being attached to the inner wall of the wind power rotor, so that the online laser speckle roughness measuring instrument works in a closed environment;
and the air draft device is arranged in the dust cover and used for quickly pumping out dust in a closed environment formed by the dust cover and the inner wall of the wind power rotor in a laminating way so as to ensure that the online laser speckle roughness measuring instrument is not interfered by the dust during working.
The embodiment of the invention relates to a specific structure of an intelligent sand blasting robot for wind power transposition. In the process of carrying out sand blasting, because the influence of the original state of the equipment can be received, detailed analysis is carried out on some special states, at least roughness is included, in the process of carrying out intelligent sand blasting, information acquisition is completed through the cooperation among all devices, and sand blasting process control is carried out according to the acquisition.
The intelligent sand blasting robot for the wind power rotor is characterized in that the online laser speckle roughness measuring instrument and the spray gun are arranged on different mechanical arms, when one mechanical arm lifts the online laser speckle roughness measuring instrument to measure the roughness of one area of the rotor magnetic yoke, the other mechanical arm can lift the spray gun to perform sand blasting operation on the other area of the rotor magnetic yoke, the sand blasting operation is not influenced, and the operation efficiency is high.
The online laser speckle roughness measuring instrument is provided with the dust cover, the dust density in the sand blasting area is large, workers often can not open eyes, and if the laser speckle roughness measuring instrument does not have an isolation area during working, laser testing can be influenced by suspended sand and the reliability of a measuring result is reduced. The edge of the opening area of the dust cover is provided with soft rubber which is attached to the inner wall of the rotor, so that the online laser speckle roughness measuring instrument can work relatively in a closed environment. After the mechanical arm of the online laser speckle roughness measuring instrument is installed and stretched out, a dust cover (the side of the rubber edge) on the online laser speckle roughness measuring instrument can be in contact with the rotor, so that the testing instrument is more stable relative to the rotor and less in shaking.
It should be noted that while the above describes the preferred embodiment of the present invention, it will be appreciated by those skilled in the art that the roughness can be detected after the gun is stopped, and the dust in the surrounding environment is still large and must be left for a long time when the gun is stopped. Therefore, the design of the dust cover is adopted, so that a relatively clean environment can be formed in a local area of a magnetic yoke of the wind power rotor or a to-be-detected area, and the accurate measurement work of a detection instrument in other areas can be carried out under the condition that the sand blasting work is not stopped.
Fig. 2 is a flowchart of a method for determining the model of a wind rotor in an intelligent sand blasting robot for the wind rotor according to an embodiment of the invention.
As shown in fig. 2, in one or more embodiments, preferably, the method for determining the model of the wind power rotor by the image recognition system specifically includes:
s201, before the image recognition system starts the sand blasting operation, scanning the wind power rotor for a circle, and measuring the inner diameter and the height of a magnetic yoke of the wind power rotor;
s202, sending the magnetic yoke inner diameter and the magnetic yoke height to the control system;
s203, comparing the inner diameter and the height of the magnetic yoke with the inner diameter and the height of the magnetic yoke of a preset model in the process of the control system;
s204, when the deviation between the inner diameter of the magnetic yoke of the preset model and the inner diameter of the magnetic yoke is lower than 5%, and the deviation between the height of the magnetic yoke of the preset model and the height of the magnetic yoke is also lower than 5%, feeding back the model of the wind power rotor which is measured by the corresponding preset model at the moment.
In the embodiment of the invention, the image recognition system scans the wind power rotor for a circle before the sand blasting operation is started, and measures the inner diameter and the height of a magnetic yoke of the wind power rotor; comparing the measured inner diameter and height of the magnetic yoke with the inner diameter and height of the magnetic yoke prestored in the control system; the robot preparation program (arm length adjustment, control program calling and sand channel selection) is called.
Fig. 3 is a flowchart of a method for measuring an inner diameter of a magnetic yoke of a wind power rotor in an intelligent sand blasting robot for the wind power rotor according to an embodiment of the invention.
As shown in fig. 3, in one or more embodiments, preferably, the method for measuring the inner diameter of the yoke of the wind power rotor specifically includes:
s301, measuring the inner diameter of the wind power rotor in the direction from 12 points to 6 points, and storing the inner diameter as a first inner diameter;
s302, measuring the inner diameter of the wind power rotor in the direction from 3 points to 9 points, and storing the inner diameter as a second inner diameter;
s303, taking the average value of the first inner diameter and the second inner diameter as the inner diameter of the magnetic yoke of the wind power rotor.
In the embodiment of the invention, the calculated values of the inner diameter are respectively obtained from two directions in the process of measuring the inner diameter, although the directions are opposite in the rotating process, the monitoring efficiency can be improved by obtaining the calculated values of the inner diameter from two directions, and meanwhile, limited filtering can be carried out on data errors in a single direction.
In one or more embodiments, preferably, during the sand blasting operation, the first mechanical arm drives the spray gun to move so that a nozzle of the spray gun is kept at a distance of 15cm from the wind power rotor and at an included angle of 30-45 degrees with an upper surface of a processing position of the wind power rotor.
In one or more embodiments, preferably, the blasting control program is configured to automatically control the telescopic arm length of the telescopic robot arm and the range of the up-down stroke of the blasting gun during the blasting operation.
In one or more embodiments, preferably, the image recognition system is further configured to recognize a state of a circle of an inner surface of the wind turbine rotor, determine whether there is any burr, rust and/or oil stain at each position, judge the severity, and record information of the severity in the memory.
Fig. 4 is a flowchart of an algorithm for identifying three cleaning states of burrs, rust and oil stains at each magnetic yoke region in an intelligent sand blasting robot for a wind power rotor according to an embodiment of the present invention.
As shown in fig. 4, in one or more embodiments, preferably, the recognition algorithm for the image recognition system to recognize three cleaning states of burrs, rust and oil stains around the yoke region of the wind turbine rotor includes:
s401, setting a preset observation distance, and extracting all pairs of sub-regions to be measured in the wind power rotor, which meet the preset observation distance, according to the preset observation distance;
s402, calculating all surface normal direction differences in the yoke region by using a first calculation formula according to the sub-region pair to be measured;
s403, calculating all distance change intensities in the yoke region by using a second calculation formula according to the sub-region pair to be measured;
s404, calculating all gray scale change intensities in the yoke region by using a third calculation formula according to the sub-region pair to be measured;
s405, calculating all average gray level differences in the yoke region by using a fourth calculation formula according to the sub-region pair to be measured;
s406, acquiring a preset unqualified surface normal direction difference range and a preset unqualified distance change strength range, and outputting that burrs exist in a magnet yoke area of the wind power rotor when the surface normal direction difference meets the unqualified surface normal direction difference range and the unqualified distance change strength range;
s407, acquiring a preset unqualified gray-scale change strength range, and outputting that the magnet yoke area of the wind power rotor is corroded when the gray-scale change strength is within the unqualified gray-scale change strength range;
s408, acquiring a preset unqualified average gray scale difference range, and outputting that oil stains exist in a magnet yoke area of the wind power rotor when the average gray scale difference is within the unqualified average gray scale difference range;
the first calculation formula is:
Ang(i,j)=arcos(Ni·Nj)
where Ang (i, j) is the surface normal direction difference, NiIs the surface unit normal vector, N, of the first sub-area ijThe surface unit normal vector of a second sub-area j which is separated from the first sub-area i by the preset observation distance is obtained;
the second calculation formula is:
wherein the content of the first and second substances,
n is the number of boundary pixels of a first sub-area i and a second sub-area j spaced from the first sub-area i by a predetermined distance, Δ Z (x) for the intensity of the distance variationm，ym) Is a pixel (x) on the boundarym，ym) The absolute value of the change quantity of the distance z value of the neighborhood;
the third calculation formula is:
wherein the content of the first and second substances,
n is the number of boundary pixels of the first sub-area i and the second sub-area j spaced apart from the first sub-area i by a predetermined distance, Δ G (x) for the intensity of the gray variationm，ym) Is a pixel (x) on the boundarym，ym) Amount of change in gray value in neighborhood, xmIs the m-th pixel abscissa, ymIs the mth pixel ordinate;
the fourth calculation formula is:
Gmd(i,j) =|Gmi-Gmj|
where Gmd (i, j) is the average gray scale difference, Gmi is the average gray scale of the first sub-region i, and Gmj is the average gray scale of the second sub-region j separated from the first sub-region i by a predetermined distance.
In the embodiment of the invention, as the surface roughness and cleanliness of the magnet yoke can be automatically identified in the sand blasting process, the intelligent sand blasting robot for the wind power rotor can complete the sand blasting process at one time without repeated detection. The image recognition system is used for monitoring the surface cleanliness of the magnet yoke of the wind power rotor in real time, and the specific scheme is as follows: block detection (the image recognition system scans the rotor yoke block by block in a production operation); the detection result of each block may be different; according to the result of the block detection, the control system controls the mechanical arm to rotate and move in the unqualified place, so that the spray gun can reach the designated position again for sand blasting treatment; and when the detection result of each area is qualified, the control system controls the robot to stop the sand blasting operation.
In one or more embodiments, preferably, the intelligent blasting robot for the wind power rotor further comprises a blasting machine airflow pressure adjusting device, and the blasting machine airflow pressure adjusting device adjusts the size of the blasting machine airflow pressure according to the size of burrs on the wind power rotor.
In one or more embodiments, preferably, a degreaser nozzle is further disposed on the telescopic mechanical arm, and the degreaser nozzle sprays degreaser to a portion where the oil contamination is detected by the image recognition system.
In one or more embodiments, preferably, the image recognition system is further configured to monitor the cleanliness of the surface of a magnet yoke of the wind turbine rotor in real time, after the cleanliness of the surface of the magnet yoke meets a preset cleanliness margin, determine whether the online laser speckle roughness measurement instrument detects that the roughness of the surface of the magnet yoke of the wind turbine rotor is lower than a preset roughness limit value, and notify the control system to exit the sand blasting control program and stop the sand blasting operation when the cleanliness margin is met and the roughness limit value is lower than the roughness limit value.
In the implementation of the present invention, the specific process of the image recognition system for monitoring the surface cleanliness of the magnet yoke of the wind power rotor in real time is as follows: block detection (the image recognition system scans the rotor yoke block by block in a production operation); the detection result of each block may be different; according to the result of the block detection, the control system controls the mechanical arm to rotate and move in the unqualified place, so that the spray gun can reach the designated position again for sand blasting treatment; and when the detection result of each area is qualified, the control system controls the robot to stop the sand blasting operation.
The intelligent sand blasting robot for the wind power rotor can complete a sand blasting process at one time without repeated detection due to the fact that the surface roughness and cleanliness of the magnet yoke can be automatically identified in the sand blasting process.
The technical scheme provided by the embodiment of the invention can have the following beneficial effects:
the intelligent sand blasting robot for the wind power rotor is provided with a telescopic mechanical arm, a spray gun is arranged on the mechanical arm, and the spray gun is driven to move up and down through the mechanical arm. The nozzle of the spray gun and the wind power rotor keep a distance of 15cm and face the surface of a position to be processed on the wind power rotor at an angle of 30-45 degrees, so that the abrasive material achieves the best effect with the least abrasion.
The intelligent sand blasting robot for the wind power rotor can be adaptive to rotors of different models without manual adjustment. Scanning wind-powered electricity generation rotor a week through image recognition system before the work, discernment wind-powered electricity generation rotor's information is compared from the system and is confirmed the wind-powered electricity generation rotor of which type of operation object to come the sandblast control program of calling correspondence, if: the required arm length and the range of up and down stroke of the nozzle.
When the intelligent sand blasting robot for the wind power rotor performs sand blasting work, the state of the inner surface (magnet yoke) of the wind power rotor in a circle can be identified, whether burrs, corrosion and oil stains exist at each position or not is determined, and the severity is judged. The information of the severity degree is recorded into a memory, and the sand blasting operation is performed with more than one spraying in a side-focusing manner.
In the sand blasting process, the intelligent sand blasting robot for the wind power rotor is provided with an online laser speckle roughness measuring instrument, and the surface roughness of the magnet yoke can be monitored in real time to meet the required process. If deviation occurs, the abrasive is automatically switched.
The intelligent sand blasting robot for the wind power rotor can complete sand blasting at one time. In the prior art, after the sand blasting worker finishes spraying, quality testing personnel detect the sand blasting worker, and the sand blasting worker consumes time and labor after being unqualified. As will be appreciated by one skilled in the art, embodiments of the present invention may be provided as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, optical storage, and the like) having computer-usable program code embodied therein.
The present invention is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (10)
1. An intelligent sandblasting robot for a wind power rotor, characterized in that it comprises: the automatic abrasive material spraying device comprises a control system, a telescopic mechanical arm, a spray gun, an image recognition system, a memory, an online laser speckle roughness measuring instrument and an automatic abrasive material switching device, wherein the telescopic mechanical arm comprises a first mechanical arm and a second mechanical arm; the spray gun is arranged at the end part of the first mechanical arm;
the first mechanical arm is used for driving the spray gun to move up and down and rotate;
the spray gun is used for spraying sand to the surface of a position to be processed on the wind power rotor;
the image recognition system is used for scanning the wind power rotor for one circle before the sand blasting work is started, recognizing the information of the wind power rotor, comparing and determining the model of the wind power rotor from the control system, and calling a sand blasting control program corresponding to the model of the wind power rotor to perform the sand blasting work;
the online laser speckle roughness measuring instrument is arranged on the second mechanical arm and used for monitoring the surface roughness of the magnet yoke in real time and meeting the required process, and automatically switching the grinding materials through the automatic grinding material switching device under the condition of deviation;
the online laser speckle roughness measuring instrument is characterized in that a dust cover and an air draft device are further arranged on the online laser speckle roughness measuring instrument, an opening area is arranged on one surface, facing the wind power rotor, of the dust cover, and soft rubber is arranged on the edge of the opening area and used for being attached to the inner wall of the wind power rotor, so that the online laser speckle roughness measuring instrument works in a closed environment;
and the air draft device is arranged in the dust cover and used for quickly pumping out dust in a closed environment formed by the dust cover and the inner wall of the wind power rotor in a laminating way so as to ensure that the online laser speckle roughness measuring instrument is not interfered by the dust during working.
2. The intelligent sandblasting robot for wind turbines as claimed in claim 1, wherein said image recognition system determines the model of said wind turbine, specifically comprising:
before the image recognition system starts the sand blasting work, scanning the wind power rotor for one circle, and measuring the inner diameter and the height of a magnetic yoke of the wind power rotor;
transmitting to the control system a signal based on the yoke inside diameter and the yoke height;
the control system compares the inner diameter and the height of the magnetic yoke with the inner diameter and the height of the magnetic yoke of a preset model in the process;
when the deviation between the inner diameter of the magnetic yoke of the preset model and the inner diameter of the magnetic yoke is lower than 5%, and the deviation between the height of the magnetic yoke of the preset model and the height of the magnetic yoke is also lower than 5%, the model of the wind power rotor, which is measured at this time, corresponding to the preset model at this time is fed back.
3. The intelligent sand blasting robot for the wind power rotor as recited in claim 2, wherein the method for measuring the inner diameter of the magnet yoke of the wind power rotor specifically comprises the following steps:
measuring the inner diameter of the wind power rotor in the direction from 12 points to 6 points, and storing the inner diameter as a first inner diameter;
measuring the inner diameter of the wind power rotor in the direction from 3 points to 9 points, and storing the inner diameter as a second inner diameter;
and taking the average value of the first inner diameter and the second inner diameter as the inner diameter of the magnetic yoke of the wind power rotor.
4. The intelligent sand blasting robot for the wind power rotor as recited in claim 1, wherein during the sand blasting operation, the first mechanical arm drives the spray gun to move so that a nozzle of the spray gun is kept at a distance of 15cm from the wind power rotor and at an included angle of 30-45 degrees with an upper surface of a processing position of the wind power rotor.
5. The intelligent sand blasting robot for the wind power rotor as claimed in claim 1, wherein the sand blasting control program is used for controlling the telescopic arm length of the telescopic mechanical arm and the range of the up-and-down stroke of the spray gun automatically during the sand blasting operation.
6. The intelligent sand blasting robot for the wind power rotor as claimed in claim 1, wherein the image recognition system is further configured to recognize the state of the inner surface of the wind power rotor, determine whether there is any burr, rust and/or oil stain at any position, judge the severity, and record the severity information into the memory.
7. The intelligent sand blasting robot for the wind power rotor as claimed in claim 1, wherein the recognition algorithm for recognizing three cleaning states of burrs, rust and oil stains at the magnet yoke region of the wind power rotor by the image recognition system comprises:
setting a preset observation distance, and extracting all pairs of sub-regions to be measured in the wind power rotor, which meet the preset observation distance, according to the preset observation distance;
calculating all surface normal direction differences in the yoke region by using a first calculation formula according to the sub-region pair to be measured;
calculating all distance change intensities in the yoke region by using a second calculation formula according to the pair of sub-regions to be measured;
calculating all the gray scale change intensities in the yoke region by using a third calculation formula according to the pair of sub-regions to be measured;
calculating all average gray level differences in the yoke region by using a fourth calculation formula according to the pair of sub-regions to be measured;
acquiring a preset surface normal direction difference unqualified range and a preset distance change strength unqualified range, and outputting burrs in a magnet yoke area of the wind power rotor when the surface normal direction difference meets the surface normal direction difference unqualified range and the distance change strength unqualified range;
acquiring a preset unqualified gray-scale change strength range, and outputting that the magnet yoke area of the wind power rotor is corroded when the gray-scale change strength is within the unqualified gray-scale change strength range;
acquiring a preset unqualified range of average gray scale difference, and outputting that oil stains exist in a magnet yoke area of the wind power rotor when the average gray scale difference is within the unqualified range of the average gray scale difference;
the first calculation formula is:
Ang(i,j)=arcos(Ni·Nj)
where Ang (i, j) is the surface normal direction difference, NiIs a first sub-regionSurface unit normal vector of i, NjThe surface unit normal vector of a second sub-area j which is separated from the first sub-area i by the preset observation distance is obtained;
the second calculation formula is:
wherein the content of the first and second substances,
n is the number of boundary pixels of a first sub-area i and a second sub-area j spaced from the first sub-area i by a predetermined distance, Δ Z (x) for the intensity of the distance variationm，ym) Is a pixel (x) on the boundarym，ym) The absolute value of the change quantity of the distance z value of the neighborhood;
the third calculation formula is:
wherein the content of the first and second substances,
n is the number of boundary pixels of the first sub-area i and the second sub-area j spaced apart from the first sub-area i by a predetermined distance, Δ G (x) for the intensity of the gray variationm，ym) Is a pixel (x) on the boundarym，ym) Amount of change in gray value in neighborhood, xmIs the m-th pixel abscissa, ymIs the mth pixel ordinate;
the fourth calculation formula is:
Gmd(i,j) =|Gmi-Gmj|
where Gmd (i, j) is the average gray scale difference, Gmi is the average gray scale of the first sub-region i, and Gmj is the average gray scale of the second sub-region j separated from the first sub-region i by a predetermined distance.
8. The intelligent sand blasting robot for the wind power rotor as recited in claim 1, wherein the intelligent sand blasting robot for the wind power rotor further comprises a sand blasting machine airflow pressure adjusting device, and the sand blasting machine airflow pressure adjusting device adjusts the size of the sand blasting machine airflow pressure according to the size of burrs on the wind power rotor.
9. The intelligent sand blasting robot for the wind power rotor as recited in claim 1, wherein a degreaser nozzle is further arranged on the telescopic mechanical arm, and the degreaser nozzle sprays degreaser on the part where the oil contamination is detected by the image recognition system.
10. The intelligent sand blasting robot for the wind power rotor according to claim 1, wherein the image recognition system is further configured to monitor the cleanliness of the surface of the magnet yoke of the wind power rotor in real time, after the cleanliness of the surface of the magnet yoke meets a preset cleanliness margin, determine whether the online laser speckle roughness measurement instrument detects that the roughness of the surface of the magnet yoke of the wind power rotor is lower than a preset roughness limit value, and when the cleanliness margin is met and lower than the roughness limit value, notify the control system to exit the sand blasting control program, and stop the sand blasting operation.
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