CN115946097B - A metal pipe quality inspection robot - Google Patents

Abstract

The invention discloses a metal pipeline quality inspection robot, which includes a main body module, a joint module, and an active universal wheel module; the main body module includes a main body shell, and a motion control module, a power supply and a signal excitation source module are placed inside the main body shell , a signal amplification and post-processing module, and an image processing module. Image acquisition devices, magnetic flux sensing probes, and active universal wheels are installed below; the joint shaft of the joint module is placed coaxially with the joint torque motor to drive the joint to generate torque to hold the pipeline tightly. Among them, elastic brush excitation signal transmitting probes are installed on the four articulated arms; the driving and steering of the active universal wheel is completed through gear transmission and laser reflection monitoring technology. By adopting the bionic structure, the invention can carry out precise detection and data feedback on metal pipes with small and medium diameters, and has strong practical significance.

Description

A metal pipe quality inspection robot

technical field

The invention relates to the field of pipeline quality detection, in particular to a robot.

Background technique

With the needs of people's daily life, a large number of pipeline systems are used in long-distance oil and gas transportation. In recent years, environmental problems and safety problems caused by pipeline leakage have become common, which puts forward higher requirements for the safety of pipeline transportation. Therefore, The detection of pipeline quality is particularly important. Manual detection consumes a lot of manpower and material resources, and there are certain security risks.

The existing external flaw detection robots on the market are compatible with pipes with large diameters, and the implementation cost is high.

Contents of the invention

The purpose of the present invention is to provide a combination of image and electromagnetic means, through the application of bionic arthropod structure, which can adapt to the quality inspection of metal pipes with different pipe diameters, and realize low-cost, high-adaptability and high-accuracy pipe inspection. Pipeline quality inspection robot.

The technical solution adopted by the present invention to solve the problems of the technologies described above is:

A metal pipeline quality inspection robot is characterized in that it includes a main body module, a joint module, and an active universal wheel module;

The main body module includes a main body shell. A motion control module is placed inside the main body shell to control the driving joint torque motor and the active universal wheel. The power supply and signal excitation source module, signal amplification and post-processing are placed inside the main body shell. module, an image processing module, an image acquisition device is installed under the image processing module, a magnetic flux sensing probe is installed under the signal amplification and post-processing module, and an active universal wheel module is placed under the main body shell;

The joint module includes a joint shaft, which is placed coaxially with the joint torque motor, and is used to drive the joint to generate torque to hold the pipeline tightly;

The active universal wheel module includes: a gear box, the gear box is fixed to the rotating shaft, the rotating motor drives the first rotating gear, the first rotating gear drives the second rotating gear, and the second rotating gear drives the rotating shaft For rotation, a laser reflector is fixed on the edge of the gearbox, and the laser reflector is used to reflect the signal emitted by the laser detector; the drive motor drives the transmission bevel gear, and the transmission bevel gear drives the other bevel gear The first drive transmission spur gear, the first drive transmission spur gear drives the second drive transmission spur gear, the second drive transmission spur gear drives the wheel shaft, and the wheel shaft drives the driving wheel to complete the drive;

The joint axis is connected to the two front and rear joint components connected to it; 4 elastic brush excitation signal transmitting probes are installed on the joint components, and the two diagonal ones form a group, and the projection lines on the pipeline form an orthogonal, the said The magnetic flux sensing probe of the main module is located at the intersection; when working, the signal generating device generates a set of sine waves, and the waveform is divided into two paths, one path is directly output to a pair of emitters in the form of high-frequency pulses through chopping, and the other path first Phase-shift the original waveform by 180 degrees to make it lag by half a cycle, and then output it to another pair of emitters in the same way; at this time, a continuously changing current field is formed in the tube wall. According to the above operation, in Directly below the magnetic flux sensing probe, the vector of the current field is macroscopically equivalent to rotating at a constant speed. The magnetic flux measured by the sensing probe sampling, amplification and filtering of the post-processing module, combined with the pose information transmitted by the motion control module, is used for the current The magnetic induction distribution of the point within a sinusoidal period is reconstructed to obtain intuitive data for analysis: when there is a defect intersecting the current field, the current deflects when it flows to the defect, the current density decreases, and the magnetic field changes; when the current field When it is orthogonal to the defect, the change reaches the extreme value, based on which the detection is realized and the defect location is qualitative;

The motion control part performs real-time feedback closed-loop control on the moving pose situation according to the absolute value encoder on each driving wheel, and sends real-time pose information to the signal amplification and post-processing module, and the signal amplification and post-processing module knows accordingly The point measured by the current magnetic flux sensor;

The image recognition module takes pictures and performs image recognition before the robot travels each time. When it detects that the flange plate cannot pass through, the robot returns to the normal position to save power, and sends a signal to the background to wait for manual processing; The universal wheel travels but can pass through the low unevenness. When passing this position, the robot rotates to make the universal wheel go to other positions; when abnormal appearance (damage, cracks, rust, etc.) is detected, it is stored locally or Upload the picture and proceed normally if there is no abnormality.

The laser reflectors are installed every 90°. When the laser detector receives the reflected laser signal, it means that the gear box turns 90° to complete a cycle of direction switching, that is, to realize an overall steering of the universal wheel.

For the joint component, the lengths of the three joints are 540mm, 600mm, and 640mm respectively from connecting the main body shell to the end connecting the driven universal wheel, and the joint shaft and the joint are passed between every two joint components. The torque motor is combined to hold the pipe wall tightly by controlling the joint torque motor.

After the active universal wheel is turned, the driving motor controls the active universal wheel to drive forward, and at this time, the driven universal wheel follows the movement of the active universal wheel for adjustment.

Furthermore, when there is a defect intersecting the current field, the current will be deflected when it flows to the defect, the current density will decrease, and the magnetic field distribution will change.

When the current field is perpendicular to the defect, the change of the magnetic field distribution reaches the extreme value, realizing the detection and positioning of the defect.

The image acquisition device detects the condition of the pipeline surface in the visible light range, identifies visible defects, and provides information for the decision-making of the motion control module.

Compared with the prior art, the beneficial effects of the patent of the present invention are:

(1) A metal pipe external quality inspection robot. By designing a new type of active universal wheel device, it can control the metal pipe external quality inspection robot in two directions perpendicular to the pipeline axis and along the axis. The direction of the robot is switched and advanced, and the torque motor at the joint is used to hold the pipe wall tightly, and the movement of the robot is realized through the control of the active universal wheel and the driven universal wheel.

(2) A robot for detecting the quality of metal pipes outside the pipe. By combining with the bionic structure, an elastic brush excitation signal transmitting probe, a magnetic flux sensing probe and an image acquisition device are arranged to realize the use of electromagnetic detection means and visible light detection means. Realize the detection of internal hidden defects and surface visible defects.

Description of drawings

The accompanying drawings are used to provide a further understanding of the present invention, and constitute a part of the description, and are used together with the embodiments of the present invention to explain the present invention, and do not constitute a limitation to the present invention. In the attached picture:

Fig. 1 is a side view and a schematic diagram of the internal structure of the main part of the present invention when the tube is normally held;

Fig. 2 is a top view of the present invention when the tube is normally held;

Fig. 3 is a schematic diagram of the relationship between the top view structure and the main equipment arrangement position of the present invention in the unfolded state;

Fig. 4 is a structural diagram of the electromagnetic detection system of the present invention;

Fig. 5 is the working flowchart of the electromagnetic detection system of the present invention;

Fig. 6 is the work flowchart of motion control module and image processing module of the present invention;

Fig. 7, Fig. 8 are respectively the structural diagram of the present invention when maximum pipe diameter and minimum pipe diameter;

Fig. 9 is a structural diagram of the active universal wheel module of the present invention;

FIG. 10 is a side view of FIG. 9 .

Fig. 11 is a schematic diagram of the steering judgment of the active universal wheel module of the present invention.

In the figure, 1- joint shaft, 2- main body shell, 3- motion control module, 4- signal amplification and post-processing module, 5- image processing module, 6- image acquisition device, 7- active universal wheel module, 8- Joint torque motor, 9-joint component, 10-gear box, 11-revolving shaft, 12-first rotating gear, 13-rotating motor, 14-driving motor, 15-second rotating gear, 16-first driving transmission straight Gear, 17-the second drive transmission spur gear, 18-axle, 19-transmission bevel gear, 20-driving wheel (in the form of universal wheel), 21-laser detector, 22-laser mirror, 23-power supply and signal Excitation source module, driven universal wheel 24.

Detailed ways

A metal pipeline quality inspection robot, including a main body module, a joint module, and an active universal wheel module;

The main body module includes a main body shell 2. A motion control module 3 is placed inside the main body shell 2 to control the driving joint torque motor and the active universal wheel. The power supply and signal excitation source module 23, A signal amplification and post-processing module 4, an image processing module 5, an image acquisition device 6 is installed under the image processing module 5, a magnetic flux sensing probe is installed under the signal amplification and post-processing module, and the main body shell 2 is placed below There is an active universal wheel module 7;

The joint module includes a joint shaft 1, which is placed coaxially with the joint torque motor 8, and is used to drive the joint to generate torque to hold the pipeline tightly;

The active universal wheel module includes: a gear box 10, the gear box 10 is fixed to the rotary shaft 11, the rotating motor 13 drives the first rotating gear 12, the first rotating gear 12 drives the second rotating gear 15, the The second rotating gear 15 drives the rotary shaft 11 to rotate, and the laser reflector 22 is fixed on the edge of the gear box, and the laser reflector 22 is used to reflect the signal emitted by the laser detector 21; the drive motor 14 drives the transmission bevel gear 19 , the transmission bevel gear 19 drives the first drive transmission spur gear 16 connected with another bevel gear, the first drive transmission spur gear 16 drives the second drive transmission spur gear 17, and the second drive transmission spur gear 17 Driving wheel shaft 18, described wheel shaft 18 drives driving wheel 20 to complete driving;

The joint axis 1 is connected to the front and rear two joint components 9 connected thereto; 4 elastic brush excitation signal transmitting probes are installed on the joint components, and the two diagonal ones form a group, and the projection lines on the pipeline form an orthogonal, The magnetic flux sensing probe of the main module is located at the intersection; when working, the signal generating device generates a group of sine waves, and the waveform is divided into two paths, one path is directly output to a pair of emitters in the form of high-frequency pulses through chopping, and the other One way first shifts the phase of the original waveform by 180 degrees to make it lag by half a cycle, and then outputs it to the other pair of emitters in the same way; at this time, a continuously changing current field is formed in the tube wall, according to the above operation , directly below the magnetic flux sensing probe, the vector of the current field is macroscopically equivalent to rotating at a constant speed. The magnetic flux measured by the sensing probe sampling, amplification and filtering of the post-processing module, combined with the pose information transmitted by the motion control module, Reconstruct the magnetic induction distribution of the current point within a sinusoidal period, and obtain intuitive data for analysis: when there is a defect intersecting the current field, the current deflects when it flows to the defect, the current density decreases, and the magnetic field changes; when When the current field is orthogonal to the defect, the change reaches the extreme value, based on which the detection is realized and the defect location is qualitative;

The motion control part performs real-time feedback closed-loop control on the moving pose according to the absolute value encoder on each driving wheel, and sends real-time pose information to the signal amplification and post-processing module, and the signal amplification and post-processing module knows accordingly The point measured by the current magnetic flux sensor;

The image recognition module takes pictures and performs image recognition before the robot travels each time. When it detects that the flange plate cannot pass through, the robot returns to the normal position to save power, and sends a signal to the background to wait for manual processing; The universal wheel travels but can pass through the low and uneven conditions. When passing this position, the robot rotates to make the universal wheel go to other positions; when abnormal appearance (damage, cracks, rust, etc.) is detected, it is stored in the local or Upload the picture and proceed normally if there is no abnormality.

The laser reflector 22 is installed every 90°. When the laser detector 21 receives the reflected laser signal, it means that the gear box 10 is rotated by 90° to complete a cycle of direction switching, that is, to realize an overall steering of the universal wheel .

The joint member 9, the length of the three joints from connecting the main body shell 2 to the end connecting the driven universal wheel 24 is 540mm, 600mm, 640mm respectively, and the joint shaft passes between every two joint members 9 1 is combined with the joint torque motor 8, and the joint torque motor 8 is controlled to hold the pipe wall tightly.

Further, the metal pipe external quality inspection robot is applicable to common pipe diameters between 15.7 inches (400mm) and 30 inches (762mm), and can generally cover long straight pipes with small and medium diameters.

After the driving wheel 20 is turned, the drive motor 14 controls the driving wheel 20 to drive forward. At this time, the driven universal wheel follows the movement of the driving wheel 20 for adjustment.

Furthermore, when there is a defect intersecting the current field, the current will be deflected when it flows to the defect, the current density will decrease, and the magnetic field distribution will change.

When the current field is perpendicular to the defect, the change of the magnetic field distribution reaches the extreme value, realizing the detection and positioning of the defect.

The image acquisition device detects the condition of the pipeline surface in the visible light range, identifies visible defects, and provides information for the decision-making of the motion control module.

Further, the power supply and signal excitation source module generate two sets of sinusoidally changing excitation pulse signals with a phase difference of 180 degrees, which are transmitted to the metal pipe through the elastic brush excitation signal transmitting probe, and then form a constant-speed rotating pulse signal in the pipe wall. periodic current.

Further, the magnetic flux sensing probe samples the magnetic flux of the excited magnetic field synchronously with the pulse signal, and the signal amplification and post-processing module performs signal amplification and filtering on the sampled signal.

Further, the signal amplification and post-processing module arranges the sampling data and reconstructs the magnetic induction distribution when the power supply and signal excitation source module complete a sine cycle.

Furthermore, when there is no defect, the induced current flows uniformly, and the magnetic field distribution is uniform without disturbance.

Claims (6)

1. An outer detection robot of metal pipeline quality buret, characterized by: the device comprises a main body module, a joint module and an active universal wheel module;

the main body module comprises a main body shell (2), a motion control module (3) is arranged in the main body shell (2) and used for controlling a driving joint torque motor and an active universal wheel, a power supply and signal excitation source module, a signal amplification and post-processing module and an image processing module (5) are arranged in the main body shell (2), an image acquisition device (6) is arranged below the image processing module (5), a magnetic flux sensing probe is arranged below the signal amplification and post-processing module, and an active universal wheel module (7) is arranged below the main body shell (2);

the joint module comprises a joint shaft (1), wherein the joint shaft (1) and a joint torque motor (8) are coaxially arranged and used for driving a joint to generate torque to hold a pipeline tightly;

the active caster module includes: the gear box (10), the gear box (10) is fixed with the rotary shaft (11), the rotary motor (13) drives the first rotary gear (12), the first rotary gear (12) drives the second rotary gear (15), the second rotary gear (15) drives the rotary shaft (11) to rotate, a laser reflector (22) is fixed on the edge of the gear box, and the laser reflector (22) is used for reflecting signals emitted by the laser detector (21); the driving motor (14) drives the transmission bevel gear (19), the transmission bevel gear (19) drives a first driving transmission straight gear (16) connected with the other bevel gear, the first driving transmission straight gear (16) drives a second driving transmission straight gear (17), the second driving transmission straight gear (17) drives the wheel shaft (18), and the wheel shaft (18) drives the driving wheel (20) to finish driving;

the joint shaft (1) is connected with a joint member (9); the lengths of the three joints of the joint members (9) are 540mm, 600mm and 640mm from the connection of the main body shell (2) to the end connection of the driven universal wheel (24), each two joints of the joint members (9) are combined through the joint shaft (1) and the joint torque motor (8), and the joint torque motor (8) is controlled to hug the pipe wall tightly; 4 elastic brush excitation signal transmitting probes are arranged on the joint component, 2 opposite angles are in a group, projection connecting lines on the pipeline form orthogonality, and the magnetic flux sensing probes of the main body module are positioned at the intersection points; when the device works, the signal generating device generates a group of sine waves, the waveform is divided into two paths, one path of sine waves is directly output to a pair of emitters in a high-frequency pulse mode through chopping, the other path of sine waves firstly shifts the phase of the original waveform by 180 degrees, so that the original waveform lags by half a period, and the sine waves are output to the other pair of emitters in the same mode; at this time, a continuously changing current field is formed in the pipe wall, according to the operation, under the magnetic flux sensing probe, the vector of the current field macroscopically equivalently rotates at a constant speed, the magnetic flux is measured through sampling of the sensing probe, amplification and filtering of a post-processing module, and the pose information transmitted by the motion control module is combined, so that the magnetic induction distribution of the current point in a sine period is reconstructed, and visual data are obtained for analysis: when a defect crossing the current field exists, deflection occurs when the current flows to the defect, the current density is reduced, and the magnetic field is changed; when the current field is orthogonal to the defect, the change reaches an extreme value, thereby realizing detection and defect positioning and characterization;

the motion control part performs real-time feedback closed-loop control on the travelling pose condition according to absolute value encoders on the driving wheels, and sends real-time pose information to the signal amplifying and post-processing module, and the signal amplifying and post-processing module obtains the point position measured by the current magnetic flux sensor according to the real-time pose information;

the image recognition module shoots pictures and recognizes images before the robot advances each time, and when the situation that the flange plate and the like cannot pass is detected, the robot is corrected to save electric quantity and sends a signal to the background to wait for manual processing; when the condition of low concave-convex which influences the running of the universal wheel but can pass through the universal wheel is detected, the robot is controlled to rotate when the universal wheel passes through the position so that the universal wheel can run at other positions; when abnormal appearance is detected, the abnormal appearance is stored locally or uploaded pictures as required, and normal running is carried out if no abnormality exists.

2. The metal pipeline quality pipe external detection robot of claim 1, wherein: the laser reflectors (22) are arranged at intervals of 90 degrees, when the laser detector (21) receives reflected laser signals, the gear box (10) is turned 90 degrees, and one-cycle direction switching is completed, so that the universal wheel is integrally turned once.

3. The metal pipeline quality pipe external detection robot of claim 1, wherein: after the steering is finished, the driving motor (14) controls the driving wheel (20) to drive forwards, and at the moment, the driven universal wheels follow the movement of the driving wheel (20) to adjust.

4. The metal pipeline quality pipe external detection robot of claim 1, wherein: further, when there is a defect crossing the current field, deflection occurs when the current flows to the defect, the current density decreases, and the magnetic field distribution changes.

5. The metal pipeline quality pipe external detection robot of claim 1, wherein: when the current field is orthogonal with the defect, the distribution change of the magnetic field reaches an extremum, so that the defect is detected, positioned and qualitative.

6. The metal pipeline quality pipe external detection robot of claim 1, wherein: the image acquisition device detects the surface condition of the pipeline in the visible light range, identifies visible defects and provides information for the decision of the motion control module.

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