CN116223527A - Corrosion detection device and detection method for hydraulic hoist piston rod - Google Patents
Corrosion detection device and detection method for hydraulic hoist piston rod Download PDFInfo
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
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Abstract
The invention provides a rust detection device and a rust detection method for a piston rod of a hydraulic hoist, wherein a plurality of coamings are spliced to form a polygonal or annular detection robot framework, a plurality of groups of climbing devices are uniformly arranged in the detection robot framework, electromagnetic adsorption devices are arranged between adjacent climbing devices, the detection device is further arranged on the upper part of the detection robot framework, the detection device rotates on the detection robot framework, and the detection device adopts a visual detection device. The device can promote the development of piston rod defect detection after promoting, promotes operating efficiency, reduces the emergence of incident, improves company's brand influence and technological innovation ability, can extensively use widely in the water and electricity trade.
Description
Technical Field
The invention relates to the field of detection of hydraulic hoist piston rods, in particular to a rust detection device and a rust detection method for a hydraulic hoist piston rod.
Background
The hydropower station is provided with a plurality of hydraulic opening and closing machines, the opening and closing machines are operated for years, and the surface of a piston rod of the opening and closing machines is corroded to a certain extent. If the piston rod is rusted to a certain extent, the sealing damage of the oil cylinder is caused in the operation process, the pollution caused by rusted and fallen pollutants can cause the pollution of oil liquid, even the blockage and failure of a control valve are caused, and finally the hoist can not be normally started and stopped. Therefore, inspection is required to be carried out on the appearance and the rust condition of the piston rod of the hydraulic hoist frequently.
Because the special spatial position environment that hydraulic hoist piston rod was located, and the piston rod is longer, lead to personnel to carry out closely detection comparatively difficult to it. The detection means adopted at present is a mode of erecting a scaffold on a gate, and manual approach detection is performed. The scaffold is large in risk, large in engineering quantity, high in risk and low in efficiency, and the requirement of frequent inspection cannot be met. Therefore, it is urgently required to explore a rapid, efficient and highly applicable inspection device to improve the inspection efficiency of the piston rod and reduce the safety risk and the inspection cost.
The hydraulic hoist is provided with a manhole beside the base, and the size of the manhole is 700mm 500 mm. The equipment design needs to consider the size of an inspection manhole, is convenient for operators to carry (the distance between the upper end of the piston rod and the vertical face of the side wall is about 800 mm), and the specific environment and the relevant size are based on the field investigation measurement of the trusted party.
Disclosure of Invention
The invention mainly aims to provide a rust detection device and a rust detection method for a hydraulic hoist piston rod, which solve the problem that a person is difficult to detect the piston rod in a short distance because the piston rod is longer.
In order to solve the technical problems, the invention adopts the following technical scheme: a corrosion detection device for hydraulic hoist piston rod, a plurality of bounding walls splice and form polygon or annular detection robot skeleton, and detection robot skeleton inside evenly is equipped with multiunit climbing device, is equipped with electromagnetic adsorption device between the adjacent climbing device, and detection robot skeleton upper portion still is equipped with detection device, and detection device rotates on detection robot skeleton, and detection device adopts visual detection device.
In the preferred scheme, the climbing device is in sliding connection with the detection robot framework, and the sliding direction of the climbing device slides towards the radial direction of the hydraulic rod piston rod;
the climbing device comprises a vertically arranged climbing frame, rollers are arranged at two ends of the climbing frame, one sides of the two rollers are connected through a synchronous transmission belt, a second motor is arranged in the climbing frame, and the second motor is connected with a driven sprocket wheel at the other side of the rollers through a driving belt;
the upper roller and the lower roller of the climbing frame are abutted against the surface of the piston rod of the hydraulic rod;
in the preferred scheme, two ends of the climbing frame are also provided with an extending support arm, the end part of the support arm is provided with an oil removing sponge, and the end face of the oil removing sponge exceeds or is flush with the furthest end of the roller in the horizontal direction;
the surface of the oil removing sponge body is attached to the outer surface of the piston rod.
In the preferred scheme, be equipped with the tensioning support arm in the frame that climbs, the tensioning support arm is equipped with the tensioning board, is equipped with a plurality of kidney-shaped holes on the tensioning board, and the screw passes kidney-shaped hole and tensioning support arm connection, tensioning board one side is equipped with the take-up pulley, and the take-up pulley supports and leans on synchronous drive belt.
In the preferred scheme, at least two first guide posts are also arranged on the climbing frame, and the first guide posts are in sliding connection with the first coaming;
the climbing frame is also provided with a threaded rod which is in threaded connection with the locking and adjusting device, a dial of the locking and adjusting device is in rotary connection with the first coaming, the dial is in threaded connection with the threaded rod, and a rotary handle is arranged outside the dial;
a lock nut is also provided which passes through the dial and abuts against the surface of the first shroud or threaded rod.
In the preferred scheme, the electromagnetic adsorption device is provided with at least two second guide posts, the second guide posts are in sliding connection with the second coaming, the tail ends of the second guide posts are provided with limiting heads, and springs are arranged between the limiting heads and the second coaming;
the electromagnetic adsorption device surface is arc structure, and arc structure and hydraulic rod piston rod surface cooperation.
In the preferred scheme, the detection device comprises a linear array camera and a laser camera, wherein an illumination device is arranged on one side of the linear array camera, the laser camera and the illumination device are respectively arranged on a rotating seat, a plurality of clamping wheels which are oppositely arranged are arranged below the rotating seat, and the clamping wheels are arranged on two sides of the annular guide rail;
the rotating seat is also provided with a motor, the output end of the motor is provided with a gear, the annular guide rail is also provided with an annular rack, and the rack is meshed with the gear;
the rotating seat is also provided with a marking block, the annular guide rail is provided with an infrared detection device, the infrared detection device is of a U-shaped structure, and the marking block penetrates through the infrared detection device.
In the preferred scheme, the laser camera is arranged with the rotating seat through the mounting folded plate, the mounting folded plate is provided with a plurality of waist-shaped holes, and the nuts penetrate through the waist-shaped holes to be connected with the rotating seat;
the linear array camera is connected with the mounting frame in a clamping manner, the mounting frame is in sliding connection with the adjusting seat, an electric push rod is arranged in the adjusting seat, the end part of the electric push rod is connected with the mounting frame, and the adjusting seat is arranged on the rotating seat;
the lofting directions of the laser camera and the linear array camera face to the center point of the skeleton of the measuring robot.
In the preferred scheme, two groups of roller blocks are arranged on two sides of a hydraulic rod cylinder body, and a winch passes through the roller blocks through a traction rope to be connected with a detection robot framework;
the anti-falling fixed anchor is fixed on the wall body and connected with the detection robot framework through a traction rope.
In the preferred scheme, be equipped with first laser range finder (7) and second laser range finder (13) on survey robot skeleton (6), first laser range finder (7) and second laser range finder (13) detect the opposite direction, and first laser range finder (7) and second laser range finder (13) detect the direction and are parallel with the piston rod.
The method comprises the following steps:
s1, a plurality of coamings and annular guide rails are assembled around a hydraulic rod piston rod, a rotating seat is installed, a linear array camera, a lighting device and a laser camera are installed on the rotating seat, a locking adjusting device is rotated, the climbing device is pushed to the surface of the hydraulic rod piston rod by the locking adjusting device, and the plurality of adjusting devices are adjusted to enable a central shaft of a skeleton of the detection robot to be coaxial with the hydraulic rod piston rod;
s2, detecting that the robot climbs to a target position of a piston rod of the hydraulic rod, and starting the visual detection equipment to move around the piston rod body;
s3, the linear array camera and the laser camera start to collect, and after one circle of collection is completed, the acquired data are sent to the rust analysis computer;
s4, processing the obtained image by an analysis computer, extracting suspicious defects, generating a report, processing data, detecting that the robot moves, returning the visual detection equipment to the original position, and starting cutting and splicing of the image acquired next time;
s4, collecting the piston rods for a plurality of times, and splicing adjacent images;
the detection robot is provided with a laser range finder for determining the actual position of the image on the piston rod, the height information obtained by the laser range finder can obtain the overlapping size of the adjacent images, and the pictures can be spliced after the corresponding size is cut down;
s5, the height information is obtained through a laser displacement sensor, the laser displacement sensor strikes a reference plate as a starting point, a height value H1 is read, the height difference H2 between the laser displacement sensor and a linear array camera as well as between the laser displacement sensor and the laser camera is measured, and the defect position is obtained relative to the height H=H2+H2 on the reference plate;
the defect circumferential information takes the position of a photoelectric sensor as an initial origin, and the circumferential position of a defect point is determined by three factors of rotation detection time T, camera sampling rate and pixel position of the defect point;
s6, defect detection is divided into defect image acquisition and transmission and defect image algorithm processing;
the linear array camera and the laser camera are high-definition cameras, each scanning round is spliced into one Gao Qingtu,
the detection robot is provided with two computers, one computer is arranged on the detection robot and is used for image acquisition and transmission;
the other one is an industrial control notebook computer, and is placed in a remote area for image algorithm processing, the two are connected through a gigabit network cable, so that the timeliness of the whole image detection can be ensured, and after the camera rotates for one circle, the image can be transmitted back to the remote notebook computer at intervals of 1-2 s;
s7, starting a detection instruction, automatically transmitting the camera image back to the industrial control notebook computer, automatically storing each piece of data in the notebook computer, and automatically analyzing the image by an algorithm to obtain suspected defect coordinate information.
The invention provides a rust detection device and a rust detection method for a hydraulic hoist piston rod, which can promote the development of defect detection of the piston rod after being popularized, improve the operation efficiency, reduce the occurrence of safety accidents, improve the brand influence and technological innovation capability of companies, and can be widely popularized and used in the hydropower industry. The piston rod rust detection robot has certain application scenes and popularization, can be used for detecting cylindrical pipelines, such as petroleum, electric power, nuclear power, energy pipelines and the like, is carried on the near surface of a precise optical camera for flaw detection, and replaces manual detection with the robot.
Drawings
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
FIG. 1 is a front view of a detection installation structure of a detection robot according to the present invention;
FIG. 2 is a diagram of the structure of the position of a piston rod of the hydraulic hoist of the present invention;
FIG. 3 is a view showing a detection installation structure of a detection robot according to the present invention;
FIG. 4 is a front view mounting block diagram of the inspection robot of the present invention;
FIG. 5 is a block diagram of the installation position of the inspection robot according to the present invention;
FIG. 6 is a general construction diagram of the inspection robot according to the present invention;
FIG. 7 is a top view of the climbing device of the present invention;
FIG. 8 is a general mounting block diagram of a climbing device of the present invention;
FIG. 9 is a front side elevational view of the climbing device of the present invention;
FIG. 10 is a rear elevational view of the climbing device of the present invention;
FIG. 11 is a front side elevational view of the electromagnetic adsorption apparatus of the present invention;
FIG. 12 is a rear side elevational view of the electromagnetic adsorption apparatus of the present invention;
FIG. 13 is a diagram of a top view of the camera detection of the present invention;
FIG. 14 is a block diagram of a camera mounting location of the present invention;
FIG. 15 is a diagram of the mounting position of the camera detection step of the present invention;
FIG. 16 is a schematic view of a camera detection of the present invention;
FIG. 17 is a flow chart of a defect image algorithm of the present invention;
FIG. 18 is a schematic diagram of the steps of a method for locating defects on a metal surface of a color image according to the present invention;
in the figure: a hydraulic rod 1; a hoist gate 2; a hoist 3; a traction rope 4; a falling-preventing fixed anchor 5; detecting a robot framework 6; a first shroud 601; a second shroud 602; a first laser range finder 7; a first motor 8; a gear 801; a line camera 9; a mounting rack 901; an adjustment seat 902; a lighting device 10; a laser camera 11; a mounting flap 1101; a rotating base 12; a pinch wheel 1201; an identification block 1202; a second laser rangefinder 13; a climbing device 14; climbing frame 1401; a support arm 1402; a deoiling sponge 1403; a roller 1404; a synchronous belt 1405; a second motor 1406; a tensioning plate 1407; tensioning arm 1408; a drive belt 1409; driven sprocket 1410; a tensioning wheel 1411; a first guide post 1412; a threaded rod 1413; a circular guide rail 15; an infrared detection device 1501; a lock adjustment device 16; a dial 1601; a lock nut 1602; an electromagnetic adsorption device 17; a second guide post 1701; a spring 1702; and a spacing head 1703.
Detailed Description
Example 1
As shown in fig. 1-18, a rust detection device for a piston rod of a hydraulic hoist is provided, a plurality of coamings are spliced to form a polygonal or annular detection robot framework 6, a plurality of groups of climbing devices 14 are uniformly arranged inside the detection robot framework 6, electromagnetic adsorption devices 17 are arranged between adjacent climbing devices 14, a detection device is further arranged on the upper portion of the detection robot framework 6, the detection device rotates on the detection robot framework 6, and the detection device adopts a visual detection device.
First, the robot can be adapted for piston rod detection of different diameter specifications. Second, a precise adjusting mechanism is adopted to adjust the feeding amount. The robot adopts three groups of spiral propulsion mechanisms with dials, and the compression amount of three groups of rubber wheels is accurately adjusted, so that the robot and the piston rod are ensured to keep high concentricity, and the image equipment carried on the robot is convenient to realize high-precision detection. Thirdly, certain anti-slip performance is satisfied. The driving wheel adopts the cambered surface line structural design, so that the contact area and the friction coefficient between the driving wheel and the piston rod can be increased, the contact force between the rubber wheel and the piston rod can be adjusted, and the positive pressure between the robot and the piston rod is improved. Fourth, there are safety precautions. The front end of the electromagnetic chuck is arranged on the outer frame base to cover rubber, when the gravity acceleration sensor detects that the robot falls and slides, the sensor directly drives the electromagnetic chuck to be electrified, the electromagnetic chuck holds the piston rod tightly, the robot is prevented from falling, and meanwhile, the protective cable is arranged as a safety means, so that the safety is ensured. Fifthly, an oil removing device is configured, so that efficient and stable operation is ensured. And a sponge body and rubber are arranged above and below the driving wheel to erase hydraulic oil, so that a surface coating of the piston rod cannot be damaged. Sixth, a defect location positioning scheme. The laser range finder, the photoelectric sensor and the like are adopted to respectively realize the height positioning and the rust spot positioning in the circumferential direction, and the defect position is accurately calibrated. Seventh, the piston rod surface detection and internal flaw detection can be realized. The robot is provided with a three-dimensional linear laser camera and a two-dimensional linear array camera, and is provided with an installation interface of eddy current flaw detection equipment and ultrasonic detection equipment, so that surface rust detection and internal flaw detection of the piston rod are realized. Eighth, higher detection efficiency. When the robot detects a piston rod with the length of 17m and the diameter of 410mm, the image detection flow time is not more than 2h, and the speed of the robot is adjustable.
In the preferred scheme, the climbing device 14 is in sliding connection with the detection robot framework 6, and the sliding direction of the climbing device 14 slides towards the radial direction of the piston rod of the hydraulic rod 1; the climbing device 14 comprises a vertically arranged climbing frame 1401, rollers 1404 are arranged at two ends of the climbing frame 1401, one side of each roller 1404 is connected through a synchronous transmission belt 1405, a second motor 1406 is arranged in the climbing frame 1401, and the second motor 1406 is connected with a driven sprocket 1410 at the other side of each roller 1404 through a driving belt 1409;
two rollers 1404 on the upper and lower sides of the climbing frame 1401 are abutted against the surface of a piston rod of the hydraulic rod 1;
in the preferred scheme, two ends of the climbing frame 1401 are also provided with an extending support arm 1402, the end part of the support arm 1402 is provided with an oil removing sponge 1403, and the end surface of the oil removing sponge 1403 exceeds the furthest end of the roller 1404 in the horizontal direction or is flush with the furthest end of the roller 1404 in the horizontal direction;
the surface of the oil removing sponge 1403 is attached to the outer surface of the piston rod.
In a preferred scheme, be equipped with tensioning support arm 1408 in climbing frame 1401, tensioning support arm 1408 is equipped with tensioning plate 1407, is equipped with a plurality of kidney-shaped holes on the tensioning plate 1407, and the screw passes kidney-shaped hole and tensioning support arm 1408 to be connected, and tensioning plate 1407 one side is equipped with take-up pulley 1411, and take-up pulley 1411 supports and leans on synchronous drive belt 1405.
In a preferred embodiment, the climbing frame 1401 is further provided with at least two first guide posts 1412, and the first guide posts 1412 are slidably connected with the first coaming 601;
the climbing frame 1401 is also provided with a threaded rod 1413, the threaded rod 1413 is in threaded connection with the locking and adjusting device 16, a dial 1601 of the locking and adjusting device 16 is in rotary connection with the first coaming 601, the dial 1601 is in threaded connection with the threaded rod 1413, and a rotary handle is arranged outside the dial 1601;
a lock nut 1602 is also provided, the lock nut 1602 bearing against the surface of the first shroud 601 or threaded rod 1413 through the dial 1601.
The whole robot device has the following characteristics, and firstly, the robot can be suitable for detecting piston rods with different diameter specifications. Through three sets of spiral locking mechanism on the adjusting robot respectively, adjust the distance between drive wheel and the piston rod for remain certain pretightning force throughout between drive wheel and the piston rod, respectively through adjusting the drive module and the detection module of robot, make the drive wheel hug closely piston rod surface all the time, detect the probe and remain reasonable distance throughout with the piston rod, and then satisfy the piston rod detection demand of different diameters, application diameter scope is between 200 mm-410 mm. Second, dial adjustment mechanism. The rotary dial is mainly used for adjusting the feeding amount of the three groups of driving mechanisms, and is beneficial to the stable climbing of the robot. The driving wheel adopts the cambered surface structural design, so that the contact area and the friction coefficient between the driving wheel and the piston rod can be increased. Thirdly, the oil removing device is configured, so that efficient and stable operation is ensured. An industrial oil absorbing cotton is arranged above the driving wheel and used for wiping hydraulic oil on the surface of the piston rod, and a coating on the surface of the piston rod cannot be damaged. Fourth, a defect position high-precision positioning scheme. The high location and the location in the circumferential direction are respectively realized by adopting the devices such as a laser range finder, a photoelectric sensor and the like, and the defect position is accurately calibrated. Fifth, piston rod surface detection and internal inspection can be achieved. The 3D laser camera and the 2D linear array camera can detect the diameter and depth of rust spots on the surface of the piston rod, meanwhile, the robot can carry other flaw detection equipment such as eddy current equipment and ultrasonic detection, and the robot opens a mechanical and software interface of the flaw detection equipment to realize surface detection and internal flaw detection of the piston rod. Sixth, the detection efficiency is high. The robot speed is adjustable.
The detection robot adopts three groups of power driving wheels, as shown in fig. 8-9, each group of power driving wheels is provided with a precise spiral locking mechanism, a screw is provided with a dial, the screw pitch is 4mm, namely, each time 360 degrees of rotation are performed, the power driving wheels feed for 4mm, the propelling precision is 0.011 mm/degree, the device is used for ensuring that the central axis of the robot coincides with the central axis of a piston rod, the robot and the piston rod keep high concentricity, and the three groups of power driving wheels are arranged as shown in fig. 8-9.
The direct current servo motor with the integrated driver, controller and speed reducer is small in size, high in control precision and small in mass, and meets the use requirements of a scheme. The two cambered surface types of the rubber wheels are all driving wheels, industrial oil absorbing cotton for removing hydraulic oil is arranged above the driving wheels, the mechanical mode is adopted for removing, a piston rod is not damaged, slipping is avoided, and motion stability is improved. The screw nut is arranged on the single-group driving wheel, the rotary dial and the screw rod are fixed on the hexagonal outer frame, and the movement between the driving wheel and the rotary dial is spiral propelling movement, so that the rotary movement of the dial is converted into the linear movement of the driving wheel. The screw rod adopts a 30-degree trapezoidal screw rod, the screw pitch is 4mm, and the screw rod has self-locking property, namely can reversely move and lock in a pre-tightening state, and always keeps the positive pressure between the rubber wheel and the piston rod.
In a preferred scheme, the electromagnetic adsorption device 17 is provided with at least two second guide posts 1701, the second guide posts 1701 are in sliding connection with the second coaming 602, the tail ends of the second guide posts 1701 are provided with limiting heads 1703, and springs 1702 are arranged between the limiting heads 1703 and the second coaming 602;
the surface of the electromagnetic adsorption device 17 is of an arc-shaped structure, and the arc-shaped structure is matched with the surface of a piston rod of the hydraulic rod 1.
In the preferred scheme, the detection device comprises a linear array camera 9 and a laser camera 11, wherein an illumination device 10 is arranged on one side of the linear array camera 9, the laser camera 11 and the illumination device 10 are respectively arranged on a rotating seat 12, a plurality of clamping wheels 1201 which are oppositely arranged are arranged below the rotating seat 12, and the clamping wheels 1201 are arranged on two sides of an annular guide rail 15; the rotating seat 12 is also provided with a motor 8, the output end of the motor 8 is provided with a gear 801, the annular guide rail 15 is also provided with an annular rack, and the rack is meshed with the gear 801;
the robot is provided with 2D and 3D camera equipment, and other mechanical interfaces are reserved at the same time and used for later-stage installation of equipment such as ultrasonic equipment, eddy-current equipment and the like for nondestructive detection. The camera detection mode is encircling detection, the detection equipment is driven by the rotating mechanism in fig. 7 to realize circumferential 360-degree detection, and the 2D linear array camera and the 3D laser camera perform scanning imaging by rotating a circumferential winding piston rod for one circle, so that annular images of each height are shot. The rotating mechanism is mainly driven by an integrated gear rack, and the driving motor can feed back the circumferential coordinates of the defect position in real time through the original point position of the photoelectric sensor.
When detecting a certain piston rod, the distance between the 2D camera and the 3D camera and the surface of the piston rod needs to be adjusted, the working distance is set to be 100mm, when detecting another piston rod with different diameters, the distance between the camera and the surface of the new piston rod needs to be adjusted to be 100, a dovetail groove sliding table is arranged below the 2D camera and the 3D camera, only the dovetail groove knobs below the two cameras need to be rotated forwards and backwards, and locking is carried out after the adjustment is finished.
The two cameras are required to be installed to ensure that the two cameras acquire the same area of the rod body. The color camera selects a proper lens according to the visual field, and determines a working distance; the depth camera is adjusted to a proper working distance according to the visual field of the color camera. Next, fig. 8 shows a top view and a side view of the camera mounting.
In the preferred scheme, be equipped with first laser range finder 7 and second laser range finder 13 on survey robot skeleton 6, first laser range finder 7 and second laser range finder 13 detect the opposite direction, and first laser range finder 7 and second laser range finder 13 detect the direction and be parallel with the piston rod.
The rotating seat 12 is also provided with a marking block 1202, the annular guide rail 15 is provided with an infrared detection device 1501, the infrared detection device 1501 is in a U-shaped structure, and the marking block 1202 penetrates through the infrared detection device 1501.
In a preferred scheme, the laser camera 11 is mounted with the rotary seat 12 through a mounting folded plate 1101, a plurality of waist-shaped holes are arranged on the mounting folded plate 1101, and nuts penetrate through the waist-shaped holes to be connected with the rotary seat 12;
the linear array camera 9 is connected with the mounting frame 901 in a clamping manner, the mounting frame 901 is connected with the adjusting seat 902 in a sliding manner, an electric push rod is arranged in the adjusting seat 902, the end part of the electric push rod is connected with the mounting frame 901, and the adjusting seat 902 is arranged on the rotating seat 12;
the lofting direction of the laser camera 11 and the linear array camera 9 faces to the center point of the skeleton 6 of the measuring robot.
In the preferred scheme, two groups of roller blocks are arranged on two sides of a cylinder body of a hydraulic rod 1, and a winch 3 passes through the roller blocks through a traction rope 4 and is connected with a detection robot framework 6;
the anti-falling fixed anchor 5 is further arranged, the anti-falling fixed anchor 5 is fixed on the wall body, and the anti-falling fixed anchor 5 is connected with the detection robot framework 6 through the traction rope 4.
Example 2
Further described in connection with embodiment 1, as in the configuration shown in fig. 1-18, after the robot control section and the camera section are separately debugged, joint debugging is started. The detection process set by the robot is automatic detection, and the robot can detect while moving only by starting an automatic detection key on the wireless remote controller, and the robot automatic detection designs two detection modes, namely top-down detection and bottom-up detection.
In order to realize automatic detection, the robot needs to automatically send shooting starting instructions and shooting stopping instructions to the camera according to sensor signals after the detection button is started, in the process, a technician is not required to operate the remote controller all the time, only one-key operation is required, and the robot is automatically stopped after the detection is completed, so that the motion controller of the robot and the image acquisition computer need to communicate, and because the motion controller and the image acquisition computer are both mounted on the computer and are provided with RS232 serial ports, the motion controller and the image acquisition computer adopt the serial ports to communicate, and only a communication protocol needs to be defined,
s1, a plurality of coamings and an annular guide rail 15 are assembled around a piston rod of a hydraulic rod 1, a rotating seat 12 is installed, a linear array camera 9, a lighting device 10 and a laser camera 11 are installed on the rotating seat 12, a locking adjusting device 16 is rotated, the locking adjusting device 16 pushes a climbing device 14 to the surface of the piston rod of the hydraulic rod 1, and the plurality of adjusting devices 16 are adjusted to enable a central shaft of a detection robot framework 6 to be coaxial with the piston rod of the hydraulic rod 1;
s2, detecting that the robot climbs to a target position of a piston rod of the hydraulic rod 1, and starting to move around the piston rod body by the visual detection equipment;
s3, the linear array camera 9 and the laser camera 11 start to collect, and after one circle of collection is completed, the acquired data are sent to a rust analysis computer;
s4, processing the obtained image by an analysis computer, extracting suspicious defects, generating a report, processing data, detecting that the robot moves, returning the visual detection equipment to the original position, and starting cutting and splicing of the image acquired next time;
s4, collecting the piston rods for a plurality of times, and splicing adjacent images;
the detection robot is provided with a laser range finder for determining the actual position of the image on the piston rod, the height information obtained by the laser range finder can obtain the overlapping size of the adjacent images, and the pictures can be spliced after the corresponding size is cut down;
s5, the height information is obtained through a laser displacement sensor, the laser displacement sensor strikes a reference plate as a starting point, a height value H1 is read, the height difference H2 between the laser displacement sensor and the linear array camera 9 as well as between the laser displacement sensor and the laser camera 11 is measured, and the height H=H2+H2 of the defect position relative to the reference plate is obtained;
the defect circumferential information takes the position of a photoelectric sensor as an initial origin, and the circumferential position of a defect point is determined by three factors of rotation detection time T, camera sampling rate and pixel position of the defect point;
s6, defect detection is divided into defect image acquisition and transmission and defect image algorithm processing;
the defect detection system mainly comprises defect image acquisition and transmission and defect image algorithm identification. Firstly, determining the accuracy requirement of identification according to the size of the defect to be detected on the piston rod, selecting a high-resolution industrial camera, and photographing and collecting images of the defect on the piston rod.
The RGB linear array camera is a Piranha4 camera of TDALSA company, and the model is P4-CC-04K04T-00-R. The camera has a resolution of 4k, a pixel size of 10.56 μm x 10.56 μm, with a highest line frequency of 40kHz. The 3D camera employs a Gocator2330 of LMI corporation. The method can realize micron-level feature measurement, and the resolution in the Z direction can reach 0.006-0.014 mm. The RGB camera light source adopts DH-P-LSC-150-W of large constant photoelectric. It is a light-gathering linear scanning light source adopting linear LED,
and after receiving the instruction of the motion control system, the data acquisition computer simultaneously starts the RGB linear array camera and the 3D camera, the acquired data is preprocessed and then sent to the rust analysis computer, and the suspicious defects are extracted through a detection algorithm to generate a report.
The system data acquisition flow is as follows:
1 the robot climbs to the target height, and the camera platform starts to move around the rod body
2 color line camera and depth camera start to collect
3 after completing one circle of collection, transmitting the obtained data to a rust analysis computer
4, processing the obtained image by the analysis computer, extracting suspicious defects and generating a report
5) When data are processed, the robot moves, and the camera platform returns to the original position and starts the next acquisition
Image cutting and splicing:
because the acquisition of the piston rod is carried out for a plurality of times, adjacent images are needed to be spliced; the robot is provided with a laser range finder for determining the actual position of the image on the rod body, as shown in fig. 16, the overlapping size of the adjacent images can be obtained according to the height information obtained by the laser range finder, and the pictures can be spliced after the corresponding size is cut down.
The linear array camera 9 and the laser camera 11 are high-definition cameras, each scanning round is spliced into one Gao Qingtu,
the detection robot is provided with two computers, one computer is arranged on the detection robot and is used for image acquisition and transmission;
the other one is an industrial control notebook computer, and is placed in a remote area for image algorithm processing, the two are connected through a gigabit network cable, so that the timeliness of the whole image detection can be ensured, and after the camera rotates for one circle, the image can be transmitted back to the remote notebook computer at intervals of 1-2 s;
s7, starting a detection instruction, automatically transmitting the camera image back to the industrial control notebook computer, automatically storing each piece of data in the notebook computer, and automatically analyzing the image by an algorithm to obtain suspected defect coordinate information.
The above embodiments are only preferred embodiments of the present invention, and should not be construed as limiting the present invention, and the scope of the present invention should be defined by the claims, including the equivalents of the technical features in the claims. I.e., equivalent replacement modifications within the scope of this invention are also within the scope of the invention.
Claims (10)
1. A corrosion detection device for hydraulic hoist piston rod, characterized by: a plurality of bounding walls splice and form polygon or annular detection robot skeleton (6), and detection robot skeleton (6) inside evenly is equipped with multiunit climbing device (14), is equipped with electromagnetic adsorption device (17) between adjacent climbing device (14), and detection robot skeleton (6) upper portion still is equipped with detection device, and detection device is rotatory on detection robot skeleton (6), and detection device adopts visual detection device.
2. The rust detection device for a hydraulic hoist piston rod according to claim 1, characterized in that: the climbing device (14) is in sliding connection with the detection robot framework (6), and the sliding direction of the climbing device (14) slides towards the radial direction of the piston rod of the hydraulic rod (1);
the climbing device (14) comprises a climbing frame (1401) which is vertically arranged, rollers (1404) are arranged at two ends of the climbing frame (1401), one sides of the two rollers (1404) are connected through a synchronous transmission belt (1405), a second motor (1406) is arranged in the climbing frame (1401), and the second motor (1406) is connected with a driven sprocket (1410) at the other side of the rollers (1404) through a driving belt (1409);
two rollers (1404) on the upper and lower sides of the climbing frame (1401) are abutted against the surface of a piston rod of the hydraulic rod (1).
3. The rust detection device for a hydraulic hoist piston rod according to claim 2, characterized in that: the two ends of the climbing frame (1401) are also provided with a stretched support arm (1402), the end part of the support arm (1402) is provided with an oil removing sponge body (1403), and the end surface of the oil removing sponge body (1403) exceeds the furthest end of the roller (1404) in the horizontal direction or is flush with the furthest end of the roller (1404) in the horizontal direction;
the surface of the oil removing sponge body (1403) is attached to the outer surface of the piston rod.
4. The rust detection device for a hydraulic hoist piston rod according to claim 2, characterized in that: the climbing frame (1401) is provided with a tensioning support arm (1408), the tensioning support arm (1408) is provided with a tensioning plate (1407), a plurality of waist-shaped holes are formed in the tensioning plate (1407), a screw penetrates through the waist-shaped holes to be connected with the tensioning support arm (1408), one side of the tensioning plate (1407) is provided with a tensioning wheel (1411), and the tensioning wheel (1411) abuts against the synchronous transmission belt (1405).
5. The rust detection device for a hydraulic hoist piston rod according to claim 2, characterized in that: at least two first guide posts (1412) are further arranged on the climbing frame (1401), and the first guide posts (1412) are in sliding connection with the first coaming (601);
a threaded rod (1413) is further arranged on the climbing frame (1401), the threaded rod (1413) is in threaded connection with the locking and adjusting device (16), a dial (1601) of the locking and adjusting device (16) is in rotary connection with the first coaming (601), the dial (1601) is in threaded connection with the threaded rod (1413), and a rotary handle is arranged outside the dial (1601);
a lock nut (1602) is also provided, the lock nut (1602) passing through the dial (1601) to abut against the surface of the first shroud (601) or threaded rod (1413).
6. The rust detection device for a hydraulic hoist piston rod according to claim 1, characterized in that: at least two second guide columns (1701) are arranged on the electromagnetic adsorption device (17), the second guide columns (1701) are connected with the second coaming (602) in a sliding mode, a limit head (1703) is arranged at the tail end of each second guide column (1701), and a spring (1702) is arranged between each limit head (1703) and each second coaming (602);
the surface of the electromagnetic adsorption device (17) is of an arc-shaped structure, and the arc-shaped structure is matched with the surface of a piston rod of the hydraulic rod (1).
7. The rust detection device for a hydraulic hoist piston rod according to claim 1, characterized in that: the detection device comprises a linear array camera (9) and a laser camera (11), wherein an illumination device (10) is arranged on one side of the linear array camera (9), the laser camera (11) and the illumination device (10) are respectively arranged on a rotating seat (12), a plurality of oppositely arranged clamping wheels (1201) are arranged under the rotating seat (12), and the clamping wheels (1201) are arranged on two sides of the annular guide rail (15);
a motor (8) is further arranged on the rotating seat (12), a gear (801) is arranged at the output end of the motor (8), an annular rack is further arranged on the annular guide rail (15), and the rack is meshed with the gear (801);
the rotary seat (12) is also provided with a marking block (1202), the annular guide rail (15) is provided with an infrared detection device (1501), the infrared detection device (1501) is in a U-shaped structure, and the marking block (1202) passes through the infrared detection device (1501);
be equipped with first laser rangefinder (7) and second laser rangefinder (13) on survey robot skeleton (6), first laser rangefinder (7) and second laser rangefinder (13) detect the opposite direction, and first laser rangefinder (7) and second laser rangefinder (13) detect the direction and are parallel with the piston rod.
8. The rust detection device for a hydraulic hoist piston rod according to claim 1, characterized in that: the laser camera (11) is mounted with the rotating seat (12) through a mounting folded plate (1101), a plurality of waist-shaped holes are formed in the mounting folded plate (1101), and nuts penetrate through the waist-shaped holes to be connected with the rotating seat (12);
the linear array camera (9) is clamped with the mounting frame (901), the mounting frame (901) is in sliding connection with the adjusting seat (902), an electric push rod is arranged in the adjusting seat (902), the end part of the electric push rod is connected with the mounting frame (901), and the adjusting seat (902) is arranged on the rotating seat (12);
the lofting directions of the laser camera (11) and the linear array camera (9) face to the center point of the skeleton (6) of the measuring robot.
9. The rust detection device for a hydraulic hoist piston rod according to claim 1, characterized in that: two groups of roller blocks are arranged on two sides of the cylinder body of the hydraulic rod (1), and the winch (3) passes through the roller blocks through the traction rope (4) to be connected with the detection robot framework (6);
the anti-falling fixed anchor (5) is further arranged, the anti-falling fixed anchor (5) is fixed on the wall body, and the anti-falling fixed anchor (5) is connected with the detection robot framework (6) through the traction rope (4).
10. The detection method of the rust detection device for the hydraulic hoist piston rod according to any one of claims 1 to 9, characterized by comprising the following steps: the method comprises the following steps:
s1, a plurality of coamings and annular guide rails (15) are assembled around a piston rod of a hydraulic rod (1), a rotating seat (12) is installed, a linear camera (9), a lighting device (10) and a laser camera (11) are installed on the rotating seat (12), a locking adjusting device (16) is rotated, the climbing device (14) is pushed to the surface of the piston rod of the hydraulic rod (1) by the locking adjusting device (16), and the adjusting devices (16) are adjusted to enable a central shaft of a detection robot framework (6) to be coaxial with the piston rod of the hydraulic rod (1);
s2, detecting that the robot climbs to a target position of a piston rod of the hydraulic rod (1), and starting to move around the piston rod body by the visual detection equipment;
s3, starting acquisition by the linear array camera (9) and the laser camera (11), and transmitting acquired data to a rust analysis computer after completing one circle of acquisition;
s4, processing the obtained image by an analysis computer, extracting suspicious defects, generating a report, processing data, detecting that the robot moves, returning the visual detection equipment to the original position, and starting cutting and splicing of the image acquired next time;
s4, collecting the piston rods for a plurality of times, and splicing adjacent images;
the detection robot is provided with a laser range finder for determining the actual position of the image on the piston rod, the height information obtained by the laser range finder can obtain the overlapping size of the adjacent images, and the pictures can be spliced after the corresponding size is cut down;
s5, the height information is obtained through a laser displacement sensor, the laser displacement sensor strikes a reference plate as a starting point, a height value H1 is read, the height difference H2 between the laser displacement sensor and a linear array camera (9) and between the laser displacement sensor and a laser camera (11) is measured, and the height H=H2+H2 of the defect position relative to the reference plate is obtained;
the defect circumferential information takes the position of a photoelectric sensor as an initial origin, and the circumferential position of a defect point is determined by three factors of rotation detection time T, camera sampling rate and pixel position of the defect point;
s6, defect detection is divided into defect image acquisition and transmission and defect image algorithm processing;
the linear array camera (9) and the laser camera (11) are high-definition cameras, each scanning round is spliced into one Gao Qingtu,
the detection robot is provided with two computers, one computer is arranged on the detection robot and is used for image acquisition and transmission;
the other one is an industrial control notebook computer, and is placed in a remote area for image algorithm processing, the two are connected through a gigabit network cable, so that the timeliness of the whole image detection can be ensured, and after the camera rotates for one circle, the image can be transmitted back to the remote notebook computer at intervals of 1-2 s;
s7, starting a detection instruction, automatically transmitting the camera image back to the industrial control notebook computer, automatically storing each piece of data in the notebook computer, and automatically analyzing the image by an algorithm to obtain suspected defect coordinate information.
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