CN117140543A - Intelligent water-cooled wall climbing maintenance operation robot and working method thereof - Google Patents
Intelligent water-cooled wall climbing maintenance operation robot and working method thereof Download PDFInfo
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- CN117140543A CN117140543A CN202311040069.2A CN202311040069A CN117140543A CN 117140543 A CN117140543 A CN 117140543A CN 202311040069 A CN202311040069 A CN 202311040069A CN 117140543 A CN117140543 A CN 117140543A
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Classifications
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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
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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
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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
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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
- B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
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- Engineering & Computer Science (AREA)
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Abstract
The invention discloses an intelligent water-cooled wall climbing maintenance operation robot and a working method thereof. The robot body is used for carrying a patrol positioning system and a use function system to complete the required flexible actions; the inspection positioning system is used for being responsible for position sensing and positioning navigation of the robot, and guaranteeing reliability of positioning data of the robot in work; the comprehensive power distribution system is used for being responsible for energy and power transmission of the whole equipment; the safe hoisting system is used for ensuring the safety of the robot on the surface of the water-cooled wall of the boiler and smoothly carrying out cable power supply; the throwing system is used for throwing the robot body to the surface of the water-cooled wall of the boiler; the functional system is provided with a functional module which accords with the protection grade and self-cleaning capability of the functional environment condition in the furnace, and can meet the long-time operation in the robot furnace. The method is used for solving the problems of overhauling, operation and maintenance of the boiler water wall tube.
Description
Technical Field
The invention belongs to the technical field of robots, and particularly relates to an intelligent water-cooled wall climbing maintenance operation robot and a working method thereof.
Background
In power plants, the safe operation of the boiler plant plays a decisive role for the production operation of the power plant, and the boiler heating surface pipes as an important component of the boiler plant are also always the focus of the safety protection inspection of the power plant. However, in recent years, more and more generator sets participate in deep peak shaving of a power grid, a large-sized unit is frequently started and stopped and runs for a long time under low load, and various problems are more likely to occur in a boiler heating surface pipe under the environment, so that the pipe is likely to fail in advance, such as bulge and fatigue crack of a water cooling wall, and the pipe is likely to be burst after (re) heat exchanger oxide skin is proliferated and falls off. The problem of leakage of a boiler heating surface pipe is one of the problems affecting the safe production operation of power generation enterprises, and seriously threatens the economical efficiency and the safety of unit operation.
According to statistical research, the boiler water wall failure accounts for the largest total number of boiler heating surface tube failures, and the loss can be effectively prevented in advance and reduced only by reinforcing the abrasion-proof and explosion-proof inspection of the boiler. The traditional boiler water wall anti-wear explosion-proof inspection mode mainly comprises visual inspection, wherein a high-altitude platform is erected for manual inspection or telescope remote observation, and the high-altitude platform is lower in working efficiency, high in cost, high in risk in the working process and high in working strength, and the telescope is required to be erected for remote observation and is relatively low in observation precision. Meanwhile, each power generation group company puts forward higher and more specific requirements on wear resistance and explosion resistance, the principle is' check when the power generation group company stops, but as the capacity of the power generation group is increased, the four-pipe structure is more and more complex, the check area is also more and more large, and as the safety requirement is improved, the annual detection frequency is increased, but the number of check personnel is reduced year by year. Therefore, a new technology for intelligently checking wear and explosion of a boiler is urgently needed to solve the problems for power generation enterprises. The abrasion-proof explosion-proof inspection level of the boiler heating surface pipe of the thermal power generation enterprise is improved, boiler leakage is reduced, and important contribution is made for guaranteeing safe and stable operation of the unit.
Disclosure of Invention
The invention provides an intelligent water wall climbing maintenance robot which is used for solving the maintenance and operation problems of a boiler water wall pipe.
The invention provides a working method of an intelligent water-cooled wall climbing maintenance operation robot, which is used for realizing maintenance operation of the intelligent water-cooled wall climbing maintenance operation robot on a boiler water-cooled wall pipe.
The invention is realized by the following technical scheme:
an intelligent water-cooled wall climbing maintenance robot comprises a robot body, a patrol positioning system, a comprehensive power distribution system, a safe hoisting system, a throwing system and a using function system;
the robot body is used for carrying a patrol positioning system and a use function system, meets the load weight requirement, can realize quick, stable and safe movement in the vertical and horizontal directions of the water-cooled wall surface of the boiler, and completes the required flexible action;
the inspection positioning system is used for taking charge of position sensing and positioning navigation of the robot, reducing errors by adopting more than two positioning calculation methods and guaranteeing reliability of positioning data of the robot in work;
the comprehensive power distribution system is used for being responsible for energy and power transmission of the whole equipment, adopts a cable mode, takes 220V alternating current in a field environment, and meets the actual power distribution required by the system equipment through comprehensive transformation;
The safe hoisting system is used for ensuring the safety of the robot on the surface of the water-cooled wall of the boiler and smoothly carrying out cable power supply;
the throwing system is used for throwing the robot body to the surface of the water-cooled wall of the boiler, so as to realize the intelligent installation and control operation process and reduce the entering operation process of personnel in the boiler;
the functional system is provided with a functional module which accords with the protection grade and self-cleaning capability of the functional environment condition in the furnace, and can meet the long-time operation in the robot furnace.
An intelligent water-cooled wall climbing maintenance robot comprises a robot body, a driving module, an adsorption module, a walking module, a visual illumination module, a communication module, a sensing module and a reserved position interface;
the driving module is a power source of the robot body, and the speed of the driving module is greater than 12m/min;
the adsorption module is permanent magnet adsorption, meets the requirements of the integral adhesion of the robot and the water-cooled wall surface of the boiler, has a maximum load of more than 30kg, and ensures that the robot can be adsorbed on the water-cooled wall surface of the boiler when the power supply is interrupted;
the walking module realizes the in-situ steering, transverse movement, longitudinal movement and four-quadrant arbitrary angle movement of the robot on the surface of the membrane water wall under a Cartesian coordinate system;
The visual illumination module meets the requirements of light intensity and angle of image data acquisition and visual observation, and is suitable for a dim and severe environment in a furnace;
the control circuit and the data circuit in the communication module are respectively independent, so that the safety of communication of the robot in the working process is ensured;
the sensing module comprises an anti-collision sensor, a temperature and humidity sensor, a laser limit sensor and a dust concentration detection sensor, wherein the working range of all the sensors is divided into six directions, namely an upper direction, a lower direction, a left direction, a right direction, a front direction, a rear direction, a front direction, a rear direction and a rear direction, and signals acquired by the sensors are transmitted to a robot terminal control system;
the reserved position interface is a national standardized software and hardware interface and is connected with a using functional system so as to adapt to the transplanting and universality of the platform.
An intelligent water-cooled wall climbing maintenance operation robot, wherein the inspection positioning system comprises a laser radar, a 3D laser positioning system, an odometer, a gyroscope, a counter, an altimeter and visual perception;
measuring data are obtained by using the measuring sensor element, and the positions of the robots are comprehensively judged through positioning algorithm processing according to the structural size parameters of the boiler and the arrangement condition of the tube rows, so that accumulated errors in operation are eliminated;
the positioning navigation is specifically to set track planning parameters by using position sensing and preset navigation programs, so that the robot can navigate in a map built-up manner in an effective working area in the furnace and autonomously walk to complete a work task.
The intelligent water-cooled wall climbing maintenance robot comprises a power module, a moment detection module, an anti-falling safety rope, an anti-falling transmission module, a power supply cable, a retraction transmission module, a cooperative control module and a hoisting state display protection module;
the power module provides rotary power moment for the whole safe hoisting system; the maximum holding torque is greater than 100n x m;
the power control box keeps torque control when the robot moves, and is suitable for the change of torque in the use process;
the moment detection module is formed by arranging a multipoint moment sensor inside the anti-falling transmission module and the winding and unwinding transmission module, perceiving moment born by the anti-falling safety rope and the power supply cable, feeding back to the power module, and guaranteeing moment control and adjustment of the robot during movement;
one end of the anti-falling safety rope is fixed on the robot body, and the other end of the anti-falling safety rope is fixed on the anti-falling transmission module and is used for preventing the robot from falling accidentally during working;
the anti-falling transmission module is driven by the power module through a speed change gear and a program control, is used for winding and unwinding the anti-falling safety rope, has two working modes of automatic winding and unwinding and manual winding and unwinding, is convenient to operate, and has the winding and unwinding speed coordinated with the movement speed of the robot body;
One end of the power supply cable is inserted into the robot body, and the other end of the power supply cable is fixed on the winding and unwinding transmission module and is used for connecting the comprehensive power distribution system with power supply of the robot equipment;
the winding and unwinding transmission module is driven by the power module through a speed change gear and a program control, is used for winding and unwinding a power supply cable, avoids the additional bearing of a robot body and causes overload of the robot, and has two working modes of automatic winding and unwinding and manual winding and unwinding, and the winding and unwinding speed is consistent with the movement speed of the robot body.
An intelligent water-cooled wall climbing maintenance operation robot, the cooperative control module is communicated with a robot terminal control system to acquire speed information of a robot body and position information of a patrol positioning system, the power module, the anti-falling transmission module and the retraction transmission module of the safe hoisting system are controlled and regulated, so that the automatic cooperative coordination of the anti-falling safety rope and the power supply cable in the movement process of the robot is realized;
the cooperative control module is provided with a multi-path braking interlocking setting, and in the automatic working process of the robot, the robot body, the collision sensor, the inspection positioning system, the moment detection module, the anti-falling transmission module, the retraction transmission module and the like are abnormal or out of sync and enter a braking interlocking state, all the states enter an interlocking state at the moment, and the unlocking mode is that the locking is gradually released after manual adjustment and confirmation;
The hoisting state display protection module comprises moment detection display, speed detection display and state detection display;
the moment detection display comprises a moment display, a moment display and a dynamic moment display;
the speed detection display comprises a speed oscilloscope for displaying the speed, the speed direction and the dynamic speed of the anti-falling safety rope and the power supply cable;
the state detection display comprises a connection state, a synchronous state, an interlocking state, an electric quantity state, a rope state, a cable state, communication quality and a power tool state of each hoisting module.
The intelligent water-cooled wall climbing maintenance robot comprises a structured automatic throwing device, a track and a line butt-joint device, wherein after a hearth is cooled to be less than or equal to 60 degrees, a robot body is installed on the structured automatic throwing device of the throwing system, enters a manhole of a boiler through the track and is adsorbed on the surface of the water-cooled wall of the boiler, and the line butt-joint device is used for automatically butt-jointing a safe hoisting system and connecting a line.
An intelligent water-cooled wall climbing maintenance robot, wherein the use function system comprises a cleaning system, a visual detection system, a nondestructive thickness measurement system, a polishing system, a welding system, a nondestructive detection system, a laser cladding system and the like, and structures, hardware and software interfaces required by other extensible function modules are reserved;
The cleaning system meets the cleaning requirement and the cleaning effect of the surface of the all-position water-cooled wall of the boiler hearth, and improves the moving safety of the robot body, the definition of image acquisition and the thickness measuring accuracy;
the system interface adopts a standardized design and is connected with the robot body for communication;
the cleaning mechanical structure adopts a standardized design, is connected with the robot body, and the tail end of the structure table can be lifted upwards, so that the cross-region operation is facilitated;
the cleaning device is used for cleaning dust and coke residues on the surface of the pipe wall; different cleaning modes are selected to effectively adapt to the cleaning requirement so as to achieve the cleaning effect;
the cleaning control module is in communication connection with the terminal control system to realize remote operation control.
An intelligent water-cooled wall climbing maintenance operation robot, wherein a visual detection system is responsible for collecting the surface state of a pipe wall and monitoring the environment, and comprises a system interface, an environment shooting module, a rotary control cradle head, a pipe wall shooting module, a mobile space platform, a function monitoring shooting module and an image storage and transmission module;
the system interface adopts a standardized design and is connected with the robot body for communication;
the environment shooting module is a high-definition camera suitable for dim and severe environments, is 45 times of optical zoom and optical anti-shake, has shooting, video recording and self-cleaning functions before a lens, and is arranged on a rotary control cradle head;
The rotary control cradle head enables the environment shooting module to rotate within the range of 0-360 degrees horizontally and 0-90 degrees vertically, is in communication connection with the terminal control system, automatically or manually adjusts the position of the camera, and realizes the inspection of the surrounding environment state;
the pipe wall shooting module is a high-definition camera suitable for dim and severe environments, is 5 times of optical zoom and optical anti-shake, has shooting, video recording and self-cleaning functions before a lens, and is arranged on a mobile space platform;
the mobile space platform enables the pipe wall shooting module to move in the front-back direction, the left-right direction, the up-down direction, the left-right direction and the up-down direction, is in communication connection with the terminal control system, automatically or manually adjusts the position of the camera, and records the state information of the pipe wall surface;
the function monitoring shooting module is a high-definition camera suitable for dim and severe environments, is 5 times optical zoom and optical anti-shake, has shooting, video recording and pre-lens self-cleaning functions, is arranged on a robot body, is in communication connection with a terminal control system, can monitor working states of a cleaning system, a visual detection system, a nondestructive thickness measurement system, a polishing system, a welding system, a nondestructive detection system, a laser cladding system and the like, and assists a specific function module to realize working condition adaptation and complete corresponding functions;
The image storage and transmission module is in communication connection with the terminal control system and returns data to an operator in real time.
An intelligent water-cooled wall climbing maintenance robot, wherein the nondestructive thickness measuring system is responsible for carrying out quick positioning screening and regular intensive scanning on the thickness of a pipe wall and comprises a system interface, an electromagnetic ultrasonic thickness measuring module, a triaxial displacement platform and a data storage and transmission module;
the system interface adopts a standardized design and is connected with the robot body for communication;
the electromagnetic ultrasonic thickness measuring module does not need a coupling agent when in work, allows paint, rust and roughness to exist on the surface of a workpiece, has a thickness measuring range of 1.5-100 mm, has a minimum curvature diameter of the surface of a measured object of more than 10mm, and has measuring precision of 0.01-0.05 mm, and is arranged on a three-axis displacement platform;
the triaxial displacement platform enables the electromagnetic ultrasonic thickness measuring module to rotate in the front-back, left-right, up-down and up-down directions and in a range, the electromagnetic ultrasonic thickness measuring module is in communication connection with the terminal control system, and is matched with the function monitoring shooting module to identify the central line position of each or the current working pipe wall, automatically track or manually adjust the position, adjust the position to a detectable relative angle and distance according to different water wall diameters, and continuously and rapidly measure the wall thickness of the pipeline;
The data storage transmission module is in communication connection with the terminal control system and transmits continuous thickness measurement data back to an operator in real time;
the wall thickness data record display inquiry and model matching display module is used for realizing real-time storage, real-time retrieval and viewing, and the wall thickness data record display inquiry and model matching display module is used for forming a thickness measurement log through host data processing, drawing a wall thickness data cloud chart of the water-cooled wall, and intuitively analyzing the overall state of the water-cooled wall.
An intelligent water-cooled wall climbing maintenance robot, wherein the polishing system is responsible for abnormal polishing treatment on the surface of a pipe wall and comprises a system interface, a mechanical polishing grinding wheel, a six-axis mechanical arm and a communication control module;
the welding system is responsible for welding treatment of pipeline leakage;
the nondestructive testing system is responsible for nondestructive testing of the pipeline;
the laser cladding system is responsible for laser surfacing treatment of the surface of the pipeline.
The working method of the intelligent water-cooled wall climbing maintenance operation robot uses the intelligent water-cooled wall climbing maintenance operation robot, and the working method specifically comprises the following steps of,
firstly, assembling an intelligent water-cooled wall climbing maintenance robot, supplying power to the whole robot, and carrying out replacement and switching management of robot configuration, management of a robot body, comprehensive power distribution, safe hoisting, a functional system, a terminal controller and accessory formation; carrying out manual control on the movement of the robot body, and synchronizing an indication lighting system, a functional lighting system, a self-cleaning system and a safe hoisting system; after reaching the appointed position, opening a visual modeling cruising task program, setting a working cruising path parameter, wherein the working cruising path parameter comprises a patrol area, a patrol path, a motion origin point, a motion inflection point and a motion end point, and starting the robot body to move for automatic control;
Starting a cleaning system, selecting a cleaning mode, adjusting a cleaning mechanical structure, controlling a cleaning device and cleaning accessories, and setting modes and parameters; after the cleaning system is executed, returning to a working starting point, starting the visual detection system and the nondestructive thickness measurement system, and controlling the nondestructive thickness measurement system of the visual detection system to prepare to execute a working task;
displaying the whole information of the boiler through an environment model, acquiring feedback data of a patrol positioning system, and representing the position and the patrol track of the robot body; displaying surrounding environment state parameters and robot body states through the environment body states;
carrying out data image acquisition record processing; if the robot body is abnormal, the function system is abnormal, the defect identification is abnormal, the data exceeds the standard, the communication is abnormal, the alarm is released by manual operation, and the task is continued;
the safety hoisting system acquires the speed information of the robot body and the position information of the inspection positioning system, so that an anti-falling safety rope and a power supply cable in the movement process of the robot are automatically matched in a cooperative manner;
finally, finishing the work task, returning to the initial setting position, manually controlling the robot body to move, and returning to the manhole at the bottom of the boiler; the robot body is separated from the safe hoisting system and moves out of the manhole of the boiler through an automatic throwing device; powering down the whole device; disassembling a patrol positioning system and an optional use function system which are arranged on the robot body; and (3) collecting cables, and installing a throwing system at a manhole at the bottom of the boiler, wherein the safe lifting system and the comprehensive power distribution system are installed at the top of the furnace.
The beneficial effects of the invention are as follows:
the invention can carry out anti-wear and anti-explosion inspection and problem treatment on the boiler water wall after the furnace is shut down, solves the problems of short anti-wear and anti-explosion standby or temporary inspection time, low efficiency, high cost, heavy task and the like of a power plant, and replaces manual four-pipe overhauling and maintenance work.
The invention can systematically adjust the set parameters according to the specific furnace type, can carry a multi-information acquisition module and a multi-task processing module according to the specific overhaul requirement, can realize remote control, realize full-automatic and rapid acquisition of four-pipe information in a hearth, replace manual maintenance work in severe operation places, improve the inspection efficiency, shorten the overhaul period, reduce the economic cost, solve the field blind area, help technicians to effectively identify defects, process the problems, make up for the insufficient experience of personnel, and further improve the safe and economic operation level of the boiler.
The robot system adopts a detachable structural design, can be combined and configured with functional modules at will according to different purposes, can be reused, operates stably, has simple logic principle, wide applicability and convenient operation, can solve a series of problems of overhauling and maintaining the water wall tube of the boiler, and also provides a selection mode for overhauling and maintaining other high-level complex environments.
Drawings
FIG. 1 is a schematic diagram of a logical analysis framework of an overall system architecture according to the present invention.
Fig. 2 is a schematic diagram of a logical analysis framework of a robot body composition structure according to the present invention.
FIG. 3 is a schematic diagram of a structural logic analysis framework of the inspection position system according to the present invention.
Fig. 4 is a schematic diagram of a structural logic analysis framework of the safe hoisting system of the invention.
FIG. 5 is a schematic diagram of a structural logic resolution framework of the functional system of the present invention.
FIG. 6 is a schematic diagram of a structural logic analysis framework for a cleaning system, which is a function of the present invention.
FIG. 7 is a schematic diagram of a logical analysis framework for a constituent structure of a visual inspection system using functions according to the present invention.
FIG. 8 is a schematic diagram of a logical analysis framework of the structure of the functional-nondestructive thickness measuring system.
Fig. 9 is a schematic diagram of a logical analysis framework of a terminal control system composition structure according to the present invention.
Fig. 10 is a schematic diagram of a logical analysis framework of a terminal control system-functional system start-stop operation control composition structure according to the present invention.
Fig. 11 is a schematic diagram of a logical analysis framework of a terminal control system, namely, environment ontology state display and data image acquisition and recording processing composition structure.
FIG. 12 is a schematic diagram of a logical analysis framework of an artificial intelligence analysis management system according to the present invention.
Detailed Description
In the following description, for purposes of explanation and not limitation, specific details are set forth such as the particular system architecture, techniques, etc., in order to provide a thorough understanding of the embodiments of the present application. It will be apparent, however, to one skilled in the art that the present application may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the present application with unnecessary detail.
It should be understood that the terms "comprises" and/or "comprising," when used in this specification and the appended claims, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
It is also to be understood that the terminology used in the description of the application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used in this specification and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
The following description of the embodiments of the present application will be made more fully with reference to the accompanying drawings, in which 1-12 are shown, it being apparent that the embodiments described are only some, but not all embodiments of the application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application, but the present application may be practiced in other ways other than those described herein, and persons skilled in the art will readily appreciate that the present application is not limited to the specific embodiments disclosed below.
By using the robot system, the wear-resistant and explosion-proof inspection and problem treatment can be performed on the boiler water wall after the furnace is shut down, so that the problems of short wear-resistant and explosion-proof standby or temporary inspection time, low efficiency, high cost, heavy task and the like of a power plant are solved, and the four-pipe overhaul and maintenance work is replaced by manual work. Meanwhile, the set parameters can be systematically adjusted according to the specific furnace type, the multi-information acquisition module and the multi-task processing module can be carried according to the specific overhaul requirements, the remote control can be realized, the full-automatic rapid acquisition of four-pipe information in the hearth is realized, the manual maintenance work in a severe operation place is replaced, the inspection efficiency is improved, the overhaul period is shortened, the economic cost is reduced, the field blind area is solved, the defects are effectively identified by technicians, the processing problem is solved, the experience of the staff is not enough, and the safe and economic operation level of the boiler is improved.
The robot system adopts a detachable structural design, can be used repeatedly according to different purposes, has the advantages of capability of configuring functional modules in an arbitrary combination mode, stable operation, simple logic principle, wide applicability and convenient operation, can solve a series of problems of overhauling and maintaining the water wall tube of the boiler, and also provides a selection mode for overhauling and maintaining other high-level complex environments.
An intelligent water-cooled wall climbing maintenance robot comprises a robot body, a patrol positioning system, a comprehensive power distribution system, a safe hoisting system, a throwing system and a using function system;
the robot body is used for carrying a patrol positioning system and a use function system, meets the load weight requirement, can realize quick, stable and safe movement in the vertical and horizontal directions of the water-cooled wall surface of the boiler, and completes the required flexible action;
the inspection positioning system is used for taking charge of position sensing and positioning navigation of the robot, reducing errors by adopting more than two positioning calculation methods and guaranteeing reliability of positioning data of the robot in work;
the error reduction method adopting more than two positioning calculation methods is characterized in that based on UWB space positioning, spatial horizontal calibration of a laser displacement sensor is performed through the calibration of a gyroscope sensing gravity direction, and spatial position information is corrected in a combined mode;
The comprehensive power distribution system is used for being responsible for energy and power transmission of the whole equipment, adopts a cable mode, takes 220V alternating current in a field environment, and meets the actual power distribution required by the system equipment through comprehensive transformation;
the comprehensive transformation is specifically that 220V on-site alternating current is transformed into safe voltage smaller than 36V actually used by a robot through an iron core coil transformer according to the principle of induced electromotive force;
the safe hoisting system is used for ensuring the safety of the robot on the surface of the water-cooled wall of the boiler and smoothly carrying out cable power supply;
the throwing system is used for throwing the robot body to the surface of the water-cooled wall of the boiler, so as to realize the intelligent installation and control operation process and reduce the entering operation process of personnel in the boiler;
the using functional systems are respectively designed by adopting a detachable structure, the industrial styles are uniform, and different functional systems are carried on the robot body according to different using purposes; the robot furnace has the function modules with protection level (more than 65 levels of waterproof and dustproof IP) and self-cleaning capability which meet the environmental conditions of the functions in the furnace, and meets the long-time operation in the robot furnace.
An intelligent water-cooled wall climbing maintenance robot, wherein the robot body is small in size, the cross section area is less than 450mm wide by 430mm high, the maximum weight is less than 50kg, and the robot has the capability of traversing a narrower space in a specific area;
The modules are integrally designed for a system, have uniform industrial style, have protection levels (more than 65 levels of waterproof and dustproof IP) and self-cleaning capability which meet the environmental conditions of functions in the furnace, and meet the long-time operation in the robot furnace;
the robot body comprises a driving module, an adsorption module, a walking module, a visual illumination module, a communication module, a sensing module and a reserved position interface;
the driving module is a power source of the robot body, and the speed of the driving module is larger than 12m/min by adopting a stepless speed change mode;
the adsorption module is permanent magnet adsorption, meets the requirements of the integral attachment of the robot and the water-cooled wall surface of the boiler, has a maximum load of more than 30kg, ensures that the robot can be adsorbed on the water-cooled wall surface of the boiler when power supply is interrupted, and prevents the robot from falling, slipping, shifting and the like;
the walking module realizes the in-situ steering, transverse movement, longitudinal movement and four-quadrant arbitrary angle movement of the robot on the surface of the membrane water wall under a Cartesian coordinate system; the robot has the capability of crossing inclined planes on one side of the water-cooled wall, the maximum climbing angle is larger than 145 degrees, the robot has the capability of crossing areas in the whole area, the maximum transverse expansion angle is larger than 145 degrees, the robot has the capability of crossing obstacles in the whole position, and the maximum obstacle crossing height is not smaller than 50mm;
The visual illumination module comprises a work indicator lamp, position indication illumination and functional illumination; the working indicator lamp is red and green, the position indication illumination is yellow, the functional illumination is integrally arranged in six directions of the robot body, the requirements of light intensity and angle of image data acquisition and visual observation are met, and the device is suitable for a dim and severe environment in a furnace;
the control circuit and the data circuit in the communication module are respectively independent, the wireless and wired modes are switched seamlessly, the redundant design of standby communication is provided, the safety of communication of the robot in the working process is ensured, and the furthest communication distance can reach 1000m;
the sensing module comprises an anti-collision sensor, a temperature and humidity sensor, a laser limit sensor and a dust concentration detection sensor, wherein the working range of all the sensors is divided into six directions, namely an upper direction, a lower direction, a left direction, a right direction, a front direction, a rear direction, a front direction, a rear direction and a rear direction, and signals acquired by the sensors are transmitted to a robot terminal control system;
the reserved position interface is a national standardized software and hardware interface and is connected with a using functional system so as to better adapt to the transplanting and universality of the platform.
An intelligent water-cooled wall climbing maintenance operation robot, wherein the inspection positioning system comprises a laser radar, a 3D laser positioning system, an odometer, a gyroscope, a counter, an altimeter and visual perception;
The position sensing is to obtain measurement data by using a measurement sensing element, and the measurement data are processed by a positioning algorithm according to the structural size parameters of the boiler and the arrangement condition of the tube rows, so that the position of the robot is comprehensively judged, and the accumulated error in the operation is eliminated
The measuring and sensing element is a laser radar, a 3D laser positioning, an odometer, a gyroscope, a counter, an altimeter and visual perception;
the positioning algorithm is a space geometric positioning algorithm based on mathematical modeling, combines the position information data with a robot inspection positioning system, and corrects the position information.
The positions of the robots comprise a global position of the boiler and a local position of the tube bank; the global position of the boiler comprises a furnace front region, a furnace rear region, a furnace left region and a furnace right region, and each region comprises an upper dip angle section, a straight section, a lower dip angle section and a negative dip angle section; the global positioning precision is less than or equal to +/-5 cm; the local positions of the tube rows comprise the identification of the tube numbers, the local positions of the tube sections of the single tube and the local positions of the gaps of the tube sections, and the local positioning precision is less than or equal to +/-5 mm;
the positioning navigation is specifically to set track planning parameters by using position sensing and preset navigation programs, so that the robot can navigate in a map built-up manner in an effective working area in the furnace and autonomously walk to complete a work task.
The intelligent water-cooled wall climbing maintenance robot comprises a power module, a moment detection module, an anti-falling safety rope, an anti-falling transmission module, a power supply cable, a retraction transmission module, a cooperative control module and a hoisting state display protection module;
the power module comprises a high-quality motor and a power control box, and provides rotary power moment for the whole safe hoisting system; the maximum holding torque is greater than 100n x m;
the power control box keeps torque control when the robot moves, and can be manually adjusted, and also can be adaptively adjusted through the torque detection module to adapt to the change of the torque in the use process;
the moment detection module is formed by arranging a multipoint moment sensor inside the anti-falling transmission module and the winding and unwinding transmission module, perceiving moment born by the anti-falling safety rope and the power supply cable, feeding back to the power module, and guaranteeing moment control and adjustment of the robot during movement;
one end of the anti-falling safety rope is fixed on the robot body, and the other end of the anti-falling safety rope is fixed on the anti-falling transmission module and is used for preventing the robot from falling accidentally during working;
the anti-falling transmission module is arranged on the furnace top of the boiler, is driven by the power module through a speed change gear and a program control, is used for winding and unwinding an anti-falling safety rope, has two working modes of automatic winding and unwinding and manual winding and unwinding, is convenient to operate, and is coordinated with the movement speed of the robot body;
One end of the power supply cable is inserted into the robot body, and the other end of the power supply cable is fixed on the winding and unwinding transmission module and is used for connecting the comprehensive power distribution system with power supply of the robot equipment;
the retractable transmission module is arranged on the top of the boiler and is driven by the power module through a speed change gear and a program control, and is used for retracting and releasing a power supply cable, so that the robot is prevented from being overloaded due to the fact that the robot body is additionally loaded, and the retractable transmission module has two working modes of automatic retraction and manual retraction, and the retraction speed is consistent with the movement speed of the robot body.
An intelligent water-cooled wall climbing maintenance operation robot, the cooperative control module is communicated with a robot terminal control system to acquire speed information of a robot body and position information of a patrol positioning system, the power module, the anti-falling transmission module and the retraction transmission module of the safe hoisting system are controlled and regulated, so that the automatic cooperative coordination of the anti-falling safety rope and the power supply cable in the movement process of the robot is realized;
the cooperative control module is provided with a multi-path braking interlocking setting, and in the automatic working process of the robot, the robot body, the collision sensor, the inspection positioning system, the moment detection module, the anti-falling transmission module, the retraction transmission module and the like are abnormal or out of sync and enter a braking interlocking state, all the states enter an interlocking state at the moment, and the unlocking mode is that the locking is gradually released after manual adjustment and confirmation;
The hoisting state display protection module comprises moment detection display, speed detection display and state detection display;
the moment detection display comprises the functions of displaying the moment, the moment direction, the dynamic moment oscillograph and the like;
the speed detection display comprises the functions of displaying the speed, the speed direction, the dynamic speed oscillograph and the like of the anti-falling safety rope and the power supply cable;
the state detection display comprises a connection state, a synchronous state, an interlocking state, an electric quantity state, a rope state, a cable state, communication quality, a power tool state and the like of each hoisting module;
the intelligent water-cooled wall climbing maintenance robot comprises a structured automatic throwing device, a track and a line butt-joint device, wherein after a hearth is cooled to be less than or equal to 60 ℃, a robot body is arranged on the structured automatic throwing device of the throwing system, enters a manhole of a boiler through the track and is adsorbed on the surface of the water-cooled wall of the boiler, and is automatically butt-jointed with a safe hoisting system by the line butt-joint device to connect a line;
the boiler manhole is a hole for a robot to enter the boiler.
An intelligent water-cooled wall climbing maintenance robot, wherein the use function system comprises a cleaning system, a visual detection system, a nondestructive thickness measurement system, a polishing system, a welding system, a nondestructive detection system, a laser cladding system and the like, and structures, hardware and software interfaces required by other extensible function modules are reserved;
The cleaning system comprises a system interface, a cleaning mechanical structure, a cleaning device and a cleaning control module, meets the cleaning requirement and the cleaning effect of the surface of the water-cooled wall at the whole position of the boiler furnace, and improves the moving safety of the robot body, the definition of image acquisition and the thickness measuring accuracy;
the system interface adopts a standardized design and is connected with the robot body for communication;
the cleaning mechanical structure adopts a standardized design, is connected with the robot body, and the tail end of the structure table can be lifted upwards, so that the cross-region operation is facilitated;
the cleaning device comprises a mechanical arm carrying grinding wheel, high-pressure atomization cleaning, compressed air blowing, laser combustion recovery, flexible rotary steel brush or rolling adsorption cleaning and other modes, and is used for cleaning dust and coke residues on the surface of the pipe wall; different cleaning modes are selected to effectively adapt to the cleaning requirement so as to achieve the cleaning effect;
the cleaning device can effectively remove the hard coke residue on the surface of the water-cooled wall, and the dust containing the magnetic coke residue falls off and cannot influence the normal movement of the robot, so that the wall of the hearth is not damaged;
when the cleaning device uses a pipeline fitting, the cleaning device is matched with a safe hoisting system, and a cleaning pipeline transmission module are added;
The cleaning control module is in communication connection with the terminal control system to realize remote operation control; the control mode comprises an automatic mode and a manual mode, a cleaning switch, a speed and the like can be manually controlled, and the cleaning can be automatically carried out according to working conditions.
The visual detection system is responsible for collecting the surface state of the pipe wall and monitoring the environment, and comprises a system interface, an environment shooting module, a rotary control cradle head, a pipe wall shooting module, a mobile space platform, a function monitoring shooting module, an image storage transmission module, an image data recording, display, inquiring and model matching display module, a self-learning identification algorithm, a defect alarm positioning algorithm and the like;
the system interface adopts a standardized design and is connected with the robot body for communication;
the environment shooting module is a high-definition camera suitable for dim and severe environments, is 45 times of optical zoom and optical anti-shake, has shooting, video recording and self-cleaning functions before a lens, and is arranged on a rotary control cradle head;
the rotary control cradle head comprises a three-dimensional motion rotating shaft and a control unit, so that the environment shooting module rotates in the range of 0-360 degrees horizontally and 0-90 degrees vertically, is in communication connection with a terminal control system, and automatically or manually adjusts the position of a camera to realize the inspection of the state of the surrounding environment;
The pipe wall shooting module is a high-definition camera suitable for dim and severe environments, is 5 times of optical zoom and optical anti-shake, has shooting, video recording and self-cleaning functions before a lens, and is arranged on a mobile space platform;
the mobile space platform comprises a three-way mobile structure and a control unit, so that the pipe wall shooting module moves in the front-back direction, the left-right direction, the up-down direction, is in communication connection with a terminal control system, automatically or manually adjusts the position of a camera, and records the state information of the pipe wall surface;
the function monitoring shooting module is a high-definition camera suitable for dim and severe environments, is 5 times optical zoom and optical anti-shake, has shooting, video recording and pre-lens self-cleaning functions, is arranged on a robot body, is in communication connection with a terminal control system, can monitor working states of a cleaning system, a visual detection system, a nondestructive thickness measurement system, a polishing system, a welding system, a nondestructive detection system, a laser cladding system and the like, and assists a specific function module to realize working condition adaptation and complete corresponding functions;
the image storage and transmission module is in communication connection with the terminal control system and returns data to an operator in real time.
The image data record display inquiry and model matching display module is integrated in the terminal control system, achieves real-time storage, real-time retrieval and viewing, and forms an image log to be matched with a model for display through host data processing, draws a three-dimensional live-action model, and intuitively analyzes the overall state of the water-cooled wall;
The self-learning identification algorithm and the defect alarm positioning algorithm are integrated in the terminal control system, and the defects of cracks, bruise, deformation, abrasion, bulge, high-temperature corrosion and the like on the local surface of the water-cooled wall are automatically identified, alarmed and positioned.
An intelligent water-cooled wall climbing maintenance robot, wherein the nondestructive thickness measuring system is responsible for carrying out quick positioning screening and regular intensive scanning on the wall thickness of a pipe, and comprises a system interface, an electromagnetic ultrasonic thickness measuring module, a triaxial displacement platform, a data storage and transmission module, a wall thickness data record, display and inquiry and model matching display module, a wall thickness prediction algorithm, an abnormal alarm positioning algorithm and the like;
the system interface adopts a standardized design and is connected with the robot body for communication;
the electromagnetic ultrasonic thickness measuring module comprises an electromagnetic acoustic transducer, a contact sensor, a working indicator lamp and a matched program, does not need a coupling agent when the module works, allows paint, rust and roughness to exist on the surface of a workpiece, has a thickness measuring range of 1.5-100 mm (steel and stainless steel), has a minimum curvature diameter of the surface of a test object of more than 10mm and has measuring precision of 0.01-0.05 mm, and is arranged on a three-axis displacement platform;
The triaxial displacement platform comprises a mobile mechanical structure and a mobile control unit, so that an electromagnetic ultrasonic thickness measuring module rotates in the moving and range of front and back, left and right, up and down directions, is in communication connection with a terminal control system, is matched with a function monitoring shooting module, recognizes the central line position of each or the current working pipe wall, automatically tracks or manually adjusts the position, adjusts to a detectable relative angle (adjustable within the range of 80 degrees) and a distance according to different water wall diameters, and continuously and rapidly measures the wall thickness of a pipeline; the forward and backward movement precision is less than 2mm, the leftward and rightward movement precision is less than 5mm, the upward and downward lifting speed is greater than 10cm/s, and the self-adaptive rotation adjustment angle is greater than 30 degrees;
the data storage transmission module is in communication connection with the terminal control system and transmits continuous thickness measurement data back to an operator in real time;
the wall thickness data record display inquiry and model matching display module is integrated in the terminal control system, achieves real-time storage, real-time retrieval and viewing, and forms a thickness measurement log to be displayed in a matching mode with the model through host data processing, and the overall state of the water-cooled wall is intuitively analyzed by drawing a water-cooled wall thickness data cloud chart (or a three-dimensional live-action model).
The wall thickness prediction algorithm and the abnormal alarm positioning algorithm are integrated in a terminal control system, and the automatic identification, alarm and positioning of the wall thickness reduction and exceeding data of the water wall pipeline are carried out, so that the residual strength life is displayed.
An intelligent water-cooled wall climbing maintenance robot, wherein the polishing system is responsible for abnormal polishing treatment on the surface of a pipe wall and comprises a system interface, a mechanical polishing grinding wheel, a six-axis mechanical arm, a communication control module and the like;
the welding system is responsible for welding treatment of pipeline leakage and comprises a system interface, a TIG welding module, a six-axis mechanical arm, a communication control module and the like;
the nondestructive detection system is responsible for nondestructive detection of the pipeline and comprises a system interface, a DR module, an MT module, a UT module, a pulse vortex module, a six-axis mechanical arm, a communication control module and the like;
the laser cladding system is responsible for laser surfacing treatment on the surface of the pipeline and comprises a system interface, a laser cladding module, a six-axis mechanical arm, a communication control module and the like.
The control system comprises a terminal control system and an artificial intelligent analysis management system;
the terminal control system is responsible for the whole flow control and management of the robot system, and coordinates the communication and control coordination among the systems, so as to realize integrated monitoring and control;
The artificial intelligence analysis management system has comprehensive management capability and comprehensively improves the overall use effect.
Further, the terminal control system comprises a robot body movement control module, a cruise path planning and setting module, a power distribution control module, a function system start-stop operation control module, an environment model display module, an environment body state display module, a data image acquisition and recording processing module, an abnormality alarm processing module, a communication centralized control transmission module and an equipment configuration management module;
the robot body movement control comprises magnetic attraction, movement walking, driving speed control, steering control, obstacle crossing and surface crossing control, indication lighting control, functional lighting control, self-cleaning control, safe hoisting system synchronous control, mode selection control and other accessory operation control;
the cruise path planning setting module comprises position sensing information processing feedback, track parameter setting and visual modeling cruise task programs; the track parameters comprise a patrol area, a patrol path, a motion origin, a motion inflection point and a motion end point;
the power distribution control module comprises power distribution control and management of each system, and a main switch and a separate switch are controlled.
Further, the start-stop operation control of the functional system is to independently control each functional system, and the start-stop operation control of the functional system comprises a cleaning system control module, a visual detection system control module, a nondestructive thickness measurement system control module, a polishing system control module, a welding system control module, a nondestructive detection system control module and a laser cladding system control module;
the cleaning system control module comprises a cleaning mode selection module, a cleaning mechanical structure control module, a cleaning device control module and a cleaning accessory control module, wherein the control modes comprise an automatic mode and a manual mode, the cleaning switch and the cleaning speed can be manually controlled, and the cleaning can be automatically carried out according to working conditions;
the visual detection system control module comprises an environment shooting module control module, a rotation control cradle head control module, a pipe wall shooting module control module, a mobile space platform control module, a function monitoring shooting control module, an image storage transmission control module, an image data record display inquiry and model matched display control module, a self-learning identification algorithm start-stop control module and a defect alarm positioning start-stop control module;
the nondestructive thickness measurement system control module comprises an electromagnetic ultrasonic thickness measurement module control module, a triaxial displacement platform control module, a data storage and transmission module control module, a wall thickness data record display inquiry and model matching display module control module, a wall thickness prediction module and an abnormal alarm positioning start-stop control module;
The polishing system control comprises mechanical polishing grinding wheel control and six-axis mechanical arm control;
the welding system control comprises a TIG welding module control and a six-axis mechanical arm control;
the nondestructive testing system control comprises DR module control, MT module control, UT module control, pulse eddy current module control and six-axis mechanical arm control;
the laser cladding system control comprises laser cladding module control and six-axis mechanical arm control.
Further, the image data record display inquiry and model matching display module performs real-time storage, real-time retrieval and viewing, and forms an image log to be matched with a model for display through host data processing, draws a three-dimensional live-action model, and intuitively analyzes the overall state of the water-cooled wall;
the self-learning identification module and the defect alarm positioning module automatically identify, alarm and position defects such as cracks, bruises, deformations, abrasion, bulges and high-temperature corrosion on the local surface of the water-cooled wall.
Further, the environment model display is a display model for displaying the whole information of the boiler through verification processing according to the specific boiler structure size and the parameter setting modeling of the arrangement condition of the tube bank, and the feedback data of the inspection position system is obtained to represent the position and the inspection track of the robot body;
The environment body state display module comprises surrounding environment state parameter display and robot body state display;
the surrounding environment state display module comprises a pipe wall surface state display, a surrounding environment monitoring interface display, a function monitoring display, an image data record inquiry processing display, a model matching rendering display, a defect identification, an alarm positioning display and a safe hoisting system state display;
the robot body state display module comprises a working terminal panel interface, an automatic/manual working mode, a machine body model, state values of various sensors, robot body speed, robot positioning information, a task state, a communication connection state, a synchronous coordination state and abnormal alarm state display.
Further, the data image acquisition record processing module comprises sensing data, image data acquired by each functional system, measurement data and record, storage, calling, processing rendering and feedback of detection data;
the data processing rendering module comprises the steps of forming an image log and model matched display, forming a thickness measurement log and model matched display, drawing a three-dimensional live-action model, drawing a water wall thickness data cloud picture, automatically identifying defects, automatically identifying wall thickness reduction exceeding standard, calculating residual strength service life and alarming and positioning problems;
The abnormal alarm processing comprises robot body abnormal alarm processing, functional system abnormal alarm processing, defect identification abnormal alarm processing, data exceeding standard alarm processing and communication abnormal alarm processing.
Furthermore, the communication centralized control transmission module comprises control centralized control transmission, data calling, data cleaning, data encryption, data analysis, data uploading, cooperative feedback among systems, seamless switching of wireless and wired modes and redundancy design of standby communication;
the equipment configuration management module comprises a plurality of robot bodies, comprehensive power distribution, safe hoisting, a using function system, a terminal controller, constituent accessories, and configuration replacement and switching.
Further, the artificial intelligent analysis management system comprises a boiler management module, a heating surface management module, a boiler overall model management module, a historical data information management module and an intelligent data analysis management module;
the boiler management module comprises boiler number, manufacturer, production date, boiler structure size and tube bank arrangement information management of the boiler;
the heating surface management module comprises heating surface partition management and heating surface pipe information management;
The heating surface partition management module is used for dividing different areas of the boiler and comprises a water-cooled wall, a superheater, a reheater and an economizer;
the heating surface pipe information management module comprises specification materials, row numbers, pipe numbers, actual lengths, actual widths, pipe spacing, pipe diameters, pipe thicknesses, fin widths and fin thickness information management;
the boiler overall model management module comprises management of models built by verifying boiler management information and heating surface management information;
the historical data information management module comprises operation and maintenance task time length and task data record of each robot, and statistics comparison of overhaul times, task time length and task data of each boiler.
Further, the intelligent data analysis management module comprises an image log module, an image rendering module, a thickness measurement log module, a three-dimensional live-action model construction module, a data and model matching module, a water wall thickness data cloud picture module, a defect image recognition module, a wall thickness reduction exceeding recognition module, a residual strength service life calculation module and a problem alarm and positioning module;
an image log module: recording and inquiring the acquired images;
And an image rendering module: the acquired image is subjected to sharpening and integrity treatment;
thickness measurement log module: collecting records and inquiring of the pipe wall thickness;
and a three-dimensional live-action model construction module: reconstructing a three-dimensional scene of the boiler space and the tube bank model;
data and model matching module: calling the data, the image and the model mutually and processing and displaying the data;
wall thickness data cloud graph module of water-cooling wall: displaying the cloud image form of the pipe wall thickness measurement data;
a defect image identification module: abnormality identification of the pipe wall state;
wall thickness reduction exceeding identification module: marking the pipe wall thickness measurement data to below 70% of the standard wall thickness;
the remaining intensity life calculation module: material strength corresponding to the pipe wall thickness data and predicting the service life of subsequent abrasion;
and (3) alarming the problem: prompting and alarming of data abnormality and module abnormality;
and a positioning module: position information of the defect image in the boiler space, and position information of the thickness measurement data in the boiler space.
The working method of the intelligent water-cooled wall climbing maintenance operation robot uses the intelligent water-cooled wall climbing maintenance operation robot, and the working method specifically comprises the following steps of,
firstly, assembling an intelligent water-cooled wall climbing maintenance operation robot, calling a boiler management program, a heating surface management program, a boiler integral model management program and an intelligent data analysis algorithm management program, inputting information such as boiler numbers, manufacturers, production date, boiler structure sizes, tube row arrangement and the like in the boiler tube, inputting information such as boiler region division, tube specification materials, row numbers, tube numbers, actual lengths, actual widths, tube spacing, tube diameters, tube thicknesses, fin widths, fin thicknesses and the like in the heating surface management program, creating a boiler model by checking boiler management information and heating surface management information, loading an image log algorithm, an image rendering algorithm, a thickness measurement log algorithm, a three-dimensional live-action model construction algorithm, a data and model matching algorithm, a water-cooled wall thickness data cloud image algorithm, a defect image recognition algorithm, a wall thickness reduction exceeding recognition algorithm, a residual strength life calculation algorithm, a problem alarm and a positioning algorithm.
Starting a terminal control system, supplying power to the whole robot, carrying out replacement and switching management of robot configuration, managing a robot body, comprehensively distributing power, safely hoisting, using a functional system, a terminal controller and forming accessories; and carrying out manual control on the movement of the robot body, and synchronizing an indication lighting system, a functional lighting system, a self-cleaning system and a safe hoisting system. After reaching the appointed position, opening a visual modeling cruising task program, setting a working cruising path parameter, including a patrol area, a patrol path, a motion origin, a motion inflection point and a motion end point, starting the robot body to move and automatically control, starting and stopping a functional system to operate the figure 10, so that the robot can build a figure navigation in an effective working area in the furnace, walk autonomously and perform a working task;
tasks are started using the terminal control system fig. 9.
Taking the combined functions of the cleaning system figure 6, the visual detection system figure 7 and the nondestructive thickness measurement system figure 8 as an example, starting the cleaning system figure 6, selecting a cleaning mode, adjusting the cleaning mechanical structure, controlling the cleaning device and cleaning accessories, and setting modes and parameters; after the cleaning system figure 6 is executed, returning to a working starting point, starting a visual detection system figure 7 and a nondestructive thickness measurement system figure 8, controlling an environment shooting module, a rotary control holder, a pipe wall shooting module, a mobile space platform, a function monitoring shooting module, an image storage transmission module, an image data record display query and model matched display module, a self-learning identification algorithm, a defect alarm positioning algorithm start-stop and the like of the visual detection system, controlling an electromagnetic ultrasonic thickness measurement module, a triaxial displacement platform, a data storage transmission module, a wall thickness data record display query and model matched display module, a wall thickness prediction algorithm, an abnormal alarm positioning algorithm start-stop and the like of the nondestructive thickness measurement system, and preparing to execute a working task;
Terminal control system figure 9 shows the overall information of the boiler through an environment model in the task execution process, acquires the feedback data of the inspection position system figure 3, and characterizes the position and the inspection track of the robot body; displaying the surrounding environment state parameters and the robot body state through the environment body state display in fig. 11; the surrounding environment state display comprises a pipe wall surface state display, a surrounding environment monitoring interface display, a function monitoring display, an image data recording and inquiring processing display, a model matching rendering display, a defect identification and alarm positioning display and a safe hoisting system state display.
The robot body state display comprises a working terminal panel interface, an automatic/manual working mode, a machine body model, state values of various sensors, robot body speed, robot positioning information, a task state, a communication connection state, a synchronous coordination state and an abnormal alarm state.
Terminal control system figure 9 is used for carrying out data image acquisition record processing figure 11 in the task execution process; the system comprises sensing data, image data collected by each functional system, measurement data and detection data, and is used for recording, storing, calling, processing rendering and feedback. The data processing rendering comprises forming an image log and model matched display, forming a thickness measurement log and model matched display, drawing a three-dimensional live-action model, drawing a water wall thickness data cloud picture, automatically identifying defects, automatically identifying wall thickness reduction exceeding standard, calculating residual strength life, alarming and positioning.
In the task execution process, the terminal control system figure 9 can give an alarm if the robot body abnormality, the function system abnormality, the defect identification abnormality, the data exceeding the standard and the communication abnormality occur, and the alarm is released by manual operation to continue the task;
in the task execution process, the terminal control system figure 9 performs control centralized control transmission, data calling, data cleaning, data encryption, data analysis, data uploading and cooperative feedback among systems through the communication centralized control transmission module, so that wireless and wired two modes can be switched seamlessly.
The safe hoisting system figure 4 is responsible for guaranteeing the safety of the operation of the robot on the water-cooled wall surface and smooth power supply of the cable in the task execution process, and comprises a power module, a moment detection module, an anti-falling safety rope, an anti-falling transmission module, a power supply cable, a winding and unwinding transmission module, a cooperative control module, a hoisting state display protection module and the like to start working.
In the task execution process, the moment control of the power module is kept through the power control box in the process of robot movement in the safety hoisting system figure 4, the control box can be adjusted manually, and the moment detection module can also feed back the moment to the power module for self-adaptive adjustment, so that the moment change in the use process is adapted. Through preventing weighing down safety rope, prevent that the unexpected whereabouts of robot during operation from taking place. And the anti-falling safety rope is retracted and released through the anti-falling transmission module, and the retraction speed is coordinated with the movement speed of the robot body. The comprehensive power distribution system is connected with the power supply of the robot equipment through the power supply cable. Through receiving and releasing the transmission module, receive and release power supply cable, avoid the additional bearing of machine body, lead to the robot overload, receive and release speed is unanimous with the robot body velocity of movement. The robot terminal control system is communicated with the cooperative control module to acquire speed information of the robot body and position information of the inspection positioning system, and the power module, the anti-falling transmission module and the retraction transmission module of the safe hoisting system are controlled and regulated to realize automatic cooperative coordination of the anti-falling safety rope and the power supply cable in the movement process of the robot;
In the process of task execution, the cooperative control module in fig. 4 is provided with a multi-path braking interlocking setting, and in the process of automatic operation of the robot, the robot body, the collision sensor, the inspection positioning system, the moment detection module, the anti-falling transmission module, the retraction transmission module and the like are abnormal or out of sync and enter a braking interlocking state, and all the states enter mutual locking. The unlocking mode is to gradually unlock after manual adjustment and confirmation.
In the process of executing the task, the safe hoisting system in fig. 4 performs moment detection display, speed detection display and state detection display through the hoisting state display protection module. The moment detection display comprises display of moment magnitude, moment direction, dynamic moment oscillography and the like. The speed detection display comprises speed, speed direction, dynamic speed oscillograms and the like for displaying the anti-falling safety rope and the power supply cable. The state detection display comprises a connection state, a synchronous state, an interlocking state, an electric quantity state, a rope state, a cable state, communication quality, a power tool state and the like of each hoisting module.
Finally, finishing the work task, returning to the initial setting position, manually controlling the robot body to move, and returning to the manhole at the bottom of the boiler; the robot body figure 2 is separated from the safe hoisting system figure 4, and is moved out of a boiler manhole through an automatic throwing device; the overall device is powered down by the terminal control system fig. 9. Disassembling the inspection position system figure 3 and the optional use function system figure 5 which are installed on the robot body figure 2; and (3) collecting cables, disassembling the safety hoisting system installed on the furnace top, and installing a throwing system at a manhole at the bottom of the boiler and integrating the power distribution system.
After use, the artificial intelligent analysis management system figure 12 can be used for checking historical data information, including the operation and maintenance task duration of each robot, task data records, the maintenance times of each boiler, the statistical comparison of the task duration and the task data, and the like. If necessary, programs such as boiler management, heating surface management, boiler overall model management, intelligent data analysis algorithm and the like can be called for information backup or modification.
Claims (10)
1. The intelligent water-cooled wall climbing maintenance robot is characterized by comprising a robot body, a patrol positioning system, a comprehensive power distribution system, a safe hoisting system, a throwing system and a use function system;
the robot body is used for carrying a patrol positioning system and a use function system, meets the load weight requirement, can realize quick, stable and safe movement in the vertical and horizontal directions of the water-cooled wall surface of the boiler, and completes the required flexible action;
the inspection positioning system is used for taking charge of position sensing and positioning navigation of the robot, reducing errors by adopting more than two positioning calculation methods and guaranteeing reliability of positioning data of the robot in work;
the comprehensive power distribution system is used for being responsible for energy and power transmission of the whole equipment, adopts a cable mode, takes 220V alternating current in a field environment, and meets the actual power distribution required by the system equipment through comprehensive transformation;
The safe hoisting system is used for ensuring the safety of the robot on the surface of the water-cooled wall of the boiler and smoothly carrying out cable power supply;
the throwing system is used for throwing the robot body to the surface of the water-cooled wall of the boiler, so as to realize the intelligent installation and control operation process and reduce the entering operation process of personnel in the boiler;
the functional system is provided with a functional module which accords with the protection grade and self-cleaning capability of the functional environment condition in the furnace, and can meet the long-time operation in the robot furnace.
2. The intelligent water-cooled wall climbing maintenance robot of claim 1, wherein the robot body comprises a driving module, an adsorption module, a walking module, a visual lighting module, a communication module, a sensing module and a reserved position interface;
the driving module is a power source of the robot body, and the speed of the driving module is greater than 12m/min;
the adsorption module is permanent magnet adsorption, meets the requirements of the integral adhesion of the robot and the water-cooled wall surface of the boiler, has a maximum load of more than 30kg, and ensures that the robot can be adsorbed on the water-cooled wall surface of the boiler when the power supply is interrupted;
the walking module realizes the in-situ steering, transverse movement, longitudinal movement and four-quadrant arbitrary angle movement of the robot on the surface of the membrane water wall under a Cartesian coordinate system;
The visual illumination module meets the requirements of light intensity and angle of image data acquisition and visual observation, and is suitable for a dim and severe environment in a furnace;
the control circuit and the data circuit in the communication module are respectively independent, so that the safety of communication of the robot in the working process is ensured;
the sensing module comprises an anti-collision sensor, a temperature and humidity sensor, a laser limit sensor and a dust concentration detection sensor, wherein the working range of all the sensors is divided into six directions, namely an upper direction, a lower direction, a left direction, a right direction, a front direction, a rear direction, a front direction, a rear direction and a rear direction, and signals acquired by the sensors are transmitted to a robot terminal control system;
the reserved position interface is a national standardized software and hardware interface and is connected with a using functional system so as to adapt to the transplanting and universality of the platform.
3. The intelligent water-cooled wall climbing maintenance robot of claim 1, wherein the inspection positioning system comprises a laser radar, a 3D laser positioning, an odometer, a gyroscope, a counter, an altimeter, and a visual perception;
measuring data are obtained by using the measuring sensor element, and the positions of the robots are comprehensively judged through positioning algorithm processing according to the structural size parameters of the boiler and the arrangement condition of the tube rows, so that accumulated errors in operation are eliminated;
The positioning navigation is specifically to set track planning parameters by using position sensing and preset navigation programs, so that the robot can navigate in a map built-up manner in an effective working area in the furnace and autonomously walk to complete a work task.
4. The intelligent water-cooled wall climbing maintenance robot according to claim 1, wherein the safe hoisting system comprises a power module, a moment detection module, an anti-falling safety rope, an anti-falling transmission module, a power supply cable, a retraction transmission module, a cooperative control module and a hoisting state display protection module;
the power module provides rotary power moment for the whole safe hoisting system; the maximum holding torque is greater than 100n x m;
the power control box keeps torque control when the robot moves, and is suitable for the change of torque in the use process;
the moment detection module is formed by arranging a multipoint moment sensor inside the anti-falling transmission module and the winding and unwinding transmission module, perceiving moment born by the anti-falling safety rope and the power supply cable, feeding back to the power module, and guaranteeing moment control and adjustment of the robot during movement;
one end of the anti-falling safety rope is fixed on the robot body, and the other end of the anti-falling safety rope is fixed on the anti-falling transmission module and is used for preventing the robot from falling accidentally during working;
The anti-falling transmission module is driven by the power module through a speed change gear and a program control, is used for winding and unwinding the anti-falling safety rope, has two working modes of automatic winding and unwinding and manual winding and unwinding, is convenient to operate, and has the winding and unwinding speed coordinated with the movement speed of the robot body;
one end of the power supply cable is inserted into the robot body, and the other end of the power supply cable is fixed on the winding and unwinding transmission module and is used for connecting the comprehensive power distribution system with power supply of the robot equipment;
the retraction transmission module is driven by the power module through a speed change gear and a program control, is used for retracting a power supply cable, avoids overload of the robot caused by additional bearing of the robot body, and has two working modes of automatic retraction and manual retraction, wherein the retraction speed is consistent with the movement speed of the robot body;
the cooperative control module is communicated with the robot terminal control system, acquires speed information of the robot body and position information of the inspection positioning system, and controls and adjusts a power module, an anti-falling transmission module and a winding and unwinding transmission module of the safe hoisting system to realize automatic cooperative coordination of an anti-falling safety rope and a power supply cable in the movement process of the robot;
the cooperative control module is provided with a multi-path braking interlocking setting, and in the automatic working process of the robot, the robot body, the collision sensor, the inspection positioning system, the moment detection module, the anti-falling transmission module, the retraction transmission module and the like are abnormal or out of sync and enter a braking interlocking state, all the states enter an interlocking state at the moment, and the unlocking mode is that the locking is gradually released after manual adjustment and confirmation;
The hoisting state display protection module comprises moment detection display, speed detection display and state detection display;
the moment detection display comprises a moment display, a moment display and a dynamic moment display;
the speed detection display comprises a speed oscilloscope for displaying the speed, the speed direction and the dynamic speed of the anti-falling safety rope and the power supply cable;
the state detection display comprises a connection state, a synchronous state, an interlocking state, an electric quantity state, a rope state, a cable state, communication quality and a power tool state of each hoisting module.
5. The intelligent water-cooled wall climbing maintenance robot according to claim 1, wherein the feeding system comprises a structured automatic feeding device, a track and a line butt-joint device, the robot body is installed on the structured automatic feeding device of the feeding system after a hearth is cooled to be less than or equal to 60 ℃, the robot body enters a manhole of a boiler through the track and is adsorbed on the surface of the water-cooled wall of the boiler, the line butt-joint device is used for automatically butt-jointing a safe hoisting system, and a line is connected.
6. The intelligent water-cooled wall climbing maintenance robot according to claim 1, wherein the functional system comprises a cleaning system, a visual detection system, a nondestructive thickness measurement system, a polishing system, a welding system, a nondestructive detection system, a laser cladding system and the like, and structures and hardware and software interfaces required by the extensible other functional modules are reserved;
The cleaning system meets the cleaning requirement and the cleaning effect of the surface of the all-position water-cooled wall of the boiler hearth, and improves the moving safety of the robot body, the definition of image acquisition and the thickness measuring accuracy;
the system interface adopts a standardized design and is connected with the robot body for communication;
the cleaning mechanical structure adopts a standardized design, is connected with the robot body, and the tail end of the structure table can be lifted upwards, so that the cross-region operation is facilitated;
the cleaning device is used for cleaning dust and coke residues on the surface of the pipe wall; different cleaning modes are selected to effectively adapt to the cleaning requirement so as to achieve the cleaning effect;
the cleaning control module is in communication connection with the terminal control system to realize remote operation control.
7. The intelligent water-cooled wall climbing maintenance robot according to claim 6, wherein the visual detection system is responsible for collecting the surface state of the pipe wall and monitoring the environment, and comprises a system interface, an environment shooting module, a rotary control holder, a pipe wall shooting module, a mobile space platform, a function monitoring shooting module and an image storage and transmission module;
the system interface adopts a standardized design and is connected with the robot body for communication;
The environment shooting module is a high-definition camera suitable for dim and severe environments, is 45 times of optical zoom and optical anti-shake, has shooting, video recording and self-cleaning functions before a lens, and is arranged on a rotary control cradle head;
the rotary control cradle head enables the environment shooting module to rotate within the range of 0-360 degrees horizontally and 0-90 degrees vertically, is in communication connection with the terminal control system, automatically or manually adjusts the position of the camera, and realizes the inspection of the surrounding environment state;
the pipe wall shooting module is a high-definition camera suitable for dim and severe environments, is 5 times of optical zoom and optical anti-shake, has shooting, video recording and self-cleaning functions before a lens, and is arranged on a mobile space platform;
the mobile space platform enables the pipe wall shooting module to move in the front-back direction, the left-right direction, the up-down direction, the left-right direction and the up-down direction, is in communication connection with the terminal control system, automatically or manually adjusts the position of the camera, and records the state information of the pipe wall surface;
the function monitoring shooting module is a high-definition camera suitable for dim and severe environments, is 5 times optical zoom and optical anti-shake, has shooting, video recording and pre-lens self-cleaning functions, is arranged on a robot body, is in communication connection with a terminal control system, can monitor working states of a cleaning system, a visual detection system, a nondestructive thickness measurement system, a polishing system, a welding system, a nondestructive detection system, a laser cladding system and the like, and assists a specific function module to realize working condition adaptation and complete corresponding functions;
The image storage and transmission module is in communication connection with the terminal control system and returns data to an operator in real time.
8. The intelligent water-cooled wall climbing maintenance robot according to claim 7, wherein the nondestructive thickness measuring system is responsible for carrying out rapid positioning screening and regular intensive scanning on the wall thickness, and comprises a system interface, an electromagnetic ultrasonic thickness measuring module, a triaxial displacement platform and a data storage and transmission module;
the system interface adopts a standardized design and is connected with the robot body for communication;
the electromagnetic ultrasonic thickness measuring module does not need a coupling agent when in work, allows paint, rust and roughness to exist on the surface of a workpiece, has a thickness measuring range of 1.5-100 mm, has a minimum curvature diameter of the surface of a measured object of more than 10mm, and has measuring precision of 0.01-0.05 mm, and is arranged on a three-axis displacement platform;
the triaxial displacement platform enables the electromagnetic ultrasonic thickness measuring module to rotate in the front-back, left-right, up-down and up-down directions and in a range, the electromagnetic ultrasonic thickness measuring module is in communication connection with the terminal control system, and is matched with the function monitoring shooting module to identify the central line position of each or the current working pipe wall, automatically track or manually adjust the position, adjust the position to a detectable relative angle and distance according to different water wall diameters, and continuously and rapidly measure the wall thickness of the pipeline;
The data storage transmission module is in communication connection with the terminal control system and transmits continuous thickness measurement data back to an operator in real time;
the wall thickness data record display inquiry and model matching display module is used for realizing real-time storage, real-time retrieval and viewing, and the wall thickness data record display inquiry and model matching display module is used for forming a thickness measurement log through host data processing, drawing a wall thickness data cloud chart of the water-cooled wall, and intuitively analyzing the overall state of the water-cooled wall.
9. The intelligent water-cooled wall climbing maintenance robot according to claim 6, wherein the polishing system is responsible for abnormal polishing treatment of the surface of the pipe wall and comprises a system interface, a mechanical polishing grinding wheel, a six-axis mechanical arm and a communication control module;
the welding system is responsible for welding treatment of pipeline leakage;
the nondestructive testing system is responsible for nondestructive testing of the pipeline;
the laser cladding system is responsible for laser surfacing treatment of the surface of the pipeline.
10. An intelligent water-cooled wall climbing maintenance operation robot working method is characterized in that the intelligent water-cooled wall climbing maintenance operation robot is used in any one of claims 1-9, the working method specifically comprises,
Firstly, assembling an intelligent water-cooled wall climbing maintenance robot, supplying power to the whole robot, and carrying out replacement and switching management of robot configuration, management of a robot body, comprehensive power distribution, safe hoisting, a functional system, a terminal controller and accessory formation; carrying out manual control on the movement of the robot body, and synchronizing an indication lighting system, a functional lighting system, a self-cleaning system and a safe hoisting system; after reaching the appointed position, opening a visual modeling cruising task program, setting a working cruising path parameter, wherein the working cruising path parameter comprises a patrol area, a patrol path, a motion origin point, a motion inflection point and a motion end point, and starting the robot body to move for automatic control;
starting a cleaning system, selecting a cleaning mode, adjusting a cleaning mechanical structure, controlling a cleaning device and cleaning accessories, and setting modes and parameters; after the cleaning system is executed, returning to a working starting point, starting the visual detection system and the nondestructive thickness measurement system, and controlling the nondestructive thickness measurement system of the visual detection system to prepare to execute a working task;
displaying the whole information of the boiler through an environment model, acquiring feedback data of a patrol positioning system, and representing the position and the patrol track of the robot body; displaying surrounding environment state parameters and robot body states through the environment body states;
Carrying out data image acquisition record processing; if the robot body is abnormal, the function system is abnormal, the defect identification is abnormal, the data exceeds the standard, the communication is abnormal, the alarm is released by manual operation, and the task is continued;
the safety hoisting system acquires the speed information of the robot body and the position information of the inspection positioning system, so that an anti-falling safety rope and a power supply cable in the movement process of the robot are automatically matched in a cooperative manner;
finally, finishing the work task, returning to the initial setting position, manually controlling the robot body to move, and returning to the manhole at the bottom of the boiler; the robot body is separated from the safe hoisting system and moves out of the manhole of the boiler through an automatic throwing device; powering down the whole device; disassembling a patrol positioning system and an optional use function system which are arranged on the robot body; and (3) collecting cables, and installing a throwing system at a manhole at the bottom of the boiler, wherein the safe lifting system and the comprehensive power distribution system are installed at the top of the furnace.
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| CN202311040069.2A CN117140543A (en) | 2023-08-18 | 2023-08-18 | Intelligent water-cooled wall climbing maintenance operation robot and working method thereof |
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| CN202311040069.2A CN117140543A (en) | 2023-08-18 | 2023-08-18 | Intelligent water-cooled wall climbing maintenance operation robot and working method thereof |
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