Disclosure of Invention
The present invention is directed to solving the above problems and providing an intelligent inspection apparatus and method for a nondestructive inspection robot.
The invention realizes the purpose through the following technical scheme:
an intelligent detection device for a nondestructive detection robot comprises a pipeline flaw detection system and a ground control system, wherein the pipeline flaw detection system sends pipeline flaw detection data to the ground control system through a wireless module;
the pipeline flaw detection system comprises a pipeline crawler running in a pipeline, an ultrasonic flaw detector arranged on the pipeline crawler, a servo motor and spraying marking equipment, wherein the servo motor drives the ultrasonic flaw detector to rotate, the rotating ultrasonic flaw detector performs flaw detection on the pipeline, and the detected pipeline defect part is sprayed and marked by the spraying marking equipment;
the ultrasonic flaw detector comprises a cylindrical rod, a plurality of probe connecting structures which are sequentially sleeved outside the cylindrical rod and are connected with ultrasonic probes, and a fixing cap which is arranged at the front end of the cylindrical rod and used for limiting the probe connecting structures, wherein the ultrasonic probes on the probe connecting structures are distributed in an annular array outside the cylindrical rod.
As a further optimization scheme of the invention, a cylindrical rod at one end of the ultrasonic flaw detector is connected with an output shaft of a servo motor, an electric telescopic rod is fixedly arranged at the bottom of the servo motor, the bottom end of the electric telescopic rod is connected with a pipeline crawler, a circuit board, an intelligent controller and a storage battery are arranged in the pipeline crawler, and the intelligent controller is connected with the circuit board through a lead.
As a further optimization scheme of the invention, the rear end of the servo motor is hinged with a connecting rod, sliding rods are fixedly arranged on both sides of one end of the connecting rod close to the pipeline crawler, a U-shaped seat is arranged on the pipeline crawler, a sliding groove corresponding to the sliding rod is arranged on the inner side wall of the U-shaped seat, and the sliding rod is slidably arranged in the sliding groove and rotates in the sliding groove.
As a further optimization scheme of the invention, an external thread is arranged on the outer wall of one end, away from the servo motor, of the cylindrical rod, a thread groove is formed in one end face, close to the external thread, of the fixing cap, the fixing cap is in threaded connection with the cylindrical rod, a plurality of limiting grooves with different lengths are formed in the outer side wall of the cylindrical rod in an annular array mode, a baffle is fixedly arranged at one end, away from the fixing cap, of the cylindrical rod, and a rotary encoder is arranged at one end, close to the servo motor, of the cylindrical rod.
As a further optimization scheme of the invention, an infrared hemispherical camera is fixedly arranged at one end of the fixing cap, which is far away from the external thread, and is used for collecting images in a pipeline, the spraying marking equipment is arranged in the fixing cap, a first plug is fixedly arranged in the thread groove, a first socket is embedded in the end face of the cylindrical rod corresponding to the first plug, and the infrared hemispherical camera and the spraying marking equipment are both connected with the intelligent controller through the first plug and the first socket.
As a further optimized scheme of the invention, the spraying and marking device comprises a pigment tank storing pigment, a spraying pipe, a pressure pump and a nozzle, wherein one end of the spraying pipe is connected with the pigment tank, the other end of the spraying pipe extends to the outer side wall of the fixed cap, the pressure pump is arranged on the spraying pipe, and the nozzle is arranged at the other end of the spraying pipe.
As a further optimization scheme of the invention, the probe connecting structure comprises a sleeve, a limiting plate and a fan-shaped connecting frame, the fan-shaped connecting frame is fixedly arranged on the outer wall of the sleeve, the ultrasonic probe is arranged on an arc-shaped frame of the fan-shaped connecting frame, the limiting plate is fixedly arranged on the inner wall of the sleeve and clamped with a limiting groove, and the diameter of the baffle is larger than the inner diameter of the sleeve.
As a further optimization scheme of the invention, two adjacent sleeves, the baffle and the sleeve on one side are connected through a second plug and a second socket, an ultrasonic probe arranged on the probe connecting structure is connected with the second plug/the second socket on the ultrasonic probe through a lead, the socket on the baffle is connected with an ultrasonic flaw detection controller in the cylindrical rod through a lead, and the ultrasonic flaw detection controller is connected with a circuit board through a lead.
As a further optimization scheme of the invention, the pipeline flaw detection system further comprises a GPS positioner, wherein the GPS positioner is used for positioning the position of the pipeline flaw detection system, and when the ultrasonic flaw detector detects the pipeline flaw, the position information of the pipeline flaw is sent to the ground control system, so that the subsequent maintenance is facilitated.
An intelligent detection method for a nondestructive detection robot comprises the following steps:
s1, driving the pipeline crawler to drive the ultrasonic flaw detector in the pipeline, and driving the ultrasonic flaw detector to rotate by the servo motor to perform flaw detection on the pipeline;
and S2, analyzing and processing the pipeline flaw detection data obtained by flaw detection by the ultrasonic flaw detector, judging whether the pipeline has a defect, if so, sending the pipeline flaw detection data to a ground control system, starting a spraying marking device to spray and mark the defect part of the pipeline, and if not, continuing to drive and detect.
The invention has the beneficial effects that:
1) according to the pipeline flaw detection system, the pipeline crawler is used for conveying the ultrasonic flaw detector, the spraying marking equipment, the camera and other structures, the ground control system is used for remotely controlling the pipeline flaw detection system to carry out flaw detection, the multi-probe rotary flaw detection technology is utilized, comprehensive intelligent detection of a pipeline can be realized, the detection precision is high, the spraying marking equipment can be controlled to mark the defect part, the defect part can be conveniently and quickly positioned during subsequent maintenance, and quick maintenance is realized;
2) the ultrasonic probes, the cameras and the spraying marking equipment are detachably designed, are convenient to disassemble, assemble and replace, have simple and ingenious structure, do not occupy space, reduce collision and are suitable for being used in narrow pipeline space.
Detailed Description
The present application will now be described in further detail with reference to the drawings, it should be noted that the following detailed description is given for illustrative purposes only and is not to be construed as limiting the scope of the present application, as those skilled in the art will be able to make numerous insubstantial modifications and adaptations to the present application based on the above disclosure.
In the description of the present invention, it is to be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention; in the description of the present invention, the meaning of "plurality" or "a plurality" is two or more unless otherwise specified.
Example 1
As shown in fig. 1-5, an intelligent detection device for a nondestructive detection robot comprises a pipelineflaw detection system 1 and aground control system 2, wherein the pipelineflaw detection system 1 transmits pipeline flaw detection data to theground control system 2 through a wireless module;
the pipelineflaw detection system 1 comprises apipeline crawler 11 running in a pipeline, anultrasonic flaw detector 12 installed on thepipeline crawler 11, aservo motor 13 and aspraying marking device 14, wherein theservo motor 13 drives theultrasonic flaw detector 12 to rotate, the rotatingultrasonic flaw detector 12 detects flaws in the pipeline, and the detected pipeline flaw parts are sprayed and marked by thespraying marking device 14.
The method for intelligently detecting the pipeline based on the intelligent detection device for the nondestructive detection robot comprises the following steps:
s1, thepipeline crawler 11 carries theultrasonic flaw detector 12 to drive in the pipeline, and theservo motor 13 drives theultrasonic flaw detector 12 to rotate so as to perform flaw detection on the pipeline;
and S2, theultrasonic flaw detector 12 analyzes and processes the flaw detection data of the pipeline obtained by flaw detection, judges whether the pipeline has a defect, if so, sends the flaw detection data of the pipeline to theground control system 2, starts thespraying marking equipment 14 to spray and mark the defect part of the pipeline, and if not, continues to drive and detect.
It should be noted that, when performing pipeline flaw detection, theground control system 2 remotely sends a crawling instruction to thepipeline crawler 11 through the wireless communication module, so that the pipeline crawler moves in the pipeline and carries theultrasonic flaw detector 12 to perform flaw detection on the pipeline, theservo motor 13 drives theultrasonic flaw detector 12 to perform rotation detection, when detecting a pipeline defect, thespraying marking device 14 is started to perform spraying marking on the pipeline defect part, and meanwhile, a detection result is output to theground control system 2, and theground control system 2 performs order adjustment for staff to perform maintenance based on the detected defect.
As shown in fig. 2-4, theultrasonic flaw detector 12 includes acylindrical rod 121, a plurality ofprobe connecting structures 123 sequentially sleeved outside thecylindrical rod 121 and connected to theultrasonic probes 122, and a fixingcap 124 installed at the front end of thecylindrical rod 121 and used for limiting theprobe connecting structures 123, wherein theultrasonic probes 122 on theprobe connecting structures 123 are distributed outside thecylindrical rod 121 in an annular array.
The output shaft ofservo motor 13 is connected to thecylinder pole 121 of 12 one ends of ultrasonic flaw detector,servo motor 13 bottom is fixed and is equipped with electrictelescopic handle 3, 3 bottom of electric telescopic handle are connected withpipeline crawler 11, be provided withcircuit board 4,intelligent control ware 5 andbattery 6 in thepipeline crawler 11,intelligent control ware 5 passes through wire connectingcircuit board 4.
The articulated connectingrod 7 that is connected with ofservo motor 13 rear end, the one end both sides that connectingrod 7 is close topipeline crawler 11 are all fixed and are equipped with slide bar 8, be provided withU type seat 9 on thepipeline crawler 11, set up thespout 10 that corresponds with slide bar 8 on theU type seat 9 inside wall, slide bar 8 slides and sets up inspout 10 and in the internal rotation ofspout 10, when electrictelescopic handle 3 drivesultrasonic flaw detector 12 and reciprocates in order to adapt to different pipe diameters, and connectingrod 7 atservo motor 13 rear end drives slide bar 8 and removes and rotate inspout 10, guarantees thatultrasonic flaw detector 12 centre of a circle position is located the pipeline middle part, avoidsultrasonic probe 122 collision pipe wall.
The outer wall of one end, far away from theservo motor 13, of thecylindrical rod 121 is provided with an external thread, a thread groove is formed in one end face, close to the external thread, of the fixingcap 124, the fixingcap 124 is in threaded connection with thecylindrical rod 121, the outer side wall of thecylindrical rod 121 is in an annular array, a plurality of limitinggrooves 1211 with different lengths are formed in the outer side wall of thecylindrical rod 121, abaffle 1212 is fixedly arranged at one end, far away from the fixingcap 124, of thecylindrical rod 121, and arotary encoder 1213 is arranged at one end, close to theservo motor 13, of thecylindrical rod 121. The fixed infraredray hemisphere camera 15 that is equipped with of one end that keeps away from the external screw thread of lockingcap 124, infraredray hemisphere camera 15 is used for gathering image in the pipeline, spraying markingdevice 14 sets up inside lockingcap 124.
Probeconnection structure 123 includessleeve 1231, limiting plate 1232, fan-shapedlink 1233 is fixed to be set up insleeve 1231 outer wall,ultrasonic probe 122 is installed on fan-shapedlink 1233's arc frame, limiting plate 1232 is fixed to be set up insleeve 1231 inner wall and with the joint ofspacing groove 1211,baffle 1212 diameter is greater thansleeve 1231 internal diameter.
The spraying and markingdevice 14 includes apigment tank 141 storing pigment, a sprayingpipe 142 with one end connected to thepigment tank 141 and the other end extending to the outer side wall of the fixingcap 124, apressure pump 143 disposed on the sprayingpipe 142, and anozzle 144 installed at the other end of the sprayingpipe 142, the outer side wall of the fixingcap 124 is further provided with a pigment adding port connected to thepigment tank 141, and a sealing plug is disposed in the pigment adding port to facilitate pigment adding.
The pipelineflaw detection system 1 further comprises a GPS (global positioning system)positioner 20, wherein theGPS positioner 20 is used for positioning the position of the pipelineflaw detection system 1, and when theultrasonic flaw detector 12 detects a pipeline flaw, the position information of the pipeline flaw is sent to theground control system 2.
It should be noted that, when the ultrasonic flaw detector 12 detects flaws, the output shaft of the servo motor 13 drives the cylindrical rod 121 to rotate, the probe connecting structure 123 is connected with the cylindrical rod 121 through the limiting plate 1232 and the limiting groove 1211, the fixing cap 124 is screwed at one end of the cylindrical rod 121 and is matched with the baffle 1212 to limit and fix the probe connecting structures 123 therebetween, so that when the cylindrical rod 121 rotates, the probe connecting structure 123 and the ultrasonic probes 122 mounted thereon are driven to rotate, and since the ultrasonic probes 122 are distributed in an annular array outside the circumferential surface of the cylindrical rod 121 and are uniformly distributed at intervals in the circumferential direction of the cylindrical rod 121, when the ultrasonic probes 122 rotate, a plurality of ultrasonic probes 122 can simultaneously detect a plurality of annular surfaces in the pipeline, and the detection data is sent to the ultrasonic flaw detection controller 125 for analysis processing, the detection efficiency is high, when the pipeline crawler 11 travels, the rotation detection paths of the ultrasonic probes 122 are a plurality of overlapped spiral lines, so that when the pipeline flaw detection system 1 slowly walks and rapidly rotates for detection, the condition of missed detection cannot be generated, and the detection is more comprehensive;
when theultrasonic probe 122 is damaged, the fixingcap 124 can be taken down, thesleeve 1231 can be directly pulled out, thesleeve 1231 drives the fan-shaped connectingframe 1233 and theultrasonic probe 122 to be separated from thecylindrical rod 121, the replacement can be carried out, the replacement is quick and convenient, and after the replacement is finished, the fixingcap 124 is installed in a threaded mode;
when a pipeline defect is detected, theultrasonic flaw detector 12 sends a defect signal to theintelligent controller 5, at the moment, therotary encoder 1213 determines the rotation angle of thecylindrical rod 121, theintelligent controller 5 controls theservo motor 13 to drive thecylindrical rod 121 to rotate based on the angle of theultrasonic flaw detector 12 on thecylindrical rod 121 and the rotation angle of thecylindrical rod 121, thepipeline crawler 11 performs position adjustment of thenozzle 144 based on the distance between theultrasonic probe 122 for detecting the defect part and thenozzle 144 until thenozzle 144 corresponds to the pipeline defect part, theintelligent controller 5 controls thepressure pump 143 to work, and extracts and sprays the pigment in thepigment tank 141 on the surface of the pipeline defect part in cooperation with the front-back position adjustment of thepipeline crawler 11, theintelligent controller 5 receives the pipeline image collected by the infraredhemispherical camera 15 and sends the pipeline image to theground control system 2, theground control system 2 can store the image and remotely observe the defect part in the pipe, so that subsequent maintenance personnel can accurately find the position for maintenance;
meanwhile, theintelligent controller 5 also sends the pipeline flaw detection data and the position information of the pipelineflaw detection system 1 positioned by theGPS positioner 20 to theground control system 2, and theground control system 2 sends the positioning information and the pipeline flaw detection data to a maintenance personnel terminal, so that the rapid positioning and maintenance are facilitated.
As shown in fig. 3-4, afirst plug 16 is fixedly arranged in the thread groove, afirst socket 17 is embedded in the end face of thecylindrical rod 121 corresponding to thefirst plug 16, and the infraredhemispherical camera 15 and thespraying marking device 14 are both connected with theintelligent controller 5 through thefirst plug 16 and thefirst socket 17.
The twoadjacent sleeves 1231 and thebaffle 1212 and thesleeve 1231 on one side are connected through asecond plug 18 and asecond socket 19, theultrasonic probe 122 mounted on theprobe connecting structure 123 is connected with thesecond plug 18/thesecond socket 19 on theultrasonic probe 122 through a wire, the socket on thebaffle 1212 is connected with the ultrasonicflaw detection controller 125 in thecylindrical rod 121 through a wire, and the ultrasonicflaw detection controller 125 is connected with thecircuit board 4 through a wire.
It should be noted that, in order to facilitate quick assembly and disassembly of the fixingcap 124 and thesleeve 1231, theultrasonic probe 122, the infraredhemispherical camera 15 and thespraying marking device 14 are powered on and communicate in a plug and socket matching manner, so that power-on communication can be realized when thesleeve 1231 and the fixingcap 124 are installed, and the structure is simple and the operation is convenient.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention.