CN115420793B - Magnetic flux leakage detection robot for full section defect of cable-stayed bridge cable - Google Patents
Magnetic flux leakage detection robot for full section defect of cable-stayed bridge cable Download PDFInfo
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Abstract
The invention discloses a magnetic flux leakage detection robot for full section defects of cable-stayed bridge cables, which consists of a climbing robot, a double-ring magnetic sensitive array magnetic flux leakage detection sensor, a detection and control system, a multi-camera module, a mechanical ranging module, a connecting mechanism and an upper computer. In the process that the climbing robot advances along the cable-stayed bridge cable, the multi-camera module shoots an image of the sheath on the surface of the cable-stayed bridge cable, and the mechanical ranging module measures the contour of the periphery of the sheath in a contact manner so as to evaluate the defects of deformation, breakage and the like of the sheath; providing direct current to an excitation coil of a double-ring magnetic-sensitive array magnetic leakage detection sensor by a bias pulse current source of a detection and control system, and testing a surface magnetic leakage field caused by surface steel wire defects by using a 32-channel Hall array, thereby realizing the detection of cable-stayed bridge cable steel wire defects; the excitation coil has the advantages of flexibility, portability and the like, and the magnetic flux leakage detection robot has the characteristics of wireless control and light weight, and can detect the defects of the full section of the cable-stayed bridge.
Description
Technical Field
The invention belongs to the technical field of nondestructive testing, and particularly relates to a cable leakage detection robot for a cable-stayed bridge, which can detect defects of a full section (comprising a sheath and inner and outer steel wires) of the cable-stayed bridge.
Background
The cable-stayed bridge cable is used as an important connecting part of the bridge tower and the main girder, and in the long-time service process, a nonmetallic sheath on the surface is easy to deform or even break, so that rainwater permeates into the inner cable body to cause the defects of corrosion, fracture and the like of the surface and the inner steel wire of the cable rope body. To evaluate the integrity of the cable-stayed bridge cable, the inner and outer defects of the nonmetallic sheath and the cable body on the surface, namely the full section defect detection, are required to be detected.
By utilizing visual and optical image acquisition methods, a detection technology of a cable-stayed bridge cable surface sheath has been developed, but the defects of corrosion, fracture and the like of a cable rope body cannot be effectively detected. The defect of the cable rope body can be detected by utilizing a magnetic leakage method, but the existing permanent magnet magnetization method cannot distinguish the inner defect and the outer defect of the cable body from detection signals, and the detection process is easy to lift off and shake to generate interference signals, more importantly, the permanent magnet magnetic circuit Pang Chong has high driving force requirement on the robot, so that the climbing robot has large mass and cannot meet the requirements of convenience and rapidness in field operation and the like.
In order to solve the problems, the invention provides a cable-stayed bridge cable magnetic leakage detection robot integrating a multi-camera module, a mechanical ranging module and a double-ring magnetic-sensing array magnetic leakage detection sensor, and provides a method for inhibiting influence of lift-off jitter on a magnetic leakage detection result by integrating multi-sensor signals and a scanning mode for identifying surface sheath defects and internal and external defects of a cable body. The adopted double-ring magnetic-sensing array magnetic leakage detection sensor greatly reduces the weight of the sensor due to the adoption of a bias pulse magnetization mode and a flexible excitation coil, and the robot and a detection and control system carried by the same are in wireless communication with an upper computer, so that the cable-stayed bridge cable magnetic leakage detection robot has the advantage of portability, and can realize the defect detection of the full section (comprising a sheath and an inner and outer steel wire) of the cable-stayed bridge cable.
Disclosure of Invention
The invention aims to design a magnetic flux leakage detection robot for full section defects of a cable-stayed bridge cable, and provides an effective method for detecting the inner and outer parts of the cable-stayed bridge cable and a sheath. The movement control of the climbing robot and the excitation collection of cable-stayed bridge cable defect signals can be remotely realized through the wireless communication module.
In order to achieve the above purpose, the invention adopts the following technical scheme:
A magnetic flux leakage detection robot for full section defects of a cable-stayed bridge cable is based on a magnetic flux leakage detection principle. The design is composed of a climbing robot, a double-ring magnetic-sensitive array magnetic leakage detection sensor, a detection and control system, a multi-camera module, a mechanical ranging module, a connecting mechanism and an upper computer.
The climbing robot consists of a crawler-type driving mechanism, a motion gesture adjusting mechanism, an adjustable clamping mechanism, an obstacle surmounting module and a frame, wherein the crawler-type crawling mechanism, the motion gesture adjusting mechanism, the adjustable clamping mechanism and the obstacle surmounting module are symmetrically arranged in two sets along the frame. The crawler-type driving mechanism consists of a driving wheel, a driven wheel, an annular rubber crawler belt, a two-stage transmission gear, a fixed side plate and a direct current motor. The direct current motor is connected with the primary gear, and the secondary gear is coaxially connected with the driving wheel; the inner surface of the annular rubber crawler belt is meshed with the driving wheel and the driven wheel, and the outer surface of the annular rubber crawler belt is contacted with the cable-stayed bridge cable; the driving wheel is fixedly connected to the fixed side plate in a clamping groove mode; the fixed side plates are connected with the obstacle crossing modules through guide rail brackets, so that climbing up and down along the cable-stayed bridge cables is realized. The obstacle surmounting module is composed of a sliding block, a pressure spring, a guide rail bracket and a supporting side plate. The sliding block is connected with the pressure spring, and is fixed on the guide rail bracket through the guide rail to form a moving pair perpendicular to the axial direction of the cable-stayed bridge cable, so that obstacle surmounting in the effective range can be realized. The motion gesture adjusting mechanism consists of a steering engine, a reversing shaft and a gear. The steering engine is fixed on the support side plate of the guide rail bracket, the gear coaxially connected with the steering engine is meshed with the gear edge of the frame, the reversing shaft and the frame are matched through a bearing, a rotating pair parallel to the axial direction of the cable stayed bridge cable is formed, the advancing direction angle of the climbing robot can be adjusted in real time, and posture correction is carried out. The adjustable clamping mechanism consists of an adjusting handle, an adjusting screw and a bearing bush. The bearing bush is fixedly arranged on a guide rail bracket of the obstacle crossing module, an adjusting screw rod penetrating through the bearing bush is connected with the guide rail bracket through threads, and an adjusting handle is connected with the adjusting screw rod through threads. The adjusting handle is rotated to apply pretightening force to the pressure spring, so that the crawler type crawling mechanism is pushed to clamp or loosen the cable-stayed bridge cable, and the crawler type crawling mechanism is suitable for cable-stayed bridge cables with diameters ranging from 80mm to 120 mm.
The double-ring magnetic sensitive array magnetic leakage detection sensor consists of an exciting coil, a 4-channel induction coil array, a 32-channel Hall array, a sensor framework, a connecting frame and a guide wheel mechanism. The excitation coil is wound on the surface of the outer layer groove of the sensor framework, and direct current or pulse current is introduced to provide a magnetic field to magnetize the cable-stayed bridge cable; the induction coil array and the Hall array are arranged at a groove on the inner surface of the sensor framework, and the magnetic field change generated by the surface and the internal defects of the cable-stayed bridge cable is detected; two identical sensor frameworks are symmetrically arranged at two sides of a cable-stayed bridge cable and are connected through bolts; the 4 groups of guide wheels are symmetrically fixed on the connecting frames at two ends of the sensor framework and connected with the climbing robot, and can move along the cable-stayed bridge cable under the traction of the climbing robot.
The detection and control system consists of an STM32H750 single-chip microcomputer, a motor control board, a steering engine control board, a bias pulse current source, a multichannel acquisition card, a wireless communication module, an attitude sensor, an encoder and a power management circuit.
The multi-camera module consists of 4 sets of FPV image transmission transmitters, FPV cameras and an annular support. The FPV image transmission transmitter, the FPV camera and the mechanical ranging module are jointly installed on the annular support, cable-stayed bridge cable sheath coverage scanning can be achieved, and the surface image of the bridge cable is displayed to the upper computer through wireless transmission.
The mechanical ranging module is formed by uniformly arranging 4 KTR linear pull rod displacement sensors on the annular support, so that the concave-convex deformation of the periphery of the bridge cable sheath can be detected.
The upper computer is provided with software capable of realizing the functions of climbing robot motion control, excitation acquisition trigger control, signal display storage and power supply electric quantity monitoring, and the functions of climbing robot motion control, excitation acquisition trigger control, signal display storage and power supply electric quantity monitoring are realized through interactive communication between the wireless communication module and the detection and control system.
Compared with the prior art, the magnetic flux leakage detection robot for the full section defect of the cable-stayed bridge cable has the substantial characteristics and remarkable progress:
(1) The double-ring magnetic-sensing array magnetic leakage detection sensor adopts a 4-channel induction coil array and a 32-channel Hall array, and can realize detection and positioning of surface and internal defects of cable surfaces of cable-stayed bridges by magnetizing the cable body through time-sharing excitation pulses and direct-current voltage signals.
(2) The climbing robot is designed with a motion gesture adjusting mechanism, and a gesture sensor and steering engine linkage mode is adopted, so that the motion direction angle of the climbing robot can be adjusted in real time, and the motion gesture is kept stable.
(3) The magnetic flux leakage detection robot for the full section defect of the cable-stayed bridge rope is provided with the adjustable clamping mechanism, can detect the cable-stayed bridge rope with the diameter of 80-120mm, and has good applicability.
Drawings
Fig. 1 is a schematic diagram of the overall structure.
Fig. 2 is a schematic diagram of the overall structure of the climbing robot.
Fig. 3 is a schematic view of the internal structure of the climbing robot.
FIG. 4 is a schematic diagram of the overall structure of a dual-ring magnetosensitive array magnetic leakage detection sensor.
FIG. 5 is an assembly schematic diagram of a dual-ring magnetically sensitive array magnetic flux leakage detection sensor.
Fig. 6 is a schematic diagram of a 4-channel induction coil array and a 32-channel hall array.
Fig. 7 is a schematic diagram of a detection and control system.
FIG. 8 is a schematic diagram of a multi-camera module and a mechanical ranging module.
FIG. 9 is a schematic diagram of the time sequence of a magnetic flux leakage detection robot for full section defects of a cable-stayed bridge.
Fig. 10 is a diagram of a 32-channel hall array and a mechanical range finder detection signal.
Fig. 11 is a diagram of a 4-channel induction coil detection signal.
In the figure: 10. the cable-stayed bridge cable 20, the climbing robot 30, the double-ring magnetic-sensitive array magnetic flux leakage detection sensor 40, the detection and control system 50, the multi-camera module 60, the mechanical ranging module 70, the upper computer 80, the connecting mechanism 201, the crawler-type driving mechanism 202, the motion gesture adjusting mechanism 203, the adjustable clamping mechanism 204, the obstacle surmounting module 205, the frame 2011, the driving wheel 2012, the driven wheel 2013, the annular rubber crawler 2014, the primary transmission gear 2015, the secondary transmission gear 2016, the fixed side plate 2017, the direct current motor 2018, the motor fixed bracket 2021, the steering engine 2022, the reversing shaft 2023, the gear 2031, the adjusting handle 2032, the adjusting screw 2041, the bearing bush 2041, the outer side block 2042, the inner side block 2043, the pressure spring 2044, the guide rail 2045, the guide rail bracket 2046, the supporting side plate 301, the connecting frame 302, the exciting coil 303, the guide wheel mechanism 304, the sensor skeleton 305, the induction coil 306, the induction coil clamping groove 307, the Hall 308, the Hall array flexible 401, the STM32H750, the motor control board 403, the motor bias control board 403, the pulse card 405, the pulse current source 405, the FPchannel power source management module 501, the FPchannel power supply management circuit, the FPchannel video camera module 408, the FPchannel power supply management module 408, the FPchannel video camera module 408, the wireless communication channel video camera module 408, and the video camera module 408.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. The embodiments described below by referring to the drawings are illustrative and intended to explain the present invention and should not be construed as limiting the invention.
The invention discloses a magnetic flux leakage detection robot for full section defects of cable-stayed bridge cables, which mainly comprises a climbing robot, a double-ring magnetic sensitive array magnetic flux leakage detection sensor, a detection and control system, a multi-camera module, a mechanical ranging module, a connecting mechanism and an upper computer. In the process that the climbing robot advances along the cable-stayed bridge cable, the multi-camera module shoots an image of the sheath on the surface of the cable-stayed bridge cable, and the mechanical ranging module measures the contour of the periphery of the sheath in a contact manner so as to evaluate the defects of deformation, breakage and the like of the sheath; providing direct current (or pulse current) to an exciting coil of a double-ring magnetic-sensitive array magnetic leakage detection sensor by a bias pulse current source of a detection and control system, and testing a surface magnetic leakage field caused by surface steel wire defects (or internal steel wire defects) by using a 32-channel Hall array (or a 4-channel induction coil array), thereby realizing the detection of cable-stayed bridge cable steel wire defects; and determining the position of lift-off jitter in the scanning process of the magnetic flux leakage detection robot by utilizing abnormal conditions such as image jitter recorded by the multi-camera module and abrupt change of an output curve of the mechanical ranging module, and detecting and positioning the surface defects of the cable rope body after removing artifacts caused by the lift-off jitter in the magnetic flux leakage scanning imaging result of the 32-channel Hall array correspondingly. The double-ring magnetic-sensitive array magnetic leakage detection sensor disclosed by the invention adopts an excitation coil with the advantages of flexibility, portability and the like, and the magnetic leakage detection robot has the characteristics of wireless control and light weight, and can detect defects of the full section (comprising a sheath and inner and outer steel wires) of the cable-stayed bridge.
The climbing robot consists of a crawler-type driving mechanism, a motion gesture adjusting mechanism, an adjustable clamping mechanism, an obstacle surmounting module and a frame which are symmetrically arranged along the circumferential direction, wherein the crawler-type driving mechanism consists of a driving wheel, an annular rubber crawler, a two-stage meshing gear, a fixed side plate and a direct current motor. The adjustable clamping mechanism can be adjusted to be suitable for cable-stayed bridge cables with diameters ranging from 80 mm to 120 mm. The detection and control system installed on the climbing robot frame receives the upper computer instruction through a wireless communication mode, drives the direct current motor to rotate, and realizes climbing up and down of the climbing robot. In the advancing process, the climbing robot obstacle crossing module can cross the cable-stayed bridge surface obstacle through a moving pair consisting of pressure springs. The detection and control system consists of an STM32H750 singlechip, a motor control board, a steering engine control board, a bias pulse current source, a multichannel acquisition card, a wireless communication module, an attitude sensor, an encoder and a power management circuit. The attitude sensor can detect whether the travelling direction angle deviates in real time, feeds back attitude information to the robot control module, drives the steering engine to rotate through the motor steering engine driving plate, and adjusts the travelling direction angle of the climbing robot in real time. The double-ring magnetic sensitive array magnetic leakage detection sensor consists of an exciting coil, a 4-channel induction coil array, a 32-channel Hall array, a sensor framework, a connecting frame and a guide wheel mechanism. The detection and control system provides direct current (or pulse current) signals for the excitation coil through wireless control bias pulse current sources to realize magnetization of cable bodies of the cable-stayed bridge, the 4-channel induction coil array and the 32-channel Hall array respectively detect and position internal and external defects of the cable-stayed bridge, and the detection and control system is connected with the wireless communication module through the multichannel acquisition card to transmit defect information data to the upper computer. The multi-camera module consists of 4 sets of FPV image transmission transmitters and FPV cameras, and can carry out video scanning on cable sheaths of the cable-stayed bridge and transmit the video scanning to an upper computer through the FPV transmitters. The mechanical ranging module can detect concave-convex deformation of the periphery of the bridge cable sheath. The upper computer is provided with software which can realize the functions of climbing robot motion control, excitation acquisition trigger control, signal display storage and power supply electric quantity monitoring. The magnetic flux leakage detection robot for the full section defects of the cable-stayed bridge cable has the characteristics of wireless control and portability, and is suitable for detecting the defects of the inner part, the surface and the sheath of the cable body of the cable-stayed bridge cable by detection personnel.
As shown in fig. 1, according to the magnetic flux leakage detection robot for full section defects of a cable-stayed bridge cable in the embodiment of the invention, the climbing robot 20 and the detection and control system 40 fixed above are arranged at the front end, the double-ring magnetic sensitive array magnetic flux leakage detection sensor 30 is arranged at the middle part, the double-ring magnetic sensitive array magnetic flux leakage detection sensor 30 is connected with the climbing robot 20 through the connecting mechanism 80, the multi-camera module 50 and the mechanical ranging module 60 are arranged at the rear end, and the double-ring magnetic sensitive array magnetic flux leakage detection sensor 30 is fixedly connected on the annular bracket 503 through a threaded hole. The whole instrument is symmetrically arranged at two sides of the cable-stayed bridge cable 10, and the upper computer 70 is arranged at the ground end and is in remote communication with the detection and control system 40 in a wireless mode.
As shown in fig. 2 to 3, the climbing robot 20 includes a crawler-type driving mechanism 201, a movement posture adjusting mechanism 202, an adjustable clamping mechanism 203, an obstacle surmounting module 204, and a frame 205. The crawler-type driving mechanism 201 is composed of a driving wheel 2011, a driven wheel 2012, an annular rubber crawler 2013, a primary transmission gear 2014, a secondary transmission gear 2015, a fixed side plate 2016, a direct current motor 2017 and a motor fixed bracket 2018. The direct current motor 2017 is coaxially connected with the primary gear 2014, and the secondary gear 2015 is coaxially connected with the driving wheel 2011; the inner surface of the annular rubber crawler 2013 is meshed with the driving wheel 2011 and the driven wheel 2012, and the outer surface is contacted with the cable-stayed bridge cable 10; the part of the structure can realize that the torque of the direct current motor 2017 is transmitted to the annular rubber crawler 2013 through the driving wheel 2011, so that the annular rubber crawler 2013 is driven to rotate around the central axes of the driving wheel and the driven wheel, and climbing up and down along the cable-stayed bridge cable is realized. The driving wheel 2011 is fixedly connected to the fixed side plate 2016 in a clamping groove mode, and is connected with the obstacle surmounting module 204 through the fixed side plate 2016 by using bolts through the guide rail bracket 2041. The obstacle detouring module 204 is composed of an outer slide block 2041, an inner slide block 2042, 4 pressure springs 2043, a guide rail 2044, two guide rail brackets 2045 and a supporting side plate 2046. The outer slide block 2041 and the inner slide block 2042 are connected through a pressure spring 2043, are matched with the guide rail in a clamping groove mode, are fixed on the guide rail brackets 2045 through bolts, a certain gap is reserved between the two guide rail brackets 2045, and the outer guide rail brackets 2045 are fixedly connected with the support side plates 2046 through bolts; when the annular rubber crawler 2013 encounters an obstacle, the driving wheel 2011 and the driven wheel 2012 drive the inner guide rail bracket to compress the pressure spring 2043 through the inner sliding block 2042 to form a moving pair perpendicular to the axial direction of the cable-stayed bridge cable 10, so that obstacle surmounting in an effective range is realized. The motion posture adjusting mechanism 202 is composed of a steering engine 2021, a reversing shaft 2022 and a gear 2023. The steering engine is fixed on the supporting side plate 2046 through bolts, the gear 2023 is coaxially connected with the steering engine 2021, the steering engine is meshed with the gear edge of the frame 205, the reversing shaft 2022 is connected with the frame 205 through bearings, a rotating pair parallel to the axial direction of the cable-stayed bridge cable 10 is formed, and the advancing direction angle of the climbing robot 20 can be adjusted in real time to correct the gesture. The adjustable clamping mechanism 203 is composed of an adjusting handle 2031, an adjusting screw 2032 and a bearing bush 2033. The bearing bush 2033 is fixedly installed on an outer guide rail bracket 2045 of the obstacle surmounting module 204, an adjusting screw 2032 penetrating through the inside of the bearing bush 2033 is connected with an outer sliding block 2041 through threads, and an adjusting handle 2031 of the inner sliding block 2041 is also connected with the adjusting screw 2032 through threads. The adjusting handle 2031 is rotated to apply a pre-tightening force to the pressure spring 2043, so that the annular rubber crawler 2013 of the crawler drive mechanism 201 is pushed to clamp or unclamp the cable 10, and the cable 10 is suitable for the cable 10 with the diameter ranging from 80mm to 120 mm. The structure and the obstacle crossing module 204 adopt a form of symmetrically arranging 4 sleeves along the axial direction and the radial direction of the cable-stayed bridge cable 10, so that the balance and stability of the whole obstacle crossing module during installation and disassembly are ensured.
As shown in fig. 4 to 6, the double-ring magnetosensitive array magnetic flux leakage detection sensor 30 is composed of a coupling frame 301, an exciting coil 302, a guide wheel mechanism 303, a sensor skeleton 304, an induction coil 305, an induction coil card slot 306, a hall 307, and a hall array flexible PCB 308. The two excitation coils 302 are symmetrically wound on the surface of the outer layer groove of the sensor skeleton 304 along the axial direction, and can apply direct current voltage and pulse voltage to magnetize the cable body of the cable-stayed bridge cable 10; the 4-channel induction coil 305 array is circumferentially and symmetrically arranged in the induction coil clamping groove 306, and each channel consists of 8 induction coils connected in series; the sensor is arranged in a groove on the inner surface of the sensor framework in a lamination way with the 32-channel Hall 307 array; the structure can realize that the 32-channel Hall array 307 picks up a leakage magnetic field generated by the surface defects of the cable body of the cable 10 of the cable-stayed bridge when the exciting coil 302 applies direct current voltage, and the 4-channel induction coil 305 array detects the magnetic flux change generated by the defects in the cable body by a mutual inductance method when the exciting coil 302 applies pulse voltage and can position the defects from 4 quadrants; two identical sensor frameworks 304 are symmetrically arranged at two sides of the cable-stayed bridge cable 10 and are fastened and connected through bolts; the 4 groups of guide wheel mechanisms 303 are symmetrically fixed on the connecting frames 301 at two ends of the sensor skeleton 304; the coupling frame 301 is connected to the climbing robot 20 by bolts through the above-mentioned connection mechanism 80, and can travel up and down along the cable 10 under the traction thereof.
As shown in fig. 7, the detection and control system 40 is composed of an STM32H750 single-chip microcomputer 401, a motor control board 402, a steering engine control board 403, a bias pulse current source 404, a multi-channel acquisition card 405, a wireless communication module 406, an attitude sensor 407, an encoder 408 and a power management circuit 409; the wireless communication module 406 and the host computer 70 adopt a 2.4G wireless communication method. The upper computer sends movement control and excitation acquisition triggering control instructions of the climbing robot 20 to the core STM32H750 singlechip 401 of the detection and control system 40, and the STM32H750 singlechip 401 controls the direct current motor 2017 to rotate by sending PWM level signals to the motor control board 402, so as to drive the climbing robot 20 to climb along the cable-stayed bridge cable 10; the steering engine control board 403 also drives the steering engine 2021 to rotate by receiving PWM level signals of the STM32H750 singlechip 401, so as to realize the adjustment of the motion attitude angle; the encoder 408 is coaxially connected with the direct current motor 2017, can output pulse signals, transmits the pulse signals to the STM32H750 singlechip 401 to be converted into travelling distance, and then transmits the travelling distance to the upper computer 70 through the wireless communication module 406 connected through a serial port; the bias pulse current source 404 is triggered by TTL instructions of the STM32H750 singlechip 401, and can output DC24V and pulse 400V voltages to the excitation coil 302 of the double-ring magnetic-sensing array magnetic leakage detection sensor 30, so that the magnetization process of the cable body of the cable-stayed bridge cable 10 is realized; the magnetic flux leakage signals shown in fig. 10 and generated by the surface defects of the cable body collected by the 32-channel hall array 307 of the double-ring magnetic-sensing array magnetic flux leakage detection sensor 30, the induction signals shown in fig. 11 and generated by the internal defects of the cable body collected by the 4-channel induction coil 305 array are all collected by the multi-channel collection card 405, and then are sent to the upper computer 70 through the wireless communication module 406 connected with an Ethernet port, and the signals are displayed and stored by the upper computer 70; the gesture sensor 407 can collect the motion gesture inclination angle of the climbing robot 20, send the motion gesture inclination angle to the STM32H750 single chip microcomputer, and transmit the motion gesture inclination angle to the upper computer 70 through the wireless communication module 406, so that whether the climbing robot 20 rotates or not is judged, the signals of the rotated double-ring magnetic-sensitive array magnetic leakage detection sensor 30 are compensated, and the real detection signals of the cable-stayed bridge cable 10 are restored; the power management circuit 409 is used for supplying power to the detection and control system 40, the direct current motor 2017 and the steering engine 2021, and the electric quantity information is sent to the upper computer 70 through the wireless communication module 406, so that the upper computer 70 can realize the function of monitoring the electric quantity of the power supply in real time, and the situation that the robot cannot be used due to insufficient electric quantity is avoided.
As shown in fig. 8, the multi-camera module 50 is composed of an FPV camera 501, an FPV image transmitter 502 and a ring-shaped frame 503. The FPV camera 501, the FPV image transmission transmitter 502 and the mechanical ranging module 60 are respectively and fixedly installed on 2 ring brackets 503 which are symmetrically fastened by bolts, so that coverage scanning of the cable-stayed bridge cable 10 sheath surface in the form of video and image shooting can be realized, and the detected video and image can be wirelessly transmitted to the upper computer 70 at the frequency of 5.8G through the non-FPV image transmission transmitter 502. The main body of the mechanical ranging module 60 adopts the principle of a slide rheostat, when interference factors affecting magnetic measurement signals, such as bulges or grooves on the surface of the sheath of the cable-stayed bridge cable 10, are encountered, the mechanical ranging module 60 can output corresponding voltage signals due to the change of internal resistance, so that the interference factors are identified and removed.
As shown in FIG. 9, the specific working time sequence logic of the magnetic flux leakage detection robot for the full section defect of the cable-stayed bridge cable is shown. In the time T1, the magnetic leakage detection robot ascends to the vertex position along the cable-stayed bridge cable 10, the exciting coil 304 is fed with direct-current voltage signals, during the period, the 32-channel Hall 307 array and the mechanical ranging module 60 work simultaneously, the defect detection of the cable-stayed bridge cable 10 body surface and the sheath can be completed, the detection signals shown in fig. 11 are generated, the peak points of the two signals can be determined to be the positions where lift-off jitter appears in the scanning process, and then the detection and positioning of the cable-stayed bridge cable 10 body surface defects after the artifacts caused by the lift-off jitter in the 32-channel Hall 307 array magnetic leakage scanning imaging result are correspondingly removed can be realized. In the time T2, the robot pauses to the vertex position of the cable-stayed bridge cable 10 and waits for the upper computer 70 to analyze the 32-channel Hall 307 array signal. In the time T3, the flux leakage detection robot starts to move down to the surface defect position area, pulse signal excitation is performed on the excitation coil 304, during this period, the 4-channel induction coil 305 array operates, the induction signal is output to the multi-channel acquisition card 405, and the upper computer 70 determines whether an internal defect exists at the marking defect position. In order to more intuitively compare the signals and the images of the detected defect positions, the multi-camera module 50 is adopted to work in a full-time period, so that the image and the video of the cable-stayed bridge cable surface can be recorded in the whole process, and the covering scanning of the cable-stayed bridge cable 10 sheath is realized.
Claims (9)
1. The magnetic flux leakage detection robot for the full section defect of the cable-stayed bridge cable is characterized by comprising a climbing robot, a double-ring magnetic sensitive array magnetic flux leakage detection sensor, a detection and control system, a multi-camera module, a mechanical ranging module, a connecting mechanism and an upper computer; the double-ring magnetic-sensing array magnetic leakage detection sensor is connected with the climbing robot through a connecting mechanism, the detection and control system is fixedly arranged on the outer side of the climbing robot, and the multi-camera module and the mechanical ranging module are both arranged on an annular bracket at the rear side of the double-ring magnetic-sensing array magnetic leakage detection sensor; the upper computer sends motion control and detection instructions to the magnetic flux leakage detection robot climbing on the cable-stayed bridge cable through the wireless communication module, and after the detection and control system receives the instructions, the magnetic flux leakage detection robot driving motor and the detection circuit are controlled;
The double-ring magnetic-sensitive array magnetic leakage detection sensor consists of an excitation coil, a 4-channel induction coil array, a 32-channel Hall array, a sensor framework, a connecting frame and a guide wheel mechanism; the excitation coil is wound on the surface of the outer layer groove of the sensor framework, and direct current or pulse current is introduced to provide a magnetic field to magnetize the cable-stayed bridge cable; the 4-channel induction coil array and the 32-channel Hall array are arranged in a groove on the inner surface of the sensor skeleton, and leakage magnetic fields generated by defects of the cable surface and the inner steel wire of the cable stayed bridge are detected; the two same sensor frameworks are symmetrically arranged at two sides of the cable-stayed bridge cable and are fastened and connected through bolts; the four groups of guide wheel mechanisms are symmetrically and fixedly arranged on the connecting frames at two ends of the sensor framework by bolts and are connected with the climbing robot by the connecting mechanisms;
the magnetic flux leakage detection robot climbs along the cable-stayed bridge, the multi-camera module and the mechanical ranging module respectively shoot the cable-stayed bridge cable surface sheath image and measure the sheath peripheral outline, and the deformation and damage defects of the sheath are evaluated; the double-ring magnetic-sensitive array magnetic leakage detection sensor works in a bias direct-current mode, and a 32-channel Hall array is utilized for magnetic leakage scanning imaging;
Determining the position of lift-off jitter in the scanning process of the magnetic flux leakage detection robot by utilizing the image jitter recorded by the multi-camera module and the abrupt change abnormal condition of the output curve of the mechanical ranging module, and detecting and positioning the surface defect of the cable rope body after removing artifacts caused by the lift-off jitter in the 32-channel Hall array magnetic flux leakage scanning imaging result correspondingly;
And according to the surface defect detection positioning result, the upper computer sends out a command again to control the magnetic leakage detection robot to move to the defect position area and scan the passing defect, and at the moment, the double-ring magnetic sensitive array magnetic leakage detection sensor works in a pulse magnetization mode, and whether the internal defect exists at the marked defect position is judged by utilizing the scanning result of the 4-channel induction coil array.
2. The magnetic flux leakage detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein the climbing robot consists of a crawler-type driving mechanism, a motion posture adjusting mechanism, an adjustable clamping mechanism, a obstacle surmounting module and a frame, wherein two sets of the same crawler-type crawling mechanism, the motion posture adjusting mechanism, the adjustable clamping mechanism and the obstacle surmounting module are symmetrically arranged along the frame and used for carrying a double-ring magnetic sensitive array magnetic flux leakage detection sensor, a detection and control system, a multi-position camera module and a mechanical ranging module to climb along the cable-stayed bridge cable.
3. The magnetic flux leakage detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein the detection and control system consists of an STM32H750 single chip microcomputer, a motor control board, a steering engine control board, a bias pulse current source, a multichannel acquisition card, a wireless communication module, an attitude sensor, an encoder and a power management circuit, and is fixedly arranged on a climbing robot frame and used for receiving and executing instructions sent by an upper computer; the STM32H750 singlechip is used as a core control board and is fixed on the same PCB bottom plate together with the motor control board, the steering engine control board and the bias pulse current source by using pin header interfaces; the encoder and the attitude sensor are connected to the STM32H750 singlechip by using UART interfaces; the 4-channel induction coil array, the 32-channel Hall array and the multi-channel acquisition card are connected through a flat cable, and the multi-channel acquisition card is connected to the wireless communication module through an Ethernet port; the power management circuit is connected with the PCB base plate, the multichannel acquisition card and the wireless communication module in a form of multipath voltage output wiring terminals, and the wireless communication module is communicated with the upper computer through an antenna at the 2.4G transmitting frequency.
4. The magnetic flux leakage detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein the multi-camera module is composed of four sets of FPV image transmission transmitters and FPV cameras, wherein the FPV image transmission transmitters, the FPV cameras and the mechanical ranging module are jointly installed on an annular support, so that covering scanning of cable-stayed bridge cable jackets can be realized, and a surface image of the cable-stayed bridge cable is displayed to an upper computer through wireless transmission; the FPV camera uses BNC interface to be connected with the FPV image transmission transmitter, and the FPV image transmission transmitter carries out wireless communication with the host computer through the antenna with 5.8G transmitting frequency.
5. The magnetic flux leakage detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein the mechanical ranging module is uniformly arranged on the annular support by four KTR linear pull rod displacement sensors, so as to realize detection of concave-convex deformation of the periphery of a cable sheath; the upper computer carries out interactive communication with the detection and control system through the wireless communication module, so as to realize the movement control, excitation acquisition trigger control, signal display storage and power supply electric quantity monitoring of the climbing robot.
6. The leakage flux detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein,
The crawler-type driving mechanism consists of a driving wheel, an annular rubber crawler, a two-stage transmission gear, a fixed side plate and a direct current motor, wherein the direct current motor is connected with a first-stage gear in the two-stage transmission gear, and a second-stage gear in the two-stage transmission gear is coaxially connected with the driving wheel; the inner surface of the annular rubber track is meshed with the driving wheel, the outer surface of the annular rubber track is contacted with the cable-stayed bridge cable, and the driving wheel is fixed on the balance frame and is connected with the obstacle crossing module through the guide rail bracket.
7. The leakage flux detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein,
The obstacle crossing module consists of a sliding block, a pressure spring, a guide rail bracket and a supporting side plate, wherein the sliding block is connected with the pressure spring and is fixed on the guide rail bracket through the guide rail, and the guide rail bracket is fixedly arranged on the supporting side plate through bolts to form a moving pair perpendicular to the length direction of a cable-stayed bridge cable.
8. The leakage flux detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein,
The motion attitude adjusting mechanism consists of a steering engine, a reversing shaft support and gears, wherein the steering engine is fixed on a supporting side plate of the guide rail support, the gears are connected with a steering engine rotating shaft and meshed with the gear edges of the frame, the reversing shaft is installed in the reversing shaft support through a sliding sleeve gland, a rotating pair parallel to the length direction of a cable-stayed bridge cable is formed, and the advancing direction angle of the climbing robot can be adjusted in real time to correct the attitude.
9. The leakage flux detection robot for full section defects of a cable-stayed bridge cable according to claim 1, wherein,
The adjustable clamping mechanism consists of an adjusting handle, an adjusting screw and a bearing bush, wherein the bearing bush is fixedly arranged on a guide rail bracket of the obstacle surmounting module, the adjusting screw penetrating through the inside of the bearing bush is connected with the guide rail bracket through threads, and the adjusting handle is connected with the adjusting screw through threads; the adjusting handle is rotated to apply pretightening force to the pressure spring, and the internal space of the crawler type crawling mechanism can be adjusted to be suitable for cable stayed bridge ropes with the diameter ranging from 80mm to 120 mm.
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| CN116519690B (en) * | 2023-05-06 | 2024-03-19 | 中交一公局集团有限公司 | Cable-stayed bridge steel cable detection device and detection method thereof |
| CN116773648A (en) * | 2023-06-30 | 2023-09-19 | 国网江苏省电力有限公司泰州供电分公司 | Crawling detection device and method for transformer substation structure support |
| CN116990235B (en) * | 2023-08-02 | 2024-06-14 | 上海天能生命科学有限公司 | Imaging equipment |
| CN117862545B (en) * | 2024-03-12 | 2024-05-28 | 江苏三耐特种设备制造有限公司 | Turning device for processing steel pipe perforating plug |
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