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【Scientific and Technological Achievement】Permanent magnet adsorption ultrasonic testing robot
With the continuous improvement of automation and intelligence level of China's heavy equipment manufacturing industry, in the construction and service of large steel components in hydropower, petrochemical, marine engineering and other fields, the demand for special robots such as all-position welding, morphology detection, polishing and modification, painting and rust removal, non-destructive inspection and other special robots is becoming increasingly urgent.
What Xiaobian brings to you today is the permanent magnet adsorption ultrasonic testing robot developed by the Institute of Industrial Automation equipment and Technology of Tianjin High-end equipment Research Institute of Tsinghua University (hereinafter referred to as "Industrial Automation Institute").
science and technology research and development
Wall climbing robot (Wall Climbing Robot) is a special robot that can climb on the vertical wall and complete the operation, because the vertical wall operation exceeds the limit of people, so it is also known as the limit operation robot in foreign countries. This type of robot adsorbs the magnetic wall surface, which can carry out non-destructive testing, cleaning and polishing of the welds of large pressure vessels and spherical tanks, and clean the large hull at sea, thus realizing the replacement of manual operation by machines in high-risk environments.
The same type of robots at home and abroad basically use the magnetic wheel technology, and the adsorption efficiency is low. The detector is separated from the probe and is susceptible to interference.
Based on the core patented technology, the Institute of Industrial Automation has continued to carry out a lot of research work based on research to solve common problems such as permanent magnetic gap adsorption, autonomous navigation and positioning, and innovative design of the body mechanism (structure) of mobile robots in complex operating environments.
At present, the team has made great efforts to explore the application of permanent magnet adsorption TOFD flaw detection technology in the production and in-service inspection of large spherical tanks and pressure vessels, and has developed two generations of "permanent magnet adsorption ultrasonic inspection robots" with independent intellectual property rights ".
science and technology innovation
Working principle
In the process of production and in-service inspection of petrochemical equipment such as large hydrogenation reactors and large spherical tanks, 100% non-destructive testing of base metal and weld seams is required to check whether they are defective. TOFD flaw detection technology, based on the working principle of ultrasonic diffraction time difference method (TOFD), is suitable for defect detection, quantification and positioning of 8-50mm wall thickness materials. (Note: The diameter of plate welding large hydrogenation reactor is generally 2-6m; The diameter of large spherical tank is generally 5-20m; The diameter of large oil storage tank is generally 10-30m.)
In addition, the permanent magnet adsorption ultrasonic testing robot can also be applied to the non-destructive testing of cylindrical tubular structures, such as large pressure vessels such as oil tanks or high-altitude equipment such as wind power towers.
Permanent magnet adsorption type ultrasonic testing robot is a wall-climbing robot suitable for non-destructive testing of large steel components. The robot adopts permanent magnet adsorption method, which can replace manual inspection work on the inner and outer walls of tube segments, columns and spherical tanks. The robot can control the robot to walk back and forth, turn in situ and other functions through industrial joystick. It can also automatically walk along the weld seam according to the image. It is equipped with different non-destructive testing systems, such as TOFD, thickness measurement and phased array. It can complete crack detection, thickness detection, storage tank flaw detection and other work. It is mainly used in non-destructive testing tasks such as reloading, petrochemical, hydropower and ships.
Main structure
The permanent magnet adsorption ultrasonic detection robot is mainly composed of robot body, mobile platform, flaw detection system, software control system, operation console and so on.
The flaw detection function can be said to be the core part of the permanent magnet adsorption ultrasonic testing robot, so what specific flaw detection functions can this robot achieve?
Let's take a look ~
Realization of TOFD Flaw Detection Function
1. Flaw detection data acquisition function
2. Flaw detection A sweep, D sweep waveform display function
3. Flaw detection parameter setting function
4. Motion control function of scanning frame
5. Flaw detection A sweep, D sweep defect calibration function
6. Other functions (customized according to user needs)
In addition, this permanent magnet adsorption ultrasonic testing robot has many other advantages!
More product advantages
Good adsorption effect:Gap adsorption, flexible movement, negative major, high utilization rate of magnetic force.
System integration:The detection system is integrated with the robot motion, the data is processed and transmitted, the transmission efficiency is high, and the anti-interference performance is strong.
Modular design:Universal platform modular design, can carry a variety of detection units and functional units.
Main technical parameters
This robot in the field test, with excellent performance once again to prove its strength!
Field Test
The permanent magnet adsorption ultrasonic detection robot is adsorbed on the outer surface of the spherical tank and can move from the vicinity of the lower polar plate of the spherical tank to the vicinity of the equatorial zone. The operation process is stable, and there are no phenomena such as bottom support and slippage. Its waveform display is clear, and the detection data is accurate, meeting the standard requirements.
application value
At present, the non-destructive testing of large pressure vessel production welds in China is mostly manual operation, especially for large pressure vessels, spherical tanks, oil storage tanks and other in-service non-destructive testing sites will produce harmful gas pollution, so the working environment is extremely difficult, and the type of work is a high-risk operation.
According to incomplete statistics, there are more than 10,000 pressure vessel equipment in China every year, both in production and in-service testing. It is urgent to improve the automation and intelligent testing level of non-destructive testing of large pressure vessels. Therefore, replacing labor with machines is the development trend. Permanent magnet adsorption ultrasonic testing robot, to solve the robot operation process of weld forming quality detection and control, than manual operation to improve the efficiency of more than 4 times, to improve the quality of reloading products, reduce testing costs is of great significance, the market application prospects.
Industrial Automation Equipment and Technology Research Institute
The Institute of Industrial Automation Equipment and Technology was formally established on August 18, 2016 at the High-end Equipment Research Institute of Tsinghua University. The team is headed by Associate Professor Sun Zhenguo of the Department of Mechanical Engineering of Tsinghua University, with Professor Chen Qiang as the consultant. It is composed of nearly 20 core members, including in-service professors and postgraduates of Tsinghua University, experts in engineering design and material technology experiments with practical work experience, and mechanical and electrical engineers. The main research fields are workshop automation design and logistics system simulation, special robots, welding technology and equipment, non-destructive testing technology and equipment, basic material research and numerical simulation of large castings and forgings. In June 2019, he was selected as the third batch of special support program for talent development in Tianjin, "High-level Innovation and Entrepreneurship Team".
Technical docking and business negotiation
Teacher Sun
Telephone: 13910003348
E-mail: sunzg@tsinghua-tj.org
Source | Institute of Industrial Automation Equipment and Technology
Editor | Zhang Shu
The final interpretation of the above related technologies belongs to the Institute of Industrial Automation Equipment and Technology.
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