CN112902660A - Rotary kiln lining refractory brick damage inspection robot - Google Patents
Rotary kiln lining refractory brick damage inspection robot Download PDFInfo
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- CN112902660A CN112902660A CN202110178414.3A CN202110178414A CN112902660A CN 112902660 A CN112902660 A CN 112902660A CN 202110178414 A CN202110178414 A CN 202110178414A CN 112902660 A CN112902660 A CN 112902660A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/20—Details, accessories or equipment specially adapted for rotary-drum furnaces
- F27B7/42—Arrangement of controlling, monitoring, alarm or like devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangement of monitoring devices; Arrangement of safety devices
- F27D21/0021—Devices for monitoring linings for wear
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangement of monitoring devices; Arrangement of safety devices
- F27D21/02—Observation or illuminating devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangement of monitoring devices; Arrangement of safety devices
- F27D21/02—Observation or illuminating devices
- F27D2021/026—Observation or illuminating devices using a video installation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Muffle Furnaces And Rotary Kilns (AREA)
Abstract
本发明公开一种回转窑窑衬耐火砖破损巡检机器人，属于特种机器人技术领域，该机器人包括行走系统、检测系统以及控制系统三部分。本发明所提供的窑衬耐火砖破损巡检机器人运用机械、传感、机械视觉和控制等技术，实现对回转窑窑衬耐火砖破损区域的自动检测，适用于不同直径、不同应用场合的回转窑，适用范围广，使用方便，检测精度高。
The invention discloses a rotary kiln lining refractory brick damage inspection robot, which belongs to the technical field of special robots. The robot includes three parts: a walking system, a detection system and a control system. The kiln lining refractory brick damage inspection robot provided by the present invention realizes the automatic detection of the damaged area of the kiln lining refractory brick of the rotary kiln by using the technologies of machinery, sensing, mechanical vision and control, and is suitable for rotary kiln lining refractory bricks with different diameters and different application occasions. The kiln has a wide range of applications, is easy to use, and has high detection accuracy.
Description
Technical Field
The invention belongs to the technical field of special robots, and particularly relates to a device and a method for inspecting the damage degree of a rotary kiln liner.
Background
The rotary kiln is a rotary calcining kiln, belongs to building material equipment, is widely applied to the fields of building materials, metallurgy, chemical industry, environmental protection and the like, has a larger combustion space and a thermal field, can supply enough combustion-supporting air, can ensure that fuel is fully combusted, and enables the material to be calcined at high temperature to change the property. When the rotary kiln is used for calcination, the internal temperature is up to thousands of ℃, and in order to prevent the kiln body from being damaged due to the phenomenon of 'red kiln' under the action of high temperature, a layer of heat-insulating refractory brick kiln lining is usually built inside the kiln body. During the use of the rotary kiln, the refractory bricks in different areas are subjected to different temperatures and different degrees of cold and heat changes, the refractory bricks in different areas are subjected to different thermal stresses, the surfaces of the refractory bricks in different areas are subjected to different impacts of hot gas flows, and particularly when materials are added to the refractory bricks in local areas are relatively heavy, the refractory bricks in local areas are subjected to relatively large mechanical impact force, so that the refractory bricks in local areas are easy to crack, crack and fall off, and even collapse in a large area, so that the damage of the local areas of the kiln liner is caused. In addition, the uneven texture of the refractory bricks and defects in the manufacturing process increase the probability of breakage of the refractory bricks. The breakage of the refractory bricks results in a reduction in the thermal insulation effect thereof, and even failure to insulate. At this time, the rotary kiln is corroded by the high-temperature materials to generate a red kiln, so that the rotary kiln cannot work or is even damaged. Therefore, timely repair of the local damaged area is required. Therefore, after the rotary kiln is used, the kiln lining needs to be continuously inspected, the damaged area on the kiln lining is identified through scanning the appearance of the kiln lining, the position of the damaged area is determined, and the subsequent local repair operation is facilitated.
Rotary kilns often produce large quantities of harmful substances during their use. For example, in the building material industry, rotary kilns are mainly used for calcining cement, and in the case of a rotary cement kiln, acid gases such as sulfides and nitrides are generated in the calcining process, and a large amount of dust is also generated. In the environmental protection industry, a rotary kiln is commonly used for burning solid wastes, such as industrial wastes, household wastes, medical wastes and the like, during the burning process, a large amount of toxic gases and a large amount of dust are generated in the kiln, and the toxic gases include dioxin, furan and other highly toxic substances generated after chloride is burned. Because the air flow in the kiln is poor, toxic gas generated by burning can remain in the kiln for a long time, the dust concentration in the kiln is high, and the physical and psychological health of kiln entering inspectors is seriously threatened. The risk that the damaged and loosened refractory bricks drop at any time exists, and the life safety of the kiln entering inspection personnel is greatly threatened. Therefore, the robot is urgently needed to replace the manual inspection.
Disclosure of Invention
The invention provides a rotary kiln lining refractory brick damage inspection robot which comprises a traveling system, a detection system and a control system.
The walking system comprises a first support group, a second support group, a polished rod, a third support group, a first lead screw, a first stepping motor and a hexagonal nut; the first support group comprises a first support base body and four first support group telescopic rods, the second support group comprises a second support base body and eight second support group telescopic rods, the third support group comprises a third support base body and four third support group telescopic rods; the first support group telescopic rod comprises a telescopic sleeve, a second lead screw, a guide pin, a shell, a tapered roller bearing, a second mounting seat, a second coupler, a speed reducer, a second stepping motor, a screw, a second bearing end cover, a travel switch, a round nut, a displacement sensor, a pressure sensor and a protective sleeve; the telescopic sleeve is in clearance fit with the through hole of the shell and is connected with the round nut through a screw; the guide pin is in interference fit with the through hole in the side face of the shell, the right end of the guide pin extends into the guide groove in the telescopic sleeve, and the guide pin is in clearance fit with the guide groove; the tapered roller bearing is mounted at the lower end of the second lead screw, the second bearing end cover is mounted on the lower end face of the shell through a screw, the tapered roller bearing is fixed with the end face in the shell hole through the second bearing end cover, and a sealing ring is mounted between the second bearing end cover and the second lead screw; the second lead screw is connected with the output shaft of the speed reducer through the second coupling; the second mounting seat is mounted on the lower end face of the shell through a screw, the speed reducer is mounted on the second mounting seat, and the second stepping motor is mounted on the speed reducer; the second stepping motor is mounted on the first support base body through the screw; the travel switch is arranged in a hole on the side surface of the shell; the displacement sensor is arranged in a threaded hole in the side face of the shell; the pressure sensor is fixed in a groove at the top end of the telescopic sleeve through a screw, and the protective sleeve is sleeved at the top end of the telescopic sleeve; the structures of the second support group telescopic rod and the third support group telescopic rod are the same as those of the first support group telescopic rod; the first support group consists of a first support base body and four first support group telescopic rods, and the first support group telescopic rods are installed on the first support base body through screws; the second support group consists of a second support base body and eight second support group telescopic rods, the second support group telescopic rods are mounted on the second support base body through screws, and the second support base body is in threaded connection with the first lead screw; the structure of the third support group is symmetrically distributed with the first support group; the polish rod sequentially passes through holes in the first supporting base body, the second supporting base body and the third supporting base body, and two ends of the polish rod are fixed through the two hexagonal nuts; the number of the polish rods is two, and the polish rods are distributed in a centrosymmetric manner by the first lead screw; the right end of the first lead screw is provided with the first angular contact ball bearing, and the first angular contact ball bearing is fixed through a shaft shoulder of the first lead screw and the end surface in the hole of the first supporting base body; the second angular contact ball bearing is mounted at the left end of the first lead screw, the first bearing end cover is mounted at the left end of the third support base body through a screw, the second angular contact ball bearing is fixed through the first bearing end cover and a shaft shoulder of the first lead screw, and a sealing ring is mounted between the first bearing end cover and the first lead screw; the first mounting seat is mounted on the right end face of the first supporting base body through a screw, and the first stepping motor is mounted on the first mounting seat; an output shaft of the first stepping motor is connected with the right end of the first lead screw through the first coupler; the detection system comprises an LED light source, an industrial camera, a memory, a camera support platform and a counter; the camera support platform is mounted at the left end of the first lead screw through a flat key, and the camera support platform and the left end of the first lead screw are fixed through the set screw; the LED light source and the industrial camera are mounted on the camera support platform through screws; the memory is installed in a groove of the camera support platform through a screw; the counter is arranged on the left end face of the third supporting base body, and an induction block of the counter is fixed on the first lead screw; the control system comprises a controller, a processor, an input screen, a travel switch, a displacement sensor and a pressure sensor; when the travel switch is pressed down by the telescopic sleeve, the second stepping motor is powered off and stops rotating, the displacement sensor measures the distance between the first support group and the second support group and feeds displacement information back to the processor (), and the pressure sensor measures the pressure between the top end of the telescopic sleeve and the kiln liner and feeds pressure information back to the processor (); the controller, the processor and the input screen are installed on the second supporting base body through screws, the input screen can input original parameters, the processor can process various signals and send action instructions to the controller, and the controller controls various terminals to execute actions through the instructions.
The invention provides a method for detecting the damage degree of a kiln liner of a rotary kiln, which comprises the following specific detection steps:
1) the inspection robot is lifted into a rotary kiln to be inspected, relevant rotary kiln parameters are input into the input screen, the processor processes data and sends an action instruction to the controller, and the controller controls the LED light source, the industrial camera and the counter to be electrified;
2) the second stepping motor of the first support group drives the second lead screw to rotate forwards after receiving the instruction of the controller, the telescopic sleeve extends outwards, the protective sleeve is attached to and expands tightly against a kiln liner of the rotary kiln, the pressure between the top end of the telescopic sleeve and the kiln liner reaches the maximum pressure value set by the pressure sensor, the pressure sensor sends a signal, the processor processes the signal and sends an action instruction to the controller, and the controller enables the second stepping motor to stop rotating; the movement of the third support group is synchronized with the first support group;
3) the first stepping motor drives the first lead screw to rotate reversely after receiving an instruction of the controller, the controller enables the counter and the industrial camera to be powered off, the second supporting base body moves leftwards, the distance between the first supporting group and the second supporting group is gradually increased to a maximum displacement value set by the displacement sensor, the displacement sensor sends a signal, the processor processes the signal and sends an action instruction to the controller, and the controller enables the first stepping motor to stop rotating;
4) a second stepping motor on the second support group drives a telescopic rod of the second support group to extend out after receiving an instruction of the controller, the top end of the telescopic rod of the second support group is attached to the kiln liner and expands tightly, the pressure sensor in the telescopic rod of the second support group sends a signal after reaching a set maximum value, the processor processes the signal and sends an action instruction to the controller, and the controller enables the second stepping motor in the second support group to stop rotating;
5) the second stepping motor of the first support group drives the second screw rod to rotate reversely after receiving the instruction of the controller, the telescopic sleeve in the first support group retracts inwards, the travel switch is triggered when the telescopic sleeve retracts to the limit position, and the travel switch in the first support group enables the second stepping motor to stop rotating; the movement of the third support group is synchronized with the first support group;
6) the first stepping motor drives the first lead screw to rotate forward after receiving an instruction of the controller, the counter and the industrial camera are powered on, the first lead screw drives the first support group and the third support group to move leftwards, the counter records the number of turns of the first lead screw, and the industrial camera shoots the appearance of the kiln lining of the rotary kiln in a spiral mode and transmits a shot image to the memory for storage; the distance between the first support group and the second support group is gradually reduced to a minimum displacement value set by the displacement sensor, the displacement sensor sends out a signal, the processor processes the signal and sends out an action instruction to the controller, and the controller controls the first stepping motor to stop working;
7) repeating the step 2);
8) the second stepping motor on the second support group drives the telescopic rod of the second support group to retract inwards after receiving the instruction of the controller, and the travel switch in the telescopic rod of the second support group is triggered when the telescopic rod of the second support group retracts to the limit position, so that the second stepping motor stops rotating;
9) repeating the steps 3) -8) until the detection of the damage of the refractory bricks of the kiln liner of the whole rotary kiln is completed;
10) after the detection work is finished, the controller sends out an instruction to disconnect the LED light source and the industrial camera power supply; repeating the steps; the inspection robot is separated from the kiln lining of the rotary kiln, and is hoisted out of the rotary kiln by a crane; and exporting the information stored in the memory, analyzing and determining the position of the damaged area of the kiln liner, and finishing the routing inspection operation.
The beneficial effect that adopts this technical scheme to bring:
1) the rotary kiln lining refractory brick damage inspection robot provided by the invention integrally adopts a supporting structure, automatic centering of the device is realized through four circumferentially distributed telescopic rods, the extension length of the telescopic rods is changed, the rotary kiln lining refractory brick damage inspection robot can work in different kiln diameter ranges, and the application range is wide.
2) The inspection robot provided by the invention mainly comprises a rod-shaped piece, a walking system of the inspection robot drives a screw nut through a motor, and the inspection robot is simple in structure, convenient to use, convenient to install and maintain and suitable for high-frequency inspection work of a rotary kiln.
3) The device provided by the invention is suspended at the axis part of the rotary kiln through the telescopic rod, and the kiln lining is shot in a scanning manner by adopting the industrial camera, so that the shooting coverage is wide, no visual field dead angle exists, and the image can be stored in time, thereby facilitating the subsequent observation of the local damaged area of the refractory brick of the kiln lining.
4) The device adopts the counter, the number of revolutions of the screw rod during the forward rotation of the screw rod is recorded, the number of revolutions of the screw rod during the backward rotation is not recorded, the accurate position of the kiln lining damage in the shot image can be determined by matching the screw pitch of the screw rod, and a large amount of time is saved for the subsequent manual investigation operation.
5) The invention uses the pressure sensor, the displacement sensor and the travel switch, realizes the automatic stop of the control motor when the telescopic rod extends out and retracts, shortens the auxiliary operation time, has reliable action and can effectively protect equipment.
6) The inspection robot provided by the invention adopts an automatic inspection mode, greatly reduces the labor intensity of workers, prevents the workers from being exposed to toxic gas or a large amount of dust for a long time, protects the physical and mental health of the workers and reduces potential safety hazards.
Drawings
FIG. 1 is a schematic view of the inspection robot of the present invention;
FIG. 2 is a schematic cross-sectional view of the structure of FIG. 1;
FIG. 3 is an enlarged view of a portion of FIG. 2 at A;
FIG. 4 is an enlarged view of a portion of FIG. 2 at B;
FIG. 5 is a schematic sectional view of the structure of the telescopic rod of the first support set;
fig. 6 is a schematic structural diagram of the detection system of the present invention.
In the figure: 1: a first support group; 2: a second support group; 3: a controller; 4: a processor; 5: an input screen; 6: a polish rod; 7: a third support group; 8: an LED light source; 9: an industrial camera; 10: a memory; 11: a camera support; 12 a counter; 13: a third support substrate; 14: a second support substrate; 15: a first lead screw; 16: a first support base; 17: a first stepper motor; 18: a first coupling; 19: a first mounting seat; 20: a hexagonal nut; 21: a first angular contact ball bearing; 22: a second angular contact ball bearing; 23: a first bearing end cap; 24: tightening the screw; 25: a first support set of telescoping rods; 26: a second support set of telescoping rods; 27: a third support group telescopic rod; 2501: a telescopic sleeve; 2502: a second lead screw; 2503: a guide pin; 2504: a housing; 2505: a tapered roller bearing; 2506: a second mounting seat; 2507: a second coupling; 2508: a speed reducer; 2509: a second stepping motor; 2510: a screw; 2511: a second bearing end cap; 2512: a travel switch; 2513: a round nut; 2514: a displacement sensor; 2515: a pressure sensor; 2516: and (6) a protective sleeve.
Detailed Description
The invention provides a rotary kiln lining refractory brick damage inspection robot which comprises a traveling system, a detection system and a control system.
The walking system comprises a first support group 1, a second support group 2, a polished rod 6, a third support group 7, a first lead screw 15 and a first stepping motor 17. First support group 1 includes first support base member 16, first support group telescopic link 25, and first support group telescopic link 25 has four, and second support group 2 includes second support base member 14, second support group telescopic link 26, and second support group telescopic link 26 has eight, and third support group 7 includes third support base member 13, third support group telescopic link 27, and third support group telescopic link 27 has four. The first support set telescopic rod 25 comprises a telescopic sleeve 2501, a second lead screw 2502, a guide pin 2503, a housing 2504, a tapered roller bearing 2505, a second mounting seat 2506, a second coupling 2507, a speed reducer 2508, a second stepping motor 2509, a screw 2510, a second bearing end cover 2511, a travel switch 2512, a round nut 2513, a displacement sensor 2514, a pressure sensor 2515 and a protective sleeve 2516. The telescopic sleeve 2501 is in clearance fit with a through hole of the housing 2504 and is connected with a round nut 2513 through a screw, the guide pin 2503 is in interference fit with the through hole in the side face of the housing 2504, the right end of the guide pin 2503 extends into a guide groove in the telescopic sleeve 2501, the guide pin 2503 is in clearance fit with the guide groove, and the telescopic sleeve 2501 can move along the axial direction without obstruction. The round nut 2513 is in threaded connection with the second lead screw 2502, two ends of a threaded shaft of the second lead screw 2502 are axial surfaces, the lower end of the second lead screw 2502 is provided with a tapered roller bearing 2505, a second bearing end cover 2511 is arranged on the lower end surface of the housing 2504, an inner ring of the tapered roller bearing 2505 is in interference fit with the second lead screw 2502, an outer ring of the tapered roller bearing 2505 is in transition fit with a through hole of the housing 2504, the tapered roller bearing 2505 is fixed with the end surface in the hole of the housing 2504 through the second bearing end cover 2511, the second bearing end cover 2511 is mainly used for preventing dust and achieving axial positioning of the bearing, the end surface in the hole mainly serves for preventing the second lead screw 2502 from sliding out of the through hole of the housing 2504, and a sealing ring is arranged between the second bearing end cover 251. The second lead screw 2502 and the output shaft of the reduction gear 2508 are connected by a second coupling 2507. Second mounting base 2506 is mounted to a lower end surface of housing 2504 by screws, speed reducer 2508 is mounted to second mounting base 2506, second stepping motor 2509 is mounted to speed reducer 2508, and second stepping motor 2509 is mounted to first support base 16 by screws 2510. The travel switch 2512 is installed in a through hole on the side surface of the housing 2504, the head of the travel switch 2512 is circular, and when the round nut 2513 descends to the travel switch 2512, the lower end of the round nut 2513 presses down the travel switch 2512, so that the second stepping motor 2509 is powered off and stops rotating. Displacement sensor 2514 is mounted in a threaded hole in the side of housing 2504. Pressure sensor 2515 is mounted by screws in a recess in the top end of bellows 2501. The protective sheath 2516 is sleeved on the top end of the telescopic sheath 2501, and the protective sheath 2516 is made of soft material and used for preventing the kiln liner from wearing the pressure sensor 2515 but not influencing the sensitivity of the pressure sensor 2515. The second support group telescoping rod 26 and the third support group telescoping rod 27 are identical in construction to the first support group telescoping rod 25. First support group 1 comprises first support base member 16 and four first support group telescopic links 25, first support group telescopic link 25 passes through screw 2510 and installs on first support base member 16, two adjacent first support group telescopic links 25 axis contained angles are 90 degrees, second support group 2 supports group telescopic link 26 by the second and constitutes with eight second support group base member 14, second support group telescopic link 26 is installed on second support base member 14, each four second support group telescopic links 26 in both ends about, two adjacent second support group telescopic links 26 axis contained angles of homonymy are 90 degrees, third support group 7 and first support group 1 symmetric distribution. The polished rod 6 passes through the through holes on the first supporting base body 16, the second supporting base body 14 and the third supporting base body 13 in sequence for realizing the guiding effect of the walking system, the two ends of the polished rod 6 are fixed through the two hexagonal nuts 20, the two hexagonal nuts 20 are installed in opposite tops to play a role in preventing looseness, and the polished rod 6 has two ends and is distributed in a central symmetry mode through the first lead screw 15. The first lead screw 15 is installed in a threaded hole of the second support base 14, and two ends of a threaded shaft of the first lead screw 15 are axial surfaces. First angular contact ball bearing 21 is installed to first lead screw 15 right-hand member, first angular contact ball bearing 21 decides fixedly through the shaft shoulder of first lead screw 15 and the downthehole terminal surface of first support base member 16, first angular contact ball bearing 21 inner circle and first lead screw 15 axle interference fit, the outer lane is with the through-hole transition fit of first support base member 16, second angular contact ball bearing 22 is installed to first lead screw 15 left end, first bearing end cover 23 is installed at third support base member 13 left end, second angular contact ball bearing 22 fixes through first bearing end cover 23 and first lead screw 15's shaft shoulder. An inner ring of the second angular contact ball bearing 22 is in interference fit with the first lead screw 15 shaft, an outer ring of the second angular contact ball bearing 22 is in transition fit with a through hole of the third support base 13, and the first angular contact ball bearing 21 and the second angular contact ball bearing 22 can bear radial force and large axial force. The first bearing end cover 23 mainly functions to realize axial positioning of the bearing, and a seal ring is installed between the first bearing end cover 23 and the first lead screw 15 and mainly plays a role in dust prevention. An output shaft of the first stepping motor 17 is connected with the right end of the first lead screw 15 through a first coupler 18. The first mounting seat 19 is mounted on the right end surface of the first support base 16 by screws, and the first stepping motor 17 is mounted on the right end surface of the first mounting seat 19 by screws.
The detection system comprises an LED light source 8, an industrial camera 9, a memory 10, a camera support platform 11 and a counter 12. The camera support platform 11 is installed at the left end of the first lead screw 15 through a flat key, so that circumferential positioning of the camera support platform 11 and the first lead screw 15 is realized, and the side surface of the camera support platform 11 is connected with the first lead screw 15 through a set screw 24 and used for realizing axial fixing of the first lead screw 15; the industrial camera 9 is installed on the camera support platform 11 through screws and used for shooting the appearance characteristics of the kiln lining of the rotary kiln and identifying the damage conditions of cracking, falling, collapsing and the like in the local area of the kiln lining. The LED light source 8 is mounted on the camera support platform 11 through screws and used for enhancing the brightness in the kiln and ensuring the definition of images shot by the industrial camera 9. The counter 12 is installed on the left end face of the third supporting base body 13, the induction block of the counter 12 is fixed on the first lead screw 15, the induction distance of the counter 12 is set, and the counter 12 can count only when the induction block is within the set distance. When the first lead screw 15 rotates and the counter 12 is powered on, the counter 12 can sense the sensing block, the first lead screw 15 rotates for a circle, the counter 12 counts once after sensing once, and data can be stored in the built-in memory 10; when the power supply of the counter 12 is interrupted, the counter 12 cannot operate, and the counter 12 does not count even if the first lead screw 15 rotates. The memory 10 is installed in a groove of the camera support platform 11 through a screw and is used for storing a series of images shot by the industrial camera 9, so that the appearance of the local damage area of the refractory brick can be observed conveniently, and the analysis and calculation in the later period are facilitated.
The control system includes a controller 3, a processor 4, an input screen 5, a travel switch 2512, a displacement sensor 2514, and a pressure sensor 2515. The travel switch 2512, the displacement sensor 2514, and the pressure sensor 2515 belong to both a travel system and a control system. The travel switch 2512 is pressed down by the telescopic sleeve 2501 retreating to the extreme position, and the second stepping motor 2509 stops rotating in a short-time power mode; the displacement sensor 2514 is used for measuring the distance between the first support group 1 and the second support group 2 and feeding back displacement information to the processor 4, and the pressure sensor 2515 is used for measuring pressure information between the top end of the telescopic sleeve 2501 and the kiln liner and feeding back a pressure value to the processor 4. The processor 4 and the input screen 5 are connected with the controller 3 through leads, the input screen 5 is mainly used for inputting original parameters of the rotary kiln, the processor 4 is mainly used for processing different signals and sending action instructions to the controller 3, and the controller 3 is mainly used for controlling various terminals to execute actions through the instructions.
The working process of the robot is described below with reference to the accompanying drawings, and the specific steps are as follows:
1) the inspection robot is lifted into a rotary kiln to be inspected, relevant parameters of the rotary kiln are input into an input screen 5, a processor 4 processes data and sends an action instruction to a controller 3, and the controller 3 enables power supplies of an LED light source 8, an industrial camera 9 and a counter 12 to be connected;
2) the second stepping motor 2509 of the first support group 1 obtains an instruction of the controller 3 to drive the second lead screw 2502 to rotate forwards, the telescopic sleeve 2501 extends outwards, the telescopic rod 25 of the first support group is attached to and expands tightly against a kiln lining of the rotary kiln, the pressure between the top end of the telescopic sleeve 2501 and the kiln lining reaches the maximum pressure value set by the pressure sensor 2515, the pressure sensor 2515 sends a signal, the processor 4 processes the signal and sends an action instruction to the controller 3, the controller 3 controls the second stepping motor 2509 to stop working, the action of the third support group 7 is synchronous with that of the first support group 1, at the moment, the telescopic rod 25 of the first support group and the telescopic rod 27 of the third support group are in an expansion state, and the robot hovers in the rotary kiln;
3) the first stepping motor 17 starts to work after receiving an instruction of the controller 3, drives the first lead screw 15 to rotate reversely, the second support base 14 moves leftwards, meanwhile, the controller 3 enables the industrial camera 9 and the counter 12 to be powered off, the counter 12 is in a working stop state, the distance between the first support group 1 and the second support group 2 is gradually increased to a maximum displacement value set by the displacement sensor 2514, the displacement sensor 2514 sends a signal, the processor 4 processes the signal and sends an action instruction to the controller 3, and the controller 3 enables the first stepping motor 17 to stop rotating;
4) after the second stepping motor 2509 in the second support group 2 receives the instruction of the controller 3, the second support group telescopic rod 26 is driven to extend out, the top end of the second support group telescopic rod 26 is attached to the kiln liner and expands tightly, a pressure sensor 2515 in the second support group telescopic rod 26 sends a signal after reaching a set maximum value, the processor 4 processes the signal and sends an action instruction to the controller 3, the controller 3 enables the second stepping motor 2509 in the second support group telescopic rod 26 to stop rotating, and at the moment, the second support group telescopic rod 26 is in an expanded state;
5) the four second stepping motors 2509 of the first support group 1 are reversely rotated after receiving the instruction of the controller 3, the second screw 2502 is driven to reversely rotate, the telescopic rods 25 of the first support group are retracted inwards, the travel switches 2512 are triggered when the telescopic rods of the first support group are retracted to the limit position, the travel switches 2512 in the telescopic rods 25 of the first support group control the second stepping motors 2509 to stop working, the movement of the third support group 7 is synchronous with the movement of the first support group 1, and at the moment, the telescopic rods 25 of the first support group and the telescopic rods 27 of the third support group are in the retracted state;
6) the first stepping motor 17 drives the first lead screw 15 to rotate forward after receiving the instruction of the controller 3, the second support group 2 is fixed, the first lead screw 15 drives the first support group 1 and the third support group 7 to move leftward, at the same time, the controller 3 energizes the counter 12 and the industrial camera 9, the first lead screw 15 rotates one turn forward, when the sensor on the counter 12 is in the closest distance with the sensing block of the first lead screw 15, the sensor on the counter 12 senses once and counts once, the industrial camera 9 shoots the kiln liner appearance of the rotary kiln spirally, the shot image is transmitted to the memory 10 to be stored, the distance between the first support group 1 and the second support group 2 is gradually reduced to the minimum displacement value set by the displacement sensor 2514, the displacement sensor 2514 sends out a signal, the processor 4 processes the displacement signal and sends out an action instruction to the controller 3, and the controller 3 enables the first stepping motor 17 to stop rotating;
7) repeating the step 2), wherein the first support group telescopic rod 25 and the third support group telescopic rod 27 are in an expansion state;
8) after the second stepping motor 2509 on the second support group 2 receives the instruction of the controller 3, the second support group telescopic rod 26 is driven to retract inwards, when the second support group telescopic rod is retracted to the limit position, a travel switch 2512 in the second support group telescopic rod 26 is triggered, the travel switch 2512 in the second support group telescopic rod 26 controls the second stepping motor 2509 to stop rotating, and at the moment, the second support group telescopic rod 26 is in a retracted state;
9) repeating the steps 3) -8) until the detection of the damage of the refractory bricks of the kiln liner of the whole rotary kiln is completed;
10) after the detection work is finished, the controller 3 sends out an instruction, the power supply of the LED light source 8 and the industrial camera 9 is disconnected, the step 5) is repeated, the first support group 1 and the third support group 7 are in a return state, at the moment, the robot is separated from the kiln lining, the robot is hoisted out of the rotary kiln by a crane, information stored in the memory 10 is exported, the position of the damaged area of the kiln lining is analyzed and determined according to the angular speed and the thread pitch of the first lead screw 15, the number of revolutions recorded by the counter 12 and the image shot by the industrial camera 9, and the inspection work is finished.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115755717A (en) * | 2022-11-29 | 2023-03-07 | 潮州市索力德机电设备有限公司 | Kiln equipment operation detecting system based on thing networking |
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| CN112902660B (en) | 2022-06-07 |
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