Intelligent rail inspection robot in chemical workshop

1Chemical inspection background

In the chemical industry, hazardous factors such as toxic, flammable and explosive gases and fumes and dusts are commonly present. In the process of chemical production, storage and transportation, under special conditions such as heating, pressurization, catalysis and reaction, the production of raw materials, intermediate products and final products have the potential risk of causing fire and explosion and human casualties. Therefore, fire and explosion prevention and poison prevention have an extremely important position in chemical safety, especially in chemical workshops. And chemical inspection, is an important means of safety monitoring.

2Comparison of human-machine inspection

In the past, the use of manual inspection, there is a strong subjectivity, workload, data recording backward, data can be poorly analyzed shortcomings, prone to omissions, wrong patrol and other mistakes, complex environment also threatens the safety of personnel.

Today, the use of orbital inspection robots, with strong adaptability, timely response, save labor costs, reduce the risk of casualties and other characteristics, can ensure the integrity and authenticity of data, improve the quality of inspection, timely make abnormal treatment, a greater degree of protection of chemical production in the safety of life and property.

3Equipment Composition

The orbital inspection robot is usually mainly composed of control center, horizontal movement mechanism, lifting movement mechanism, chassis module, track assembly, front-end monitoring equipment and other core equipment, detection equipment and other auxiliary equipment. According to the specific use environment, it contains gimbal, pickup, infrared thermal imager, visible light camera, flammable and explosive gas sensor, toxic gas sensor, smoke sensor, dust sensor, LIDAR, laser vibrometer, antenna, anti-collision switch and other devices.

4 Overall Functionality

The orbital inspection robot can carry out all-day, all-round and all-autonomous intelligent inspection and safety protection of the chemical workshop, including automatic cruise, automatic call head preset position detection, intelligent meter reading, image recognition, infrared temperature measurement, oil and gas leak detection, toxic and harmful gas reconnaissance, real-time video back transmission and other functions. Equipment inspectors can conduct inspection in the monitoring background, realize manual and automatic control, replace traditional manual with intelligent and advanced means, and complete daily inspection of equipment and special fault identification. Timely discovery of instrumentation abnormalities, equipment failures, harmful gas leaks, temperature abnormalities and other safety hazards greatly reduces the work pressure and intensity of operation and maintenance personnel, and efficiently enhances the safety protection level.

5 System Features

5.1 Video image capture function

Through the infrared thermal imager carried on the orbital inspection robot to achieve the image acquisition of workshop equipment, cables, pipes, production, etc., image information through the gigabit wireless communication, transmitted to the remote host computer display and storage. By browsing and analyzing the images, it determines the opening and closing of gates, the status of indicators, the existence of abnormal equipment, the degree of equipment damage, the location of faults, etc. Combined with image recognition technology for data information such as pointer meter, digital display meter, flip chart liquid level meter, bearing oil level, electrical switch and valve position in the inspection area. Based on HD inspection and video intelligent analysis algorithm, realize early warning of abnormal behaviors such as animal intrusion, personnel gathering, wandering, boundary crossing detection, area intrusion, etc., and confirm whether there is a need for shutdown and maintenance, and whether there are personnel operating in violation of regulations. Carry out automatic data identification, uploading, automatic generation of reports and trend curves, and judgment of alarms.

5.2 Sound capture function

Real-time collection of on-site sound, through the wireless network real-time transmission to the remote host computer. When equipment failure occurs during the operation of the monitored equipment, the failure part often produces more obvious sound abnormalities, and through automatic analysis of the collected sound, it can determine whether the equipment is abnormal, so that the failure can be found in time to avoid further expansion of the failure.

5.3 Gas, smoke, dust and temperature monitoring functions

The inspection robot body can be installed with multi-gas detection sensors, with temperature and humidity, gas, smoke and other sensors, real-time monitoring of the environment CO, H2S, CH4, O2, dust, etc.. If there is an abnormal gas concentration in the environment, the alarm will be activated in time and the environmental auxiliary system will be effectively linked. Equipment operation process equipment failure point will exist in the phenomenon of high local temperature, infrared temperature sensor can quickly detect the location of the damaged equipment, and at the same time can remotely point to the thermometer to accurately collect the temperature of the object being detected.

5.4 Leak detection function

According to different media and working conditions, through the leakage cable, acoustic piezometer, video identification, infrared temperature measurement and other technologies, the orbital inspection robot can realize the automatic detection of water, oil, acid, alkali, gas and steam running and dripping from the site pipelines and storage tanks.

5.5 Wireless communication function

Adopt network communication system with WiFi or 4G/5G wireless signal conforming to TCP/IP, remote mobile monitoring and real-time data transmission to centralized management and control center. With excellent anti-interference, load balance optimization function, suitable for seamless roaming transmission operation in all kinds of harsh environments.

5.6 Automatic power detection, charging, remote positioning function

The rail inspection robot can be powered by lithium battery and automatically monitor the battery power, and automatically find the nearest wireless charging point for charging when the power is insufficient. The inspection robot has the function of automatic inspection and manual operation of personnel, and the manual operation level is higher than automatic inspection.

5.7 Upper computer system functions

Rail inspection robot system for its own state information, configuration inspection tasks, the collected data through the robot comes with WIFI and field WIFI communication, to achieve data collection, storage, transmission, and in the background to achieve records, analysis, reports, trends, alarms and other functions; support secondary development, can achieve self-diagnosis of equipment abnormalities, can continue to improve the relevant functions.