面向储罐异形结构的智能除锈机器人系统设计与应用

Design and application of an intelligent rust removal robot system for irregular storage tank structures

  • 摘要: 大型油气储罐外壁的定期除锈防腐是保障其安全运行的关键环节。传统人工检修方式效率低、安全性差,且难以应对加强圈、抗风圈等异形结构。本文研发了一套集自主导航、多模态作业与智能控制于一体的磁吸附爬壁机器人系统。该系统采用模块化设计,包括高强度磁吸附移动平台、六自由度协作机械臂、恒力柔性除锈末端及可回收喷砂设备。通过融合激光同步定位与地图构建(Simultaneous Localization and Mapping,SLAM)、视觉传感器与惯性测量单元(Inertial Measurement Unit,IMU)的多传感器导航系统,实现了复杂罐壁环境下的高精度定位与自适应路径规划。针对异形结构,设计了专用越障工装与自适应作业算法。实验表明,该系统除锈效率达20 ~ 30 m2/h,除锈质量满足Sa2.5级标准,可稳定越障并完成异形结构处理,显著提升了储罐检修的自动化水平与作业安全。

     

    Abstract: Regular rust removal and corrosion protection for the outer walls of large oil and gas storage tanks is critical to their safe operation. Conventional manual maintenance methods are characterized by low efficiency, high safety risks, and limited adaptability to irregular structures such as stiffening rings and wind girders. To address these challenges, this paper develops a magnetic adsorption wall-climbing robot system that integrates autonomous navigation, multimodal operation and intelligent control. The system is of a modular design, including a high-strength magnetic adsorption mobile platform, a six-degree-of-freedom collaborative robotic arm, a constant-force flexible rust-removal end-effector, and a recyclable abrasive blasting unit. A multi-sensor navigation system combining Simultaneous Localization and Mapping (SLAM), vision sensors, and an Inertial Measurement Unit (IMU) enables high-precision positioning and adaptive path planning in complex tank-wall environments. In addition, dedicated obstacle-crossing tools and adaptive operation algorithms are designed for irregular structures. Experiments show that the proposed system achieves a rust removal efficiency of 20 ~ 30 m2/h while satisfying the Sa2.5 surface preparation standard. It can reliably cross obstacles and effectively process irregular structures, significantly improving the automation level and operation safety of storage tank maintenance.

     

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