Magnetic Adsorption High - Altitude Flaw Detection Integrated System For Creep Control And Ultrasonic Testing

The traditional ultrasonic detecting method mainly relies on detecting personnel to visit the detection field to personally detect. This method has some disadvantages,such as low inspect efficiency, difficulty to evaluate defects and so on. Especially,there are some security risks for inspectors to work in the high altitude environment.Therefore, it has very important significance to develop this study. But the existing flaw detection system has low integration degree to each function module and can’t control each subsystem, such as detection subsystem, vision subsystem, motion control subsystem of robot. According to the needs of Kunming Xinhui detection Co.Ltd., we designed and researched an accurate, stable and reliable software control system for wall-climbing and high altitude detecting robot. In this thesis, Based on the design of wall-climbing robot’s body structure, we designed a two level control structure with the upper machine and lower machine control system, and completed the following studies:1. The upper machine control system control and communicate with PLC in advanced language programming. In fact, the PLC can only use the manufacturer’s configuration software to develop programs and its own production of touch screen to send control instructions, so the system can’t integrate well. For this, we add the Ethernet module to PLC, and make use of the Modbus/TPC protocol and Socket programming to realize the communication with the PLC. And by sending the complete data frame to the PLC, so as to controlling the PLC.2. In this thesis, we designed and implement a 4-channels ultrasonic flaw detection subsystem. This system consists of the upper machine data analysis sever and IPC data collection terminal with the PCI bus mode of ultrasonic data acquisition board. Making use of Socket programming, complete the communication between them. Date collection terminal send the ultrasonic data to data analysis terminal and set data collection board working parameters. Based on these ultrasonic data, the data analysis terminal plots the waveform and DAC curve. And then,sending the command to the lower machine data collection terminal, thus to changing of the parameters of the board. When saving ultrasonic data, the system set save and playback data and detection results by algorithms.3. We complete the design and implement of the upper machine vision monitoring subsystem, which achieve the video data transmission and PTZ control by calling the SDK functions.4. The upper machine software control system design a man-machine interface system and realize highly integrated and unified control of subsystem and serial conversation, including motion of wall-climbing, scanning operation mechanism,vision monitoring subsystem and 4-channels ultrasonic flaw detection subsystem.The innovation of the dissertation is indicated as follows:(1) used advanced language programming to control the upper machine of PLC;(2) The data and detection results can be set, saved and playback by the system.(3) Completed the design and implement of the control system of wall-climbing robot, and realized integration and unity of each machine control interfaces.