JP5066012B2 - Remote inspection and repair system, calibration method and repair method thereof - Google Patents

Description

  The present invention relates to a remote inspection and repair system that realizes reliable and efficient inspection and repair work for a structure in a complicated and narrow environment that is difficult for humans to enter, and a calibration method and a repair method thereof.

  In general, inspection and repair work for structures performed by introducing a remote control device is equipped with a drive mechanism and a TV camera for inspection and repair work at the site (where inspection and repair work is performed), and the operator drives the drive mechanism. In many cases, the construction head is operated while monitoring the surrounding conditions.

  However, when performing operations such as inspections such as scratch detection and repairs such as welding, severe driving conditions such as high-precision positioning control using a multi-joint mechanism and constant speed scanning control are required. The burden is large for the operator to perform remote operation. In addition, a great deal of training and implementation period will be required.

  Therefore, various external sensors (TV cameras, distance sensors, contact sensors, etc.) are incorporated into the remote control device to perform positioning automatically in order to ensure high-precision positioning accuracy and constant speed scanning. Remote equipment that automatically scans has been developed. Such high-precision remote control devices are being put to practical use in places with relatively good environmental conditions where people are easily accessible, such as manufacturing factories, but complex and narrow plants that are difficult for people to enter. In this environment, there are the following problems, making it difficult to put it to practical use.

-It is necessary to reduce the size and weight of the drive mechanism in order to drive in a complicated and narrow environment, but it is difficult to reduce the size because there is no space for mounting many sensors.
・ There is no small, highly accurate sensor that can be measured over a wide range, which can be adapted to environmental conditions (temperature, humidity, vibration, radiation, underwater, etc.) that are difficult for humans to enter.
・ If a large number of sensors are installed, the number of sensor cables increases and the device becomes complicated, making operation difficult. Moreover, it becomes an expensive apparatus with low cost performance.
・ The shape and dimensions of the surrounding structure may not be clear, unlike the design drawing and the actual product, and it is difficult to measure the shape easily in a complicated and narrow environment.

Recently, there has been proposed an apparatus of a type that realizes miniaturization by newly using a drive mechanism dedicated to shape measurement, independently of a drive mechanism for inspection / repair work.
JP-A-5-26638 High-speed optical cutting method profile measurement system, Optware Corporation, Internet, <URL: http://www.optoware.co.jp/densen.pdf>

However, the above method also has the following problems, and improved development is required.
・ There is a high possibility that the displacement of the drive mechanism dedicated to shape measurement and the drive mechanism for inspection / repair work will occur, and this displacement amount detection function and displacement correction function are required.
-A function to reduce the pasting error of the shape measurement data to the coordinate system of the drive mechanism for repair work and the target positioning error due to the different characteristics (backlash, deflection, backlash, positioning accuracy) of each mechanism is required. .
-By providing two mechanisms, the equipment and operation become complicated and man-hours and costs increase. There is a need for improved reliability, simplified equipment, and faster processing.

  Therefore, in order to realize reliable and efficient inspection / repair work in a complicated and narrow environment where it is difficult for people to enter, it is necessary to construct a new device that solves the above problems.

  On the other hand, as a small shape measurement sensor, for example, a sensor based on a light cutting method composed of a slit-shaped (fan-shaped) laser light source and a camera that visualizes the laser light source has been put into practical use (for example, Patent Document 1 and Non-Patent Document 1). Patent Document 1).

  Therefore, it is desirable to have a system that can reliably and efficiently perform inspection and repair work by measuring the shape and dimensions of surrounding structures using one mechanism and a small number of small sensors with excellent environmental resistance. It is. The purpose of the present invention is to incorporate a small number of existing small sensors into one mechanism so that the system configuration is simple and easy to operate, and remote inspection that enables the operator to efficiently remotely control the shape measurement, inspection, and repair. The purpose is to provide a repair system.

In order to solve the above-mentioned problems, a remote inspection and repair system of the present invention has a laser emitting unit for repair construction, a head unit to which a TV camera for monitoring a construction target and detecting a repaired part is attached. The shape measurement sensor for measuring the three-dimensional shape of the structure, the shape measurement sensor and the drive mechanism of the head unit, and the three-dimensional shape position data of the repaired portion of the structure by signals from the shape measurement sensor And generating a drive data of the drive mechanism based on the construction path of the head unit, and a control device for remotely controlling the drive mechanism, in the remote inspection and repair system, the drive mechanism is swiveling, It has a multi-joint arm portion attached to a moving member that moves up and down, the shape measuring sensor is attached to the moving member, and the head portion is positioned at the tip of the multi-joint arm portion. And posture, characterized in that it is changed.

The remote inspection and repair method of the present invention is a remote inspection and repair method using the above remote inspection and repair system,
The step of detecting the repaired portion of the structure from the video of the TV camera, the step of measuring the three-dimensional shape of the structure by the shape measuring sensor, and the three-dimensional shape position data of the repaired portion of the structure are obtained. And a step of generating drive data of the drive mechanism based on a construction path from the three-dimensional shape position data, and a step of driving and controlling the drive mechanism based on the drive data.

A calibration method of the remote inspection and repair system of the present invention is a calibration method of the remote inspection and repair system,
When inspecting and repairing in an underwater environment, the drive mechanism is calibrated in advance in the water tank using the shape measurement sensor and the television camera.

Another remote inspection and repair system calibration method of the present invention is the above-described remote inspection and repair system calibration method,
When performing inspection and repair work in an underwater environment, the drive mechanism is operated in advance in a water tank, and the distance measurement calibration of the shape measurement sensor and the video position calibration of the TV camera are performed. To do.

  According to the present invention, it is possible to reliably and efficiently perform inspection and repair work by measuring the shape and dimensions of a target structure using a single mechanism and a small number of small sensors having excellent environmental resistance.

  Hereinafter, embodiments of a remote inspection and repair system according to the present invention will be described with reference to the drawings. In each embodiment, a system for inspection / repair work of a reactor bottom (water depth 30 m) of a nuclear power plant reactor will be described as an example of a structure in a complicated and narrow environment that is difficult for humans to enter.

(Embodiment 1)
FIG. 1 is a diagram illustrating a configuration of a remote inspection and repair system for a furnace bottom structure in the first embodiment.
The drive mechanism 1 for performing shape measurement and inspection / repair includes a multi-joint arm having a drive mechanism body 2 and a drive mechanism head (hereinafter referred to as “head”) 4 attached to the drive mechanism body 2 at the tip. There is part 3. The drive mechanism main body 2 performs a turning operation, and the column member 2a and the moving member 2b inside thereof are engaged by screws, and the moving member 2b moves up and down by the rotation of the column member 2a. The head unit 4 is changed in position and posture by the drive mechanism 1 and is inspected and repaired. The head unit 4 includes a laser emitting unit 4a that emits a laser to repair the scratch 5a that is a repaired part. A television camera 17 that monitors the state of the surrounding structure 5 and detects a repair location is attached to the side surface of the head portion 4.

  The furnace bottom structure, which is the surrounding structure 5 to be inspected and repaired in the present embodiment, is a stub tube, a CRD (control rod drive mechanism) housing, and an ICM (in-core motor) housing. The shape measuring sensor 6 is housed in a watertight case, is attached to a moving member 2b in a position where the position does not change even when the articulated arm 3 is driven, and a laser generator 7 that generates a fan-shaped laser beam 9 and a television. Using the camera 8 as a component device, the three-dimensional shape of the structure is measured by a light cutting method.

  The control device 11 is provided in the area of the above-ground part (operation floor at the top of the furnace vessel). The control device 11 receives a drive mechanism control panel 12 for driving the drive mechanism 1, a drive controller 13 for controlling the drive mechanism control panel 12, and display data (position / attitude data, etc.) transmitted from the drive controller 13. Then, a shape measuring device is configured together with the state display controller 14 for displaying the positional relationship between the drive mechanism 1 and the surrounding structure 5 and the shape measuring sensor 6, and a signal from the shape measuring sensor 6 is processed to generate distance data. The signal processing unit 15, the distance data generated by the signal processing unit 15 and the position / posture data of the head unit 4 at the tip of the driving mechanism 1 from the driving controller 13 are input, and the shape position from the origin of the driving mechanism 1 A data processing device 16 that generates data (3D CAD data) and transmits the data to the drive controller 13 and the state display controller 14 is provided.

The signal cable 10 transmits signals between the control device 11 and the drive mechanism 1 and between the control device 11 and the shape measurement sensor 6.
The hub (HUB) 18 functions as a relay station for transmitting and receiving signals between the drive controller 13, the status display controller 14, and the data processing device 16 via the LAN.
The monitor 19 monitors the video of the television camera 17 attached to the head unit 4.

Next, an operation procedure from inspection to repair of the furnace bottom structure by the remote inspection and repair system of the present embodiment will be described.
FIG. 2 is a diagram showing a procedure for inspection and repair construction of a furnace bottom structure by the remote inspection and repair system in the present embodiment.

The work procedure from inspection to repair is as follows, and the procedures (1) to (9) correspond to steps S1 to S9 in FIG. A series of operations are performed by operating only one drive mechanism.
(1) Mechanism insertion pre-processing (2) Drive mechanism insertion into the furnace (3) Scratch search (4) Scratch coordinate detection and repair range formulation (5) Repair point shape measurement (6) Repair processing plan generation (7) Repair work (8) Confirmation of repair work results (9) Lifting of drive mechanism

  In procedure (1), an air operation test and an underwater operation test are performed as pretreatments before the drive mechanism 1 is inserted into the furnace bottom. It is confirmed that the drive mechanism 1, the shape measurement sensor 6 and the television camera 17 can operate normally and have the required positioning performance. Calibration, generation of a flaw search path and drive data, and interference check by simulation of drive data are performed.

The calibration performs the following processing.
・ Drive mechanism calibration ・ Shape measurement sensor calibration ・ TV camera calibration

The calibration process in the mechanism pre-insertion process is performed in order to confirm the accurate performance close to the furnace bottom environment, and is performed in an underwater environment by installing a drive mechanism in the water tank in advance.
In step (2), confirm underwater operation.
In step (5), laser beam irradiation and irradiation point coordinates are calculated.
In step (6), interference check is performed by generating drive data and simulating drive data.

  3A and 3B are diagrams for explaining a calibration method for a shape measuring sensor and a monitoring television camera of the remote inspection and repair system according to the first embodiment. FIG. 3A is an overall sketch, and FIGS. 3B to 3D are initial diagrams. It is a figure which shows an attitude | position, a raising / lowering movement, and a back-and-forth movement.

  In the driving mechanism calibration, the driving mechanism 1 is installed on the simulated furnace bottom structure 26 in the water tank 25, and the shape measuring sensor 6 and the head portion attached to the moving member 2b that does not move by driving the articulated arm portion 3. 4 is performed using a television camera 17 attached to 4. The position at which the tip of the drive mechanism (head part 4) is irradiated with the laser beam 9 from the shape measuring sensor 6 at a plurality of positions / attitudes set according to the command from the drive controller 13 using the drive mechanism control panel 12.・ Move to posture. Distance data obtained by performing signal processing on the actually measured position / posture data and the data from the shape measurement sensor 6 at the signal processing unit 15 is collected, and a deviation from the set data is obtained. Then, it is confirmed that the deviation falls within the allowable range. When the deviation is large, the position / posture deviation of each part of the drive mechanism 1 is obtained and changed to normal position / posture data.

  In addition, the head mechanism 4 can be photographed by the TV camera 17 attached to the head section 4 at a plurality of set positions and postures using the drive mechanism control panel 12 in accordance with a command from the drive controller 13. Move to posture. Collect actual measured position / posture data and video. If the viewpoint position deviates from the set position, the amount of deviation is obtained. When it is actually inserted into the furnace bottom, an image taken at the time of drive mechanism calibration is compared with an image taken when inserted into the furnace bottom to confirm that there is no change.

  In the shape measurement sensor calibration, the drive mechanism 1 is moved in the up-and-down direction and the front-rear direction to confirm that a change in distance corresponding to the amount of movement can be measured within an allowable range. When the measurement cannot be performed within the allowable range, a correction characteristic that matches the movement amount and the measurement data is obtained.

  In the TV camera calibration, the head unit 4 is moved to a position / posture at which the drive mechanism body 2 can be photographed by the TV camera 17 attached to the head unit 4 at a plurality of set positions / postures. Collect posture data and video. If the viewpoint position of the video is shifted from the set position, the amount of deviation is obtained. When it is actually inserted into the furnace bottom, an image taken at the time of drive mechanism calibration is compared with an image taken when inserted into the furnace bottom to confirm that there is no change.

  Next, flaw search route generation and simulation are performed. Usually, when repair work is performed, information indicating that there is likely to be a scratch in the vicinity is obtained in advance with another monitoring camera or the like. Therefore, since the insertion place and the rough direction of the drive mechanism 1 can be assumed, an efficient scratch search path (movement path of the television camera 17) can be generated in advance. When generating the flaw search path, the shape data of the surrounding structure 5 (3D CAD data: if there is accurate shape data of the surrounding structure 5 of the as-built) is used by the data processing device 16 from the design data. If the operator sets the search range information (search start position and search end position), the scanning path can be obtained mechanically.

  And the drive data of the drive mechanism 1 is calculated | required from the created movement path | route of the television camera 17, and interference check with the surrounding structure 5 is performed by the drive simulation using 3D CAD data. Since the inspection is performed from a distance away from the surrounding structure 5, even if a simulation is performed with the shape data of the surrounding structure 5 generated from the design data, the drive mechanism 1 and the surrounding structure 5 may interfere with each other. Almost no.

  The remote inspection and repair system first collects information necessary for the repair work when performing the check and repair work. Specifically, the drive mechanism 1 is inserted into the nearest stub tube based on information obtained in advance by another monitoring camera or the like. Then, in order to confirm that the apparatus function is normally maintained in an environment of 3 atm underwater, a preset operation check is performed.

  If the drive mechanism 1 is inserted and the operation is confirmed to confirm that there is no change in the air, then a detailed scratch search is performed using the TV camera 17 attached to the head part 4 of the drive mechanism 1, The video of the position of the scratch 5a is collected. Then, from the collected video and the position / posture data of the head unit 4 when the video is shot, the detailed position (coordinates from the origin of the drive mechanism) and size (range for repair work) of the scratch 5a are calculated. The shape measurement sensor calibration process is performed during the mechanism pre-treatment, and it has been confirmed that there is no change from the calibration when the furnace bottom is inserted, so accurate and efficient position detection of the scratch 5a is possible. It becomes.

  FIG. 4 is a diagram illustrating a method for obtaining the coordinates of a scratch and a repair construction range from a scratch image in the first embodiment, (a) is a furnace bottom structure having a scratch, (b) is a part of the drive mechanism, (C), (d) is a figure which respectively shows the state which moved the head part.

  In the present embodiment, the method for calculating the coordinates of the scratch 5 a first displays the video collected by the television camera 17 attached to the head unit 4 on the monitor 19. The drive mechanism 1 is turned (θm) and moved back and forth (R) so that the position φ (end point) of the scratch 5a is at the center of the screen. That is, the head portion 4 is tilted by an angle Δs, swung from an angle θm1 to θm2, and moved from R1 to R2 in the radial direction. The position / posture data of the head unit 4 at that time is collected, and coordinates of the scratch 5a from the origin of the drive mechanism 1 and the repair work range are obtained by calculating coordinates from the collected position / posture data. It can be easily obtained without performing troublesome processing such as image processing.

FIG. 5 is a diagram illustrating a processing result of furnace bottom shape measurement by the remote inspection and repair system according to the first embodiment, where (a) is a sketch of the entire system, and (b) is a three-dimensional shape of the furnace bottom structure. It is a figure which shows a result.
In FIG.5 (b), the three-dimensional shape of the furnace bottom part structure containing a crack is shown.

  The fan-shaped laser beam 9 from the laser generator 7 of the shape measuring sensor 6 is irradiated to the surrounding surrounding structure 5 (furnace bottom structure) in the downward direction, and the furnace bottom structure irradiated with the laser beam 9 is irradiated with the TV camera 8. Shoot with.

  The captured image is transmitted as a video signal to the signal processing unit 15 provided in the control device 11, and the irradiation of the laser beam 9 is performed from the image captured by the television camera 8 using the principle of triangulation in the signal processing unit 15. Calculate the coordinates of the point. The calculation of the coordinate data in the signal processing unit 15 is performed by calibrating the position in the television camera coordinate system from the irradiation point position of the laser beam 9 in the image taken in the water tank in the drive mechanism insertion pre-processing. Because there is, it can be determined accurately and efficiently.

  In the present embodiment, the drive mechanism 1 captures an image of the furnace bottom structure irradiated with the laser beam 9 by changing the turning angle, and the signal processing unit 15 irradiates the irradiation point of the furnace bottom structure in the television camera coordinate system. Calculate the coordinates. The calculated irradiation point coordinate data of the furnace bottom structure in the television camera coordinate system is transmitted to the data processing device 16. The data processing device 16 receives the received irradiation point coordinate data and the position / posture data of the head unit 4 from the drive controller 13, and calculates the irradiation point coordinates of the furnace bottom structure from the origin of the drive mechanism. The positional relationship between the origin of the drive mechanism 1 and the origin of the TV camera 8 of the shape measurement sensor 6 is accurately known, and the irradiation point of the laser beam 9 in the image taken in the water tank in the drive mechanism insertion pretreatment Since the position in the TV camera coordinate system is calibrated from the position, the shape position data of the furnace bottom structure (the irradiation point coordinates of the furnace bottom structure from the origin of the drive mechanism) can be obtained easily and accurately. be able to.

  Further, the 3D CAD data for displaying the state of the drive mechanism 1 and the surrounding structure 5 by the state display controller 14 can be easily obtained because the origin coordinates of the drive mechanism are known. Therefore, since the shape measurement result of the repaired part can be displayed as a 3D state display image on the state display controller 14, the operator can easily determine whether or not the operator can normally process.

Next, repair construction data is generated.
6A and 6B are diagrams for explaining construction data generation by the remote inspection and repair system according to the first embodiment. FIG. 6A is a sketch of an articulated arm portion and a scratch, and FIGS. 6B to 6D are calculation of construction point coordinates. FIG.

In the present embodiment, repair construction data generation is performed using the data processing device 16. In the data processing device 16,
Setting repair conditions
→ Construction route generation (construction point coordinate calculation)
→ Drive data calculation of drive mechanism
Follow the procedure.

First, the following conditions are set for repair construction condition setting.
・ Construction range ・ Scanning direction ・ Scanning speed (scanning pitch)
・ Feeding pitch ・ Distance between the head of the drive mechanism and the surface to be constructed ・ Inclination between the head and the surface to be constructed

  Except for the construction range, construction conditions are determined in advance, and a method described in an initial setting file and referred to when generating repair construction data is used. When processing by the data processing device 16, the position of the scratch 5 a (R, θ at the origin of the drive mechanism 1) of the furnace bottom structure is obtained in the scratch search process performed earlier, so the construction range data is Can be set mechanically.

  The construction point coordinates are calculated based on the set repair construction conditions. The construction point is mechanically determined by the coordinates of the grid points divided by the scanning pitch and the feeding pitch described in the initial setting file. Therefore, construction route generation (construction point coordinate calculation) is possible using the initial setting file in the data processing device 16 and the position data and shape measurement data (3D CAD data) of the scratch 5a calculated by the processing.

  Subsequently, drive data is generated by the data processing device 16. Since construction route generation (construction point coordinate calculation) has already been calculated and the distance and inclination between the head unit 4 and the construction target surface are set in the initial setting file, drive data of the drive mechanism 1 can be generated by mechanical calculation. .

The generated drive data is transmitted to the state display controller 14, and the state display controller 14 checks the interference between the drive mechanism 1 and the furnace bottom structure by simulation to confirm the soundness of the data. In the event of interference, the distance and inclination data between the head portion 4 and the construction target surface in the initial setting file are changed to generate data again, and drive data that does not interfere with the drive mechanism 1 and the furnace bottom structure is generated. .
The normally generated drive data is transmitted to the drive controller 13, and the drive controller 13 controls the drive mechanism control panel 12 to drive the drive mechanism 1 to perform repair work.

When the repair work by the drive controller 13 is completed, the post-construction confirmation is performed using the TV camera 17 provided in the head unit 4.
When it is confirmed that the repair work has been normally performed, the drive mechanism 1 is pulled up, and a series of work is completed.

Therefore, the remote inspection and repair system according to the present embodiment can perform a series of repair processing for the furnace bottom structure using one drive mechanism 1. In particular, the mechanism for pre-insertion of the mechanism calibrates the drive mechanism 1, the shape measurement sensor 6, and the television camera 17 in an underwater environment, thereby enabling accurate and efficient work. Further, by correcting the known points of the structure, it is possible to superimpose each other's data even when the apparatus is moved, so that it is possible to learn wide-area shape measurement data.
In addition, the state can be confirmed by a three-dimensional animation display for each process, and the burden on the operator is small, and a reliable and efficient operation can be performed.

  By adopting the above system configuration and procedure, a series of inspection and repair work can be realized for structures in the pressure vessel of the nuclear reactor, particularly scratches in the vicinity of the narrow welded portion of the bottom of the reactor where the shape measurement conditions are severe.

  According to the present embodiment, it is possible to grasp the shape of the furnace as-built in the air during the manufacturing process and during the periodic inspection after the start of operation, so inspection, repair, replacement, and preventive maintenance work can be performed. When performing, it is possible to confirm the interference with the device and the tolerance of the device design, shorten the construction period, and improve the reliability.

(Embodiment 2)
Embodiment 2 of the remote inspection and repair system and method according to the present invention will be described with reference to FIGS. Portions common to the first embodiment are denoted by the same reference numerals.

FIG. 7 is a view showing a means for protecting the monitoring television camera from overheating and adhesion of impurities due to the repair work in the second embodiment.
The television camera 17 attached to the front end portion (head portion 4) of the drive mechanism 1 in FIG. 7 is very close to the construction surface when performing repair construction. In the repair construction of this embodiment, welding construction is performed, but when the welding construction is performed, the construction surface is overheated to about 1000 ° C. It also emits powerful rays. The TV camera 17 attached to a place close to the construction surface has a high possibility of malfunction due to radiant heat and conduction heat during welding construction. In addition, impurities generated during welding work adhere to the lens surface of the TV camera, making it difficult to capture normal images.

  The television camera 17 attached to a place close to the construction surface does not monitor images during welding construction because there is a strong light beam emitted by welding.

Therefore, in the present embodiment, first, the cleaning water hose 20 extending from the water pump 21 provided in the control device 11 is provided, and the cleaning water is allowed to flow from the tip of the cleaning water hose 20 to the lens of the TV camera 17 so that the TV camera and the lens are connected. This is a combination of cooling and lens cleaning.
Although the cleaning water hose 20 is described as one, a plurality of cleaning water hoses 20 can be provided as necessary.

  In the present embodiment, the cooling of the television camera 17 and the lens and the cleaning process of the lens are not limited to measures using cleaning water. Measures are taken against strong rays in welding.

  FIGS. 8A and 8B are diagrams showing a means for protecting the surveillance television camera from the heat rays of intense light emitted by the repair work in this embodiment, where FIG. 8A includes a shutter mechanism and FIG. 8B includes a reflecting mirror. It is.

  As shown in FIG. 8 (a), a shutter mechanism 22 for remotely blocking the light beam is provided in front of the lens, so that it is possible to prevent the lens from being burned by a strong light beam during construction. In addition, as shown in FIG. 8B, the television camera 17 may be rotated 90 degrees so that a strong light beam does not directly enter the television camera 17, and an image can be taken through the reflection mirror 23. Is possible.

  From the above, it is possible to monitor with a normal image even when a TV camera is installed in a place where the vicinity of the work surface becomes hot or adhesion of impurities occurs in repair processing such as welding. An inspection and repair system can be provided.

(Embodiment 3)
Embodiment 3 of the remote inspection and repair system and method according to the present invention will be described with reference to FIGS. Portions common to the first embodiment are denoted by the same reference numerals.

  In the first and second embodiments, the shape measurement sensor 6 and the TV camera 17 are attached to the drive mechanism 1 of the remote inspection and repair system, and the positional relationship between the shape measurement sensor 6 and the TV camera 17 and the drive mechanism 1 is clarified. In this system, the position of the scratch 5a that is a repair location is detected, the shape of the repair location is measured, the drive data of the drive mechanism 1 that can be automatically constructed is generated, and the system is constructed.

The third embodiment realizes a system having the same flaw search and shape measurement functions as those of the first embodiment without attaching the shape measurement sensor 6 and the television camera 17 to the drive mechanism 1 of the first embodiment.
The scratch search and shape measurement according to the third embodiment are performed using a monitoring camera inserted into the furnace bottom independently of the drive mechanism 1. This monitoring camera is intended to monitor the state of the drive mechanism 1 and the surrounding structure 5 and monitor the routing of signal cables and hoses from the drive mechanism 1.

  FIG. 9 is a diagram illustrating a configuration of a system in which a plurality of fixed television cameras are inserted around the drive mechanism of the remote inspection and repair system in the present embodiment, and a scratch search and shape measurement are performed using a data processing device.

  The waterproof TV camera (hereinafter referred to as “TV camera”) 30 (30-1, 30-2, 30-3) is mounted on a pan head having a pivot axis and a lift axis, and has a waterproof structure (or stored in a waterproof case). Is. The TV camera 30 is fixed to the surrounding stub tube where the drive mechanism 1 is inserted, and takes an image of the surrounding structure 5 (furnace bottom structure) to be inspected and repaired. The television camera 30 of the present embodiment uses a network camera that can remotely control the viewpoint position, zooming, focus adjustment, and iris (IRIS) using a LAN. The network camera can easily control the viewpoint position, magnification, focus adjustment, and iris by operating from a personal computer. In addition, when an arbitrary portion of an image displayed on a personal computer is clicked with a mouse, the clicked portion is placed at the center of the image, and accurate pan head attitude data is collected and output.

  The video of the television camera 30 of this embodiment is taken into the data processing device 33 (personal computer) of the control device 11 via the signal cable 31 (31-1, 31-2, 31-3) and the multiplexer (HUB) 32. . The viewpoint position, zooming, focus adjustment, and remote control of the iris of the TV camera 30 are similarly performed by the data processing device 33 (personal computer).

  In order to accurately collect position data and shape data (3D CAD data) from the origin of the drive mechanism 1 by searching for scratches and measuring the shape with the TV camera 30, the positions and postures of the drive mechanism 1 and the respective TV cameras 30 are accurately determined. Need to be detected.

  The position / posture of each television camera 30 is detected by remotely controlling a plurality of (for example, three) television cameras 30 from the data processing device 33. First, the data processing device 33 sets the position / posture at which the three television cameras 30 face each other, and obtains pan / tilt head position / posture data at that time. Since the distance between the stub tubes is known, the coordinates and orientations (orientations) of the three television cameras 30 from the origin of the drive mechanism 1 can be uniquely determined. When there is a deviation in the position where the TV camera 30 is attached, images are collected with the viewpoint directed to the known joint shape (end) of the drive mechanism 1, and the cloud when the end comes to the center of the image The table position / posture data can be obtained, and the coordinates and postures (orientations) of the three television cameras from the origin of the drive mechanism 1 can be obtained.

  Next, the furnace bottom part structure is irradiated with a laser beam 35 from a laser generating part 34 attached to the tip part (head part 4) of the driving mechanism 1. The laser beam 35 is connected to a laser generator power source 37 via a signal cable 36. The data processing device 33 (personal computer) moves the viewpoint position of the three television cameras 30, collects images in which the laser beam 35 irradiated from the laser generator 34 hits the furnace bottom structure, Remote control is performed so that the center of the laser beam 35 comes to the center. Also, the pan head position / posture data at that time is obtained. Since the coordinates and orientations (orientations) of the three television cameras from the origin of the drive mechanism 1 have already been obtained, the coordinates of the laser beam 35 irradiated on the furnace bottom structure can be obtained.

  Therefore, the position and shape measurement of the flaw 5a at the bottom of the furnace is obtained by moving the laser generator 34, collecting the images, obtaining corresponding points, and performing coordinate conversion processing to obtain the position coordinates from the origin of the drive mechanism 1. This is possible.

  As another modification, a method is proposed in which the position and shape of the scratch 5a at the bottom of the furnace can be measured without fixing a television camera (network camera) to the stub tube.

  FIG. 10 is a diagram showing a configuration of a system in which a swimming robot is inserted around the drive mechanism of the remote inspection and repair system in the present embodiment, and a scratch search and shape measurement are performed using a data processing device.

  A plurality of (for example, three) swimming robots 40 (40-1, 40-2, 40-3) are provided with television cameras 48 (48-1, 48-2, 48-3). The swimming robot 40 is moved around the furnace bottom structure. For the position / posture movement of the swimming robot 40, a remote command is output from the data processing device 43, the signal cable 41 (41-1, 41-2, 41-3), the swimming robot drive control device 42 (42-1, 42). -2, 42-3). The video from the TV camera 48 attached to the swimming robot 40 is collected by the swimming robot drive control device 42 and transmitted to the data processing device 43. The laser beam 45 is connected to a laser generator power supply 47 via a signal cable 46.

  The data processor 43 detects the position / posture (coordinates of the TV camera) of the swimming robot 40. The data processing device 43 takes in images from each swimming robot 40 and performs the following data processing to obtain the position / posture.

(1) The position / posture of the swimming robot 40 is moved so that the TV camera 48 can photograph the furnace bottom structure.
(2) The laser generator 44 attached to the head unit 4 irradiates the furnace bottom structure.
(3) The position / posture data of the head unit 4 at that time is obtained.
(4) The irradiation point coordinates of the laser generator 45 are obtained from the image of the television camera 48.
(5) Repeat steps (2) to (4) several times.
(6) Corresponding points of the entire video are determined from the irradiation point coordinates and the corresponding position / posture data of the head unit 4.
(7) The coordinate data is obtained from the center of the image for the corresponding point of each determined image, and the three-dimensional position coordinates are calculated.

  Therefore, the shape of the furnace bottom structure and the position coordinates of the scratch 5a are obtained by irradiating the laser generator 44 and obtaining the corresponding points of each image using the data processing device 43 from the image from the swimming robot 40. Can be obtained.

  From the above, the system of the present invention uses a single mechanism and a small number of small sensors with excellent environmental resistance, and measures and measures the shape and dimensions of surrounding structures for reliable and efficient inspection and repair. Work can be performed. Further, the system of the present invention has a simple configuration and is easy to operate. Since a small number of existing small sensors are incorporated, it can be manufactured at low cost.

The figure which shows the structure of the remote inspection repair system for the furnace bottom part structure in Embodiment 1. FIG. The figure which shows the procedure of the inspection repair construction of the furnace bottom part structure by the remote inspection repair system in Embodiment 1. FIG. It is a figure explaining the calibration method of the shape measurement sensor of the remote inspection repair system in Embodiment 1, and the television camera for monitoring, (a) is a sketch of the whole, (b)-(d) is an initial posture, and an up-and-down movement, respectively. The figure which shows a back-and-forth movement. It is a figure which shows the method of calculating | requiring the coordinate and repair construction range of a crack from the image | video of a crack in Embodiment 1, (a) is a furnace bottom part structure which has a crack, (b) is a part of drive mechanism, (c), (D) is a figure which shows the state which moved the head part, respectively. It is a figure which shows the processing result of the furnace bottom part shape measurement by the remote inspection repair system in Embodiment 1, (a) is a sketch of the whole system, (b) is a figure which shows the result of having created the three-dimensional shape of the furnace bottom part structure . It is a figure explaining construction data generation by the remote inspection repair system in Embodiment 1, (a) is a sketch of an articulated arm part and a crack, and (b)-(d) is a figure showing calculation of construction point coordinates. The figure which shows the means to protect the television camera for monitoring from the overheating by repair construction in Embodiment 2, and adhesion of an impurity. It is a figure which shows a means to protect the television camera for surveillance from the heat ray of the intense light beam | light emitted by the repair construction in Embodiment 2, (a) is provided with a shutter mechanism, (b) is a figure when a reflection mirror is provided. The figure which shows the structure of the system which inserts a some fixed mela around the drive mechanism of the remote inspection repair system in Embodiment 3, and performs a flaw search and shape measurement using a data processor. The figure which shows the structure of the system which inserts a swimming robot around the drive mechanism of the remote inspection repair system in Embodiment 3, and performs a flaw search and shape measurement using a data processor.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Drive mechanism, 2 ... Drive mechanism main-body part, 3 ... Articulated arm part, 4 ... Drive mechanism head part, 4a ... Laser emission part, 5 ... Surrounding structure, 5a ... Scratch, 6 ... Shape measuring sensor, 7 ... Laser generator, 8 ... TV camera, 9 ... Laser beam, 11 ... Control device, 15 ... Signal processor, 16 ... Data processor, 17 ... TV camera, 20 ... Water hose for cleaning, 21 ... Water pump, 22 ... Shutter Mechanism: 23 ... reflective mirror, 30 ... waterproof TV camera, 40 ... swimming robot, 48 ... TV camera.

Claims (7)

A laser emitting unit for repair construction, a head part to which a TV camera for monitoring a construction object to be constructed and detecting a repaired part is attached, a shape measurement sensor for measuring the three-dimensional shape of the structure; The three-dimensional shape position data of the repair portion of the structure is obtained from the shape measurement sensor and the drive mechanism of the head unit, and the signal from the shape measurement sensor, and the drive mechanism of the drive mechanism based on the construction path of the head unit is obtained. In a remote inspection and repair system comprising a control device that generates drive data and remotely controls the drive mechanism ,
The drive mechanism has an articulated arm portion attached to a moving member that turns and moves up and down, the shape measurement sensor is attached to the moving member, and the head portion is located at a tip of the articulated arm portion.・ Remote inspection and repair system characterized by changing posture . The shape measurement sensor has a laser generating unit and the television camera for irradiating a fan-shaped laser beam on the structure, to claim 1, characterized in that to measure the three-dimensional shape of the structure by light section method The remote inspection repair system described. The remote inspection and repair system according to claim 1 or 2 , wherein washing water is poured on the front surface of the television camera to prevent adhesion of impurities and overheating due to radiant heat and conduction heat during repair work. A reflecting mirror for deflecting the shutter or light blocking light rays in front of the television camera provided, impurity deposition and radiant heat during repair construction, any of claims 1 to 3, characterized in that prevented overheating by conductive heat remote diagnostics repair system according to any one of claims. A remote inspection and repair method using the remote inspection and repair system according to claim 1,
The step of detecting the repaired portion of the structure from the video of the TV camera, the step of measuring the three-dimensional shape of the structure by the shape measuring sensor, and the three-dimensional shape position data of the repaired portion of the structure are obtained. And a step of generating drive data of the drive mechanism based on the construction path of the head unit from the three-dimensional shape position data, and a step of controlling the drive mechanism by the drive data. Remote inspection repair method to do. A remote inspection repair system calibration method according to claim 1,
Calibration of a remote inspection / repair system characterized in that when performing inspection and repair work in an underwater environment, the drive mechanism is calibrated in advance in the water tank using the shape measurement sensor and the TV camera. Method. A remote inspection repair system calibration method according to claim 1,
When performing inspection and repair work in an underwater environment, the drive mechanism is operated in advance in a water tank, and the distance measurement calibration of the shape measurement sensor and the video position calibration of the TV camera are performed. How to calibrate the remote inspection and repair system.

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