Design of cleaning robot for steel structure in valve hall

doi:10.3785/j.issn.1006-754X.2025.05.109

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (4): 438-451 DOI: 10.3785/j.issn.1006-754X.2025.05.109

Robotic and Mechanism Design

Design of cleaning robot for steel structure in valve hall

Xuxu WANG^1,²(

),Hanyu ZHENG¹,Bin YAO^1,²,Xuan DU¹(

),Xiang LI¹

^1.College of Mechanical and Power Engineering, China Three Gorges University, Yichang 443002, China
^2.State Grid UHV Engineering Construction Company, Beijing 100032, China

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Abstract

Aiming at the problems of low operation efficiency and high safety risks in the manual cleaning process of the complex steel structures at the top of converter station valve halls, a cleaning robot featuring the split multi-unit structure and the clasp-arm mechanism has been proposed based on axiomatic design theory, and its feasibility is verified through prototype experiments. Firstly, the function-structure model of the robot and the corresponding design matrix were constructed. The independence axiom was applied to ensure the independence of functional requirements, while the information axiom was used to optimize the design solution. The mobile unit of this robot adopted a split three-unit multi-clasp-arm structure, which could cross obstacles located above and below the steel structure and walk on steel beams in different directions by steering. The cleaning unit adopted symmetrically arranged three-degree-of-freedom cleaning arms, which could meet the cleaning demands of various areas in the valve hall. Then, based on the actual layout of the steel structure at the top of valve hall, the obstacle-crossing and steering motion postures of the robot were designed for specific scenarios, and a complete motion control system was also designed. Next, a mechanical analysis was conducted on key components of the robot. Meanwhile, the structural layout analysis and topology optimization were carried out on the components that significantly affected the overall performance, which achieved compact and lightweight structure, thereby enhancing the operational stability of the robot. Finally, the robot prototype experiments were carried out on the steel structure at the top of valve hall. The results showed that the robot could stably complete obstacle crossing, steering and cleaning tasks on steel structures. It could cross obstacles with a maximum height of 712 mm, and the cleaning speed exceeded 100 m²/h. The designed robot can effectively enhance the cleaning efficiency and operational safety of steel structures at the top of converter station valve halls, which has good engineering applicability.

Key words： converter station valve hall cleaning robot axiomatic design split multi-unit structure motion posture

Received: 10 February 2025 Published: 01 September 2025

CLC:

TP 242

Corresponding Authors: Xuan DU E-mail: 976063854@qq.com;xdu@ctgu.edu.cn

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Cite this article:

Xuxu WANG,Hanyu ZHENG,Bin YAO,Xuan DU,Xiang LI. Design of cleaning robot for steel structure in valve hall. Chinese Journal of Engineering Design, 2025, 32(4): 438-451.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.05.109 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I4/438

阀厅钢结构清扫机器人设计

针对换流站阀厅顶部复杂钢结构人工清扫过程中存在的作业效率低、安全风险高等问题，基于公理设计理论提出了一种以分体式多单元结构与抱臂机构为核心的清扫机器人，并通过样机实验验证了其可行性。首先，构建了机器人的功能—结构模型及对应的设计矩阵，利用独立公理确保功能需求的独立性，并结合信息公理优化了设计方案。该机器人的移动单元采用分体式三单元多抱臂结构，能够跨越钢结构上下方的障碍，并能通过转向实现在不同方向钢梁上的行走；清扫单元采用对称分布的三自由度清扫臂，可满足阀厅不同区域的清扫需求。然后，根据阀厅顶部钢结构的实际布局，设计了机器人适应特定场景的越障、转向运动姿态，并设计了完整的运动控制系统。接着，对机器人的关键部件进行了力学分析，同时对显著影响整机性能的部件进行了结构布局分析与拓扑优化，实现了结构的紧凑化与轻量化，进而提高了机器人的运行稳定性。最后，在阀厅顶部钢结构上开展了机器人样机实验。结果表明，该机器人能够稳定地在钢结构上完成越障、转向和清扫任务，其可跨越最大高度为712 mm的障碍，且清扫速度超过100 m²/h。所设计的机器人可有效提升换流站阀厅顶部钢结构的清扫效率与作业安全性，具备良好的工程适用性。

关键词： 换流站阀厅, 清扫机器人, 公理设计, 分体式多单元结构, 运动姿态

Fig.1 Steel structure at the top of valve hall

功能需求（FRs）

设计参数（DPs）

设计方程

FR₁₁：可以夹紧顶部钢结构

FR₁₂：可以伸缩以适应不同钢结构

DP₁₁：抱臂夹持机构

DP₁₂：抱臂伸缩机构

F R 11 F R 12 = X 0 0 X × D P 11 D P 12

FR₂₁：能够进行平稳精准的移动

FR₂₂：可以跨越障碍物

FR₂₃：可以在钢结构上实现转向

DP₂₁：移动机构

DP₂₂：越障机构

DP₂₃：转向机构

F R 21 F R 22 F R 23 = X 00 0 X 0 X X X × D P 21 D P 22 D P 23

FR₃₁：能伸展至待清扫区域

FR₃₂：能确保机器人姿态的稳定性

FR₃₃：能进行清扫作业

DP₃₁：清扫臂

DP₃₂：对称放置

DP₃₃：清扫机构

F R 31 F R 32 F R 33 = X 00 0 X 0 X 0 X × D P 31 D P 32 D P 33

FR₄₁：能自主运行

FR₄₂：能识别场景信息

DP₄₁：运动控制处理器

DP₄₂：图像识别处理器

F R 41 F R 42 = X 0 0 X × D P 41 D P 42

FR₅₁：控制机器人姿态稳定安全

FR₅₂：断电保护

DP₅₁：安全控制系统

DP₅₂：电机自锁机构

F R 51 F R 52 = X 0 0 X × D P 51 D P 52

FR₆₁：能持续供电

FR₆₂：能转换不同的电压

DP₆₁：不间断供电设备

DP₆₂：稳压设备

F R 61 F R 62 = X 0 0 X × D P 61 D P 62

Table 1 Second-level decomposition of FRs and DPs and corresponding design equations

Table 2 Corresponding design matrix for second-level FRs and DPs of robot

Fig.2 Decomposition diagram of robot FRs

Table 3 Technical specifications of each design scheme for clasp-arm telescopic mechanism

Table 4 Information content of each design scheme for clasp-arm telescopic mechanism

Table 5 Technical specifications of each design scheme for split multi-unit structure

Table 6 Information content of each design scheme for split multi-unit structure

Table 7 Technical specifications of each design scheme for cleaning arm

Table 8 Probability corresponding to each design scheme for cleaning arm

Fig.3 Structure of robot body

Fig.4 Second mobile sub-unit model

Fig.5 Decomposition of obstacle-crossing motion posture for robot

Fig.6 Decomposition of steering motion posture for robot

Fig.7 Structure of clasp-arm telescopic mechanism

Fig.8 Coordinate system of clasp-arm telescopic mechanism

Fig.9 Comparison of motion trajectory of mobile wheel before and after optimization

Fig.10 Deformation of key components of robot

Fig.11 Comparison of key components of robot before and after topology optimization

Fig.12 Robot control system architecture

Fig.13 Robot prototype

Fig.14 Structure diagram of test bench

Fig.15 Motion test for robot on test bench

Fig.16 Robot located at the top steel structure of valve hall

Fig.17 Motion test of robot at the steel structure in valve hall

Fig.18 Cleaning tests of robot at different positions of steel structure in valve hall


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