Defect detection and recognition device for crane rails

Abstract

The utility model relates to a crane track defect detection and identification device relates to crane track detection technical field, it can realize to the high efficiency, accurate detection and identification of crane track surface and internal defect, and guarantee the safe operation of crane and the long -term stability of track. Crane track defect detection and identification device, the eddy current sensor is used for close crane track surface but does not produce physical contact, and through generating high frequency magnetic field to excite the eddy current effect in the track and detect the small change of track surface and inside, the eddy current sensor through wireless transmission module real -time sends the data gathered to remote receiver, and the data received by remote receiver is amplified, filtered, digitized processing and defect identification by data processing and analysis system, and through display module shows the data analysis result and the specific position and severity of defect that the eddy current sensor feedbacks.

Description

Technical Field

[0001] This utility model relates to the field of crane track detection technology, and in particular to a crane track defect detection and identification device. Background Technology

[0002] Currently, in modern industrial production and logistics transportation, cranes are important material handling equipment, and their operational safety and reliability are of paramount importance.

[0003] As the infrastructure supporting crane operation, the condition of crane rails directly affects the crane's operating efficiency and safety. However, in practical applications, crane rails are prone to various defects, such as cracks, peeling, and deformation, due to long-term heavy loads, wear, and environmental erosion. These defects not only reduce the crane's operational stability but may also lead to serious safety accidents, causing significant losses to personnel and property.

[0004] Traditional methods for detecting defects in crane rails primarily rely on manual inspection. This method is not only inefficient but also susceptible to human error, leading to missed or false detections. Furthermore, with the increasing automation and intelligence of industrial production, manual inspection is no longer sufficient to meet the high safety requirements of modern industrial production for crane rail inspection.

[0005] In recent years, the rapid development of machine vision, image processing, and automation control technologies has provided new technical means for crane rail defect detection. Some advanced detection devices have begun to be applied in the field of rail inspection, such as using high-definition cameras to capture rail images and analyzing them using computer vision technology to detect defects on the rail surface. While this method improves detection efficiency and accuracy to some extent, it still has some limitations. For example, the detection effect of some devices is not stable enough in complex environments (such as changes in light, rail surface contamination, etc.), and its ability to detect internal defects in the rail is limited. In addition, ultrasonic testing and electromagnetic testing methods are also applied to rail defect detection; for example, ultrasonic testing uses ultrasonic reflection signals to detect the internal structure and defects of the rail, but this method usually requires contact testing, which is relatively cumbersome.

[0006] Therefore, how to provide a crane track defect detection and identification device that can efficiently, accurately, and non-contactly detect surface and internal defects of crane tracks to improve the safety and reliability of crane operation and effectively reduce the cost and risk of manual inspection has become a technical problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0007] The purpose of this invention is to provide a crane track defect detection and identification device. It utilizes eddy current sensor technology and accurately measures and analyzes the data fed back by the eddy current sensor through wireless transmission. This allows for the timely detection of defects such as cracks, corrosion, and wear on the track, thereby enabling efficient and accurate detection and identification of surface and internal defects of the crane track, and ensuring the safe operation of the crane and the long-term stability of the track.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A crane rail defect detection and identification device includes: an eddy current sensor and a remote receiver connected to the eddy current sensor via a wireless transmission module; the eddy current sensor is used to closely adhere to the surface of the crane rail without making physical contact, and generates a high-frequency magnetic field to excite the eddy current effect inside the rail and detect minute changes on and inside the rail surface; the eddy current sensor transmits the collected data to the remote receiver in real time via the wireless transmission module, and the data received by the remote receiver is amplified, filtered, digitized, and defect identified by a data processing and analysis system, and the data analysis results fed back by the eddy current sensor and the specific location and severity of the defects are displayed through a display module.

[0010] In practical applications, the eddy current sensor is kept in a non-conductive medium space with the crane rail to avoid direct physical contact.

[0011] The eddy current sensor is installed at the probe of the detection device, and the probe is in the shape of a flat coil to adapt to the geometric features of the crane track; the detection device is provided with a housing, and the housing is provided with an adjustable mechanical support structure.

[0012] Specifically, the detection device is installed above the wheel tracks on both sides of the crane trolley and moves with the crane to scan, detect and identify the tracks.

[0013] Furthermore, the remote receiver also includes an alarm module, which is used to issue an alarm signal when a track defect is detected.

[0014] Furthermore, the data processing and analysis system in the remote receiver is connected to the wireless transmission module and the alarm module, and is also connected to the display module through the display interface module.

[0015] Furthermore, the data processing and analysis system is also connected to a data storage module, a button module, and a power module, and the power module is connected to a battery power supply.

[0016] Compared with existing technologies, the crane track defect detection and identification device of this utility model has the following advantages:

[0017] The crane track defect detection and identification device provided by this utility model utilizes an eddy current sensor that can closely adhere to the crane track surface without physical contact, thus avoiding potential damage caused by traditional detection methods. The eddy current sensor generates a high-frequency magnetic field, exciting the eddy current effect inside the track, thereby detecting minute changes on and inside the track surface. When defects such as cracks, corrosion, or wear exist in the track, the feedback signal of the eddy current sensor changes significantly, and these changes are accurately captured and recorded by the device. Simultaneously, to achieve real-time data transmission and analysis, advanced wireless transmission technology is employed. The data collected by the eddy current sensor is transmitted in real-time to a remote receiver via a built-in wireless module. The receiver then further processes and analyzes the data, thereby improving detection efficiency and enabling operators to monitor the track status in real-time from a distance, thus promptly identifying and addressing potential safety hazards. Furthermore, the display module can deeply analyze the data fed back by the eddy current sensor, accurately identifying various types of defects on the track and their severity, effectively improving the accuracy and reliability of detection and providing strong protection for the safe operation of the crane. Attached Figure Description

[0018] Figure 1 A schematic diagram of the usage state of the crane track defect detection and identification device provided in this embodiment of the utility model;

[0019] Figure 2 A schematic diagram of the frame structure of the remote receiver in the crane track defect detection and identification device provided in this embodiment of the utility model.

[0020] Figure label:

[0021] 11-Eddy current sensor; 12-Adjustable mechanical support structure;

[0022] 2-Remote receiver; 21-Data processing and analysis system; 22-Wireless transmission module; 23-Display module; 231-Display interface module; 24-Alarm module; 25-Data storage module; 26-Button module; 27-Power supply module; 271-Battery power supply;

[0023] 3-track; 4-wheel. Detailed Implementation

[0024] For ease of understanding, the crane track defect detection and identification device provided in the embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0025] This utility model embodiment provides a crane track defect detection and identification device, such as... Figure 1 and Figure 2 As shown, it includes: an eddy current sensor 11, and a remote receiver 2 connected to the eddy current sensor 11 via a wireless transmission module 22; the eddy current sensor 11 is used to closely adhere to the surface of the crane rail 3 without making physical contact, and generates a high-frequency magnetic field to excite the eddy current effect inside the rail and detect minute changes on and inside the rail surface; the eddy current sensor 11 transmits the collected data to the remote receiver 2 in real time via the wireless transmission module 22, and the data received by the remote receiver 2 is amplified, filtered, digitized and defect identified by the data processing and analysis system 21, and the data analysis results fed back by the eddy current sensor 11 and the specific location and severity of the defects are displayed by the display module 23.

[0026] Compared with the prior art, the crane track defect detection and identification device described in this embodiment of the present invention has the following advantages:

[0027] The crane track defect detection and identification device provided in this embodiment utilizes an eddy current sensor that can closely adhere to the crane track surface without physical contact, thus avoiding potential damage from traditional detection methods. The eddy current sensor generates a high-frequency magnetic field, exciting eddy current effects within the track, thereby detecting minute changes on and inside the track surface. When defects such as cracks, corrosion, or wear exist in the track, the feedback signal from the eddy current sensor changes significantly, and these changes are accurately captured and recorded by the device. Simultaneously, to achieve real-time data transmission and analysis, advanced wireless transmission technology is employed. The data collected by the eddy current sensor is transmitted in real-time to a remote receiver via a built-in wireless module. The receiver then further processes and analyzes the data, thereby improving detection efficiency and enabling operators to monitor the track status in real-time from a distance, allowing for timely detection and handling of potential safety hazards. Furthermore, the display module can deeply analyze and process the data fed back by the eddy current sensor, accurately identifying various types of defects on the track and their severity, effectively improving the accuracy and reliability of detection and providing strong protection for the safe operation of the crane.

[0028] In practical applications, a non-conductive medium space (e.g., a flexible silicone layer covering the surface) can be maintained between the eddy current sensor 11 and the crane rail 3 to avoid direct physical contact.

[0029] Among them, such as Figure 1As shown, the eddy current sensor 11 can be installed at the probe of the detection device, and the probe can be in the shape of a flat coil to adapt to the geometric features of the crane rail; the detection device can be provided with a housing (the housing is made of a high-protection material to adapt to harsh industrial environments), and the housing can be provided with an adjustable mechanical support structure 12; the adjustable mechanical support structure 12 can be made of stainless steel, and the length can be adjusted in the range of 10-50mm to adapt to wheel diameters of 200-1500mm.

[0030] Specifically, the bottom of the adjustable mechanical support structure 12 can adopt an adsorption-bolt composite installation structure, the base adopts magnetic attraction, and the magnetic base can be equipped with a built-in temperature compensation module to adapt to the working environment of -20℃~80℃; the bolt and the magnetic base can be connected by a universal joint and have an angle adjustment of ±15° to ensure that the sensor probe is perpendicular to the measuring surface (installation error ≤0.1mm).

[0031] Furthermore, such as Figure 1 As shown, the detection device can be installed above the rails 3 on both sides of the crane trolley wheels 4 and follow the crane's movement to scan, detect and identify the rails 3.

[0032] Furthermore, such as Figure 2 As shown, the remote receiver 2 may further include an alarm module 24, which is capable of issuing an alarm signal when a track defect is detected.

[0033] Furthermore, such as Figure 2 As shown, the data processing and analysis system 21 in the remote receiver 2 is connected to a wireless transmission module 22 and an alarm module 23, and can be connected to a display module 23 via a display interface module 231.

[0034] Furthermore, such as Figure 2 As shown, the data processing and analysis system 21 can also be connected to a data storage module 25, a button module 26, and a power module 27, and the power module 27 can be connected to a battery power supply 271.

[0035] The working process of the crane track defect detection and identification device provided in this embodiment of the present invention will be described in detail below with reference to the accompanying drawings:

[0036] Eddy current sensors generate a high-frequency magnetic field, exciting eddy currents within the track. The sensors are positioned close to the track surface but not in direct contact, maintaining a non-conductive medium space. Under the influence of the changing magnetic field, induced currents are generated on and within the crane track, forming eddy currents. The reverse magnetic field generated by these eddy currents interacts with the original magnetic field of the sensor probe, causing changes in the equivalent impedance or inductance of the sensor coil. These changes are precisely captured by the eddy current sensor and converted into electrical signals. To enable real-time transmission and analysis of these signals, the device incorporates an advanced wireless transmission module. Data collected by the eddy current sensors is transmitted in real-time to a remote receiver via this module. The remote receiver receives the data and performs further processing and analysis, thereby improving detection efficiency and allowing operators to monitor the track status remotely, enabling timely detection and handling of potential safety hazards.

[0037] During the data processing and analysis phase, the data acquisition system receives electrical signals from the eddy current sensor and amplifies, filters, and digitizes them. The processed data is then sent to the defect identification module, which utilizes advanced signal processing technology to perform in-depth analysis of the eddy current sensor data, accurately identifying the types and severity of defects such as cracks, corrosion, and wear on the track. To achieve more precise defect location and identification, the eddy current sensor is precisely mounted on the probe of the detection device. The probe is designed in a flat coil shape to adapt to the geometry of the crane track. The detection device is typically installed above the wheel rails on both sides of the crane trolley, scanning and identifying the track as the crane travels. When the detection device is activated, the eddy current sensor begins to work, scanning the crane track surface in close proximity. Once a defect is detected, the device immediately issues an alarm and displays the specific location and severity of the defect on the display module. Operators can quickly locate the defect based on the alarm information and display prompts, and repair or replace it to ensure the safe operation of the crane.

[0038] In addition, the device has a real-time monitoring function, which can continuously track the changes in the condition of the crane rails. Through continuous detection and analysis, operators can understand the wear and tear of the rails in a timely manner, prevent potential safety risks, and provide strong protection for the safe operation of the crane.

[0039] In summary, the crane track defect detection and identification device provided by this utility model embodiment has the following advantages:

[0040] 1. Under the influence of a changing magnetic field, induced currents are generated on and inside the crane rail, forming eddy currents. The reverse magnetic field generated by the eddy currents interacts with the original magnetic field of the sensor probe, causing changes in the equivalent impedance or equivalent inductance of the sensor coil. The sensor converts these changes into electrical signals, which are then processed by a preamplifier and transmitted to the data acquisition system. The data acquisition system receives the electrical signals from the eddy current sensor, amplifies, filters, and digitizes them, and performs in-depth analysis of the data from the eddy current sensor to identify defects such as cracks, corrosion, and wear on the rail.

[0041] Second, the detection and identification device has a real-time monitoring function, which can continuously track the status changes of the crane track. Once a defect is detected, the device will immediately issue an alarm signal and display the specific location and severity of the defect. Operators can quickly locate the defect based on the alarm information and repair or replace it to ensure the safe operation of the crane.

[0042] Third, the data processing and analysis system can be scalable, allowing for the addition of new defect identification algorithms or the optimization of existing algorithms based on actual needs.

[0043] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the protection scope of the claims.

Claims

1. A crane track defect detection and identification device, characterized in that, include: An eddy current sensor and a remote receiver connected to the eddy current sensor via a wireless transmission module are included. The eddy current sensor is used to closely adhere to the surface of the crane rail without making physical contact, and generates a high-frequency magnetic field to excite the eddy current effect inside the rail and detect minute changes on and inside the rail surface. The eddy current sensor transmits the collected data to the remote receiver in real time via the wireless transmission module. The data received by the remote receiver is amplified, filtered, digitized, and defect identified by a data processing and analysis system. The data analysis results fed back by the eddy current sensor and the specific location and severity of the defects are displayed through a display module.

2. The crane track defect detection and identification device according to claim 1, characterized in that, The eddy current sensor is kept in a non-conductive medium space with the crane rail to avoid direct physical contact.

3. The crane track defect detection and identification device according to claim 2, characterized in that, The eddy current sensor is installed at the probe of the detection device, and the probe is in the shape of a flat coil to adapt to the geometry of the crane track; The detection device is provided with a housing, and the housing is provided with an adjustable mechanical support structure.

4. The crane track defect detection and identification device according to claim 3, characterized in that, The detection device is installed above the wheel tracks on both sides of the crane trolley and moves with the crane to scan, detect and identify the tracks.

5. The crane track defect detection and identification device according to claim 4, characterized in that, The remote receiver also includes an alarm module, which is used to issue an alarm signal when a track defect is detected.

6. The crane track defect detection and identification device according to claim 5, characterized in that, The data processing and analysis system in the remote receiver is connected to the wireless transmission module and the alarm module, and is also connected to the display module through the display interface module.

7. The crane track defect detection and identification device according to claim 6, characterized in that, The data processing and analysis system is also connected to a data storage module, a button module, and a power module, and the power module is connected to a battery power supply.

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