Deformation measurement method for bridge crane rails

Abstract

The present invention provides a method for measuring the deformation of a bridge crane track, which belongs to the field of track detection technology and includes: setting up a receiver on one side of the track. The measuring vehicle is moved from one end of the track to the other end, and a calibration signal is sent to the receiver in real time during the movement of the measuring vehicle. The current spatial angle of the measuring vehicle is fitted based on the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal and the position of the measuring vehicle relative to the receiver. The fitting surface of the track at the current position is judged based on the spatial angle, and the fitting surfaces at different positions are integrated to determine the deformation of the track. The bridge crane track deformation measurement method provided by the present invention determines the deformation of the track by changing the angle of the measuring vehicle. The data obtained is more intuitive and can detect various deformations of the track, providing accurate data support for the repair of the track.

Description

Technical Field

[0001] The present invention belongs to the technical field of track detection, and more specifically, relates to a method for measuring deformation of a bridge crane track. Background Art

[0002] Crane tracks are the primary mechanism for crane travel, and track straightness and other parameters are crucial for safe and stable crane operation. Crane wheel gnawing, rail clamp failure, and various other factors can lead to reduced straightness and excessive gauge geometry, severely impacting the safety and stability of the crane's travel mechanism and the service life of the rails.

[0003] Traditional crane track adjustment methods rely primarily on visual inspection and empirical judgment, resulting in low accuracy and difficulty achieving desired results. Existing methods utilize sensors for measurement, but these still fail to effectively assess the overall track condition. This results in significant vibration during crane operation even after repairs. Summary of the Invention

[0004] The purpose of the present invention is to provide a method for measuring the deformation of a bridge crane track, aiming to solve the problem of being unable to make an effective judgment on the deformation of the track.

[0005] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is to provide a method for measuring the deformation of a bridge crane track, comprising:

[0006] Set up a receiver on one side of the track;

[0007] The measuring vehicle moves from one end of the track to the other end, and sends a calibration signal to the receiver in real time during the movement of the measuring vehicle;

[0008] fitting a current spatial angle of the measuring vehicle according to a receiving position of the calibration signal received by the receiver, a transmission angle of the calibration signal, and a position of the measuring vehicle relative to the receiver;

[0009] The fitting surface of the track at the current position is determined according to the spatial angle, and the fitting surfaces at different positions are integrated to determine the deformation of the track.

[0010] In one possible implementation, moving the measuring vehicle from one end of the track to the other end includes:

[0011] The measuring vehicle sends a position signal to a receiving plate at the end of the track;

[0012] Determine the distance between the receiving plate and the measuring vehicle and the position point where the position signal is received using the receiving plate and the position signal;

[0013] When the distance between the position points at different times exceeds a threshold, the angle of the measuring vehicle is adjusted.

[0014] In a possible implementation, the calibration signal emission angle combined with the position of the measurement vehicle relative to the receiver includes:

[0015] The position of the measuring vehicle relative to the receiver is determined from the relative position between the receiver and the track and the relative position between the measuring vehicle and the track.

[0016] In a possible implementation, the determining, based on a receiving position of the calibration signal received by the receiver, a transmission angle of the calibration signal, and a position of the measurement vehicle relative to the receiver, includes:

[0017] When the receiving position and the transmitting angle exceed the maximum preset standard, the position of the measuring vehicle at this time is recorded for subsequent repair.

[0018] In a possible implementation, the determining, based on a receiving position of the calibration signal received by the receiver, a transmission angle of the calibration signal, and a position of the measurement vehicle relative to the receiver, includes:

[0019] The calibration signal sequentially passes through the first sensing sleeve and the second sensing sleeve on the receiver, and changes the state of the first sensing sleeve and the second sensing sleeve at the contact points with the calibration signal, thereby forming the receiving position;

[0020] The emission angle is determined according to the receiving positions on the first induction sleeve and the second induction sleeve.

[0021] In a possible implementation, fitting the current spatial angle of the measuring vehicle further includes:

[0022] The spatial angle is calibrated according to the gyroscope on the measuring vehicle.

[0023] In a possible implementation, fitting the current spatial angle of the measuring vehicle includes:

[0024] calibrating the receiver and the measuring vehicle in a spatial coordinate system according to the relative positions of the measuring vehicle and the receiver;

[0025] The measuring vehicle is deflected by a corresponding angle from a calibration position according to the receiving position and the transmitting angle in the spatial coordinate system, and the deflected angle is used as the spatial angle.

[0026] In a possible implementation, determining the fitting surface of the track at the current position according to the spatial angle includes:

[0027] The fitting surface in contact with the roller of the measuring vehicle is fitted below the measuring vehicle.

[0028] In a possible implementation, determining, based on the spatial angle, a fitting surface of the contact surface of the track at the current position includes:

[0029] The contact point between the track and the roller of the measuring vehicle is determined, and the fitting surface is adjusted according to the angle of the contact point relative to the measuring vehicle.

[0030] In a possible implementation, integrating the fitting surfaces at different positions to determine the deformation of the track includes:

[0031] Determining a model of the track according to the fitting surfaces at different positions;

[0032] The deformation condition is determined according to the model, and the maximum deformation position is determined according to the model and repaired.

[0033] The advantageous effect of the bridge crane track deformation measurement method provided by the present invention lies in that, compared to existing technologies, the measuring vehicle in this method transmits a calibration signal to a receiver in real time while in motion. The receiving position is determined based on the position at which the receiver receives the calibration signal. The spatial angle of the measuring vehicle is then fitted using the transmission angle and the position of the measuring vehicle relative to the track. Track changes are directly reflected in the spatial angle of the measuring vehicle, which is used to determine the fitting surface at the current track position. Finally, the deformation of the track can be determined using the fitting surfaces at different positions.

[0034] In this application, the deformation of the track is determined by measuring the angle change of the vehicle. The obtained data is more intuitive and can detect various deformations of the track, providing accurate data support for track repair. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0036] Figure 1 A flow chart of a bridge crane track deformation measurement method provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0037] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0038] See also Figure 1 The bridge crane track deformation measurement method provided by the present invention is now described. The bridge crane track deformation measurement method includes:

[0039] Set up the receiver on one side of the track.

[0040] The measuring vehicle moves from one end of the track to the other, and sends calibration signals to the receiver in real time during the movement of the measuring vehicle.

[0041] The current spatial angle of the measuring vehicle is fitted based on the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal and the position of the measuring vehicle relative to the receiver.

[0042] The fitting surface of the track at the current position is determined according to the spatial angle, and the fitting surfaces at different positions are integrated to determine the deformation of the track.

[0043] The advantageous effect of the bridge crane track deformation measurement method provided by the present invention lies in that, compared to existing technologies, the measuring vehicle in this method transmits a calibration signal to a receiver in real time while in motion. The receiving position is determined based on the position at which the receiver receives the calibration signal. The spatial angle of the measuring vehicle is then fitted using the transmission angle and the position of the measuring vehicle relative to the track. Track changes are directly reflected in the spatial angle of the measuring vehicle, which is used to determine the fitting surface at the current track position. Finally, the deformation of the track can be determined using the fitting surfaces at different positions.

[0044] In this application, the deformation of the track is determined by measuring the angle change of the vehicle. The obtained data is more intuitive and can detect various deformations of the track, providing accurate data support for track repair.

[0045] A bridge crane consists of two parallel guide rails. The crane moves along the length of the rails to lift and transfer objects. A traction rope connects the crane to the object being hoisted. The unevenness of the rails causes the crane to vibrate. This vibration, amplified by the traction rope, can cause the object to sway significantly. Therefore, the guide rails are crucial to ensuring stable crane operation.

[0046] Track unevenness can only be detected by sensors when it exceeds a certain threshold. Several existing methods exist for measuring track unevenness, but these methods often rely on simple sensors, resulting in low accuracy. More importantly, even if the deformation can be located and repaired, the crane still cannot maintain stable operation along the track, as even small deformations can still cause significant vibrations.

[0047] Therefore, in combination with existing technologies, it is necessary to provide an accurate and efficient track unevenness measurement method that can reflect the actual situation of the track, thereby providing strong data support for the stable operation of the crane.

[0048] In some embodiments of the bridge crane track deformation measurement method provided in this application, moving the measuring vehicle from one end of the track to the other end includes:

[0049] The measuring vehicle sends a position signal to the receiving plate at the end of the track.

[0050] The distance between the receiving plate and the measuring vehicle and the position point where the position signal is received are determined by the receiving plate and the position signal.

[0051] When the distance between position points at different times exceeds a threshold, the angle of the measuring vehicle is adjusted.

[0052] When the measuring vehicle reaches a deformed location, the deformation of the track causes the vehicle to tilt. This tilt shifts the location at which the receiver receives the calibration signal. The vehicle's spatial angle can be determined based on the receiver and the vehicle's position relative to the track. Because the rollers on the vehicle's bottom contact the track, the deformed shape of the track can be determined, providing robust data support for track repair. In one embodiment, when the track is intact and the receiver is extended to the height of the track, multiple calibration signals emitted by the measuring vehicle are received only at the same location on the receiver. This allows the determination that the track flatness meets requirements.

[0053] To accurately determine the position of the measuring vehicle, it's necessary to determine how far along the track the vehicle has traveled. To enable real-time and efficient pickup, a distance sensor is installed on the measuring vehicle, and a receiving board is mounted at the end of the track. The distance sensor emits a position signal to measure the distance to the calibration board. The receiving board transmits this information to a host computer via a controller. The host computer then communicates with the receiver, which determines the spatial angle of the measuring vehicle based on the angle of the signal received by the receiver and the distance feedback from the receiving board. If the measuring vehicle deviates from the track, the calibration signal received by the receiver will change, affecting the accuracy of the results. Ideally, the measuring vehicle should move continuously along the length of the track.

[0054] In some embodiments of the bridge crane track deformation measurement method provided in this application, calibrating the signal emission angle and combining it with the position of the measuring vehicle relative to the receiver includes:

[0055] The position of the measuring vehicle relative to the receiver is determined by the relative position between the receiver and the track and the relative position between the measuring vehicle and the track.

[0056] Since there are many types of deformation on the track, in order to improve the measurement accuracy, the receiver can not only receive the calibration signal, but also determine the location and area where the calibration signal is received, and the receiver can also determine at what angle the calibration signal is transmitted.

[0057] First, the position of the measuring vehicle relative to the track must be determined. The position of the receiver relative to the track is also predetermined. The host computer can then determine the position of the measuring vehicle relative to the receiver. The measuring vehicle emits a calibration signal at a specific angle. Since the transmitter on the measuring vehicle, which sends the calibration signal, is already positioned relative to the measuring vehicle, the transmitter will always send the calibration signal at a specific angle. Assuming the receiver sends the calibration signal in the opposite direction to the measuring vehicle, the relative position of the receiver and the measuring vehicle can be used to determine the spatial angle of the measuring vehicle. Based on the spatial angle of the measuring vehicle, the shape of the track beneath the measuring vehicle can be determined. As the measuring vehicle moves from its starting point to its end point, the unevenness of the entire track can be determined.

[0058] In some embodiments of the bridge crane track deformation measurement method provided in this application, the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal, and the position of the measuring vehicle relative to the receiver include:

[0059] When the receiving position and the transmitting angle exceed the maximum preset standard, the position of the measuring vehicle at this time will be recorded for subsequent repair.

[0060] The receiver will determine the change in the position of the received calibration signal and determine whether the deformation of the track exceeds the threshold based on the magnitude of the position change.

[0061] In an embodiment, when the track is set horizontally and the transmitter sends a calibration signal within the horizontal range, and the position where the receiver receives the calibration signal is at the same height as the transmitter, then when the measuring vehicle moves to a flat position on the track, the position where the receiver receives the calibration signal will not change. When the measuring vehicle moves to an uneven position on the track, both the receiving position and the transmitting angle will change. When the amplitude of the above-mentioned change exceeds a preset standard, the position of the measuring vehicle is recorded to facilitate subsequent repair of the track at that position.

[0062] In some embodiments of the bridge crane track deformation measurement method provided in this application, the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal, and the position of the measuring vehicle relative to the receiver include:

[0063] The calibration signal passes through the first sensing sleeve and the second sensing sleeve on the receiver in sequence, and changes the state of the first sensing sleeve and the second sensing sleeve at the contact point with the calibration signal, thereby forming a receiving position.

[0064] The emission angle is determined according to the receiving positions on the first induction sleeve and the second induction sleeve.

[0065] When the measuring vehicle emits a calibration signal, certain locations on the receiver sense it and can determine the angle at which the calibration signal was transmitted. In one embodiment, the measuring vehicle emits a beam of light of a certain wavelength, which is emitted in a fan-shaped pattern by a transmitter on the measuring vehicle. This allows the receiver to effectively receive the calibration signal. The receiver is provided with a first sensing sleeve and a second sensing sleeve, with the first sleeve positioned inside the second sleeve. The calibration signal passes through the first sleeve and strikes the second sleeve. Since the calibration signal is a constant beam, the illumination intensity at corresponding locations on the first and second sleeves changes after striking them. This allows the location at which the state change occurs to be determined, ultimately representing the receiving location. When the calibration signal passes obliquely through the first and second sleeves, the height at which the state changes occur in the first and second sleeves differs. By detecting the difference in the position of the state change between the first and second sleeves, the propagation angle of the calibration signal, or the transmission angle, can be determined.

[0066] In some embodiments of the bridge crane track deformation measurement method provided in this application, fitting the current spatial angle of the measuring vehicle further includes:

[0067] The spatial angle is calibrated based on the gyroscope on the measuring vehicle.

[0068] Typically, bridge crane tracks have a certain width, and track deformation doesn't occur in a specific direction. Therefore, when the measuring vehicle encounters a deformed track area, the vehicle's spatial angle tilts. While the first and second sensing sleeves can accurately determine the calibration signal's emission angle, there's a certain amount of error. To improve data accuracy, a gyroscope is installed inside the measuring vehicle. This gyroscope senses the direction and angle of the vehicle's deflection and transmits this information to a host computer. The host computer then compares the gyroscope's feedback signal with the calculated calibration signal's emission angle. Any discrepancy between the two is considered a questionable point, requiring manual inspection.

[0069] In some embodiments of the bridge crane track deformation measurement method provided in this application, fitting the current spatial angle of the measuring vehicle includes:

[0070] According to the relative positions of the measuring vehicle and the receiver, the receiver and the measuring vehicle are calibrated in the spatial coordinate system.

[0071] In the spatial coordinate system, the measuring vehicle is deflected by a corresponding angle from the calibration position according to the receiving position and the transmitting angle, and the deflection angle is used as the spatial angle.

[0072] First, mark the receiver in the spatial coordinate system. Then, create a model of the measuring vehicle and add it to the spatial coordinate system. The position of the measuring vehicle relative to the receiver is determined based on the position of the receiver relative to the track and the position of the measuring vehicle relative to the track. The receiving position and the transmission angle determine the spatial angle at which the measuring vehicle sends the calibration signal. If deformation occurs, the angle between the track and the measuring vehicle will change, and the relative position of the measuring vehicle and the track will not change in the direction perpendicular to the measuring vehicle's motion. Even after deformation, the axial direction of the track and the direction of motion of the measuring vehicle will not change, thus eliminating the influence of other factors. Therefore, the spatial angle of the measuring vehicle can reflect the deformation of the track.

[0073] It is important to note that the measuring vehicle will not deviate from the track during its movement. Since the position of the measuring vehicle relative to the track is fixed in the spatial coordinate system, the shape of the track at that moment can be determined based on the measuring vehicle's rollers.

[0074] In some embodiments of the bridge crane track deformation measurement method provided in this application, determining the fitting surface of the track at the current position according to the spatial angle includes:

[0075] A fitting surface that contacts the rollers of the measuring vehicle is fitted under the measuring vehicle.

[0076] To improve detection accuracy, the calibration signal emitted by the measuring vehicle propagates along a straight line with a wide angle. In one embodiment, a transmitter for transmitting the calibration signal is mounted on the measuring vehicle's side near the receiver. The calibration signal emitted by the transmitter can propagate horizontally over a 180° range from the side of the measuring vehicle. The top of the receiver is at the same height as the top surface of the track, while the bottom is lower than the bottom surface, ensuring that the receiver can effectively receive the calibration signal.

[0077] Since there is a certain distance between the measuring vehicle and the track, the deformation of the track will be amplified by the measuring vehicle and the calibration signal, making it easier to detect the degree of deformation of the track.

[0078] In some embodiments of the bridge crane rail deformation measurement method provided in this application, determining the fitting surface of the rail contact surface at the current position based on the spatial angle includes:

[0079] The contact point between the track and the measuring vehicle roller is determined, and the fitting surface is adjusted according to the angle of the contact point relative to the measuring vehicle.

[0080] Due to the wide track and the need for stable movement of the measuring vehicle, at least two rollers are required. If the track is deformed, the bottoms of the measuring vehicle's rollers may lose contact with the track at certain locations while the measuring vehicle is operating on the deformed track, potentially reducing the final measurement results. To address this issue, the present application installs a stress sensor on each roller. The stress sensor is mounted on the roller. The stress sensor determines the contact point between the track and the roller, as well as the position of the contact point relative to the roller.

[0081] After the spatial angle of the measuring vehicle is determined through the calibration signal, the current position of the track relative to the measuring vehicle can be determined through multiple stress sensors, thereby more accurately fitting the shape of the track and providing more intuitive data for judging the unevenness of the track.

[0082] In some embodiments of the bridge crane track deformation measurement method provided in this application, integrating the fitting surfaces at different positions to determine the track deformation includes:

[0083] The track model is determined based on the fitting surfaces at different positions.

[0084] Determine the deformation situation based on the model, determine the maximum deformation position based on the model and perform repairs.

[0085] The measuring vehicle emits a calibration signal outward within a certain range. To ensure that the receiver can receive the calibration signal, the angle of the calibration signal should be as large as possible. In practical applications, the measuring vehicle emits multiple calibration signals in a fan-shaped shape. In one embodiment, when the track surface is not deformed, and the fan-shaped surface of the calibration signal emitted by the measuring vehicle is parallel to the length of the track, the receiving position of the calibration signal on the receiver remains unchanged. When the track surface deforms, the spatial angle of the measuring vehicle will change accordingly. After the spatial angle of the measuring vehicle changes, the area on the receiver used to receive the calibration signal will also change. The spatial angle of the measuring vehicle can be used to determine the shape of the underlying track. Since the measuring vehicle moves from one end of the track to the other, after the measuring vehicle completes its movement, a model of the entire track can be fitted. The fitted model is the contact surface with the measuring vehicle roller. Since the track model can be displayed on the host computer, it is easier to determine whether the track is deformed.

[0086] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for measuring deformation of a bridge crane track, characterized in that: include: Set up a receiver on one side of the track; The measuring vehicle moves from one end of the track to the other end, and sends a calibration signal to the receiver in real time during the movement of the measuring vehicle; fitting a current spatial angle of the measuring vehicle according to a receiving position of the calibration signal received by the receiver, a transmission angle of the calibration signal, and a position of the measuring vehicle relative to the receiver; Determining the fitting surface of the track at the current position according to the spatial angle, and integrating the fitting surfaces at different positions to determine the deformation of the track; The moving of the measuring vehicle from one end of the track to the other end comprises: The measuring vehicle sends a position signal to a receiving plate at the end of the track; Determine the distance between the receiving plate and the measuring vehicle and the position point where the position signal is received using the receiving plate and the position signal; When the distance between the position points at different times exceeds a threshold, adjusting the angle of the measuring vehicle; Fitting the current spatial angle of the measuring vehicle according to the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal, and the position of the measuring vehicle relative to the receiver includes: The position of the measuring vehicle relative to the receiver is determined from the relative position between the receiver and the track and the relative position between the measuring vehicle and the track.

2. The bridge crane track deformation measurement method according to claim 1, characterized in that: The fitting of the current spatial angle of the measuring vehicle according to the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal, and the position of the measuring vehicle relative to the receiver includes: When the receiving position and the transmitting angle exceed the maximum preset standard, the position of the measuring vehicle at this time is recorded for subsequent repair.

3. The bridge crane track deformation measurement method according to claim 1, wherein: The fitting of the current spatial angle of the measuring vehicle according to the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal, and the position of the measuring vehicle relative to the receiver includes: The calibration signal sequentially passes through the first sensing sleeve and the second sensing sleeve on the receiver, and changes the state of the first sensing sleeve and the second sensing sleeve at the contact points with the calibration signal, thereby forming the receiving position; The emission angle is determined according to the receiving positions on the first induction sleeve and the second induction sleeve.

4. The bridge crane track deformation measurement method according to claim 1, wherein: The fitting of the current spatial angle of the measuring vehicle according to the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal, and the position of the measuring vehicle relative to the receiver further includes: The spatial angle is calibrated according to the gyroscope on the measuring vehicle.

5. The bridge crane track deformation measurement method according to claim 1, wherein: The fitting of the current spatial angle of the measuring vehicle according to the receiving position of the calibration signal received by the receiver, the emission angle of the calibration signal, and the position of the measuring vehicle relative to the receiver includes: calibrating the receiver and the measuring vehicle in a spatial coordinate system according to the relative positions of the measuring vehicle and the receiver; The measuring vehicle is deflected from a calibration position by a corresponding angle in the spatial coordinate system according to the receiving position and the transmitting angle, and the deflected angle is used as the spatial angle.

6. The bridge crane track deformation measurement method according to claim 1, wherein: Determining the fitting surface of the track at the current position according to the spatial angle, and integrating the fitting surfaces at different positions to determine the deformation of the track includes: The fitting surface in contact with the roller of the measuring vehicle is fitted below the measuring vehicle.

7. The bridge crane track deformation measurement method according to claim 1, wherein: Determining the fitting surface of the track at the current position according to the spatial angle, and integrating the fitting surfaces at different positions to determine the deformation of the track includes: The contact point between the track and the roller of the measuring vehicle is determined, and the fitting surface is adjusted according to the angle of the contact point relative to the measuring vehicle.

8. The bridge crane track deformation measurement method according to claim 1, wherein: Determining the fitting surface of the track at the current position according to the spatial angle, and integrating the fitting surfaces at different positions to determine the deformation of the track includes: Determining a model of the track according to the fitting surfaces at different positions; The deformation condition is determined according to the model, and the maximum deformation position is determined according to the model and repaired.

Images