A dynamic monitoring and response system for relative height of overhead crane track

Abstract

The present invention discloses a dynamic monitoring and response system for the relative height of an overhead crane track, comprising: a data acquisition module, which is connected to the overhead crane and slides along the overhead crane track; the data acquisition module includes a symmetrically arranged transmitting module and receiving module; a data processing module, which is communicatively connected to the receiving module and calculates the height difference h of the overhead crane track; and is also used to output the out-of-tolerance point; a calibration module, which is used to measure the static height difference s between the overhead crane tracks and send it to the receiving module, and is also used to collect the position p of the overhead crane track and send it to the receiving module; and a response module, which controls the output of a response signal according to the out-of-tolerance point. The present invention can meet the needs of dynamic benchmark online monitoring, and by measuring the posture data of the transmitting module and the receiving module, it can realize real-time calibration of the track height difference and record the response. No manual intervention is required, which saves detection costs, avoids personnel safety accidents, and ensures work efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of track measuring instruments, and in particular to a dynamic monitoring and response system for the relative height of an overhead crane track. Background Art

[0002] Overhead crane rails are common structures on large lifting equipment, used to support overhead cranes for grabbing, lifting, and moving cargo and workpieces. With the gradual advancement of intelligent and unmanned operations in industries like transportation and manufacturing, on-site staffing is decreasing. This shortage of personnel has led to an urgent need for unmanned on-site inspections and monitoring.

[0003] Furthermore, the steel structure supporting the overhead crane track is subject to dynamic deformation, making it difficult to maintain a fixed reference point, as is the case with running tracks. Existing technologies only allow for offline measurements during idle and unloaded conditions, failing to meet the requirements for real-time online monitoring under dynamic references and unable to respond promptly to height deviations.

[0004] In summary, it is now necessary to design a dynamic monitoring and response system for the relative height of overhead crane tracks to solve the problems in the existing technology. Summary of the Invention

[0005] The present invention provides a dynamic monitoring and response system for the relative height of an overhead crane track, which solves the problem in the prior art that the overhead crane track cannot be dynamically monitored and the change of the height difference cannot be responded to in real time.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A dynamic monitoring and response system for the relative height of an overhead traveling vehicle track comprises:

[0008] A data acquisition module is connected to the overhead traveling crane and slides along the overhead traveling crane track; the data acquisition module comprises a transmitting module and a receiving module which are symmetrically arranged, the transmitting module being used to transmit laser signals, and the receiving module being used to receive and record the laser signals;

[0009] A data processing module, which is in communication with the receiving module and calculates the height difference h of the overhead crane track; the data processing module is also used to output the out-of-difference point;

[0010] a calibration module, which is used to measure the static height difference s between the overhead crane tracks and send it to the data processing module, and is also used to collect the position p of the overhead crane tracks and send it to the data processing module;

[0011] a response module, which is in communication with the data processing module and controls the output of a response signal according to the out-of-tolerance point position;

[0012] The height difference h is calculated as follows: h = cosβ·(xd·tanα)-h'

[0013] Wherein, d is the spacing of the overhead crane track, x is the displacement of the laser signal on the receiving unit; α is the deflection angle of the transmitting module relative to the overhead crane track, β is the deflection angle of the receiving module relative to the overhead crane track; and h' is the calibration value.

[0014] In some embodiments of the present invention, the transmitting module includes a fixed first mounting member and a transmitting unit, the first mounting member is connected to the overhead traveling crane and slides along one of the overhead traveling crane tracks; the first mounting member includes a first mounting cavity and a first connecting portion, the transmitting unit is located in the first mounting cavity, the first mounting cavity is provided with a transmitting end face, and the transmitting end face is arranged toward the receiving module; the first connecting portion is located at the bottom of the first mounting cavity; the first connecting portion contacts the overhead traveling crane track and slides relative to the overhead traveling crane track; the transmitting unit includes a laser, an optical fiber and a fiber collimator; the two ends of the optical fiber are respectively connected to the laser and the fiber collimator; the fiber collimator is integrated in the transmitting end face, and the laser and the optical fiber are arranged in the first mounting cavity.

[0015] In some embodiments of the present invention, the receiving module includes a fixed second mounting member and a receiving unit, the second mounting member is connected to the overhead crane and slides along another overhead crane track; the second mounting member includes a second mounting cavity and a second connecting portion; the second mounting cavity is provided with a receiving end face, and the receiving end face is arranged opposite to the transmitting end face; the receiving unit is provided with a photoelectric detection unit, which is communicatively connected to the data processing module; the photoelectric detection unit is integrated on the receiving end face of the data processing module.

[0016] In some embodiments of the present invention, the data acquisition period of the transmitting module and the receiving module is t, and the data processing module is also used to draw a relationship diagram between the height difference h and the position p, and output the out-of-difference point after weighted accumulation of the relationship diagrams of each period.

[0017] In some embodiments of the present invention, the calibration module includes a static height difference measurement unit and a track horizontal position calibration unit; the static height difference measurement unit includes a rangefinder symmetrically fixed on both sides of the overhead crane track and a reflection device located below the rangefinder; the track horizontal position calibration unit includes several groups of symmetrically distributed encoders, and the spacing between each group of encoders is equal along a direction parallel to the overhead crane track.

[0018] In some embodiments of the present invention, the rangefinder is a laser rangefinder, and the spacing between the reflective devices is equal to the spacing between the laser emission points of the rangefinder.

[0019] In some embodiments of the present invention, the calculation formula of the calibration value h' is: h'=as, where a is the initial height difference calculated by the data processing module based on the position data of the laser signal when the overhead crane is stationary.

[0020] In some embodiments of the present invention, both the first connecting portion and the second connecting portion are groove structures, and the width of the groove structure is not less than the width of any of the overhead crane tracks.

[0021] In some embodiments of the present invention, an attitude measurement unit is fixedly provided in each of the first mounting member and the second mounting member, the attitude measurement unit is communicatively connected with the data processing module, and the attitude measurement unit is used to measure the deflection angle α and the deflection angle β; the attitude measurement unit adopts a micro gyroscope and an acceleration sensor.

[0022] In some embodiments of the present invention, the monitoring method of the dynamic monitoring response system includes the following steps:

[0023] S1. Install and debug the positions of the transmitting module and the receiving module, and the data processing module records the initial position C of the laser signal;

[0024] S2, the calibration unit measures the static height difference s of the overhead travelling vehicle track and sends the result to the data processing module; the data processing module calculates the initial height difference a;

[0025] S3, starting the overhead crane to drive the transmitting module and the receiving module to slide along the overhead crane track, while the attitude measurement unit and the receiving unit collect data, and the track horizontal position calibration unit collects the position p of the overhead crane track and sends it to the data processing module;

[0026] S4, the data processing module calculates the height difference h of the overhead traveling vehicle track according to the data in steps S1-S3;

[0027] S5. The data processing module filters the height difference h and outputs an excess point, and the response module controls the output of a corresponding response signal according to the level of the excess point.

[0028] In some embodiments of the present invention, step S5 specifically includes the following steps:

[0029] S51, the data processing module draws a relationship diagram between the height difference h and the position p according to the height difference h in step S4 and the position p in step S3, and performs filtering on the relationship diagram according to the speed data of the overhead crane;

[0030] S52, the data processing module performs weighted calculation on the height difference h of each position p according to the period t, and outputs the out-of-difference point;

[0031] S53: After receiving the out-of-tolerance point, the response module selects to output a response signal according to the out-of-tolerance position and the out-of-tolerance range.

[0032] In some embodiments of the present invention, step S4 specifically includes the following steps:

[0033] S41, the data processing module calculates the calibration value h'=as according to the static height difference s and the initial height difference a in step S2;

[0034] S42. The data processing module calculates the height difference h= cosβ·(xd·tanα)-h' based on the collected data.

[0035] In some embodiments of the present invention, the step S3 further includes the encoder sending position calibration data to the data processing module according to the operating status of the overhead crane.

[0036] In some embodiments of the present invention, the data collected by the receiving unit in step S3 is the moving position D of the laser signal on the photoelectric detection unit.

[0037] In some embodiments of the present invention, step S4 is further used to calculate a displacement x, where the displacement x is the distance between a horizontal line where the initial position C is located and a horizontal line where the moving position D is located.

[0038] The technical solution of the present invention has the following technical effects compared with the prior art:

[0039] The present invention can meet the needs of online dynamic benchmark monitoring, that is, it can simultaneously meet the requirements of real-time and dynamic benchmark monitoring. Because the device monitors the relative height difference between the two rails rather than absolute height, the transmitting and receiving units can record the height difference of the rails in real time through the change of the light spot. The transmitting and receiving modules can move with the overhead crane, and by measuring the attitude data of the transmitting and receiving modules, the entire track can be scanned and monitored. In particular, during lifting, it can effectively monitor the stress deformation of the track under heavy loads.

[0040] The present invention also uses velocity information to transform trajectory into time-domain / frequency-domain filtering and then into trajectory, obtaining a filtered elevation-position trajectory diagram. The elevation difference is then calibrated by averaging the height difference multiple times. The response module issues a single alarm for any single point deviation, registering the alarm in the system. After leveling, maintenance personnel reset the system using an authorized account and begin the next measurement cycle. This eliminates the need for manual intervention, saving testing costs, preventing safety incidents, and ensuring work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. 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.

[0042] Figure 1 A schematic diagram of the structure of a dynamic monitoring and response system for the relative height of an overhead traveling vehicle track shown in the embodiment Figure 1 .

[0043] Figure 2 A schematic diagram of the structure of a dynamic monitoring and response system for the relative height of an overhead traveling vehicle track shown in the embodiment Figure 2 .

[0044] Figure 3 Schematic diagram of the cross section of a dynamic monitoring and response system for the relative height of an overhead travelling crane track shown in an embodiment.

[0045] Figure 4 Schematic diagram of the structure of the transmitting module and the receiving module shown in the embodiment.

[0046] Figure 5 Schematic diagram of the structure of the calibration module shown in the embodiment.

[0047] Reference numerals: 100 - transmitting module; 110 - first mounting member; 111 - first mounting cavity; 112 - first connecting portion; 113 - transmitting end face; 114 - first light shielding plate; 115 - first wiping portion; 120 - transmitting unit; 121 - laser; 122 - optical fiber; 123 - optical fiber collimator; 200 - receiving module; 210 - second mounting member; 211 - second mounting cavity; 212 - second connecting portion; 213 - receiving end face; 214 - second light shielding plate ;215 second wiping part;220-receiving unit;221-photoelectric detection unit;310-first trolley track;320-second trolley track;400-spring pressure piece;500-attitude measurement unit;600-data processing module;700-calibration module;710-static height difference measurement unit;711-rangefinder;712-reflection device;720-encoder;800-response module;810-sound and light alarm device;820-alarm signal integrated display terminal. DETAILED DESCRIPTION

[0048] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0049] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections. A person of ordinary skill in the art can understand the specific meanings of the above terms in the present invention in specific circumstances. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in any appropriate manner in any one or more embodiments or examples.

[0050] Reference Figure 1 and Figure 2 As shown, a dynamic monitoring and response system for the relative height of an overhead traveling vehicle track comprises:

[0051] A data acquisition module is connected to the overhead traveling crane and slides along the overhead traveling crane track. The data acquisition module includes a symmetrically arranged transmitting module 100 and a receiving module 200. The transmitting module 100 is used to transmit laser signals, and the receiving module 200 is used to receive and record the laser signals.

[0052] Specifically, the launch module 100 includes a first mounting member 110 and a launch unit 120 that are fixedly connected. The first mounting member 110 is connected to the overhead traveling vehicle and slides along one of the overhead traveling vehicle tracks, that is, along the first overhead traveling vehicle track 310.

[0053] The receiving module 200 includes a second mounting member 210 and a receiving unit 220, wherein the second mounting member 210 is connected to the overhead traveling vehicle and slides along another overhead traveling vehicle track, that is, along the second overhead traveling vehicle track 320;

[0054] A data processing module 600 is connected to the receiving module 200 for communicating with the receiving module and calculating the height difference h of the overhead travelling vehicle track; the data processing module 600 is further configured to output the out-of-difference point;

[0055] The calibration module 700 is used to measure the static height difference s between the overhead traveling vehicle tracks and send it to the data processing module 600; and is also used to collect the position p of the overhead traveling vehicle tracks and send it to the data processing module 600;

[0056] a response module 800, which is in communication with the data processing module 600 and controls the output of a response signal according to the out-of-tolerance point position;

[0057] The height difference h is calculated as h=cosβ·(xd·tanα)-h'

[0058] Wherein, d is the spacing between the overhead crane tracks, i.e., the spacing between the first overhead crane track 310 and the second overhead crane track 320; x is the displacement of the laser signal on the receiving unit 220; α is the deflection angle of the transmitting module 100 relative to the overhead crane track (i.e., the first overhead crane track 310); β is the deflection angle of the receiving module relative to the overhead crane track (i.e., the second overhead crane track 320); and h' is the calibration value.

[0059] The calculation formula of the calibration value h' is: h'=as, where a is the initial height difference calculated by the data processing module 600 based on the position data of the laser signal when the overhead crane is in a stationary state.

[0060] Specifically, the transmitting module 100 and the receiving module 200 can move with the overhead crane, and the entire track can be scanned and monitored by measuring the posture data of the transmitting module 100 and the receiving module 200, while meeting the requirements of real-time and dynamic benchmark monitoring.

[0061] In some embodiments of the present invention, reference Figure 5As shown, the calibration module 700 includes a static height difference measurement unit 710 and a track horizontal position calibration unit; the static height difference measurement unit 710 includes a rangefinder 711 symmetrically fixed on both sides of the overhead crane track and a reflection device 712 located below the rangefinder; the track horizontal position calibration unit includes a plurality of groups of symmetrically distributed encoders 720, and the spacing between each group of encoders 720 is equal along the direction parallel to the overhead crane track.

[0062] In some embodiments of the present invention, the rangefinder 711 is a laser rangefinder, and the spacing between the reflective devices 712 is equal to the spacing between the laser emission points of the rangefinder 711 .

[0063] Specifically, a rangefinder 711 is fixedly installed on both sides of the first overhead crane track 310 and the second overhead crane track 320, that is, it is stationary relative to each track. There are also two transmitting devices 612, which are respectively located below each rangefinder 711. Figure 5 As shown, two equal-height pillars are fixed to the ground beneath the overhead crane track, with reflectors 712 fixed to their top surfaces. As a reference point, the distance between the cross-sectional centers of the two pillars is equal to the spacing between the laser emission points of the two rangefinders 711. During operation, when a rangefinder 711 is directly above the reflectors 712, the laser beams emitted by the rangefinders 711 simultaneously strike their respective reflectors 712, allowing the static height difference s between the first overhead crane track 310 and the second overhead crane track 320 to be measured and calculated. Regarding the encoders 720, the same number of encoders 720 are installed on both the first and second overhead crane tracks 310 and 320, with each encoder 720 positioned in a one-to-one correspondence. On a single overhead crane track, the spacing between adjacent encoders 720 can range from 20m to 50m.

[0064] In some embodiments of the present invention, data processing module 600 processes laser signals, primarily using algorithms to modify the collected raw data, extract key information, and determine track deviations. Specifically, data processing module 600 is further configured to plot a relationship between the height difference h and the position p, and perform a weighted accumulation of the relationship graphs for each cycle to output the deviation point.

[0065] In some embodiments of the present invention, reference Figure 3As shown, the first mounting member 110 has the same structure as the second mounting member 210. Taking the first mounting member 110 as an example, the first mounting member 110 includes a first mounting cavity 111 and a first connecting portion 112. The transmitting unit 120 is located in the first mounting cavity 111. The first mounting cavity 111 is provided with a transmitting end surface 113, and the transmitting end surface 113 is arranged toward the receiving module 200; the first connecting portion 112 is located at the bottom of the first mounting cavity 111; the first connecting portion 112 contacts the first overhead crane track 310 and slides relative to the first overhead crane track 310.

[0066] Specifically, refer to Figure 1 As shown, the first mounting member 110 can be made of density board or metal plate. If metal plate is used, it must be treated with anti-corrosion. The first mounting member 110 is also provided with a first light shielding plate 114 for shielding the emitting end surface 113 from light. The end surface of the first mounting member 110 has an inverted trapezoidal structure, wherein the first connecting portion 112 is located at the upper bottom edge of the trapezoidal structure and is specifically a long strip groove structure provided along the first overhead crane track 310. The width of the long strip groove structure is not less than the width of the first overhead crane track 310, that is, it can be slightly larger than the width of the first overhead crane track 310.

[0067] During assembly, the first connecting portion 112 is buckled onto the first overhead crane track 310. Furthermore, a wear-resistant layer is fixedly laid inside the first connecting portion 112, i.e., inside the groove structure. The wear-resistant layer can be made of a material such as wear-resistant canvas to increase friction between the first connecting portion 112 and the first overhead crane track 310.

[0068] The emitting end surface 113 , which serves as a component plane of the first mounting cavity 111 , is perpendicular to the top surface of the first overhead crane track 310 , i.e., the emitting end surface 113 is a vertical surface facing the receiving module 200 ; the laser emission port of the emitting unit 120 is located on the emitting end surface 113 .

[0069] In addition, the first light shielding plate 114 is arranged around the periphery of the emitting end surface 113, and the length of the upper baffle is greater than that of the lower baffle, which can effectively block strong light and avoid the influence of the external environment on the laser signal.

[0070] The emission end surface 113 is provided with a first wiping portion 115 which rotates relative to a point on the emission end surface 113 to clean the emission port of the laser signal to prevent the emission intensity of the laser signal from being affected.

[0071] In some embodiments of the present invention, reference Figure 4As shown, the emitting unit 120 includes a laser 121, an optical fiber 122 and a fiber collimator 123; the two ends of the optical fiber 122 are respectively connected to the laser 121 and the fiber collimator 123; the laser is a point laser; the fiber collimator 123 is integrated into the emitting end face 113, and the laser 121 and the optical fiber 122 are arranged in the first mounting cavity 111.

[0072] Specifically, the fiber optic collimator 123 is fixed at the center of the emitting end face 113. During use, the laser is emitted by the laser 121 and transmitted through the optical fiber 122, entering the fiber optic collimator 123 at the center of the emitting end face 133 of the transmitting module 100, and emitting the laser to the receiving module 200.

[0073] In some embodiments of the present invention, as described above, reference Figure 2 As shown, the second mounting member 210 has the same structure as the first mounting member 110, specifically, it includes a second mounting cavity 211 and a second connecting portion 212; the second mounting cavity 211 is provided with a receiving end surface 213, and the receiving end surface 213 is arranged opposite to the transmitting end surface 113; the second connecting portion 212 is buckled on the second vehicle track 320.

[0074] The receiving unit 220 includes a photoelectric detection unit 221, which is in communication with the data processing module 600. The photoelectric detection unit 221 is integrated into the receiving end surface 213. Specifically, the photoelectric detection unit 221 utilizes a two-dimensional PSD screen. Similarly, a second light shielding plate 214 is provided around the periphery of the receiving end surface 213 to prevent sunlight and reflected light from interfering with the measurement results.

[0075] Similarly, a second wiping portion 215 is provided on the receiving end surface 213, and the second wiping portion 215 is slidingly connected to the receiving end surface 213; the length of the second wiping portion 215 is not less than the vertical width of the two-dimensional PSD screen, and the two-dimensional PSD screen can be cleaned in time to avoid affecting the reception of laser signals.

[0076] In some embodiments of the present invention, an attitude measurement unit 500 is fixedly provided in each of the first mounting member 110 and the second mounting member 210. The attitude measurement unit 500 is communicatively connected to the data processing module 600 and is used to measure the deflection angle α and the deflection angle β. The attitude measurement unit adopts a micro gyroscope and an acceleration sensor, wherein the micro gyroscope mainly measures rotation-related parameters, and the accelerometer mainly measures translation-related parameters, and has the characteristics of low cost, low power consumption, small size and high stability.

[0077] In some embodiments of the present invention, reference is made to Figure 4As shown, the installation method of the transmitting module 100 and the receiving module 200 on the overhead crane is that the first mounting member 110 and the second mounting member 210 are both hinged to the overhead crane via hinges. Therefore, during the operation of the overhead crane, the position of the transmitting module 100 and the receiving module 200 may change.

[0078] In some embodiments of the present invention, the tops of the first and second mounting members 110, 210 are connected to the overhead traveling vehicle via a spring compression piece 400. Specifically, one end of the spring compression piece 400 is fixedly connected to the overhead traveling vehicle, while the other end abuts against the tops of the first and second mounting members 110, 210. Accordingly, fixing members (not shown) are provided at the tops of the first and second mounting members 110, 210 to restrain the spring compression piece 400. The spring compression piece 400 applies pressure to the first and second mounting members 110, 210, preventing them from falling off the first and second overhead traveling vehicle rails 310, 320.

[0079] In some embodiments of the present invention, the receiving unit 220 and the transmitting unit 120 are both connected to the power supply module of the overhead crane, that is, the receiving unit 220 and the transmitting unit 120 are powered by the power supply module of the overhead crane, and the first wiping part 115 on the first mounting member 110 and the second wiping part 215 on the second mounting member 210 can also be powered.

[0080] In some embodiments of the present invention, the monitoring method of the dynamic monitoring response system includes the following steps:

[0081] S1. Install and debug the positions of the transmitting module 100 and the receiving module 200, and the photoelectric detection unit records the initial position C of the laser signal;

[0082] Specifically, after the transmitting module 100 and the receiving module 200 are fixed to the overhead crane through hinges, the first connecting portion 112 of the transmitting module 100 is buckled on the first overhead crane track 310, and the second connecting portion 212 of the receiving module is buckled on the second overhead crane track 320; then, a certain pressure is applied to the transmitting module 100 and the receiving module 200 using a spring pressure sheet 400 to prevent them from falling off the overhead crane track.

[0083] After the transmitting module 100 and the receiving module 200 are powered on, the overhead crane is in a stationary state. The transmitting module 100 emits laser light, and the photoelectric detection unit 221 of the receiving module 200 receives the laser signal. Then, the hinge and the spring pressing piece 400 are adjusted so that the laser light emitted by the optical fiber collimator 123 is captured at the center position of the photoelectric detection unit 221, which is the initial position C. Figure 3 shown.

[0084] S2. The calibration unit 600 measures the static height difference s of the overhead travelling vehicle track and sends the result to the data processing module 600; the data processing module 600 calculates the initial height difference a.

[0085] Specifically, after the overhead crane track is zeroed, the overhead crane is stopped at a fixed position so that the rangefinder 711 is stationary directly above the reflector 712 , thereby measuring the stationary height difference s of the overhead crane track, and then sending the stationary height difference s to the data processing module 600 .

[0086] The data processing unit 600 calculates the initial height difference a of the overhead travelling vehicle track according to the initial position C when the overhead travelling vehicle is in a stationary state.

[0087] S3. Start the overhead crane to drive the transmitting module 100 and the receiving module 200 to slide along the overhead crane track. At the same time, the attitude measurement unit 500 and the receiving unit 220 collect data. The track horizontal position calibration unit collects the position information of the overhead crane track and sends it to the data processing module 600.

[0088] Specifically, the data collection period is t, for example, t is 5ms, that is, every 5ms, the attitude measurement unit 500 and the receiving unit 220 synchronously collect data;

[0089] The attitude measurement unit 500 measures the deflection angle α of the transmitting module 100 relative to the first overhead crane track 310 and the deflection angle β of the receiving module 200 relative to the second overhead crane track 320. In this embodiment, the measurement of the attitude measurement unit 500 is acquired through six micro gyroscopes and two accelerometers, and each deflection angle is measured in the form of spherical polar coordinates and plane rectangular coordinates.

[0090] Specifically, the micro gyroscope on the attitude measurement unit 500 is used to measure the angular acceleration values of the transmitting module 100 and the receiving module 200, and obtain the deflection angle α and the deflection angle β after performing secondary integration respectively;

[0091] The data collected by the receiving unit 220 is the moving position D of the laser signal on the photoelectric detection unit 221 .

[0092] As the overhead crane runs, the encoder 720 provides real-time feedback on the position of the overhead crane on the track, that is, the positions of the transmitting module 100 and the receiving module 200 on the track can be sent to the data processing module 600 .

[0093] S4. The data processing module calculates the height difference h of the overhead traveling vehicle track according to the data in step S2.

[0094] Specifically, the following steps are included:

[0095] S41. After the receiving unit overhead crane is in operation, the data processing module 600 calculates the displacement x of the laser signal on the photoelectric detection unit 221, where the displacement x is the distance between the horizontal line where the initial position C is located and the horizontal line where the moving position D is located, that is, the horizontal displacement of the laser signal on the photoelectric detection unit 221 is ignored.

[0096] S42: The data processing module 600 calculates a calibration value h'=as according to the initial height difference a in step S2 and the received static height difference s.

[0097] S43, the data processing module 600 reads the calibration value h' and calculates the height difference h using the formula h=cosβ·(xd·tanα)-h', that is, the height difference h in step S32 is corrected using the calibration value h' and then outputted;

[0098] In actual operation, due to the problems of zero-point drift and error accumulation, data calibration is required. Although data drift exists in all three different sensors, since this embodiment focuses on the height difference between the two sides of the overhead crane track, all errors can be expressed in the height difference during calibration. Therefore, the height difference between the calibrated height difference and the standard value is defined as h', which is the calibration value. When the second trolley track 320 is higher than the first trolley track 310, the calibration value h' is negative; when the first trolley track 310 is higher than the second trolley track 320, the calibration value h' is positive.

[0099] S5. The data processing module 600 filters the height difference h and outputs an excess point. The response module 800 controls the output of a corresponding response signal according to the level of the excess point.

[0100] The step S5 specifically includes the following steps:

[0101] S51, the data processing module 600 draws a relationship diagram between the height difference h and the position p according to the height difference h in step S4 and the position p in step S3, and performs filtering on the relationship diagram according to the speed data of the overhead crane;

[0102] Since filtering requires the extraction of frequency domain information, the speed information of the transmitting module 100 and the receiving module 200 are first combined and the position is calibrated through the encoder 720 to draw a "height difference-position" diagram. Then, the trajectory information is converted into frequency domain information according to the uniform speed of the data processing module 600 (for example, the container overhead crane is at 4m / s), and then the filtering operation is performed.

[0103] The filtering operation specifically uses the empirical mode decomposition method to decompose the obtained frequency domain signal into a series of intrinsic mode functions (Intrinsic Mode Function) and a residue. The residue is retained and other information is removed. The residue information is converted into a "height difference-position" map after filtering.

[0104] S52: The data processing module performs a weighted calculation of the height difference h at each position p based on the period t and outputs the out-of-tolerance points. The module also performs a weighted accumulation of the information for each point in the "height difference-position" graph for all remaining items daily (0:00-23:59), outputs the results, and analyzes the results. If any out-of-tolerance points are found, the system records the specific location and height of the out-of-tolerance point. The results are then transmitted to the response unit, which responds.

[0105] S53: After receiving the out-of-tolerance point, the response module 800 selects to output a response signal according to the out-of-tolerance position and the out-of-tolerance range.

[0106] Specifically, refer to Figure 4 As shown, the response module 800 includes an audible and visual alarm device 810 and an alarm signal integrated display terminal 820. The audible and visual alarm device 810 is set at the site where the overhead crane is running, and the on-site maintenance personnel can directly receive the alarm signal. When the response module 800 receives the out-of-tolerance point, the audible and visual alarm device 810 first reminds the on-site maintenance personnel. After seeing the alarm signal, the on-site maintenance personnel register the specific location and amount of the out-of-tolerance, and then the alarm signal is eliminated.

[0107] In addition, the out-of-tolerance point information will also be sent to the alarm signal integrated display terminal 820, automatically recorded in the system log, and the central control room personnel will perform a one-click confirmation process.

[0108] When the response module 800 receives the same deviation at the same point, it will not issue a repeated alarm before performing the corresponding leveling operation. It will only issue an alarm again when deviations occur at other points or when the deviation at the same point increases further. The technical solution of the present invention has the following technical effects compared to the prior art:

[0109] The present invention can meet the needs of online dynamic benchmark monitoring, that is, it can simultaneously meet the requirements of real-time and dynamic benchmark monitoring. Because the device monitors the relative height difference between the two rails rather than absolute height, the transmitting and receiving units can record the height difference of the rails in real time through the change of the light spot. The transmitting and receiving modules can move with the overhead crane, and by measuring the attitude data of the transmitting and receiving modules, the entire track can be scanned and monitored. In particular, during lifting, the stress deformation of the track under heavy load can be effectively monitored.

[0110] At the same time, the present invention uses speed information to achieve trajectory-time domain / frequency domain filtering-trajectory conversion, obtains the trajectory diagram of the height difference-position after filtering, and calibrates the height difference by calculating the average multiple times; and the response module alarms once for the same deviation of a single point and records it in the system. After the maintenance personnel use an authorized account to reset the system after leveling, the measurement in the next cycle begins. The present invention does not require manual intervention, saves detection costs, avoids personnel safety accidents, and ensures work efficiency. In the description of the above embodiment, specific features, structures, materials or characteristics can be combined in a suitable manner in any one or more embodiments or examples.

[0111] The above are only specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A dynamic monitoring and response system for the relative height of an overhead crane track, characterized in that: include: A data acquisition module is connected to the overhead traveling crane and slides along the overhead traveling crane track; the data acquisition module comprises a transmitting module and a receiving module which are symmetrically arranged, the transmitting module being used to transmit laser signals, and the receiving module being used to receive and record the laser signals; A data processing module, which is in communication with the receiving module and calculates the height difference h of the overhead crane track; the data processing module is also used to output the out-of-difference point; a calibration module, which is used to measure the static height difference s between the overhead crane tracks and send it to the data processing module, and is also used to collect the position p of the overhead crane tracks and send it to the data processing module; a response module, which is in communication with the data processing module and controls the output of a response signal according to the out-of-tolerance point position; The height difference h is calculated as follows: h = cosβ·(xd·tanα)-h' Wherein, d is the spacing of the overhead crane track, x is the displacement of the laser signal on the receiving module; α is the deflection angle of the transmitting module relative to the overhead crane track, and β is the deflection angle of the receiving module relative to the overhead crane track; h' is the calibration value; the calculation formula of the calibration value h' is: h'=as, wherein a is the initial height difference calculated by the data processing module based on the position data of the laser signal when the overhead crane is stationary.

2. The dynamic monitoring and response system for the relative height of an overhead crane track according to claim 1, characterized in that: The transmitting module includes a fixed first mounting part and a transmitting unit, wherein the first mounting part is connected to the overhead traveling crane and slides along one of the overhead traveling crane tracks; the transmitting unit includes a laser, an optical fiber and a fiber collimator; the two ends of the optical fiber are respectively connected to the laser and the fiber collimator; the fiber collimator is integrated on the surface of the first mounting part, and the laser and the optical fiber are arranged inside the first mounting part.

3. The dynamic monitoring and response system for the relative height of an overhead crane track according to claim 2, characterized in that: The receiving module includes a second fixed mounting member and a receiving unit, wherein the second mounting member is connected to the overhead traveling vehicle and slides along another overhead traveling vehicle track; the receiving unit is provided with a photoelectric detection unit, which is in communication with the data processing module; the photoelectric detection unit is integrated on the surface of the second mounting member; An attitude measurement unit is fixedly provided in each of the first mounting member and the second mounting member, and the attitude measurement unit is communicatively connected with the data processing module.

4. The dynamic monitoring and response system for the relative height of an overhead crane track according to claim 1, characterized in that: The data collection period of the transmitting module and the receiving module is t, and the data processing module is further used to draw a relationship diagram between the height difference h and the position p, and output the out-of-difference point after weighted accumulation of the relationship diagrams of each period.

5. The dynamic monitoring and response system for the relative height of an overhead travelling vehicle track according to claim 3, characterized in that: The calibration module includes a static height difference measurement unit and a track horizontal position calibration unit; the static height difference measurement unit includes a rangefinder symmetrically fixed on both sides of the overhead crane track and a reflection device located below the rangefinder; the track horizontal position calibration unit includes several groups of symmetrically distributed encoders, and the spacing between each group of encoders is equal along the direction parallel to the overhead crane track.

6. The monitoring method of the dynamic monitoring response system for the relative height of an overhead traveling vehicle track according to claim 5, characterized in that: The following steps are involved: S1. Install and debug the positions of the transmitting module and the receiving module, and the data processing module records the initial position C of the laser signal; S2, the calibration module measures the static height difference s of the overhead travelling vehicle track and sends it to the data processing module; the data processing module calculates the initial height difference a; S3, starting the overhead crane to drive the transmitting module and the receiving module to slide along the overhead crane track, while the attitude measurement unit and the receiving unit collect data, and the track horizontal position calibration unit collects the position p of the overhead crane track and sends it to the data processing module; S4, the data processing module calculates the height difference h of the overhead traveling vehicle track according to the data in steps S1-S3; S5. The data processing module filters the height difference h and outputs an excess point, and the response module controls the output of a corresponding response signal according to the level of the excess point.

7. The monitoring method according to claim 6, characterized in that: The step S4 specifically includes the following steps: S41, the data processing module calculates the calibration value h'=as according to the static height difference s and the initial height difference a in step S2; S42. The data processing module calculates the height difference h= cosβ·(xd·tanα)-h' based on the collected data.

8. The monitoring method according to claim 6, characterized in that: The step S5 specifically includes the following steps: S51, the data processing module draws a relationship diagram between the height difference h and the position p according to the height difference h in step S4 and the position p in step S3, and performs filtering on the relationship diagram according to the speed data of the overhead crane; S52, the data processing module performs weighted calculation on the height difference h of each position p according to the period t, and outputs the out-of-difference point; S53: After receiving the out-of-tolerance point, the response module selects to output a response signal according to the out-of-tolerance position and the out-of-tolerance range.

9. The monitoring method according to claim 8, characterized in that: The data collected by the receiving unit in step S3 is the moving position D of the laser signal on the receiving unit; step S4 is also used to calculate the displacement x, which is the distance between the horizontal line where the initial position C is located and the horizontal line where the moving position D is located.

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