A detection system and method for crane rails in a dock based on FLAG board

Abstract

The present invention proposes a detection system for crane tracks in docks based on FLAG boards, including a controller, a photoelectric switch detection sensor, multiple FLAG boards, a laser distance sensor, and a magnetic induction switch detection sensor; when the laser searchlight detection point is located at the damaged position and the detection distance fed back by the laser distance sensor is greater than the threshold, the controller obtains a second damage trigger signal through the laser distance sensor; the controller forms second positioning information by coordinating the photoelectric detection signal of the photoelectric switch detection sensor, accurately determines the position of the rail crane according to the first positioning information and the second positioning information, and confirms the position of the rail damage according to the triggering conditions of the first damage trigger signal and the second damage trigger signal and the position of the rail crane. The present invention further proposes a detection method, including: obtaining the first and second damage trigger signals, obtaining the first positioning information; determining the second positioning information; and obtaining the precise positioning of the rail damage position. The present invention improves the detection accuracy of broken rails.

Description

Technical Field

[0001] The present invention relates to the technical field of automated wharf hoisting equipment and crane track detection, and in particular to a FLAG board-based crane track detection system and method in a wharf. Background Art

[0002] In recent years, in order to ensure smooth and efficient production, terminals have introduced artificial intelligence to achieve the ability of unmanned terminals to carry out uninterrupted transportation operations. Automated terminals use unmanned IGVs, rail-mounted cranes, and bridge cranes to load and unload containers in the yard, so regular maintenance and adjustment of the tracks are essential. At present, track detection technologies at home and abroad are mostly used in various railway systems. There are many track detection methods. For example, in high-speed railways in European countries, laser radars and high-precision cameras are used for track surface detection; Japan is committed to developing ultrasonic and magnetic measurement technologies to achieve comprehensive monitoring of track structures and geological conditions; China has introduced artificial intelligence technology, using high-precision sensor networks and real-time data analysis to monitor the real-time status of tracks.

[0003] Most existing detection devices use various sensor technologies, such as strain sensors, acoustic sensors, thermal imaging sensors and other sensor technologies to monitor and analyze track status in real time. However, these application technologies require a large number of communication devices to establish signal channels to issue alarms. Existing detection devices have the following disadvantages: (1) High false alarm rate: After on-site field investigations, the sensor system may be affected by environmental factors, resulting in a high false alarm rate; for example, due to changes in meteorological conditions, interference from the surrounding environment or the activities of plants and animals, the sensor may cause false alarms, reducing the reliability of the system; (2) High energy consumption: Some sensor systems require a lot of energy to operate, especially in places far away from power sources; this may lead to a high dependence on electricity for the system, increasing the system's energy consumption cost and dependence on power infrastructure; (3) Weak real-time performance: Some sensor systems may have incomplete information recognition in data transmission and processing, which may affect real-time performance. (4) High maintenance cost: The detection range of traditional sensor detection systems is limited, and the integrated signals of several sensors are required to complete the detection function of the track and a large amount of communication equipment maintenance, which increases the on-site maintenance cost; (5) Complex integration: The integration of multiple sensor technologies may face challenges; the sensor system and various different types of systems on site may use different communication protocols and data formats, so a complex, high-cost, and inconvenient maintenance integration method is required to ensure data consistency and mutual coordination. When an automated terminal has the above shortcomings, it will greatly affect the port's operating efficiency and management efficiency. Summary of the invention

[0004] In view of this, it is necessary to propose a detection system and method for crane rails in the wharf based on a FLAG board to address the above-mentioned problems, so as to overcome the shortcomings of the above-mentioned background technology, thereby solving the technical problem of how to improve the detection accuracy of broken rails of rail-mounted cranes and the operating efficiency of port equipment under low cost and easy maintenance conditions.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] The present invention proposes a detection system for a crane track in a dock based on a FLAG board, which is applied to a rail crane in a dock. The detection system includes a controller, a photoelectric switch detection sensor installed on the rail crane, and a plurality of FLAG boards. Each FLAG board is arranged at intervals along the crane track and is located on one side of the crane track. The photoelectric switch detection sensor is used to detect the FLAG board and transmit a photoelectric detection signal to the controller. The controller obtains first positioning information for positioning the rail crane through an encoder of a trolley travel drive motor of the rail crane. The detection system also includes a laser rangefinder sensor and a magnetic induction switch detection sensor.

[0007] The controller is electrically connected to the photoelectric switch detection sensor, the laser distance sensor, and the magnetic induction switch detection sensor respectively; the magnetic induction switch detection sensor and the laser distance sensor are both installed on the rail crane; the sensing head of the magnetic induction switch detection sensor is located directly above the crane track and the normal top surface of the crane track is located within the detection range of the magnetic induction switch detection sensor, and the laser searchlight detection point of the laser distance sensor is located on the crane track;

[0008] When the sensing head of the magnetic induction switch detection sensor is located above a damaged position on the crane track and the damaged position is not within the detection range of the magnetic induction switch detection sensor, the controller obtains a first damage trigger signal through the magnetic induction switch detection sensor; when the laser searchlight detection point of the laser ranging sensor is located on the damaged position and the detection distance fed back by the laser ranging sensor is greater than a threshold, the controller obtains a second damage trigger signal through the laser ranging sensor; the controller forms second positioning information for positioning the rail crane by coordinating the photoelectric detection signal of the photoelectric switch detection sensor, and the controller accurately locates the rail crane according to the first positioning information and the second positioning information; the controller confirms the damaged position of the rail according to the triggering conditions of the first damage trigger signal and the second damage trigger signal and the position of the rail crane.

[0009] Furthermore, the magnetic induction switch detection sensor and the laser ranging sensor are both located above the crane track, and the magnetic induction switch detection sensor and the laser ranging sensor are spaced apart from each other.

[0010] Furthermore, the virtual center point of the lateral distance between the magnetic induction switch detection sensor and the laser ranging sensor is the virtual end point of the virtual center line of the trolley of the rail-mounted crane.

[0011] Furthermore, the length direction of the crane track is horizontal; the virtual axis of the magnetic induction switch detection sensor is perpendicular to the length direction of the crane track; and the laser emission direction of the laser ranging sensor is perpendicular to the length direction of the crane track.

[0012] Furthermore, the controller warns or records positioning information about the damaged position of the track according to the triggering conditions of the first damage trigger signal and the second damage trigger signal and the position of the rail-mounted crane.

[0013] Furthermore, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, that is, the damage position passes through the magnetic induction switch detection sensor and is not within the detection range of the magnetic induction switch detection sensor, and the damage position passes through the laser ranging sensor and the detection distance of the laser ranging sensor to the track damage position is greater than a threshold, the controller uses the position of the FLAG plate corresponding to the specified FLAG plate of the photoelectric switch detection sensor and the number of pulses specified by the encoder of the trolley travel drive motor to determine the position of the rail crane and the damage position of the track.

[0014] The present invention further proposes a detection method for crane rails in a dock based on a FLAG board, which is applied to the detection system as described in any one of the above items. The detection method comprises the following steps performed in sequence:

[0015] Step S1, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, the controller obtains the first positioning information through the encoder of the vehicle travel drive motor;

[0016] Step S2, the controller determines the second positioning information according to the photoelectric detection signal of the photoelectric switch detection sensor to the FLAG board;

[0017] In step S3, the controller adjusts the second positioning information according to the first positioning information, the speed position compensation value corresponding to the reaction time of the laser ranging sensor, and the speed position compensation value corresponding to the reaction time of the magnetic induction switch detection sensor, so as to obtain accurate positioning of the track damage position.

[0018] Further, in step 3, the controller obtains the first broken rail position value of the corresponding magnetic induction switch detection sensor through the first positioning information and the speed position compensation value of the reaction time of the corresponding magnetic induction switch detection sensor, and the controller obtains the second broken rail position value of the corresponding laser ranging sensor through the first positioning information and the speed position compensation value of the reaction time of the corresponding laser ranging sensor; the controller performs mutual verification of the first broken rail position value and the second broken rail position value, thereby obtaining accurate positioning of the track damage position.

[0019] The present invention further proposes a detection method for crane rails in a dock based on a FLAG board, which is applied to the detection system as described in any one of the above items. The detection method comprises the following steps performed in sequence:

[0020] Step S1, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, the controller obtains the first positioning information through the encoder of the vehicle travel drive motor;

[0021] Step S2, the controller determines the second positioning information according to the photoelectric detection signal of the photoelectric switch detection sensor to the FLAG board;

[0022] In step S3, the controller adjusts the second positioning information according to the first positioning information and the speed position compensation value corresponding to the reaction time of the laser ranging sensor, so as to obtain accurate positioning of the track damage position.

[0023] Further, in step S3, the precise positioning of the track damage position is determined by the trolley position value F, the installation coordinate value of the laser distance measuring sensor and the installation coordinate value of the magnetic induction switch detection sensor;

[0024] The trolley position value F=Flag board real position value=Flag board basic position value X+ / -FLAG board width compensation value W+speed position compensation value C corresponding to the reaction time of the laser ranging sensor+FLAG board infrared counter-radiation device installation position compensation value D+value E calculated from the encoder pulse of the trolley travel drive motor;

[0025] The value E calculated from the encoder pulse of the vehicle travel drive motor corresponds to the first positioning information;

[0026] The Flag board basic position value X corresponds to the second positioning information.

[0027] The beneficial effects of the present invention are:

[0028] The present invention reduces the maintenance cost and difficulty of crane tracks in docks, improves emergency repair efficiency, reduces a large amount of port operation energy consumption, and also reduces the false alarm rate of dock equipment, providing multi-layer protection restrictions for dock equipment operation, and can perform multiple checks on broken tracks. The present invention provides a track break detection function for rail cranes in automated docks to prevent serious derailment of equipment, solves the problem of existing sensor systems being highly dependent on power infrastructure, especially in places far away from power sources, and can effectively reduce energy consumption problems. The present invention also has the following advantages: 1) It can utilize the low-voltage DC power supply provided by the rail crane and has the characteristics of combining equipment mobility, so that the rail crane can achieve full-range emergency braking effect according to the track state, avoid the trolley mechanism from causing a larger gap in the broken rail, thereby reducing the difficulty of track maintenance and the workload of track inspection, and providing great convenience and more accurate positioning information for maintenance and servicing; 2) It realizes the most direct protection limit, position information calculation and mutual verification; 3) It reduces the difficulty of repairing the tracks in the wharf, reduces the problem of high energy consumption, and simplifies the integration problem of the detection system; 4) It can perform multiple verifications on the location information of cracks, effectively solve the problems of high energy consumption, difficult maintenance, and slow emergency processing, greatly increase the efficiency of emergency repair work, and quickly restore the equipment production state; 5) It can combine the advantages of equipment mobility and sustainable energy supply, solve the costs of sensor installation, maintenance, and high energy consumption, avoid the secondary enlargement of the track gap, and have a certain real-time performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings are included to provide a further understanding of the present invention, and are incorporated into and constitute a part of this specification. The accompanying drawings illustrate exemplary embodiments of the present invention and, together with the description, are used to explain the principles of the present invention. These drawings are for illustration only and are not intended to limit the present invention.

[0030] Figure 1 It is a schematic diagram of the structural principle of a detection system for crane rails in a dock based on a FLAG board of the present invention;

[0031] Figure 2 It is a front view of the rail-mounted crane involved in the present invention;

[0032] Figure 3 It is a schematic diagram of the installation structure of the laser distance measuring sensor and the magnetic induction switch detection sensor involved in the present invention;

[0033] Description of reference numerals:

[0034] Rail mounted crane 100; crane rail 200; magnetic induction switch detection sensor 300; laser distance measuring sensor 400; virtual center line c. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be further clearly and completely described in combination with the embodiments of the present invention. It should be noted that 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 work are within the scope of protection of the present invention.

[0036] The terms "first", "second", "third", "fourth", etc. are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the definition of "first", "second", "third", "fourth" features may explicitly or implicitly include one or more of the features.

[0037] The following is a detailed description of an embodiment of the invention depicted in the accompanying drawings. The embodiments are detailed in order to clearly convey the invention. However, the number of details provided is not intended to limit the intended variations of the embodiments; on the contrary, the intention is to cover all modifications, equivalents, and substitutes that fall within the spirit and scope of the invention as defined by the appended claims.

[0038] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0039] Embodiments of the present invention include various steps, which are described below. These steps can be performed by hardware components, or can be contained in machine executable instructions, which can be used for general or special purpose processors programmed with instructions to perform these steps. Alternatively, the steps can be performed by a combination of hardware, software and firmware and / or a human operator.

[0040] The various methods described herein can be practiced by combining one or more machine-readable storage media containing codes according to the present invention with appropriate standard computer hardware to execute the codes contained therein. Apparatus for implementing various embodiments of the present invention may include one or more computers (or one or more processors within a single computer) and a storage system containing or having network access to computer programs encoded according to the various methods described herein, and the method steps of the present invention may be completed by modules, routines, subroutines or sub-parts of a computer program product.

[0041] If the specification states that a component or feature "may," "could," "might," or "might" include or have a feature, that particular component or feature is not required to be included or have that feature.

[0042] As used in the specification herein and the claims that follow, the meanings of “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0043] Exemplary embodiments will now be described more fully below with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided for illustrative purposes only, and so that the present invention is thorough and complete, and the scope of the present invention is fully conveyed to those of ordinary skill in the art. However, the disclosed invention can be implemented in many different forms and should not be interpreted as being limited to the embodiments set forth herein. Various modifications are apparent to those skilled in the art. Without departing from the spirit and scope of the present invention, the general principles defined herein can be applied to other embodiments and applications. In addition, all statements of the embodiments of the present invention and their specific examples described herein are intended to cover their structural and functional equivalents. In addition, these equivalents are intended to include currently known equivalents and equivalents developed in the future (i.e., any element developed to perform the same function, regardless of the structure). Moreover, the terms and wording used are for the purpose of describing exemplary embodiments and should not be considered restrictive. Therefore, the present invention will be given the widest scope, including multiple replacements, modifications and equivalents consistent with the disclosed principles and features. For the sake of clarity, the details of the technical materials known in the technical field related to the present invention are not described in detail, so as not to unnecessarily obscure the present invention.

[0044] Therefore, for example, it will be understood by those of ordinary skill in the art that schematic diagrams, schematic diagrams, diagrams, etc. represent conceptual views or processes that embody the systems and methods of the present invention. The functions of the various elements shown in the figures can be provided by using dedicated hardware and hardware capable of executing related software. Similarly, any switches shown in the figures are only conceptual. Their functions can be performed by the operation of program logic, by dedicated logic, by the interaction of program control and dedicated logic, or even manually, and specific techniques can be selected by the entity that implements the present invention. It will be further understood by those of ordinary skill in the art that the exemplary hardware, software, processes, methods and / or operating systems described herein are for illustrative purposes and are therefore not intended to be limited to any specific named elements.

[0045] Example 1

[0046] like Figure 1-Figure 3 As shown:

[0047] This embodiment proposes a detection system for crane tracks in a dock based on a FLAG board, which is applied to a rail crane 100 in a dock. The detection system includes a controller, a photoelectric switch detection sensor installed on the rail crane 100, and a plurality of FLAG boards. Each FLAG board is arranged at intervals along the crane track 200 (each FLAG board is preferably installed on the ground) and is located on one side of the crane track 200. The photoelectric switch detection sensor is used to detect the FLAG board and transmit a photoelectric detection signal to the controller. The controller obtains first positioning information for positioning the rail crane through an encoder of a trolley travel drive motor of the rail crane 100. The detection system also includes a laser rangefinder sensor 400 and a magnetic induction switch detection sensor 300.

[0048] The controller is electrically connected to the photoelectric switch detection sensor, the laser distance sensor 400, and the magnetic induction switch detection sensor 300 respectively; the magnetic induction switch detection sensor 300 and the laser distance sensor 400 are both installed on the rail crane 100; the sensing head of the magnetic induction switch detection sensor 300 is located directly above the crane track 200 and the normal top surface of the crane track 200 is located within the detection range of the magnetic induction switch detection sensor 300, and the laser search detection point of the laser distance sensor 400 is located on the crane track 200;

[0049] When the sensing head of the magnetic induction switch detection sensor 300 is located above a damaged position of the crane rail 200 and the damaged position is not within the detection range of the magnetic induction switch detection sensor 300, the controller obtains a first damage trigger signal through the magnetic induction switch detection sensor 300; when the laser searchlight detection point of the laser ranging sensor 400 is located at the damaged position and the detection distance fed back by the laser ranging sensor 400 is greater than a threshold, the controller obtains a second damage trigger signal through the laser ranging sensor 400; the controller forms second positioning information for positioning the rail crane by coordinating the photoelectric detection signal of the photoelectric switch detection sensor, and the controller determines the position of the rail crane 100 according to the first positioning information and the second positioning information; the controller confirms the damaged position of the rail according to the triggering conditions of the first damage trigger signal and the second damage trigger signal and the position of the rail crane 100.

[0050] Optimally, the magnetic induction switch detection sensor 300 and the laser distance measurement sensor 400 are both located above the crane track 200 , and the magnetic induction switch detection sensor 300 and the laser distance measurement sensor 400 are spaced apart from each other.

[0051] Further optimized, the length direction of the crane rail 200 is horizontal, and the longitudinal coordinate of the virtual center point of the detection head of the magnetic induction switch detection sensor 300 is equal to the longitudinal coordinate of the virtual center point of the detection head of the laser ranging sensor 400.

[0052] Optimally, the virtual center point of the lateral distance between the magnetic induction switch detection sensor 300 and the laser ranging sensor 400 is the virtual end point of the virtual center line c of the trolley of the rail-mounted crane 100 .

[0053] Optimally, the length direction of the crane rail 200 is horizontal; the virtual axis of the magnetic induction switch detection sensor 300 is perpendicular to the length direction of the crane rail 200; and the laser emission direction of the laser ranging sensor 400 is perpendicular to the length direction of the crane rail 200.

[0054] Optimally, the controller warns or records the positioning information about the damaged position of the rail according to the triggering conditions of the first damage trigger signal and the second damage trigger signal and the position of the rail mounted crane 100 .

[0055] Optimally, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, that is, the damage position passes through the magnetic induction switch detection sensor 300 and is not within the detection range of the magnetic induction switch detection sensor 300, and the damage position passes through the laser ranging sensor 400 and the detection distance of the laser ranging sensor 400 to the track damage position is greater than a threshold, the controller uses the position of the FLAG plate corresponding to the specified sensor of the photoelectric switch detection sensor and the number of pulses specified by the encoder of the trolley travel drive motor to determine the position of the rail crane and the damage position of the track.

[0056] Example 2

[0057] Embodiment 2 is a further optimization and improvement based on embodiment 1;

[0058] like Figure 1-Figure 3 As shown:

[0059] This embodiment proposes a detection method for crane rails in a dock based on a FLAG board, characterized in that it is applied to the detection system as described in any technical solution of Embodiment 1, and the detection method comprises the following steps performed in sequence:

[0060] Step S1, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, the controller obtains the first positioning information through the encoder of the vehicle travel drive motor;

[0061] Step S2, the controller determines the second positioning information according to the photoelectric detection signal of the photoelectric switch detection sensor to the FLAG board;

[0062] In step S3, the controller adjusts the second positioning information according to the first positioning information, the speed position compensation value corresponding to the reaction time of the laser ranging sensor 400, and the speed position compensation value corresponding to the reaction time of the magnetic induction switch detection sensor 300, so as to obtain accurate positioning of the track damage position.

[0063] Optimally, in step 3, the controller obtains the first broken rail position value corresponding to the magnetic induction switch detection sensor 300 through the first positioning information and the speed position compensation value of the reaction time of the magnetic induction switch detection sensor 300, and the controller obtains the second broken rail position value corresponding to the laser ranging sensor 400 through the first positioning information and the speed position compensation value of the reaction time of the laser ranging sensor 400. The controller verifies the first broken rail position value and the second broken rail position value with each other, thereby obtaining accurate positioning of the track damage position.

[0064] Specifically, the magnetic induction switch detection sensor 300 and the laser distance measurement sensor 400 are combined and applied, and the magnetic induction switch detection sensor 300 and the laser distance measurement sensor 400 are respectively placed at an equal distance at the center of the vehicle (such as Figure 3 The two sides of the virtual center line c) are perpendicular to the track surface; the detection method is: the first broken rail position value Y 磁 = FLAG board real position value (when the signal of the magnetic induction switch detection sensor 300 is activated or the controller obtains the first damage trigger signal, the FLAG board real position value is the real-time position of the vehicle) + a value (a value is the installation position point of the magnetic induction switch detection sensor 300 and Figure 3 The lateral distance between the virtual center line c)-2000mm / s (maximum speed of the trolley)*trolley percentage speed / 100*magnetic induction limit reaction time of the magnetic induction switch detection sensor 300; the second broken rail position value Y 激光 = FLAG board real position value (when the signal of the laser ranging sensor 400 is activated or the controller obtains the second damage trigger signal, the real position value of the FLAG board is the real-time position of the vehicle) - b value (b value is the installation position point of the laser ranging sensor 400 and Figure 3 The lateral distance between the virtual center line c) - 2000mm / s (maximum speed of the truck) * truck percentage speed / 100 * laser sensing limit response time of the laser ranging sensor 400; and a value = b value.

[0065] Specifically, the laser ranging sensor 400 is installed on the rail crane through an L-shaped fixed bracket with adjustable angle. The laser ranging sensor 400 is specifically an LR-T series amplifier built-in TOF laser sensor (the preferred model is LR-TB5000); the laser of the laser ranging sensor 400 is directed at the track surface at a vertical angle, the distance is set and the distance is detected in real time to detect cracks, gaps, etc. in the track.

[0066] Specifically, according to the requirements of the on-site environment, equipment detection distance requirements and accuracy, the full metal magnetic proximity switch MF210 is selected as the magnetic induction switch detection sensor 300 of the present invention, and the magnetic induction switch detection sensor 300 is vertically placed in the center of the large vehicle (such as Figure 3 on the dotted center line c) and maintain a detection distance of 20 mm on the track.

[0067] Specifically, in step S3, the precise positioning of the track damage position is determined by the trolley position value F, the installation coordinate value of the laser ranging sensor, and the installation coordinate value of the magnetic induction switch detection sensor.

[0068] Example 3

[0069] Embodiment 3 is a further optimization and improvement based on embodiment 1;

[0070] like Figure 1-Figure 3 As shown:

[0071] This embodiment proposes a detection method for crane rails in a dock based on a FLAG board, which is applied to the detection system described in any technical solution of Embodiment 1. The detection method includes the following steps performed in sequence:

[0072] Step S1, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, the controller obtains the first positioning information through the encoder of the vehicle travel drive motor;

[0073] Step S2, the controller determines the second positioning information according to the photoelectric detection signal of the photoelectric switch detection sensor to the FLAG board;

[0074] In step S3, the controller adjusts the second positioning information according to the first positioning information and the speed position compensation value corresponding to the reaction time of the laser ranging sensor 400, so as to obtain the accurate positioning of the track damage position.

[0075] Optimally, in step S3, when the controller adjusts the second positioning information by using the first positioning information and the speed position compensation value corresponding to the reaction time of the laser ranging sensor 400, the accurate positioning of the track damage position is obtained;

[0076] The precise positioning of the track damage position is determined by the trolley position value F, the installation coordinate value of the laser distance sensor 400 and the installation coordinate value of the magnetic induction switch detection sensor 300;

[0077] The trolley position value F = Flag board real position value = Flag board basic position value X + / - Flag board width compensation value W + speed position compensation value C corresponding to the reaction time of the laser ranging sensor 400 + Flag board infrared counter-radiation device installation position compensation value D + value E calculated from the encoder pulse of the trolley travel drive motor;

[0078] The value E calculated from the encoder pulse of the vehicle travel drive motor corresponds to the first positioning information;

[0079] The Flag board basic position value X corresponds to the second positioning information.

[0080] Specifically, the basic position value X of the flag plate is an integer multiple of 6000mm (because the distance between each flag plate in the yard is 6m); the width compensation value W of the flag plate is 180mm. When looking from the electrical room side to the non-electrical room side, the trolley subtracts this value to the left and adds this value to the right; the speed position compensation value C corresponding to the reaction time of the laser ranging sensor 400 = the maximum speed of the trolley 2000mm / s* the corresponding speed percentage of the trolley

[0081] / 100* corresponds to the reaction time of the laser distance sensor 400 of 0.006s (fixed value); the installation position compensation value D of the infrared radiation device of the FLAG board is the position between the laser distance sensor 400 and the center of the trolley (such as Figure 3 The distance from the virtual center line c) is equal to 608mm; the value E calculated by the encoder pulse of the trolley travel drive motor = Factor*pulse value+offset (Factor and offset are fixed values);

[0082] Specifically, in step three, the broken rail position calculated by the laser sensing signal and the magnetic induction limit signal is checked against each other. The checking process is detailed in the following single-machine double-check logic for judging broken rails; in step three, the a value and the b value are respectively the physical quantities of the distance between the limit installation position and the center of the trolley, and the a value = b value is convenient for calculating the broken rail position; since there is a fracture width in the broken rail, when the two sensors are actuated and |y magnetic - y laser position| ≤ the set threshold, the broken rail position is determined to reduce false alarms of a single sensor.

[0083] The logic of single machine double check to judge the broken track is: if the magnetic induction limit trigger Magnetism_ls is TRUE;

[0084] Then Y_Magnetism = actual value of the trolley flag plate + 500cm (the distance acm between the limit installation position and the center position of the trolley) - 2000mm / s (maximum speed of the trolley) * trolley percentage speed / 100 * 0.04 (magnetic induction limit reaction time);

[0085] If the laser sensing limit trigger laser_ls is TRUE;

[0086] Then Y_laser = actual value of the trolley flag plate + 500cm (the distance between the limit installation position and the center position of the trolley, bcm) - 2000mm / s (maximum speed of the trolley) * trolley percentage speed / 100 * 0.025 (magnetic induction limit reaction time);

[0087] If Y_Magnetism-Y_laser<60, then Rail_Break (rail break detection variable) is true and it is confirmed to be a rail break;

[0088] After confirming the broken rail position, you can press the reset button to restore the broken rail detection variable to False.

[0089] Example 4

[0090] Embodiment 4 is a further optimization and improvement based on embodiment 1;

[0091] The detection system of the present invention also includes a camera and a remote communication connection device. The position of the broken rail is checked through the remote communication connection device, and the information is confirmed by using the camera to check the track status, so as to restore the equipment operation and production, effectively solving the false alarm problem of the prior art, and being able to remotely judge the quality of the track and the sensor, facilitating the selection of a day for maintenance, thereby ensuring the smoothness of production.

[0092] The above-mentioned embodiments only express several implementation methods of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the patent of the present invention. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A detection system for crane tracks in a dock based on a FLAG board, which is applied to a rail crane in a dock. The detection system comprises a controller, a photoelectric switch detection sensor installed on the rail crane, and a plurality of FLAG boards. Each FLAG board is arranged at intervals along the crane track and is located on one side of the crane track. The photoelectric switch detection sensor is used to detect the FLAG board and transmit a photoelectric detection signal to the controller. The controller obtains first positioning information for positioning the rail crane through an encoder of a trolley travel drive motor of the rail crane, and is characterized in that: The detection system also includes a laser distance sensor and a magnetic induction switch detection sensor; The controller is electrically connected to the photoelectric switch detection sensor, the laser distance sensor, and the magnetic induction switch detection sensor respectively; the magnetic induction switch detection sensor and the laser distance sensor are both installed on the rail crane; the sensing head of the magnetic induction switch detection sensor is located directly above the crane track and the normal top surface of the crane track is located within the detection range of the magnetic induction switch detection sensor, and the laser searchlight detection point of the laser distance sensor is located on the crane track; When the sensing head of the magnetic induction switch detection sensor is located above a damaged position on the crane track and the damaged position is not within the detection range of the magnetic induction switch detection sensor, the controller obtains a first damage trigger signal through the magnetic induction switch detection sensor; when the laser searchlight detection point of the laser ranging sensor is located on the damaged position and the detection distance fed back by the laser ranging sensor is greater than a threshold, the controller obtains a second damage trigger signal through the laser ranging sensor; the controller forms second positioning information for positioning the rail crane by coordinating the photoelectric detection signal of the photoelectric switch detection sensor, and the controller accurately locates the rail crane according to the first positioning information and the second positioning information; the controller confirms the damaged position of the rail according to the triggering conditions of the first damage trigger signal and the second damage trigger signal and the position of the rail crane.

2. The detection system for crane rails in a dock based on a FLAG board according to claim 1 is characterized in that: The magnetic induction switch detection sensor and the laser distance measuring sensor are both located above the crane track, and the magnetic induction switch detection sensor and the laser distance measuring sensor are spaced apart from each other.

3. The detection system for crane rails in a dock based on a FLAG board according to claim 2 is characterized in that: The virtual center point of the lateral distance between the magnetic induction switch detection sensor and the laser distance measuring sensor is the virtual end point of the virtual center line of the trolley of the rail-mounted crane.

4. The detection system for crane rails in a dock based on a FLAG board according to claim 1, characterized in that: The length direction of the crane track is horizontal; the virtual axis of the magnetic induction switch detection sensor is perpendicular to the length direction of the crane track; and the laser emission direction of the laser ranging sensor is perpendicular to the length direction of the crane track.

5. The detection system for crane rails in a dock based on a FLAG board according to claim 1, characterized in that: The controller warns or records the positioning information about the damaged position of the track according to the triggering conditions of the first damage trigger signal and the second damage trigger signal and the position of the rail crane.

6. The detection system for crane rails in a dock based on a FLAG board according to claim 1, characterized in that: When the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, that is, the damage position passes through the magnetic induction switch detection sensor and is not in the detection range of the magnetic induction switch detection sensor, and the damage position passes through the laser ranging sensor and the detection distance of the laser ranging sensor to the track damage position is greater than a threshold, the controller uses the position of the FLAG plate corresponding to the specified FLAG plate of the photoelectric switch detection sensor and the number of pulses specified by the encoder of the trolley travel drive motor to determine the position of the rail crane and the damage position of the track.

7. A method for detecting crane tracks in a dock based on a FLAG board, characterized in that: Applied to the detection system according to any one of claims 1 to 6, the detection method comprises the following steps performed in sequence: Step S1, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, the controller obtains the first positioning information through the encoder of the vehicle travel drive motor; Step S2, the controller determines the second positioning information according to the photoelectric detection signal of the photoelectric switch detection sensor to the FLAG board; In step S3, the controller adjusts the second positioning information according to the first positioning information, the speed position compensation value corresponding to the reaction time of the laser ranging sensor, and the speed position compensation value corresponding to the reaction time of the magnetic induction switch detection sensor, so as to obtain accurate positioning of the track damage position.

8. The method for detecting crane rails in a dock based on a FLAG board according to claim 7, characterized in that: In step 3, the controller obtains the first broken rail position value of the corresponding magnetic induction switch detection sensor through the first positioning information and the speed position compensation value of the reaction time of the corresponding magnetic induction switch detection sensor. The controller obtains the second broken rail position value of the corresponding laser ranging sensor through the first positioning information and the speed position compensation value of the reaction time of the corresponding laser ranging sensor. The controller verifies the first broken rail position value and the second broken rail position value against each other to obtain accurate positioning of the track damage position.

9. A method for detecting crane tracks in a dock based on a FLAG board, characterized in that: Applied to the detection system according to any one of claims 1 to 6, the detection method comprises the following steps performed in sequence: Step S1, when the controller obtains the first damage trigger signal and the second damage trigger signal at the same time, the controller obtains the first positioning information through the encoder of the vehicle travel drive motor; Step S2, the controller determines the second positioning information according to the photoelectric detection signal of the photoelectric switch detection sensor to the FLAG board; In step S3, the controller adjusts the second positioning information according to the first positioning information and the speed position compensation value corresponding to the reaction time of the laser ranging sensor, so as to obtain accurate positioning of the track damage position.

10. The method for detecting crane rails in a dock based on a FLAG board according to claim 9, characterized in that: In step S3, the precise positioning of the track damage position is determined by the trolley position value F, the installation coordinate value of the laser distance sensor and the installation coordinate value of the magnetic induction switch detection sensor; The trolley position value F = the actual position value of the FLAG board = the basic position value X of the FLAG board + / - the width compensation value W of the FLAG board + the speed position compensation value C corresponding to the reaction time of the laser ranging sensor + the installation position compensation value D of the FLAG board infrared counter-radiation device + the value E calculated by the encoder pulse of the trolley travel drive motor; The value E calculated from the encoder pulse of the vehicle travel drive motor corresponds to the first positioning information; The FLAG board basic position value X corresponds to the second positioning information.

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