Coal mine monorail track automatic inspection device

Abstract

The present application provides a kind of coal mine monorail track automatic inspection device of monorail, including first and second machine case and machine case mounting frame;First machine case includes first box, first and second CCD cameras and wireless communication module arranged in first box;Second machine case includes second box, third CCD camera, first and second laser range finder arranged in second box, industrial computer for main control and image processing;First to third CCD camera, first and second laser range finder and wireless communication module are electrically connected with industrial computer;When using, first and second machine case are fixed on the top of the two sides of the cab of monorail vehicle by machine case mounting frame and make monorail track pass through between first and second machine case, and first and second machine case take power from the cab of monorail vehicle;Industrial computer is wirelessly communicated with coal mine monorail operation monitoring background by wireless communication module.The present application is relative to the similar device of prior art, its structure is simple, cost is lower, and work reliability is higher.

Description

Technical Field

[0001] This invention relates to the field of track inspection technology, specifically to an automatic track inspection device for a coal mine monorail crane. Background Technology

[0002] The monorail auxiliary transportation system is one of the most important auxiliary transportation systems in coal mines. The monorail system uses suspended rails, and the heavy-load monorail locomotives operate on these rails for extended periods, making them prone to cracks, misalignment, deformation, bending, loosening, and detachment of rail connectors. If these problems are not detected in time, they can lead to safety hazards and even accidents. Therefore, the monorail system needs to be inspected regularly to identify potential problems. Traditionally, monorail system inspections in coal mines rely on manual inspections. Manual inspections suffer from high labor intensity for inspectors, long inspection cycles, and reliance on the inspector's experience and subjective factors. In short, manual inspections clearly lack real-time capability, have low efficiency, and are unreliable. To address the aforementioned problems of manual inspection, the industry has focused on developing devices capable of automatically inspecting monorail tracks in coal mines in recent years. For example, Chinese patent document CN114909582A discloses a monorail track inspection robot, which mainly consists of a base plate 1, moving parts 2, guiding parts 3, driving parts 4, sensing parts 5, and a shell 6. This monorail track inspection robot is a battery-powered, automatically driven wheeled robot that can automatically inspect monorail tracks, solving the problems of traditional manual inspection. The monorail track inspection robot has the following shortcomings: First, because it operates autonomously on the monorail track, it can only perform inspections when no monorail crane is running on the track, significantly impacting its real-time performance and potentially posing safety hazards during monorail crane operation. Second, the robot relies on batteries for power, and since monorail tracks are typically long, batteries need frequent replacements, which is inconvenient. Third, the robot has a complex structure, high cost, and low reliability. Summary of the Invention

[0003] The purpose of this invention is to provide an automatic inspection device for coal mine monorail crane tracks that is simple in structure, low in cost, and has high real-time inspection and reliability during operation, in order to solve the problems existing in the prior art.

[0004] The technical solution of the present invention is as follows: The automatic inspection device for monorail cranes in coal mines of the present invention is characterized by the following structural features: it includes a first housing, a second housing, and a housing mounting frame; the first housing includes a first box body, a first CCD camera, a second CCD camera, and a wireless communication module disposed within the first box body; the second housing includes a second box body, a third CCD camera disposed within the second box body, first and second laser rangefinders for correspondingly issuing start and stop shooting trigger signals for the first to third CCD cameras, and a device for main control and image analysis processing to determine whether the monorail crane track is in good condition. The industrial control computer malfunctions; the first to third CCD cameras, the first and second laser rangefinders, and the wireless communication module are electrically connected to the industrial control computer; in use, the first and second chassis are fixed on the top of the monorail crane cab on both sides by chassis mounting brackets, so that the monorail crane track passes between the first and second chassis, and the first and third CCD cameras are set opposite each other, and the second CCD camera is set facing the front of the monorail crane. The first and second chassis are powered from the monorail crane cab; the industrial control computer communicates wirelessly with the coal mine monorail crane operation monitoring backend through the wireless communication module.

[0005] A further embodiment is as follows: the first chassis of the aforementioned first chassis includes a first base plate, a first mounting plate fixedly mounted on the first base plate, and a first cover detachably and fixedly connected to the first base plate and covering the first mounting plate inside. An observation hole is provided on each of the upper two sides of the first cover. The first and second CCD cameras and the wireless communication module are respectively fixedly mounted on the first mounting plate and located inside the first cover. The mounting positions of the first and second CCD cameras are respectively matched with one observation hole of the first cover.

[0006] A further embodiment is as follows: the first chassis further includes a first power module and a first circuit board sealed box, which are fixedly mounted on the first mounting plate and located inside the first cover. The first circuit board sealed box is provided with a first circuit board for controlling the opening and closing actions of the first and second CCD cameras. The first power module is used to draw power from the monorail locomotive cab and convert it into the working power required by the first chassis.

[0007] A further embodiment is as follows: The second enclosure of the aforementioned second chassis includes a second base plate, a second mounting plate fixedly mounted on the second base plate, and a second cover detachably fixedly connected to the second base plate and covering the second mounting plate inside. The upper side of the second cover is provided with an observation hole at the front, middle, and rear. The third CCD camera, the first and second laser rangefinders, and the industrial control computer are respectively fixedly mounted on the second mounting plate and located inside the second cover. The installation positions of the first laser rangefinder, the third CCD camera, and the second laser rangefinder are respectively matched with the observation holes at the front, middle, and rear of the second cover.

[0008] A further embodiment is that the second chassis also includes a second power module and a second circuit board sealed box, which are fixedly mounted on the second mounting plate and located inside the second housing. The second circuit board sealed box is provided with a second circuit board for controlling the opening and closing actions of the third CCD camera and the first and second laser rangefinders. The second power module is used to draw power from the monorail locomotive cab and convert it into the working power required by the second chassis.

[0009] A further solution is to make the aforementioned industrial control computer an embedded industrial control computer.

[0010] A further solution is that the aforementioned automatic inspection device for the monorail crane in coal mines is fixedly installed on the top of the monorail crane cab at both the front and rear ends.

[0011] A further solution is that the aforementioned automatic inspection device for coal mine monorails also includes a gas concentration sensor installed on the first housing, or on the second housing, or on both the first and second housings, for real-time detection of the concentration of harmful gases in the monorail's operating environment.

[0012] The present invention has the following positive effects: (1) The inspection device of the present invention adopts the structural design of the first and second housings, and when in use, the first and second housings are fixedly installed on the top of the monorail crane cab and move with the monorail crane. It automatically detects the track status of the monorail crane in real time, thereby effectively solving the technical problem that the existing self-propelled inspection device can only carry out inspection when there is no monorail crane running on the monorail track, which leads to insufficient real-time inspection and still causes safety hazards in the operation of the monorail crane. (2) The inspection device of the present invention is powered by the monorail crane on which it is installed, and the inspection distance is almost unlimited, thereby effectively solving the technical problem that the inspection distance of the existing self-propelled inspection device is limited and the battery replacement is very inconvenient. (3) The inspection device of the present invention adopts two box-type structures, which can be conveniently and reliably installed on the monorail crane. During inspection, it moves with the monorail crane. Compared with the existing self-propelled inspection device, its structure is simple, its cost is low, and its work reliability is higher. (4) All relevant detection components of the inspection device of the present invention are housed inside the box, thereby enabling it to be effectively applied to the harsh working environment of coal mines. (5) By setting up a gas sensor, the inspection device of the present invention can detect the concentration of harmful gases in underground coal mines in real time, further increasing its cost-effectiveness. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the first chassis of the present invention; Figure 2 To remove Figure 1 A schematic diagram of the structure behind the first casing; Figure 3 To and Figure 2 Observe the structural diagram when the orientation is reversed; Figure 4 This is a schematic diagram of the structure of the second chassis of the present invention; Figure 5 To remove Figure 4 A schematic diagram of the structure behind the second cover. Figure 6 This is a schematic diagram of the structure of the present invention installed above the cab of a monorail crane during use.

[0014] The reference numerals in the above figures are as follows: First chassis 1, first housing 11, first cover 11-1, first base plate 11-2, first mounting plate 11-3, first CCD camera 12, second CCD camera 13, first power module 14, first circuit board sealing box 15, wireless communication module 16. Second chassis 2, second enclosure 21, second cover 21-1, second base plate 21-2, second mounting plate 21-3, third CCD camera 22, first laser rangefinder 23, second laser rangefinder 24, industrial computer 25, second power module 26, second circuit board sealing box 27, gas concentration sensor 28. Chassis mounting bracket 3; Monorail track 101, track connector 102, lifting chain 103, monorail locomotive cab 104. Detailed Implementation

[0015] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0016] (Example 1) See Figures 1 to 6 The automatic track inspection device for a coal mine monorail crane in this embodiment is an image detection-based track inspection device, which mainly consists of a first housing 1, a second housing 2, and two housing mounting frames 3.

[0017] See Figures 1 to 3 The first chassis 1 mainly consists of a first housing 11 and a first CCD camera 12, a second CCD camera 13, a first power module 14, a first circuit board sealing box 15 and a wireless communication module 16 disposed in the first housing 11.

[0018] As a specific implementation, the first housing 11 is mainly composed of a first cover 11-1, a first base plate 11-2 and a first mounting plate 11-3. The first mounting plate 11-3 is vertically fixed on the first base plate 11-2. The first cover 11-1 is detachably fixed to the first base plate 11-2 and covers the first mounting plate 11-3 inside. An observation hole is opened on each of the upper two sides of the first cover 11-1.

[0019] The first CCD camera 12, the second CCD camera 13, the first power module 14, the first circuit board sealing box 15, and the wireless communication module 16 are respectively fixed on the first mounting plate 11-3 and located inside the first cover 11-1. The installation positions of the first CCD camera 12 and the second CCD camera 13 each mate with an observation hole in the first cover 11-1. The first CCD camera 12 and the second CCD camera 13 are used to capture images during inspection. The first power module 14 is used to convert external power into the power required for the operation of the first chassis 1. The first circuit board sealing box 15 contains a first circuit board (not shown in the figure) for controlling the opening and closing of the first CCD camera 12 and the second CCD camera 13. The purpose of covering the first circuit board with the first circuit board sealing box 15 is to prevent the circuits and electronic components on the first circuit board from malfunctioning or being damaged by coal mine dust, thereby increasing its operational reliability. The wireless communication module 16 is used in this embodiment for the automatic inspection device of the coal mine monorail track to remotely communicate with the monorail operation monitoring backend in the coal mine during inspection, so as to send the detection results to the monitoring backend. In this embodiment, the wireless communication module 16 preferably uses a commercially available wireless bridge. It should be noted that the first CCD camera 12 and the second CCD camera 13 are both commercially available components, and the first power module 14 and the first circuit board located in the first circuit board sealed box 15 are both mature technologies, and their specific structures and working principles will not be described in detail.

[0020] See Figure 4 and Figure 5 The second chassis 2 mainly consists of a second housing 21, a third CCD camera 22, a first laser rangefinder 23, a second laser rangefinder 24, an industrial control computer 25, a second power module 26, a second circuit board sealing box 27, and a gas concentration sensor 28.

[0021] As a specific implementation, the second housing 21 mainly consists of a second cover 21-1, a second base plate 21-2, and a second mounting plate 21-3. The second mounting plate 21-3 is vertically fixed on the second base plate 21-2. The second cover 21-1 is detachably fixed to the first base plate 21-2 and covers the second mounting plate 21-3 inside. The upper side of the second cover 11-1 is provided with an observation hole in the front, middle, and rear (distinguished by the direction of travel during use). Preferably, the second cover 11-1 is also provided with a gas sensor mounting hole.

[0022] The third CCD camera 22, the first laser rangefinder 23, the second laser rangefinder 24, the industrial control computer 25, the second power module 26, and the second circuit board sealing box 27 are all fixedly mounted on the second mounting plate 21-3 and located inside the second cover 21-1. The installation positions of the first laser rangefinder 23, the third CCD camera 22, and the second laser rangefinder 24 are respectively matched with the observation holes at the front, middle, and rear of the second cover 11-1. The third CCD camera 22 is used to capture images during inspection. The first laser rangefinder 23 and the second laser rangefinder 24 are respectively used to provide trigger signals for each CCD camera to start and stop capturing images to the industrial control computer 25. The industrial control computer 25 is used for the main control of this device and to determine whether a track fault has occurred through image analysis and processing. In this embodiment, the industrial control computer 25 is preferably an embedded industrial control computer with advantages such as dustproof, moisture-proof, vibration-proof, strong anti-electromagnetic interference capability, and wide temperature operation capability, so as to adapt to the harsh working conditions in the coal mine. The second power module 26 converts the external power supply into the power required for the operation of the second chassis 2. The second circuit board sealed box 27 contains a second circuit board (not shown in the figure) for controlling the opening and closing of the third CCD camera 22, the first laser rangefinder 23, and the second laser rangefinder 24. Similarly, the third CCD camera 22, the first laser rangefinder 23, the second laser rangefinder 24, and the industrial control computer 25 are all commercially available components. The second power module 26 and the second circuit board in the second circuit board sealed box 27 represent mature technologies, and their specific structures and working principles will not be elaborated upon. The industrial control computer 25 analyzes and processes images captured by each CCD camera to determine whether a track fault has occurred; this is also a mature existing technology and will not be elaborated upon.

[0023] Gas concentration sensor 28 is a preferred configuration. Gas concentration sensor 28 is used to detect the concentration of harmful gases such as methane and carbon monoxide in the monorail operating environment in real time. The number and type of gas concentration sensor 28 can be set according to the needs of detecting the type of harmful gas. Gas concentration sensor 28 can be set on the second housing 2, or on the first housing 1, or on both the second housing 2 and the first housing 1.

[0024] The aforementioned first CCD camera 12 and second CCD camera 13 are electrically connected to the industrial control computer 25 via the first circuit board. The third CCD camera 22, the first laser rangefinder 23, and the second laser rangefinder 24 are electrically connected to the industrial control computer 25 via the second circuit board. The wireless communication module 16 and the gas concentration sensor 28 are electrically connected to the industrial control computer.

[0025] The installation and working principle of the automatic inspection device for coal mine monorails in this embodiment are briefly described below: See Figure 6 In this embodiment, when the automatic inspection device for a coal mine monorail is used, two mounting brackets 3 are fixedly installed on the upper sides of the monorail locomotive cab 104. The first housing 1 and the second housing 2 are each detachably fixed on one mounting bracket 3, with the first CCD camera 12 of the first housing 1 and the third CCD camera 22 of the second housing 2 facing each other. The first housing 1 and the second housing 2 are respectively located on both sides of the monorail track 101, and the heights of the first CCD camera 12, the third CCD camera 22, the first laser rangefinder 23, and the second laser rangefinder 24 are matched with the height of the track connector 102. The first power module 14 of the first housing 1 and the second power module 26 of the second housing 2 are electrically connected to the power supply of the monorail locomotive cab 104 so that the device is powered from the monorail locomotive cab 104.

[0026] During the operation of the monorail crane on the monorail track 101, the first laser rangefinder 23 and the second laser rangefinder 24 are powered on. When the monorail crane cab 104 moves towards the track connector 102, the laser emitted by the first laser rangefinder 23 is blocked by the track connector 102, causing a sudden signal change in the signal sent by the first laser rangefinder 23 to the industrial control computer 25. That is, the first laser rangefinder 23 sends a trigger signal to the industrial control computer 25 to start shooting. At this time, the industrial control computer 25 controls the first CCD camera 12, the second CCD camera 13, and the third CCD camera 22 to start shooting. The first CCD camera 12 and the third CCD camera 22 respectively shoot both sides of the track connector 102. The system takes pictures of the monorail track 101, the next track connector 102, and the chain 103 above it. Simultaneously, a second CCD camera 13, located at the front of the first housing 1, takes pictures of the monorail track 101, the next track connector 102, and the chain 103 above it, all located in front of the monorail locomotive cab 104. These pictures are sent to the industrial control computer 25, which automatically analyzes and processes them to determine if the monorail track 101 is bent or deformed, or if the track connector 102 and chain 103 are broken. When the industrial control computer 25 detects a fault, it sends an alarm to the monorail operation monitoring backend via the wireless communication module 16 and uploads the corresponding image files. When the second laser rangefinder 24 sends a trigger signal to the industrial control computer 25 to stop shooting, the industrial control computer 25 controls the first CCD camera 12, the second CCD camera 13 and the third CCD camera 22 to stop shooting until the monorail crane cab 104 moves to the next track connector 102 and repeats the above actions. This cycle is repeated to achieve full automatic inspection of the monorail crane track 101 on which the monorail crane runs.

[0027] During the operation of the monorail crane, the gas concentration sensor 28 continuously detects the concentration of the corresponding harmful gases in the environment and sends the detection signal to the industrial control computer 25. When the industrial control computer 25 determines that the harmful gas exceeds the standard, it alarms the monorail crane operation monitoring background through the wireless communication module 16 and uploads the corresponding data.

[0028] Since monorail cranes in actual operation usually travel in both directions, each monorail crane has a driver's cab 104 at both the front and rear ends. Therefore, as a preferred embodiment, an automatic track inspection device for coal mine monorail cranes is also installed on the rear monorail crane driver's cab 104 of the monorail crane with two driver's cabs 104. On the one hand, the inspection device at the rear end can re-inspect the track after the monorail crane has passed to prevent the track from malfunctioning after the monorail crane has passed, thereby improving the real-time performance of track inspection. On the other hand, it facilitates track inspection when the monorail crane is returning.

[0029] The above embodiments are descriptions of specific implementations of the present invention, and not limitations thereof. Those skilled in the art can make various modifications and changes without departing from the spirit and scope of the present invention to obtain corresponding equivalent technical solutions. Therefore, all equivalent technical solutions should be included in the patent protection scope of the present invention.

Claims

1. An automatic inspection device for a coal mine monorail crane track, characterized in that: The system includes a first chassis, a second chassis, and a chassis mounting bracket. The first chassis includes a first housing, a first CCD camera, a second CCD camera, and a wireless communication module disposed within the first housing. The second chassis includes a second housing, a third CCD camera disposed within the second housing, first and second laser rangefinders for correspondingly issuing start and stop shooting trigger signals from the first to third CCD cameras, and an industrial control computer for main control and determining whether a fault has occurred in the monorail track through image analysis and processing. The first to third CCD cameras, the first and second laser rangefinders, and the wireless communication module are respectively connected to the industrial control computer. In use, the first and second housings are fixed on the top of the monorail crane cab on both sides by the housing mounting bracket, so that the monorail crane track passes between the first and second housings. The first and third CCD cameras are set opposite each other, and the second CCD camera is set facing the front of the monorail crane. The first and second housings are powered by the monorail crane cab. The industrial control computer communicates wirelessly with the coal mine monorail crane operation monitoring backend through the wireless communication module.

2. The automatic inspection device for monorail crane tracks in coal mines according to claim 1, characterized in that: The first enclosure of the first chassis includes a first base plate, a first mounting plate fixedly mounted on the first base plate, and a first cover detachably fixedly connected to the first base plate and covering the first mounting plate inside. An observation hole is provided on each of the upper two sides of the first cover. The first and second CCD cameras and the wireless communication module are respectively fixedly mounted on the first mounting plate and located inside the first cover. The mounting positions of the first and second CCD cameras are respectively matched with one observation hole of the first cover.

3. The automatic inspection device for coal mine monorail cranes according to claim 2, characterized in that: The first chassis also includes a first power module and a first circuit board sealed box, which are fixedly mounted on the first mounting plate and located inside the first cover. The first circuit board sealed box is provided with a first circuit board for controlling the opening and closing of the first and second CCD cameras. The first power module is used to draw power from the cab of the monorail crane and convert it into the working power required by the first chassis.

4. The automatic inspection device for coal mine monorail cranes according to claim 1, characterized in that: The second enclosure of the second chassis includes a second base plate, a second mounting plate fixedly mounted on the second base plate, and a second cover detachably fixedly connected to the second base plate and covering the second mounting plate inside. The upper side of the second cover is provided with an observation hole at the front, middle, and rear. The third CCD camera, the first and second laser rangefinders, and the industrial control computer are respectively fixedly mounted on the second mounting plate and located inside the second cover. The installation positions of the first laser rangefinder, the third CCD camera, and the second laser rangefinder are respectively matched with the observation holes at the front, middle, and rear of the second cover.

5. The automatic inspection device for coal mine monorail cranes according to claim 4, characterized in that: The second chassis also includes a second power module and a second circuit board sealed box, which are fixedly mounted on the second mounting plate and located inside the second cover. The second circuit board sealed box is provided with a second circuit board for controlling the opening and closing actions of the third CCD camera and the first and second laser rangefinders. The second power module is used to draw power from the monorail locomotive cab and convert it into the working power required by the second chassis.

6. The automatic inspection device for coal mine monorail cranes according to claim 1, characterized in that: The industrial control computer is an embedded industrial control computer.

7. The automatic inspection device for monorail crane tracks in coal mines according to any one of claims 1 to 6, characterized in that: It has a set of monorail cranes fixedly installed on the top of the cabs at both the front and rear ends.

8. The automatic inspection device for coal mine monorail cranes according to any one of claims 1 to 6, characterized in that: It also includes a gas concentration sensor, which is installed on the first chassis, or on the second chassis, or on the first and second chassis respectively, for real-time detection of the concentration of harmful gases in the monorail operating environment.

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