Guide rail verticality detection system

Abstract

The invention relates to a guide rail verticality detection system, which comprises a single-chip microcomputer control module, a wireless communication module, a data acquisition module and an upper computer interaction module, and is characterized in that the data acquisition module comprises a two-dimensional PSD sensor, a laser range finder, a digital optical fiber sensor, a motor module and a guide rail robot; the two-dimensional PSD sensor, the laser range finder and the digital optical fiber sensor are all installed on the guide rail robot and are in bidirectional connection with the single-chip microcomputer control module, the two-dimensional PSD sensor collects the perpendicularity of the guide rails, the laser range finder collects the distance between the guide rails, and the digital optical fiber sensor collects the connection condition of the guide rails.

Description

Technical Field

[0001] The invention specifically relates to a guide rail verticality detection system. Background Art

[0002] The elevator first appeared in 1854. At the World Expo held in New York, American Elisha Graves Otis first showed his elevator to the world. Up to now, elevators are mainly divided into two types, escalator elevators and vertical lift elevators, of which vertical lift elevators account for 85% of the total number of existing elevators. From the emergence of elevators to today, elevator technology has been continuously optimized and updated. With the development of society and the advancement of science and technology, the improvement of elevator comfort and safety has become the basis for the development of elevators at a higher speed. With the continuous increase in high-rise buildings, the number of car-type elevators has also increased. The safety, efficiency and comfort of elevators have also become the basic and important technical performance requirements for elevator operation. Therefore, the installation and maintenance of elevators have also received more and more attention. As the guide device of the elevator, the elevator guide rail plays a vital role in the elevator system. The quality of its manufacturing and installation will directly affect whether the elevator can run safely and smoothly. In general, the elevator guide rails have undergone strict quality inspections before leaving the factory, and the manufacturing error has been controlled within a relatively ideal range. Therefore, the installation error generated during the installation process has become a factor affecting the final quality level of the elevator guide rail. The verticality error of the elevator guide rail is one of the main factors causing the vibration of the elevator car and accelerating the wear of the guide rail. The detection of the verticality error of the elevator guide rail is not only a key task in the elevator installation stage, but also in the normal use of the elevator, as the elevator running time increases, the elevator shaft foundation will settle, and the deformation caused by the elevator movement vibration will cause the guide rail to displace and deform, causing the elevator to shake, and further aggravate the deformation, resulting in a vicious cycle. Therefore, regular measurement of the verticality of the elevator guide rail to ensure the stable operation of the elevator is an important part of the daily maintenance of the elevator. The commonly used elevator guide rail verticality measurement method currently has the defects of cumbersome operation, long measurement time, low measurement accuracy, etc., which makes the installation and debugging of the guide rail require a lot of manpower and material resources to complete, increasing the installation cost of the elevator and reducing the competitiveness of the enterprise. Therefore, there is an urgent need for a measuring device that can be conveniently used for the verticality measurement of the guide rail during the installation and maintenance stage of the guide rail, saving a lot of manpower and material resources, and enhancing the intelligence of the elevator monitoring system. Summary of the invention

[0003] In view of the deficiencies in the prior art, the technical problem to be solved by the present invention is to provide a guide rail verticality detection system.

[0004] In order to solve the above technical problems, the technical solution adopted by the present invention is: a guide rail verticality detection system, including a single-chip control module, a wireless communication module, a data acquisition module and a host computer interaction module, the data acquisition module includes a two-dimensional PSD sensor, a laser rangefinder, a digital fiber optic sensor, a motor module and a guide rail robot; the two-dimensional PSD sensor, the laser rangefinder, and the digital fiber optic sensor are all installed on the guide rail robot and bidirectionally connected to the single-chip control module, the two-dimensional PSD sensor collects the verticality of the guide rail, the laser rangefinder sensor collects the guide rail spacing, and the digital fiber optic sensor collects the connection status of the guide rail.

[0005] Preferably, the wireless communication module includes a host computer wireless transmission station and a guide rail robot wireless transmission station.

[0006] A guide rail verticality detection method, using the guide rail verticality detection system, comprises the following steps: The host computer interaction module gives the initial signal to the single-chip control module through the wireless communication module. After the initialization is completed, the single-chip control module gives the data acquisition module a start signal; The guide rail robot moves along the direction of the elevator guide rail and starts to collect data, and sends the data back to the single-chip microcomputer module; The single-chip computer module transmits the data to the host computer interaction module through the wireless communication module. The transmitted data is processed by the processing software of the host computer interaction module and displayed in the form of charts. The staff uses charts to determine whether the data detected by the elevator guide rails at the sampling points meets the requirements.

[0007] Compared with the prior art, the present invention has the following beneficial effects: the present invention is based on the traditional elevator guide rail verticality detection robot, overcomes the shortcomings of the prior art, and further improves the interactive function of the elevator guide rail robot, can independently complete the elevator guide rail verticality detection, and can collect multi-parameter auxiliary guide rail verticality measurement such as working surface spacing, bracket deviation and guide rail joint, and transmit the test data for fusion processing to the host computer, thereby realizing automatic detection, real-time processing and transmission display of guide rail verticality data, and assisting decision-making. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 Schematic diagram of a guide rail robot control scheme according to an embodiment of the present invention.

[0009] Figure 2 Schematic diagram of the control principle of the motor according to the embodiment of the present invention. DETAILED DESCRIPTION

[0010] In order to make the above features and advantages of the present invention more obvious and easy to understand, embodiments are given below with reference to the accompanying drawings for detailed description as follows.

[0011] like Figure 1~2 As shown, a guide rail verticality detection system includes a single-chip control module, a wireless communication module, a data acquisition module and a host computer interaction module. The data acquisition module includes a two-dimensional PSD sensor, a laser rangefinder, a digital fiber sensor, a motor module and a guide rail robot; the two-dimensional PSD sensor, the laser rangefinder, and the digital fiber sensor are all installed on the guide rail robot and bidirectionally connected to the single-chip control module. The two-dimensional PSD sensor collects the verticality of the guide rail, the laser rangefinder collects the distance between the guide rails, and the digital fiber sensor collects the connection status of the guide rails. The motor module includes a motor driver and a motor.

[0012] In this embodiment, the wireless communication module includes a host computer wireless transmission station and a guide rail robot wireless transmission station.

[0013] A guide rail verticality detection method, using the guide rail verticality detection system, comprises the following steps: The host computer interaction module gives the initial signal to the single-chip control module through the wireless communication module. After the initialization is completed, the single-chip control module gives the data acquisition module a start signal; The guide rail robot moves along the direction of the elevator guide rail and starts to collect data, and sends the data back to the single-chip microcomputer module; The single-chip computer module transmits the data to the host computer interaction module through the wireless communication module. The transmitted data is processed by the processing software of the host computer interaction module and displayed in the form of charts. The staff uses charts to determine whether the data detected by the elevator guide rails at the sampling points meets the requirements.

[0014] With the single-chip microcomputer as the core, the guide rail robot is equipped with two-dimensional PSD sensors, laser rangefinders, digital fiber optic sensors and other acquisition devices. It outputs driving signals to drive the guide rail robot to move up and down on the guide rail according to the control instructions transmitted by the host computer through the wireless module to complete the detection work, and transmits the data back to the host computer through the wireless transmission module for storage, processing and display.

[0015] The control instructions are sent to the guide robot by the host computer through the wireless transmission module, which are divided into three basic signals: start, stop, and reverse. After receiving the signal instruction, the single-chip microcomputer sends a PWM drive signal to the motor driver. The motor receives the instruction and executes the command, drives the car to run the corresponding trajectory, and collects relevant data. The two-dimensional PSD sensor collects the verticality of the guide rail, the laser ranging sensor collects the spacing between the guide rails, and the digital fiber optic sensor collects the connection status of the guide rails. The collected data is transmitted to the single-chip microcomputer for processing and then transmitted to the host computer.

[0016] Data transmission includes the host computer transmitting it to the single-chip microcomputer through the wireless communication module, converting it into a driver control signal, and sending it to the guide robot as an operating instruction; the guide rail verticality, guide rail spacing and guide rail connection status data collected by each sensor are transmitted to the single-chip microcomputer for fusion processing and sent to the host computer through the wireless module for visual display, which is stored, analyzed and processed by the host computer.

[0017] The single-chip microcomputer in the single-chip microcomputer control module adopts a chip of STMicroelectronics (STMicroelectronics), model STM32F103C8T6.

[0018] The motor is driven by a PWM signal. The elevator guide rail verticality detection robot not only performs detection before installation, but can also replace traditional methods for maintenance purposes during later maintenance. The environment inside the elevator shaft is complex and there is serious signal interference. The PWM drive method of digital signals solves this problem well. It will not be affected by external noise like analog signals, nor will it be distorted and attenuated during the conversion between digital and analog signals. It solves the detection error and detection efficiency caused by environmental interference in the elevator shaft.

[0019] The guide rail detection data mainly adopts two-dimensional PSD sensors, laser ranging sensors, and digital fiber optic sensors. The collected information includes the verticality of the elevator guide rails, the location of the joints between the guide rails, and the distance between the guide rails. Each parameter is completed by an independent sensor, and the collection method uses a standard communication protocol to achieve universality as much as possible and facilitate the selection of devices.

[0020] PSD consists of three layers on a planar silicon substrate: the P-type layer on the surface, the N-type layer on the other side, and the I-layer in between. The incident light falling on the PSD is converted into photoelectrons, which are detected by the electrodes at both ends of the P-type layer and form a photocurrent. When a beam of light falls on the PSD, charges corresponding to the light energy are generated at the incident point, and the charges are collected by the electrodes through the P-type resistance layer. The P-type layer is a uniform resistance layer, and the photocurrent collected by the electrode is inversely proportional to the incident point and the electrode spacing. From this, the following formula can be derived: I1 and I2 are the photocurrents of the electrodes, and L and I0 represent the electrode spacing and the total photocurrent, respectively.

[0021] When the PSD geometric center is set as the coordinate origin: When one end of the PSD is set as the coordinate origin: As shown by formulas (3), (4), (7), and (8), different ratios can give corresponding positions of incident light points that are independent of light energy.

[0022] The LR-TB5000 laser sensor produced by KEYENCE is used to measure the distance between the top working surfaces of the guide rails. The detection range of this sensor is 60 to 5000mm, and the maximum accuracy is 0.1mm. This type of laser is a semiconductor laser. Compared with other types of lasers, it has high efficiency, small size, light weight, and simple structure, but low output power, poor directivity, and is greatly affected by ambient temperature. It is often used in occasions of ranging or aiming. Measurement principle: Install the laser sensor on the guide robot so that it can vertically illuminate the top working surface of the opposite guide rail. At the same time, refer to the spacing designed on the guide rail drawing, compare the measured value plus the distance from the laser emitting surface to the top working surface of the guide rail where the robot is located, and the spacing deviation between the two guide rails can be obtained. Assume that the theoretical spacing of the guide rails (that is, the size indicated on the drawing) is A, the measured value of the laser sensor is B, and the distance from the laser emitting surface to the top working surface of the guide rail where the robot is located is C, then the spacing deviation between the top surfaces of the two guide rails of the elevator is B+CA.

[0023] The data output by the sensor needs to be processed by the data acquisition module. Through the analysis of the PSD sensor and the laser rangefinder, their outputs are both voltage-type analog signals. In order to collect data with the designed accuracy of the sensor, the AD conversion chip needs to have 14-bit accuracy when converting the analog voltage signal of the sensor into a digital signal. The output end of the PSD-100 sensor is 4 analog outputs, and the laser sensor is 1 analog output, that is, the processor needs to collect 5 analog data channels. The AD converter integrated in the control chip used by the robot is 12-bit 10 channels. Although there are enough channels, it cannot achieve the accuracy that the sensor can measure. After multiple comparisons, the AD7606 chip produced by AD company was finally selected. The resolution of this type of conversion chip is 16 bits, and it can perform 8-channel synchronous data sampling simultaneously, with a sampling rate of up to 200k. For the filtering algorithm of data processing, in order to ensure the accuracy of system measurement, the method of sampling the same point multiple times to obtain the average value is generally used to reduce the error. However, the robot itself may also slide relative to the guide rail or cause data errors due to external vibration during operation. If the controller issues a measurement command, the robot may have moved between the next measurement command and the last measurement, causing additional errors. Through the analysis of the AD7606 chip, the maximum sampling depth supported by the chip is 8, that is, the chip can continuously sample the voltage up to 8 times and take the average value. Using this feature, continuous data measurement can be completed directly at the conversion chip end, improving the data measurement accuracy of the guide rail.

[0024] During the installation and use of the guide rail, the mounting parts and the guide rail joint position may become loose or misaligned due to installation errors or long-term use, or even fall off completely, causing serious safety hazards during the use of the elevator. Therefore, it is necessary to detect the joint position of the T-shaped guide rail and the mounting parts used to fix the guide rail to ensure that all parts are not missing. A digital fiber optic sensor is installed on the robot. When the robot moves to the joint position between the guide rails, the digital fiber optic sensor will feedback a signal different from the top surface position of the guide rail. In this way, it is possible to detect whether the guide rail joint position is correct.

[0025] The environment in the elevator shaft is complex, and there are many metal parts that may interfere with the signal. The distance of the elevator shaft is also relatively long. If wireless communication is used as the data exchange method between the host computer and the robot control system, it is easy for the robot to suddenly lose control or miss the data reception during the movement, resulting in large errors or even errors in the measurement results. In addition, the wireless method has high requirements for the robot power supply, which reduces the robot's endurance. Therefore, after analyzing the RS485 and CAN bus data communication modes, this system uses the industrial field CAN bus solution to complete the data interaction between the host computer and the inspection robot. The biggest feature of the CAN protocol is that there is no concept of host and slave, non-point-to-point transmission, and through the shielding of the filter, it can broadcast all devices on the bus, and theoretically supports unlimited node information on the network. At the same time, the CAN protocol has a unique error code, which can make the communication network have a strong error correction capability and allow asynchronous transmission and reception, which is very suitable for use in high-interference environments.

[0026] The start, stop, flip and other control functions of the single-chip microcomputer require a signal transmitter, and during the operation of the robot, the real-time detected PSD data, rail spacing data and rail joint conditions and other data need to be stored, analyzed and processed by the receiving device. After comprehensive consideration, the host computer is a more suitable command transmitter, and it can store and process the detection data in real time, and intuitively display the intuitive diagram of the rail verticality error. The length of the rail detected by the robot is different, and the length of the rail is generally tens of meters or even hundreds of meters. Therefore, the communication between the host computer and the single-chip microcomputer should not choose a wired connection method, which requires the selection of an intermediate medium that can realize the wireless transmission function. This application adopts the LM96 series of wireless data transmission modules produced by Shenzhen Huaaotong Company. In order to facilitate the connection with the single-chip microcomputer and the computer, the two LM96s are respectively equipped with HAC-UP / M1 and HAC-UP / MU shell interfaces. This module can control the robot through the wall. When the baud rate is 9600, the wireless transmission distance can reach 2000 meters. Control instructions can be sent and data can be received at any position within the detection range allowed by the data transmission module. To achieve normal transmission, the two modules need to set the same channel transmission through the 123rd position of the dip switch, and set the same verification mode through the fifth position of the dip switch. The communication between the single-chip microcomputer and the host computer is completed through the data transmission module. The start, stop, and reverse control signals of the motor are controlled by the host computer. After the system is powered on and initialized, the host computer sends a start signal, and the robot moves forward along the guide rail. When the robot moves forward, the PSD sensor, laser ranging sensor, and optical fiber sensor transmit the verticality data to the host computer through the data transmission module. When the host computer sends a stop and reverse signal, the control system executes the corresponding interrupt program.

[0027] Based on the detection principle and combined with the limitations of laboratory experimental conditions, in order to detect the accuracy of the robot's repeated test results, the robot's starting position was set to a fixed value. Due to the large amount of experimental data, we took the 10th to 20th detection points uploaded by the guide rail verticality detection device as sampling points for analysis and conducted three sets of experiments.

[0028] Experiment 1: The verticality deviation of the two guide rails is 0°; the parallel tilt deviation of the two guide rails is 5°; the tilt deviation of the tested guide rail A is 5°, and the opposite guide rail B is vertical; the tested guide rail is vertical and the tilt deviation of the opposite guide rail is 5°.

[0029] Table 1 Data records of Experiment 1

[0030] The experimental results show that when the verticality of both rails is 0°, the detection device feedback data, the PSD sensor feedback value deviation is 0°, the difference between the laser distance sensor measurement result and the standard distance is zero, and the fiber optic sensor feedback value is normal. When the dual rails are tilted and deviated by 5° at the same time, the detection device feedback data, the PSD sensor feedback value deviation is 5°, the difference between the laser distance sensor measurement result and the standard distance is zero, and the fiber optic sensor feedback value is normal. When the measured rail A is tilted and deviated by 5°, and the opposite rail B is vertical, the detection device feedback data, the PSD sensor return data deviation is 5.0°, the difference between the laser distance sensor measurement result and the standard distance is abnormal, and the fiber optic sensor feedback value is normal. When the measured rail A is vertical and has no deviation, and the opposite rail B is tilted, the detection device feedback data, the PSD sensor feedback value deviation is 0°, the difference between the laser distance sensor measurement result and the standard distance is abnormal, and the fiber optic sensor feedback value is normal. The above data show that in the tests of rail verticality, distance between rails, and rail joints, the detection effect is good and the automation reliability is high.

[0031] Experiment 2: Four groups of experiments were conducted with the guide rail being vertical, with a tilt deviation of 5°, a deviation of 10°, and a tilt deviation of 15°. The robot was also set up with fast and slow speed running experiments at each position of the guide rail, which can more accurately reflect whether the repeatability of the test results meets the requirements.

[0032] Table 2 Data records of Experiment 2

[0033] The experimental results show that when the verticality of the guide rail is intact, the PSD feedback value is 0° in the slow running test of the detection device, and the PSD feedback value is still 0° in the fast running test of the detection device. When the guide rail tilts and deviates by 5°, the PSD feedback value is 5° in the slow running test of the detection device, and the PSD feedback value is still 5° in the fast running test of the detection device. When the guide rail tilts and deviates by 10°, the PSD feedback value is 10° in the slow running test of the detection device, and the PSD feedback value is still 10° in the fast running test of the detection device. When the guide rail tilts and deviates by 15°, the PSD feedback value is 15° in the slow running test of the detection device, and the PSD feedback value is still 15° in the fast running test of the detection device. The above data show that in the test of the verticality of the guide rail, although there are occasional minor errors in the process of multiple experiments in the fast test, the overall detection effect is good and the automation reliability is high.

[0034] Experiment 3: Two groups of continuous guide rail tests were conducted, namely a standard group and a poor guide rail connection group.

[0035] Table 3 Experiment 3 data records

[0036] The experimental results show that when the rail joint is connected normally, the data returned by the acquisition device is normal, and when the rail joint is poorly connected, the acquisition device returns data and detects abnormal conditions. The detection effect is good.

[0037] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Any simple modification, equalization change and modification made to the above embodiment by any technician familiar with the field without departing from the content of the technical solution of the present invention according to the technical essence of the present invention shall fall within the scope of the present invention.

Claims

1. A guide rail verticality detection system, characterized in that: It includes a single-chip control module, a wireless communication module, a data acquisition module and a host computer interaction module. The data acquisition module includes a two-dimensional PSD sensor, a laser rangefinder, a digital fiber optic sensor, a motor module and a guide rail robot. The two-dimensional PSD sensor, the laser rangefinder and the digital fiber optic sensor are all installed on the guide rail robot and bidirectionally connected to the single-chip control module. The two-dimensional PSD sensor collects the verticality of the guide rail, the laser rangefinder collects the distance between the guide rails, and the digital fiber optic sensor collects the connection status of the guide rails.

2. The guide rail verticality detection system according to claim 1, characterized in that: The wireless communication module includes a host computer wireless transmission station and a guide rail robot wireless transmission station.

3. A guide rail verticality detection method, using the guide rail verticality detection system as claimed in claim 1, characterized in that: The following steps are included: The host computer interaction module gives the initial signal to the single-chip control module through the wireless communication module. After the initialization is completed, the single-chip control module gives the data acquisition module a start signal; The guide rail robot moves along the direction of the elevator guide rail, starts to collect data, and sends the data back to the single-chip microcomputer module; The single-chip computer module transmits the data to the host computer interaction module through the wireless communication module. The transmitted data is processed by the processing software of the host computer interaction module and displayed in the form of charts. (4) The staff uses the chart to determine whether the data detected by the elevator guide rail at the sampling point meets the requirements.

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