Monitoring system for crack and broken rail of chain rail

Abstract

The invention discloses a chain track crack and broken track monitoring system, and relates to the technical field of chain tracks. The chain track crack and broken track monitoring system comprises an equipment end and a system module end, and the system module end comprises a sensor module, a graph acquisition module, a data acquisition and transmission module, a data layer analysis and processing module, an early warning and display module and a power supply and protection module; the equipment end comprises an ultrasonic sensor, a laser displacement sensor, an industrial high-definition camera, an image processor, a multi-channel high-speed data acquisition card, a high-speed Ethernet switch, an optical fiber transceiver, a data analysis server, a GPU acceleration card, an audible and visual alarm, a large-screen display, an uninterruptible power supply, a power adapter and a waterproof, dustproof and shockproof shell; according to the system, the monitoring precision can be improved, micro cracks and deformation inside and on the surface of the chain track can be more accurately detected by adopting various advanced sensors, missing detection is effectively avoided, and the real-time performance and the reliability are enhanced.

Description

Technical Field

[0001] The invention relates to the technical field of chain tracks, and in particular to a monitoring system for cracks and broken tracks of chain tracks. Background Art

[0002] Chain tracks play an important role in material transportation and transmission in many industrial fields. However, due to long-term operation, load changes, environmental factors and other factors, chain tracks are prone to cracks and even broken tracks. Traditional monitoring methods often rely on regular manual inspections, which is not only inefficient, but also difficult to detect early tiny cracks, which can easily lead to missed detections. At the same time, some monitoring systems based on simple sensors have problems such as low accuracy and insufficient reliability, and cannot meet the high requirements for the safe operation of chain tracks. With the continuous improvement of the degree of industrial automation, the demand for systems that can monitor chain track cracks and broken tracks in real time, accurately and intelligently is becoming increasingly urgent. Summary of the invention

[0003] The purpose of the present invention is to solve at least one of the technical problems existing in the prior art and to provide a chain track crack and broken rail monitoring system that can solve the above-mentioned problem.

[0004] To achieve the above object, the present invention provides the following technical solutions: a chain track crack and broken rail monitoring system, comprising a device end and a system module end, wherein the system module end comprises a sensor module, a graphics acquisition module, a data acquisition and transmission module, a data layer analysis and processing module, an early warning and display module and a power supply and protection module;

[0005] The equipment side includes ultrasonic sensors, laser displacement sensors, industrial high-definition cameras, image processors, multi-channel high-speed data acquisition cards, high-speed Ethernet switches, fiber optic transceivers, data analysis servers, GPU accelerator cards, sound and light alarms, large-screen displays, uninterruptible power supplies, power adapters and waterproof, dustproof and shockproof casings.

[0006] Preferably, the ultrasonic sensor and laser displacement sensor are electrically connected to the sensor module, the industrial high-definition camera and image processor are electrically connected to the image acquisition module, the multi-channel high-speed data acquisition card, high-speed Ethernet switch and optical fiber transceiver are signal-connected to the data acquisition and transmission module, the data analysis server and GPU accelerator card are electrically connected to the data analysis and processing module, the sound and light alarm and large-screen display are electrically connected to the early warning and display module, and the uninterruptible power supply, power adapter and waterproof, dustproof and shockproof casing are all external devices of the power supply and protection module.

[0007] Preferably, the ultrasonic sensor is used to detect cracks and defects inside the chain track, and the laser displacement sensor measures the displacement and deformation of the chain track to assist in determining cracks and broken rails.

[0008] Preferably, the industrial high-definition camera takes real-time images of the chain track, and the image processor performs denoising, enhancement and other processing on the collected images.

[0009] Preferably, the multi-channel high-speed data acquisition card collects data from the sensor and the image module, and the high-speed Ethernet switch and the optical fiber transceiver transmit the collected data to the analysis module quickly and stably.

[0010] Preferably, the data analysis server runs complex algorithms and models to analyze and judge the data.

[0011] Preferably, the sound and light alarm will promptly sound an alarm when an abnormality is detected.

[0012] Compared with the prior art, the present invention has the following beneficial effects:

[0013] 1. The chain track crack and broken rail monitoring system can improve the monitoring accuracy: by adopting a variety of advanced sensors, such as ultrasonic sensors and laser displacement sensors, it can more accurately detect tiny cracks and deformations inside and on the surface of the chain track, effectively avoiding missed detection, and enhancing real-time and reliability: the system can collect and analyze data in real time, quickly issue early warnings, and promptly detect potential cracks and broken rail risks, greatly improving the reliability of chain track operation and reducing labor costs: reducing dependence on manual inspections, saving labor costs, while avoiding the subjectivity and inaccuracy that may exist in manual inspections, and preventing accidents in advance: early detection of cracks and broken rail hazards buys valuable time for taking repair and maintenance measures, helps prevent major accidents, and ensures the safety of personnel and equipment.

[0014] 2. The chain track crack and broken monitoring system improves production efficiency: reduces production interruptions and equipment damage caused by chain track failures, thereby improving the efficiency and stability of the entire production process. Intelligent data analysis: with the help of machine learning and deep learning technology, a large amount of monitoring data is deeply analyzed to better understand and predict the health of the chain track, providing a scientific basis for maintenance decisions. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention is further described below in conjunction with the accompanying drawings and embodiments:

[0016] Figure 1 It is a schematic diagram of the connection between the system modules and devices of the present invention. DETAILED DESCRIPTION

[0017] This section will describe in detail the specific embodiments of the present invention. The preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the accompanying drawings is to supplement the description of the text part of the specification with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present invention, but it cannot be understood as a limitation on the scope of protection of the present invention.

[0018] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., and orientations or positional relationships indicated are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0019] In the description of the present invention, "greater than", "less than", "exceed" etc. are understood as not including the number itself, and "above", "below", "within" etc. are understood as including the number itself. If there is a description of "first" or "second", it is only used for the purpose of distinguishing technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features.

[0020] In the description of the present invention, unless otherwise clearly defined, terms such as setting, installing, connecting, etc. should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in the present invention in combination with the specific content of the technical solution.

[0021] See also Figure 1 ,The present invention provides a technical solution: a chain track crack and broken rail monitoring system, including a device end and a system module end, the system module end includes a sensor module, a graphics acquisition module, a data acquisition and transmission module, a data layer analysis and processing module, an early warning and display module and a power supply and protection module;

[0022] The equipment side includes ultrasonic sensors, laser displacement sensors, industrial high-definition cameras, image processors, multi-channel high-speed data acquisition cards, high-speed Ethernet switches, fiber optic transceivers, data analysis servers, GPU accelerator cards, sound and light alarms, large-screen displays, uninterruptible power supplies, power adapters and waterproof, dustproof and shockproof casings.

[0023] Furthermore, the ultrasonic sensor and laser displacement sensor are electrically connected to the sensor module, the industrial high-definition camera and image processor are electrically connected to the image acquisition module, the multi-channel high-speed data acquisition card, high-speed Ethernet switch and fiber optic transceiver are signal-connected to the data acquisition and transmission module, the data analysis server and GPU accelerator card are electrically connected to the data analysis and processing module, the sound and light alarm and large-screen display are electrically connected to the early warning and display module, and the uninterruptible power supply, power adapter and waterproof, dustproof and shockproof casing are all external devices of the power supply and protection module.

[0024] Furthermore, ultrasonic sensors are used to detect cracks and defects inside the chain track, and laser displacement sensors measure the displacement and deformation of the chain track to assist in determining cracks and broken rails.

[0025] Furthermore, the industrial high-definition camera: takes real-time images of the chain track, and the image processor: performs denoising and enhancement on the collected images;

[0026] Furthermore, a multi-channel high-speed data acquisition card collects data from sensors and image modules, and a high-speed Ethernet switch and optical fiber transceiver transmit the collected data to the analysis module quickly and stably.

[0027] Furthermore, the data analysis server: runs complex algorithms and models to analyze and judge the data.

[0028] Furthermore, the sound and light alarm can sound an alarm in time when an abnormality is detected.

[0029] Furthermore, the system can improve monitoring accuracy: by adopting a variety of advanced sensors, such as ultrasonic sensors and laser displacement sensors, it can more accurately detect tiny cracks and deformations inside and on the surface of the chain track, effectively avoiding missed detection, and enhancing real-time and reliability: the system can collect and analyze data in real time, quickly issue early warnings, and promptly detect potential cracks and broken rails, greatly improving the reliability of chain track operation and reducing labor costs: reducing dependence on manual inspections, saving labor costs, while avoiding the subjectivity and inaccuracy that may exist in manual inspections, and preventing accidents in advance: early detection of cracks and broken rails buys valuable time for taking repair and maintenance measures, helps prevent major accidents, and ensures the safety of personnel and equipment.

[0030] Furthermore, the system improves production efficiency: it reduces production interruptions and equipment damage caused by chain track failures, thereby improving the efficiency and stability of the entire production process, and intelligent data analysis: with the help of machine learning and deep learning technology, in-depth analysis of large amounts of monitoring data can better understand and predict the health of the chain track, providing a scientific basis for maintenance decisions.

[0031] The embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Various changes can be made within the knowledge scope of ordinary technicians in the technical field without departing from the purpose of the present invention.

Claims

1. A chain track crack and broken rail monitoring system, comprising a device end and a system module end, characterized in that: The system module end includes a sensor module, a graphics acquisition module, a data acquisition and transmission module, a data layer analysis and processing module, an early warning and display module, and a power supply and protection module; The equipment side includes ultrasonic sensors, laser displacement sensors, industrial high-definition cameras, image processors, multi-channel high-speed data acquisition cards, high-speed Ethernet switches, fiber optic transceivers, data analysis servers, GPU accelerator cards, sound and light alarms, large-screen displays, uninterruptible power supplies, power adapters and waterproof, dustproof and shockproof casings.

2. A chain track crack and broken rail monitoring system according to claim 1, characterized in that: The ultrasonic sensor and laser displacement sensor are electrically connected to the sensor module, the industrial high-definition camera and image processor are electrically connected to the image acquisition module, the multi-channel high-speed data acquisition card, the high-speed Ethernet switch and the optical fiber transceiver are electrically connected to the data acquisition and transmission module signal, the data analysis server and the GPU accelerator card are electrically connected to the data analysis and processing module, the sound and light alarm and the large-screen display are electrically connected to the early warning and display module, and the uninterruptible power supply, the power adapter and the waterproof, dustproof and shockproof casing are all external devices of the power supply and protection module.

3. A chain track crack and broken rail monitoring system according to claim 1, characterized in that: The ultrasonic sensor is used to detect cracks and defects inside the chain track. The laser displacement sensor measures the displacement and deformation of the chain track to assist in determining cracks and broken rails.

4. A chain track crack and broken rail monitoring system according to claim 1, characterized in that: The industrial high-definition camera takes real-time images of the chain track, and the image processor performs denoising, enhancement and other processing on the collected images.

5. A chain track crack and broken rail monitoring system according to claim 1, characterized in that: The multi-channel high-speed data acquisition card collects data from the sensor and the image module, and the high-speed Ethernet switch and the optical fiber transceiver transmit the collected data to the analysis module quickly and stably.

6. A chain track crack and broken rail monitoring system according to claim 1, characterized in that: The data analysis server runs complex algorithms and models to analyze and judge the data.

7. A chain track crack and broken rail monitoring system according to claim 1, characterized in that: The sound and light alarm will sound an alarm in time when an abnormality is detected.

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