Crane track detection device and system

Abstract

The invention relates to the technical field of hoisting machinery detection devices, in particular to a crane track detection device and system.The device comprises a base, a battery fixing bin fixed to the upper portion of the base and an upper cover fixed to the upper portion of the battery fixing bin; a clamping mechanism used for clamping the side wall of the track is arranged below the base. A pair of wheels used for being placed on a rail is hinged to the lower portion of each of the front side and the rear side of the battery fixing bin, and the wheels are driven by a driving device to rotate. A connecting block is fixed to the front side of the battery fixing bin, and a prism is fixed to a connecting rod. The crane track detection device designed by the invention can be used for stably detecting the quality of the crane track.

Description

Technical Field

[0001] The invention belongs to the technical field of crane machinery detection devices, and in particular relates to a crane track detection device and system. Background Art

[0002] The crane running track is an important part of the crane. A common problem in the operation of the crane running on the track is that the wheel bites the track. The wheel flange and the side of the track have serious friction, causing wear and deformation of the wheel flange and the track, affecting the safe operation of the crane; when the track bite is serious, it may cause a derailment accident. Therefore, it is necessary to measure the track and judge its installation quality.

[0003] Traditionally, the quality inspection of crane rail installation is carried out manually, using a theodolite or steel ruler to measure the straightness of the rail, a level or spirit level to measure the elevation and levelness, and a thickness and slope ruler or steel ruler to measure the gap and offset of the rail joints.

[0004] Manual inspection of the installation quality of crane rails is cumbersome and easily affected by external factors. Therefore, a detection device and system capable of detecting crane rails is needed to stably detect the quality of crane rails. Summary of the invention

[0005] In order to solve the problem that the existing crane running track installation quality inspection is cumbersome and easily affected by external factors through manual inspection, the present invention provides a crane track inspection device and system, which can stably perform quality inspection on the crane track.

[0006] The technical solution of the present invention is as follows:

[0007] A crane track detection device comprises a base, a battery fixing compartment fixed above the base, and an upper cover fixed above the battery fixing compartment;

[0008] A clamping mechanism for clamping the side wall of the track is provided below the base;

[0009] A pair of wheels for being placed on the track are hingedly connected to the lower part of the front and rear sides of the battery fixing compartment, and the wheels are driven to rotate by a driving device;

[0010] A connecting block is fixed on the front side of the battery fixing compartment, and a prism is fixed on the connecting rod.

[0011] Preferably, the clamping mechanism comprises a first swing arm, a second swing arm and a threaded adjustment rod, a downwardly extending connecting rod and a bearing located at the rear side of the connecting rod are fixed below the base, the threaded adjustment rod passes through the bearing and is connected with the bearing, the threaded adjustment rod has threads, a left slider is positively threadedly connected to the left side of the threaded adjustment rod, a right slider is reversely threadedly connected to the right side of the threaded adjustment rod, and the first swing arm and the second swing arm are fixedly connected to the left slider and the right slider respectively;

[0012] The middle parts of the first swing arm and the second swing arm are both hingedly connected to the connecting rod;

[0013] The first swing arm and the second swing arm are both provided with a relief hole for accommodating the threaded adjustment rod;

[0014] Clamping wheels are fixed below both ends of the first swing arm and the second swing arm.

[0015] Preferably, the clamping wheel is a rubber wheel.

[0016] Preferably, the driving device is a permanent magnet synchronous motor, and the output end of the permanent magnet synchronous motor is fixedly connected to the wheel.

[0017] Preferably, the permanent magnet synchronous motor is located in the battery fixing compartment.

[0018] Preferably, a wireless receiver for receiving signals is fixed on the top of the upper cover, and the wireless receiver is connected to a controller, and the controller controls the movement of the trolley.

[0019] Preferably, the connecting block is L-shaped, including a horizontal plate and a vertical plate, the vertical plate is fixedly connected to the battery fixing compartment, and the horizontal plate is fixedly connected to the prism.

[0020] Preferably, an infrared sensor is provided on the base.

[0021] A crane track detection system is realized by the above-mentioned crane track detection device, including a measuring robot, the crane track detection device is placed on the crane track, the driving device drives the wheels to rotate, the crane track detection device runs along the crane track, and the laser emitted by the measuring robot is collected through a prism, so that the measuring robot can automatically obtain the track coordinate point data of the whole process, and the track is divided into two left and right tracks;

[0022] The detection system includes a terminal and a data forwarder;

[0023] The terminal is connected to the measuring robot via a data forwarder to perform signal interaction;

[0024] The terminal is connected to the crane track detection device via a Bluetooth signal to perform signal interaction;

[0025] The terminal is connected to the data forwarder via Bluetooth;

[0026] The crane track detection device and the data forwarder perform signal interaction via Lora wireless connection;

[0027] The data forwarder is connected to the measuring robot via an RS232 data line.

[0028] Preferably, the measuring robot is a total station with automatic tracking of the target prism and automatic measurement functions.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] (1) The crane rail detection device designed by the present invention has a simple structure, a small size, a compact and stable structure, and is easy for operators to operate.

[0031] (2) The detection in the present invention is stable. The wheels drive the overall movement, and the swing arm and the clamping wheel can clamp the side wall of the track to ensure the stability of the detection process. The prism can be used to complete the detection of the installation quality of the crane track.

[0032] (3) The automatic track detection method of the present invention has a high degree of automation, is easy to operate, has high detection accuracy and ensures the safety of high-altitude detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present invention;

[0034] Figure 2 is a schematic diagram of the bottom of the present invention;

[0035] Figure 3 Schematic diagram of a left slider and a right slider of the present invention;

[0036] Figure 4 A schematic diagram of the avoidance hole of the device of the present invention;

[0037] Figure 5 This is a schematic diagram of the station setup for the measurement robot;

[0038] Figure 6 This is a calculation diagram of the three-point measurement method;

[0039] Figure 7 It is a schematic diagram of interactive control of the system of the present invention;

[0040] In the figure: 1-base, 2-battery fixing compartment, 3-upper cover, 4-clamping mechanism, 41-first swing arm, 42-second swing arm, 43-threaded adjustment rod, 44-clamping wheel, 45-connecting rod, 46-bearing, 47-left slider, 48-right slider, 49-avoidance hole, 5-wheel, 6-prism, 7-wireless receiver, 8-connecting block, 81-vertical plate, 82-horizontal plate. DETAILED DESCRIPTION

[0041] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0042] See also Figure 1-2 , a crane track detection device, comprising a base 1, a battery fixing compartment 2 fixed above the base 1, and an upper cover 3 fixed above the battery fixing compartment 2;

[0043] A clamping mechanism 4 for clamping the side wall of the track is provided below the base 1;

[0044] A pair of wheels 5 for being placed on the track are hingedly connected to the lower part of the front and rear sides of the battery fixing compartment 2, and the wheels 5 are driven to rotate by a driving device;

[0045] A connecting block is fixed on the front side of the battery fixing compartment 2, and a prism 6 is fixed on the connecting rod.

[0046] See also Figure 2-4 In one embodiment of the present invention, the clamping mechanism 4 includes a first swing arm 41, a second swing arm 42 and a threaded adjustment rod 43. A downwardly extending connecting rod 45 and a bearing 46 located at the rear side of the connecting rod 45 are fixed below the base 1. The threaded adjustment rod 43 passes through the bearing 46 and is connected to the bearing 46. The threaded adjustment rod 43 has threads. A left slider 47 is positively threadedly connected to the left side of the threaded adjustment rod 43. A right slider 48 is reversely threadedly connected to the right side of the threaded adjustment rod 43. The first swing arm 41 and the second swing arm 42 are fixedly connected to the right slider 48 and the left slider 47 respectively.

[0047] The middle parts of the first swing arm 41 and the second swing arm 42 are both hingedly connected to the connecting rod 45;

[0048] The first swing arm 41 and the second swing arm 42 are both provided with a relief hole 49 for making way for the threaded adjustment rod 43;

[0049] Clamping wheels 44 are fixed below both ends of the first swing arm 41 and the second swing arm 42 .

[0050] Before the crane track inspection is carried out in the present invention, since the thread directions of the first swing arm 41 and the second swing arm 42 are opposite, when the threaded adjustment rod 43 is rotated, the two can only move in opposite directions or move in the opposite direction, so opening and closing or clamping can be achieved; the first swing arm 41 and the second swing arm 42 are driven to open by rotating the threaded adjustment rod 43, and the opening and closing size is greater than the track width. At this time, the entire device is placed on the track, and the clamping wheel 44 is made to fit with the side wall of the track by rotating the threaded adjustment rod 43 in the opposite direction to achieve clamping, thereby improving the stability of the inspection process.

[0051] Based on the previous embodiment, the clamping wheel is a flexible rolling wheel, which can be a single-layer rubber wheel or a double-layer rubber wheel.

[0052] In another embodiment of the present invention, the driving device is a permanent magnet synchronous motor, and the output end of the permanent magnet synchronous motor is fixedly connected to the wheel 5 .

[0053] Furthermore, the permanent magnet synchronous motor is located in the battery fixing compartment 2 .

[0054] In one embodiment of the present invention, a wireless receiver 7 for receiving signals is fixed on the top of the upper cover 6, and the wireless receiver 7 is connected to a controller, and the controller controls the movement of the trolley.

[0055] The wireless receiver is connected to the driving device for signal interaction, and the controller can set the single running distance of the crane track detection device and control the moving direction of the crane track detection device.

[0056] Specifically, the controller may be a smart phone, which can be connected to a wireless receiver of the crane track detection device through a designed APP to control and receive measured data.

[0057] In addition, the measurement information can be transmitted to a tablet computer or laptop computer via WiFi communication through a wireless receiver to ensure the efficiency and reliability of data transmission; at the same time, the wireless sensor continuously receives the execution command signal issued by the tablet computer or laptop computer, and the driving device drives the wheel to rotate to realize the measurement function.

[0058] When working, first, place the total station in a position close to the center in front of the two crane rails, connect the controller to the total station and turn it on. At this time, install the device, first confirm the working condition of the crane rail on site, and control the opening and closing size of the clamping wheel 44 by adjusting the threaded adjustment rod 43 according to the width of the crane rail, so that the clamping wheels 44 on both sides can clamp on the side wall of the crane rail. Control the driving device through the controller to drive the driving wheel to rotate, so that the entire device runs along the crane rail. The total station calibrates the laser light source through the spiral twist below, and the laser hits the prism. The crane rail is detected through the prism. The angle of the prism can be adjusted according to the measurement needs. The device is powered by a battery. After the test of a single track is completed, it is transferred to the other track for measurement.

[0059] In one embodiment of the present invention, the prism 6 is a 360° prism; a 360° prism can perform all-round reflection and has a better measurement effect.

[0060] In one embodiment of the present invention, the connecting block 8 is L-shaped, and includes a horizontal plate 82 and a vertical plate 81 , wherein the vertical plate 81 is fixedly connected to the battery fixing compartment 2 , and the horizontal plate 81 is fixedly connected to the prism.

[0061] In one embodiment of the present invention, an infrared sensor (not shown) is provided on the base to prevent the device from falling when it runs to the two ends of the track.

[0062] See also Figure 7 A crane track detection system includes a measuring robot, a crane track detection device is placed on the crane track, a driving device drives the wheels to rotate, the crane track detection device runs along the crane track, and the laser emitted by the measuring robot is collected through a prism, so that the measuring robot can automatically obtain the track coordinate point data of the entire process, and the track is divided into two left and right tracks;

[0063] The detection system includes a terminal and a data forwarder;

[0064] The terminal is connected to the measuring robot via a data forwarder to perform signal interaction;

[0065] The terminal is connected to the crane track detection device via a Bluetooth signal to perform signal interaction;

[0066] The terminal is connected to the data forwarder via Bluetooth;

[0067] The crane track detection device and the data forwarder perform signal interaction via Lora wireless connection;

[0068] The data forwarder is connected to the measuring robot via an RS232 data line.

[0069] Among them, in a preferred embodiment of the present invention, the measuring robot can use a total station with automatic tracking target prism and automatic measurement functions, and should also have an SDK development interface or an open data communication protocol.

[0070] When in use, the terminal sends measurement instructions to the total station through the data forwarder. The total station automatically tracks the prism on the track crawler, measures its position data in real time, and transmits the data back to the terminal through the data forwarder for recording;

[0071] The terminal sends movement instructions to the track crawler through the data transponder. The track crawler moves forward or backward a set distance according to the instructions, and transmits the position information back to the handheld terminal through the data transponder for recording;

[0072] The terminal can set the total station to tracking mode and continuous measurement mode. The laser hits the vicinity of the prism, automatically tracks the center of the prism, and automatically adjusts as the prism moves.

[0073] The measurement method during operation is as follows:

[0074] (1) Set up the measuring robot near the crane track to facilitate observation of the two entire tracks, and adjust the measuring robot to ensure the level of the instrument; enter the coordinate measurement module, and after free station setting, you can start three-dimensional coordinate measurement.

[0075] (2) A crane track detection device is installed on the track, and a prism with a horizontal adjustment function is installed thereon in turn, with the prism facing the measuring robot.

[0076] (3) See Figure 3 , use the terminal to control the crane track detection device to move slowly along track I; stop running every 5m, use the measuring robot to automatically track the prism position, and measure the three-dimensional coordinates of the prism one by one.

[0077] (4) See Figure 4 , set up a crane track detection device on track II, stop running every 5m, then control it to move forward 1m to measure point A, and move back 2m to measure point B. Use a measuring robot to automatically track the prism position and measure the three-dimensional coordinates.

[0078] (5) The measuring robot uploads the coordinates of each group of three points measured in the above steps. After the terminal calculates the track height difference and span deviation data and the height difference data, it compares the data according to the standard GB / T 10183-2005 "Tolerances for the manufacture and installation of bridge and gantry cranes" (the limit deviation of the top surface of the crane track relative to the theoretical height is ±10mm, and the theoretical height can be horizontal or a theoretical camber curve) and gives a test conclusion.

[0079] The basic principle of three-point measurement is to use a measuring robot to measure the coordinates of a point on one track, measure the coordinates of two points at nearby positions on another track, project the coordinates of the first point onto the line connecting the two points, and obtain the coordinates of the fourth point. The trigonometric relationship of these four points is then used to calculate the height difference and span deviation of the track with the same section.

[0080] according to Figure 3 Set up a station freely and measure a point on track I, denoted as point C(X c’ Y c’ Z c ); then measure two points on track II and record them as point A and point B, using A(X A’ Y A’ Z A ) and B(X B’ Y B’ Z B ). CD and L C’D Respectively represent the height difference and track span, such as Figure 3 shown.

[0081] Figure 3 Where C' is the projection of C on the AB line, and D is the projection of C' on the Z axis where C is located. Then the equation of the AB line can be set to

[0082]

[0083] in is the direction vector, Since the projection point C' of point C on line AB also satisfies the equation of line AB, we can set the parameter t to represent the coordinate C', where:

[0084] X c’ =(X B -X A )t+X A ;

[0085] Y c′ =(Y B -Y A )t+Y A ;

[0086] Z c’ =(Z B -Z A )t+Z A ;

[0087] Get direction vector

[0088] Line CC' is perpendicular to line AB, so Then we can find the parameter t and get the C' coordinate (Xc’ Y c’ Z c ). Thus, the height difference of the track top H can be obtained CD and the measured track span L C’D They are:

[0089] H CD =|Z C’ -Z C |;

[0090]

[0091] From this we can get the orbit deviation value L' C’D is the measured track span L C’D Difference from the designed track span L:

[0092] L′ C’D =L C’D -L;

[0093] In most real-world inspection situations, the track is close to a straight line, which is suitable for the above three-point measurement method. However, there may be cases where the track is partially curved too much. In this case, if the measurement interval is 5m, there may be a large error between the coordinates of the projection point C' of point C on the AB line and the projection point D on the Z axis and the actual point C on the same section of the other track. In order to avoid the error caused by this phenomenon. We will measure the corresponding cross-sectional points of the measuring points on the other track to compare whether there is a large error with the projection point C'. When the error exceeds the allowable range, the inspector will adjust the measurement density. Reduce the measurement interval and increase the measurement density to reduce the measurement error.

[0094] Error verification is to compare data according to the standard GB / T 10183-2005 "Tolerances for the manufacture and installation of bridge and gantry cranes" (the limit deviation of the top surface of the crane track relative to the theoretical height is ±10mm, and the theoretical height can be horizontal or a theoretical camber curve) and give a test conclusion.

[0095] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A crane track detection device, characterized in that: It includes a base, a battery fixing compartment fixed above the base, and an upper cover fixed above the battery fixing compartment; A clamping mechanism for clamping the side wall of the track is provided below the base; A pair of wheels for being placed on the track are hingedly connected to the lower part of the front and rear sides of the battery fixing compartment, and the wheels are driven to rotate by a driving device; A connecting block is fixed on the front side of the battery fixing compartment, and a prism is fixed on the connecting rod.

2. A crane rail detection device according to claim 1, characterized in that: The clamping mechanism comprises a first swing arm, a second swing arm and a threaded adjustment rod, a downwardly extending connecting rod and a bearing located at the rear side of the connecting rod are fixed below the base, the threaded adjustment rod passes through the bearing and is connected with the bearing, the threaded adjustment rod has threads, a left slider is positively threadedly connected to the left side of the threaded adjustment rod, a right slider is reversely threadedly connected to the right side of the threaded adjustment rod, and the first swing arm and the second swing arm are fixedly connected to the left slider and the right slider respectively; The middle parts of the first swing arm and the second swing arm are both hingedly connected to the connecting rod; The first swing arm and the second swing arm are both provided with a relief hole for accommodating the threaded adjustment rod; Clamping wheels are fixed below both ends of the first swing arm and the second swing arm.

3. A crane rail detection device according to claim 2, characterized in that: The clamping wheel is a rubber wheel.

4. A crane rail detection device according to claim 1, characterized in that: The driving device is a permanent magnet synchronous motor, and the output end of the permanent magnet synchronous motor is fixedly connected to the wheel.

5. A crane rail detection device according to claim 4, characterized in that: The permanent magnet synchronous motor is located in the battery fixing compartment.

6. A crane track detection device according to claim 1, characterized in that: A wireless receiver for receiving signals is fixed on the top of the upper cover, and the wireless receiver is connected to a controller, and the controller controls the movement of the trolley.

7. A crane track detection device according to claim 1, characterized in that: The connecting block is L-shaped and comprises a horizontal plate and a vertical plate, wherein the vertical plate is fixedly connected to the battery fixing compartment, and the horizontal plate is fixedly connected to the prism.

8. The crane track detection device according to claim 1, characterized in that: An infrared sensor is arranged on the base.

9. A crane track detection system, implemented by a crane track detection device as claimed in any one of claims 1 to 8, characterized in that: It includes a measuring robot, which places the crane track detection device on the crane track. The driving device drives the wheels to rotate. The crane track detection device runs along the crane track. The laser emitted by the measuring robot is collected through a prism, so that the measuring robot can automatically obtain the track coordinate point data of the entire process. The track is divided into two left and right tracks; The detection system includes a terminal and a data forwarder; The terminal is connected to the measuring robot via a data forwarder to perform signal interaction; The terminal is connected to the crane track detection device via a Bluetooth signal to perform signal interaction; The terminal is connected to the data forwarder via Bluetooth; The crane track detection device and the data forwarder exchange signals via Lora wireless connection; the data forwarder and the measuring robot are connected via an RS232 data line.

10. A crane track detection system, characterized in that: The measuring robot is a total station with automatic tracking target prism and automatic measurement functions.

Images