Flap pulley slide rail wear monitoring method and device based on laser and dimension chain

Abstract

The invention relates to the field of laser measurement technology application, and provides a flap pulley slide rail wear monitoring method and device based on laser and a dimension chain, and the method comprises the following steps: S1, laser displacement sensors are installed on a pulley slide rail assembly, and each pair of pulley slide rails is equipped with two laser displacement sensors; s2, performing zero setting operation on the installed laser displacement sensor; s3, calibrating a motion gap; s4, performing an abrasion test under the actual working condition of the pulley and slide rail assembly, and collecting data of the laser displacement sensor; and S5, calculating the abrasion loss and the movement gap variation of the pulley slide rail by utilizing the surface position change measured in real time by the laser displacement sensor through the dimension chain and combining the initial calibration data. According to the invention, through dynamic online monitoring, the problem of delayed discovery of wear change caused by data discontinuity is effectively avoided, the efficient operation and safety of equipment are ensured, and the monitoring precision and real-time performance are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the application field of laser measurement technology, and in particular to a flap pulley and rail wear monitoring method and device based on laser and dimension chain. Background Art

[0002] Pulley rail assemblies are widely used in mechanical transmission and precision equipment, particularly in aerospace applications, where flap pulley rail assemblies play a critical role in aircraft maneuverability and controllability. Over long-term use, repeated mechanical motion and external loads can cause wear at the contact surface between the rail and the pulley, compromising the accuracy and reliability of the equipment and potentially leading to significant safety hazards and economic losses. Therefore, a method for high-precision, real-time monitoring of pulley rail wear is urgently needed.

[0003] To address these issues, numerous studies have explored wear monitoring technologies for pulleys and rails. Existing technologies include vibration analysis, which uses changes in vibration signals generated during wear to predict wear status; visual sensor technology, which uses surface topography changes to analyze wear trends; and electrostatic sensors, which detect the charge generated during friction to infer wear conditions. However, these methods generally suffer from the following limitations: They lack precision. Traditional vibration and electrostatic sensors are not sensitive enough to minor wear and cannot accurately detect problems in their early stages. They are severely affected by environmental interference. Visual sensors have strict requirements for light, and vibration sensors are easily affected by external noise, resulting in unstable monitoring data. Furthermore, they have poor real-time performance. Many wear measurement methods require system shutdown for testing, which cannot meet real-time monitoring requirements.

[0004] Laser measurement technology has been widely used in recent years due to its non-contact, high-precision, and fast-response characteristics. Laser displacement sensors accurately measure minute displacements of a target surface by emitting a laser beam and capturing the reflected light signal, overcoming many of the shortcomings of traditional methods. However, due to the difficulty in directly measuring the clearance of pulley and rail assemblies, relying solely on single-sided measurements with a laser rangefinder cannot fully reflect the wear status. Therefore, a new method is needed to accurately monitor the wear status of pulley and rail assemblies in real time. Summary of the Invention

[0005] In view of the defects in the prior art, the purpose of the present invention is to provide a flap pulley rail wear monitoring method and device based on laser and dimension chain.

[0006] According to the present invention, a flap pulley rail wear monitoring method based on laser and dimension chain is provided, comprising the following steps:

[0007] S1: Install laser displacement sensors on the pulley-rail assembly. Two laser displacement sensors are equipped for each pair of pulley-rail to monitor the wear conditions of the pulley and the rail in real time;

[0008] S2: Zero the installed laser displacement sensors to ensure that the readings of the laser displacement sensors in the non-worn state are the reference values;

[0009] S3: Calibrate the movement clearance. Fill the initial movement clearance between the pulley and the rail with a standard block, and verify and ensure that the deviation of the readings of the laser displacement sensors is within the allowable range;

[0010] S4: Conduct a wear test under the actual working conditions of the pulley-rail assembly, collect the data of the laser displacement sensors, and record the data of the position of the pulley-rail contact surface changing with time;

[0011] S5: Use the dimension chain analysis method. Through the surface position changes measured by the laser displacement sensors in real time and combined with the initial calibration data, calculate the wear amount of the pulley-rail and the change amount of the movement clearance.

[0012] Preferably, the installation positions of the laser displacement sensors include a first position and a second position to ensure that the measurement data cover all the worn surfaces of the pulley-rail assembly. Among them, the first position is arranged on the front or rear side of the pulley with the laser emission direction facing the rail to detect the wear condition of the rail surface, and the second position is arranged on the upper or lower side of the pulley on the side where the pulley is facing away from the rail and the laser emission direction faces the rail and passes through the center of the pulley to detect the wear condition of the pulley surface. The laser emission directions of the two laser displacement sensors at the first position and the second position are parallel.

[0013] Preferably, the laser displacement sensors are measured by being symmetrically arranged on both sides of the rail.

[0014] Preferably, the dimension chain analysis method combines the structural dimensions of the pulley-rail and the real-time data of the laser displacement sensors to calculate and compensate for the errors caused by the pulley shaking.

[0015] Preferably, the S4 includes setting different load conditions to make the pulley-rail assembly operate dynamically under the actual load, and the laser displacement sensors synchronously record the changes in the surface positions of the pulley-rail to provide real-time data for calculating the wear amount.

[0016] Preferably, the standard block is used to fill the initial movement clearance between the pulley and the rail during the calibration process. By comparing the readings of the laser displacement sensors with the size of the standard block, ensure that the measurement error of the laser displacement sensors is controlled within a predetermined range.

[0017] A flap pulley slide rail wear monitoring device based on laser and dimensional chain according to the present invention includes a slider, a slide rail, a first standard block, a first laser displacement sensor, a second laser displacement sensor, an upper pulley, a third laser displacement sensor, a fourth laser displacement sensor, and a lower pulley, all of which are arranged on the slider.

[0018] The inner side of the upper pulley is in sliding or rotational fit with the upper side of the slide rail, and the inner side of the lower pulley is in sliding or rotational fit with the lower side of the slide rail. The first standard block is used to be arranged between the upper pulley and the slide rail and / or between the lower pulley and the slide rail for calibrating the reference value of the laser displacement sensor, where:

[0019] The first laser displacement sensor is arranged outside the upper pulley and faces the outer side of the upper pulley, and the axis of the laser emission beam passes through the center of the upper pulley. The second laser displacement sensor is arranged on the front or rear side of the upper pulley, and the laser emission beam irradiates on the upper side of the slide rail. The third laser displacement sensor is arranged outside the lower pulley and faces the outer side of the lower pulley, and the axis of the laser emission beam passes through the center of the lower pulley. The fourth laser displacement sensor is arranged on the front or rear side of the lower pulley, and the laser emission beam irradiates on the lower side of the slide rail.

[0020] Preferably, the axes of the laser emission beams of the first laser displacement sensor and the second laser displacement sensor are parallel, the axes of the laser emission beams of the third laser displacement sensor and the fourth laser displacement sensor are parallel, and the axes of the laser emission beams of the second laser displacement sensor and the fourth laser displacement sensor coincide.

[0021] Preferably, it further includes a second standard block, a third standard block, a first side pulley, a second side pulley, a third side pulley, a fourth side pulley, a fifth laser displacement sensor, a sixth laser displacement sensor, a seventh laser displacement sensor, an eighth laser displacement sensor, a ninth laser displacement sensor, a tenth laser displacement sensor, an eleventh laser displacement sensor, and a twelfth laser displacement sensor, all of which are arranged on the slider.

[0022] The inner sides of the first side pulley and the second side pulley are respectively in sliding or rotational fit with the upper side of the slide rail, and the inner sides of the third side pulley and the fourth side pulley are respectively in sliding or rotational fit with the lower side of the slide rail. The second standard block is used to be arranged between the first side pulley and the slide rail and / or between the third side pulley and the slide rail, and the third standard block is used to be arranged between the second side pulley and the slide rail and / or between the fourth side pulley and the slide rail, where:

[0023] The fifth laser displacement sensor is arranged outside the first side pulley and faces the outer side surface of the first side pulley, and the axis of the laser emission beam passes through the center of the first side pulley. The sixth laser displacement sensor is arranged in front of or behind the first side pulley, and the laser emission beam irradiates the upper side surface of the slide rail;

[0024] The seventh laser displacement sensor is arranged outside the second side pulley and faces the outer side surface of the second side pulley, and the axis of the laser emission beam passes through the center of the second side pulley. The eighth laser displacement sensor is arranged in front of or behind the second side pulley, and the laser emission beam irradiates the lower side surface of the slide rail;

[0025] The ninth laser displacement sensor is arranged outside the third side pulley and faces the outer side surface of the third side pulley, and the axis of the laser emission beam passes through the center of the third side pulley. The tenth laser displacement sensor is arranged in front of or behind the third side pulley, and the laser emission beam irradiates the upper side surface of the slide rail;

[0026] The eleventh laser displacement sensor is arranged outside the fourth side pulley and faces the outer side surface of the fourth side pulley, and the axis of the laser emission beam passes through the center of the fourth side pulley. The twelfth laser displacement sensor is arranged in front of or behind the fourth side pulley, and the laser emission beam irradiates the lower side surface of the slide rail.

[0027] Preferably, the axes of the laser emission beams of the fifth laser displacement sensor and the sixth laser displacement sensor are parallel, the axes of the laser emission beams of the ninth laser displacement sensor and the tenth laser displacement sensor are parallel, and the axes of the laser emission beams of the sixth laser displacement sensor and the tenth laser displacement sensor coincide;

[0028] The axes of the laser emission beams of the seventh laser displacement sensor and the eighth laser displacement sensor are parallel, the axes of the laser emission beams of the eleventh laser displacement sensor and the twelfth laser displacement sensor are parallel, and the axes of the laser emission beams of the eighth laser displacement sensor and the twelfth laser displacement sensor coincide.

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

[0030] 1. The present invention installs multiple sets of laser displacement sensors on the pulley slide rail assembly and collects the distance changes from the surface of the pulley slide rail in real time. By using dimensional chain analysis to compensate for the slider sway error, the wear amount can be obtained. The laser displacement sensor has the characteristics of fast response and real-time monitoring, and can capture the changes in the wear state in real time under the condition of high-speed operation of the system. It can perform non-contact dynamic monitoring during high-speed operation of the system, avoiding the inconvenience caused by downtime measurement. Through dynamic online monitoring, the present invention effectively avoids the problem of delayed discovery of wear changes caused by discontinuous data, thus realizing real-time wear state update in the true sense, ensuring the efficient operation and safety of the equipment, and significantly improving the monitoring accuracy and real-time performance.

[0031] 2. The present invention adopts a multi-sensor symmetric measurement layout, combines the initial calibration value and the structural dimension relationship, and accurately calculates the total wear amount of the pulley and the slide rail. Compared with traditional methods, it can achieve high-precision measurement, does not damage the measurement surface, extends the service life of the equipment, and is applicable to high-reliability requirements.

[0032] 3. By introducing laser measurement technology, the present invention significantly improves the accuracy, real-time performance and applicability of wear monitoring, while reducing equipment loss, providing a solid guarantee for the healthy operation of the pulley slide rail assembly.

[0033] 4. Different from traditional sensors that rely on vibration signals or electrostatic effects, the laser displacement sensor in the present invention is a high-precision non-contact measurement, and can achieve a measurement accuracy of the micron level. In the stage of minor wear or early wear, traditional methods are prone to false negatives due to weak signals or interference factors, while the laser measurement technology in the present invention can accurately detect these subtle surface deformations, thus providing more reliable data support to help equipment maintenance personnel discover potential problems in time and take preventive measures.

[0034] 5. The present invention has strong environmental adaptability. Due to its physical measurement principle, the laser measurement technology is less sensitive to external noise and electromagnetic interference and is applicable to a variety of complex working conditions. Whether in a strong noise environment, near equipment with large vibrations, or under harsh conditions such as high temperature and low temperature, the laser displacement sensor can maintain stable performance, ensuring the continuity and reliability of wear monitoring data. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] By reading the detailed description of the non-limiting embodiments with reference to the following drawings, other features, objects and advantages of the present invention will become more apparent:

[0036] Figure 1 It is a flowchart of the method for measuring the movement clearance of the pulley slide rail of the present invention;

[0037] Figure 2 It is a schematic diagram of the installation position of the laser displacement sensor in the present invention;

[0038] Figure 3 Schematic diagram for calibrating the initial movement clearance of the upper and lower pulley slide rails;

[0039] Figure 4 Schematic diagram for calibrating the initial movement clearance of the upper and lower pulley slide rails, where a standard block is shown in the figure;

[0040] Figure 5 Schematic diagram for calibrating the initial movement clearance of the side pulley slide rails, where a standard block is shown in the figure;

[0041] Figure 6 Schematic diagram for calibrating the initial movement clearance of the side pulley slide rails, where the standard block is not shown in the figure;

[0042] Figure 7 Schematic diagram of the working condition when there is an inclination between the side pulley and the slide rail;

[0043] Figure 8 Schematic diagram of the movement clearance dimension chain of the side pulley slide rail.

[0044] As shown in the figure:

[0045] The first laser displacement sensor 1;

[0046] The second laser displacement sensor 2;

[0047] The slider 3;

[0048] The upper pulley 4;

[0049] The third laser displacement sensor 5;

[0050] The fourth laser displacement sensor 6;

[0051] The lower pulley 7;

[0052] The slide rail 8;

[0053] The first standard block 9;

[0054] The first side pulley 10;

[0055] The second side pulley 11;

[0056] The third side pulley 12;

[0057] The fourth side pulley 13;

[0058] The fifth laser displacement sensor 14;

[0059] The sixth laser displacement sensor 15;

[0060] The seventh laser displacement sensor 16;

[0061] The eighth laser displacement sensor 17;

[0062] The ninth laser displacement sensor 18;

[0063] The tenth laser displacement sensor 19;

[0064] The eleventh laser displacement sensor 20;

[0065] The twelfth laser displacement sensor 21;

[0066] The second standard block 22;

[0067] The third standard block 23. Specific implementation manner

[0068] The present invention will be described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any form. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several changes and improvements can still be made. These all fall within the protection scope of the present invention.

[0069] Embodiment 1:

[0070] In order to overcome the problems of low accuracy, poor real-time performance, and susceptibility to environmental interference in the prior art for monitoring the wear of pulley slide rails, the present invention provides a method for monitoring the wear of flap pulley slide rails based on laser and dimensional chain. By arranging multiple sets of laser displacement sensors in the pulley slide rail assembly and combining dimensional chain analysis to calculate the wear amount, high-precision and real-time monitoring of the wear state is achieved, and the limitations of traditional methods in detecting minor wear or under harsh working conditions are effectively avoided, including the following steps:

[0071] S1: Install laser displacement sensors on the pulley slide rail assembly. Each pair of pulley slide rails is equipped with two laser displacement sensors for real-time monitoring of the wear of the pulley and the slide rail; the installation positions of the laser displacement sensors include the first position and the second position to ensure that the measurement data covers each wear surface of the pulley slide rail assembly. The laser displacement sensors are measured in a form of being symmetrically arranged relative to the slide rail to ensure that the laser emission and reception optical paths of the laser displacement sensors are always within the effective measurement range during the measurement process, thereby avoiding systematic errors and signal loss.

[0072] S2: Perform a zero adjustment operation on the installed laser displacement sensors to ensure that the reading of the laser displacement sensors in the non-worn state is the reference value;

[0073] S3: Calibrate the motion clearance. Fill the initial motion clearance between the pulley and the slide rail with a standard block, and verify and ensure that the deviation of the reading of the laser displacement sensor is within the allowable range. During the calibration process, the standard block is compared with the size of the standard block through the reading of the laser displacement sensor to ensure that the measurement error of the laser displacement sensor is controlled within a predetermined range.

[0074] S4: Conduct a wear test under the actual working conditions of the pulley-slide rail assembly, collect the data of the laser displacement sensor, and record the data of the position of the pulley-slide rail contact surface changing with time. It should be noted that different load conditions can be set for the wear test to enable the pulley-slide rail assembly to operate dynamically under the actual load. The sensor synchronously records the change in the position of the pulley-slide rail surface to provide real-time data for calculating the wear amount.

[0075] S5: Use the dimension chain analysis method. Through the change in the surface position measured in real time by the laser displacement sensor and combined with the initial calibration data, calculate the wear amount and the change amount of the motion clearance of the pulley-slide rail.

[0076] The dimension chain analysis method combines the structural dimensions of the pulley-slide rail and the real-time data of the sensor to calculate and compensate for the errors generated by the pulley wobbling, improving the calculation accuracy of the wear amount. The laser displacement sensor can perform real-time dynamic monitoring during the operation of the pulley-slide rail assembly, thus realizing online and non-contact wear monitoring, avoiding the inconvenience and time delay brought by shutdown inspection in the traditional method. By introducing laser measurement technology, the present invention can non-contactly dynamically monitor the wear condition of the pulley-slide rail, overcoming the defects of insufficient accuracy, poor real-time performance, and susceptibility to interference in the traditional wear monitoring method, and significantly improving the accuracy and reliability of wear monitoring.

[0077] The non-contact laser measurement technology adopted in the present invention completely avoids the direct physical contact between the sensor and the surface of the slide rail, reducing equipment wear. In contrast, the traditional contact measurement method will inevitably generate additional loads on the surface of the equipment, increasing the wear risk. This measurement method in the present invention not only protects the integrity of the equipment and the sensor, but also extends the service life of both, reduces the overall maintenance cost of the equipment, and saves resources and time for the enterprise.

[0078] Embodiment 2:

[0079] This embodiment is a preferred example of Embodiment 1. This embodiment provides a flap pulley-slide rail wear monitoring device based on laser and dimension chain, as Figure 3 、 Figure 4As shown, it includes a slider 3, a slide rail 8, a first standard block 9, and a first laser displacement sensor 1, a second laser displacement sensor 2, an upper pulley 4, a third laser displacement sensor 5, a fourth laser displacement sensor 6, and a lower pulley 7, all of which are arranged on the slider 3. The inner side of the upper pulley 4 is in sliding or rotational cooperation with the upper side of the slide rail 8, preferably rotational cooperation. The inner side of the lower pulley 7 is in sliding or rotational cooperation with the lower side of the slide rail 8, preferably rotational cooperation. The first standard block 9 is used to be arranged between the upper pulley 4 and the slide rail 8 and / or between the lower pulley 7 and the slide rail 8 for calibrating the reference value of the laser displacement sensor. Among them, the first laser displacement sensor 1 is arranged on the outer side of the upper pulley 4 and faces the outer side of the upper pulley 4, and the axis of the laser beam emitted by the first laser displacement sensor 1 passes through the center of the upper pulley 4. The second laser displacement sensor 2 is arranged on the front or rear side of the upper pulley 4, and the laser beam is irradiated on the upper side of the slide rail 8. The third laser displacement sensor 5 is arranged on the outer side of the lower pulley 7 and faces the outer side of the lower pulley 7, and the axis of the laser beam passes through the center of the lower pulley 7. The fourth laser displacement sensor 6 is arranged on the front or rear side of the lower pulley 7, and the laser beam is irradiated on the lower side of the slide rail 8.

[0080] It should be noted that the axes of the laser beams emitted by the first laser displacement sensor 1 and the second laser displacement sensor 2 are parallel. The axes of the laser beams emitted by the third laser displacement sensor 5 and the fourth laser displacement sensor 6 are parallel. The axes of the laser beams emitted by the second laser displacement sensor 2 and the fourth laser displacement sensor 6 coincide.

[0081] Such as Figure 5As shown, the device in the present invention further includes a second standard block 22, a third standard block 23, and a first side pulley 10, a second side pulley 11, a third side pulley 12, a fourth side pulley 13, a fifth laser displacement sensor 14, a sixth laser displacement sensor 15, a seventh laser displacement sensor 16, an eighth laser displacement sensor 17, a ninth laser displacement sensor 18, a tenth laser displacement sensor 19, an eleventh laser displacement sensor 20, and a twelfth laser displacement sensor 21, all of which are arranged on the slider 3. The inner sides of the first side pulley 10 and the second side pulley 11 are respectively in sliding or rotational cooperation with the upper side surface of the slide rail 8, preferably rotational cooperation. The inner sides of the third side pulley 12 and the fourth side pulley 13 are respectively in sliding or rotational cooperation with the lower side surface of the slide rail 8, preferably rotational cooperation. The second standard block 22 is used to be arranged between the first side pulley 10 and the slide rail 8 and / or between the third side pulley 12 and the slide rail 8. The third standard block 23 is used to be arranged between the second side pulley 11 and the slide rail 8 and / or between the fourth side pulley 13 and the slide rail 8. Among them, the fifth laser displacement sensor 14 is arranged on the outer side of the first side pulley 10 and faces the outer side surface of the first side pulley 10, and the axis of the laser emission beam of the fifth laser displacement sensor 14 passes through the center of the first side pulley 10. The sixth laser displacement sensor 15 is arranged on the front side or the rear side of the first side pulley 10 and the laser emission beam irradiates on the upper side surface of the slide rail 8. The seventh laser displacement sensor 16 is arranged on the outer side of the second side pulley 11 and faces the outer side surface of the second side pulley 11 and the axis of the laser emission beam passes through the axis of the second side pulley 11. The eighth laser displacement sensor 17 is arranged on the front side or the rear side of the second side pulley 11 and the laser emission beam irradiates on the lower side surface of the slide rail 8. The ninth laser displacement sensor 18 is arranged on the outer side of the third side pulley 12 and faces the outer side surface of the third side pulley 12, and the axis of the laser emission beam of the ninth laser displacement sensor 18 passes through the center of the third side pulley 12. The tenth laser displacement sensor 19 is arranged on the front side or the rear side of the third side pulley 12 and the laser emission beam irradiates on the upper side surface of the slide rail 8. The eleventh laser displacement sensor 20 is arranged on the outer side of the fourth side pulley 13 and faces the outer side surface of the fourth side pulley 13 and the axis of the laser emission beam passes through the center of the fourth side pulley 13. The twelfth laser displacement sensor 21 is arranged on the front side or the rear side of the fourth side pulley 13 and the laser emission beam irradiates on the lower side surface of the slide rail 8.

[0082] Further, the axes of the laser emission beams of the fifth laser displacement sensor 14 and the sixth laser displacement sensor 15 are parallel, the axes of the laser emission beams of the ninth laser displacement sensor 18 and the tenth laser displacement sensor 19 are parallel, and the axes of the laser emission beams of the sixth laser displacement sensor 15 and the tenth laser displacement sensor 19 coincide; the axes of the laser emission beams of the seventh laser displacement sensor 16 and the eighth laser displacement sensor 17 are parallel, the axes of the laser emission beams of the eleventh laser displacement sensor 20 and the twelfth laser displacement sensor 21 are parallel, and the axes of the laser emission beams of the eighth laser displacement sensor 17 and the twelfth laser displacement sensor 21 coincide.

[0083] This embodiment also provides a method for monitoring the wear of a flap pulley slide rail based on lasers and dimension chains, including the following steps. See Figure 1 as shown:

[0084] S1. Install laser displacement sensors on the pulley slide rail assembly. Each pair of pulley slide rails is equipped with two laser displacement sensors for real-time monitoring of the wear conditions of the pulley and the slide rail; the installation positions of the laser displacement sensors include a first position and a second position to ensure that the measurement data covers all the worn surfaces of the pulley slide rail assembly. The laser displacement sensors are arranged symmetrically on both sides of the track for measurement, ensuring that the laser emission and reception optical paths of the laser displacement sensors are always within the effective measurement range during the measurement process, thereby avoiding systematic errors and signal loss. In this embodiment, 24 sets of laser displacement sensors are installed on the pulley slide rail wear test bench. Each pulley is equipped with two sets of sensors, which are respectively used to measure the wear conditions of the pulley and the corresponding slide rail. 24 sets of laser displacement sensors are used to simultaneously monitor 12 groups of pulley slide rail assemblies, including 4 upper pulleys 4, 4 side pulleys, and 4 lower pulleys 7, so as to comprehensively monitor the wear conditions of the pulley and the slide rail in all directions, including up and down and side directions. For the sake of convenience of explanation, the installation positions are now defined. The first position is the position arranged on the front or rear side of the pulley with the laser emission direction facing the slide rail, which is used to detect the wear condition of the slide rail surface. The second position is the position arranged on the upper or lower side of the pulley on the side opposite to the slide rail. The laser emission direction of the sensor at the second position faces the slide rail and passes through the center of the pulley, which is used to detect the wear condition of the pulley surface. The laser emission directions of the two laser displacement sensors at the first position and the second position are parallel. See Figure 2, wherein, the distances from the first position to the slide rail and from the second position to the pulley both need to consider the range of the laser displacement sensor, and it is necessary to ensure that the distance between the laser emission site and the measurement site of the laser displacement sensor is always within the range of the laser displacement sensor during the wear monitoring process. The laser displacement sensor located at the second position is used to measure the wear condition of the outer side of the pulley; the laser displacement sensor located at the first position is used to measure the wear condition of the slide rail in the vertical direction, ensuring that the wear conditions of the pulley and slide rail in all directions can be comprehensively and accurately monitored. To ensure the consistency of the measurement data within the same cross-section, when installing the laser displacement sensor, the optical path needs to coincide with the cross-section of the slide rail to reduce the error caused by system jitter.

[0085] S2. Perform a zeroing operation on the installed laser displacement sensors to ensure that the readings of the laser displacement sensors in the non-worn state are the reference values, that is, the readings of each laser displacement sensor are 0; make the upper pulley 4 closely adhere to the slide rail 8, and zero the 16 laser displacement sensors for measuring the wear of the 4 upper pulleys 4, 4 lower pulleys 7, and the corresponding slide rails. Make the two side pulleys on one side of the slider 3 closely adhere to the slide rail 8, and form an initial movement gap at the pulley-slide rail moving pair on the other side of the slider 3, as Figure 5 shown, and zero the 8 laser displacement sensors for measuring the wear of the 4 side pulleys and the corresponding slide rails.

[0086] S3. Calibrate the movement gap. Fill the initial movement gap between the pulley and the slide rail with a standard block to verify that the deviation of the laser displacement sensor reading is within the allowable range; the standard block is used to fill the initial movement gap between the pulley and the slide rail during the calibration process. By comparing with the sensor reading, ensure that the measurement error of the sensor is controlled within the predetermined range. The initial movement gap includes the calibration of the initial movement gap between the upper and lower pulleys and the slide rail and the calibration of the initial movement gap between the side pulleys and the slide rail;

[0087] Specifically, during the calibration of the initial movement gap between the upper and lower pulleys and the slide rail, a gap is formed between the upper pulley 4 and the upper surface of the slide rail 8 by flipping the pulley-slide rail assembly, and the gap is filled with the first standard block 9. Subsequently, compare the total thickness of the first standard block 9 with the sensor reading to verify that the deviation of the sensor reading is within the allowable range.

[0088] S4. Conduct a wear test under the actual working conditions of the pulley-rail assembly, collect sensor data, and record the data of the position of the pulley-rail contact surface changing with time. The wear test steps include setting different load conditions to make the pulley-rail assembly operate dynamically under the actual load. The sensors synchronously record the changes in the surface position of the pulley-rail to provide real-time data for wear amount calculation. Conduct a wear test on the pulley-rail and collect data. By setting the load conditions of the pulley-rail, keep the equipment running continuously and synchronously collect the data of all sensors. The laser displacement sensor records the real-time changes in the position of the pulley-rail contact surface to provide basic data for subsequent wear amount calculation.

[0089] S5. Using the principle of dimensional chain, combine the surface position changes measured in real time by the laser displacement sensor with the initial calibration data to calculate the wear amount and the change amount of the movement clearance of the pulley-rail. The dimensional chain analysis method combines the structural dimensions of the pulley-rail and the real-time data of the sensor to calculate and compensate for the errors caused by pulley wobbling, improving the calculation accuracy of the wear amount.

[0090] As Figures 1 to 8 shown, the working principle of the present invention is as follows:

[0091] Install sensors on the pulley-rail assembly. 24 sets of sensors are installed on the pulley-rail wear test bench. Two sets of sensors are equipped for each pulley, which are respectively used to measure the wear conditions of the pulley and the corresponding rail. These 24 sets of sensors can simultaneously monitor 12 groups of pulley-rail assemblies, including 4 upper pulleys, 4 side pulleys, and 4 lower pulleys.

[0092] The installation directions of the sensors are respectively aligned with the pulley axis and perpendicular to the rail surface direction. As Figure 2 shown, when installing the sensors, the range of the sensor should be fully considered. It is necessary to ensure that the distance between the laser emission site of the sensor and the measurement site remains within the range of the laser displacement sensor during the wear monitoring process. Some sensors are arranged along the circumferential direction of the pulley to measure the circumferential wear of the pulley; some sensors are arranged perpendicular to the rail direction to measure the wear of the rail in the vertical direction, ensuring that the wear conditions of the pulley-rail in all directions can be comprehensively and accurately monitored. To ensure the consistency of the measurement data in the same cross-section, when installing the sensors, the optical path needs to coincide with the rail cross-section to reduce the errors caused by system wobbling.

[0093] Before starting the wear test of the pulley-rail, it is necessary to calibrate the initial movement clearance of the pulley-rail assembly, including the up-and-down movement clearance and the side movement clearance. The specific method is as follows:

[0094] Figure 3 And Figure 4Among them, the assembly formed by the upper and lower pulleys and the slide rail includes the first laser displacement sensor 1, the second laser displacement sensor 2, the slider 3, the upper pulley 4, the third laser displacement sensor 5, the fourth laser displacement sensor 6, the lower pulley 7, the slide rail 8, and the first standard block 9. The initial movement gap calibration of the upper and lower pulleys and the slide rail is as follows:

[0095] Zero adjustment operation. Press the upper pulley tightly against the upper surface of the slide rail. As Figure 3 shown, only one upper pulley 4 and one lower pulley 7 among all the pulleys are demonstrated in the figure, and the operations of the remaining pulleys are the same. Perform zero adjustment operations on the 16 laser sensors that measure the wear of the 4 upper pulleys 4, the 4 lower pulleys 7, and the corresponding slide rail 8. Through zero adjustment, ensure that the readings of all laser displacement sensors that measure the wear of the upper pulley 4, the lower pulley 7, and the corresponding slide rail 8 are the reference values in the non-worn state.

[0096] Gap calibration: Calibrate the readings of the laser displacement sensors through the first standard block 9. Flip the tabletop so that a movement gap is formed between the upper pulley 4 and the outer side of the slide rail 8, and fill the movement gap with the first standard block 9. As Figure 4 shown, take out the first standard block 9, and compare the total thickness of the first standard block 9 with the readings of the laser displacement sensors to ensure that the deviation of the readings of the laser displacement sensors is within the allowable range; at the same time, the sum of the readings of the second laser displacement sensor 2 and the fourth laser displacement sensor 6 deviates from 0 by no more than the allowable range to ensure that the optical paths of the laser displacement sensors are on the same cross-section of the slide rail 8.

[0097] As Figure 5 shown, the side pulley and slide rail assembly includes the first side pulley 10, the second side pulley 11, the third side pulley 12, the fourth side pulley 13, the fifth laser displacement sensor 14, the sixth laser displacement sensor 15, the seventh laser displacement sensor 16, the eighth laser displacement sensor 17, the ninth laser displacement sensor 18, the tenth laser displacement sensor 19, the eleventh laser displacement sensor 20, the twelfth laser displacement sensor 21, the second standard block 22, and the third standard block 23. The initial movement gap calibration operation of the side pulley and the slide rail is as follows:

[0098] Zero adjustment operation: Press the first side pulley 10 and the second side pulley 11 on one side of the slider 3 tightly against the surface of the slide rail 8, and use the second standard block 22 and the third standard block 23 to fill the gaps between the third side pulley 12 and the fourth side pulley 13 on the other side and the slide rail 8 respectively. Perform zero adjustment operations on the 8 laser displacement sensors that measure the wear of the 4 side pulleys and the corresponding slide rail. Through zero adjustment, ensure that the readings of all laser displacement sensors that measure the wear of the side pulleys and the corresponding slide rail are the reference values in the non-worn state.

[0099] Sensor reading verification: Remove the second standard block 22 and the third standard block 23, and make the third side pulley 12 and the fourth side pulley 13 on the other side of the slider 3 closely adhere to the surface of the slide rail 8, as Figure 6 shown. At this time, the readings of the sixth laser displacement sensor 15 and the eighth laser displacement sensor 17 should be the size of the initial side movement gap. Compare the readings of the sixth laser displacement sensor 15 and the eighth laser displacement sensor 17 with the total thickness of the second standard block 22 and the third standard block 23 to ensure that the deviation of the sensor readings is within the allowable range; at the same time, the deviation of the sum of the readings of the sixth laser displacement sensor 15 and the tenth laser displacement sensor 19 from 0 does not exceed the allowable range, and the deviation of the sum of the readings of the eighth laser displacement sensor 17 and the twelfth laser displacement sensor 21 from 0 does not exceed the allowable range to ensure that the sensor optical paths are on the same slide rail cross-section.

[0100] Wear test and data acquisition:

[0101] After completing the initial calibration, conduct a wear test on the pulley slide rail. During the test, set the load conditions of the pulley slide rail, drive the slider to move back and forth along the slide rail, keep the equipment running continuously, and synchronously collect the data of all laser displacement sensors. The sensors record the changes in the position of the contact surface between the pulley and the slide rail in real time, providing basic data for the subsequent calculation of the wear amount.

[0102] Real-time movement gap and wear amount calculation:

[0103] The present invention combines the structural dimensions of the pulley slide rail, the initial calibration value and the real-time readings of the sensors, and uses the dimension chain analysis method to calculate the change amount of the movement gap and the total wear amount of each pulley slide rail assembly in real time, including the movement gap between the upper and lower pulley slide rails and the movement gap between the side pulley slide rails. Define the movement gap as the sum of the shortest distances from the opposite side pulleys to the slide rail. The specific calculation steps are as follows:

[0104] Calculation of the movement gap of the side pulley slide rail:

[0105] Due to the existence of the movement gap between the side pulley slide rails, the movement trajectory of the slider 3 is not completely parallel to the extension direction of the slide rail 8. In most working conditions, there is a certain inclination angle between the side pulley and the slide rail 8, as Figure 7As shown. Denote the angle formed by the side of the slider and the side of the slide rail as θ. The reading of the fifth laser displacement sensor 14 is d1, the reading of the sixth laser displacement sensor 15 is h1, the reading of the seventh laser displacement sensor 16 is d3, the reading of the eighth laser displacement sensor 17 is h3, the reading of the ninth laser displacement sensor 18 is d2, the reading of the tenth laser displacement sensor 19 is h2, the reading of the eleventh laser displacement sensor 20 is d4, the reading of the twelfth laser displacement sensor 21 is h4. The radius of the first side pulley 10 is r1, the radius of the second side pulley 11 is r3, the radius of the third side pulley 12 is r2, the radius of the fourth side pulley 13 is r4. The width of the slide rail 8 is L. The movement clearance between the first side pulley 10, the third side pulley 12 and the slide rail 8 is c1, and the movement clearance between the second side pulley 11, the fourth side pulley 13 and the slide rail 8 is c2. After calibration, each reading is 0, and the initial calibration values of the movement clearances are c 10 and c 20 , the initial width of the slide rail 8 is L0, the distance between the sixth laser displacement sensor 15 and the tenth laser displacement sensor 19 is a fixed value D, and the axle distance between the first side pulley 10 and the third side pulley 12 is a fixed value E. Establish the dimensional chain relationship of the movement clearance between the side pulley and the slide rail, see Figure 8 as shown, and derive the measurement method of the movement clearance from this. Since the calculation methods of the movement clearances c1 and c2 are the same, only the derivation process of the movement clearance c1 is introduced here:

[0106] The wear amounts Δr1 and Δr2 of the first side pulley 10 and the third side pulley 12 can be obtained from the following formula:

[0107] r1 + d1 = r 10 + d 10

[0108] Δr1 = r1 - r 10 = d 10 - d1 = -d1

[0109] Similarly, it can be known that: Δr2 = r2 - r 20 = d 20 - d2 = -d2

[0110] The inclination angle θ can be obtained from the readings of the tenth laser displacement sensor 19 and the twelfth laser displacement sensor 21. Among them, the optical path distance s between the tenth laser displacement sensor 19 and the twelfth laser displacement sensor 21 is known:

[0111]

[0112] Since the distance between the sixth laser displacement sensor 15 and the tenth laser displacement sensor 19 is a fixed value D, there is a dimensional chain relationship:

[0113]

[0114] Therefore, the wear amount ΔL of the slide rail can be obtained by the following formula, where Δh1 and Δh2 respectively represent the reading changes of the sixth laser displacement sensor 15 and the tenth laser displacement sensor 19:

[0115]

[0116] It can be known from the initial clearance calibration process that:

[0117] E = L0 + r 10 + r 20 + c 10

[0118] Then the movement clearance c1 can be obtained by the following formula:

[0119] c1 + L + r1 + r2 = E cosθ

[0120]

[0121] The change amount Δc1 of the real-time movement clearance value of the pulley slide rail can be obtained by the following formula:

[0122]

[0123] Thus, after measuring the initial radius of the pulley and calibrating the initial clearance c 10 of the pulley slide rail, according to the real-time data measured by the laser displacement sensor, the wear amount Δr1 of the first-side pulley 10, the wear amount Δr2 of the third-side pulley 12, the total wear amount ΔL of the surface of the slide rail 8 side, the change amount Δc1 of the pulley slide rail movement clearance, and the pulley slide rail clearance value c1 can be obtained respectively, where the movement clearance and its change amount are only related to the reading of the laser displacement sensor and the known quantities in the pulley slide rail assembly.

[0124] Calculation of the movement clearance of the upper and lower pulley slide rails:

[0125] When measuring the movement clearance of the upper and lower pulley slide rails, the measurement principle is basically the same as that of measuring the movement clearance of the side pulley slide rail. The side view schematic diagram of the pulley slide rail assembly is as Figure 3 shown. Due to the influence of the load, the upper pulley 4 is in close contact with the upper surface of the slide rail 8 during movement. Therefore, without considering the upper pulley 4 detaching from the surface of the slide rail 8, the movement clearance of the upper and lower pulley slide rails and its change magnitude can be obtained. Denote the reading of the first sensor 1 as d5, the reading of the second sensor 2 as h5, the reading of the fifth sensor 5 as d6, the reading of the sixth sensor 6 as h6, the radius of the upper pulley 4 as r5, the radius of the lower pulley 7 as r6, the thickness of the slide rail 8 as T, the movement clearance between the lower pulley 7 and the slide rail 8 as c3, and its initial movement clearance calibration value as c 30, the initial thickness of the slide rail 8 is T0, and the readings of each sensor are all 0 after initial calibration. For the specific derivation process, please refer to the above text. The derived result formula is as follows:

[0126] The wear amount Δr5 of the upper pulley 4 = d5

[0127] The wear amount Δr6 of the lower pulley 7 = d6

[0128] The wear amount ΔT in the thickness direction of the slide rail 8 = h5 + h6

[0129] The movement clearance c3 between the upper and lower pulleys and the slide rail = h5 + h6 + d5 + d6 + c 30

[0130] The increase amount Δc3 of the movement clearance between the upper and lower pulleys and the slide rail = c3 - c 30 = h5 + h6 + d5 + d6 = Δr5 + Δr6 + ΔT

[0131] That is, the increase amount of the movement clearance between the upper and lower pulleys and the slide rail is the sum of the wear amounts of the upper pulley 4, the lower pulley 7, and the slide rail 8 in the thickness direction.

[0132] Through the above method, after completing the initial radius measurement and initial clearance calibration, according to the real-time data measured by the laser displacement sensor, the wear amounts of each pulley, the total wear amount on the side surface or in the thickness direction of the slide rail, and the size and change of the real-time movement clearance can be calculated respectively. Some parameters (such as D, s, E, r1, etc.) in the above steps can be obtained during the experimental assembly or calibration process, and those skilled in the art can adjust them according to the specific structure and requirements, which are not limited to the above numerical relationships.

[0133] In the description of the present application, it should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying 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 construed as a limitation to the present application.

[0134] The specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Without conflict, the embodiments of the present application and the features in the embodiments can be combined with each other arbitrarily.

Claims

1. A method for monitoring the wear of the flap pulley slide rail based on laser and dimensional chain, characterized in that It includes the following steps: S1: Install laser displacement sensors on the pulley rail assembly. Two laser displacement sensors are equipped for each pair of pulley rails to monitor the wear conditions of the pulleys and rails in real time; S2: Perform a zeroing operation on the installed laser displacement sensors to ensure that the readings of the laser displacement sensors in the non-worn state are the reference values; S3: Calibrate the movement clearance. Fill the initial movement clearance between the pulley and the rail with a standard block, and verify and ensure that the deviation of the readings of the laser displacement sensors is within the allowable range; S4: Conduct a wear test under the actual working conditions of the pulley rail assembly, collect the data of the laser displacement sensors, and record the data of the positions of the pulley rail contact surfaces changing with time; S5: Use the dimension chain analysis method. Through the surface position changes measured in real time by the laser displacement sensors and combined with the initial calibration data, calculate the wear amount and the change amount of the movement clearance of the pulley rail; 2. The flap pulley slide rail wear monitoring method based on laser and dimensional chain according to claim 1, wherein The installation positions of the laser displacement sensors include a first position and a second position to ensure that the measurement data cover all the worn surfaces of the pulley rail assembly. Among them, the first position is arranged on the front side or the rear side of the pulley with the laser emission direction facing the rail to detect the wear condition of the rail surface, and the second position is arranged on the upper side or the lower side of the pulley on the side where the pulley faces away from the rail with the laser emission direction facing the rail and passing through the center of the pulley to detect the wear condition of the pulley surface. The laser emission directions of the two laser displacement sensors at the first position and the second position are parallel; 3. The flap pulley slide wear monitoring method based on laser and dimensional chain according to claim 1, characterized in that, The laser displacement sensors are measured by being symmetrically arranged on both sides of the rail; 4. The flap pulley slide rail wear monitoring method based on laser and dimensional chain according to claim 1, characterized in that, The dimension chain analysis method is to calculate and compensate for the errors caused by the pulley wobbling by combining the structural dimensions of the pulley rail and the real-time data of the laser displacement sensors; 5. The flap pulley slide rail wear monitoring method based on laser and dimensional chain according to claim 1, characterized in that S4 includes setting different load conditions to make the pulley rail assembly operate dynamically under the actual load, and the laser displacement sensors synchronously record the changes in the positions of the pulley rail surfaces to provide real-time data for the wear amount calculation; 6. The flap pulley slide rail wear monitoring method based on laser and dimension chain according to claim 1, wherein The standard block is used to fill the initial movement clearance between the pulley and the rail during the calibration process. By comparing the readings of the laser displacement sensors with the dimensions of the standard block, ensure that the measurement error of the laser displacement sensors is controlled within a predetermined range; 7. A flap pulley slide rail wear monitoring device based on laser and dimensional chain, characterized in that It includes a slider (3), a rail (8), a first standard block (9), and a first laser displacement sensor (1), a second laser displacement sensor (2), an upper pulley (4), a third laser displacement sensor (5), a fourth laser displacement sensor (6), and a lower pulley (7) all configured on the slider (3); The inner side of the upper pulley (4) is in sliding or rotational fit with the upper side surface of the rail (8), and the inner side of the lower pulley (7) is in sliding or rotational fit with the lower side surface of the rail (8). The first standard block (9) is used to be configured between the upper pulley (4) and the rail (8) and / or between the lower pulley (7) and the rail (8) to calibrate the reference value of the laser displacement sensor, where: The first laser displacement sensor (1) is arranged outside the upper pulley (4) and faces the outer side surface of the upper pulley (4), and the axis of the laser emission beam passes through the center of the upper pulley (4). The second laser displacement sensor (2) is arranged on the front side or the rear side of the upper pulley (4), and the laser emission beam irradiates the upper side surface of the slide rail (8). The third laser displacement sensor (5) is arranged outside the lower pulley (7) and faces the outer side surface of the lower pulley (7), and the axis of the laser emission beam passes through the center of the lower pulley (7). The fourth laser displacement sensor (6) is arranged on the front side or the rear side of the lower pulley (7), and the laser emission beam irradiates the lower side surface of the slide rail (8).

8. The flap pulley slide rail wear monitoring device based on laser and dimensional chain according to claim 7, characterized in that The axes of the laser emission beams of the first laser displacement sensor (1) and the second laser displacement sensor (2) are parallel. The axes of the laser emission beams of the third laser displacement sensor (5) and the fourth laser displacement sensor (6) are parallel. The axes of the laser emission beams of the second laser displacement sensor (2) and the fourth laser displacement sensor (6) coincide.

9. The flap pulley slide rail wear monitoring device based on laser and dimensional chain according to claim 7, characterized in that, It further includes a second standard block (22), a third standard block (23), a first side pulley (10), a second side pulley (11), a third side pulley (12), a fourth side pulley (13), a fifth laser displacement sensor (14), a sixth laser displacement sensor (15), a seventh laser displacement sensor (16), an eighth laser displacement sensor (17), a ninth laser displacement sensor (18), a tenth laser displacement sensor (19), an eleventh laser displacement sensor (20), and a twelfth laser displacement sensor (21) all arranged on the slider (3); The inner sides of the first side pulley (10) and the second side pulley (11) are respectively in sliding or rotational fit with the upper side surface of the slide rail (8). The inner sides of the third side pulley (12) and the fourth side pulley (13) are respectively in sliding or rotational fit with the lower side surface of the slide rail (8). The second standard block (22) is used to be arranged between the first side pulley (10) and the slide rail (8) and / or between the third side pulley (12) and the slide rail (8). The third standard block (23) is used to be arranged between the second side pulley (11) and the slide rail (8) and / or between the fourth side pulley (13) and the slide rail (8), where: The fifth laser displacement sensor (14) is arranged outside the first side pulley (10) and faces the outer side surface of the first side pulley (10), and the axis of the laser emission beam passes through the center of the first side pulley (10). The sixth laser displacement sensor (15) is arranged on the front side or the rear side of the first side pulley (10), and the laser emission beam irradiates the upper side surface of the slide rail (8); The seventh laser displacement sensor (16) is arranged outside the second side pulley (11), facing the outer side surface of the second side pulley (11), and the axis of the laser emission beam passes through the center of the second side pulley (11). The eighth laser displacement sensor (17) is arranged on the front or rear side of the second side pulley (11), and the laser emission beam irradiates the lower side surface of the slide rail (8). The ninth laser displacement sensor (18) is arranged outside the third side pulley (12), facing the outer side surface of the third side pulley (12), and the axis of the laser emission beam passes through the center of the third side pulley (12). The tenth laser displacement sensor (19) is arranged on the front or rear side of the third side pulley (12), and the laser emission beam irradiates the upper side surface of the slide rail (8). The eleventh laser displacement sensor (20) is arranged outside the fourth side pulley (13), facing the outer side surface of the fourth side pulley (13), and the axis of the laser emission beam passes through the center of the fourth side pulley (13). The twelfth laser displacement sensor (21) is arranged on the front or rear side of the fourth side pulley (13), and the laser emission beam irradiates the lower side surface of the slide rail (8).

10. The flap pulley slide rail wear monitoring device based on laser and dimensional chain according to claim 9, characterized in that The axes of the laser emission beams of the fifth laser displacement sensor (14) and the sixth laser displacement sensor (15) are parallel. The axes of the laser emission beams of the ninth laser displacement sensor (18) and the tenth laser displacement sensor (19) are parallel. The axes of the laser emission beams of the sixth laser displacement sensor (15) and the tenth laser displacement sensor (19) coincide. The axes of the laser emission beams of the seventh laser displacement sensor (16) and the eighth laser displacement sensor (17) are parallel. The axes of the laser emission beams of the eleventh laser displacement sensor (20) and the twelfth laser displacement sensor (21) are parallel. The axes of the laser emission beams of the eighth laser displacement sensor (17) and the twelfth laser displacement sensor (21) coincide.

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