Rail detection device and method for large arm box girder of ship unloader

Abstract

The invention belongs to the technical field of steel structure monitoring, and particularly relates to a rail detection device and method for a ship unloader large arm box girder, and the device comprises a device main body which is integrated with a detection sensor and a processing unit, and further comprises a rail system which is arranged in a box girder and spans a rib partition plate, and comprises a bearing frame and a rail body, the bottom of the track body is connected to the bearing frame, and the bottom of the bearing frame is connected with a horizontal wing of the L-shaped quick release structure. The L-shaped quick release structure comprises two L-shaped adapter plates, and each L-shaped adapter plate is composed of a horizontal wing and a vertical wing; the two L-shaped adapter plates are arranged on the two sides of the rib partition plate in the mode that the vertical wings are opposite. The vertical wings and the rib partition plates which are oppositely arranged are clamped and fixed, and rapid connection between the track system and the box girder rib partition plates is achieved. A modular rib-crossing track system is formed, and non-blind-area and high-precision scanning of a key structure below is achieved.

Description

Technical Field

[0001] This invention belongs to the field of steel structure monitoring technology, specifically a track-based detection device and method for the box girder of a ship unloader boom. Background Technology

[0002] The statements in this section only refer to the background technology related to this invention and do not necessarily constitute prior art.

[0003] The steel box girder boom of the ship unloader is the main load-bearing component. Its interior is a closed box structure, subjected to alternating loads and complex environmental conditions over long periods, making it prone to fatigue cracks, corrosion, and other defects. Regular internal inspections are necessary to ensure structural safety. Current mainstream technologies involve pre-installing or temporarily laying tracks inside the structure to be inspected, using inspection trolleys or robots carrying sensors to perform linear scanning inspections along these tracks. This method improves the automation level of the inspection to some extent and reduces the risks associated with manual work at heights and in enclosed spaces.

[0004] However, when this type of track-based inspection solution is directly applied to the inside of the steel box girder boom of a ship unloader, a large number of transverse diaphragms (also called transverse ribs or rib diaphragms) are evenly distributed along the length of the box girder. These diaphragms are key stiffening and load-bearing components of the box girder, set perpendicular to the boom axis, and their tops are connected to the inner wall of the box girder top plate, forming a series of transverse rigid obstacles in the internal space of the box girder. If the inspection track is directly laid or fixed to the bottom plate or side wall of the box girder, the track line will be physically blocked by each transverse diaphragm, and the inspection trolley will be forced to stop when it reaches a transverse diaphragm, making it impossible to achieve one-stop continuous inspection of the entire boom length. If the area on the other side of the diaphragm needs to be inspected, the device must be disassembled, manually carried to the next section, and reinstalled, which is extremely inefficient and extremely inconvenient and dangerous to operate in high-altitude and confined spaces.

[0005] Some solutions attempting to overcome obstacles, such as using wheeled or tracked robots to directly climb crossbars, suffer from unpredictable trajectories and are prone to slipping and getting stuck on complex steel structures. Furthermore, the robot's violent shaking and pose uncertainty can severely impact the detection accuracy and reliability of sensors requiring stable coupling or precise spacing, such as ultrasonic and eddy current sensors, leading to data distortion. Summary of the Invention

[0006] This invention provides a rail-guided inspection device and method for the box girder of a ship unloader boom, which solves the problems of discontinuous inspection, blind spots, unstable operation and low accuracy caused by the obstruction of internal diaphragms in the prior art, and realizes safe, efficient and full-coverage automated non-destructive inspection.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: The first aspect of this invention discloses a track-guided detection device for the boom box girder of a ship unloader, comprising a device body, on which detection sensors and a processing unit are integrated, and further comprising: The track system, located inside the box girder and spanning the ribs, includes a load-bearing frame and a track body. The bottom of the track body is connected to the load-bearing frame, and the bottom of the load-bearing frame is connected to the horizontal wing of an L-shaped quick-release structure. The L-shaped quick-release structure includes two L-shaped transition plates, each consisting of a horizontal wing and a vertical wing. The two L-shaped transition plates are arranged on both sides of the ribs with their vertical wings facing each other. The track system is quickly connected to the box girder ribs by clamping and fixing the track system with the ribs through the oppositely arranged vertical wings.

[0008] Furthermore, the L-shaped quick-release structure is symmetrically connected to both sides of the transverse partition, and the two ends of the load-bearing frame are respectively connected to the horizontal wings of the two L-shaped quick-release structures located on the same axis.

[0009] Furthermore, the detection sensors integrated on the main body of the device include at least: a coating thickness gauge for detecting rust damage, an ultrasonic transmitting sensor and an ultrasonic receiving sensor for detecting cracks and stress, and a camera for acquiring surface images.

[0010] Furthermore, the ultrasonic transmitting sensor is a multi-directional rotating probe, and the ultrasonic receiving sensor contains multiple probes, whose receiving directions include at least vertically downward and directions at an acute angle to the vertical direction.

[0011] Furthermore, the track connection device includes an electromechanical integrated pulley assembly and an anti-derailment hook; the electromechanical integrated pulley assembly is connected to the main body of the device through a suspension base and engages with the track body to provide driving force; the anti-derailment hook is located on both sides of the electromechanical integrated pulley assembly and is used to hook the track body to prevent derailment.

[0012] Furthermore, the main body of the device is equipped with a central core signal processing unit, which is used to receive and process signals from various sensors, and to perform stress calculations, corrosion assessments, and crack detections; it is also equipped with an image and signal transmission device, which is used to send the processed data to a remote server.

[0013] Furthermore, the main body of the device has a hollow structure on its surface for weight reduction.

[0014] Furthermore, the main body of the device is equipped with a battery unit and a USB charging interface module.

[0015] Furthermore, the track body is a rack and pinion track.

[0016] The second aspect of this invention discloses a rail-based inspection method for the boom box girder of a ship unloader, comprising the following steps: S1: The vertical wing of the L-shaped quick-release structure is fixed to the side of the adjacent transverse diaphragm inside the box girder; S2: The assembled load-bearing frame and track body are mounted on the horizontal wing of the L-shaped quick-release structure and fixed with fasteners to form a continuous overhead track. S3: The main body of the device is mounted on the track body via the track connection device at its bottom; S4: The device starts up and the main body of the device runs automatically along the track. During the operation, the detection sensors on it continuously and without blind spots scan and detect the bottom plate, diaphragm and weld of the box girder below. S5: After the sensor data is processed by the processing unit, it is transmitted wirelessly to the server to generate a structural condition assessment report.

[0017] Compared with existing technologies, one or more of the above technical solutions have the following beneficial effects: 1. The track system's structure enables rapid installation, precise positioning, and high-strength load-bearing of the inspection track on the steel box girder ribs of the ship unloader. The track body and load-bearing frame can be pre-welded to ensure the overall rigidity and flatness of the track section; the load-bearing frame and the L-shaped quick-release structure's horizontal wings are connected by high-strength fasteners, forming a stable and reliable force transmission path; and the L-shaped quick-release structure allows the two vertical wings to synchronously and effectively clamp the ribs, thus firmly anchoring the entire track system inside the box girder without damaging the original structure. This design not only meets the technical requirement of the track plane being higher than the rib plane, facilitating continuous crossing of the inspection device, but also significantly improves the efficiency of track assembly and disassembly, ensuring operational safety and structural recoverability in confined high-altitude environments.

[0018] 2. The track is raised and fixed to the side of the diaphragm using an L-shaped adapter plate, creating a continuous overhead path above the diaphragm. When the inspection device operates on this path, the detection range of various sensors mounted below (such as ultrasonic probes and electromagnetic thickness gauges) completely avoids the obstruction of the diaphragm itself. This allows for direct and unobstructed scanning of blind spots and critical vulnerable areas traditionally detected, such as the bottom plate of the box girder, the fillet welds connecting the diaphragm and the bottom plate, and the diaphragm's own facade. This achieves one-stop, full-coverage inspection of all high-risk parts inside the steel box girder, greatly improving the completeness and reliability of the assessment.

[0019] 3. The entire track system can be prefabricated in the factory in a modular manner, and only standardized connection and installation are required on site, which avoids a large number of difficult welding operations inside the box girder, reducing installation risks and labor intensity.

[0020] 4. The L-shaped transition plate directly transfers all the loads of the track system (the weight of the device and the dynamic load of operation) to the main load-bearing structure of the box girder, the transverse diaphragm. The mechanical transmission path is clear and reliable, ensuring that the entire detection system can maintain extremely high overall stability even when the unloader boom sways slightly or is subjected to wind load. Attached Figure Description

[0021] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0022] Figure 1 This is a schematic diagram of the overall structure of the track detection device provided in one or more embodiments of the present invention; Figure 2 This is a partial structural view of a track detection device provided in one or more embodiments of the present invention; Figure 3 This is a schematic diagram of the main structure of a track detection device provided in one or more embodiments of the present invention; Figure 4 This is a schematic diagram of the internal structure of the anti-detachment hook of the track detection device provided in one or more embodiments of the present invention; Figure 5 This is a schematic diagram of the L-shaped quick-release structure of the track detection device provided in one or more embodiments of the present invention; Figure 6 This is a schematic diagram of the installation position of the track detection device provided in one or more embodiments of the present invention; Figure 7 This is a schematic diagram of the upper arm detection principle provided by one or more embodiments of the present invention.

[0023] In the diagram: 1. Main body of the device; 2. Track connection device; 3. Track body; 4. Load-bearing frame; 5. High-definition wide dynamic range engineering camera; 6. High-intensity lighting; 7. USB charging interface module; 8. Fasteners; 9. Electromagnetic induction turbine-type coating thickness gauge; 10. Multi-channel high-precision electromagnetic signal processing host; 11. Piezoelectric energy converter; 12. Central core signal processing unit; 13. Rechargeable lithium battery power supply; 14. Image and signal transmitting device; 15. Industrial-grade ultra-high-performance camera. 16. Acoustic wave emitting sensor; 17. Electromechanical pulley assembly; 18. Suspension base; 19. Anti-detachment hook; 20. L-shaped quick-release structure; 21. Horizontal wing; 22. Vertical wing; 23. Industrial-grade ultrasonic receiving sensor; 24. Rib partition; 25. Power supply conductive strip; 26. Sliding contact power supply device; 271. Pressure wrench; 272. Accelerometer; 273. Gyroscope; 274. Return spring; 275. Electric connecting rod; 276. Locking pin structure; 2777. Hook body. Detailed Implementation

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0025] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0026] As described in the background section, the mainstream technical solution for automated inspection of the interior of similar steel box girder structures is to use a track-mounted inspection trolley or robot. Specifically, a track is pre-installed or temporarily laid inside the structure to be inspected, and the inspection device, equipped with sensors, moves along the track to achieve linear scanning inspection. This method improves the level of automation to a certain extent and reduces the risks associated with manual work at heights and in enclosed spaces.

[0027] However, applying this type of track-based inspection solution directly to the inside of the steel box girder boom of a ship unloader faces a fundamental technical obstacle caused by its structural characteristics: a large number of transverse diaphragms (also known as transverse ribs or rib diaphragms) are evenly distributed along the length of the box girder. These transverse diaphragms are key stiffening and load-bearing components of the box girder, set perpendicular to the boom axis, and their tops are connected to the inner wall of the box girder top plate, forming a series of transverse rigid obstacles in the internal space of the box girder.

[0028] In existing track-based inspection solutions, if the inspection track is directly laid or fixed to the bottom plate or side wall of the box girder, the track line will be physically blocked by each diaphragm. The inspection trolley is forced to stop when it reaches a diaphragm, making it impossible to achieve continuous one-stop inspection of the entire boom length. To inspect the area on the other side of the diaphragm, the device must be disassembled, manually carried to the next section, and reinstalled, which is extremely inefficient and inconvenient and dangerous to operate at heights and in confined spaces.

[0029] It is important to note that the diaphragm itself, as well as the welds and corner areas connecting it to the base plate, are high-risk areas for fatigue cracks and corrosion, and are key areas for inspection. However, if the track is located on the base plate, when the trolley moves in front of the diaphragm, the detection line of its onboard bottom sensors (such as probes used for thickness measurement or flaw detection) is blocked by the diaphragm itself, making it impossible to effectively scan these critical areas, creating blind spots and seriously affecting the completeness of the assessment.

[0030] Meanwhile, some solutions attempting to overcome obstacles, such as using wheeled or tracked robots to directly climb crossbars, suffer from unpredictable trajectories and are prone to slipping and getting stuck on complex steel structures. Furthermore, the robot's violent shaking and pose uncertainty can severely impact the detection accuracy and reliability of sensors requiring stable coupling or precise spacing, such as ultrasonic and eddy current sensors, leading to data distortion.

[0031] In summary, the core flaw of the existing technology lies in the fact that its track system or motion mechanism is incompatible with the inherent transverse diaphragm obstacles inside the steel box girder of the ship unloader, resulting in a discontinuous detection process, blind spots in key areas, and difficulty in ensuring the stability and high accuracy of the detection data.

[0032] Therefore, this solution provides a rail-based detection device and method for the boom box girder of a ship unloader. It adopts a modular "cross-rib" track system consisting of an L-shaped transition plate, a load-bearing frame, and a track body. By raising the track above the top plane of the transverse diaphragm, a continuous and smooth overhead running path is formed, enabling the detection platform equipped with sensors to cross all transverse diaphragms without obstacles, and achieving blind-spot-free and high-precision scanning of the key structure below.

[0033] like Figures 1-7 As shown, the rail-guided detection device for the boom box girder of the ship unloader includes a main body 1. The bottom of the main body 1 is provided with a rail connection device 2. The rail connection device 2 cooperates with the rail assembly, and the rail assembly is connected to the load-bearing frame 4.

[0034] The track connection device 2 includes an electromechanical integrated pulley assembly 16 and an anti-detachment hook 18 disposed at the bottom of the device body 1. The electromechanical integrated pulley assembly 16 is connected to the bottom of the device body 1 via a suspension base 17, and the anti-detachment hook 18 is connected to the bottom edge of the device body 1.

[0035] The track assembly includes a track body 3, with electromechanical pulley assemblies 16 on both sides of the track body 3. By rotating the electromechanical pulley assemblies 16, the drive device body 1 runs along the direction of the track body 3. During operation, the anti-derailment hook 18 prevents the device body 1 from derailing by hooking the track body 3.

[0036] The bottom is equipped with the detection end of the electromagnetic induction turbine-type coating thickness gauge 9. One end of the main body 1 is equipped with an industrial-grade ultrasonic receiving sensor 22, and the other end is equipped with a high-intensity lighting lamp 6. The side is equipped with a USB charging interface module 7. The main body 1 is equipped with the host end of the electromagnetic induction turbine-type coating thickness gauge 9, a high-definition wide dynamic range engineering camera 5, a multi-channel high-precision electromagnetic signal processing host 10, a piezoelectric energy converter 11, a central core signal processing unit 12, an image and signal transmitting device 14, and an industrial-grade ultrasonic transmitting sensor 15. The main body 1 is also equipped with a rechargeable lithium battery power supply 13.

[0037] The USB charging interface module 7 is placed on the side surface of the device. The high-definition wide dynamic range engineering camera 5 and the high-intensity lighting lamp 6 are installed at the head of the device. The USB charging interface module 7 is placed on the side facade. The industrial-grade ultrasonic transmitting sensor 15, the multi-channel high-precision electromagnetic signal processing host 10, and the piezoelectric energy converter 11 are placed on the upper surface of the device. The electromagnetic induction turbine-type coating thickness gauge 9 is placed in the equipment installation channel that runs vertically through the middle of the main body 1 of the device. The industrial-grade ultrasonic receiving sensor 22 is installed at the tail of the device.

[0038] A high-definition wide dynamic range engineering camera 5 and a high-intensity lighting lamp 6 are mounted side by side at the head of the device. An electromagnetic induction turbine-type coating thickness gauge 9, a multi-channel high-precision electromagnetic signal processing host 10, a piezoelectric energy converter 11, a central core signal processing unit 12, and an image and signal transmitting device 14 are mounted side by side at the middle and rear of the upper surface of the device. An industrial-grade ultrasonic transmitting sensor 15 is mounted at the middle and front of the upper surface of the device, and an industrial-grade ultrasonic receiving sensor 22 is mounted at the middle and rear of the upper surface of the device. The central axes of the above devices are all coincident, and the components are arranged in a compact manner, which can greatly reduce the size of the device and is more suitable for the narrow space when inspecting the steel box girder boom of a ship unloader.

[0039] The high-definition wide dynamic range engineering camera 5 collects image information of the boom surface and transmits the collected images to the image and signal transmitting device 14. It can send the data to the server in the local area network and export the data to show whether there are obvious cracks on the surface of the steel box girder boom of the ship unloader.

[0040] The device also includes a rechargeable lithium battery power supply, which is detachably mounted and located at the edge of the device for easy replacement of old lithium batteries. The lithium battery power supply can be charged via a USB charging interface module.

[0041] The device includes a piezoelectric energy converter 11, which converts electrical signals into ultrasonic vibrations. Ultrasonic waves are emitted by an industrial-grade ultrasonic transmitting sensor 15, which can rotate 360° horizontally and 180° vertically, allowing for a wider range of ultrasonic wave emission and expanding the detection range. An ultrasonic receiver 22 receives and captures reflected echo signals. Three ultrasonic receiving probes are installed, one of which faces vertically downwards, while the other two are at 45° angles to the vertical line, enabling omnidirectional reception of ultrasonic waves reflected from the steel box girder boom, reducing detection errors. The signal is transmitted to the central core signal processing unit 12 for noise reduction and conversion into a digital signal. The processed signal is then transmitted to the image and signal transmitting device 14, which can send the data to a server on the local area network and export and display the stress deformation and fatigue cracks inside the steel box girder boom of the unloader.

[0042] The device includes an electromagnetic induction turbine-type coating thickness gauge 9. The device emits an electromagnetic field that acts on the coating being measured. The reflected electromagnetic field is received and converted into a digital signal, which is then transmitted back to the multi-channel high-precision electromagnetic signal processing host 10. The digital signal is then transmitted to the central core signal processing unit 12 for processing. The processed signal is then transmitted to the image and signal transmitting device 14, which can send the data to a server in the local area network and export and display the rust damage inside the steel box girder boom of the ship unloader.

[0043] The central core signal processing unit 12 has both storage function and the ability to accurately receive signals from sensors or other sources. It also has the ability to effectively suppress noise and interference in the signal. The central core signal processing unit 12 also has fast data processing and computing capabilities, and can complete the calculation and processing of a large amount of different types of data in a short time.

[0044] The main body 1 has two track connection devices 2 connected to the track. The track is engaged with the track through the electromechanical pulley assembly 16. The upper surface and the two side surfaces of the main body 1 have rectangular cutouts to reduce the weight of the device and improve the power supply endurance. The main body 1 is made of 316 stainless steel, which has good corrosion resistance and high temperature resistance and can be adapted to the dock environment.

[0045] like Figure 1 and Figure 3 As shown, the track connection device 2 is equipped with an electromechanical integrated pulley assembly 16, a suspension base 17, and an anti-detachment hook 18. The electromechanical integrated pulley assembly 16 is installed on the suspension base 17, and the anti-detachment hook 18 is installed on both sides of the electromechanical integrated pulley assembly 16. The anti-detachment hook 18 can prevent the main body 1 of the device from slipping off the track frame and ensure safety during operation.

[0046] The hook of the anti-detachment hook 18 maintains a non-rigid fit with the track body under normal operating conditions, serving only a protective function and not affecting the smooth operation of the main body of the device along the track. The anti-detachment hook 18 integrates an attitude sensing and motion monitoring unit, which can be composed of a gyroscope and an accelerometer, and is used to continuously collect the tilt angle change, angular velocity, linear acceleration and instantaneous impact signal of the main body of the device during operation.

[0047] When the detection device is running normally along the track, its attitude parameters and acceleration changes are within the preset safety threshold range. The anti-detachment hook remains in standby state. Under the action of the built-in elastic component, the hook body maintains a clearance fit with the track and does not generate additional resistance to the normal movement of the pulley assembly. When the detection device exhibits an abnormal posture due to localized track deformation, abrupt changes in the diaphragm structure, or overall vibration of the unloader boom, the attitude perception and motion monitoring unit will capture this change in real time and transmit the corresponding signal to the control module inside the anti-derailment hook. The control module compares the current state parameters with pre-set safety thresholds. Once it determines that there is a potential risk of derailment or instability, that is, before the device has substantially derailed, the anti-derailment hook 18 begins to function.

[0048] like Figure 4 As shown, the anti-detachment hook 18 includes an accelerometer 271, a gyroscope 272, a return spring 273, an electric linkage 274, a locking pin structure 275, and a hook body 276. The hook body 276 is mounted on the main body of the device via the return spring 273. One end of the return spring 273 is fixed to the main body of the device, and the other end is connected to the hook body 276. In the non-working state, the hook body 276 is in a standby position, and in the standby state, the return spring 273 is in a compressed state. When the anti-detachment hook 18 needs to function, the return spring 273 releases energy, pushing the hook body 276 to rotate and pop out quickly, causing the hook body to automatically contact the preset force-bearing part of the track, achieving "active pop-out hooking". This process does not require continuous external force and is completed solely by the elasticity of the return spring 273.

[0049] The locking pin structure 275 is connected to the main body of the device via an electric connecting rod 274. The locking pin structure 275 and the hook body 276 are designed with mutually engaging surfaces. After the hook body 276 pops out and enters the working position, the locking pin structure 275 begins to function. Under the action of gravity, the locking pin structure 275 automatically enters the locking position, firmly holding the hook body 276 in its current position and creating a rigid engagement between the hook body 276 and the track. When it is necessary to release the anti-detachment function of the anti-detachment hook 18, it can be operated via the electric connecting rod 274 on the main body of the device. The electric connecting rod 274 pulls the locking pin structure 275 out of the engagement position with the hook body. The preset return spring 273 provides continuous pull-back force after the lock is released, actively pulling the hook body 276 back to the standby position, while the return spring 273 is compressed again. The entire process realizes a complete cycle of "pop-lock-unlock-reset," and the use of the anti-detachment hook 18 effectively ensures operational safety.

[0050] The track body 3 is a rack and pinion track. The electromechanical integrated pulley assembly 16 is powered by a rechargeable lithium battery power supply 13, which can control the detection device to move forward or backward at a constant speed along the track, and can also control the stopping of the detection device. The rechargeable lithium battery power supply 13 is detachably installed at the edge of the device for easy replacement of old lithium batteries. The lithium battery power supply can be charged via a USB charging interface module 7, which corresponds to the rechargeable lithium battery. The rechargeable lithium battery provides a stable power supply to all detection components. The components inside the device are arranged compactly, which better adapts to the narrow space of the steel box girder boom, reduces battery power consumption, and improves endurance.

[0051] like Figure 2 and Figure 3 As shown, the rechargeable lithium battery power supply 13 is also powered by the track power supply system. The track power supply system integrates the power supply function with the running track of the detection device, so as to realize the continuous power supply of the detection device during its movement along the predetermined path inside the box girder.

[0052] The running track adopts an integrated structure, with independent power supply conductive strips 24 laid inside the track, such as... Figure 3 As shown, the power supply conductive strip 24 is electrically isolated from the steel box girder structure, and one end of it is connected to an external industrial power supply through a power supply terminal, thereby forming a continuous and stable power supply channel along the entire operating path.

[0053] like Figure 2 and Figure 3 As shown, the main body 1 of the device is equipped with a sliding contact power-collecting device 25 that matches the power supply conductive strip 24. During the movement of the detection device along the track, the sliding contact power-collecting device 25 maintains continuous and reliable contact with the conductive strip, enabling real-time acquisition of electrical energy. Through the coordinated operation of all components, a safe, stable, and continuous power supply without frequent battery replacements can be achieved inside the enclosed and narrow boom box girder of the ship unloader, thereby effectively improving the continuity and overall reliability of the detection operation.

[0054] The power supply conductive strip 24 is made of a highly conductive and wear-resistant metal material. The conductive strip only serves as a power supply channel and does not form an electrical circuit with the steel box girder structure. There are four sliding contact power supply devices 25, which are located inside each anti-detachment hook 18. The sliding contact power supply device 25 includes a sliding contact brush that matches the conductive strip. The brush is made of copper-based alloy and graphite composite material and is installed on the main body of the device by a spring compression component. It is always subjected to a preload force pressing against the conductive strip in the radial direction, so that the sliding contact brush can automatically compensate for the displacement caused by thermal deformation or vibration of the track when the main body of the device moves along the track, and ensure that the brush and the conductive strip always maintain a stable electrical contact state. When the detection device is started, the sliding contact power-generating device moves along the track with the main body of the device. Its sliding brush continuously contacts the surface of the power supply conductive strip under the action of elastic preload. During movement, relative sliding occurs between the sliding brush and the conductive strip, forming a stable, low-resistance sliding electrical contact interface. This allows external industrial power to continuously supply power to the sliding contact power-generating device through the conductive strip. After being introduced through the sliding brush, the electrical energy is transmitted through internal wires to the rechargeable lithium battery power supply 13 in the main body of the device, which can directly power the mechatronic pulley assembly, sensor system, and signal processing unit. During operation, even with slight track irregularities or low-frequency vibrations from the unloader's boom, the sliding contact power supply device can automatically adjust the brush position using its elastic structure, preventing power interruptions due to momentary poor contact. This ensures the continuous and stable operation of various sensors, lighting devices, and communication modules during the testing process. When the testing device stops operating or is removed from the track, the sliding contact power supply device naturally separates from the conductive strip. The entire power supply process requires no manual cable plugging or unplugging or additional operations, significantly improving usability within the confined space inside the box girder. The sliding contact power supply device 25 inside the unloader's boom box girder provides a stable and reliable power supply, avoiding the limited range and frequent power replacement issues associated with relying solely on battery power.

[0055] like Figure 3 and Figure 6 As shown, the bottom of the track body 3 is pre-welded to the load-bearing frame 4. After welding, the length of both ends of the track body 3 can exceed that of the load-bearing frame 4. The bottom of the load-bearing frame 4 is quickly locked to the rib plate 23 through the L-shaped quick-release structure 19, and the final connection between the L-shaped quick-release structure 19 and the rib plate 23 is achieved through fasteners 8.

[0056] The L-shaped quick-release structure 19 includes two L-shaped adapter plates arranged side by side. Each L-shaped adapter plate includes a horizontal wing 20 and a vertical wing 21. The two L-shaped adapter plates are arranged in a "back-to-back" manner, that is, the vertical wing 21 faces inward and the horizontal wing 20 faces outward. The two vertical wings 21 form a clamping space. The two vertical wings 21 are brought close to each other to achieve quick locking with the rib partition 23. After locking, the L-shaped quick-release structure 19, together with the load-bearing frame 4, is finally connected to the rib partition 23 through the fasteners 8 on the horizontal wing 20.

[0057] The L-shaped quick-release structure 19 is mechanically fixed to the rib plate 23. The L-shaped quick-release structure 19 is set on the rib plate 23 to enable the track system to be quickly installed and dismantled without destructive disassembly. The quick-release structure uses the L-shaped quick-release structure 19 as the basic connecting component. The load-bearing steel frame 4 is connected to the horizontal wing 21 of the L-shaped quick-release structure 19 with high-strength bolts. The horizontal wing 21 serves as a detachable support interface for the track load-bearing frame, allowing the load-bearing steel frame 4 and the track to be quickly assembled and disassembled while maintaining sufficient structural rigidity and load-bearing capacity.

[0058] During installation, the load-bearing steel frame 4 is simply lifted and placed on the L-shaped quick-release structure horizontal wing 20, so that the load-bearing frame naturally fits the horizontal wing support surface under the action of gravity, and is automatically aligned through the preset bolt hole positions. The operator only needs to tighten the corresponding high-strength bolts inside the box girder to complete the fixation, without the need for on-site welding or other operations.

[0059] When dismantling is required, simply loosen the fasteners sequentially inside the box girder. The load-bearing steel frame 4 and the track body above it can then detach as a whole from the horizontal wing 20 of the L-shaped transition plate. The entire process will not damage the diaphragm body or the box girder structure, and no subsequent repairs are necessary. This quick-release structure design significantly reduces the construction difficulty and manual operation risks in the high-altitude, confined space environment inside the box girder. Moreover, after the inspection task is completed, the original structural state inside the box girder can be quickly restored, avoiding the adverse effects of long-term residual facilities on the structural service performance.

[0060] The track body 3 and the load-bearing frame 4 can be divided into multiple sections. The bottom of each section is connected to an L-shaped quick-release structure 19, which enables quick clamping and fastening with the rib partition 23.

[0061] The main body of the L-shaped quick-release structure 19 consists of two L-shaped adapter plates arranged side by side, with a quick-release structure on the L-shaped adapter plates.

[0062] In one embodiment, the quick-release structure includes a mechanical knob disposed on the end face of the L-shaped adapter plate. Inside the L-shaped adapter plate, a gear is disposed that is driven to rotate by the mechanical knob. The gear meshes with two racks, which are respectively connected to the vertical wing 21. The vertical wing 21 is provided with a guide groove to guide the movement of the racks. By utilizing the gear and rack structure, the two racks are tightened to the two L-shaped adapter plates, thereby achieving quick locking of the L-shaped adapter plate and the rib partition.

[0063] In another embodiment, the quick-release structure includes a quick-release clamp, such as a latch-type quick-release clamp, disposed on the end face of the L-shaped adapter plate. The clamp includes a locking point, a base, and a handle 26. The locking point and base are respectively arranged on the end faces of the two L-shaped adapter plates. The handle is rotatably connected to the base. After the locking element on the handle is connected to the locking point, pressing the handle and pulling back the locking point causes the two L-shaped adapter plates to quickly clamp the rib plate 23. The quick-release clamp in this embodiment is an existing, mature product; here, only the example of... Figure 5 As an example.

[0064] In the track laying process, a laser level is used as the core technology, relying on the linear propagation characteristics of laser light and automatic leveling technology to construct a high-precision, unified horizontal reference surface, achieving accurate horizontal track installation. First, based on the construction drawings and elevation design requirements of the steel box girder boom, reference control points are laid out along the track axis in the construction area, with one point added every 50 meters. Precise calibration is completed using a total station trigonometric leveling method, ensuring that the elevation deviation between control points is strictly controlled within ≤0.1mm / m, forming a reliable elevation control network. Then, a 360° rotating projection-type automatic leveling laser level with a horizontal accuracy of ≤0.3mm / m is selected and fixed on a leveled tripod, positioned at the center of the steel box girder boom construction area, ensuring unobstructed laser propagation and full coverage of all track installation points. The instrument's automatic leveling function is activated, and after the laser output stabilizes, the reference surface is calibrated using the elevation adjustment knob, ensuring precise alignment with the design elevation of each control point, with an overlap error of ≤0.05mm. Next, laser receiving targets are placed at each track installation point according to the designed spacing. The installation height of the track supports is adjusted to ensure that the upper surface of the track is completely aligned with the laser reference plane, and nuts are tightened to prevent displacement. After fixing, a second check is performed to ensure no deviation. Finally, a digital height gauge is used to check the entire length of the track in sections, with each 20m section serving as a check section. The elevation deviation within a section is ≤0.2mm / m, the overall deviation is ≤0.3mm / m, and the maximum deviation at a single point is ≤0.5mm. This operation procedure avoids environmental interference such as strong light and strong winds, and can complete the high-precision and stable installation of the track.

[0065] like Figure 6 As shown, this solution uses a rechargeable lithium battery to power a high-definition wide dynamic range engineering camera, an industrial-grade ultrasonic transmitting sensor, an industrial-grade ultrasonic receiving sensor, and an electromagnetic induction turbine-type coating thickness gauge. The collected electromagnetic signals are transmitted to a multi-channel high-precision electromagnetic signal processing host, and together with the collected ultrasonic signals, they are transmitted to the central core signal processing unit. After processing and analysis, the signals are transmitted to the image and signal transmitting device, and finally to the server in the local area network.

[0066] like Figure 6As shown, the data transmitted to the server can be cleaned using computational software such as Python, Matlab, and JavaScript to remove noise and outliers, repair missing data, and unify and standardize data from different sources such as cameras and sensors through format conversion. Subsequently, the cleaned data is stored and integrated in database systems such as MySQL, PostgreSQL, and Oracle Database. Through their retrieval management and query optimization, centralized management and rapid retrieval of multi-source data are achieved, laying a stable data foundation for subsequent analysis. In the further data analysis stage, tools such as NumPy, SciPy, and Pandas can be used for statistical analysis, linear or nonlinear model fitting, error analysis, and trend prediction of mechanical models. Simultaneously, visualization tools such as Matplotlib, Seaborn, and Plotly can be used to visually present the server's data information in the form of curves, scatter plots, heatmaps, or 3D structural reconstructions, showing structural state changes and stress distribution characteristics from multiple perspectives. Finally, the analysis results, along with charts, model outputs, and other content, can be automatically generated into a detection report using word processing software such as Microsoft Word and LibreOfficeWriter, making the data analysis results readable. The report may include health assessment, data indicator comparison, early warning prompts, etc., to assist engineers in determining the structural status and making maintenance decisions, thereby completing a complete data processing loop from data collection to server data integration, result visualization, and decision-making.

[0067] During operation, the electromechanical pulley assembly 16 is powered by the rechargeable lithium battery 13, which causes the main body 1 of the device to move at a constant speed in the track direction. As the main body 1 of the device moves, the high-definition wide dynamic range engineering camera 5 and the high-intensity lighting 6 located at the head of the device begin to work synchronously.

[0068] The high-intensity lighting lamp 6 automatically adjusts the brightness under different lighting conditions. The high-definition wide dynamic range engineering camera 5 can capture images within 180° and, together with the high-intensity lighting lamp 6, completes high-definition video recording in different environments. The captured images are transmitted to a server in the local area network through the image and signal transmitting device 14. The received boom surface image can be exported and used to identify whether there is large-area rust or obvious cracks on the boom surface of the unloader.

[0069] When the device begins detection, the industrial-grade ultrasonic transmitter 15 emits high-frequency ultrasonic waves and performs two full-segment data acquisitions according to the program settings. These two data acquisitions occur continuously during the round trip. After the two full-segment data acquisitions are completed, the ultrasonic crack detector automatically enters standby mode and ceases data acquisition according to the program settings.

[0070] The industrial-grade ultrasonic transmitting sensor 15 emits ultrasonic waves at a frequency of 0.5MHz. The ultrasonic waves propagate inside the steel box girder arm and reflect when they encounter a crack. The industrial-grade ultrasonic receiving sensor 22 receives the reflected signal and converts it into a digital signal. The digital signal is then processed by the central core signal processing unit 12. By analyzing the changes in wave velocity and amplitude, and because the ultrasonic wave returns to the crack in a shorter time than when it does not encounter a crack, the central core signal processing unit 12 can depict the location and extent of the crack through high-frequency ultrasonic wave transmission and reception. After that, it is connected to the image and signal transmitting device 14 to send relevant signals to the server in the local area network. The data on propagation time and amplitude information can be exported and a relevant 3D model can be drawn, thereby determining the location and extent of the crack.

[0071] When detecting stress, an industrial-grade ultrasonic transmitter 15 emits a specific 0.5MHz ultrasonic wave into the object being tested. This ultrasonic wave propagates along the interior of the object. During propagation, the propagation speed of the ultrasonic wave changes due to the stress inside the object. The magnitude and direction of the stress affect the degree of speed change. The industrial-grade ultrasonic receiver 22 captures the ultrasonic wave signal reflected back after propagating through the object's interior, and records the propagation time or speed change. This information is then transmitted to the central core signal processing unit 12. The signal processing system filters, analyzes, and calculates the received signal data, converting the change in ultrasonic wave propagation speed into a specific stress value. This value is then transmitted to a server on the local area network via an image and signal transmitter 14. The propagation time and speed data can be exported, and a stress-velocity curve of the received data can be established. By comparing the stress-velocity curve under pre-calibrated standard conditions, the internal stress damage can be determined, completing the detection process.

[0072] When the main body 1 of the device starts working, the electromagnetic induction turbine coating thickness gauge 9 starts working continuously. The electromagnetic induction turbine coating thickness gauge 9 starts to emit a regular electromagnetic field through the power supply of the rechargeable lithium battery power supply 13. During the operation, it will collect information for the whole section. After the information collection for the whole section is completed, the electromagnetic induction turbine coating thickness gauge 9 will automatically enter the standby state and stop collecting information according to the program settings.

[0073] During the operation of the electromagnetic induction turbine-type coating thickness gauge 9, the electromagnetic field reflected by the coating being measured is captured. When this electromagnetic field acts on the metal substrate of the object being measured, eddy currents are induced on the substrate surface. These eddy currents generate a reverse electromagnetic field, which affects the impedance of the probe coil. The thicker the coating of the object being measured, the more obvious the influence of the eddy currents. The internal circuit of the instrument converts this into a processable digital signal and sends it back to the multi-channel high-precision electromagnetic signal processing host 10. The multi-channel high-precision electromagnetic signal processing host 10 amplifies and reduces noise in the digital signal and extracts the effective signal components. Then, the effective signal is sent to the central core signal processing unit 12 for processing. The central core signal processing unit 12 converts the impedance change signal in the electromagnetic induction thickness measurement into the corresponding thickness value. At the same time, it compares the eddy current anomaly signal in the electromagnetic flaw detection with the standard defect signal to identify the defect location and size. The processed signal is sent to the image and signal transmitting device 14 to send data to the server in the local area network. The data can be exported to infer whether there is rust damage on the steel box girder boom of the unloader and the degree and location of the rust damage.

[0074] The detection method implemented by the above-mentioned track detection device includes the following steps: S1: High-definition wide dynamic range engineering camera 5 continuously acquires image information.

[0075] S2: Electromagnetic induction turbine-type coating thickness gauge 9, industrial-grade ultrasonic transmitting sensor 15, industrial-grade ultrasonic receiving sensor 22 periodically collects the reverse magnetic field strength of the eddy current in the boom and the characteristics and reflection time of the ultrasonic echo.

[0076] S3: Image data and sensor signals are transmitted to the central core signal processing unit 12 for data analogy and signal conversion, while stress calculation, corrosion assessment and crack judgment are performed.

[0077] S4: The calculation and processing results can be sent to a server in the local area network via the image and signal transmitting device 14. The data such as the reverse magnetic field strength, ultrasonic reflection time, amplitude of the reflected wave, and wavelength of the reflected wave can be exported and displayed. Then, relevant software can be used to perform data calculation and generate a test report.

[0078] S5: The mechatronic pulley assembly 16 and the rechargeable lithium battery 13 ensure that the detection system can operate stably and effectively for a long time.

[0079] The S1-S5 operation allows for comprehensive testing of the stress condition, crack condition, and corrosion degree inside the steel box girder boom of the ship unloader.

[0080] The aforementioned solution uses an L-shaped adapter plate to lift and fix the track to the side of the diaphragm, creating a continuous overhead path above the diaphragm. When the inspection device operates on this path, the detection range of various sensors mounted below (such as ultrasonic probes and electromagnetic thickness gauges) completely avoids the obstruction of the diaphragm itself. This allows for direct and unobstructed scanning of blind spots and critical vulnerable areas traditionally detected, including the bottom plate of the box girder, the fillet welds connecting the diaphragm and the bottom plate, and the diaphragm's own facade. This achieves, for the first time, one-stop, full-coverage inspection of all high-risk parts inside the steel box girder, greatly improving the completeness and reliability of the assessment.

[0081] The modular track system connects to the L-shaped transition plate via a load-bearing frame, creating a flat, rigid, continuous track between adjacent diaphragms. The inspection device does not need to stop, disassemble, or traverse complex obstacles when encountering diaphragms, and can smoothly and uniformly complete the automated scanning of the entire box girder length along the track. This fixed guide path completely eliminates the slippage, bumps, and positional drift that can occur with wheeled or tracked mobile platforms, providing an extremely stable working platform for non-destructive testing technologies such as ultrasonic and eddy current testing, which have stringent requirements for coupling and spacing. This ensures high accuracy and repeatability of data acquisition, and improves inspection efficiency several times compared to traditional segmented manual methods.

[0082] The entire track system can be prefabricated modularly in the factory, requiring only standardized bolt connections on site. This avoids extensive and complex welding work inside the box girder, reducing installation risks and labor intensity. The testing process is fully automated and remotely controlled. Operators do not need to enter the confined and dangerous interior of the box girder, nor do they need to perform high-risk climbing and positioning, fundamentally eliminating personal safety accidents. The device's power supply and signal are both wireless or built-in, avoiding the entanglement and safety hazards caused by dragging cables.

[0083] The L-shaped adapter plate directly transfers the entire load of the track system (equipment self-weight and dynamic load during operation) to the main load-bearing structure of the box girder, the diaphragm. This clear and reliable mechanical transmission path ensures the entire detection system maintains extremely high overall stability even under slight swaying of the unloader boom or wind loads. The main body of the device is made of 316 stainless steel with a perforated design, combining excellent corrosion resistance, structural strength, and lightweight characteristics. The modular design also facilitates partial replacement and maintenance, resulting in a long system lifespan and making it ideal for the harsh working conditions of ports with high humidity and high salt spray.

[0084] By integrating multiple sensors, including high-definition vision, ultrasonic stress / crack detection, and electromagnetic eddy current corrosion detection, this device can simultaneously collect multi-dimensional data such as appearance, internal defects, material thickness, and stress state during a single pass. The central processing unit performs real-time fusion analysis and transmits standardized data to the back-end server wirelessly. It can automatically generate a comprehensive report including 3D defect imaging, trend analysis, and health assessment, providing comprehensive and objective data support for structural maintenance decisions and promoting the intelligent transformation and upgrading of inspection work from "human experience judgment" to "data-driven decision-making."

[0085] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A track-based detection device for the box girder of a ship unloader's boom, comprising a main body, wherein the main body integrates detection sensors and a processing unit, characterized in that, Also includes: The track system, located inside the box girder and spanning the ribs, includes a load-bearing frame and a track body. The bottom of the track body is connected to the load-bearing frame, and the bottom of the load-bearing frame is connected to the horizontal wing of an L-shaped quick-release structure. The L-shaped quick-release structure includes two L-shaped transition plates, each consisting of a horizontal wing and a vertical wing. The two L-shaped transition plates are arranged on both sides of the ribs with their vertical wings facing each other. The track system is quickly connected to the box girder ribs by clamping and fixing the track system with the ribs through the oppositely arranged vertical wings.

2. The rail-guided detection device for the unloader boom box girder as described in claim 1, characterized in that, The L-shaped quick-release structure is symmetrically connected to both sides of the transverse partition, and the two ends of the load-bearing frame are respectively connected to the horizontal wings of the two L-shaped quick-release structures located on the same axis.

3. The rail-guided detection device for the unloader boom box girder as described in claim 1, characterized in that, The detection sensors integrated on the main body of the device include at least: a coating thickness gauge for detecting rust damage, an ultrasonic transmitting sensor and an ultrasonic receiving sensor for detecting cracks and stress, and a camera for acquiring surface images.

4. The rail-guided detection device for the unloader boom box girder as described in claim 3, characterized in that, The ultrasonic transmitting sensor is a multi-directional rotating probe, and the ultrasonic receiving sensor contains multiple probes, whose receiving directions include at least vertically downward and directions forming an acute angle with the vertical direction.

5. The rail-guided detection device for the unloader boom box girder as described in claim 1, characterized in that, The track connection device includes an electromechanical integrated pulley assembly and an anti-derailment hook; the electromechanical integrated pulley assembly is connected to the main body of the device through a suspension base and engages with the track body to provide driving force; the anti-derailment hook is located on both sides of the electromechanical integrated pulley assembly and is used to hook the track body to prevent derailment.

6. The rail-guided detection device for the unloader boom box girder as described in claim 1, characterized in that, The device is equipped with a central core signal processing unit inside, which is used to receive and process signals from various sensors, and to perform stress calculations, corrosion assessments, and crack detections; it is also equipped with an image and signal transmission device, which is used to send the processed data to a remote server.

7. The rail-guided detection device for the unloader boom box girder as described in claim 1, characterized in that, The main body of the device has a hollow structure on its surface for weight reduction.

8. The rail-guided detection device for the unloader boom box girder as described in claim 1, characterized in that, The main body of the device is equipped with a battery unit and a USB charging interface module.

9. The rail-guided detection device for the unloader boom box girder as described in claim 1, characterized in that, The track body is a rack and pinion track.

10. A method for track-based detection of the boom box girder of a ship unloader based on the device described in any one of claims 1-9, characterized in that, Includes the following steps: The vertical wing of the L-shaped quick-release structure is fixed to the side of the adjacent transverse diaphragm inside the box girder; The assembled load-bearing frame and track body are mounted on the horizontal wing of the L-shaped quick-release structure and fixed with fasteners to form a continuous overhead track. The main body of the device is mounted on the track body via a track connection device at its bottom; Once the device is started, the main body of the device will automatically run along the track. During the operation, the detection sensors on it will continuously and without blind spots scan and detect the bottom plate, diaphragm and welds of the box girder below. After being processed by the processing unit, the sensor data is transmitted wirelessly to the server to generate a structural condition assessment report.

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