Monitoring system

Abstract

The invention is directed to a monitoring system (1) for moving machine parts (2), in particular of drilling equipment (3), having a sensor device (4), which comprises a plurality of adjacent sensors (12), which at least partially surround the machine part (2) to be monitored; a reference profile (5), which is arranged spaced apart from the sensor device (4), wherein the sensors (12) of the sensor device (4) are each configured to transmit measurement beams (M1, M2, M3, M4, M5, M6) to the reference profile (5); and a control device (7) having an evaluation unit (8), which is configured to compare the measured values (W1, W2, W3, W4, W5, W6) resulting from the measurement beams (M1, M2, M3, M4, M5, M6) with associated reference measured values (R1, R2, R3, R4, R5, R6) and to determine a measurement span (Δ) therefrom.

Description

title SURVEILLANCE SYSTEM Technical field

[0001] The invention relates to a monitoring system for moving machine parts, in particular of drilling equipment, according to the introductory part of independent claim 1.

[0002] Generally, machines have moving parts due to their function. These can include shafts, spindles, press dies, drive elements, conveyors, and the like. These parts are driven with comparatively high force. People and / or objects can therefore be seriously injured if they are in the path of moving machine parts. Furthermore, there is a risk that if the machine malfunctions, its parts could break off and become potentially lethal projectiles.

[0003] To protect people and property from the aforementioned hazards, it is common practice, and in some cases mandatory, to enclose machines, at least partially, with so-called machine guards. This serves two purposes: firstly, it can catch potentially flying debris, and secondly, it prevents unauthorized access to the machine from the outside. Machine guards vary in design depending on the manufacturer and feature different mesh sizes and / or angled edges.

[0004] Machine guards as mechanical barriers are quick and easy to implement and, at first glance, offer a significant safety advantage. However, experience shows that such barriers often make working with the equipment so difficult that the operating crew has to find creative solutions to their advantage. To fulfill the task. This solution therefore has significant disadvantages that should be avoided if possible.

[0005] The aforementioned disadvantages of mechanical separation devices are partially overcome by light barriers, which, however, can only detect the presence or absence of an object.

[0006] The same principle applies to light curtains or safety light curtains, which are used to monitor an entire area. Essentially, several one-way light barriers are simply placed next to each other. As soon as a beam is interrupted, this is detected by the receiver. State of the art

[0007] For example, DE 20 2011 051 295 U1 discloses a light grid with light emitters and light receivers that form pairs of individual, parallel-aligned light barriers, wherein the light emitters and light receivers are arranged in at least one elongated aluminum housing and are each assigned to optical modules. The housing has a front window through which the light beams of the light barriers pass, and the housing can be fixed to a mounting surface by means of at least one bracket. An optical module comprises a one-piece multiple lens with several lenses arranged adjacent to each other in the longitudinal direction of the housing, as well as a one-piece tube body with several tubes arranged adjacent to each other in the longitudinal direction of the housing, and a one-piece aperture carrier with several aperture openings arranged adjacent to each other in the longitudinal direction of the housing.In this system, a tube, a lens, and an aperture are aligned relative to each other, defining an optical axis for a light beam. This alignment is achieved by assembling the tube body, multiple lens, and aperture carrier to form the optical module. The coefficients of thermal expansion of the tube body, aperture carrier, and aluminum housing are all the same.

[0008] However, even with this solution, the distance to an object cannot be detected.

[0009] 3D cameras, on the other hand, provide optical images for object recognition, which are additionally equipped with depth information. This is achieved through TOF measurement technology (TOF stands for Time-of-Flight). Depth information can be used to determine how far objects in an image are from the camera. By defining different zones, it's possible to distinguish between permitted and prohibited areas.

[0010] A corresponding 3D camera is described, for example, in DE 20 2014 101 550 U1, where the 3D camera is specifically equipped with an image sensor for capturing three-dimensional image data from a field of view and with a panoramic mirror optic positioned in front of the image sensor. The geometry of the panoramic mirror optic does not form a solid of revolution, thus improving the optics. By foregoing the solid of revolution, continuous monitoring over a large angular range is ensured, while the shape allows for a redistribution of measurement points, enabling more precise capture of particularly interesting areas at the expense of less interesting areas.

[0011] However, it should be noted that 3D cameras have relatively high purchase costs, which are often not worthwhile, especially for monitoring drilling equipment. Furthermore, 3D cameras are often not robust enough for use in drilling operations.

[0012] The present invention is therefore based on the objective of providing a solution for a non-mechanical protective grid for, in particular, moving machine parts of drilling equipment, which ensures reliable and at the same time cost-effective distance measurement. Description of the invention

[0013] The problem is solved according to the invention by a monitoring system as defined in independent claim 1. Advantageous embodiments of the invention are set forth in the dependent claims.

[0014] The essence of the invention is as follows: A monitoring system for moving machine parts, and in particular for moving machine parts of drilling rigs. The monitoring system comprises a sensor device comprising a plurality of sensors arranged side by side, which at least partially surround the machine part to be monitored. The monitoring system further comprises a reference profile spaced apart from the sensor device. The system is arranged in such a way that the sensors of the sensor device are each configured to emit measuring beams towards the reference profile. Finally, the monitoring system includes a controller with an evaluation unit which is configured to compare the measured values ​​resulting from the measuring beams with corresponding reference measured values ​​and to determine a measurement range from this.

[0015] This method of differential measurement allows the system to be independent of the current position of the moving machine part (and the sensor device). Application areas include all types of drilling equipment. Applications in other fields, such as construction or warehousing, are also conceivable (i.e., generally where moving machine parts could pose a hazard to personnel).

[0016] The term "emit measuring beam" here encompasses the output of a sensor signal, usually in a radial shape, and the reception of a corresponding return signal, usually in a radial shape, reflected by a known body or by a foreign body.

[0017] The term "reference profile" here encompasses, for example, the surface of a known body scanned by the sensors (such as a crusher surrounding the borehole and possibly part of the drill rig, etc.) and possibly another surface that does not belong to the known body and may be at a different elevation than the surface of the known body (such as a ground surface surrounded by the crusher, etc.). In principle, the reference profile can also consist solely of a ground surface and / or another device-independent surface.

[0018] Preferably, the evaluation unit is configured to determine the measurement range from the difference between the maximum deviation of a (distance) measurement from the corresponding (distance) reference value and the minimum deviation of a (distance) measurement from the corresponding (distance) reference value. This form of evaluation has proven to be particularly efficient and reliable in practice.

[0019] Preferably, the controller is also configured to trigger a detection signal when the measurement span determined by the evaluation unit exceeds a certain threshold. a predefined limit is reached or exceeded. In this way, a moving machine part or the associated machine can be quickly stopped upon detection of a foreign object.

[0020] Preferably, the sensor device moves with the machine part to be monitored during operation. The sensor device is usually attached to the moving machine part, such as a drill rig, which makes its use particularly accurate and effective.

[0021] Preferably, the sensors of the sensor device comprise laser distance sensors, each of which includes a laser diode for emitting a laser beam to the reference profile and an (integrated) receiver for receiving the laser beam reflected by the reference object or by an extraneous object. The laser beam is thus the measuring beam. The use of laser distance sensors (time-of-flight measurement) has proven to be both cost-effective and reliable. However, other types of distance measuring sensors, such as those using triangulation or phase modulation, can also be used to perform the distance measurement according to the invention. The use of radar sensors is also conceivable.

[0022] In principle, it is also possible to carry out the distance measurement according to the invention using one or more 3D cameras; however, this is usually less efficient for cost reasons.

[0023] Preferably, the sensor device is formed from one or more measuring bars encompassing the sensors, which surround the machine part to be monitored. These can be easily arranged or mounted, for example, at the upper end of a drill rig and have proven to be practical modular units for the sensors.

[0024] Preferably, one or more measuring bars form a laser grid around the machine part being monitored during operation. This virtual laser grid offers more effective protection than, in particular, the often bulky mechanical separating devices (i.e., such as the machine guards mentioned earlier).

[0025] Preferably, one or more measuring bars are configured to form a polygonal, rectangular, square, triangular, round, or oval laser grid around the machine part to be monitored. The geometric design of the laser safety grid is regularly adapted to the respective application and location. In particular, the measuring bars with the sensors are guided linearly along or parallel to the drilling or central axis, so that the individual sensors of the laser grid always move along the same vertical line.

[0026] Preferably, the minimum distance between the machine part to be monitored and the laser grid is approximately 5 cm, preferably approximately 10 cm, and more preferably approximately 12 cm. These distances provide optimal protection, particularly for use with drilling equipment. Other distances are conceivable for other applications.

[0027] Preferably, the measuring bars have a length of approximately 400 mm to approximately 500 mm, and preferably a length of approximately 450 mm. These dimensions have proven particularly practical for use with drilling equipment. Other lengths are conceivable for other applications.

[0028] Preferably, the number of sensors per measuring bar is from about 10 to about 18, and preferably from about 14 to about 16. These quantities have proven particularly efficient for use in drilling equipment. Other quantities are conceivable for other applications.

[0029] Preferably, the center-to-center distance between the individual sensors is from about 25 mm to about 35 mm, and preferably about 30 mm. This allows for the smallest possible protective mesh while minimizing mutual interference between the sensors.

[0030] Preferably, the measuring distance of the sensor device is between about 1 cm and about 10 m, more preferably between about 5 cm and about 5 m, and more preferably between 3 cm and 3 m. Within these distances, the monitoring system according to the invention operates particularly reliably.

[0031] Preferably, the sensors have a measurement frequency of approximately 10 Hz to approximately 50 Hz, and preferably approximately 30 Hz. These frequency ranges provide a particularly good system response time and thus high measurement accuracy.

[0032] Preferably, the sensors are controlled sequentially. This measure also serves in particular to ensure a particularly high level of measurement accuracy. Brief description of the drawings

[0033] Further advantageous embodiments of the invention will become apparent from the following description of exemplary embodiments of the invention with the aid of the schematic drawing. In particular, the system according to the invention will be described in more detail below with reference to the accompanying drawings and exemplary embodiments. The drawings show: Fig. 1: an exemplary measuring bar for a sensor device in a monitoring system according to the invention; Fig. 2: a schematic representation of the structure of a monitoring system according to the invention using an exemplary drilling rig; Fig. 3: a schematic representation of a device according to the invention Monitoring system during the recording of reference measurements; Fig. 4: a schematic representation of a device according to the invention Monitoring system in an exemplary scenario A in which no foreign object is present; Fig. 5: a schematic representation of a monitoring system according to the invention in an exemplary scenario B in which a foreign object is present; and Fig. 6: a table with exemplary numerical values ​​for, in particular, the reference values, measured values ​​and measuring ranges of the present example scenarios A and B. Ways to carry out the invention

[0034] Certain terms are used in the following description for practical reasons and are not to be understood restrictively. The words "right," "left," "below," and "above" denote directions in the drawing to which reference is made. The terms "inward," "outward," "below," "above," "left," "right," or similar are used to describe the arrangement of designated parts relative to one another, the movement of designated parts relative to one another, and the directions toward or away from the geometric center of the invention and of designated parts thereof, as shown in the figures. These spatial relative terms also include positions and orientations other than those shown in the figures. For example, if a part shown in the figures is turned upside down, elements or features described as "below" are then "above."The terminology includes the words explicitly mentioned above, derivatives of the same, and words of similar meaning.

[0035] To avoid repetition in the figures and the associated descriptions of the various aspects and embodiments, certain characteristics should be understood as common to different aspects and embodiments. The omission of an aspect in the description or a figure does not imply that this aspect is missing in the corresponding embodiment. Rather, such an omission may serve to improve clarity and prevent repetition. In this context, the following rule applies to all subsequent descriptions: If a figure contains reference symbols for the purpose of graphical clarity, but these are not mentioned in the immediately associated descriptive text, reference is made to their explanation in preceding figure descriptions.Furthermore, if the descriptive text directly pertaining to a figure mentions reference symbols that are not included in the figure itself, reference is made to the preceding and following figures. Similar reference symbols in two or more figures represent similar or identical elements.

[0036] Figure 1 illustrates an exemplary measuring bar 10 for a sensor device of a monitoring system according to the invention. The measuring bar 10 comprises a housing 16 in which a sensor holder 15 for the individual sensors 12 is arranged. Each of the sensors 12 shown, which are here represented by example as The laser sensor assembly comprises a laser diode 13 for emitting a laser beam and a receiver 14 for receiving the laser beam reflected by a neutral object (e.g., a stone) or a foreign object. A connector 11 is arranged laterally on the housing 16 of the measuring bar 10. In this example, the measuring bar 10 includes a total of fourteen laser sensors 12; however, depending on the application, there may be more or fewer sensors. The distance between the individual sensors 12, or between the laser beams emitted by the LED, is referred to here as the center-to-center distance S. To minimize potential mutual interference, the center-to-center distance S between the individual sensors should be approximately 25 mm to approximately 35 mm, and preferably approximately 30 mm. Sequential control of the sensors is provided as a possible corrective measure.

[0037] Figure 2 schematically illustrates the structure of a monitoring system 1 according to the invention using an exemplary drilling rig 3. The drilling rig 3, with its central or drill axis Z, comprises a drill carriage 2 as a movable machine part. At the upper end of the drill carriage 2, a measuring bar 10 of a sensor device 4 is shown, the sensor device 4 being mounted on the drill carriage 2 or on the drilling rig 3. During operation, the sensor device 4 moves with the drill carriage 2 in the Y-direction and comprises the (laser) sensors that emit the individual measuring beams M. The entirety of the measuring beams M forms the laser grid 18 around the drill carriage 2. In the area of ​​the base 9, the drill carriage 2 is at least partially surrounded by a reference object or a crusher 5, which, together with the base 9, forms a reference profile 5, 9 used to determine the reference measured values ​​R.The sensor device 4 is connected to a controller 7, which has an evaluation unit 8. The connection between the sensor device 4 and the controller 7 can be made using suitable connecting elements (e.g., cables or wires, etc.) or wirelessly. The controller 7 is also connected to a drive of the drilling rig 3, which is not shown separately here.

[0038] Figure 3 shows an exemplary schematic representation of a monitoring system 1 according to the invention during the acquisition of reference measurements R1-6. The acquisition of reference measurements R1-6 can be carried out in any position of the drill rig 2 with the sensor device 4. In this example, the distance between the lower edge of the sensor device 4 and the ground 9 is three meters. The crusher 5 has a height of one meter. The measuring beams Mi, M2, M3, M4, M5, and Mß of the corresponding sensors, now shown individually for better illustration, form the laser grating 18, with the reference profile 5, 9 formed by the top of the crusher 5 and the surface of the ground 9. As shown in the table in Fig. 6, the reference measurements Ri and R2 of 200 cm are obtained for measuring beams Mi and M2, respectively; the reference measurements R3, R4, and R5 of 300 cm are obtained for measuring beams M3, M4, and M5; and the reference measurement Rß of 200 cm is obtained for measuring beam Mß.

[0039] When the drilling rig 3 or the drill carriage 2 with the sensor device 4 is moved downwards during operation, the following example scenarios A and B, illustrated below with reference to Figures 4 and 5, result for the functioning of the monitoring system 1 according to the invention and for determining whether a foreign object is located in the area monitored by the laser grid 18 around the moving machine part or the drill carriage 3. It should also be noted that the sensor device 4 is guided linearly along or parallel to the drilling or central axis Z, so that the individual sensors of the laser grid 18 are always moved along the same vertical line, which is represented here by the measuring beams Mi, M2, M3, M4, M5 and Mß.

[0040] Figure 4 shows a schematic representation of a monitoring system 1 according to the invention in exemplary scenario A, in which no foreign object is located in the area monitored by the laser grid 18. The distance between the lower edge of the sensor device 4 and the ground 9 is now only two and a half meters. The crusher 5 still has a height of one meter. Below the drill rig 3, there are stones or neutral bodies 6 on the ground 9. The stone under the measuring beam M3 has a size or height of 5 cm, the stone under the measuring beam M4 has a size or height of 10 cm, and the stone under the measuring beam M5 has a size or height of 7 cm.

[0041] For measuring beams Mi and M2, the measured values ​​W1 = 151 cm and W2 = 152 cm are obtained. For measuring beams M3, M4, and M5, the measured values ​​W3 = 243 cm, W4 = 239 cm, and W5 = 244 cm are obtained, and for measuring beam Mß, the measured value Wß is 150 cm. These measured values ​​W1, W2, W3, W4, W5, and Wß are, in turn, The table in Fig. 6 shows the results for scenario A. From the smallest difference between measured value W2 and reference value R2 and the largest difference between measured value M4 and reference value R4, the evaluation unit 8 determines the measuring span AA = 13 cm. The threshold for triggering a detection signal by the controller 7 was set at 15 cm for the two example scenarios A and B discussed here, so that no detection signal is triggered by the determined measuring span A (i.e., because only stones or neutral bodies 6 were detected and no foreign body).

[0042] Figure 5 shows a schematic representation of a monitoring system 1 according to the invention in exemplary scenario B, in which a foreign object 17 (i.e., for example, the arm or hand of a worker) with a height or size of 10 cm is located in the area monitored by the laser grid 18 (i.e., on the right side of the crusher 5 under the measuring beams M5 and MB; the foreign object does not necessarily have to be on the crusher 5, the system according to the invention detects a foreign object in any position between the crusher 5 and the sensor device 4 or between the ground 9 and the sensor device 4). The distance between the lower edge of the sensor device 4 and the ground 9 is again two and a half meters. The crusher 5 again has a height of one meter. In this example, stones or neutral bodies 6 are also located on the ground 9 below the drill rig 3.The stone under measuring beam M3 has a size or height of 5 cm, the stone under measuring beam M4 has a size or height of 10 cm, and the stone under measuring beam M5 has a size or height of 7 cm.

[0043] For measuring beams Mi and M2, the measured values ​​W1 = 150 cm and W2 = 149 cm are obtained. For measuring beams M3, M4, and M5, the measured values ​​W3 = 247 cm, W4 = 241 cm, and W5 = 140 cm are obtained, and for measuring beam Mß, the measured value Wß is 141 cm. These measured values ​​W1, W2, W3, W4, W5, and Wß are shown accordingly in the table according to Fig. 6 for scenario B. From the smallest difference between measured value W1 and reference value Ri and the largest difference between measured value M5 and reference value R5, the evaluation unit 8 determines the measuring span AB = 110 cm. As mentioned, the threshold for triggering a detection signal by the controller 7 was set at 15 cm for the two example scenarios A and B discussed here, so that the measuring span AB represents a A detection signal DS is triggered (i.e., because a foreign object 17 has been detected). The detection signal DS can, for example, cause the drive of the drilling rig 3 to be switched off immediately.

[0044] As explained previously, Fig. 6 includes the table with the numerical values ​​for, in particular, the reference values ​​Ri to Re, the measured values ​​Mi to Me and the measuring ranges AA and B of the two previously discussed example scenarios A and B for the operation of the monitoring system 1 according to the invention.

[0045] The present disclosure also includes embodiments of the system according to the invention with any combination of features mentioned or shown above or below in relation to various embodiments. It also includes individual features in the figures, even if they are shown there in connection with other features and / or are not mentioned above or below. Furthermore, the alternative embodiments described in the figures and the description, and individual alternatives of their features, may be excluded from the subject matter of the invention or from the disclosed subject matter. The disclosure includes embodiments that comprise exclusively the features described in the claims or in the exemplary embodiments, as well as those that include additional features.

[0046] Furthermore, the expression "comprise" and derivatives thereof do not exclude other elements or steps. Likewise, the indefinite article "a" and its derivatives do not exclude a plurality. The functions of several features listed in the claims can be fulfilled by a single unit or step. The terms "essentially," "about," "approximately," and the like, when used in conjunction with a property or value, also define precisely that property or value. The terms "about" and "approximately" in connection with a given numerical value or range can refer to a value or range that lies within 20%, within 10%, within 5%, or within 2% of the given value or range. List of reference symbols: 1 monitoring system 2 drill rigs 3 Drilling machine 4 Sensor device 5 Reference object (crusher) 6 neutral bodies (stones etc.) 7 Control 8 evaluation units 9 Floor 10 measuring bars 11 connectors 12 Sensor 13 Laser diode 14 recipients 15 sensor holders 16 cases 17 foreign bodies 18 laser grids DS detection signal L Length measuring bar MI-6 measuring beams RI-6 Reference Values S axle spacing W1-6 measured values Y direction of movement Z central or drill axis AA,B measuring spans

Claims

Claims Claim 1: Monitoring system (1) for moving machine parts (2), in particular of drilling rigs (3), comprising a sensor device (4) which includes a plurality of sensors (12) arranged side by side which at least partially surround the machine part (2) to be monitored; a reference profile (5, 9) which is arranged at a distance from the sensor device (4), wherein the sensors (12) of the sensor device (4) are each configured to emit measuring beams (Mi, M2, M3, M4, M5, Mß) to the reference profile (5); and a control unit (7) with an evaluation unit (8) which is configured to compare the measured values ​​(W1, W2, W3, W4, W5, Wß) resulting from the measuring beams (Mi, M2, M3, M4, M5, Mß) with associated reference measured values ​​(Ri, R2, R3, R4, Rs, Rß) and to determine a measuring span (A) therefrom. Claim 2: Monitoring system (1) according to claim 1, wherein the evaluation unit (8) is configured to determine the measurement span (A) from the difference between the maximum deviation of a measured value (W1, W2, W3, W4, W5, Wß) from the associated reference value (Ri, R2, R3, R4, Rs, Rß) and the minimum deviation of a measured value (W1, W2, W3, W4, W5, Wß) from the associated reference value (Ri, R2, R3, R4, Rs, Rß). Claim 3: Monitoring system (1) according to claim 2, wherein the controller (7) is configured to trigger a detection signal when the measurement span (A) determined by the evaluation unit (8) reaches or exceeds a predefined limit value. Claim 4: Monitoring system (1) according to one of the preceding claims, wherein the sensor device (4) moves with the machine part (2) to be monitored during operation. Claim s: Monitoring system (1) according to one of the preceding claims, wherein the sensors (12) of the sensor device (4) comprise laser distance sensors, each comprising a laser diode (13) for emitting a laser beam to the reference profile (5, 9) and a receiver (14) for receiving the laser beam reflected by the reference object (5) or by a foreign object (17). Claims: Monitoring system (1) according to one of the preceding claims, wherein the sensor device (4) is formed from one or more measuring bars (10) comprising the sensors (12) which surround the machine part (2) to be monitored. Claim ?: Monitoring system (1 ) according to one of the preceding claims, wherein the one or more measuring bars (10) form a laser grid (18) around the machine part (2) to be monitored during operation. Claim s: Monitoring system (1) according to one of the preceding claims, wherein the one or more measuring bars (10) are configured to form a polygonal, rectangular, square, triangular, round or oval laser grid (18) around the machine part (2) to be monitored. Claim 9: Monitoring system (1) according to one of the preceding claims, wherein the minimum distance between the machine part (2) to be monitored and the laser grid (18) is about 5 cm, preferably about 10 cm and further preferably about 12 cm. Claim 10: Monitoring system (1) according to any of the preceding claims, wherein the measuring bars (10) have a length (L) of about 400 mm to about 500 mm and preferably a length (L) of about 450 mm. Claim 11: Monitoring system (1) according to one of the preceding claims, wherein the number of sensors (12) per measuring bar (10) is from about 10 to about 18 and preferably from about 14 to about 16. Claim 12: Monitoring system (1) according to one of the preceding claims, wherein the axial distance (S) between the individual sensors is from about 25 mm to about 35 mm and preferably about 30 mm. Claim 13: Monitoring system (1) according to one of the preceding claims, wherein a measuring distance of the sensor device (4) is between about 1 cm and about 10 m, preferably between about 5 cm and about 5 m and further preferably between 3 cm and 3 m. Claim 14: Monitoring system (1) according to one of the preceding claims, wherein the measurement frequency of the sensors (12) is from about 10 Hz to about 50 Hz and preferably about 30 Hz. Claim 15: Monitoring system (1) according to one of the preceding Claims, wherein the sensors (12) are controlled sequentially.

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