Measurement system

Abstract

To measure abrasion or deformation of a rail with a simple configuration.SOLUTION: A measurement system S includes: a measurement part 3 which is arranged below a rail 1 arranged in a travel direction Z of a conveyance body 4 of a heavy object and having a horizontal plate part 111 formed with an upper surface 113 for wheels 42 to travel, so as to measure a position of the rail 1 based on reflection light against the rail 1 using light emitted to the rail 1; a reflection part 2 which is arranged above the horizontal plate part 111, so as to reflect emitted light C toward the upper surface 113 and to reflect first reflection light D against the upper surface 113 to the measurement part 3; an acquisition part 521 for acquiring a virtual image position V of a virtual image of the upper surface 113 based on the first reflection light D and a lower surface position Q of a lower surface 114 based on second reflection light E against the lower surface 114 of the upper surface 113; and an output part 523 for outputting an actual upper surface position R of the upper surface 113 obtained by correcting the virtual image position V based on position relation between the reflection part 2 and the measurement part 3 and the lower surface position Q acquired by the acquisition part.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a measurement system for measuring the shape of a rail for a carrier.

Background Art

[0002] There is known a technique for measuring the wear of a pair of left and right rails having a cross-sectional U-shape with openings facing each other, which are rails on which a carrier travels. In Patent Document 1, based on an image of a first light projector that irradiates light toward the inner surface of the lower flange of the rail through a plurality of mirrors and a first camera that receives reflected light from the inner surface through a plurality of mirrors, a second light projector that irradiates light toward the outer surface of the lower flange through a plurality of mirrors and a second camera that receives reflected light from the outer surface through a plurality of mirrors, a technique is disclosed for calculating the difference between the thickness of the lower flange from the image of the second camera to the image of the first camera and a reference thickness as the wear amount.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the technique of Patent Document 1, two light projectors, two cameras, and a plurality of mirrors are required for each of the pair of left and right rails, and the configuration has become complicated.

[0005] Therefore, the present invention has been made in view of these points, and an object thereof is to measure rail wear and deformation with a simple configuration.

Means for Solving the Problems

[0006] In an aspect of the present invention, it is provided below a rail having a horizontal plate portion along the traveling direction of a carrier for transporting a heavy object, on which a traveling surface on which the wheels of the carrier travel is formed. A measuring unit irradiates light toward the rail and measures the position of the rail based on the reflected light reflected from the rail. A reflecting unit is provided above the horizontal plate portion, reflects the light irradiated from the measuring unit toward the traveling surface, and reflects the first reflected light reflected from the traveling surface toward the measuring unit. An acquisition unit acquires a first position of a virtual image of the traveling surface measured by the measuring unit based on the first reflected light, and a second position of the opposite surface measured by the measuring unit based on the second reflected light reflected from the opposite surface of the horizontal plate portion opposite to the traveling surface. A correction unit corrects the first position based on the positional relationship between the reflecting unit and the measuring unit to calculate an actual third position of the traveling surface. An output unit outputs the third position calculated by the correction unit and the second position acquired by the acquisition unit, and provides a measurement system having these components.

[0007] The reflecting unit may have a reflecting surface that is inclined with respect to the horizontal plate portion at an angle such that the light can be reflected on the traveling surface and the first reflected light reflected from the traveling surface can be reflected to the measuring unit.

[0008] The measuring unit may measure the first position while changing the incident angle of the light with respect to the reflecting unit, and measure the second position while changing the incident angle of the light with respect to the opposite surface.

[0009] The reflecting surface may be inclined at an acute angle with respect to a second straight line perpendicular to a first straight line passing through the measuring unit and the reflecting unit as viewed from the traveling direction.

[0010] The measuring unit may measure the first position and the second position in a plane perpendicular to the traveling direction.

[0011] The correction unit may calculate the third position by subjecting the first position to a target transformation to a position that is line-symmetric with respect to a straight line passing through the reflecting surface that reflects the light of the reflecting unit in the plane.

[0012] The correction unit may calculate the coordinates representing each of the plurality of third positions of the running surface by multiplying a rotation matrix for subject-converting a coordinate matrix including the coordinates representing each of the plurality of first positions of the running surface and the coordinate matrix.

[0013] The acquisition unit acquires an inclination angle of the measurement unit with respect to a horizontal direction perpendicular to the vertical direction, and the correction unit may rotationally move the first position and the second position by the inclination angle before correcting the first position to calculate the third position.

[0014] The output unit may output, as the wear amount of the horizontal plate portion, a difference between an actually measured distance between the acquired second position and the calculated third position and a reference thickness of the horizontal plate portion.

[0015] The output unit may output, as a deformation amount of the horizontal plate portion, a distance between a reference position of the third position determined by the acquired second position and the reference thickness of the horizontal plate portion and the calculated third position.

[0016] It has a transport unit that moves the measurement unit and the reflection unit along the traveling direction, and the measurement unit may measure the first position and the second position while being moved in the traveling direction by the transport unit.

[0017] The output unit may output, in association with each other, a fourth position of the measurement unit in a plane parallel to the traveling direction and the first position and the second position measured by the measurement unit at the fourth position.

[0018] The transport unit moves the measurement unit and the reflection unit along the traveling direction while the carrier is transporting the heavy object, and the measurement unit may measure the first position and the second position while being moved in the traveling direction by the transport unit while the carrier is transporting the heavy object.

[0019] The rail includes a first rail provided on the left side of the reflection part when viewed from the traveling direction, and a second rail provided on the right side of the reflection part. The measurement unit measures the first position and the second position of the first rail, and the first position and the second position of the second rail. The correction unit may correct the first position of the first rail to calculate the third position of the first rail, and correct the first position of the second rail to calculate the third position of the second rail.

[0020] The reflection part has a first reflection surface that can reflect the light on the running surface of the first rail and is inclined with respect to the horizontal plate part at an angle that can reflect the first reflected light reflected from the running surface of the first rail to the measurement unit, and a second reflection surface that can reflect the light on the running surface of the second rail and is inclined with respect to the horizontal plate part at an angle that can reflect the first reflected light reflected from the running surface of the second rail to the measurement unit. The first reflection surface is inclined at an acute angle with respect to the running surface of the first rail on the left side of the straight line passing through the measurement unit and the reflection part when viewed from the traveling direction. The second reflection surface is inclined at an acute angle with respect to the running surface of the second rail on the right side of the straight line passing through the measurement unit and the reflection part when viewed from the traveling direction. One end of the first reflection surface and one end of the second reflection surface may be connected.

Advantages of the Invention

[0021] According to the present invention, it is possible to measure wear and deformation of a rail with a simple configuration.

Brief Description of the Drawings

[0022]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0023] [Overview of the Conveying System U] FIG. 1 is a diagram for explaining the overview of the conveying system U. The conveying system U is installed, for example, in an automobile assembly plant. The conveying system U is provided at a predetermined height from the floor of the assembly plant and conveys heavy objects such as engines. The conveying system U is provided, for example, at a position higher than the workers working in the assembly plant.

[0024] The conveying system U includes a carrier 4, a left rail 11 which is the first rail, and a right rail 12 which is the second rail. The carrier 4 conveys heavy objects such as engines. The carrier 4 has a housing 41, wheels 421, wheels 422, and a shaft 43. The housing 41 is a chassis for conveying heavy objects. The wheel 421 travels on the left rail 11, and the wheel 422 travels on the right rail 12. The wheels 421 and 422 are connected by a shaft 43. The shaft 43 is provided so as to penetrate the housing 41.

[0025] The carrier 4 is pushed and moved by a side ring pusher provided with a chain provided on a power rail (not shown) provided above the left rail 11 and the right rail 12. Specifically, when the side ring pusher catches on a hold-packed dock (not shown) provided on the housing 41 of the carrier 4, the housing 41 of the carrier 4 and the chain are connected. Then, the carrier 4 is conveyed in the moving direction of the chain in conjunction with the movement of the side ring pusher due to the rotation of the chain.

[0026] The left rail 11 and the right rail 12 are provided along the traveling direction Z of the carrier 4. The left rail 11 is provided on the left side of the carrier 4 as viewed from the traveling direction Z. The right rail 12 is provided on the right side of the carrier 4 as viewed from the traveling direction Z.

[0027] The left rail 11 includes a horizontal plate portion 111, a wall portion 112, and an upper plate portion 115. The left rail 11 has a U-shaped configuration that is open on the right side as viewed from the traveling direction Z. The lower end of the wall portion 112 is connected to the end of the horizontal plate portion 111 that is far from the carrier 4 among the two ends of the horizontal plate portion 111 in the horizontal direction X perpendicular to the vertical direction Y. The upper plate portion 115 is connected to the upper end of the wall portion 112. The upper surface 113 of the horizontal plate portion 111 forms a running surface on which the wheels 421 of the carrier 4 run. The lower surface 114 of the horizontal plate portion 111 forms an opposite surface on the side opposite to the upper surface 113 of the horizontal plate portion 111.

[0028] The right rail 12 is provided symmetrically with the left rail 11 on the opposite side of the left rail 11 across the carrier 4 as viewed from the traveling direction Z of the carrier 4. The right rail 12, similar to the left rail 11, includes a horizontal plate portion 121, a wall portion 122, and an upper plate portion 115. The right rail 12 is provided in a U-shaped configuration that is open on the left side as viewed from the traveling direction Z. On the horizontal plate portion 121, an upper surface 123 on which the wheels 422 run and a lower surface 124 on the side opposite to the upper surface 123 are formed.

[0029] The upper surface 113 of the left rail 11 is worn as the wheels 421 of the carrier 4 that support the heavy object run thereon. FIG. 2 is a diagram for explaining the wear of the rail 1. The upper surface 113 of the horizontal plate portion 111 is worn as the wheels 421 run on the upper surface 113. Similarly, the upper surface 123 of the horizontal plate portion 121 is worn as the wheels 422 run on the upper surface 123. The dent M is caused by the wear. When the wear amount A of the upper surface 113 increases, the thickness of the horizontal plate portion 111 decreases, so the strength of the horizontal plate portion 111 decreases. When the strength of the horizontal plate portion 111 decreases, the horizontal plate portion 111 is deformed by the weight of the heavy object carried by the carrier 4.

[0030] FIG. 3 is a diagram for explaining the deformation of the horizontal plate portion 111. As shown in FIG. 3, the entire horizontal plate portion 111 is deformed so as to hang downward in the vertical direction Y from the end portion not connected to the wall portion 112 of the horizontal plate portion 111. As the entire horizontal plate portion 111 is deformed and the deformation amount B becomes larger exceeding a predetermined allowable amount, the upper surface 113 is inclined, and the carrier 4 may not be properly conveyed, or the wheels 421 of the carrier 4 may be derailed from the horizontal plate portion 111 of the left rail 11, and the carrier 4 may fall from the rail 1. Therefore, the administrator of the transport system U has to stop the production of the factory to perform the inspection work in order to measure the wear amount A of the rail 1 located at a position higher than himself or visually check the deformation amount B. As a result, the working hours of the administrator have increased and the productivity of the factory has decreased.

[0031] Therefore, during the running of the carrier 4, the measurement system S measures the positions of the upper surface 113 and the lower surface 114 by irradiating the upper surface 113 and the lower surface 114 with the irradiation light C, and calculates the wear amount A and the deformation amount B. Hereinafter, the configuration of the measurement system S will be described with reference to FIGS. 4 and 5. FIG. 4 is a diagram for explaining the configuration of the measurement system S. FIG. 5 is a schematic view of the measurement system S as seen from the horizontal direction X perpendicular to the traveling direction Z so that the left rail 11 can be seen. The measurement system S includes a reflection unit 2, a measurement unit 3, a measurement device 5, and a transport unit 7.

[0032] The conveying unit 7 has a housing 71 and wheels 72. The housing 71 is provided with a reflecting unit 2, a measuring unit 3, and a measuring device 5. The measuring unit 3 is provided inside the housing 71 so as to be below the rail 1 in the vertical direction Y. The reflecting unit 2 is provided on the housing 71 between the left rail 11 and the right rail 12 and above the horizontal plate portion 111. Specifically, the reflecting unit 2 is supported by a support column extending upward in the vertical direction Y from the housing 71 and is provided above the horizontal plate portion 111 and below the upper plate portion 115. The measuring unit 3 and the reflecting unit 2 are installed such that when the installation surface on which the measuring unit 3 is installed on the conveying unit 7 is parallel to the horizontal direction X, the first straight line 61 passing through the centers of the measuring unit 3 and the reflecting unit 2 is perpendicular to a straight line parallel to the horizontal direction X. The measuring device 5 is housed inside the housing 71.

[0033] The housing 71 is connected to the conveying body 4. The wheels 72 are wheels that travel on the upper surface 113. The wheels 72 are connected to the housing 71 by a connecting portion 73. The wheels 72 are freely rotatable with respect to the connecting portion 73.

[0034] The conveying unit 7 moves in conjunction with the movement of the conveying body 4. When the conveying body 4 moves, the conveying unit 7 moves the reflecting unit 2, the measuring unit 3, and the measuring device 5 installed on the housing 71 along the traveling direction Z in conjunction with the movement of the conveying body 4. For example, when the conveying body 4 is conveying a heavy object, the conveying unit 7 moves the reflecting unit 2, the measuring unit 3, and the measuring device 5 along the traveling direction Z. Specifically, the conveying unit 7 is connected to the conveying body 4 while the latter is conveying a heavy object and moves in conjunction with the movement of the conveying body 4, thereby moving the reflecting unit 2, the measuring unit 3, and the measuring device 5 installed on the housing 71 along the traveling direction Z.

[0035] The conveying unit 7 has a following mechanism corresponding to the degree of bending of the rail 1. The following mechanism moves the measurement unit 3 and the reflection unit 2 so that the first straight line 61 passing through the measurement unit 3 and the reflection unit 2 passes through the midpoint between the left rail 11 and the right rail 12 according to the degree of bending of the rail 1. Since the following mechanism can utilize known techniques, the description thereof is omitted. Thereby, even when passing through the rail 1 with a large curvature, the conveying unit 7 can irradiate the left rail 11 and the right rail 12 with the irradiation light C irradiated from the measurement unit 3.

[0036] While being moved in the traveling direction Z by the conveying unit 7, the measurement unit 3 irradiates the object with the irradiation light C and measures the position of the surface of the object based on the reflected light from the object. Specifically, while the carrier 4 is being moved along the traveling direction Z by the conveying unit 7 during the conveyance of the heavy object, the measurement unit 3 irradiates the rail 1 and the reflection unit 2 with the irradiation light C and measures the position of the surface of the rail 1 based on the reflected light from the rail 1 and the reflection unit 2. The measurement unit 3 is, for example, a two-dimensional laser displacement meter, but is not limited thereto. The measurement interval of the measurement unit 3 is set according to the speed of the conveying unit 7. The measurement interval of the measurement unit 3 is set to a time shorter than the reference time as the speed of the conveying unit 7 is higher. The reference time is, for example, 100 milliseconds.

[0037] The measurement unit 3 includes an irradiation unit 31, a light receiving unit 32, and a calculation unit 33. The irradiation unit 31 irradiates the irradiation light C. The irradiation light C is, for example, a blue semiconductor laser with a wavelength of 405 nanometers and an output of 4.8 milliwatts (mW), but is not limited thereto. In FIGS. 4 and 5, the optical path of the irradiation light C is indicated by a solid line arrow, and the reflected light obtained by reflecting the irradiation light C from the object is indicated by a dotted line arrow. The light receiving unit 32 receives the reflected light obtained by reflecting the irradiation light C from the object. The calculation unit 33 controls the irradiation unit 31 to irradiate the object with the irradiation light C. The calculation unit 33 calculates the position of the object based on the reflected light from the object received by the light receiving unit 32. Specifically, the calculation unit 33 measures the relative position of the object with respect to the measurement unit 3 based on the irradiation angle of the irradiation light C and the incident angle of the reflected light obtained by reflecting the irradiation light C from the object.

[0038] The calculation unit 33 causes the irradiation unit 31 to irradiate the irradiation light C toward the rail 1, and measures the position of the rail 1 based on the reflected light obtained by reflecting the irradiation light C from the rail 1. For example, the calculation unit 33 controls the irradiation unit 31 to irradiate the lower surface 114 of the horizontal plate portion 111 of the left rail 11 with the irradiation light C. The light receiving unit 32 receives the second reflected light E obtained by reflecting the irradiation light C from the lower surface 114. The calculation unit 33 measures the second position, which is the lower surface position Q of the lower surface 114, based on the second reflected light E reflected from the lower surface 114 received by the light receiving unit 32. The lower surface position Q is the relative position of the lower surface 114 with respect to the measurement unit 3. Specifically, the calculation unit 33 measures the lower surface position Q based on the second reflected light E reflected from the lower surface 114 while changing the incident angle of the irradiation light C with respect to the lower surface 114.

[0039] The calculation unit 33 controls the irradiation unit 31 to irradiate the reflection unit 2 with the irradiation light C. For example, the calculation unit 33 controls the irradiation unit 31 to irradiate the reflection unit 2 with the irradiation light C while changing the incident angle of the irradiation light C with respect to the reflection unit 2.

[0040] The reflection unit 2 has a left reflection surface 21 and a right reflection surface 22 that reflect the irradiation light C. The left reflection surface 21 has a first reflection surface that reflects light. The right reflection surface 22 has a second reflection surface that reflects light. The left reflection surface 21 and the right reflection surface 22 are, for example, mirrors formed by silver plating on the surface of glass, but are not limited thereto. The reflection unit 2 is an isosceles triangle when viewed from the traveling direction Z. In other words, the cross section obtained by cutting the reflection unit 2 in the XY plane is an isosceles triangle. The two hypotenuses of the reflection unit 2 are each provided in a direction toward the measurement unit 3. The vertex where the two hypotenuses of the reflection unit 2 are connected faces the measurement unit 3.

[0041] The left reflection surface 21 and the right reflection surface 22 are connected. Specifically, one end of the left reflection surface 21 and one end of the right reflection surface 22 are connected. More specifically, one end of the left reflection surface 21 and one end of the right reflection surface 22 are connected on a straight line passing through the center of the reflection unit 2 and the measurement unit 3.

[0042] The left reflecting surface 21 is provided on the left side of the first straight line 61 passing through the measuring unit 3 and the reflecting unit 2 as viewed from the traveling direction Z. In other words, the left reflecting surface 21 is provided on the left hypotenuse of the two hypotenuses of the reflecting unit 2 among the first straight line 61.

[0043] The left reflecting surface 21 can reflect light on the upper surface 113 of the left RAIL 11. The left reflecting surface 21 is inclined with respect to the horizontal plate portion 111 at an angle θ such that the first reflected light D reflected from the upper surface 113 of the left rail 11 can be reflected to the measuring unit 3. Specifically, the left reflecting surface 21 is inclined at an acute angle with respect to the second straight line 62 perpendicular to the first straight line 61. The angle θ formed by the second straight line 62 and the straight line passing through the left reflecting surface 21 is greater than 0 degrees and less than 90 degrees. Desirably, the angle θ is 15 degrees or more and 45 degrees or less. The specific value of the angle θ is 30 degrees, but it is not limited thereto. The angle θ may be appropriately determined based on the width of the upper surface 113 and the positional relationship among the measuring unit 3, the reflecting unit 2, and the upper surface 113.

[0044] The right reflecting surface 22 is provided on the right side of the first straight line 61 as viewed from the traveling direction Z. In other words, the right reflecting surface 22 is provided on the right hypotenuse of the two hypotenuses of the reflecting unit 2 among the first straight line 61. The right reflecting surface 22 can reflect light on the upper surface 113 of the right RAIL 12. The left reflecting surface 21 is inclined with respect to the horizontal plate portion 121 at an angle θ such that the first reflected light D reflected from the upper surface 113 of the right rail 12 can be reflected to the measuring unit 3. Specifically, the right reflecting surface 22 is inclined at an acute angle with respect to the second straight line 62. The angle θ formed by the second straight line 62 and the straight line passing through the right reflecting surface 22 is the same as the angle θ formed by the second straight line 62 and the straight line passing through the left reflecting surface 21.

[0045] The irradiation light C irradiated toward the left reflecting surface 21 is reflected by the left reflecting surface 21 and enters the upper surface 113. The irradiation light C that has entered the upper surface 113 is reflected by the upper surface 113. The first reflected light D reflected by the upper surface 113 enters the left reflecting surface 21. The first reflected light D that has entered the left reflecting surface 21 is reflected by the left reflecting surface 21 and enters the light receiving portion 32. Thus, by providing the left reflecting surface 21, the irradiation light C also enters the upper surface 113 on the opposite side of the measuring portion 3 with the lower surface 114 interposed therebetween. In other words, by providing the left reflecting surface 21, the irradiation light C is irradiated onto the upper surface 113 that the irradiation light C would not reach if the left reflecting surface 21 were not provided, and the first reflected light D from the upper surface 113 enters the light receiving portion 32.

[0046] The light receiving portion 32 receives the reflected light of the irradiation light C reflected by the rail 1 (see FIG. 5). The light receiving portion 32 receives the first reflected light D of the irradiation light C reflected by the upper surface 113 via the reflecting portion 2. In FIG. 5, in order to make the optical path of the irradiation light C and the optical path of the reflected light easy to understand, the irradiation angle is changed on the ZY plane, but actually, the irradiation angle of the irradiation light C changes on the XY plane (see FIG. 4). The calculation unit 33 measures the first position, which is the virtual image position V of the upper surface 113 in the XY plane perpendicular to the traveling direction Z, based on the first reflected light D reflected by the upper surface 113 and the reflecting portion 2.

[0047] FIG. 6 is a diagram for explaining the virtual image position V, the lower surface position Q, and the upper surface position R. In FIG. 6, the position of the irradiation port of the irradiation unit 31 is taken as the origin. The horizontal axis in FIG. 6 indicates the distance from the origin in the horizontal direction X. The vertical axis indicates the distance from the origin in the vertical direction Y.

[0048] The lower surface position Q of the lower surface 114 will be described. The calculation unit 33 measures the position of the object based on the reflected light on the premise that the reflected light incident on the light receiving portion 32 is the reflected light directly reflected from the object. Therefore, the lower surface position Q of the lower surface 114 is the actual relative position of the lower surface 114 with respect to the measuring portion 3.

[0049] On one hand, at the upper surface position R of the upper surface 113, the irradiated light C reflected by the left reflecting surface 21 of the reflecting portion 2 is irradiated. The first reflected light D reflected at the upper surface position R is reflected by the reflecting portion 2 and enters the light receiving portion 32. The angle and optical path length of the first reflected light D entering the light receiving portion 32 are the same as those of the reflected light from the position of the virtual image of the upper surface 113. Therefore, the calculation unit 33 measures the virtual image position V of the virtual image of the upper surface 113 based on the first reflected light D.

[0050] Therefore, the measuring device 5 corrects the measured virtual image position V and calculates the upper surface position R. Hereinafter, the specific configuration of the measuring device 5 will be described (see FIG. 4). The measuring device 5 is a computer having a storage unit 51 and a control unit 52. The computer may be a notebook PC, a desktop PC, or a tablet PC, but is not limited thereto.

[0051] The storage unit 51 is a storage medium including a ROM (Read Only Memory), a RAM (Random Access Memory), a hard disk, and the like. The storage unit 51 stores a program executed by the control unit 52.

[0052] The control unit 52 is a computing resource including a processor such as a CPU (Central Processing Unit). The control unit 52 realizes functions as an acquisition unit 521, a correction unit 522, and an output unit 523 by executing the program stored in the storage unit 51.

[0053] The acquisition unit 521 acquires the virtual image position V and the lower surface position Q. For example, every time the virtual image position V is measured, the acquisition unit 521 acquires the coordinates indicating the measured virtual image position V. The coordinates indicating the virtual image position V are coordinates on the XY plane. Specifically, the acquisition unit 521 acquires a first coordinate matrix including the coordinates representing each of a plurality of virtual image positions V of the upper surface 113. The first coordinate matrix can be approximated by a straight line VL1 when represented on the XY plane (see FIG. 6). In the case where the upper surface 113 of the left rail 11 is worn so that the recess M occurs as shown in FIG. 2, the first coordinate matrix cannot be approximated by a straight line, but for the sake of simplicity of explanation, it will be described as if the first coordinate matrix can be approximated by the straight line VL1.

[0054] The acquisition unit 521 acquires the coordinates indicating the bottom surface position Q every time the bottom surface position Q is measured. The coordinates indicating the bottom surface position Q are the coordinates on the XY plane. Specifically, the acquisition unit 521 acquires a second coordinate matrix including the coordinates of each of a plurality of bottom surface positions Q of the bottom surface 114. The second coordinate matrix can be approximated by a straight line QL1 when represented on the XY plane (see FIG. 6).

[0055] The acquisition unit 521 acquires the fourth position of the measurement unit 3 in the YZ plane parallel to the traveling direction Z when the measurement unit 3 measures the virtual image position V and the bottom surface position Q. A known technique can be used as a method for acquiring the fourth position. For example, the acquisition unit 521 includes a GPS (Global Positioning System) receiver, receives radio waves transmitted from GPS artificial satellites, and acquires the coordinates indicating the position of the GPS receiver when the measurement unit 3 measures the virtual image position V and the bottom surface position Q as the fourth position. The acquisition unit 521 may acquire the coordinates indicating the position of the GPS receiver when the virtual image position V or the bottom surface position Q is acquired as the fourth position.

[0056] The correction unit 522 corrects the virtual image position V and calculates the third position, which is the actual upper surface position R of the upper surface 113. For example, the correction unit 522 corrects the virtual image position V based on the positional relationship between the reflection unit 2 and the measurement unit 3 and calculates the upper surface position R. The relative position of the left reflection surface 21 of the reflection unit 2 with respect to the measurement unit 3 has been measured in a state where the left reflection surface 21 cannot reflect the irradiation light C with respect to the upper surface 113 and is stored in the storage unit 51. The relative position of the left reflection surface 21 of the reflection unit 2 with respect to the measurement unit 3 has been measured, for example, in a state where an opaque film is attached to the left reflection surface 21.

[0057] The correction unit 522 symmetrically transforms the virtual image position V based on the first reflected light D from the upper surface 113 to a position that is line-symmetric with respect to the third straight line E1 passing through the left reflecting surface 21 of the reflecting unit 2. Specifically, the correction unit 522 calculates a third coordinate matrix by multiplying a rotation matrix for symmetrically transforming the virtual image position V based on the first reflected light D from the upper surface 113 and a first coordinate matrix. The rotation matrix is a matrix for symmetrically transforming the first coordinate matrix with respect to the third straight line E1. The third coordinate matrix is a matrix including coordinates representing each of a plurality of upper surface positions R of the upper surface 113. Further, the correction unit 522 may rotate and move the virtual image position V counterclockwise by an angle that is twice the angle formed between the straight line passing through the incident point P and the virtual image position V and the third straight line E1 with the incident point P of the irradiation light C on the left reflecting surface 21 in the XY plane as a base point to calculate the upper surface position R.

[0058] The third coordinate matrix can be approximated by a straight line RL1 when represented on the XY plane (see FIG. 6). In this way, the correction unit 522 can calculate the actual upper surface position R of the upper surface 113 by symmetrically transforming the virtual image position V of the virtual image of the upper surface 113 with respect to the third straight line E1.

[0059] The correction unit 522 also corrects the virtual image position V of the upper surface 123 in the same manner as the upper surface 113 to calculate the upper surface position R of the upper surface 123. The correction unit 522 calculates a fourth coordinate matrix including coordinates representing the actual upper surface position R of the upper surface 123 by multiplying a rotation matrix for symmetrically transforming a third coordinate matrix including coordinates representing each of a plurality of lower surface positions Q of the upper surface 123 with respect to the fourth straight line E2 and the coordinate matrix. Further, the correction unit 522 may rotate and move the virtual image position V clockwise by an angle that is twice the angle formed between the straight line passing through the incident point and the virtual image position V and the fourth straight line E2 with the incident point of the irradiation light C on the right reflecting surface 22 in the XY plane as a base point to calculate the upper surface position R of the upper surface 123.

[0060] The third coordinate matrix representing the virtual image of the upper surface 123 can be approximated by a straight line VL2 (see FIG. 6). The fourth coordinate matrix representing the actual position of the upper surface 123 can be approximated by a straight line RL2 when represented on the XY plane (see FIG. 6). In this way, the correction unit 522 can calculate the actual positions of both the upper surface 113 of the left rail 11 and the upper surface 123 of the right rail 12.

[0061] The output unit 523 outputs the upper surface position R calculated by the correction unit 522 and the lower surface position Q acquired by the acquisition unit 521 to the external device 6. The external device 6 is, for example, a display for displaying information or an information processing device (server). The output unit 523 causes, for example, a display to display a data table associating a fourth position with the upper surface position R and the lower surface position Q. Further, the output unit 523 transmits a data table associating the fourth position with the upper surface position R and the lower surface position Q calculated by correcting the virtual image position V measured by the measurement unit 3 at the fourth position to the information processing device. By doing so, the administrator of the conveyance system U can grasp the current upper surface position R and the lower surface position Q of the horizontal plate portion 111 at each of a plurality of positions on the rail 1. As a result, the administrator can calculate the wear amount A and the deformation amount B of the horizontal plate portion 111 at each of a plurality of positions on the rail 1.

[0062] (Processing for outputting the wear amount A) The output unit 523 may output the wear amount A of the horizontal plate portion 111. In this case, the output unit 523 calculates the difference between the actually measured distance between the acquired lower surface position Q and the calculated upper surface position R and the reference thickness of the horizontal plate portion 111. The reference thickness of the horizontal plate portion 111 is stored in the storage unit 51. The reference thickness of the horizontal plate portion 111 is determined according to the specifications of the left rail 11. The output unit 523 calculates, for example, the difference between each of the plurality of lower surface positions Q of the second coordinate matrix representing the lower surface 114 and the upper surface position R corresponding to each lower surface position Q. More specifically, the output unit 523 calculates the difference in the Y coordinates of the lower surface position Q and the upper surface position R having the same X coordinate for each of the plurality of lower surface positions Q of the second coordinate matrix and the plurality of upper surface positions R of the third coordinate matrix.

[0063] The output unit 523 outputs the calculated difference as the wear amount A of the horizontal plate portion 111. The output unit 523 outputs the statistical quantity of a plurality of differences as the wear amount A. For example, the output unit 523 calculates the average value of a plurality of differences as the wear amount A. The output unit 523 may calculate the maximum value among a plurality of differences as the wear amount A. The output unit 523 associates the wear amount A with the fourth position at which the lower surface position Q and the upper surface position R corresponding to the wear amount A are calculated, and transmits the result to the server. Thereby, the administrator of the transport system U can grasp the current wear amount A of the horizontal plate portion 111 at each of the plurality of positions of the rail 1 without calculating the difference between the upper surface position R and the lower surface position Q, and it becomes easier to manage the horizontal plate portion 111.

[0064] (Process of outputting the deformation amount B) The output unit 523 may output the deformation amount B of the horizontal plate portion 111. In this case, the output unit 523 calculates the reference position of the upper surface position R determined by the acquired lower surface position Q and the reference thickness of the horizontal plate portion 111. For example, the output unit 523 calculates, as the reference position of the upper surface position R, a position vertically upward by the reference thickness from the acquired lower surface position Q. Specifically, the output unit 523 calculates, as the reference position of the upper surface position R of the upper surface 113, a position vertically upward by the reference thickness from the lower surface position Q of the end portion to which the wall portion 112 is connected among the two end portions of the lower surface 114.

[0065] The output unit 523 calculates the distance between the reference position of the upper surface position R and the calculated upper surface position R. Specifically, the output unit 523 calculates the distance between the reference position of the upper surface position R and the calculated upper surface position R. Then, the output unit 523 outputs the calculated distance as the deformation amount B of the horizontal plate portion 111. For example, the output unit 523 outputs the statistical quantity of a plurality of distances as the deformation amount B. Specifically, the output unit 523 outputs the maximum value among a plurality of distances as the deformation amount B, and associates it with the fourth position at which the deformation amount B is calculated. Thereby, the administrator of the transport system U can grasp the current deformation amount B of the horizontal plate portion 111 at each of the plurality of positions of the rail 1, and it becomes easier to manage the horizontal plate portion 111. Note that the output unit 523 can output the wear amount A and the deformation amount B of the horizontal plate portion 121 in the same manner as the output methods of the wear amount A and the deformation amount B of the horizontal plate portion 111.

[0066] (Process for correcting the inclination of the measurement unit 3) Incidentally, in the process of the correction unit 522 described above, when the first straight line 61 is perpendicular to the horizontal direction X, the virtual image position V of the virtual image of the horizontal plate portion 111 is moved to the actual upper surface position R of the horizontal plate portion 111. However, when the horizontal plate portion 111 is worn or deformed, the measurement unit 3 may be inclined with respect to the horizontal direction X. When the measurement unit 3 is inclined with respect to the horizontal direction X and the first straight line 61 is not perpendicular to the horizontal direction X, the process of the correction unit 522 described above moves the virtual image position V to a position different from the actual upper surface position R of the horizontal plate portion 111. Therefore, when the measurement unit 3 is inclined with respect to the horizontal direction X, the measurement system S rotates and moves the virtual image position V and the lower surface position Q according to the inclination. Hereinafter, the process of rotating the virtual image position V and the lower surface position Q according to the inclination will be described.

[0067] The acquisition unit 521 acquires the inclination angle of the measurement unit 3 with respect to the horizontal direction X. For example, the acquisition unit 521 acquires the angle formed by the straight line representing the lower surface position Q acquired by the measurement unit 3 and the horizontal direction X as the inclination angle. Specifically, the acquisition unit 521 acquires the angle formed by the straight line QL1, which is the approximate straight line of each of the plurality of lower surface positions Q, and the straight line parallel to the horizontal direction X as the inclination angle. Note that the acquisition unit 521 may have an angle sensor that detects the angle with respect to the horizontal direction X, and acquire the angle with respect to the horizontal direction X detected by the angle sensor as the inclination angle of the measurement unit 3.

[0068] The correction unit 522 moves the virtual image position V and the lower surface position Q based on the inclination angle of the measurement unit 3. For example, the correction unit 522 rotates the virtual image position V and the lower surface position Q counterclockwise by the inclination angle with respect to the origin, which is the irradiation point where the irradiation light C is irradiated from the irradiation unit 31. Specifically, the correction unit 522 moves the virtual image position V and the lower surface position Q by multiplying each of the first coordinate matrix and the second coordinate matrix by a rotation matrix for rotating a point on the XY plane counterclockwise by the inclination angle with respect to the origin. The moved virtual image position V and lower surface position Q coincide with the virtual image position V and lower surface position Q measured when the first straight line 61 is perpendicular to the horizontal direction X. Thereby, even if the measurement unit 3 is inclined with respect to the horizontal direction X, the measurement system S can correct the inclination of the measurement unit 3 and measure the actual lower surface position Q and upper surface position R.

[0069] Incidentally, the rotational movement on the plane may be performed in a different order. That is, the measurement system S may perform a target transformation (rotational movement) on the virtual image position V with respect to the third straight line E1, and then perform a rotational movement on the target-transformed upper surface position R and lower surface position Q to correct the inclination. Specifically, the correction unit 522 multiplies the first coordinate matrix by a rotation matrix for symmetrically transforming the virtual image position V with respect to the third straight line E1 to calculate a third coordinate matrix, and then multiplies each of the third coordinate matrix and the second coordinate matrix by a rotation matrix for rotating a point on the XY plane by the inclination angle. Further, the correction unit 522 rotates the virtual image position V clockwise by an angle twice the angle formed between the straight line passing through the incident point and the virtual image position V and the fourth straight line E2 with respect to the incident point of the irradiation light C on the right reflecting surface 22 in the XY plane to calculate the upper surface position R, and then rotates the upper surface position R and the lower surface position Q counterclockwise by the inclination angle with respect to the origin. By doing so, the measurement system S can also correct the inclination of the measurement unit 3 and output the actual lower surface position Q and upper surface position R.

[0070] [Process of measuring the position of the surface of the horizontal plate portion 111] FIG. 7 is a flowchart showing an example of the process of measuring the position. The process of measuring the position of the surface of the horizontal plate portion 111 is executed when the reflection unit 2 and the measurement unit 3 are moving along the traveling direction Z.

[0071] The measurement unit 3 irradiates the irradiation light C toward the left rail 11 (step S1). Specifically, the measurement unit 3 irradiates the reflection unit 2 with the irradiation light C while changing the incident angle of the irradiation light C with respect to the reflection unit 2, and irradiates the lower surface 114 with the irradiation light C while changing the incident angle of the irradiation light C with respect to the lower surface 114.

[0072] The measurement unit 3 measures the position of the surface of the horizontal plate portion 111 based on the reflected light from the left rail 11 (step S2). For example, the measurement unit 3 acquires the position of the surface corresponding to the reflected light of the irradiation light C. Specifically, when the irradiation light C is reflected by the upper surface 113, the measurement unit 3 measures the virtual image position V of the virtual image of the upper surface 113 based on the upper surface 113 and the first reflected light D reflected by the reflection unit 2. When the irradiation light C is reflected by the lower surface 114, the measurement unit 3 measures the lower surface position Q of the lower surface 114 based on the second reflected light E from the lower surface 114.

[0073] The acquisition unit 521 acquires the virtual image position V or the lower surface position Q measured by the measurement unit 3 (step S3). Specifically, when the measurement unit 3 measures the virtual image position V, the acquisition unit 521 acquires the virtual image position V, and when the measurement unit 3 measures the lower surface position Q, the acquisition unit 521 acquires the lower surface position Q. In addition, the acquisition unit 521 acquires the fourth position when the measurement unit 3 measures the virtual image position V or the lower surface position Q.

[0074] The correction unit 522 determines whether the position measured by the measurement unit 3 is the virtual image position V (step S4). When the position measured by the measurement unit 3 is included in a predetermined range on the XY plane (Yes in step S4), the correction unit 522 determines that the position measured by the measurement unit 3 is the virtual image position V. The predetermined range is a range in which the virtual image position V can be measured, and is determined according to the positional relationship among the measurement unit 3, the reflection unit 2, and the upper surface 113. When the position measured by the measurement unit 3 is outside the predetermined range (No in step S4), the correction unit 522 determines that the position measured by the measurement unit 3 is the lower surface position Q.

[0075] When the position measured by the measurement unit 3 is the virtual image position V, the correction unit 522 corrects the virtual image position V to calculate the upper surface position R (step S5). Specifically, the correction unit 522 calculates the upper surface position R by symmetrically transforming the virtual image position V with respect to the third straight line E1. Specifically, the correction unit 522 rotates and moves the virtual image position V by an angle that is twice the angle formed by the third straight line E1 passing through the left reflecting surface 21 in the XY plane and the horizontal direction X to calculate the upper surface position R. More specifically, the correction unit 522 rotates and moves the virtual image position V counterclockwise by an angle that is twice the angle formed by the third straight line E1 and the straight line passing through the incident point P and the virtual image position V with the incident point of the irradiation light C on the left reflecting surface 21 in the XY plane as the base point to calculate the upper surface position R.

[0076] The output unit 523 determines whether or not the upper surface position R corresponding to the acquired lower surface position Q has been calculated (step S6). For example, when the upper surface position R with the X coordinate that matches the X coordinate of the lower surface position Q has been calculated (Yes in step S6), the output unit 523 determines that the upper surface position R corresponding to the lower surface position Q has been calculated. When the upper surface position R with the X coordinate that matches the X coordinate of the lower surface position Q has not been calculated (No in step S6), the output unit 523 returns to step S1.

[0077] When the upper surface position R corresponding to the lower surface position Q has been calculated, the output unit 523 outputs the wear amount A of the horizontal plate portion 111 (step S7). Specifically, the output unit 523 outputs the distance between the Y coordinate of the lower surface position Q and the Y coordinate of the upper surface position R corresponding to the lower surface position Q as the wear amount A. The output unit 523 outputs the wear amount A and the fourth position in association with each other to the measuring device 5.

[0078] The acquisition unit 521 determines whether the reflection unit 2 and the measurement unit 3 have stopped (step S8). For example, the acquisition unit 521 determines whether the reflection unit 2 and the measurement unit 3 have stopped based on the speed detected by a speed sensor installed in the transport unit 7 that moves the reflection unit 2 and the measurement unit 3. When the speed detected by the speed sensor is equal to or less than a predetermined value (for example, zero) (Yes in step S8), the acquisition unit 521 determines that the reflection unit 2 and the measurement unit 3 have stopped and ends the process of measuring the position. When the speed detected by the speed sensor is greater than the predetermined value (No in step S8), the acquisition unit 521 determines that the reflection unit 2 and the measurement unit 3 are moving and returns to step S1.

[0079] The process of measuring the position is executed while the reflection unit 2 and the measurement unit 3 are moving and ends when the reflection unit 2 and the measurement unit 3 stop. Also, the process of measuring the position is executed again when the stationary reflection unit 2 and measurement unit 3 start moving.

[0080] [Effect of the measurement system S] As described above, the measurement system S is provided below the rail 1 including the horizontal plate portion 111 provided along the traveling direction Z of the carrier 4 and having the upper surface 113 on which the wheels 42 travel. The measurement system S irradiates the irradiation light C toward the rail 1 and measures the position of the rail 1 based on the reflected light obtained by the reflection of the irradiation light C from the rail 1. The measurement system S includes a measurement unit 3, a reflection unit 2 provided above the horizontal plate portion 111, an acquisition unit 521, and an output unit 523. The reflection unit 2 reflects the irradiation light C toward the upper surface 113 and reflects the first reflected light D from the upper surface 113 toward the measurement unit 3. The acquisition unit 521 acquires the virtual image position V of the virtual image of the upper surface 113 based on the first reflected light D and the lower surface position Q of the lower surface 114 measured based on the second reflected light E from the lower surface 114 of the upper surface 113. The output unit 523 outputs the actual upper surface position R and the lower surface position Q of the upper surface 113 obtained by correcting the virtual image position V based on the positional relationship between the reflection unit 2 and the measurement unit 3.

[0081] By having the reflection unit 2, the measurement system S can irradiate the upper surface 113 on the opposite side of the measurement unit 3 across the lower surface 114 with the irradiation light C. Specifically, the irradiation light C incident on the reflection unit 2 is reflected by the reflection unit 2 and then incident on the upper surface 113. The first reflected light D reflected by the upper surface 113 is incident on the reflection unit 2, reflected by the reflection unit 2, and then incident on the light receiving unit 32. Thus, by providing the reflection unit 2, the measurement system S can irradiate the upper surface 113 on the opposite side of the measurement unit 3 across the lower surface 114 with the irradiation light C, not just the lower surface 114.

[0082] Since the positional relationship between the reflection unit 2 and the measurement unit 3 is determined when configuring the measurement system S, the measurement system S can calculate the actual upper surface position R of the upper surface 113 by correcting the virtual image position V based on the first reflected light D according to the positional relationship between the reflection unit 2 and the measurement unit 3. That is, the measurement system S can measure the virtual image position V of the upper surface 113 and the lower surface position Q of the lower surface 114 of the horizontal plate portion 111 of the rail 1 with a simple configuration of one measurement unit 3 and one reflection unit 2. As a result, the administrator can measure the wear and deformation of the horizontal plate portion 111.

[0083] As described above, the present invention has been described using the embodiments. However, the technical scope of the present invention is not limited to the scope described in the above embodiments, and various modifications and changes are possible within the scope of the gist. For example, all or part of the device can be configured by functionally or physically dispersing and integrating it in any unit. Also, new embodiments resulting from any combination of multiple embodiments are included in the embodiments of the present invention. The effects of the new embodiments resulting from the combination have the effects of the original embodiments combined.

Explanation of Reference Numerals

[0084] 1 Rail 2 Reflection Unit 3 Measurement Unit 4 Carrier 5 Measuring Device 6 External Device 7 Conveying Unit 11 Left Rail 12 Right Rail 21 Left reflecting surface 22 Right reflecting surface 31 Irradiation unit 32 Light receiving unit 33 Calculation unit 41 Housing 42 Wheel 43 Shaft 51 Memory unit 52 Control unit 61 First straight line 62 Second straight line 71 Housing 72 Wheel 73 Connecting part 111 Horizontal plate part 112 Wall part 113 Upper surface 114 Lower surface 115 Upper plate part 121 Horizontal plate part 122 Wall part 123 Upper surface 124 Lower surface 421 Wheel 422 Wheel 521 Acquisition unit 522 Correction unit 523 Output unit S Measurement system U Conveying system

Claims

1. It is provided below a rail having a horizontal plate portion along the traveling direction of a carrier for transporting a heavy object, on which a traveling surface on which the wheels of the carrier run is formed, irradiates light toward the rail, and measures the position of the rail based on the reflected light of the light reflected from the rail. A measuring unit; It is provided above the horizontal plate portion, reflects the light irradiated from the measuring unit toward the traveling surface, and reflects the first reflected light reflected from the traveling surface toward the measuring unit. A reflecting unit; An acquisition unit that acquires a first position of a virtual image of the traveling surface measured by the measuring unit based on the first reflected light, and a second position of the opposite surface measured by the measuring unit based on second reflected light reflected from the opposite surface of the horizontal plate portion opposite to the traveling surface; A correction unit that corrects the first position based on the positional relationship between the reflecting unit and the measuring unit, and calculates an actual third position of the traveling surface; An output unit that outputs the third position calculated by the correction unit and the second position acquired by the acquisition unit; A measurement system having the above.

2. The reflecting unit has a reflecting surface that is inclined with respect to the horizontal plate portion at an angle that can reflect the light on the traveling surface and can reflect the first reflected light reflected from the traveling surface to the measuring unit. The measurement system of Claim 1.

3. The measuring unit measures the first position while changing an incident angle of the light with respect to the reflecting unit, and measures the second position while changing an incident angle of the light with respect to the opposite surface. The measurement system of Claim 2.

4. The reflecting surface is inclined at an acute angle with respect to a second straight line perpendicular to a first straight line passing through the measuring unit and the reflecting unit as viewed from the traveling direction. The measurement system of Claim 3.

5. The measuring unit measures the first position and the second position in a plane perpendicular to the traveling direction. The measurement system of Claim 1.

6. The correction unit calculates the third position by subjecting the first position to a target transformation to a position that is line-symmetric with respect to a straight line passing through a reflecting surface that reflects the light of the reflecting unit in the plane. The measurement system of Claim 5.

7. The correction unit multiplies a coordinate matrix including coordinates representing each of the plurality of first positions of the traveling surface by a rotation matrix for the target transformation to calculate coordinates representing each of the plurality of third positions of the traveling surface. The measurement system of Claim 6.

8. The acquisition unit acquires the inclination angle of the measurement unit with respect to the horizontal direction perpendicular to the vertical direction, Before the correction unit corrects the first position to calculate the third position, the correction unit rotationally moves the first position and the second position by the inclination angle, The measurement system according to claim 1.

9. The output unit outputs, as the wear amount of the horizontal plate portion, the difference between the actually measured distance between the acquired second position and the calculated third position and the reference thickness of the horizontal plate portion, The measurement system according to any one of claims 1 to 8.

10. The output unit outputs, as the amount of deformation of the horizontal plate portion, the distance between the reference position of the third position determined by the acquired second position and the reference thickness of the horizontal plate portion and the calculated third position, The measurement system according to any one of claims 1 to 8.

11. It has a transport unit that moves the measurement unit and the reflection unit along the traveling direction, While being moved in the traveling direction by the transport unit, the measurement unit measures the first position and the second position, The measurement system of claim 1.

12. The output unit outputs, in association with each other, the fourth position of the measurement unit in a plane parallel to the traveling direction and the first position and the second position measured by the measurement unit at the fourth position, The measurement system of claim 11.

13. The transport unit moves the measurement unit and the reflection unit along the traveling direction while the carrier is transporting the heavy object, While being moved in the traveling direction by the transport unit while the carrier is transporting the heavy object, the measurement unit measures the first position and the second position, The measurement system according to claim 11 or 12.

14. The rail includes a first rail provided on the left side of the reflection unit when viewed from the traveling direction and a second rail provided on the right side of the reflection unit, The measurement unit measures the first position and the second position of the first rail and the first position and the second position of the second rail, The correction unit corrects the first position of the first rail to calculate the third position of the first rail, and corrects the first position of the second rail to calculate the third position of the second rail, The measurement system of claim 1.

15. The reflection unit is a first reflecting surface that is capable of reflecting the light on the running surface of the first rail and is inclined with respect to the horizontal plate portion at an angle capable of reflecting the first reflected light reflected from the running surface of the first rail to the measuring unit; a second reflecting surface that is capable of reflecting the light on the running surface of the second rail and is inclined with respect to the horizontal plate portion at an angle capable of reflecting the first reflected light reflected from the running surface of the second rail to the measuring unit; and the first reflecting surface is provided to be inclined at an acute angle with respect to the running surface of the first rail on the left side of a straight line passing through the measuring unit and the reflecting unit as viewed from the traveling direction; the second reflecting surface is provided to be inclined at an acute angle with respect to the running surface of the second rail on the right side of a straight line passing through the measuring unit and the reflecting unit as viewed from the traveling direction; one end of the first reflecting surface and one end of the second reflecting surface are connected; The measurement system according to claim 14.

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