Diagnostic system and diagnostic method

Abstract

To provide a diagnostic system and a diagnostic method capable of acquiring three-dimensional shape data over a longitudinal direction of a rail.SOLUTION: A diagnostic system includes: a diagnostic apparatus body provided with a positioning target that moves on a rail along a longitudinal direction of the rail; a three-dimensional measurement device that measures a three-dimensional position of the diagnostic apparatus body by irradiating the positioning target with an electromagnetic wave or a sound wave; a rail shape measurement device that is provided in the diagnostic apparatus body and measures a shape of the rail; and a control device that calculates a three-dimensional shape of the rail based on three-dimensional position data indicating the three-dimensional position of the diagnostic apparatus body and rail shape data indicating the shape of the rail.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] TECHNICAL FIELD The present disclosure relates to a diagnostic system and a diagnostic method, and more particularly to a diagnostic system and a diagnostic method for a rail on which a mobile machine runs. [Background technology]

[0002] Conventionally, inspections of rails on which mobile equipment such as cranes travel have been performed visually for wear or cracks, but such rail inspections generally require a wide inspection range, making it difficult to carry out inspections at short intervals.

[0003] As an example of technology for automatic rail inspection, Patent Document 1 discloses a displacement detection device mounted on a vehicle that runs on rails. This displacement detection device measures the shape of the rail using a measurement unit and detects deviations in its own position using a self-position detection unit, thereby detecting rail displacement. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-136352 Summary of the Invention [Problem to be solved by the invention]

[0005] The technology of Patent Document 1 enables diagnosis of rail damage, left and right rail spans, etc. However, although the technology of Patent Document 1 can diagnose the two-dimensional shape of the rail at the measurement point, it cannot obtain three-dimensional shape data over the entire length of the rail, such as bending in the longitudinal direction of the rail.

[0006] The present disclosure has been made in view of the above circumstances, and aims to provide a diagnostic system and diagnostic method that can acquire three-dimensional shape data over the entire length of a rail. [Means for solving the problem]

[0007] (1) A diagnostic system according to an embodiment of the present disclosure includes: a diagnostic device body provided with a positioning target that moves on a rail along the longitudinal direction of the rail; a three-dimensional measuring device that measures the three-dimensional position of the diagnostic device body by irradiating the positioning target with electromagnetic waves or sound waves; a rail shape measuring device provided in the diagnostic device body for measuring the shape of the rail; The diagnostic device includes a control device that calculates the three-dimensional shape of the rail based on three-dimensional position data that indicates the three-dimensional position of the diagnostic device main body and rail shape data that indicates the shape of the rail.

[0008] (2) As one embodiment of the present disclosure, in (1), The control device calculates the deviation between pre-stored three-dimensional shape data of the rail and the calculated three-dimensional shape data of the rail, and performs an abnormality diagnosis of the rail based on the deviation.

[0009] (3) As an embodiment of the present disclosure, in (1) or (2), The diagnostic device main body is connected to a moving machine that runs on the rails, and is pulled by the moving machine to move on the rails.

[0010] (4) As an embodiment of the present disclosure, in (3), a trajectory calculation device for calculating a travel trajectory of the mobile device on the rail; The control device diagnoses an abnormality in the mobile device based on the calculated three-dimensional shape data of the rail and the travel trajectory of the mobile device.

[0011] (5) As an embodiment of the present disclosure, in any one of (1) to (4), The diagnostic device main body is housed in a mobile unit that travels on the rails.

[0012] (6) A diagnostic method according to an embodiment of the present disclosure includes: measuring the three-dimensional position of the diagnostic device body by irradiating electromagnetic waves or sound waves onto a positioning target provided on the diagnostic device body that moves on the rail along the longitudinal direction of the rail, using a three-dimensional measuring device; measuring the shape of the rail by a rail shape measuring device provided in the diagnostic device body; Calculating the three-dimensional shape of the rail based on three-dimensional position data indicating the three-dimensional position of the diagnostic device main body and rail shape data indicating the shape of the rail. [Effects of the Invention]

[0013] According to the present disclosure, it is possible to provide a diagnostic system and a diagnostic method that can acquire data on the three-dimensional shape of a rail along its length. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a diagram illustrating an overview of a diagnostic system according to an embodiment of the present disclosure. [Figure 2A] FIG. 2A is a diagram showing an example of the configuration of the diagnostic device main body. [Figure 2B] FIG. 2B is a diagram showing an example of the configuration of the diagnostic device main body. [Figure 2C] FIG. 2C is a diagram showing an example of the configuration of the diagnostic device main body. [Figure 3A] FIG. 3A is a diagram for explaining the processing of the calculation unit. [Figure 3B] FIG. 3B is a diagram for explaining the processing of the calculation unit. [Figure 4] FIG. 4 is a diagram for explaining the processing of the evaluation unit. [Figure 5A] FIG. 5A is a diagram for explaining the processing of the wheel derailment sign monitoring unit. [Figure 5B] FIG. 5B is a diagram for explaining the processing of the wheel derailment sign monitoring unit. [Figure 6] FIG. 6 is a diagram showing the configuration of a diagnostic system in the embodiment. [Figure 7] FIG. 7 is a diagram showing locations diagnosed as abnormal in the example. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, a diagnostic system and a diagnostic method according to an embodiment of the present disclosure will be described with reference to the drawings.

[0016] <Diagnostic system> FIG. 1 shows an overview of a diagnostic system according to this embodiment. The diagnostic system according to this embodiment can acquire the three-dimensional shape of a rail and diagnose abnormalities in the rail and moving devices on the rail based on the three-dimensional shape of the rail. The diagnostic system comprises a diagnostic device main body, a three-dimensional measuring device, and a control device. The diagnostic device main body is configured to include a rail shape measuring device. The diagnostic system may further comprise a trajectory calculation device. Details of the components of the diagnostic system will be described later.

[0017] In this embodiment, the rail to be diagnosed is installed on the ceiling of a factory. However, the rail is not limited to being installed on the ceiling of a factory. Also, in this embodiment, the moving machine is an overhead crane. However, the moving machine is not limited to an overhead crane. For example, the moving machine may be a stacker or reclaimer used in a raw material yard. In this case, the rail to be diagnosed may be a rail on which the stacker or reclaimer runs.

[0018] In this embodiment, the crane frame (the frame portion of the overhead crane, which is the mobile machine) travels on rails using crane travel wheels. The hook of the overhead crane may be attached to the crane frame between the rails (see Figure 6). If dust accumulates on the side of the rails, it may affect the travel of the crane frame and the diagnostic device itself. Therefore, a dust scraper for removing dust may be installed on the crane frame.

[0019] <Diagnostic device body> The diagnostic device body moves on the rail along the longitudinal direction of the rail. The diagnostic device body is installed on the rail to be diagnosed and can move forward and backward along the longitudinal direction of the rail. A positioning target (see Figure 2A) is provided on the diagnostic device body.

[0020] In this embodiment, the diagnostic device main body is connected to the crane frame via a jig and a wire. This connection restricts the diagnostic device main body to the crane frame only in the traveling direction. That is, in this embodiment, the diagnostic device main body is connected to an overhead crane (an example of a mobile machine) that travels on rails and is towed by the overhead crane to move along the rails. The length of the wire is adjusted by the movement of the crane frame so that the crane frame and the diagnostic device main body do not come into contact with each other. Furthermore, the diagnostic device main body is connected to the wire to prevent it from falling from the ceiling. Here, as another configuration example, the diagnostic device main body may be a self-propelled type that incorporates a drive means instead of a towable type. As another configuration example, the diagnostic device main body may be built into the crane frame. In a configuration in which the diagnostic device main body is included in a mobile machine (e.g., built into the crane frame) or is fixed to the mobile machine, the way in which it is built into or fixed to the mobile machine is not limited to a specific mode as long as it can measure the rail shape while moving along the rail. Furthermore, a link mechanism combining multiple mechanical parts may be used instead of the jig and the wire to restrict the diagnostic device main body to the crane frame only in the traveling direction.

[0021] 2A, 2B, and 2C show examples of the configuration of a diagnostic device main body. As described above, the diagnostic device main body includes a rail shape measuring device. As in this embodiment, the diagnostic device main body may further include a trajectory calculation device. In this embodiment, the diagnostic device main body also includes a traveling unit for traveling on the rail, a battery, and data storage. Here, in this embodiment, the rail shape measuring device includes a distance measurement sensor unit composed of a group of parts including a distance measurement sensor.

[0022] The traveling unit has guide wheels that grip and restrain the side surfaces of the rail from both sides, and traveling wheels for traveling on the upper surface of the rail. The traveling unit may also have a spring that generates a gripping force to stably grip the side surfaces of the rail. The traveling unit may also be configured so that the spacing between the left and right guide wheels can be adjusted as desired to accommodate various rail sizes. The materials for the traveling wheels and guide wheels are not limited to a specific material, but are preferably hard rubber, which is lightweight and highly durable.

[0023] The rail shape measuring device is installed in the diagnostic device main body and measures the shape of the rail. The rail shape measuring device includes a distance measuring sensor that measures the distance between the diagnostic device main body and the rail, a sensor amplifier, and a rail shape measurement controller (simply referred to as "controller" in FIG. 2B). The distance measuring sensor in the rail shape measuring device may be a known sensor capable of two-dimensional profile measurement. When diagnosing the entire cross-sectional shape of the rail, including not only the top surface but also the side surfaces, it is desirable to install two or more distance measuring sensors. It is also desirable to configure the rail shape measuring device so that parts can be replaced or added. Here, the rail shape measuring device may be configured to include a camera unit or an ultrasonic inspection unit in addition to the distance measuring sensor unit. By using the camera unit to photograph the rail, it is possible to simultaneously record rail shape and other information, such as video information of the rail. Furthermore, by using the ultrasonic inspection unit to irradiate the rail with ultrasonic waves, it is possible to perform non-destructive testing, which allows simultaneous recording of information such as cracks inside the rail in addition to the rail shape.

[0024] The trajectory calculation device calculates the travel trajectory of the mobile machine on the rails. In this embodiment, the trajectory calculation device has a distance measurement sensor for measuring the distance (relative position) between the diagnostic device main body and the crane frame. The distance measurement sensor of the trajectory calculation device may be a known sensor capable of two-dimensional profile measurement. It is desirable that the distance measurement sensor of the trajectory calculation device measures one coordinate point of a representative point of the crane frame, for example, a corner portion (see FIG. 5A).

[0025] The battery supplies power to, for example, a distance measurement sensor of the rail shape measurement device and a distance measurement sensor of the trajectory calculation device. The data storage stores measurement data from, for example, the distance measurement sensor of the rail shape measurement device and the distance measurement sensor of the trajectory calculation device. The battery and data storage may be mounted on the diagnostic device main body. Alternatively, the battery and data storage may be external to the diagnostic device main body, and may supply power and receive measurement data via, for example, a power supply cable and a data reception signal line connected to the diagnostic device main body along with wires. For example, the battery and data storage may be located in the crane cab that operates the overhead crane. This allows the diagnostic device main body to be lightweight. Alternatively, power may be supplied to the diagnostic device main body from the crane cab without using a battery.

[0026] Here, the diagnostic device main body may be configured to further include a single-axis distance measuring sensor. When measuring the shape of a rail, for example, when measuring a joint in the longitudinal direction of the rail, high-precision measurement with an allowable error of, for example, -0.5 mm to +0.5 mm may be required. For example, depending on the traveling speed of an overhead crane, it may not be possible to set a measurement cycle that satisfies the required accuracy with a distance measuring sensor that performs two-dimensional profile measurement. In such cases, the diagnostic device main body can use a single-axis distance measuring sensor to perform measurements with the required accuracy.

[0027] As described above, the diagnostic device body is provided with a positioning target. Electromagnetic waves or sound waves are irradiated onto the positioning target from the three-dimensional measuring device. Electromagnetic waves or sound waves include laser light such as visible light laser, infrared rays, and ultrasound waves. In this embodiment, the three-dimensional measuring device is described as irradiating a laser. While a device other than a laser may be used, it is preferable to use a laser because it has a measurement distance of over 100 m and can achieve an accuracy of within ±1 mm. In this embodiment, the positioning target is also used as a reference point for the diagnostic device body. The reference point for the diagnostic device body is a point that represents the three-dimensional position of the diagnostic device body and is used for alignment in a coordinate system.

[0028] <3D measuring device> The 3D measuring device measures the 3D position of the diagnostic device main body by irradiating a laser onto a positioning target. The 3D measuring device is installed independently from the diagnostic device main body. It is desirable that the 3D measuring device be installed in a location that is not affected by the movement of the mobile device. In this embodiment, the 3D measuring device is installed in a location that is not affected by vibrations caused by the travel of the overhead crane or deformation caused by the weight of the overhead crane.

[0029] Here, the positioning target is provided at a position on the diagnostic device body that can be constantly tracked by the three-dimensional measuring device. The three-dimensional measuring device may be a measuring instrument such as a total station or laser tracker with an automatic tracking function. The total station or laser tracker emits a laser to a positioning target (e.g., a reflector) that is in contact with the object to be measured, and measures the distance to the object to be measured using the light reflected from the positioning target. The distance measurement may be performed using an optical radar method. Specific examples of the optical radar method include a time-of-flight method that uses the time difference between the emission of a laser and the return of reflected light, and a phase difference method that uses the phase difference between the emitted light and the reflected light.

[0030] When the 3D measuring device is a laser tracker, the laser light emission source is mounted on the laser tracker body so that it can rotate around two axes. Therefore, by measuring the rotation angle with an encoder, the direction (vertical angle and horizontal angle) of the object to be measured can be measured. In addition, by determining the distance and direction to the object, the 3D position of the object can be identified. When the 3D measuring device is a total station, the direction (vertical angle and horizontal angle) of the object can be measured using a theodolite (transit) from the position of the reflected light when the object is collimated with a lens. In addition, the automatic tracking function allows the 3D position of the object to be identified in real time.

[0031] <Control device> The control device calculates the three-dimensional shape of the rail based on three-dimensional position data indicating the three-dimensional position of the diagnostic device main body and rail shape data indicating the shape of the rail. As described above, the three-dimensional position data is measured by a three-dimensional measuring device. Furthermore, the rail shape data is measured by a rail shape measuring device. The three-dimensional position data of the diagnostic device main body and measurement data measured by a distance measuring sensor mounted on the diagnostic device main body are collected in the control device. Here, the measurement data may be accumulated in a data storage during measurement, for example, and transmitted to the control device after measurement is completed. Furthermore, the measurement data may be constantly transmitted to the control device by, for example, a wireless unit.

[0032] The control device may also calculate the deviation (shift) between pre-stored three-dimensional rail shape data and the calculated three-dimensional rail shape data, and perform rail abnormality diagnosis based on the deviation. The control device may also perform rail abnormality diagnosis based on the deviation between three-dimensional rail shape data measured in the past and the latest three-dimensional rail shape data. The control device may also perform mobile device abnormality diagnosis based on the calculated three-dimensional rail shape data and the mobile device's travel trajectory.

[0033] In this embodiment, the control device includes a calculation unit, an evaluation unit, and a wheel derailment sign monitoring unit. The control device may be an information processing device such as a computer. When the control device is a computer, an arithmetic processing device such as a CPU (Central Processing Unit) executes a program to function as the calculation unit, the evaluation unit, and the wheel derailment sign monitoring unit.

[0034] <Arithmetic section> 3A and 3B are diagrams for explaining the processing of the calculation unit. As shown in FIG. 3A, three-dimensional position data indicating the three-dimensional position of the diagnostic device main body is measured by a three-dimensional measuring device. The three-dimensional position of the diagnostic device main body is determined with the position of the three-dimensional measuring device as the origin. The three-dimensional position data is also calculated based on the measurement time (t1, ..., t i ,…t n ) includes the three-dimensional position of the diagnostic device main body at each time point. As shown in FIG. 3A, rail shape data (an example of measurement data) is measured by a distance measurement sensor mounted on the diagnostic device main body. The rail shape is measured as two-dimensional data on the ZX plane in FIG. 3A. The rail shape data is stored as data at measurement times (t1, ..., t i ,…t n ) includes the rail shapes of each of the rails. As shown in FIG. 3B, the calculation unit acquires three-dimensional position data and rail shape data. The three-dimensional position data and rail shape data are configured so that the three-dimensional position of the diagnostic device main body and the rail shape can be synchronized (associated) at least by time. It is preferable that the measurement cycles of the three-dimensional position data and rail shape data are aligned. Furthermore, if the measurement cycles do not match, the calculation unit may perform correction processing such as data interpolation or averaging to enable synchronization (association).

[0035] As described above, the three-dimensional position data is time-series data indicating the three-dimensional position of the diagnostic device main body. Furthermore, the rail shape data is time-series data indicating the rail shape. The calculation unit performs correction processing if necessary and performs time synchronization on the three-dimensional position data and rail shape data. Here, because the rail shape is measured as two-dimensional data on the ZX plane, the calculation unit performs processing (coordinate conversion) to convert the coordinates into a three-dimensional coordinate system (xyz coordinate system) with the position of the three-dimensional measuring device as the origin. Through these processes, the calculation unit calculates the three-dimensional shape of the rail in the three-dimensional coordinate system.

[0036] <Evaluation Department> FIG. 4 is a diagram illustrating the processing of the evaluation unit. As shown in FIG. 4, the evaluation unit evaluates the condition of the rail by comparing the three-dimensional shape of the rail calculated by the calculation unit with pre-stored three-dimensional shape data of the rail in a normal state. The three-dimensional shape data of the rail in a normal state may be stored in advance in, for example, the data storage of the control device. The three-dimensional shape data of the rail in a normal state may be data described using 3D CAD. Here, the normal state refers to, for example, the state at the time of design or immediately after manufacture, where there is no deterioration such as bending or wear that occurs due to use.

[0037] Here, the 3D shape of the rail calculated by the calculation unit is described in the above-mentioned 3D coordinate system, so it may not match the coordinate system of the 3D CAD. For alignment, the evaluation unit may set three or more reference points at the measurement site and in the 3D CAD and perform coordinate transformation to match the coordinates of the reference points. Alternatively, as a simpler method, the evaluation unit may perform alignment by fitting the 3D shape of the rail calculated by the calculation unit with the 3D shape of the rail in a normal state, minimizing the least squares error.

[0038] After alignment, the evaluation unit calculates the deviation between the 3D shape of the rail calculated by the calculation unit and the 3D shape of the rail in a normal state. Based on the deviation, it is possible to quantitatively evaluate control indicators such as the amount of wear on the rail surface and the amount of rail bending. It is also possible to visualize abnormal conditions based on the magnitude of the deviation, for example, by displaying a contour. Rail inspectors can easily determine whether or not an abnormal condition exists by looking at the magnitude of the visualized deviation. Furthermore, by looking at the magnitude of the deviation between 3D shape data of the rail measured in the past and the latest 3D shape data, it is possible to easily grasp changes in the rail's abnormal condition.

[0039] Also, an allowable range of deviation may be set in advance. In this case, the evaluation unit can output an alarm (warning) to the rail inspector if the deviation exceeds the allowable range. The alarm issued based on a comparison with the allowable range makes it possible to create a rail repair plan without any omissions. Here, various indexes can be set as control indexes, not limited to the amount of wear on the rail surface and the amount of rail bending. Also, an allowable range of deviation may be set for each control index. Furthermore, the evaluation unit may comprehensively evaluate the deviation of each control index and diagnose rail abnormalities.

[0040] <Slippage Warning Unit> 5A and 5B are diagrams for explaining the processing of the wheel derailment sign monitoring unit. The wheel derailment sign monitoring unit can diagnose abnormalities in the overhead crane (mobile machine) based on measurement data from the trajectory calculation device. The wheel derailment sign monitoring unit extracts the cross-sectional shape of the rail from the calculated three-dimensional shape of the rail and calculates the position of the center of gravity of the rail. The wheel derailment sign monitoring unit calculates the trajectory of the center of gravity in the longitudinal direction of the rail from the position of the center of gravity of the rail at each cross section, and diagnoses signs of wheel derailment by comparing the trajectory of the center of gravity of the rail with the traveling trajectory of the crane frame.

[0041] As described above, the diagnostic device main body may include a trajectory calculation device. The trajectory calculation device has a distance measurement sensor for measuring the distance between the diagnostic device main body and the crane frame, and calculates the travel trajectory of a representative point of the crane frame on the rail. As shown in FIG. 5A, the representative point of the crane frame may be one coordinate point of a corner portion. The representative point of the crane frame is calculated based on the measurement time (t1, ..., t i ,…t n ) are measured as two-dimensional data on the ZX plane. The wheel slippage warning monitoring unit performs coordinate transformation in the same way as the calculation unit, and calculates the three-dimensional travel trajectory of the crane frame in a three-dimensional coordinate system with the position of the 3D measuring device as the origin.

[0042] As shown in FIG. 5B , the wheel derailment sign monitoring unit calculates the distance based on the relative positions of the rail's center of gravity trajectory and the crane frame's travel trajectory. When the crane travel wheels are traveling stably on the rail, the rail's center of gravity trajectory and the crane frame's travel trajectory are parallel, and the distance is constant. For example, if the rail is worn by the crane travel wheels, causing the crane frame to shift laterally, a deviation (deviation from the fixed distance) in the distance occurs. Furthermore, if the flanges on the crane travel wheels, which are designed to prevent the wheels from derailing from the rail, wear due to friction, causing the crane frame to shift laterally, a deviation (deviation from the fixed distance) in the distance occurs. Similarly to the evaluation unit, the wheel derailment sign monitoring unit may calculate the deviation and output an alarm indicating a wheel derailment sign if the deviation exceeds a preset tolerance range. Similarly to the evaluation unit, the wheel derailment sign monitoring unit may visualize the position of the rail for which a wheel derailment sign is determined to exist. By incorporating the wheel derailment sign into a repair plan, wheel derailment can be prevented.

[0043] As described above, the diagnostic system according to this embodiment can acquire 3D shape data along the rail's length by executing the diagnostic method. The diagnostic method includes measuring the 3D position of the diagnostic device by using a 3D measuring device to project a laser onto a positioning target attached to the diagnostic device, which moves along the rail's length. The diagnostic method also includes measuring the rail's shape using a rail shape measuring device attached to the diagnostic device. The diagnostic method also includes calculating the 3D shape of the rail based on 3D position data indicating the 3D position of the diagnostic device and rail shape data indicating the rail's shape. The acquired 3D shape data of the rail contains a large amount of information corresponding to various inspection items related to rail damage and rail position (e.g., wear, cracks, bends, spans, etc.). The acquired 3D shape data of the rail can also be imported into a CAE (Computer Aided Engineering) tool that performs structural analysis to improve rail life.

[0044] The acquired 3D rail shape data can be used in various dynamics simulations. In other words, detailed analysis can be performed by importing the 3D rail shape data into various dynamics simulation tools. For example, the 3D rail shape data can be imported into a mechanism analysis (dynamics simulation), and rails with accurate 3D shapes can be placed in a virtual space. A simulation can then be performed in which an overhead crane travels on the rails placed in the virtual space. The simulation can also identify potential skewing or derailment during operation of the overhead crane. Furthermore, the simulation can identify rail sections that have a significant impact on the operation of the overhead crane. By formulating a repair plan that prioritizes rail sections that have a significant impact on operation, it is possible to prevent problems such as derailment.

[0045] Furthermore, the quantitative evaluation of the management index by the evaluation unit enables trend management, which was difficult with conventional technology. This facilitates feedback to rail repair planning, such as planning repairs before an abnormal state is reached. Furthermore, in the past, inspections of rails on which mobile machines travel for wear or cracks were sometimes performed after the mobile machines had stopped their normal operations. The diagnostic system according to this embodiment can measure the rail shape during normal operations by the mobile machines (without affecting productivity).

[0046] Furthermore, by towing the diagnostic equipment body to the crane frame, there is no need to mount a drive system on the diagnostic equipment body, which simplifies the structure of the diagnostic equipment body. Furthermore, connecting the diagnostic equipment body to the crane frame with a wire prevents the diagnostic equipment body from falling from the ceiling, enabling safe operation.

[0047] In addition, the comparison of the rail's center of gravity trajectory with the crane frame's travel trajectory by the wheel-slip warning monitoring unit makes it possible to detect dynamic rail deformation or abnormalities in the moving machine, and to detect abnormalities that could lead to wheel-slip problems with high accuracy.

[0048] The effects of the present disclosure will be specifically described below based on examples, but the present disclosure is not limited to these examples.

[0049] The diagnostic system according to the above embodiment was applied to an overhead crane in a factory. Figure 6 shows the configuration of the diagnostic system in this example. The 3D measuring device was installed at the center of the crane span (rail span) near the end of the factory building. Rails were installed along the factory building, and two diagnostic device units were installed on the rails. Power to the diagnostic device units was supplied externally from the crane's cab. Data required for diagnostic calculations, including data from the rail shape measuring device and the 3D measuring device, was transmitted and received via wireless communication and collected in the control device. In this example, a battery and data storage device were installed in the crane's cab, which operated the overhead crane. Power was supplied and measurement data was received via a power supply cable and a data reception signal line. This enabled the diagnostic device unit to be lightweight.

[0050] Figure 7 shows the locations diagnosed as abnormal in this example. In this example, the diagnostic system was able to obtain the following information: The accurate three-dimensional shape of the rails installed along the factory building was obtained. For one rail (r1 in Figure 7), by comparing it with the three-dimensional shape of the rail in a normal state, it was diagnosed that the rail had bent beyond the allowable value (upper limit of the allowable range) and that the rail span also exceeded the allowable value. It was also diagnosed that there were signs of a rail derailment at this location, and these abnormalities were able to be visualized. It was also diagnosed that the other rail (r2 in Figure 7) had rail wear beyond the allowable value, and this abnormality was able to be visualized.

[0051] As described above, the diagnostic system and diagnostic method according to this embodiment measure the three-dimensional position of the diagnostic device main body and the shape of the rail, and acquire three-dimensional shape data over the longitudinal direction of the rail based on the three-dimensional position data of the diagnostic device main body and the rail shape data. The diagnostic system and diagnostic method according to this embodiment can accurately diagnose the condition of the rail based on the acquired three-dimensional shape data.

[0052] Although the embodiments of the present disclosure have been described based on the drawings and examples, it should be noted that those skilled in the art would easily be able to make various modifications or alterations based on the present disclosure. Therefore, it should be noted that these modifications and alterations are included within the scope of the present disclosure. For example, functions included in each component or step (process) can be rearranged so as not to cause logical inconsistencies, and multiple components or steps can be combined or divided into one. The embodiments of the present disclosure can also be realized as a program executed by a processor included in an apparatus or a storage medium on which a program is recorded. It should be understood that these are also included within the scope of the present disclosure.

Claims

1. a diagnostic device body provided with a positioning target that moves on a rail along the longitudinal direction of the rail; a three-dimensional measuring device that measures the three-dimensional position of the diagnostic device body by irradiating the positioning target with electromagnetic waves or sound waves; a rail shape measuring device provided in the diagnostic device body for measuring the shape of the rail; a control device that calculates a three-dimensional shape of the rail based on three-dimensional position data that indicates a three-dimensional position of the diagnostic device main body and rail shape data that indicates a shape of the rail.

2. 2. The diagnostic system according to claim 1, wherein the control device calculates a deviation between pre-stored three-dimensional shape data of the rail and the calculated three-dimensional shape data of the rail, and performs an abnormality diagnosis of the rail based on the deviation.

3. 3. The diagnostic system according to claim 1, wherein the diagnostic device body is connected to a mobile device that runs on the rails, and moves on the rails while being towed by the mobile device.

4. a trajectory calculation device for calculating a travel trajectory of the mobile device on the rail; The diagnostic system according to claim 3 , wherein the control device diagnoses an abnormality in the mobile device based on the calculated three-dimensional shape data of the rail and a travel locus of the mobile device.

5. 3. The diagnostic system according to claim 1, wherein the diagnostic device main body is built into a mobile machine that travels on the rail.

6. measuring the three-dimensional position of the diagnostic device body by irradiating electromagnetic waves or sound waves onto a positioning target provided on the diagnostic device body, which moves on the rail along the longitudinal direction of the rail, using a three-dimensional measuring device; measuring the shape of the rail by a rail shape measuring device provided in the diagnostic device body; calculating a three-dimensional shape of the rail based on three-dimensional position data indicating a three-dimensional position of the diagnostic device main body and rail shape data indicating a shape of the rail.

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