Measuring device

Abstract

The position where the rail shape was measured is appropriately identified. [Solution] The measuring device 200 includes a plurality of wheels 220 that travel on the running surface 23 of a free rail 2 on which a transporter that carries heavy objects travels, a measuring unit 250 that measures the shape of the free rail 2 as the wheels 220 travel on the running surface 23, a sensor 230 that outputs a signal corresponding to each wheel a predetermined number of times while each of the plurality of wheels 220 rotates by a predetermined amount, a determination unit 272 that determines the total travel distance from a reference position by adding a length corresponding to the circumference of the wheel and a predetermined amount as the travel distance during the predetermined number of signal outputs each time the number of signal outputs corresponding to any of the plurality of wheels reaches a predetermined number of times, and a storage control unit 273 that stores the determined total travel distance and the shape of the rail measured when the total travel distance was determined in a storage unit in association with each other.

Description

Technical Field

[0001] The present invention relates to a measuring device for measuring the shape of a rail on which a carrier travels.

Background Art

[0002] In order to observe wear, deformation, etc. of a rail on which a carrier travels, a technique for measuring the shape of the rail is known. Patent Document 1 discloses a technique for measuring the shape of a rail based on a camera image obtained by irradiating the rail with light and imaging the reflected light from the rail.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, even if the shape of the rail could be measured, it was not known at which position of the rail the measured shape was obtained.

[0005] Therefore, the present invention has been made in view of these points, and an object thereof is to appropriately specify the position where the shape of the rail is measured.

Means for Solving the Problems

[0006] In one aspect of the present invention, a measuring device is provided comprising: a plurality of wheels that travel on the running surface of a rail on which a transporter that transports heavy objects travels; a measuring unit that measures the shape of the rail when the wheels travel on the running surface; a sensor that outputs a signal corresponding to each wheel a predetermined number of times while each of the plurality of wheels rotates by a predetermined amount; a determination unit that determines the total distance traveled from a reference position by adding a length corresponding to the circumference of the wheel and the predetermined amount as the distance traveled during the predetermined number of times the signal corresponding to any of the plurality of wheels is output; and a storage control unit that stores in a storage unit the determined total distance traveled and the shape of the rail measured when the total distance traveled are determined in association with each other.

[0007] The system may include a counting unit that counts the number of outputs of the signal for each of the plurality of wheels, and when the number of outputs of the signal corresponding to any of the plurality of wheels reaches a predetermined number, it sets the number of outputs of the signal corresponding to all of the plurality of wheels to 0.

[0008] The determination unit may determine a new total travel distance by multiplying the circumference of the wheel by the predetermined amount and adding the resulting length to the total travel distance as the travel distance.

[0009] The device has an acquisition unit that acquires a set speed, which is set as the moving speed of the measuring device when the plurality of wheels are traveling on the running surface. The determination unit determines the total travel distance when the ratio of the travel distance to the time it takes for the signal corresponding to any of the plurality of wheels to be output a predetermined number of times is less than or equal to the set speed, and does not need to determine the total travel distance when the ratio is greater than the set speed.

[0010] The measuring unit measures the shape of the rail at predetermined time intervals and outputs the first time when the shape of the rail was measured in association with the shape of the rail to the storage control unit; the determining unit outputs the second time when the total travel distance was determined in association with the total travel distance to the storage control unit; and the storage control unit may store in the storage unit the total travel distance corresponding to the second time in association with the shape of the rail associated with the first time closest to the second time.

[0011] The memory control unit may, after associating the total travel distance corresponding to the second time with the rail shape associated with the first time closest to the second time, store it in the memory unit, then identify a value obtained by dividing the travel distance by the number of rail shapes measured during the period from the time the total travel distance was previously determined to the time the total travel distance is determined this time, and store in the memory unit the sum of the total travel distance associated with the rail shape measured immediately before the rail shape was measured and the value obtained by the division, as the total travel distance for one or more rail shapes that were measured during the period and to which the total travel distance is not associated. [Effects of the Invention]

[0012] According to the present invention, the shape of the rail can be accurately determined at the measured position. [Brief explanation of the drawing]

[0013] [Figure 1] This is a schematic diagram showing an example of a transport device. [Figure 2] This is a diagram illustrating wear on the running surface. [Figure 3] This is a diagram illustrating the configuration of the measuring device. [Figure 4] This is a perspective view of the measuring device. [Figure 5] This is a diagram illustrating the specific configuration of the measurement unit. [Figure 6] This diagram illustrates the process of counting the number of outputs. [Figure 7]This diagram illustrates the process of relating rail shape to total distance traveled. [Figure 8] This flowchart shows an example of a process for measuring the shape of a rail. [Modes for carrying out the invention]

[0014] <Overview of the transport equipment> Figure 1 is a schematic diagram showing an example of a transport device. Figure 1 is a side view of the transport device. The transport device is installed, for example, in a vehicle assembly plant, at a position higher than the heads of the workers in the assembly plant. The transport device transports heavy objects H in the assembly plant. Heavy objects H are, for example, devices or parts that make up a vehicle, such as engines, transmissions, and axles. In Figure 1, a conveyor A is shown as an example of a transport device.

[0015] In conveyor A, a drive chain 1 extending in the conveying direction Z, a free rail 2 extending parallel to the drive chain 1 below the drive chain 1, front and rear free trolleys 3 (front free trolley 3a and rear free trolley 3b) which are conveying bodies that run on the free rail 2, and a carrier 4 that is stretched between the front and rear free trolleys 3 and from which a heavy object H is suspended are shown.

[0016] In the drive chain 1, pushers 5 are provided so as to protrude downward to push the front and rear free trolleys 3, which support the heavy object H, in the transport direction Z. The rear free trolley 3b is provided with a dog 6 that can be freely engaged with and disengaged from the pusher 5. In the conveyor A, as the drive chain 1 moves, the pusher 5 engages with the dog 6 and pushes the dog 6, causing the wheels 3c of the free trolley 3 to travel on the running surface 23 of the free rail 2. The heavy object H is transported as the wheels 3c travel on the running surface 23 of the free rail 2.

[0017] The running surface 23 of the free rail 2 is worn due to the running of the wheels 3c of the free trolley 3. FIG. 2 is a diagram for explaining the wear of the running surface 23. FIG. 2 is a cross-sectional view of the free rail 2 as viewed from the conveying direction Z. As shown in FIG. 2, the free rail 2 is composed of a right rail 21 and a left rail 22. The right rail 21 and the left rail 22 are channel steels. The running surfaces 23 of the right rail 21 and the left rail 22 are worn due to the running of the wheels 3c of the free trolley 3.

[0018] The dent M is a dent formed on the running surface 23 due to wear. When the dent M becomes large, the thickness of the free rail 2 becomes small, so the strength of the free rail 2 decreases. When the strength of the free rail 2 decreases, the free rail 2 is deformed by the weight of the heavy object H carried by the free trolley 3. When the free rail 2 is deformed, the free trolley 3 cannot be properly conveyed, or the wheels 3c of the free trolley 3 are disengaged from the free rail 2 and the free trolley 3 falls from the free rail 2. Therefore, the administrator of the conveyor A (transport device) has to stop the production of the factory to perform the confirmation work in order to measure the dent M of the free rail 2 provided at a position higher than the administrator's head or visually confirm the deformation of the free rail 2. As a result, the working hours of the administrator increase, and the productivity of the factory decreases.

[0019] <Overview of the measuring device> The measuring device according to the embodiment is supported by the flatbed trolley 3 while the heavy object H is being transported, and moves in conjunction with the movement of the flatbed trolley 3. The measuring device measures the shape of the free rail 2 while moving together with the flatbed trolley 3. In the following description, the shape of the free rail 2 is referred to as the shape of the rail. The measuring device irradiates light on the surface of the free rail 2 and measures the shape of the rail based on the reflected light from the surface of the free rail 2. Further, the measuring device associates the measured shape of the rail with the total travel distance of the measuring device 200 from the reference position when the shape of the rail was measured, and stores it in the storage unit. Thereby, the administrator can grasp the measured shape of the rail and how far the position where the shape of the rail was measured is from the reference position, so that it becomes possible to appropriately specify the position where the shape of the rail was measured.

[0020] [Configuration of Measuring Device 200] Hereinafter, the configuration of the measuring device 200 will be described with reference to FIGS. 3 and 4. FIG. 3 is a diagram for explaining the configuration of the measuring device 200. FIG. 3 is a schematic view of the measuring device 200 seen from the horizontal direction X perpendicular to the transport direction Z so that the left rail 22 can be seen. FIG. 4 is a diagram showing the wheels 220 of the measuring device 200 and the free rail 2 on which the wheels 220 travel. In FIG. 4, the four wheels 220 of the measuring device 200 and the shaft connecting the wheels 220 are illustrated, and other configurations are omitted. The measuring device 200 includes a battery 210, four wheels 220, a plurality of sensors 230, an acquisition unit 240, a measurement unit 250, a storage unit 260, and a control unit 270.

[0021] The battery 210 is a power source for operating the measuring device 200. The battery 210 is, for example, a lithium-ion secondary battery, but is not limited thereto. The battery 210 supplies power to each part of the measuring device 200. Specifically, the battery 210 supplies power to the sensor 230, the acquisition unit 240, the measurement unit 250, the storage unit 260, and the control unit 270. By receiving power supply from the battery 210, the measuring device 200 can measure the shape of the rail while moving along the free rail 2 without receiving power supply from the outside.

[0022] Each of the four wheels 220 travels on a running surface 23. As shown in Figure 4, wheels 220a and 220c travel on the running surface 23 of the left rail 22. Wheels 220b and 220d travel on the running surface 23 of the right rail 21. Of the four wheels 220, wheels 220a and 220b are supported by shaft 211a. Wheels 220c and 220d are supported by shaft 211b. Each wheel 220 is free to rotate relative to the shaft. Specifically, each wheel 220 has a bearing, and each wheel 220 rotates freely relative to the shaft by inserting the shaft into a hollow part provided in the center of the bearing. Each wheel 220 is made of metal. Each wheel 220 is made of, for example, stainless steel, steel, or aluminum, but may be made of other metals. The diameter of each wheel 220 in this embodiment is 80 millimeters, but is not limited to this.

[0023] The reflective portion 222 is provided on each wheel 220 (see Figure 3). The reflective portion 222 reflects light emitted from the sensor 230, which will be described later. The reflective portion 222 is a metal tape that reflects light emitted from the sensor 230. The metal tape can be aluminum tape, stainless steel tape, or zinc tape, but any material that can reflect light is acceptable.

[0024] A predetermined number of reflective sections 222 are provided along the circumferential direction of each wheel 220. In this embodiment, five reflective sections 222 are provided on each wheel 220 at 72-degree intervals along the outer circumference of each wheel 220.

[0025] Each of the multiple sensors 230 is provided on each of the multiple wheels 220. Since the measuring device 200 of this embodiment has four wheels 220, four sensors 230 are provided in this embodiment, one for each of the four wheels 220. Each sensor 230 irradiates light onto each wheel 220. Specifically, each sensor 230 irradiates infrared light toward the outer circumference of each wheel 220 corresponding to the sensor 230. The infrared light irradiated by the sensor 230 toward the outer circumference of each wheel 220 is reflected by the reflectors 222 provided on each wheel 220. If the infrared light irradiated by the sensor 230 is incident on any of the five reflectors 222 provided along the outer circumference of each wheel 220, it is reflected by the incident reflector 222. If the infrared light irradiated by the sensor 230 is not incident on any of the reflectors 222, it is not reflected.

[0026] Sensor 230 receives reflected light reflected by the reflector 222. When sensor 230 receives reflected light, it outputs a signal to the counting unit 271 of the control unit 270. Since each wheel 220 is provided with five reflectors 222, sensor 230 outputs a signal corresponding to each wheel 220 to the counting unit 271 only six times during one rotation of each of the multiple wheels 220. Sensor 230 outputs a signal to the counting unit 271 that includes identification information corresponding to each wheel 220. The identification information is information that can distinguish each of the multiple signals. For example, the identification information is a unique alphanumeric string, such as 1, 2, 3 and 4, or A, B, C and D, but is not limited to these.

[0027] The acquisition unit 240 acquires the set speed of the measuring device 200. The set speed is the speed set as the moving speed of the measuring device 200 when the multiple wheels 220 are traveling on the running surface 23. The acquisition unit 240 acquires the set speed by receiving input of the set speed from the administrator, for example, before the measuring device 200 starts traveling on the free rail 2. The acquisition unit 240 is a keyboard or touch panel, but other input interfaces may also be used.

[0028] The measuring unit 250 is, for example, a two-dimensional laser displacement meter, and measures the shape of the rail. The measuring unit 250 measures the shape of the rail as the wheel 220 travels on the running surface 23 of the free rail 2. The measuring unit 250 moves in the transport direction Z, irradiates the free rail 2 with light, and measures the shape of the rail based on the reflected light from the free rail 2. The measuring unit 250 measures the shape of the rail at predetermined measurement intervals. The measurement interval is set according to the set speed. The faster the set speed, the shorter the measurement interval is set compared to the reference time. The reference time is, for example, 100 milliseconds.

[0029] The specific configuration of the measurement unit 250 will now be described. Figure 5 is a diagram illustrating the specific configuration of the measurement unit 250. The measurement unit 250 includes a case 251, an illumination unit 252, a reflection unit 253, a light receiving unit 254, and a calculation unit 255. The case 251 is a housing that accommodates the illumination unit 252, the light receiving unit 254, and the calculation unit 255.

[0030] The irradiation unit 252 irradiates the free rail 2 with irradiation light C. The irradiation unit 252 irradiates the free rail 2 with irradiation light C, for example, a blue semiconductor laser with a wavelength of 405 nanometers and an output of 4.8 milliwatts (mW), but is not limited to this. The irradiation unit 252 irradiates the irradiation light C toward the reflecting unit 253 and the free rail 2. In Figure 5, the optical path of the irradiation light C is shown by solid arrows. The optical path of the first reflected light D reflected from the running surface 23 and the optical path of the second reflected light E reflected from the lower surface 24 opposite to the running surface 23 of the free rail 2 are shown by dashed arrows.

[0031] The reflecting part 253 is provided at the tip of a support column 256 provided on the case 251. The reflecting part 253 has a reflective surface that reflects the incident light C. The reflective surface is, for example, a mirror with a silver-plated surface on glass, but is not limited to this. The reflecting part 253 reflects the incident light C onto the reflective surface and irradiates the incident light C onto the running surface 23. The incident light C irradiated onto the running surface 23 is reflected by the running surface 23 and incident again on the reflecting part 253 as first reflected light D. The first reflected light D reflected by the reflecting part 253 is incident on the light receiving part 254.

[0032] The light-receiving unit 254 receives the first reflected light D, which is formed when the irradiated light C is reflected by the running surface 23 and the reflecting unit 253. The light-receiving unit 254 also receives the second reflected light E, which is formed when the irradiated light C is reflected by the lower surface 24. In Figure 5, the irradiation angle of the irradiated light C is changed on the ZY plane to make the optical paths of the irradiated light C and the reflected light easier to understand, but in reality, the irradiation angle of the irradiated light C changes on the XY plane.

[0033] The calculation unit 255 measures the position of the free rail 2 in the XY plane perpendicular to the transport direction Z based on the first reflected light D and the second reflected light E. Specifically, the calculation unit 255 measures the position of the running surfaces 23 of the right rail 21 and the left rail 22 in the XY plane based on the first reflected light D. The calculation unit 255 also measures the position of the lower surfaces 24 of the right rail 21 and the left rail 22 in the XY plane based on the second reflected light E.

[0034] The calculation unit 255 outputs the positions of the running surfaces 23 of the right rail 21 and the left rail 22, and the positions of the lower surfaces 24 of the right rail 21 and the left rail 22, as the rail shape to the control unit 270. The calculation unit 255 associates the measured rail shape with the first time point at which the rail shape was measured and outputs this to the memory control unit 273 of the control unit 270.

[0035] The memory unit 260 is a storage medium including ROM (Read Only Memory), RAM (Random Access Memory), and a hard disk. The memory unit 260 stores the program that the control unit 270 executes.

[0036] The control unit 270 is a computing resource that includes a processor such as a CPU (Central Processing Unit). The control unit 270 performs the functions of the counting unit 271, the determination unit 272, and the memory control unit 273 by executing a program stored in the memory unit 260.

[0037] The counting unit 271 counts the number of signal outputs for each of the multiple wheels 220. Figure 6 is a diagram illustrating the process of counting the number of outputs. The horizontal axis in Figure 6 represents time. At time TK1, the number of signal outputs for all wheels 220 is assumed to be 0. The black circles in Figure 6 indicate the timing when a signal was output from the sensor 230.

[0038] The counting unit 271 counts the number of times a signal is output from the sensor 230 for each of the multiple identification information. The counting unit 271 counts the number of outputs in association with the identification information contained in the signal. When a signal containing identification information [A] is output from the sensor 230, the counting unit 271 increments the output count of the signal for identification information [A] by 1. Similarly, when a signal corresponding to identification information [B] is output from the sensor 230, the counting unit 271 increments the output count of the signal for identification information [B] by 1.

[0039] The counting unit 271 determines that the wheel 220 has rotated a predetermined amount when the number of signal outputs reaches a predetermined number. Since the wheel 220 in this embodiment is equipped with five reflectors 222, the counting unit 271 determines that the wheel 220 has completed one rotation when the number of signal outputs corresponding to any of the multiple wheels 220 reaches six. As shown in Figure 6, at time TK2, the number of signal outputs for identification information [C] reached six. At time TK2, when the number of signal outputs for identification information [C] reached six, the counting unit 271 determines that one of the multiple wheels 220 has completed one rotation.

[0040] Since the movement speed of the free trolley 3 changes according to the work process in the assembly plant, the movement speed of the measuring device 200, which moves in conjunction with the free trolley 3, also changes. When the movement speed of the measuring device 200 changes, the rotation speed of the wheels 220 changes, and the timing at which the number of signal outputs becomes 6 changes (see Figure 6). The counting unit 271 can appropriately determine that the wheels 220 have completed one rotation, even if the rotation speed of the wheels 220 changes, by determining whether or not the number of signal outputs has become 6.

[0041] Incidentally, there are cases where the wheel 220 rotates without contacting the running surface 23. For example, if the wheel 220 lifts off the running surface 23 due to distortion, dents, or vibrations in the free rail 2, the wheel 220 will rotate without contacting the running surface 23. In particular, if the wheel 220 lifts off the running surface when the free rail 2 is running on a downward-sloping section, the rotational speed of the lifted wheel 220 increases. In this case, the lifted wheel 220 rotates faster than the wheel 220 that is in contact with the running surface 23. Therefore, the number of signal outputs corresponding to the lifted wheel 220 becomes 6, faster than the number of signal outputs corresponding to the wheel 220 that is in contact with the running surface 23.

[0042] Therefore, the counting unit 271 determines that the wheel 220 has completed one rotation while in contact with the running surface 23 if the speed of the wheel 220 is less than or equal to the set speed. The speed of the wheel 220 is expressed as the ratio of the circumference of the wheel to the elapsed time taken for the signal output to reach six times. The elapsed time is the time from the time the first signal is output to the time the sixth signal is output. Alternatively, the elapsed time may be the time from the time the sixth signal is output (time TK1) to the time the next sixth signal is output (time TK2).

[0043] The counting unit 271 determines that the wheel 220 has completed one rotation while in contact with the running surface 23 if the speed of the wheel 220 is less than or equal to the set speed. This allows the counting unit 271 to appropriately determine that the wheel 220 has completed one rotation while in contact with the running surface 23. If the speed of the wheel 220 is greater than the set speed, the counting unit 271 determines that the wheel 220 has completed one rotation without being in contact with the running surface 23, or that the wheel 220 in contact with the running surface 23 has not completed one rotation.

[0044] The counting unit 271 resets the output count when it determines that a wheel 220 has completed one rotation while in contact with the running surface 23. Specifically, when the counting unit 271 determines that a wheel 220 has completed one rotation while in contact with the running surface 23, it sets the output count of the signals corresponding to all of the multiple wheels 220 to 0. For example, at time TK3, when the output count of the signal for identification information [D] reaches 6, the counting unit 271 determines that one of the multiple wheels 220 has completed one rotation and sets the output count of all of them to 0. In this way, every time the output count of the signal corresponding to any of the multiple wheels 220 reaches 6, the counting unit 271 sets the output count of the signals corresponding to all of the multiple wheels 220 to 0. After setting the signal output count to 0, the counting unit 271 counts the signal output count again.

[0045] The counting unit 271 notifies the determination unit 272 that the wheel 220 has rotated once when it determines that the wheel 220 has rotated once while in contact with the running surface 23. The counting unit 271 notifies the determination unit 272 that the wheel 220 has rotated once each time it determines that the wheel 220 has rotated once while in contact with the running surface 23. The counting unit 271 does not notify the determination unit 272 that the wheel 220 has rotated once if it determines that the wheel 220 has rotated once while not in contact with the running surface 23, or if the wheel 220 that is in contact with the running surface 23 has not rotated once.

[0046] When the determination unit 272 receives notification from the counting unit 271 that the wheel 220 has completed one rotation, it determines the total distance traveled by the measuring device 200 from the reference position. The reference position is, for example, the position where the measuring device 200 started moving, but is not limited to this. When the wheel 220 completes one rotation while in contact with the running surface 23, the measuring device 200 moves a distance equal to the circumference of the wheel 220. Therefore, the determination unit 272 adds the circumference of the wheel 220 as the distance traveled by the measuring device 200 to the total distance traveled, thereby determining a new total distance traveled. The determination unit 272 outputs the newly determined total distance traveled to the memory control unit 273. Specifically, the determination unit 272 outputs the newly determined total distance traveled to the memory control unit 273, associating it with the second time point at which the total distance traveled was determined.

[0047] The memory control unit 273 associates the measured rail shape with the determined total distance traveled and stores it in the memory unit 260. Figure 7 is a diagram illustrating the process of associating the rail shape with the total distance traveled. In Figure 7, it is assumed that the rail shape is measured at measurement intervals t. As shown in Figure 7, the timing of determining the total distance traveled and the timing of measuring the rail shape are different. This is because the measurement timing is constant, while the timing of determining the total distance traveled (i.e., the timing of one rotation of the wheel 220) changes. The memory control unit 273 appropriately associates the total distance traveled and the rail shape, which have different timings, and stores them in the memory unit 260. The process of associating the total distance traveled and the rail shape will be explained in detail below.

[0048] At time TK1, the determination unit 272 determined the total distance traveled L1 when the sixth signal was output from the sensor 230. The memory control unit 273 associates the total distance traveled L1 determined at time TK1 with the rail shape measured at the time the total distance traveled L1 was determined and stores it in the memory unit 260. In the example in Figure 7, the memory control unit 273 associates the total distance traveled L1 corresponding to time TK1 (second time) with the rail shape D1 measured at time TD1 (first time), which is closest to time TK1 (second time), when the total distance traveled L1 was determined, and stores it in the memory unit 260. As a result, the memory control unit 273 can associate the rail shape measured at the time closest to the timing when the total distance traveled was determined.

[0049] At time TK2, following time TK1, the sensor 230 outputs a sixth signal, causing the determination unit 272 to determine the total distance traveled L2. The memory control unit 273 associates the total distance traveled L2 with the rail shape D3 measured at time TD3 (first time), which is closest to time TK2 (second time), when the total distance traveled L2 was determined, and stores it in the memory unit 260.

[0050] The memory control unit 273 associates the total travel distance L2 with the rail shape D3 and stores it in the memory unit 260, and then associates the total travel distance with the rail shape D2 that has not yet been associated with it. Specifically, the memory control unit 273 associates the total travel distance with the rail shape D2 that has not yet been associated with the total travel distance L2 among the rail shapes D2 and rail shapes D3 measured during period P1. Period P1 is the period from the time TK1 when the previous total travel distance L1 was determined to the time TK2 when the current total travel distance L2 was determined.

[0051] First, when the memory control unit 273 associates the total travel distance with a rail shape D2 that does not currently have a total travel distance associated with it, it identifies a value [K / 2] obtained by dividing the travel distance K by the number of rail shapes measured during period P1 [2]. Next, the memory control unit 273 identifies a distance L3 which is the sum of the value [K / 2] obtained by dividing the total travel distance K by the total travel distance L1 associated with the rail shape D1 measured immediately before the rail shape D2 was measured. Then, the memory control unit 273 associates the distance L3 with the rail shape D2 as the total travel distance at the time the rail shape D2 was measured and stores it in the memory unit 260.

[0052] If there are two or more rail shapes that are not associated with the total distance traveled, the memory control unit 273 associates the total distance traveled in order of the earliest first time when the rail shape was measured. The process of associating the total distance traveled in order of the earliest first time will be explained with reference to the example of period P2 shown in Figure 7. Period P2 is the period from time TK2 when the total distance traveled L2 was determined to time TK3 when a new total distance traveled L4 was determined. It is assumed that the memory control unit 273 associates the rail shape D6 measured at time TD6, which is closest to time TK3, with the total distance traveled L4 determined at time TK3 and stores it in the memory unit 260.

[0053] The memory control unit 273 first identifies a value [K / 3] obtained by dividing the travel distance K by the number of rail shapes [3] measured during period P2. Next, the memory control unit 273 identifies the total travel distance associated with rail shape D4, which was measured at the earliest time TD4 (first time step) among the two rail shapes D4 and rail shape D5 measured during period P2. Specifically, the memory control unit 273 identifies a distance L5 obtained by adding the divided value [K / 3] to the total travel distance L2 associated with rail shape D3, which was measured immediately before rail shape D4. Then, the memory control unit 273 associates distance L5 as the total travel distance with rail shape D4 and stores it in the memory unit 260.

[0054] The memory control unit 273 associates the total travel distance with the rail shape D4, and then associates the total travel distance with the rail shape D5, which has not yet been associated with the total travel distance. Specifically, the memory control unit 273 associates the rail shape D5 with a distance L6, which is the total travel distance obtained by adding a specific value [K / 3] to the total travel distance (distance L5) associated with the rail shape D4 measured immediately before the rail shape D5, and stores this distance in the memory unit 260. In this way, the memory control unit 273 associates the total travel distance from the reference position with each of the multiple rail shapes measured during one rotation of the wheel 220 and stores it in the memory unit 260.

[0055] By checking the rail shape and total distance traveled stored in the memory unit 260 of the measuring device 200, the manager can appropriately identify the location where the rail shape was measured. As a result, the manager can check for dents and distortions in the free rail 2 without actually visually inspecting the free rail 2. This reduces the workload associated with managing the free rail 2, thereby improving factory productivity.

[0056] [Process for measuring rail shape] Figure 8 is a flowchart illustrating an example of the process for measuring the shape of the rails. The process for measuring the shape of the rails is executed when the measuring device 200 starts moving. The measuring unit 250 measures the shape of the rails every 100 milliseconds while the measuring device 200 is moving. The sensor 230 also illuminates each of the multiple wheels 220 with light while the measuring device 200 is moving, and outputs a signal each time it receives reflected light from the reflector 222 of each wheel 220.

[0057] The counting unit 271 counts the number of times a signal is output from the sensor 230 (step S1). Specifically, each time a signal containing identification information corresponding to each wheel 220 is output from the sensor 230, the counting unit 271 counts the number of times the signal is output for each piece of identification information. The counting unit 271 determines whether the number of times the signal has been output has reached six (step S2). Specifically, the counting unit 271 determines whether the number of times the signal has been output for any of the multiple pieces of identification information has reached six. If the number of times the signal has been output is less than six (No in step S2), the counting unit 271 returns to step S1 and continues counting the number of times the signal has been output until the number of times the signal has been output six.

[0058] If the number of signal outputs reaches six (Yes in step S2), the counting unit 271 determines whether the speed of the wheel 220 is less than or equal to the set speed (step S3). Specifically, the counting unit 271 determines whether the speed of the wheel 220, expressed as the ratio of the circumference (distance traveled) of the wheel 220 to the time taken for the signal to be output six times, is less than or equal to the set speed. If the speed of the wheel 220 is greater than the set speed (No in step S3), the counting unit 271 returns to step S1.

[0059] If the speed of the wheels 220 is less than or equal to the set speed (Yes in step S3), the counting unit 271 sets the number of signal outputs for all wheels 220 to 0 (step S4). Then, the counting unit 271 notifies the determination unit 272 that the wheels 220 have completed one rotation while in contact with the running surface 23 (step S5). Note that the processing in step S5 may be performed before step S4, or it may be performed in parallel with step S4.

[0060] When the determination unit 272 receives notification from the counting unit 271 that the wheel 220 has completed one rotation while in contact with the running surface 23, it determines the total distance traveled from the reference position of the measuring device 200 (step S6). Specifically, the determination unit 272 determines a new total distance traveled by adding the circumference of the wheel 220 as the travel distance to the total distance traveled previously determined.

[0061] After the determination unit 272 determines the total distance traveled, the memory control unit 273 associates the rail shape with the total distance traveled and stores it in the memory unit 260 (step S7). Specifically, the memory control unit 273 associates the rail shape measured at the first time step closest to the second time step in which the total distance traveled was determined with the said total distance traveled and stores it in the memory unit 260.

[0062] The measuring device 200 repeatedly performs the process of measuring the shape of the rail until it reaches the end position where it ends its journey. The end position is the same as the starting position, for example, if the free rail 2 is circular. In other words, the measuring device 200 repeatedly performs the process of measuring the shape of the rail from the starting position, traveling along the free rail 2, and returning to the starting position.

[0063] (Variation 1) The measuring device 200 in this embodiment had four wheels 220, but the number of wheels 220 does not have to be four. The number of wheels on the measuring device 200 can be even, and may be two or six.

[0064] (Modification 2) In this embodiment, the counting unit 271 notified the determination unit 272 that the wheel 220 had rotated once when the number of signal outputs reached six. However, the counting unit 271 may also notify the determination unit 272 that the wheel 220 has rotated by a predetermined amount based on the number of signal outputs. For example, when the number of signal outputs reaches a predetermined number, the counting unit 271 notifies the determination unit 272 that the wheel 220 has rotated by a predetermined amount corresponding to the predetermined number. Specifically, the counting unit 271 notifies the determination unit 272 that the wheel 220 has rotated twice when the number of signal outputs reaches twelve. When the determination unit 272 receives notification from the counting unit 271 that the wheel 220 has rotated by a predetermined amount, it determines a new total travel distance by adding a length obtained by multiplying the circumference of the wheel 220 by a predetermined amount to the total travel distance. Specifically, when the determination unit 272 receives notification from the counting unit 271 that the wheel 220 has rotated twice, it determines a new total distance traveled by adding the length obtained by multiplying the circumference of the wheel 220 by 2 to the total distance traveled.

[0065] (Variation 3) In this embodiment, the memory control unit 273 stores the total distance traveled in the memory unit 260, associating it with the shape of the rail associated with a first time point that is earlier than the second time point in which the total distance traveled was determined. However, the memory control unit 273 may also store the total distance traveled in the memory unit 260, associating it with the shape of the rail associated with a first time point that is later than the second time point in which the total distance traveled was determined. The memory control unit 273 stores the total distance traveled in the memory unit 260, associating it with the shape of the rail measured at the first time point closest to the second time point, among the first time point of the rail shape measured before the second time point and the first time point of the rail shape measured after the second time point.

[0066] [Effects of measuring device 200] As explained above, the measuring device 200 measures the shape of the rail as the free trolley 3, which transports a heavy object H, travels on the running surface 23 of the free rail 2 with multiple wheels 220. The measuring device 200 determines the total distance traveled from the reference position by adding the circumference of the wheels 220 as the travel distance each time the number of signals output from a sensor that outputs a signal a predetermined number of times (6 times) while the wheels 220 rotate a predetermined amount (1 time). The measuring device 200 then stores the determined total distance traveled and the shape of the rail measured at the time the total distance traveled in the storage unit 260, associating them.

[0067] The manager can understand how far the measured rail shape is from the reference position, making it possible to accurately identify the location where the rail shape was measured. As a result, the manager can check for dents and distortions in the free rail 2 without actually visually inspecting it. This reduces the workload involved in managing the free rail 2, thereby improving factory productivity.

[0068] Although the present invention has been described above using embodiments, 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 its gist. For example, all or part of the apparatus can be configured by functionally or physically distributing and integrating in any unit. Furthermore, new embodiments resulting from any combination of multiple embodiments are also included in the embodiments of the present invention. The effects of the new embodiments resulting from the combinations are combined with the effects of the original embodiments. [Explanation of symbols]

[0069] 2 Free Rail 3 Free trolley 200 measuring devices 220 wheels 230 sensors 240 Acquisition Department 250 Measuring section 260 Storage section 270 Control Unit 271 Counting Department 272 Decision Section 273 Memory Control Unit

Claims

1. Multiple wheels that run on the running surface of the rail on which a transporter that carries heavy objects travels, A measuring unit that measures the shape of the rail when the wheel runs on the running surface, A sensor that outputs a signal corresponding to each wheel a predetermined number of times while each of the aforementioned plurality of wheels rotates by a predetermined amount, A determination unit determines the total distance traveled from a reference position by adding a length corresponding to the circumference of the wheel and a predetermined amount to the distance traveled during the predetermined number of times the signal corresponding to any of the plurality of wheels is output, each time the number of times the signal is output reaches a predetermined number of times. A storage control unit that stores in a storage unit the determined total travel distance and the shape of the rail measured when the total travel distance was determined, in association with each other. A measuring device having the following features.

2. The system includes a counting unit that counts the number of outputs of the signal for each of the plurality of wheels, and when the number of outputs of the signal corresponding to any of the plurality of wheels reaches a predetermined number, it sets the number of outputs of the signal corresponding to all of the plurality of wheels to 0. The measuring device according to claim 1.

3. The determination unit determines the new total travel distance by adding the length obtained by multiplying the circumference of the wheel by the predetermined amount to the total travel distance. The measuring device according to claim 1.

4. The device has an acquisition unit that acquires a set speed, which is set as the moving speed of the measuring device when the plurality of wheels are traveling on the running surface. The determination unit determines the total distance traveled if the ratio of the travel distance to the time it takes for the signal corresponding to any of the plurality of wheels to be output a predetermined number of times is less than or equal to the set speed, and does not determine the total distance traveled if the ratio is greater than the set speed. The measuring device according to claim 1.

5. The measuring unit measures the shape of the rail at predetermined time intervals, and outputs the first time point at which the shape of the rail was measured to the storage control unit, relating it to the shape of the rail. The determination unit outputs the second time in which the total travel distance was determined to the storage control unit in relation to the total travel distance. The memory control unit stores in the memory unit the total travel distance corresponding to the second time, associated with the shape of the rail associated with the first time closest to the second time. The measuring device according to claim 1.

6. The memory control unit, After associating the total travel distance corresponding to the second time with the shape of the rail associated with the first time closest to the second time and storing it in the storage unit, the value obtained by dividing the travel distance by the number of rail shapes measured during the period from the time the total travel distance was previously determined to the time the total travel distance was determined this time is identified. For one or more rail shapes that have been measured during the aforementioned period and to which the total distance traveled is not associated, the sum of the total distance traveled associated with the rail shape measured immediately before the rail shape was measured and the value obtained by the division is associated with the rail shape and stored in the storage unit as the total distance traveled. The measuring device according to claim 5.

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