Measurement system

Abstract

A simple configuration is used to measure rail wear and deformation. [Solution] The measurement system S has a measurement unit 3 that is arranged below a rail 1 having a horizontal plate portion 111 that is arranged along the traveling direction Z of a heavy load transport body 4 and has an upper surface 113 on which wheels 42 run, and measures the position of the rail 1 based on light reflected from the rail 1, a reflection unit 2 that is arranged above the horizontal plate portion 111 and reflects the irradiated light C toward the upper surface 113 and reflects first reflected light D from the upper surface 113 to the measurement unit 3, an acquisition unit 521 that acquires a virtual image position V of the virtual image of the upper surface 113 based on the first reflected light D and a bottom surface position Q of the bottom surface 114 based on second reflected light E from the bottom surface 114 of the upper surface 113, and an output unit 523 that outputs an actual upper surface position R 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, and the bottom surface position Q acquired by the acquisition unit.

Description

[Technical field]

[0001] The present invention relates to a measurement system for measuring the shape of a rail for a transport body. [Background technology]

[0002] There is a known technology for measuring wear on a pair of left and right rails on which a conveyor runs and which have a U-shaped cross section with openings facing each other.Patent Document 1 discloses a technology in which, using an image taken by a first light projector that irradiates light via multiple mirrors toward the inner surface of the lower flange of the rail and a first camera that receives the light reflected from the inner surface via multiple mirrors as a reference, the difference between the thickness of the lower flange from an image taken by a second light projector that irradiates light via multiple mirrors toward the outer surface of the lower flange and an image taken by a second camera that receives the light reflected from the outer surface via multiple mirrors and the first camera image is calculated as the amount of wear and the difference between the reference thickness. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2003-207312 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, the technology of Patent Document 1 requires two projectors, two cameras, and a plurality of mirrors for each of a pair of left and right rails, resulting in a complex configuration.

[0005] The present invention has been made in consideration of these points, and has an object to measure rail wear and deformation with a simple configuration. [Means for solving the problem]

[0006] In one aspect of the present invention, a measurement system is provided that has a measurement unit that is arranged along the traveling direction of a transport body that transports a heavy object, below a rail having a horizontal plate portion on which a running surface along which wheels of the transport body run is formed, and that irradiates light toward the rail and measures the position of the rail based on the light reflected from the rail; a reflection unit that is arranged above the horizontal plate portion and reflects the light irradiated from the measurement unit toward the running surface and reflects a first reflected light reflected from the running surface toward the measurement unit; an acquisition unit that acquires a first position of a virtual image of the running surface measured by the measurement unit based on the first reflected light and a second position of the opposite surface measured by the measurement unit based on second reflected light reflected from the opposite surface of the horizontal plate portion opposite the running surface; a correction unit that corrects the first position based on the positional relationship between the reflection unit and the measurement unit to calculate an actual third position of the running surface; and an output unit that outputs the third position calculated by the correction unit and the second position acquired by the acquisition unit.

[0007] The reflecting portion may have a reflecting surface that is inclined with respect to the horizontal plate portion at an angle that is capable of reflecting the light to the traveling surface and reflecting the first reflected light reflected from the traveling surface to the measurement portion.

[0008] The measurement section may measure the first position while changing an angle of incidence of the light with respect to the reflecting section, and may measure the second position while changing an angle of incidence 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 line perpendicular to a first line passing through the measurement unit and the reflecting unit when viewed from the traveling direction.

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

[0011] The correction section may calculate the third position by symmetrically converting the first position into a position that is line-symmetric with respect to a straight line that passes through a reflecting surface of the reflecting section that reflects the light on the plane.

[0012] The correction unit may calculate coordinates representing each of the multiple third positions on the driving surface by multiplying a rotation matrix for the object transformation of a coordinate matrix including coordinates representing each of the multiple first positions on the driving surface by the coordinate matrix.

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

[0014] The output section may output a difference between an actual distance between the acquired second position and the calculated third position and a reference thickness of the horizontal plate section as an amount of wear of the horizontal plate section.

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

[0016] The measuring device may further include a transport unit that moves the measurement unit and the reflection unit along the traveling direction, and the measurement unit measures the first position and the second position while being moved in the traveling direction by the transport unit.

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

[0018] The conveying unit may move the measurement unit and the reflection unit along the traveling direction while the conveying body is conveying the heavy object, and the measurement unit may measure the first position and the second position while being moved along the traveling direction by the conveying unit while the conveying body is conveying the heavy object.

[0019] The rails may be a first rail provided on the left side of the reflecting section when viewed from the direction of travel, and a second rail provided on the right side of the reflecting section, and 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, and 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 reflecting section has a first reflecting surface capable of reflecting the light onto the running surface of the first rail and inclined with respect to the horizontal plate section at an angle such that the first reflected light reflected from the running surface of the first rail can be reflected to the measurement section, and a second reflecting surface capable of reflecting the light onto the running surface of the second rail and inclined with respect to the horizontal plate section at an angle such that the first reflected light reflected from the running surface of the second rail can be reflected to the measurement section, wherein the first reflecting surface is provided on the left side of a straight line passing through the measurement section and the reflecting section as viewed from the traveling direction, and the second reflecting surface is provided on the right side of a straight line passing through the measurement section and the reflecting section as viewed from the traveling direction, and is inclined at an acute angle with respect to the running surface of the second rail, and one end of the first reflecting surface and one end of the second reflecting surface may be connected. Effect of the Invention

[0021] The present invention has an advantage that wear and deformation of a rail can be measured with a simple configuration. [Brief description of the drawings]

[0022] [Figure 1] FIG. 1 is a diagram for explaining an overview of a transport system. [Diagram 2] FIG. 1 is a diagram for explaining wear of a rail. [Diagram 3] 13A and 13B are diagrams for explaining deformation of the horizontal plate portion. [Figure 4] FIG. 2 is a diagram for explaining the configuration of a measurement system. [Diagram 5] FIG. 2 is a schematic diagram of the measurement system as viewed from a horizontal direction perpendicular to the traveling direction. [Figure 6] 11A and 11B are diagrams for explaining a virtual image position, a lower surface position, and an upper surface position. [Figure 7] 11 is a flowchart illustrating an example of a process for measuring a position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] [Overview of Transport System U] FIG. 1 is a diagram for explaining an overview of a 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 at a position higher than the workers working in the assembly plant, for example.

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

[0025] The conveyor 4 moves by being pushed by a side ring pusher provided on a chain attached to a power rail (not shown) provided above the left rail 11 and the right rail 12. Specifically, the side ring pusher is caught on a hold pack dog (not shown) provided on the housing 41 of the conveyor 4, thereby connecting the housing 41 of the conveyor 4 to the chain. Then, the conveyor 4 is conveyed in the movement 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 transport body 4. The left rail 11 is provided on the left side of the transport body 4 when viewed from the traveling direction Z. The right rail 12 is provided on the right side of the transport body 4 when viewed from the traveling direction Z.

[0027] The left rail 11 comprises a horizontal plate portion 111, a wall portion 112, and an upper plate portion 115. The left rail 11 has a U-shape with an open right side when viewed from the traveling direction Z. The lower end of the wall portion 112 is connected to one of the two ends of the horizontal plate portion 111 in the horizontal direction X perpendicular to the vertical direction Y, the end farther from the conveyor 4. 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 conveyor 4 run. The lower surface 114 of the horizontal plate portion 111 forms the opposite surface opposite the upper surface 113 of the horizontal plate portion 111.

[0028] The right rail 12 is provided on the opposite side of the left rail 11 across the conveyor 4, so as to be symmetrical to the left rail 11, when viewed from the traveling direction Z of the conveyor 4. Like the left rail 11, the right rail 12 is provided with a horizontal plate portion 121, a wall portion 122, and an upper plate portion 115. The right rail 12 is provided so as to have a U-shape with an open left side when viewed from the traveling direction Z. The horizontal plate portion 121 is formed with an upper surface 123 on which the wheels 422 run, and a lower surface 124 opposite to the upper surface 123.

[0029] The upper surface 113 of the left rail 11 is worn by the wheels 421 of the carrier 4 supporting a heavy load running over it. FIG. 2 is a diagram for explaining wear of the rail 1. The upper surface 113 of the horizontal plate portion 111 is worn by the wheels 421 running over the upper surface 113. Similarly, the upper surface 123 of the horizontal plate portion 121 is worn by the wheels 422 running over the upper surface 123. The dent M is caused by wear. When the wear amount A of the upper surface 113 increases, the thickness of the horizontal plate portion 111 decreases, and 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 load 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 that the end of the horizontal plate portion 111 that is not connected to the wall portion 112 hangs downward in the vertical direction Y. If the entire horizontal plate portion 111 is deformed and the upper surface 113 is tilted to such an extent that the deformation amount B exceeds a predetermined allowable amount, the conveyance body 4 will not be conveyed properly, or the wheels 421 of the conveyance body 4 will derail from the horizontal plate portion 111 of the left rail 11, causing the conveyance body 4 to fall from the rail 1. For this reason, the manager of the conveyance system U had to stop production at the factory to measure the wear amount A of the rail 1 that is higher than himself or visually check the deformation amount B. This has increased the manager's work man-hours and reduced the productivity of the factory.

[0031] Therefore, 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 irradiation light C while the transport body 4 is traveling, and calculates the amount of wear A and the amount of deformation B. The configuration of the measurement system S will be described below 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 diagram of the measurement system S viewed from a horizontal direction X perpendicular to the traveling direction Z, so that the left rail 11 is visible. The measurement system S has a reflecting unit 2, a measuring unit 3, a measuring device 5, and a transport unit 7.

[0032] The transport 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 lower than the rail 1 in the vertical direction Y. The reflecting unit 2 is provided in 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 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 provided so that when the installation surface on which the measuring unit 3 is installed on the transport unit 7 is parallel to the horizontal direction X, a 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 accommodated inside the housing 71.

[0033] The housing 71 is connected to the carrier 4. The wheels 72 are wheels that run 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 transport unit 7 moves in conjunction with the movement of the transport body 4. When the transport body 4 moves, the transport unit 7 moves the reflection unit 2, the measurement unit 3, and the measurement device 5 installed in the housing 71 along the traveling direction Z in conjunction with the movement of the transport body 4. For example, the transport unit 7 moves the reflection unit 2, the measurement unit 3, and the measurement device 5 along the traveling direction Z while the transport body 4 is transporting a heavy object. Specifically, the transport unit 7 is connected to the transport body 4 transporting a heavy object, and moves in conjunction with the movement of the transport body 4, thereby moving the reflection unit 2, the measurement unit 3, and the measurement device 5 installed in the housing 71 along the traveling direction Z.

[0035] The transport unit 7 has a tracking mechanism that corresponds to the degree of curvature of the rail 1. The tracking mechanism moves the measurement unit 3 and the reflection unit 2 in accordance with the degree of curvature of the rail 1 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. The tracking mechanism can use known technology, so a description thereof will be omitted. This allows the transport unit 7 to ensure that the irradiation light C irradiated from the measurement unit 3 is irradiated onto the left rail 11 and the right rail 12 even when passing through a rail 1 with a large curvature.

[0036] The measuring unit 3 irradiates the object with the irradiation light C while being moved in the traveling direction Z by the conveying unit 7, and measures the position of the surface of the object based on the reflected light from the object. Specifically, while the conveying body 4 is being moved along the traveling direction Z by the conveying unit 7 while conveying the heavy object, the measuring unit 3 irradiates the rail 1 and the reflecting 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 reflecting unit 2. The measuring unit 3 is, for example, a two-dimensional laser displacement meter, but is not limited thereto. The measurement interval of the measuring unit 3 is set according to the speed of the conveying unit 7. The measurement interval of the measuring unit 3 is set to a time shorter than the reference time as the speed of the conveying unit 7 increases. 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 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 FIG. 4 and FIG. 5, the optical path of the irradiation light C is indicated by a solid arrow, and the reflected light of the irradiation light C reflected by the object is indicated by a dotted arrow. The light receiving unit 32 receives the reflected light of the irradiation light C reflected by the object. The calculation unit 33 controls the irradiation unit 31 to irradiate the irradiation light C to the object. 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 of the irradiation light C reflected by the object.

[0038] The calculation unit 33 causes the irradiation unit 31 to irradiate the irradiated light C toward the rail 1, and measures the position of the rail 1 based on the reflected light of the irradiated light C reflected from the rail 1. For example, the calculation unit 33 controls the irradiation unit 31 to irradiate the irradiated light C to the lower surface 114 of the horizontal plate portion 111 of the left rail 11. The light receiving unit 32 receives the second reflected light E of the irradiated light C reflected by the lower surface 114. The calculation unit 33 measures a second position, which is the lower surface position Q of the lower surface 114, based on the second reflected light E reflected by 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 by the lower surface 114 while changing the incident angle of the irradiated 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 reflecting unit 2 has a left reflecting surface 21 and a right reflecting surface 22 that reflect the irradiated light C. The left reflecting surface 21 is formed with a first reflecting surface that reflects light. The right reflecting surface 22 is formed with a second reflecting surface that reflects light. The left reflecting surface 21 and the right reflecting surface 22 are, for example, mirrors with silver plating on the surface of glass, but are not limited thereto. The reflecting unit 2 is an isosceles triangle when viewed from the traveling direction Z. In other words, the cross section of the reflecting unit 2 cut by the XY plane is an isosceles triangle. The reflecting unit 2 is provided with two hypotenuses each facing the measuring unit 3. The vertex where the two hypotenuses of the reflecting unit 2 are connected faces the measuring unit 3.

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

[0042] The left reflection surface 21 is provided on the left side of a first straight line 61 that passes through the measurement unit 3 and the reflection unit 2 when viewed from the traveling direction Z. In other words, the left reflection surface 21 is provided on the oblique side of the reflection unit 2, one of the two oblique sides, which is on the left side of the first straight line 61.

[0043] The left reflecting surface 21 can reflect light to 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 at which the first reflected light D reflected from the upper surface 113 of the left rail 11 can be reflected to the measurement 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 between 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 is not limited thereto. The angle θ may be appropriately determined based on the width of the upper surface 113 and the positional relationship between the measurement unit 3, the reflecting unit 2, and the upper surface 113.

[0044] The right reflection surface 22 is provided on the right side of the first straight line 61 when viewed from the traveling direction Z. In other words, the right reflection surface 22 is provided on the oblique side of the reflection unit 2 on the right side of the first straight line 61. The right reflection surface 22 can reflect light to the upper surface 113 of the right rail 12. The left reflection surface 21 is inclined with respect to the horizontal plate portion 121 at an angle θ that allows the first reflected light D reflected from the upper surface 113 of the right rail 12 to be reflected to the measurement unit 3. Specifically, the right reflection surface 22 is inclined at an acute angle with respect to the second straight line 62. The angle θ of the angle between the second straight line 62 and the straight line passing through the right reflection surface 22 is the same as the angle θ of the angle between the second straight line 62 and the straight line passing through the left reflection 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 incident on 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 incident on the left reflecting surface 21 is reflected by the left reflecting surface 21 and enters the light receiving unit 32. In this way, by providing the left reflecting surface 21, the irradiation light C also enters the upper surface 113 on the opposite side of the measurement unit 3 across the lower surface 114. In other words, by providing the left reflecting surface 21, the irradiation light C is also irradiated to the upper surface 113, which the irradiation light C would not reach if the left reflecting surface 21 was not provided, and the first reflected light D from the upper surface 113 enters the light receiving unit 32.

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

[0047] Fig. 6 is a diagram for explaining a virtual image position V, a lower surface position Q, and an upper surface position R. In Fig. 6, the position of the irradiation port of the irradiation unit 31 is set as the origin. The horizontal axis of 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 assumption that the reflected light incident on the light receiving unit 32 is 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 measurement unit 3.

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

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

[0051] The storage unit 51 is a storage medium including a read only memory (ROM), a random access memory (RAM), a hard disk, etc. The storage unit 51 stores a program that the control unit 52 executes.

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

[0053] The acquisition unit 521 acquires the virtual image position V and the lower surface position Q. For example, the acquisition unit 521 acquires coordinates indicating the measured virtual image position V each time the virtual image position V is measured. 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 coordinates indicating each of the multiple virtual image positions V on the upper surface 113. The first coordinate matrix can be approximated to a straight line VL1 when represented on the XY plane (see FIG. 6). Note that when the upper surface 113 of the left rail 11 is worn to the extent that a dent M occurs as shown in FIG. 2, the first coordinate matrix cannot be approximated to a straight line, but for the sake of simplicity, the first coordinate matrix is ​​assumed to be approximated to a straight line VL1.

[0054] The acquiring unit 521 acquires coordinates indicating the lower surface position Q each time the lower surface position Q is measured. The coordinates indicating the lower surface position Q are coordinates on the XY plane. Specifically, the acquiring unit 521 acquires a second coordinate matrix including the coordinates of each of the multiple lower surface positions Q of the lower surface 114. When the second coordinate matrix is ​​represented on the XY plane, it can be approximated to a straight line QL1 (see FIG. 6).

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

[0056] The correction unit 522 corrects the virtual image position V to calculate a 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 to calculate 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 is measured in a state in which the left reflection surface 21 cannot reflect the irradiated light C 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 is measured in a state in which an opaque film is attached to the left reflection surface 21, for example.

[0057] The correction unit 522 symmetrically transforms the virtual image position V based on the first reflected light D from the upper surface 113 into a position that is linearly 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 subjecting the virtual image position V based on the first reflected light D from the upper surface 113 to an object transformation and the first coordinate matrix. The rotation matrix is ​​a matrix for subjecting the first coordinate matrix to an object transformation 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. The correction unit 522 may also calculate the upper surface position R by rotating the virtual image position V counterclockwise by an angle twice the angle between the third straight line E1 and a straight line passing through the incident point P and the virtual image position V, with the incident point P of the irradiation light C on the left reflecting surface 21 in the XY plane as a base point.

[0058] The third coordinate matrix can be approximated to a straight line RL1 when expressed on the XY plane (see FIG. 6). In this manner, the correction unit 522 can calculate the actual upper surface position R of the upper surface 113 by subjecting the virtual image position V of the virtual image of the upper surface 113 to symmetric conversion 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, and calculates the upper surface position R of the upper surface 123. The correction unit 522 multiplies a third coordinate matrix including coordinates representing each of the multiple lower surface positions Q of the upper surface 123 by a rotation matrix for symmetrically converting the third coordinate matrix with respect to the fourth straight line E2, thereby calculating a fourth coordinate matrix including coordinates representing the actual upper surface position R of the upper surface 123. The correction unit 522 may also calculate the upper surface position R of the upper surface 123 by rotating the virtual image position V clockwise by an angle twice the angle between the fourth straight line E2 and a straight line passing through the incident point and the virtual image position V, with the incident point being the base point of the incident light C on the right reflecting surface 22 in the XY plane.

[0060] The third coordinate matrix representing the virtual image of top surface 123 can be approximated by a straight line VL2 (see FIG. 6). The fourth coordinate matrix representing the actual position of top surface 123 can be approximated by a straight line RL2 when represented on the XY plane (see FIG. 6). In this way, correction unit 522 can calculate the actual positions of both top surface 113 of left rail 11 and top surface 123 of 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 that displays information or an information processing device (server). The output unit 523 displays, for example, a data table in which the upper surface position R and the lower surface position Q are associated with the fourth position on the display. The output unit 523 also transmits to the information processing device a data table in which the fourth position is associated 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. In this way, the manager of the conveying system U can grasp the current upper surface position R and lower surface position Q of the horizontal plate portion 111 at each of the multiple positions of the rail 1. This allows the manager to calculate the wear amount A and the deformation amount B of the horizontal plate portion 111 at each of the multiple positions of the rail 1.

[0062] (Process to output 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 actual distance between the acquired bottom surface position Q and the calculated top 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 by the specifications of the left rail 11. The output unit 523 calculates, for example, the difference between each of the multiple bottom surface positions Q in the second coordinate matrix representing the bottom surface 114 and the top surface position R corresponding to each bottom surface position Q. More specifically, the output unit 523 calculates the difference in Y coordinate between the bottom surface position Q and the top surface position R having the same X coordinate for each of the multiple bottom surface positions Q in the second coordinate matrix and the multiple top surface positions R in 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 a statistic of the multiple differences as the wear amount A. For example, the output unit 523 calculates an average value of the multiple differences as the wear amount A. The output unit 523 may calculate a maximum value of the multiple differences as the wear amount A. The output unit 523 associates the wear amount A with the fourth position at which the bottom surface position Q and the top surface position R corresponding to the wear amount A are calculated, and transmits them to the server. This allows the manager of the conveying system U to grasp the current wear amount A of the horizontal plate portion 111 at each of the multiple positions of the rail 1 without calculating the difference between the top surface position R and the bottom surface position Q, making it easier to manage the horizontal plate portion 111.

[0064] (Process to output 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 a 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 a position vertically upward by the reference thickness from the acquired lower surface position Q as the reference position of the upper surface position R. Specifically, the output unit 523 calculates 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, out of the two ends of the lower surface 114, as the reference position of the upper surface position R of the upper surface 113.

[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 a statistic of a plurality of distances as the deformation amount B. Specifically, the output unit 523 outputs the maximum value of the plurality of distances as the deformation amount B in association with the fourth position at which the deformation amount B was calculated. This allows the manager of the conveying system U to grasp the current deformation amount B of the horizontal plate portion 111 at each of the plurality of positions of the rail 1, making it easier to manage the horizontal plate portion 111. The output unit 523 can output the wear amount A and the deformation amount B of the horizontal plate portion 121 in a manner similar to the method of outputting the wear amount A and the deformation amount B of the horizontal plate portion 111.

[0066] (Processing for correcting the inclination of the measuring unit 3) Incidentally, the above-mentioned process of the correction unit 522 moves the virtual image position V of the virtual image of the horizontal plate part 111 to the actual upper surface position R of the horizontal plate part 111 when the first straight line 61 is perpendicular to the horizontal direction X. However, when the horizontal plate part 111 is worn or deformed, the measurement part 3 may be inclined with respect to the horizontal direction X. When the measurement part 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 above-mentioned process of the correction unit 522 moves the virtual image position V to a position different from the actual upper surface position R of the horizontal plate part 111. Therefore, when the measurement part 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 tilt angle of the measurement unit 3 with respect to the horizontal direction X. For example, the acquisition unit 521 acquires, as the tilt angle, the angle between a straight line representing the bottom surface positions Q acquired by the measurement unit 3 and the horizontal direction X. Specifically, the acquisition unit 521 acquires, as the tilt angle, the angle between a straight line QL1 that is an approximation straight line of each of the multiple bottom surface positions Q and a straight line parallel to the horizontal direction X. 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 tilt angle of the measurement unit 3.

[0068] The correction unit 522 moves the virtual image position V and the bottom surface position Q based on the tilt angle of the measurement unit 3. For example, the correction unit 522 rotates the virtual image position V and the bottom surface position Q counterclockwise by the tilt 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 bottom 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 tilt angle with respect to the origin. The virtual image position V and the bottom surface position Q after the movement match the virtual image position V and the bottom surface position Q measured when the first straight line 61 is perpendicular to the horizontal direction X. As a result, even if the measurement unit 3 is tilted with respect to the horizontal direction X, the measurement system S can measure the actual bottom surface position Q and top surface position R by correcting the tilt of the measurement unit 3.

[0069] Incidentally, the order of rotational movement on the plane may be changed. That is, the measurement system S may perform symmetric transformation (rotational movement) of the virtual image position V with respect to the third straight line E1, and then rotate and move the object-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. In addition, the correction unit 522 may rotate and move the virtual image position V clockwise by an angle twice the angle between the fourth straight line E2 and the incident point of the irradiation light C on the right reflecting surface 22 on the XY plane as a base point to calculate the upper surface position R, and then rotate the upper surface position R and the lower surface position Q counterclockwise by the inclination angle with respect to the origin. In this manner, 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 for measuring the surface position of the horizontal plate portion 111] 7 is a flowchart showing an example of a process for measuring a position. The process for measuring the position of the surface of the horizontal plate portion 111 is executed when the reflecting unit 2 and the measuring 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 irradiation light C onto the reflecting unit 2 while changing the incident angle of the irradiation light C onto the reflecting unit 2, and irradiates the irradiation light C onto the lower surface 114 while changing the incident angle of the irradiation light C onto 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 according to the reflected light of the irradiated light C. Specifically, when the irradiated 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 first reflected light D reflected by the upper surface 113 and the reflecting unit 2. When the irradiated 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, the acquisition unit 521 acquires the virtual image position V when the measurement unit 3 measures the virtual image position V, and acquires the lower surface position Q when the measurement unit 3 measures the lower surface position Q. In addition, the acquisition unit 521 acquires a 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). If 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 between the measurement unit 3, the reflector 2, and the upper surface 113. If 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 top surface position R (step S5). Specifically, the correction unit 522 calculates the top surface position R by symmetrically transforming the virtual image position V with respect to the third straight line E1. Specifically, the correction unit 522 calculates the top surface position R by rotating and moving the virtual image position V by an angle twice the angle between the third straight line E1 passing through the left reflecting surface 21 in the XY plane and the horizontal direction X. More specifically, the correction unit 522 calculates the top surface position R by rotating and moving the virtual image position V counterclockwise by an angle twice the angle between the third straight line E1 and the straight line passing through the incident point P and the virtual image position V, using the incident point of the irradiation light C on the left reflecting surface 21 in the XY plane as a base point.

[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, if the upper surface position R of the X coordinate that coincides with 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. If the upper surface position R of the X coordinate that coincides with 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 to the measuring device 5 in association with the fourth position.

[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. If the speed detected by the speed sensor is equal to or less than a predetermined value (e.g., 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 positions. If the speed detected by the speed sensor is greater than a 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 reflecting unit 2 and the measuring unit 3 are moving, and ends when the reflecting unit 2 and the measuring unit 3 stop. In addition, the process of measuring the position is executed again when the stopped reflecting unit 2 and measuring unit 3 start moving.

[0080] [Effects of measurement system S] As described above, the measurement system S includes a measurement unit 3 that is arranged below the rail 1, which is provided along the traveling direction Z of the conveyor 4 and has a horizontal plate portion 111 on which an upper surface 113 along which the wheels 42 run, and that irradiates irradiation light C toward the rail 1 and measures the position of the rail 1 based on the reflected light of the irradiation light C reflected from the rail 1, a reflection unit 2 that is arranged above the horizontal plate portion 111 and reflects the irradiation light C toward the upper surface 113 and reflects a first reflected light D from the upper surface 113 to the measurement unit 3, an acquisition unit 521 that acquires a virtual image position V of the virtual image of the upper surface 113 based on the first reflected light D and a lower surface position Q of the lower surface 114 measured based on a second reflected light E from the lower surface 114 of the upper surface 113, and an output unit 523 that outputs the actual upper surface position R and 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 including the reflecting unit 2, the measurement system S can also irradiate the irradiation light C to the upper surface 113 on the opposite side of the measurement unit 3 with the lower surface 114 in between. Specifically, the irradiation light C incident on the reflecting unit 2 is reflected by the reflecting unit 2 and incident on the upper surface 113. The first reflected light D reflected by the upper surface 113 is incident on the reflecting unit 2, reflected by the reflecting unit 2, and incident on the light receiving unit 32. In this way, by providing the reflecting unit 2, the measurement system S can irradiate the irradiation light C not only to the lower surface 114, but also to the upper surface 113 on the opposite side of the measurement unit 3 with the lower surface 114 in between.

[0082] The positional relationship between the reflecting unit 2 and the measuring unit 3 is determined when the measuring system S is constructed, so the measuring 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 based on the positional relationship between the reflecting unit 2 and the measuring unit 3. In other words, the measuring system S can measure the virtual image position V of the upper surface 113 of the horizontal plate portion 111 of the rail 1 and the lower surface position Q of the lower surface 114 with a simple configuration of one measuring unit 3 and one reflecting unit 2. As a result, the manager can measure the wear and deformation of the horizontal plate portion 111.

[0083] Although the present invention has been described above using the 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 the gist of the present invention. For example, all or part of the device can be configured by distributing or integrating functionally or physically in any unit. In addition, new embodiments resulting from any combination of multiple embodiments are also included in the embodiments of the present invention. The effect of the new embodiment resulting from the combination combines the effect of the original embodiment. [Explanation of symbols]

[0084] 1 Rail 2 Reflector 3 Measuring part 4. Carrier 5. Measuring Equipment 6 External device 7. Conveyor 11 Left rail 12 Right Rail 21 Left reflective surface 22 Right reflective surface 31 Irradiation unit 32 Light receiving part 33 Calculation section 41 Case 42 wheels 43 Shaft 51 Storage section 52 Control section 61 First straight line 62 Second straight line 71 Case 72 wheels 73 Connecting part 111 Horizontal plate section 112 Wall 113 Top surface 114 Bottom surface 115 Upper plate 121 Horizontal plate section 122 Wall 123 Top surface 124 Bottom surface 421 Wheels 422 wheels 521 Acquisition Department 522 Correction Section 523 Output section S Measurement System U Conveyor System

Claims

1. a measuring unit that is provided below a rail having a horizontal plate portion that is provided along a traveling direction of a transport body that transports a heavy load and on which a running surface along which wheels of the transport body run is formed, the measuring unit irradiating light toward the rail and measuring a position of the rail based on light reflected from the rail; a reflecting section that is provided above the horizontal plate section and that reflects the light irradiated from the measuring section toward the travel surface and reflects a first reflected light reflected from the travel surface toward the measuring section; an acquisition unit that acquires a first position of a virtual image of the running surface measured by the measurement unit based on the first reflected light, and a second position of the opposite surface measured by the measurement unit based on a second reflected light reflected from an opposite surface of the horizontal plate portion opposite to the running surface; a correction unit that corrects the first position based on a positional relationship between the reflecting unit and the measuring unit, and calculates an actual third position of the travel surface; an output unit that outputs the third position calculated by the correction unit and the second position acquired by the acquisition unit; having the acquisition unit acquires, as a tilt angle of the measurement unit, an angle detected by an angle sensor that detects an angle of the measurement unit with respect to a horizontal direction perpendicular to a vertical direction; the correction unit rotates and moves the first position and the second position by the tilt angle with respect to an origin, which is an irradiation point where the light is irradiated from the measurement unit, before correcting the first position and calculating the third position. A measurement system that:

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

3. The measurement 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 measurement unit and the reflecting unit as viewed from the traveling direction. The measurement system of claim 3.

5. The measurement unit measures the first position and the second position on 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 symmetrical conversion with respect to a line passing through a reflecting surface of the reflecting unit that reflects the light on the plane. The measurement system of claim 5.

7. The correction unit calculates coordinates representing each of the plurality of third positions on the traveling surface by multiplying a rotation matrix for the object transformation of a coordinate matrix including coordinates representing each of the plurality of first positions on the traveling surface by the coordinate matrix. The measurement system of claim 6.

8. The output unit outputs a difference between an actual distance between the acquired second position and the calculated third position and a reference thickness of the horizontal plate portion as a wear amount of the horizontal plate portion. A measurement system according to any one of claims 1 to 7.

9. The output unit outputs a distance between a reference position of the third position determined by the acquired second position and a reference thickness of the horizontal plate portion and the calculated third position as a deformation amount of the horizontal plate portion. A measurement system according to any one of claims 1 to 7.

10. a conveying unit that moves the measurement unit and the reflection unit along the traveling direction, The measurement unit measures the first position and the second position while being moved in the traveling direction by the transport unit. The measurement system of claim 1 .

11. The output unit outputs 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 in association with each other. The measurement system of claim 10.

12. The conveying unit moves the measuring unit and the reflecting unit along the traveling direction while the conveying body is conveying the heavy object, The measurement unit measures the first position and the second position while the transport body is moved along the traveling direction by the transport unit while transporting the heavy object.

12. A measuring system according to claim 10 or 11.

13. the rails include a first rail provided on the left side of the reflecting portion as viewed from the traveling direction, and a second rail provided on the right side of the reflecting portion, 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 .

14. The reflecting portion is a first reflecting surface that is inclined with respect to the horizontal plate portion at an angle that can reflect the light toward the running surface of the first rail and can reflect the first reflected light reflected from the running surface of the first rail to the measurement portion; a second reflecting surface that is inclined with respect to the horizontal plate portion at an angle that can reflect the light toward the running surface of the second rail and can reflect the first reflected light reflected from the running surface of the second rail to the measurement portion, the first reflecting surface is provided on the left side of a straight line passing through the measurement unit and the reflecting unit as viewed from the traveling direction, and is inclined at an acute angle with respect to the running surface of the first rail, the second reflecting surface is provided on the right side of a straight line passing through the measurement unit and the reflecting unit as viewed from the traveling direction, and is inclined at an acute angle with respect to the running surface of the second rail, One end of the first reflecting surface and one end of the second reflecting surface are connected to each other. The measurement system of claim 13.

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