3D Laser Scanner for Crane Rail Alignment Survey
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Solution Overview
Problem
Existing methods for surveying overhead crane rail alignment are time-consuming, require crane downtime, and involve manual access, leading to inefficiencies and increased costs, as they fail to accurately measure rail span and alignment without direct measurement.
Innovation Solution
A non-contact rail survey system using a 3D laser scanner to collect data on crane runway beams and rails, allowing for stationary measurement and processing to determine alignment, camber, warp, and lean, enabling direct span measurement without disrupting crane operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual surveying methods are used to measure rail alignment, then measurement accuracy can be achieved, but crane downtime increases and operational efficiency decreases
Solution Approach 1:
The patent replaces traditional mechanical contact-based surveying tools (tape measures, alignment tools requiring manual access) with a 3D laser scanning system that uses optical fields to measure rail alignment non-contactly. The laser scanner emits laser beams that reflect off the rail surfaces, capturing precise spatial coordinates without physical contact, thereby eliminating the need for crane shutdowns while maintaining measurement accuracy
Solution Approach 2:
The patent introduces a 3D laser scanner as an intermediary device positioned in the crane bay to capture rail geometry data. This intermediary system acts as a mediator between the measurement objective and the rail structure, enabling data collection without direct human access to the rail components, thus allowing continuous crane operation during surveys
2Measurement precision
If manual access to crane components is required for surveying, then direct measurement capability is improved, but safety risks and operational disruption increase
Solution Approach 1:
The patent substitutes manual mechanical measurement processes with an automated 3D laser scanning system. The laser scanner automatically captures point cloud data of the rail structure from multiple positions in the crane bay, eliminating the need for surveyors to physically access hazardous areas near moving crane components, thereby improving both safety and operational convenience
Solution Approach 2:
The 3D laser scanning system performs self-positioning and automated data collection throughout the crane bay. The system independently navigates to optimal measurement positions and captures rail geometry data without requiring manual intervention or access to crane components, making the surveying process both safer and more operationally convenient
3Loss of information
If traditional surveying methods are used, then comprehensive rail data can be collected, but time consumption and survey costs increase
Solution Approach 1:
The patent employs a dynamic 3D laser scanning system that can rapidly reposition and capture data from multiple angles and distances within the crane bay. The system adapts its measurement positions and orientations to comprehensively capture rail geometry information in a fraction of the time required by static manual surveying methods, collecting complete survey data without prolonged crane downtime
Solution Approach 2:
The system performs preliminary positioning and rapid data acquisition from optimal vantage points in the crane bay before any crane maintenance or shutdown activities. By capturing comprehensive rail alignment data proactively during normal operations, the system eliminates the need for time-consuming post-installation surveying, reducing both time loss and operational disruption
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces downtime, allows for accurate and efficient measurement of crane rail alignment, and enables pre-scheduled maintenance, improving operational efficiency and reducing costs by eliminating the need for manual access and direct contact with the crane components.
Implementation Method 1
use of a 3D laser scanner to collect data
Data Source
AI summary
A method and system for conducting a non-contact survey of an overhead crane runway system using a survey apparatus that is alternately located in the crane bay or on a crane bridge girder. Disclosed more particularly are a method and system for testing an overhead crane runway beam 3D alignment or an overhead crane runway rail 3D alignment using a 3D laser scanner.