Crane Rail Measuring Device with Encoder and Angle Sensor
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Solution Overview
Problem
Current rail measuring devices for crane rails face limitations in accuracy, cost, energy consumption, and require line of sight, making them inefficient and unsafe for high-access locations.
Innovation Solution
A single-piece rail measuring device equipped with an angle sensor, encoder, microprocessor, object sensor, and energy-efficient components like a Li-ion battery and DC motor, allowing for high-resolution measurements without range or line of sight limitations, and enabling detection of irregular heights and lateral shifts with low energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser sensors are used for autonomous rail measurement, then measurement capability is improved, but cost and energy consumption increase
Solution Approach 1:
The patent replaces optical laser sensors with a mechanical measurement system consisting of a measuring wheel and encoder. The measuring wheel rolls along the rail and rotates an encoder disc, converting mechanical motion into electrical signals for measurement. This mechanical substitution eliminates the need for expensive, high-energy-consumption laser sensors while maintaining measurement functionality.
Solution Approach 2:
The patent employs simple, low-cost mechanical components (measuring wheel, encoder disc, Hall effect sensor) instead of expensive laser sensors. These mechanical components are durable, easy to manufacture, and consume minimal energy, providing a cost-effective alternative to sophisticated optical systems.
2Measurement precision
If laser sensors are used for autonomous rail measurement, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex optical systems (laser transmitter, receiver, alignment mechanisms) with simple mechanical components. The measuring wheel with encoder disc and Hall effect sensor creates a straightforward mechanical-to-electrical conversion system that is easier to implement, maintain, and integrate into the rail measurement device.
3Measurement precision
If laser sensors are used for autonomous rail measurement, then measurement capability is improved, but installation complexity increases due to line of sight requirements
Solution Approach 1:
The patent replaces line-of-sight-dependent optical systems with a mechanical rolling measurement system. The measuring wheel physically contacts and rolls along the rail, eliminating the need for complex alignment between transmitter and receiver components. This mechanical approach simplifies installation and removes ambient condition constraints.
4Measurement precision
If high measurement resolution is achieved, then measurement precision is improved, but energy consumption increases
Solution Approach 1:
The patent achieves high measurement resolution through mechanical precision rather than optical complexity. The encoder disc with multiple segments and Hall effect sensor provides high-resolution measurements through simple mechanical rotation detection, consuming minimal energy compared to high-precision laser systems.
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 device achieves high accuracy measurements up to 0.02 mm, significantly higher resolution than existing devices, with reduced energy consumption and lower production costs, while ensuring safe and efficient quality control of crane rails.
Implementation Method 1
at least one angle sensor that detects the angle change of the rail
Implementation Method 2
an encoder to measure how far the rail measuring device has traveled on the rail
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a crane rail measuring device (10) which is moved on the crane rail with energy provided by a power source (14) and drive from an electric motor (13), characterized by comprising, at least one angle sensor (17) that detects the angle change of the rail, an encoder (15) to measure how far the rail measuring device (10) has traveled on the rail and to receive the displacement data, and a microprocessor (16) that controls the data from the sensors by controlling the rail measuring device (10).