JP2022018991A - Elevator rope inspection device and elevator rope inspection method - Google Patents

Abstract

To accurately check abnormalities in a rope surface shape in a non-contact manner without the need for prior calibration work by using distance information from an elevator rope.SOLUTION: There is provided a control analysis device 4 that measures a rope diameter from distance information to a rope R measured in time series by an optical cutting type camera 2, and detects rope mountains based on the measured rope diameter. Then, the device corrects a position using a rope vibration amount when observing the same line on a rope surface, and detects a portion where a distance to the rope mountain is continued by a threshold value or more as a wear mark. The device also detects a broken wire of the rope if there is a distance change of the threshold value or more at the point detected as the wear mark.SELECTED DRAWING: Figure 1

Description

The present invention relates to an apparatus and a method for inspecting an elevator rope based on sensor information.

The elevator rope is composed of a wire rope in which a plurality of strands are twisted around the outer circumference of the rope core. For example, Patent Documents 1 and 2 are known as techniques for inspecting an elevator rope.

In the inspection method of Patent Document 1, the amount of unevenness of the crown portion (the apex part of the surface shape of the rope) of the elevator rope is measured based on the three-dimensional shape data of the elevator rope, and the amount of unevenness measured is used to determine the surface shape of the elevator rope. Detect anomalies.

In the inspection method of Patent Document 2, a plurality of threads on a measuring roll are scanned to measure the surface shape of the threads, and the outer diameter of the threads is measured based on the measured surface shape data.

JP-A-2018-179632 JP 2006-64502 Japanese Patent Application Laid-Open No. 2020-33137

However, the inspection method of Patent Document 1 may lack accuracy because the abnormality of the surface shape is determined only from the information on both the unevenness of the elevator rope. Further, since the inspection method of Patent Document 2 is a contact type, it may not be suitable for inspection of an elevator rope.

An object of the present invention is to accurately inspect an abnormality in the surface shape of the rope by a non-contact method by using the distance information with the elevator rope without requiring a prior calibration work.

(1) One aspect of the present invention is a device for inspecting the elevator rope using the distance information to the elevator rope measured in time series by a sensor.
A detection unit that detects the rope end of the elevator rope based on the distance information, measures the distance between the detected rope ends as the rope diameter, and detects the rope ridge based on the measured rope diameter.
It is characterized by including an inspection processing unit that detects an abnormality in the surface shape of the rope ridge based on the fluctuation of the distance information with respect to the same line on the rope surface of the elevator rope and inspects the elevator rope.

(2) Another aspect of the present invention is a method in which a computer inspects the elevator rope from the distance information to the elevator rope measured in time series by a sensor.
A detection step of detecting the rope end of the elevator rope based on the distance information, measuring the distance between the detected rope ends as the rope diameter, and detecting the rope ridge based on the measured rope diameter.
It is characterized by having an inspection processing step of detecting an abnormality in the surface shape of the rope ridge based on the fluctuation of the distance information with respect to the same line on the rope surface of the elevator rope and inspecting the elevator rope.

According to the present invention, by using the distance information from the elevator rope, it is possible to accurately inspect the abnormality of the rope surface shape without the need for prior calibration work.

The device block diagram of Example 1. The functional block diagram of the control analysis device. A chart diagram showing the processing contents. A graph showing the relationship between the distance from the camera and the measurement position of the measurement data. Graph showing interpolation of the back plate by the same linear regression. A graph showing the setting of the same measurement threshold. A partially enlarged view showing the position of the rope mountain. (A) is a graph showing time-series unevenness data of the rope end, and (b) is a graph showing the detection of the rope ridge portion of (a). A partially enlarged view showing a method of detecting rope wear marks. Same graph The graph which shows the detection method of a rope wire breakage. The chart figure which shows the processing content of Example 2. The device block diagram of Example 3. Chart diagram of the same rope mountain detection.

Hereinafter, an elevator rope inspection device (inspection method) according to an embodiment of the present invention will be described. This inspection device performs maintenance and inspection of the elevator rope by detecting abnormalities on the rope surface (wear marks, broken wires, etc.) based on the distance information to the elevator rope (wire rope) measured by the sensor. Details of this inspection device will be described based on Examples 1 to 3.

The first embodiment of the inspection device will be described with reference to FIGS. 1 to 11. 1 in FIG. 1 shows an inspection system mainly composed of the inspection device. Here, the elevator rope is inspected in real time using the optical cutting method.

In the light cutting method, a 3D image scanning device (light cutting type camera) is used, and a line-shaped laser light source is irradiated on an inspection target, that is, an elevator rope R (hereinafter referred to as a rope R), and the reflected light thereof is applied. Is acquired by an imaging sensor (CMOS sensor) as height data (profile).

At this time, three-dimensional distance information (three-dimensional distance data) can be obtained by performing triangular distance measurement, and the inspection target is moved at the time of inspection to acquire the three-dimensional shape of the entire rope R. Here, a back plate B is installed on the back surface of the rope R to be inspected.

The inspection system 1 includes an optical disconnection type camera 2 (1 unit), an elevator controller 3 that controls an elevator device (not shown), and a control analysis device that executes control / analysis based on input information from both 2 and 3. 4 is configured, and each configuration 2 to 4 is freely connected to send and receive data via a wired / wireless network.

(1) Configuration Example of Control Analysis Device 4 The control analysis device 4 detects an abnormality in the rope surface shape of the rope R by analysis, and constitutes the inspection device. The control analysis device 4 receives a position signal of the elevator device by an external input such as an elevator controller 3, and executes synchronous control between the position of the rope R and the shooting line (shooting position) E of the camera 2.

Specifically, the control analysis device 4 is composed of a computer and includes hardware resources (for example, CPU, RAM, ROM, etc.) of a normal computer. As a result of the collaboration between the hardware resource and the software resource (OS, application, etc.), the control analysis device 4 has a distance measuring unit 5, a rope diameter measuring unit 6, a rope shaking measuring unit 7, as shown in FIG. A rope mountain detection unit 8, a rope position correction unit 9, and an abnormality detection unit 10 are mounted.

(2) Processing contents of the control analysis device 4 The details of the processing contents of the control analysis device 4 will be described with reference to FIG. The processing of the control analysis device 4 is executed when the elevator device is in operation. At this time, the camera 2 continuously irradiates the rope R passing through the photographing position P with the laser beam by the elevator device in operation, receives the reflected light by the imaging sensor, and photographs the rope R.

S01: When the processing of the control analysis device 4 is started, the distance measuring unit 5 measures the distance between the rope R and the camera 2 using the camera 2. That is, the distance measuring unit 5 controls the camera 2 to acquire the distance information (measured distance / measured value) between the two 4 and R for each measurement position in a certain time-series section.

The distance information from the camera 2 measured here includes the measurement data D1 of the rope R and the measurement data D2 of the back plate B shown in FIG. 4, which are input to the control analysis device 4 via the network, respectively.

S02: The rope diameter measuring unit 6 calculates the diameter of the rope R (rope diameter / rope diameter) from the distribution of the distance information of the measurement data D1 and D2 input in S01. In that case, it is necessary to distinguish between the measurement data D1 of the rope R and the measurement data D2 of the back plate B.

Therefore, as shown in FIG. 5, the rope diameter measuring unit 6 detects the back plate B by using a linear regression method. The back plate B can be estimated by using a robust estimation method such as "RANSAC" or "LMedS" as a linear regression method.

D3 (thick line portion of the straight line) in FIG. 5 shows the estimated data of the back plate B estimated by the linear regression method, and a predetermined distance from the estimated data D3 is set as the detection threshold value S of the rope R. There is. By using this threshold value S, the distance information to the back plate B is interpolated, and both data D1 and D2 can be clearly distinguished.

The time-series measurement data D1 thus distinguished is stored in the storage device such as RAM. The rope end of the rope R is detected by detecting the minimum and maximum values of the measurement position from the time-series measurement data D1 stored here.

R1 and R2 in FIG. 5 indicate the detected rope ends R1 and R2, and the distance between the rope ends R1 and R2 is detected as the rope diameter. Information on the detected time-series rope ends R1 and R2 and the rope diameter is also stored in the storage unit in the same manner as the measurement data D1.

S03: The rope sway measuring unit 7 acquires the measurement data D1 and the information of the rope ends R1 and R2 from the storage device, and calculates the center R3 between the rope ends R1 and R2 as shown in FIG. Then, based on the measurement data D1, the time-series position change of the rope center R3 is detected as the rope sway. At this time, the change amount of the position change is measured as the vibration amount of the rope R, and the measured vibration amount is stored in the storage device together with the time series information of the rope center R3.

S04: The rope mountain detection unit 8 acquires information on the rope ends R1 and R2 from the storage device and detects the rope mountain. Here, the rope ridge means the convex portion M in FIG. 7 in the stranded wire shape of the rope R. For example, at the installation site of the elevator device, the diameter value in the convex portion M is controlled by a caliper. Hereinafter, it will be referred to as a rope mountain M.

Specifically, the rope mountain detection unit 8 searches for the measurement positions of the maximum value (maximum value) and the minimum value (minimum value) based on the time-series information of the rope ends R1 and R2 shown in FIG. 8A. After that, as shown in FIG. 8B, the measurement position of the maximum value is detected as the portion of the rope ridge M, and the detection result is stored in the storage device.

S05: The rope position correction unit 9 acquires the time series information of the measurement data D1, the rope center R3, and the vibration amount from the storage device, and executes the position correction. That is, in the detection of rope wear marks and the detection of broken rope wires in S06 to S09, attention is paid to the change in the distance between the rope surface of the rope R and the camera 2. Therefore, as shown in FIG. 9, it is necessary to observe the time-series line C of the rope R based on the measurement data D1.

However, in the actual rope R, the position changes due to the rope shaking caused by the operation of the elevator device. Therefore, the rope position correction unit 9 executes the position correction of the measurement data D1 based on the vibration amount detected in S03. For example, processing such as adjusting the rope center R3 in the measurement data D1 by the amount of the vibration is executed, and the measurement data D1 of the storage device is updated after the position correction. This makes it possible to always observe the data at the same location when observing the same line C.

S06, S07: The abnormality detection unit 10 acquires the measurement data D1 after the position correction of S06 with reference to the storage device, observes the time-series line C of the rope R (see FIG. 9), and wear marks W. Judge the presence or absence of.

The wear mark W determined here is generated by scraping the unevenness on the surface of the wire of the rope R. Therefore, at the location where the wear mark W is generated, as shown in FIG. 10, the measurement distance of the measurement data D1 does not fluctuate, and constant values are continuous.

Therefore, the abnormality detection unit 10 confirms whether or not the measurement distance has continuous constant values over a preset threshold value (S06). As a result of the confirmation, if it is the continuous portion, it is detected as a location where the wear mark W is generated (S07). On the other hand, if not, the process proceeds to S10.

S08, S09: Since the wire breakage F of the rope R often occurs at the place where the rope wear progresses, as shown in FIG. 11, when the rope wear occurs, the measurement distance becomes constant due to the occurrence of the wear mark W. The measurement distance changes during the process.

Therefore, the abnormality detection unit 10 also confirms whether or not the measurement distance suddenly changes beyond a predetermined threshold value during the detection of the wear marks W of S07 and S08 (S08). As a result of the confirmation, if the change is abrupt, it is detected as a place where the rope wire breakage (break) F occurs (S09). On the other hand, if not, the process proceeds to S10. The detection results of S07 and S09 are stored in the storage device and can be output to an external device such as a monitor.

S10: It is confirmed whether or not the shooting of the camera 2 is completed. As a result of the confirmation, if the shooting is not completed, the process returns to S01 and the process is continued. On the other hand, if the photographing is completed, the processing of the control analysis device 4 is terminated.

According to such a control analysis device 4, conventionally, the abnormality of the surface shape is determined only from the unevenness information of the rope R, but by using the distance information from the camera 2, prior calibration work is required. The effect of accurately detecting abnormalities such as rope diameter, wear marks W, and wire breakage F can be obtained without doing so.

The second embodiment of the inspection device will be described. In this embodiment, the inspection device using the color light cutting camera is provided.

Here, by using a color light cutting camera for the camera 2, not only the distance information between the camera 2 and the rope R but also the image information is acquired at the same time. Therefore, by combining the distance information and the image information, it is possible to detect the wear mark W and the wire breakage with higher accuracy.

According to FIG. 12, the control analysis device 4 of this embodiment includes an image processing unit 11 that processes image information from the color light cutting camera 2. As the image processing G (S11 to S20) by the image processing unit 11, for example, the method described in Patent Document 3 can be used.

To explain with reference to FIG. 12, when the processing of the control analysis device 4 is started, the image processing of S11 to S16 (see Patent Document 3) and the processing based on the distance information of S01 to S07 (see Example 1). Are executed in parallel, and the process proceeds to the process after S17.

That is, it is confirmed whether or not the detection points of the wear marks W are the same in the image processing of S11 to S16 and the processing based on the distance information of 01 to S07 (S17). As a result of the confirmation, if the detection points are different, the process proceeds to S10, while if the detection points are the same, it is determined that a wear mark W has occurred (S18), and then the processing of S19 and S20 and the processing of S08 and S09 are performed in parallel. And execute.

Further, the abnormality detection unit 10 confirms whether or not the wire breakage detection points are the same as a result of the processing of S19 and S20 and the processing of S08 and S09 (S21). As a result of the confirmation, if the detection points are different, the process proceeds to S10 without determining the detection of the broken rope wire. On the other hand, if the detection points are the same, the rope wire break F is detected, and the process proceeds to S10. In this S10, the same processing as in the first embodiment is performed.

According to the second embodiment, by combining the image processing in addition to the distance information from the camera 2 to the rope R, it is possible to measure the surface abnormality of the rope R with high accuracy. In addition, by combining images, it becomes possible to perform confirmation work by human eyes at the same time.

The third embodiment of the inspection device will be described with reference to FIGS. 13 and 14. The control analysis device 4 of this embodiment is used in the inspection system 12 shown in FIG. Here, the rope R is simply inspected by using the ToF camera 13 as a ToF (Time-of Flat) sensor instead of the optical cut-off type camera 2.

Although the ToF camera 13 has a spatially high resolution, it may not be suitable for measurement of the elevator device operating at high speed because the shooting cycle is low. Therefore, in this embodiment, the stopped rope R is analyzed and used for detecting the rope ridge as an alternative to the caliper measurement at the installation site of the elevator device.

Here, the shooting data (measurement information) of the ToF camera 13 is used for the rope diameter measurement of S02 and the rope mountain detection of S04. That is, as shown in FIG. 14, the shooting data of the ToF camera 13 is input to the control analysis device 4 at the start of processing (S31). The diameter of the rope R is measured based on the captured data of the three-dimensional information input here (S32), the rope ridge is detected from the measured diameter value (S33), and the process is terminated.

At this time, as the processing method for S32 and S33, the same method as for S02 and S04 can be used, and the processing for S03 and S05 to S10 is executed in the same manner as in the first embodiment to carry out the wear marks W and element of the rope R. It is possible to detect the line break F.

The present invention is not limited to the above embodiment, and can be modified and implemented within the scope described in each claim. For example, the device configuration of the control analysis device 4 is not limited to FIG. 2, and it is assumed that the processes of FIGS. 3, 12, and 14 can be executed.

1,12 ... Inspection system 2 ... Light-cutting camera (sensor)
3 ... Elevator controller 4 ... Control analysis device (elevator rope inspection device)
5 ... Distance measurement unit 6 ... Rope diameter measurement unit 7 ... Rope sway measurement unit 8 ... Rope mountain detection unit 9 ... Rope position correction unit 10 ... Abnormality detection unit 11 ... Image processing unit 13 ... ToF camera (ToF sensor)
R ... Elevator rope B ... Back plate

Claims (9)

A device that inspects the elevator rope using the distance information to the elevator rope measured in time series by a sensor.
A detection unit that detects the rope end of the elevator rope based on the distance information, measures the distance between the detected rope ends as the rope diameter, and detects the rope ridge based on the measured rope diameter.
An inspection processing unit that detects an abnormality in the surface shape of the rope ridge based on the fluctuation of the distance information with respect to the same line on the rope surface of the elevator rope and inspects the elevator rope.
Elevator rope inspection device characterized by being equipped with. The elevator rope inspection device according to claim 1, wherein the sensor is an optical cutting type sensor. While the back plate is placed on the back of the elevator rope,
The detection unit distinguishes between the rope and the back plate by using a preset distance from the back plate as a threshold value.
The elevator rope inspection device according to claim 1 or 2, wherein the rope end is detected based on the distance information distinguished as the rope. A rope sway measuring unit that detects a time-series position change of the center of the rope as a rope sway based on the time-series data of the distance information and measures the change amount of the position change as a rope vibration amount.
A rope position correction unit that corrects the position using the rope vibration amount when the inspection processing unit observes the same line on the rope surface.
The elevator rope inspection device according to any one of claims 1 to 3, further comprising. The inspection processing unit
The elevator rope inspection device according to any one of claims 1 to 4, wherein the distance information to the rope ridge is detected as a wear mark at a continuous portion having a constant value exceeding a preset threshold value. If the inspection processing unit changes the distance by a preset threshold value or more at the location where the wear mark is detected, the inspection processing unit may change the distance.
The elevator rope inspection device according to claim 5, further comprising detecting a broken wire of the elevator rope. By using a color light cutting sensor for the sensor, image information of the elevator rope is acquired together with the distance information.
It is equipped with an image processing unit that inspects the elevator rope based on the image information.
An elevator rope inspection device for inspecting an elevator rope by combining the inspection process based on the distance information according to claims 3 to 6 and the inspection process of the image processing unit. ToF (Time-of Flight) The elevator rope inspection device according to claim 1, wherein the rope ridge is measured using measurement information by a ToF type sensor. A method in which a computer inspects the elevator rope from the distance information to the elevator rope measured in time series by a sensor.
A detection step of detecting the rope end of the elevator rope based on the distance information, measuring the distance between the detected rope ends as the rope diameter, and detecting the rope ridge based on the measured rope diameter.
An inspection process step of detecting an abnormality in the surface shape of the rope ridge based on the fluctuation of the distance information with respect to the same line on the rope surface of the elevator rope and inspecting the elevator rope.
How to inspect an elevator rope, characterized by having.

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