CN201327383Y - Automatic measuring system of natural glide quantity of fork truck fork - Google Patents

Abstract

The utility model discloses an automatic measurement system for the natural sliding amount of a fork of a forklift. Including CCD image acquisition system, two-dimensional rotating platform, target LED and hydraulic system. The CCD image acquisition system is composed of PC, image acquisition CCD, image acquisition card, long focal length lens and short focal length lens; the two-dimensional rotating platform is composed of angle encoder, two-dimensional turret and driving motor, and the long and short focal length lenses are installed In the two-dimensional turret, use the drive motor to drive the two-dimensional turret to rotate, track the target LED through lens imaging, and install the angle encoder on the rotating shaft to record the angle; install the fork of the forklift on the fork test bench, and then put the target LED It is fixed on the fork wall of the forklift and powered by the hydraulic system instead of the forklift power system. The amount of natural slump is accurately detected by the image processing software through the image formed by the long focal length lens. The measurement accuracy of the natural sliding amount of the fork of the forklift exceeds the accuracy requirement of the current market by an order of magnitude.

Description

An automatic measurement system for the natural sliding amount of the fork of a forklift

technical field

The utility model relates to an automatic measurement system, in particular to an automatic measurement system for the natural sliding amount of a fork of a forklift.

Background technique

At present, the proportion of logistics cost in my country's whole society to GDP has hovered around 21.3% for seven consecutive years, while the level of foreign logistics developed countries is about 10%. The domestic logistics industry is still in the stage of rapid development. As an important tool for logistics, forklifts will greatly reduce the logistics cost of enterprises. In the face of this huge market segment, all the advanced forklift brands in the world have entered the Chinese market in various forms. China's local forklift construction machinery factories should improve the quality of their products to occupy the Chinese market without delay. (Hangzhou Forklift Engineering Machinery Co., Ltd. is one of the backbone enterprises in the domestic forklift industry. From 2001 to 2005, the average sales growth rate was 41.8%, and the market share in 2005 reached 35.9%. But in 2005, due to the limitation of production technology Sales growth is limited by only 8%. It is obviously lower than the domestic average level.) Forklift mast is the lifting working device of forklift and is the main component of forklift. Its quality directly determines the performance of the forklift. Forklifts are moving towards high lifts. The height of the three-story mast reaches more than 6 meters. The performance of the high mast is more important to the overall performance of the forklift. At present, the production technology of domestic masts, especially the detection methods are relatively backward, mainly using manual and primitive methods, which seriously restricts the improvement of product quality and overall machine performance. (The current relatively advanced technology for detecting the height and speed of the mast is to use a laser rangefinder. However, the laser rangefinder is characterized by only measuring the movement of one point on the mast. It takes more time to determine the movement of the entire mast. The first laser range finder works from different directions at the same time. Since the mast needs to be lifted and transported by a crane during the production process, the laser range finder is not allowed to be installed in some directions. And different masts have different shapes and sizes , when using a laser rangefinder, it is necessary to adjust the position of the rangefinder. Since the mast can rise to a height of more than 6 meters, it is difficult to adjust the position. Therefore, it is difficult for the laser rangefinder to measure multiple parameters such as the front, rear, left, and right tilt of the forklift mast. .) Among them, there is no relatively advanced method to measure the natural slide of the forklift fork, and the accuracy is not high. Free slide is a very important quality performance parameter of forklift forks. To improve the quality of forklifts requires an advanced measurement technology to solve this problem.

Contents of the invention

The purpose of this utility model is to provide an automatic measurement system for the natural slide of the fork of a forklift, which uses fast image acquisition target LED images and image processing software to process the collected images, so that the measurement accuracy of the natural slide of the fork of the forklift exceeds the current market Accuracy requires an order of magnitude.

The technical scheme that the utility model solves its technical problem adopts is:

Including CCD image acquisition system, two-dimensional rotating platform, target LED structure and hydraulic system; among them:

1) CCD image acquisition system: the image acquisition CCD is respectively connected behind the long focal length lens and the short focal length lens, the image acquisition card is connected with the CCD, and the image acquisition card is inserted into the PC;

2) Two-dimensional rotating platform: a fixed supporting plate is installed on the bottom plate, and a horizontal plane driving motor and a horizontal direction angle encoder are respectively installed under the fixed supporting plate. The output shaft of the horizontal plane driving motor is equipped with a synchronous pulley, and the level of the horizontal direction angle encoder is The direction rotation shaft passes through the fixed support plate, and the horizontal direction rotation shaft located under the fixed support plate is equipped with a synchronous pulley, and the synchronous belt pulley on the horizontal plane drive motor is connected with the synchronous belt pulley on the horizontal direction angle encoder by a synchronous belt. The horizontally rotating U-frame is installed on the end face of the horizontally rotating shaft on the fixed supporting plate, and the vertically rotating U-frame is installed in the horizontally rotating U-frame, and the right side of the horizontally rotating U-frame is installed with a vertical drive motor, The direction drive motor shaft passes through the horizontal plane to rotate the U-shaped frame and is fixedly connected with the vertical direction rotating U-shaped frame. The other end is connected to the vertical direction angle encoder, a short focal length lens and a long focal length lens are installed on the bottom surface of the vertically rotating U-shaped frame, and the control circuit board is connected with the horizontal drive motor and the vertical direction drive motor;

3) Target LED:

A light hole is opened on the front panel and a fixed magnet is installed, and a circuit board is installed on the rear panel. The four LEDs on the circuit board are respectively aligned with the four light holes on the front panel. The light emitted by the LED is captured by the short focal length lens and the long focal length Lens tracking, fix the target LED on the fork of the forklift, and the hydraulic system replaces the forklift power system.

The beneficial effect that the utility model has is

At present, there is no measurement system at home and abroad that can accurately measure the natural sliding amount of forklift forks. The amount of natural slump is accurately detected by the image processing software through the image formed by the long focal length lens in this system. The measurement accuracy of the natural sliding amount of the fork of the forklift exceeds the accuracy requirement of the current market by an order of magnitude. It has greatly improved the production quality and market competitiveness of my country's forklifts, making forklifts safer and more convenient in actual logistics applications.

Description of drawings

Fig. 1 is the framework diagram of the automatic detection of the utility model.

Fig. 2 is a schematic diagram of the arrangement of target LEDs in the present invention.

Fig. 3 is a front view of the target LED structure of the utility model.

Fig. 4 is one of the top views of the target LED structure of the utility model.

Fig. 5 is the second top view of the target LED structure of the utility model.

Fig. 6 is a front view of the two-dimensional rotating platform of the present invention.

Fig. 7 is a right view of the two-dimensional rotating platform of the present invention.

Fig. 8 is a top view of the two-dimensional rotating platform of the present invention.

Fig. 9 is the control circuit board of the two-dimensional rotating platform of the present invention.

Fig. 10 is a schematic diagram of the target LED circuit board of the present utility model.

Fig. 11 is a circuit board diagram of the two-dimensional rotating platform of the present invention.

In the figure: 1-fixing magnet, 2-handle, 3-fixing screw, 4-circuit board, 5-power supply battery, 6-LED, 7-front panel, 8-rear panel, 9 left panel, 10-right panel , 11-lower bottom plate, 12-magnet fixed plate, 13-upper top plate, 14-fixed screw hole 15-battery fixed plate, 16-horizontal drive motor, 17-fixed support plate, 18-synchronous drive shaft, 19-fixed bracket Board, 20-bearing, 21-horizontal plane rotation U-shaped frame, 22-vertical direction angle encoder, 23-left vertical direction rotation shaft, 24-control circuit board, 25-protective cover, 26-left side plate, 27-short Focal length lens, 28-long focal length lens, 29-right side plate, 30-vertical direction driving motor, 31-vertical direction driving motor shaft, 32-vertical direction rotating U-shaped frame, 33-fixed bushing, 34-horizontal direction rotation Shaft, 35-synchronous drive shaft, 36-horizontal direction angle encoder, 37-fixed support plate, 38-bottom plate, 39-fixed screw, 40-power port, 41-control circuit board, 42-drive circuit board, 43U type fixed seat.

Detailed ways

Below in conjunction with accompanying drawing and embodiment the utility model is described further.

As shown in Figure 1, the utility model comprises the following parts:

1) CCD image acquisition system: it consists of a PC, an image acquisition CCD, an image acquisition card, a long focal length lens 28 and a short focal length lens 27. The image acquisition CCD is respectively connected behind the long focal length lens 28 and the short focal length lens 27, and the image acquisition card is connected with the CCD, and the image acquisition card is inserted on the PC.

2) Two-dimensional rotating platform: it consists of an angle encoder, a two-dimensional turret and a drive motor. Install the long focal length lens and the short focal length lens on the two-dimensional turret, use the drive motor to drive the two-dimensional turret to rotate two-dimensionally through the lens imaging to track the target LED, and the angle encoder is installed on the rotating shaft to record the angle.

3) Hydraulic system: Install the forklift fork on the fork test bench, and then fix the target LED on the fork wall of the forklift, and provide power through the hydraulic system instead of the forklift power system.

In Figure 2, it consists of four LEDs with a diameter of d, the four light sources are arranged in a square, and the distance between the center points of the diagonal light sources is D. The four LEDs pass through the frosted glass to make the brightness of light in all directions consistent, and then exit through the light hole on the front panel. Using LED has the following advantages: bright light source, small size, high luminous efficiency, long life, DC power supply, safe and reliable.

In Fig. 3, Fig. 4, among Fig. 5, open 4 light-through holes on the front panel 7, emit LED6 from the light-through holes, open a hole on the front panel 7 to install the switch of the fixed magnet 1, on the right side plate 10 Install handle 2. Fix the circuit board 4 by fixing screws on the rear panel, so that the four LEDs on the circuit board are just aligned with the four light holes of the front panel 7 . The power supply battery 5 is fixed on the left side plate with the battery fixing plate 15 . The lower bottom plate 11 has a charging slot. Six side panels form a square box with fixing screws.

In Fig. 6, Fig. 7, Fig. 8, and Fig. 9, four fixed support plates 17 are installed on the bottom plate 38 to support the fixed pallet 19. Below the fixed pallet 19, a fixed U-shaped seat 43 is installed. Horizontal plane drive motor 16 is installed on fixing U-shaped seat 43, and horizontal plane drive motor 16 connects synchronous belt pulley 18, and synchronous belt pulley 18 connects synchronous belt pulley 35 with belt, and synchronous belt pulley 35 drives horizontal direction rotating shaft 34 and is fixed on the shaft The horizontal plane rotates the U-shaped frame 21 and rotates in the horizontal direction. Wherein the fixed axle sleeve 33 is installed on the fixed supporting plate 19, the bearing 20 is installed in the fixed axle sleeve 33, and the horizontal direction rotating shaft 34 is installed in the bearing 20 li. A horizontal direction angle encoder 36 is installed below the horizontal direction rotation shaft 34, and the horizontal direction angle encoder 36 is used to record the angle rotated in the horizontal direction. The vertical direction driving motor 30 is installed on the right side plate of the horizontal plane rotating U-shaped frame 21, and the vertical direction driving motor drives the right horizontal direction rotating shaft 34. The vertical direction rotating U-shaped frame 32 can rotate in the vertical direction in the horizontal plane rotating U-shaped frame 21 through the left vertical direction rotating shaft 23 and the right horizontal direction rotating shaft frame 34 . A vertical angle encoder 22 is installed on the left side of the left vertical rotation shaft 23, which is used to record the angle turned in the vertical direction. Rotate the U-shaped frame 32 in the vertical direction and install two lenses with long and short focal lengths. The short focal length lens 27 and the long focal length lens 28. The control circuit board 24 is fixed on the base plate 38 . Finally, the protective cover 25 is used to cover the whole two-dimensional rotating platform.

In Fig. 10, two triodes Q1 and Q2 are installed on the circuit board 4 respectively, the first diode D1, the second diode D2 and the second resistance R2 are connected in series, the first LED1 and the second LED2 are connected in series, The base of the first transistor Q1 is connected to the cathode of the second diode D2 and one end of the second resistor R2, the emitter of the first transistor Q1 is connected to one end of the first resistor R1, and the collector of the first transistor Q1 is connected to The anode of the first LED1 is connected; the third diode D3, the fourth diode D4 and the fourth resistor R4 are connected in series, the third LED3 and the fourth LED4 are connected in series, the base of the second triode Q2 is connected to the fourth diode The negative pole of D4 is connected to one end of the fourth resistor R4, the emitter of the second triode Q2 is connected to one end of the third resistor R3, the collector of the second triode Q2 is connected to the positive pole of the third LED3; the fifth resistor R5, The reverse voltage regulator D5 is connected in series with the fifth LED5, the negative pole of the fourth LED4, the other end of the fourth resistor R4, the negative pole of the second LED2, the other end of the second resistor R2 and the negative pole of the fifth LED5 are connected. The negative pole of the battery; the other end of the third resistor R3, the positive pole of the third diode D3, the other end of the first resistor R1, the positive pole of the first diode D1 and the other end of the fifth resistor R5 are connected to the positive pole of the battery through the switch SW1 . Among them, LED1, LED2, LED3, and LED4 are the four target light sources, and LED5 is used as the indicator light of the power supply.

In Fig. 11, the HV interfaces of the first circuit driver DR1 and the second circuit driver DR2 on the control circuit board 24 are respectively connected to the first transformer TR1 and the second transformer TR2, and the two transformers are connected to a 220V power supply; the first circuit The U, V, and W ports of the driver DR1 are connected to the U, V, and W ports of the horizontal plane driving motor 16; the U, V, and W ports of the second circuit driver DR2 are connected to the U, V, and W ports of the vertical driving motor 30; two The OPTO, CP, DIR, FREE of the driver are respectively connected to the CP+, DIR+, EN+, negative potential of the first single-chip microcomputer cpu1 and the second single-chip cpu2 of the respective single-chip microcomputers through the bus; the limit switch bus of the first single-chip microcomputer cpu1 and the second single-chip microcomputer cpu2 They are connected with respective 12V limiters; the first single-chip microcomputer cpu1 and the second single-chip microcomputer cpu2 are connected in series with the PC through the RS232 serial port.

First, place the fork of the forklift to be tested on the hydraulic fork test bench, and then fix the target LED on the fork wall of the forklift through the fixed magnet 1, so that it can be raised and lowered together with the fork. At a distance of 4 meters from the level of the fixed test platform, fix the two-dimensional rotating platform at a height of 4 meters from the ground, and make the long and short focal length lenses face the direction of the target LED, take the protective cover 25, prepare to track the target LED, and perform image collection. Set the working mode of the hydraulic station through the console to provide power for the lifting of the fork. After the system is initialized through the PC, it enters the detection stage.

The system utilizes a short focal length lens 27 and a long focal length lens 28 for imaging, and the imaging target is the distance D between two diagonal LEDs. The LEDs are arranged regularly for easy image recognition. When the fork moves, the imaging of the LED on the CCD will form a smear. Since the smears of the two LEDs are basically the same, the diagonal centers D between the LEDs can be considered to remain unchanged. Therefore, the diagonal center distance of two LEDs can be used as the target height. The design of this target light source provides great convenience for image processing.

Two imaging lenses are mounted on a two-dimensional rotating platform. The imaging of the short focal length lens 27 has a larger field of view angle, which ensures that the target LED can always be within the field of view of the short focal length lens 27 when the fork moves up and down, so that the two-dimensional rotating platform can track the target LED in real time. The long focal length lens 28 has a small field of view for imaging, and forms a magnified image of the imaging target, which is used to measure small changes in the position of the target. When the fork moves to a specified height and stops, the target LED is tracked by the rotation of the two-dimensional rotating platform, and the long focal length lens 28 is used for imaging, so that the target LED is completely imaged on the CCD image plane of the long focal length lens. Through the image acquisition system, the targets at different times are collected and transmitted back to the collected data and the angle information recorded by the angle encoder through Bluetooth wireless transmission. The system can calculate the moving height and speed of the forklift by using the image processing software to process the target image formed by the short focal length lens 27 . After the gantry stops at the designated height, the long focal length lens 28 tracks the target LED and performs image acquisition. The system can calculate the natural micro-slip amount by using the image processing software to process the target image formed by the long focal length lens 28. Among them, the natural slight sliding amount is when the forklift fork lifts to the specified point and the forklift fork stops moving. Since the forklift fork will slowly move down in the actual situation, this small amount is called the natural sliding amount.

Among them, the CCD used in this system is 1/3 inch in size, 800×600 pixels in size, the focal length of the long focal length lens is 200mm, and the focal length of the short focal length lens is 35mm. The Bluetooth wireless transmission uses the GC-05 Bluetooth integrated block produced by Nanjing Guochun Electric Equipment Co., Ltd., and the image acquisition card uses CG300.

At present, there is no measurement system at home and abroad that can accurately measure the natural sliding amount of forklift forks. The amount of natural glide is accurately detected in this system by a long focal length lens. The specific principle is as follows: On the CCD image plane, the pixel corresponding to the LED center distance D is N, and the object height a corresponding to 1 pixel:

a=D/N

If after a period of time, the center point of the LED light source moves down by n pixels, the natural slide amount Δs

Δs=a×n

When the long focal length is 40cm, D is 10cm, and the object distance is 4 meters, a is about 0.14mm. The error of natural glide is determined by CCD pixel resolution. According to the previous analysis, one pixel corresponds to 0.14mm, which is the measurement error of the slight downward shift. 100mm corresponds to a relative measurement error of 0.14%. This measurement accuracy meets actual production requirements and exceeds an order of magnitude accuracy.

Hydraulic workstation configuration:

Oil storage tank: 1000 liters of oil storage capacity (including oil inlet and outlet holes, liquid level display, etc.)

Three-phase motor: 28KW 1470rpm

Hydraulic pump: 80SCY14-1B

Cooling method: air cooling

Anti-vibration pressure gauge: 25MPa×6

Reversing valve: one up and down direction control valve, one front and rear tilt direction control valve, down flow control valve, front and rear tilt speed control valve

Electric control box (lower computer): Inverter: 28KW

Contactor:

Reversing control relay:

Control switch:

Current transformer and ammeter: 75A

Main technical indicators of hydraulic workstation:

Applicable range: Tonnage: 2.5 tons. The maximum height is 4.5 meters.

Adjustable range of descending speed: 300-600mm/s

Adjustable ascent speed, maximum 500mm/s

Adjustable range of tilting speed: 1-5mm/s.

Claims (3)

1, a kind of automatic measurement system of natural downslide amount of forklift fork is characterized in that: comprise ccd image acquisition system, two-dimentional rotatable platform, target LED structure and hydraulic system; Wherein:

1) ccd image acquisition system: gather CCD at long-focus lens (28) and short focal length lens (27) back difference map interlinking picture, image pick-up card links to each other with CCD, and image pick-up card is inserted on the PC;

2) two-dimentional rotatable platform: fixedly supporting plate (19) is housed at base plate (38), below fixing supporting plate (19), surface level drive motor (16) and horizontal direction angular encoder (36) are installed respectively, on surface level drive motor (16) output shaft synchronous pulley (18) is housed, the horizontal direction rotation axis (34) of horizontal direction angular encoder (36) passes fixedly supporting plate (19), be positioned on the horizontal direction rotation axis (34) below the fixing supporting plate (19) synchronous pulley (35) is housed, synchronous pulley (35) on synchronous pulley (18) on the surface level drive motor (16) and the horizontal direction angular encoder (36) is rotationally connected with being with synchronously, the U type frame (21) that surface level rotates is installed in and is positioned at fixedly horizontal direction rotation axis (34) end face above the supporting plate (19), vertical direction is rotated U type frame (32) and is installed in the surface level rotation U type frame (21), surface level rotates the right side of U type frame (21) vertical direction drive motor (30) is installed, vertical direction drive motor axle (31) passes surface level rotation U type frame (21) fixedlys connected with vertical direction rotation U type frame (32), after left side vertical rotation axle (23) passes surface level rotation U type frame (21), the one end rotates U type frame (32) with vertical direction fixedlys connected, left side vertical rotation axle (23) other end connects vertical direction angular encoder (22), rotate an installation short focal length lens (27) and a long-focus lens (28) on U type frame (32) bottom surface in vertical direction, control circuit board (24) is connected with the vertical direction drive motor with the horizontal drive motor;

3) target LED:

Open 4 light holes in front on the plate (7) and fixed magnet (1) is housed, circuit board (4) is housed on the plate in the back, four LED on the circuit board (4) aim at four light holes of front panel (7) respectively, the light that LED sends is followed the tracks of by short focal length lens (27) and long-focus lens (28), target LED is fixed on the fork of forklift truck, and hydraulic system replaces the fork truck power system.

2, the automatic measurement system of a kind of natural downslide amount of forklift fork according to claim 1, it is characterized in that: first circuit driver (DR1) on the described control circuit board (24) is connected with second transformer (TR2) with first transformer (TR1) respectively with the HV interface of second circuit driver (DR2), and two transformers connect the 220V power supply; U, the V of U, the V of first circuit driver (DR1), W port water receiving plane drive motor (16), W port; U, the V of second circuit driver (DR2), W port connect U, V, the W port of vertical direction drive motor (30); First single-chip microcomputer (cpu1) of single-chip microcomputer and CP+, DIR+, EN+, the negative potential of second singlechip (cpu2) link to each other respectively with separately by bus for the OPTO of two drivers, CP, DIR, FREE; First single-chip microcomputer (cpu1) and the limit switch bus of second singlechip (cpu2) link to each other with the stop of separately 12V; First single-chip microcomputer (cpu1) is connected after the RS232 serial ports links to each other with PC with second singlechip (cpu2).

3, the automatic measurement system of a kind of natural downslide amount of forklift fork according to claim 1, it is characterized in that: two triode (Q1 are housed respectively on the described circuit board (4), Q2), first diode (D1), second diode (D2) and second resistance (R2) series connection, first LED1 and second LED2 series connection, the base stage of first triode (Q1) is connected with an end of second diode (D2) negative pole and second resistance (R2), the emitter of first triode (Q1) is connected with an end of first resistance (R1), and the collector of first triode (Q1) is connected with the positive pole of first LED1; The 3rd diode (D3), the 4th diode (D4) and the 4th resistance (R4) series connection, the 3rd LED3 and the 4th LED4 series connection, the base stage of second triode (Q2) is connected with an end of the 4th diode (D4) negative pole and the 4th resistance (R4), the emitter of second triode (Q2) is connected with an end of the 3rd resistance (R3), and the collector of second triode (Q2) is connected with the positive pole of the 3rd LED3; The 5th resistance (R5), oppositely stabilivolt (D5) and the 5th LED5 series connection, the negative pole of the negative pole of the negative pole of the 4th LED4, the other end of the 4th resistance (R4), second LED2, the other end of second resistance (R2) and the 5th LED5 connects the negative pole of battery; The other end of positive pole of the other end of the positive pole of the other end of the 3rd resistance (R3), the 3rd diode (D3), first resistance (R1), first diode (D1) and the 5th resistance (R5) connects the positive pole of battery through switch (SW1).

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