Anti-collision and angle safety monitoring control device and method for transfer system

Abstract

The present application relates to nursing training auxiliary equipment technical field, specifically for a kind of transfer system anti-collision and angle safety monitoring control device and method, including the anti-collision detection module being arranged in the bottom of host computer, angle monitoring module, and motor driver control module motor is driven by PLC controller and electric hoist belt;Control method includes: S1, system initialization and parameter configuration;S2, multidimensional real-time signal acquisition;S3, safety boundary logic determination;S4, multi-information filtering and collaborative control;S5, closed loop cycle and data record;The present application can detect the angle and height of electric hoist belt in real time by setting anti-collision detection module and angle monitoring module, and motion intention and safety analysis are carried out through PLC controller, when user suddenly falls or electric hoist belt is lifted too high, can quickly respond, brake and stop, effectively improve the security of user in training.

Description

Technical Field

[0001] This invention relates to the field of nursing training auxiliary equipment technology, specifically to a collision prevention and angle safety monitoring and control device and method for a transport system. Background Technology

[0002] With the accelerating aging of society and the continuous increase in demand for motor function training, the intelligence, safety, and precision of elderly care training equipment have become core directions for industry development. Training ceiling rail systems, as key equipment that assists users in gait and balance training through a suspension system, are widely used in medical institution nursing areas, nursing homes, and home care settings due to their advantages of providing stable support and reducing risks during training. These systems are fixed to the building roof via a ceiling rail unit and connected to the user's body using a safety belt, suspending and traction the user to assist in completing various training movements or to assist in the transfer of users with mobility difficulties. The stability and safety of the system directly affect the user experience and personal safety.

[0003] However, existing overhead track training equipment has gradually revealed many technical defects that urgently need to be addressed during actual operation. Among these, the risk of collision between the harness and the main unit, as well as the insufficient accuracy of the safety belt tilt angle monitoring, are particularly prominent. When users are training in multiple directions and at multiple angles, due to changes in the range of body movements and the uncertainty of the movement trajectory, the safety belt is prone to colliding with critical parts such as the support structure and transmission components of the overhead track main unit. This can not only cause wear and tear on equipment parts and generate abnormal noises, affecting the service life of the equipment, but also cause users to lose their balance due to the impact force, leading to falls, sprains, and other safety accidents, seriously threatening the training safety of users.

[0004] Meanwhile, the harness tilt angle is one of the core parameters affecting the stability and effectiveness of user training. In different training programs, such as gait correction and weight transfer training, the harness tilt angle needs to be controlled within a specific range to ensure appropriate support and traction for the user. However, most current mainstream ceiling rail care equipment lacks a dedicated high-precision angle monitoring mechanism, relying solely on manual observation or simple mechanical limits to roughly judge the harness angle, failing to obtain its tilt angle parameters in the vertical plane in real time and accurately. This limitation leads to two problems: firstly, it's difficult to adjust the equipment's support status based on the user's real-time movements, significantly reducing the training's relevance and effectiveness; secondly, when the harness tilt angle exceeds the safety threshold, it cannot issue timely warnings and take intervention measures, further exacerbating instability during user training and affecting the normal training process.

[0005] To address the aforementioned issues, some industry players have attempted improvements by adding mechanical buffer structures or single sensors. However, mechanical buffer structures only provide passive protection after a collision occurs, failing to prevent collision risks from the outset. Single-sensor monitoring methods suffer from insufficient data dimensions and susceptibility to environmental interference, making it difficult to predict collision risks in advance and accurately monitor tilt angles. Therefore, developing a control method and device for ceiling-rail nursing equipment capable of real-time multi-dimensional data acquisition, collision risk warning, and precise angle monitoring is an urgent need to improve the safety and efficiency of ceiling-rail nursing equipment and a crucial direction for promoting the intelligent development of elderly care equipment. Summary of the Invention

[0006] The purpose of this invention is to provide a method and device for preventing collisions between the sling and the main unit housing, and for accurately monitoring and controlling the anti-collision and angle safety of the sling transfer system.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A collision avoidance and angle safety monitoring and control device for a transfer system includes a limiting base installed at the bottom of the main unit of the transfer system. A collision avoidance detection module is installed at the bottom of the limiting base, and an angle monitoring module is installed on one side of the limiting base. A motor driver is installed on the limiting base, and the motor driver is connected to a module motor. The module motor is connected to a drum, and a sling is wound on the drum. The free end of the sling passes through the collision avoidance detection module. A detection shaft is provided inside the limiting base, with a gap in the detection center, through which the sling passes. The angle monitoring module is connected to the detection shaft. The angle monitoring module, the collision avoidance detection module, and the motor driver are all electrically connected to a PLC controller. A braking resistor is electrically connected to the module motor. The PLC controller is connected to a data storage device.

[0009] The angle monitoring module is used to collect the angle signal of the sling relative to the host in real time and transmit the angle signal to the PLC controller. The angle monitoring module adopts a high-precision angle sensor, whose detection range covers the full angle range of the sling's movement, and the detection accuracy is not less than 0.1°.

[0010] The anti-collision monitoring module is used to collect the distance signal between the sling limiter and the lower shell of the limit base in real time, and transmit the distance signal to the PLC controller. The anti-collision monitoring module uses a micro switch sensor. When the distance between the sling limiter and the bottom surface of the limit base is less than the preset safe distance threshold, the anti-collision monitoring module is triggered to output a trigger signal.

[0011] The PLC controller module is electrically connected to the angle monitoring module, the anti-collision monitoring module, the module motor module, and the audible and visual warning module. It is used to receive the angle signal transmitted by the angle monitoring module and the distance signal transmitted by the anti-collision monitoring module. After analyzing and processing the signals, it outputs control commands to the module motor module and the audible and visual warning module to determine whether the host can follow the movement.

[0012] The modular motor is used to control the motor operation according to the instructions of the PLC controller, realizing the start, stop, acceleration and deceleration of the host; when the modular motor controls the motor to stop in an emergency according to the control instructions of the PLC controller, it cuts off the motor power output and locks the motor shaft.

[0013] Preferably, the two ends of the detection shaft are rotatably connected to the limiting base via bearings, and the angle monitoring module is equipped with an angle sensor that is coaxial with the detection shaft.

[0014] Preferably, the anti-collision detection module includes a micro switch sensor, and the end of the sling is provided with a sling limiter that cooperates with the micro switch sensor.

[0015] Preferably, an audible and visual warning module is provided on the lower side of the main unit's casing, and the audible and visual warning module is electrically connected to the PLC controller; an alarm light is provided on the audible and visual warning module; the audible and visual warning module is used to issue audible and visual warning signals according to the control instructions of the PLC controller to remind medical staff and users to pay attention to safety.

[0016] A method for collision avoidance and angle safety monitoring and control of a transfer system includes the following steps:

[0017] S1. System Initialization and Parameter Configuration: Turn on the power, and the PLC controller performs initialization self-tests on each hardware module, reading and setting system operating parameters. Parameters include: slow angle change threshold, sudden angle change threshold, and upper limit value of electronic limit height. and lower limit value The initial state vector and covariance matrix of the Kalman filter;

[0018] S2. Multi-dimensional Real-time Signal Acquisition: Once the system enters operation, it acquires the following signals in real-time through multiple sensors and transmits them to the PLC controller:

[0019] Attitude signal: The tilt angle of the sling relative to the vertical is acquired through the angle monitoring module. ;

[0020] Spatial position signal: The physical distance between the sling limiter and the limit base is collected through the anti-collision monitoring module. The vertical height of the sling is collected by the absolute encoder of the module motor. ;

[0021] Dynamics and kinematic signals: Acquiring motor output torque Running speed and running acceleration ;

[0022] S3. Safety Boundary Logic Determination: The PLC controller performs safety logic analysis on the signals acquired in step S2, specifically including:

[0023] Physical collision avoidance judgment: If the distance D is less than the preset safe distance, or the micro-switch sensor of the collision avoidance monitoring module is triggered, the first-level emergency stop command is immediately executed and the audible and visual warning module is triggered.

[0024] Electronic limit judgment: Determines real-time vertical height Is it in If the motor exceeds the specified range, it is prohibited to output torque in the direction of the over-limit. It is only allowed to run in the reverse direction and a limit switch warning will be triggered.

[0025] S4. Multi-information filtering and coordinated control: When both physical anti-collision judgment and electronic limit judgment in step S3 are effective, the PLC controller processes the signals collected in step S2 using an algorithm and outputs control commands, specifically including:

[0026] Signal filtering and fusion: The position, velocity, acceleration and torque signals collected in step S2 are fused using the Kalman filter algorithm to remove high-frequency noise and mechanical vibration interference, and to calculate the optimal motion state estimate.

[0027] Horizontal following and fall detection: Calculate the change in angle signal per unit time; if the change is within the slow change threshold set in step S1, the horizontal movement module of the control host is allowed to follow the movement; if the change exceeds the sudden change threshold, it is determined to be a fall risk, the module motor is immediately locked and an alarm is triggered through the sound and light warning module.

[0028] Vertical weight reduction control: Based on filtered motion state data, the compensation torque is calculated by combining the impedance control model, and the dynamic torque output of the control module motor is controlled to counteract system inertia and maintain a constant weight reduction force applied to the user;

[0029] S5. Closed-loop cycle and data recording: Continuously execute steps S2 to S4, and write the original sensor data, filtered data, control commands and fault logs into the data storage device in real time until the device is shut down.

[0030] Preferably, the electronic limit determination in step S3, the safety boundary logic determination, includes a soft landing mechanism, specifically comprising:

[0031] When vertical height Approaching the upper limit or lower limit value When the belt reaches the preset buffer zone, the PLC controller dynamically reduces the maximum allowable speed and acceleration of the module motor based on the difference between the belt and the limit value, so that the belt approaches the limit value in a decelerated state.

[0032] Preferably, the physical collision avoidance determination in step S3, the security boundary logic determination, has the highest priority hardware interrupt authority, specifically including:

[0033] The collision avoidance monitoring module includes two micro-switch sensors. Regardless of the control mode of the system, as long as either sensor is triggered, the system will immediately cut off the torque output of the module motor through a hardware interrupt and lock the brake.

[0034] Preferably, the specific process of signal filtering fusion in step S4, multi-information filtering and coordinated control, includes:

[0035] Model definition:

[0036] Define the system in discrete time state vector :

[0037]

[0038] in, These represent the vertical position, vertical velocity, and vertical acceleration of the sling, respectively.

[0039] The state observation equation of the system is defined as follows:

[0040]

[0041] in, Here, H represents the sensor observations, and H is the observation matrix. To observe noise;

[0042] State prediction:

[0043] The PLC controller, based on the previous moment... posterior estimate Predict the current moment Prior estimate :

[0044]

[0045] Simultaneously predict the error covariance matrix :

[0046]

[0047] in, Here is the state transition matrix. To control the input matrix, To control the input amount, The process noise covariance matrix;

[0048] Gain calculation and state correction:

[0049] Calculate Kalman gain :

[0050]

[0051] Using the actual observations of the current sensor The prior estimate is corrected to obtain the optimal posterior state estimate at the current time. :

[0052]

[0053] in, To measure the noise covariance matrix;

[0054] Covariance update and output:

[0055] Update the error covariance matrix:

[0056]

[0057] Final output The velocity and acceleration components are used for subsequent weight reduction control.

[0058] Preferably, the vertical weight reduction control in step S4, multi-information filtering and coordinated control, adopts an impedance-based control strategy, and the specific process includes:

[0059] The controller has a pre-set ideal target impedance model:

[0060]

[0061] in, Human-computer interaction power These are virtual mass, virtual damping, and virtual stiffness, respectively. The filtered acceleration, velocity, and position;

[0062] The PLC controller calculates the compensation torque that the module motor needs to output based on the above model, so that the equipment exhibits compliant characteristics with low inertia and low damping in the vertical direction.

[0063] Preferably, the preset angle slow change threshold range, angle sudden change threshold, and safety distance threshold in step S1 can all be customized and adjusted by the PLC controller to adapt to the usage needs of users with different weights and different rehabilitation stages, thereby improving the versatility of the equipment.

[0064] Preferably, the sound and light warning module uses an alarm light and a buzzer with adjustable volume and flashing frequency. Medical staff can adjust the volume and flashing frequency of the warning signal according to the noise and light conditions of the rehabilitation training environment to ensure that the warning signal can be clearly perceived.

[0065] The beneficial effects of this invention are:

[0066] This invention uses an anti-collision monitoring module to monitor the distance between the end of the sling and the main unit casing in real time. When the distance is less than a preset safety threshold, the motor is immediately stopped and an audible and visual warning is issued, which can effectively prevent the sling from colliding with the main unit casing and ensure the safety of the equipment and the user. The anti-collision detection module adopts a redundant design, using two micro-switch sensors to monitor the anti-collision danger distance simultaneously. When one of the micro-switch sensors is triggered, a hardware interrupt is immediately initiated with the highest priority to prevent the sling from being retracted too much and causing a collision between the user and the main unit.

[0067] This invention employs an angle monitoring module equipped with an angle sensor to collect the sling angle signal in real time. The PLC controller analyzes the angle change, enabling accurate judgment of the user's activity status. When the angle changes slowly, the control host is allowed to follow the movement, ensuring smooth user activity and improving the rehabilitation training effect. When the angle changes abruptly, it is judged as an emergency such as a user falling, triggering an emergency stop and warning, which can respond to the user's sudden actions in a timely manner and reduce safety risks.

[0068] The device of this invention has a simple structure, and the modules work together stably and reliably. It has high accuracy in angle monitoring and anti-collision distance monitoring, and fast control response speed. At the same time, the preset threshold can be customized and adjusted to meet the needs of different users, making it highly versatile. Attached Figure Description

[0069] Figure 1 This is a schematic diagram of the overall structure of Embodiment 1 of the present invention;

[0070] Figure 2 This is a partial rear view of Embodiment 1 of the present invention;

[0071] Figure 3 This is a schematic diagram of the anti-collision detection device in Embodiment 1 of the present invention;

[0072] Figure 4 This is a schematic diagram of the other side of the anti-collision detection device in Embodiment 1 of the present invention;

[0073] Figure 5 This is a schematic diagram of the angle detection module structure in Embodiment 1 of the present invention;

[0074] Figure 6 This is a schematic diagram of the light warning module in Embodiment 1 of the present invention;

[0075] Figure 7 This is a schematic diagram of the sling connection structure in Embodiment 1 of the present invention;

[0076] Figure 8 This is a schematic diagram of the control method flow in Embodiment 2 of the present invention;

[0077] Figure 9 This is a schematic diagram of the multi-information filtering and weight reduction control algorithm in Embodiment 2 of the present invention.

[0078] In the diagram: Module motor 1; Sling 2; PLC controller 3; Motor driver 4; Anti-collision monitoring module 5; Braking resistor 11; Limiting base 21; Lower shell of limiting base 22; Spring limiting seat 23; Spring 24; Micro switch sensor 25; Angle monitoring module 41; Detection shaft 42; Audible and visual warning module 51; Sling drum 61; Sling 62; Sling limiting component 63. Detailed Implementation

[0079] Example 1

[0080] The following is a further explanation of the present invention in conjunction with specific embodiments, such as... Figure 1-7 As shown, this embodiment is a collision avoidance and angle safety monitoring and control device for a transfer system. It is installed below the main unit of the transfer system and is fixedly connected to the main unit through a limiting base 21. A horizontal moving module that cooperates with the track is provided on the top of the main unit, which can drive the main unit to move horizontally along the track. A module motor 1 is provided inside the main unit. The output shaft of the module motor 1 is connected to the sling drum 61 through a transmission mechanism, which can control the sling drum 61 to rotate forward or backward, thereby controlling the sling 62 wound on the sling drum 61 to be wound up and down.

[0081] The module motor 1 is electrically connected to the motor driver 4 and the braking resistor 11 respectively. The motor driver 4 is used to control the start, stop, speed and torque of the module motor 1, and can lock the output shaft of the module motor 1 when a braking command is received, and together with the braking resistor 11, it can achieve emergency braking of the module motor 1.

[0082] Angle monitoring module 41 is installed on limit base 21, and includes a detection shaft 42. Both ends of the detection shaft 42 are rotatably installed inside the limit base 21 through bearings, allowing it to rotate freely around the shaft. A gap is provided in the middle of the detection shaft 42 along its length, allowing the sling 62 to pass through. An angle sensor of angle monitoring module 41 is coaxially connected to one end of detection shaft 42, which can read the rotation angle and rotation angular velocity of detection shaft 42 in real time. Its detection accuracy is 0.05°, and the angle measurement range is -90° to 90°. Angle monitoring module 41 is electrically connected to PLC controller 3 through RS485 bus, and transmits the collected angle signal to PLC controller 3 in real time.

[0083] The anti-collision detection module 41 is mounted on the lower shell 22 of the limiting base 21, which is located on the bottom surface of the limiting base 21. It includes a pair of micro-switch sensors 25. The lower shell 22 of the limiting base is connected to the spring and the limiting base 21 through the spring limiting seat 23, creating a reserved space. The pair of micro-switch sensors 25 are respectively mounted on both sides of the lower shell 22 of the limiting base. They are mounted at the same height and their detection direction is parallel to the movable plane of the sling 62. They can collect the distance signal between the sling limiting member 63 at the end of the sling 62 and the lower shell 22 of the limiting base in real time. The detection range is 0~10mm and the detection accuracy is 0.1mm. The anti-collision monitoring module 41 is electrically connected to the PLC controller 3 through a signal line to transmit the distance signal to the PLC controller 3.

[0084] The input terminals of the PLC controller 3 are electrically connected to the angle monitoring module 41 and the anti-collision monitoring module 5, respectively, and the output terminals are electrically connected to the module motor 1 and the light warning module 51, respectively. The PLC controller 3 has a built-in data storage device for storing preset angle slow change threshold range and angle sudden change threshold.

[0085] The audible and visual warning module 51 is installed on the outer bottom surface of the main unit casing and is equipped with an alarm light that can emit a red flashing light. After receiving the warning command from the PLC controller 3, the audible and visual warning module 51 immediately starts the alarm light to flash.

[0086] Example 2

[0087] This embodiment describes a method for collision prevention and angle safety monitoring and control of a transfer system based on the anti-collision and angle safety monitoring and control device proposed in Embodiment 1. The method specifically includes the following steps:

[0088] S1. System Initialization and Parameter Configuration: Turn on the power, and the PLC controller 3 performs initialization self-tests on each hardware module, reading and setting the system operating parameters; parameters include: slow angle change threshold, sudden angle change threshold, and upper limit value of electronic limit height. and lower limit value The initial state vector and covariance matrix of the Kalman filter are determined, and the specific process includes:

[0089] Parameter loading: Read preset parameters from non-volatile memory: Angle following threshold set to The angle of fall mutation threshold is set to The upper and lower limits of the electronic limit height are set to .

[0090] Static calibration: Before the user puts on the harness, the system automatically controls the motor to lift the harness 2 to a position 1 meter off the ground and bring it to a stop. The PLC controller 3 records the motor holding current value at this time. This value corresponds to the weight of the sling and the mechanical friction. In subsequent weight reduction calculations, this value will be subtracted as a baseline zero point to ensure that the weight reduction force acts only on the patient's body.

[0091] S2. Multi-dimensional Real-time Signal Acquisition: Once the system enters operation, it uses a sampling period of 10ms (100Hz) to acquire the following signals in real-time through multiple sensors and transmits them to the PLC controller:

[0092] Attitude signal: The tilt angle of the sling relative to the vertical is acquired through the angle monitoring module. ;

[0093] Spatial position signal: The physical distance between the sling limiter and the limit base is collected through the anti-collision monitoring module. The vertical height of the sling is collected by the absolute encoder of the module motor. ;

[0094] Dynamics and kinematic signals: Acquiring motor output torque Running speed and running acceleration All raw data is transmitted to PLC controller 3 via EtherCAT bus.

[0095] S3. Safety Boundary Logic Determination: The PLC controller performs safety logic analysis on the signals acquired in step S2, specifically including:

[0096] Physical collision avoidance judgment: If the distance D is less than the preset safe distance, or the micro switch sensor of the collision avoidance monitoring module is triggered, the first-level emergency stop command is immediately executed and the audible and visual warning module is triggered. The collision avoidance monitoring module includes two micro switch sensors. Regardless of the control mode of the system, as long as either sensor is triggered, the system will immediately cut off the torque output of the module motor through hardware interrupt and lock the brake.

[0097] Physical collision avoidance determination has the highest priority hardware interrupt privileges. Specifically, if the collision avoidance sensor detects the distance to an obstacle... If the microswitch is triggered, the PLC immediately cuts off the enable signal of the servo driver through the hardware interrupt pin and controls the module motor to lock the brake to prevent inertial impact.

[0098] Electronic limit judgment: Determines real-time vertical height Is it in If the motor exceeds the specified range, it is prohibited from outputting torque in the direction of the over-limit; only reverse operation is permitted, and a limit switch warning will be triggered. Specifically, the buffer zone is set to 20cm before the upper and lower limit values.

[0099] when Enter During the interval, the controller forcibly limits the maximum ascent speed to 10% of the normal speed to achieve a soft landing.

[0100] when When this occurs, the module motor is prohibited from outputting positive (rising) current and only responds to descent commands.

[0101] S4. Multi-information filtering and coordinated control: When both physical anti-collision judgment and electronic limit judgment in step S3 are effective, the PLC controller processes the signals collected in step S2 using an algorithm and outputs control commands, specifically including:

[0102] Signal filtering and fusion: The position, velocity, acceleration, and torque signals acquired in step S2 are fused using a Kalman filter algorithm to remove high-frequency noise and mechanical vibration interference, calculate the optimal motion state estimate, and resolve sensor noise and hysteresis. The specific process includes:

[0103] Model definition:

[0104] Selecting the state vector :

[0105]

[0106] Where x represents position, v represents velocity, and a represents acceleration.

[0107] State transition matrix :

[0108] Based on Newton's kinematics formulas, let the sampling time be... ;

[0109]

[0110] Observation matrix :

[0111] This system directly measures the position (motor encoder) and acceleration provided by module motor 1, therefore the observation matrix is ​​set as follows:

[0112]

[0113] Define the system in discrete time state vector :

[0114]

[0115] in, These represent the vertical position, vertical velocity, and vertical acceleration of the sling, respectively.

[0116] The state observation equation of the system is defined as follows:

[0117]

[0118] in, Here, H represents the sensor observations, and H is the observation matrix. To observe noise;

[0119] State prediction:

[0120] The PLC controller, based on the previous moment... posterior estimate Predict the current moment Prior estimate :

[0121]

[0122] Simultaneously predict the error covariance matrix :

[0123]

[0124] in, Here is the state transition matrix. To control the input matrix, To control the input amount, The process noise covariance matrix;

[0125] Gain calculation and state correction:

[0126] Calculate Kalman gain :

[0127]

[0128] Using the actual observations of the current sensor The prior estimate is corrected to obtain the optimal posterior state estimate at the current time. :

[0129]

[0130] in, To measure the noise covariance matrix;

[0131] Covariance update and output:

[0132] Update the error covariance matrix:

[0133]

[0134] Final output The velocity and acceleration components are used for subsequent weight reduction control.

[0135] PLC controllers utilize formulas Iteration is performed. The measurement noise covariance matrix is ​​adjusted. The system can balance "trusting the encoder" versus "trusting the accelerometer." For example, when the system detects severe vibration, it dynamically increases the noise covariance weight of the accelerometer, relying more on the encoder's differential data, thus outputting a smooth velocity. and acceleration .

[0136] Horizontal tracking and fall detection: Calculate the change in angle signal per unit time; if the change is within the slow change threshold set in step S1, the horizontal movement module of the control host is allowed to follow; if the change exceeds the sudden change threshold, a fall risk is determined, the module motor is immediately locked, and an alarm is triggered via the audible and visual warning module; the specific process includes:

[0137] The controller calculates the rate of change of the filtered angle. :

[0138] like The system is judged to be stationary, and the host does not move.

[0139] like Furthermore, the rate of change is stable, indicating a walking intention, and it is determined that the speed of the horizontal drive mechanism can be controlled to keep the sling vertical.

[0140] like or rate of change exceeding If a fall or loss of balance is detected, a Level 2 emergency stop is immediately triggered, locking the vertical motor to prevent the patient from collapsing and issuing an alarm.

[0141] Vertical weight reduction control: Based on filtered motion state data, and combined with an impedance control model, a compensation torque is calculated to control the module motor to output dynamic torque, counteracting system inertia and maintaining a constant weight reduction force applied to the user; the specific process includes:

[0142] To ensure that patients do not feel the mechanical inertia and friction during training, the controller uses an impedance model to calculate the output torque of module motor 1. .

[0143] The controller has a pre-set ideal target impedance model:

[0144]

[0145] in, Human-computer interaction force (preset weight reduction force, such as reducing the patient's weight by 20%). The virtual mass is set to a small value (e.g., 1kg) to compensate for the original large inertia of the motor rotor through the algorithm, making the system lighter during rapid start-up and shutdown. The virtual damping is set to a moderate value to provide slight motion resistance and prevent system overshoot oscillation. For virtual stiffness, The filtered acceleration, velocity, and position;

[0146] Torque composition:

[0147]

[0148] in, The Coulomb friction compensation value is obtained by looking up a table based on the current velocity direction.

[0149] Effects of use: When the patient attempts to squat (downward acceleration) When the resistance increases, the compensation torque calculated by the impedance algorithm will cause the module motor 1 to quickly release the rope, so the patient will not feel "pulled" by the rope; when the patient stands up, the motor quickly retracts the rope to maintain a constant support force.

[0150] The PLC controller calculates the compensation torque that the module motor needs to output based on the above model, so that the equipment exhibits compliant characteristics with low inertia and low damping in the vertical direction.

[0151] S5. Closed-loop loop and data recording: Continuously execute steps S2 to S4 in a loop, and record... Fault codes are written to the data storage device in real time until the device is shut down.

[0152] The above description is merely a further explanation of the present invention in conjunction with specific embodiments. All descriptions made do not imply any limitation on the scope of protection of the present invention. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A collision prevention and angle safety monitoring and control device for a transfer system, comprising a limiting base installed at the bottom of the main unit, characterized in that: The bottom of the limiting base is equipped with an anti-collision detection module, and an angle monitoring module is installed on one side of the limiting base. A motor driver is installed on the limiting base, and the motor driver is connected to a modular motor. The modular motor is connected to a drum, and a sling is wound around the drum. The free end of the sling passes through the anti-collision detection module. A detection shaft is provided inside the limiting base, and a gap is provided in the middle of the detection shaft. The sling passes through the gap in the detection shaft. The angle monitoring module is connected to the detection shaft, and the angle monitoring module, the anti-collision detection module, and the motor driver are all electrically connected to a PLC controller. The module motor is electrically connected to a braking resistor; the PLC controller is connected to a data storage device.

2. The anti-collision and angle safety monitoring and control device for the transfer system according to claim 1, characterized in that: The two ends of the detection shaft are rotatably connected to the limiting base via bearings, and the angle monitoring module is equipped with an angle sensor that is coaxial with the detection shaft.

3. The anti-collision and angle safety monitoring and control device for the transfer system according to claim 1, characterized in that: The anti-collision detection module includes a micro switch sensor, and the end of the sling is provided with a sling limiter that cooperates with the micro switch sensor.

4. The anti-collision and angle safety monitoring and control device for the transfer system according to claim 1, characterized in that; An audible and visual warning module is installed on the lower side of the host's casing, and the audible and visual warning module is electrically connected to the PLC controller; an alarm light is installed on the audible and visual warning module.

5. A method for collision avoidance and angle safety monitoring and control of a transfer system, characterized in that, Includes the following steps: S1. System Initialization and Parameter Configuration: Turn on the power, and the PLC controller performs initialization self-tests on each hardware module, reading and setting system operating parameters; these parameters include: slow angle change threshold, sudden angle change threshold, and upper limit value of electronic limit height. and lower limit value The initial state vector and covariance matrix of the Kalman filter; S2. Multi-dimensional Real-time Signal Acquisition: Once the system enters operation, it acquires the following signals in real-time through multiple sensors and transmits them to the PLC controller: Attitude signal: The tilt angle of the sling relative to the vertical is acquired through the angle monitoring module. ; Spatial position signal: The physical distance between the sling limiter and the limit base is collected through the anti-collision monitoring module. The vertical height of the sling is collected by the absolute encoder of the module motor. ; Dynamics and kinematic signals: Acquiring motor output torque Running speed and running acceleration ; S3. Safety Boundary Logic Determination: The PLC controller performs safety logic analysis on the signals acquired in step S2, specifically including: Physical collision avoidance judgment: If the distance D is less than the preset safe distance, or the micro-switch sensor of the collision avoidance monitoring module is triggered, the first-level emergency stop command is immediately executed and the audible and visual warning module is triggered. Electronic limit judgment: Determines real-time vertical height Is it in If the motor exceeds the specified range, the module motor is prohibited from outputting torque in the over-limit direction; it is only allowed to run in the reverse direction, and a limit switch warning will be triggered. S4. Multi-information filtering and coordinated control: When both physical anti-collision judgment and electronic limit judgment in step S3 are effective, the PLC controller processes the signals collected in step S2 using an algorithm and outputs control commands, specifically including: Signal filtering and fusion: The position, velocity, acceleration and torque signals collected in step S2 are fused using the Kalman filter algorithm to remove high-frequency noise and mechanical vibration interference, and to calculate the optimal motion state estimate. Horizontal following and fall detection: Calculate the change in angle signal per unit time; if the change is within the slow change threshold set in step S1, the horizontal movement module of the control host is allowed to follow the movement; if the change exceeds the sudden change threshold, it is determined to be a fall risk, the module motor is immediately locked and an alarm is triggered through the sound and light warning module. Vertical weight reduction control: Based on filtered motion state data, the compensation torque is calculated by combining the impedance control model, and the dynamic torque output of the control module motor is controlled to counteract system inertia and maintain a constant weight reduction force applied to the user; S5. Closed-loop cycle and data recording: Continuously execute steps S2 to S4, and write the original sensor data, filtered data, control commands and fault logs into the data storage device in real time until the device is shut down.

6. The anti-collision and angle safety monitoring and control method for a transfer system according to claim 5, characterized in that, Step S3, the electronic limit determination in the safety boundary logic determination, includes a soft landing mechanism, specifically: When vertical height Approaching the upper limit or lower limit value When the belt reaches the preset buffer zone, the PLC controller dynamically reduces the maximum allowable speed and acceleration of the module motor based on the difference between the belt and the limit value, so that the belt approaches the limit value in a decelerated state.

7. The anti-collision and angle safety monitoring and control method for a transfer system according to claim 5, characterized in that, The physical collision avoidance determination in step S3, the security boundary logic determination, has the highest priority hardware interrupt privilege, specifically including: The collision avoidance monitoring module includes two micro-switch sensors. Regardless of the control mode of the system, as long as either sensor is triggered, the system will immediately cut off the torque output of the module motor through a hardware interrupt and lock the brake.

8. The anti-collision and angle safety monitoring and control method for a transfer system according to claim 7, characterized in that: The specific process of signal filtering fusion in step S4, multi-information filtering and coordinated control, includes: Model definition: Define the system in discrete time state vector : in, These represent the vertical position, vertical velocity, and vertical acceleration of the sling, respectively. The state observation equation of the system is defined as follows: in, Here, H represents the sensor observations, and H is the observation matrix. To observe noise; State prediction: The PLC controller, based on the previous moment... posterior estimate Predict the current moment Prior estimate : Simultaneously predict the error covariance matrix : in, Here is the state transition matrix. To control the input matrix, To control the input amount, The process noise covariance matrix; Gain calculation and state correction: Calculate Kalman gain : Using the actual observations of the current sensor The prior estimate is corrected to obtain the optimal posterior state estimate at the current time. : in, To measure the noise covariance matrix; Covariance update and output: Update the error covariance matrix: Final output The velocity and acceleration components are used for subsequent weight reduction control.

9. The anti-collision and angle safety monitoring and control method for a transfer system according to claim 8, characterized in that: The vertical weight reduction control in step S4, multi-information filtering and coordinated control, adopts an impedance-based control strategy. The specific process includes: The controller has a pre-set ideal target impedance model: in, Human-computer interaction power These are virtual mass, virtual damping, and virtual stiffness, respectively. The filtered acceleration, velocity, and position; The PLC controller calculates the compensation torque that the module motor needs to output based on the above model, so that the equipment exhibits compliant characteristics with low inertia and low damping in the vertical direction.

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