An excavator safety monitoring and control method and device

Abstract

The present invention discloses an excavator safety monitoring and control method and device, which relates to the technical field of excavator safety monitoring, and includes a remote monitoring server, a real-time monitoring module, a safety analysis module, and a human-machine interaction module; the existing excavator safety monitoring and control methods are mainly used to ensure the safety and stability of the excavator during operation, including using sensors and monitoring systems to monitor various parameters of the excavator in real time. However, the defects of the existing technology lie in problems such as insufficient monitoring accuracy, untimely data processing, and lack of intelligent analysis; by analyzing the safety monitoring data and equipment status data through this excavator safety monitoring and control method, the defects of the existing technology are solved; this method improves the safety of excavator operation and the reliability of the equipment, effectively reduces the risk of failures and accidents, ensures the safety of operators, and provides a strong guarantee for the smooth implementation of engineering projects.

Description

Technical Field

[0001] The present invention relates to the technical field of excavator safety monitoring, and specifically provides an excavator safety monitoring and control method and device. Background Art

[0002] Existing excavator safety monitoring and control methods are mainly used to ensure the safe and stable operation of excavators during operation, including using sensors and monitoring systems to monitor various parameters of excavators in real time, such as hydraulic pressure, working temperature, working angle, and vibration, etc.

[0003] However, the defects of the existing technology are insufficient monitoring accuracy, untimely data processing, lack of intelligent analysis, low work efficiency, low operation safety, potential safety hazards caused by anti-fatigue operation, and inability to ensure the long-term stable operation of the equipment, etc. Summary of the Invention

[0004] The purpose of the present invention is to propose an excavator safety monitoring and control method and device in order to solve the problems of insufficient monitoring accuracy, untimely data processing, lack of intelligent analysis, low work efficiency, low operation safety, potential safety hazards caused by anti-fatigue operation, and inability to ensure the long-term stable operation of the equipment.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] In the first aspect, the present invention provides an excavator safety monitoring and control method, including: S1: Collecting excavator safety monitoring and control data through a collection sensor; installing the sensor at key parts of the excavator to monitor its working state; and sending the collected excavator safety monitoring and control data to a remote monitoring server for storage in a storage database.

[0007] S2: Analyzing the safety monitoring data and equipment status data, and the specific steps are as follows:

[0008] S21: Analyzing the safety monitoring data to obtain the safety value of the excavator;

[0009] S22: Analyzing the equipment status data, and collecting the load data of each working component through a sensor, and specifically:

[0010] S221: Analyzing the engine state to obtain the engine factory state value and the engine real-time state value;

[0011] S222: Analyze the status of the hydraulic system. By obtaining the hydraulic pressure, hydraulic flow rate, hydraulic oil temperature, and hydraulic oil quality, and through the number CGN of the hydraulic pressure sensor, label the corresponding hydraulic circuit as circuit CGN, label the pressure value collected by the hydraulic pressure sensor from circuit CGN as the CGN pressure value, compare the CGN pressure value with the preset corresponding CGN pressure range. If the CGN pressure value does not belong to the preset corresponding CGN pressure range, generate a CGN pressure anomaly signal; then monitor the hydraulic flow rate to generate a CGN flow anomaly signal; monitor the hydraulic oil temperature and hydraulic oil quality to generate a hydraulic oil temperature too high signal and a hydraulic oil temperature too low signal.

[0012] S3: Analyze the operator data. The operator data mainly includes the usage frequency of the joystick, the usage frequency of the control buttons, and the operation time data. Specifically:

[0013] S31: Analyze the usage frequency of the joystick and the usage frequency of the control buttons to obtain the total joystick value.

[0014] S32: Then, through the operation sensor, collect the usage times, frequencies, and operation times of each function button of the control button usage frequency, and analyze to obtain the control button value.

[0015] As a preferred embodiment of the present invention, analyze the safety monitoring data to obtain the excavator safety value. The specific process is as follows:

[0016] Collect the real-time position, body tilt angle, traveling speed, and acceleration of the excavator through the corresponding acquisition sensors; analyze the real-time position, body tilt angle, traveling speed, and traveling acceleration of the excavator; and through the formula Output the excavator safety value WAZ, where v W 、r W 、a W and ω W respectively represent the traveling speed, body tilt angle, acceleration, and rotational speed of the slewing platform; v W ’、r W ’、a W ’and ω W ’respectively represent the maximum threshold of the traveling speed, the maximum threshold of the body tilt angle, the maximum threshold of the acceleration, and the maximum threshold of the rotational speed of the slewing platform; β1, β2, β3, and β4 are preset weight factors. Match the excavator safety value WAZ with the preset excavator safety anomaly range. If the excavator safety value WAZ belongs to the preset excavator safety anomaly range, generate an excavator safety anomaly signal and execute the S22 command.

[0017] As a preferred embodiment of the present invention, analyzing the engine state to obtain the engine factory state value and the engine real-time state value, the specific process is as follows:

[0018] Collect the engine speed through a Hall effect sensor, and collect the oil pressure through an oil pressure sensor; collect the temperature through a thermocouple; and through the formula Output the engine factory state value FDJZ 初 , ω f 初 , P y 初 , c s 初 and c f 初 represent the engine factory speed, the engine factory oil pressure, the engine factory coolant temperature value, and the engine factory exhaust temperature value respectively; α1 and α2 are preset weight factors; then match the engine factory state value FDJZ 初 with the preset allowable difference interval, and then through the formula Output the engine real-time state value FDJZ 实 , ω f 实 , P y 实 , c s 实 and c f 实 represent the engine real-time speed, the engine real-time oil pressure, the engine real-time coolant temperature value, and the engine real-time exhaust temperature value respectively; α3 is the correction factor for the total usage duration of the engine; and when ω f 实 is equal to ω f 初 , the start duration is the same; subtract the absolute difference between FDJZ 初 and FDJZ 实 , match it with the preset allowable difference interval, if the absolute difference does not belong to the preset allowable difference interval, then generate an engine state abnormal signal; otherwise, execute S222.

[0019] As a preferred embodiment of the present invention, analyzing the usage frequency of the operating lever and the usage frequency of the control button to obtain the operating lever value, specifically:

[0020] Collect the usage times, frequencies, durations of each operation, and operation forces of each joystick by operating the sensors; mark the usage times, frequencies, durations of each operation, and operation forces of the first control arm as j1, k1, g1, and f1 respectively, then mark the usage times, frequencies, durations of each operation, and operation forces of the second control arm as j2, k2, g2, and f2 respectively; mark the usage times, frequencies, durations of each operation, and operation forces of the bucket as j d 、k d 、g d and f d , mark the usage times, frequencies, durations of each operation, and operation forces of the slewing as j h 、k h 、g h and f h , and then output the joystick value CKZ s through the formula CKZ s =j s ×ε1 + k s ×ε2 + g s ×ε3 + f s ×ε4, where ε1, ε2, ε3, and ε4 are all preset weight factors, and s = 1 or 2 or h or d; sum CKZ1, CKZ2, CKZ d and CKZ h to obtain the total joystick value CKZZ.

[0021] As a preferred embodiment of the present invention, the specific process of analyzing to obtain the control button value is as follows:

[0022] Mark the usage times, frequencies, and operation times of the start control button as κ q 、γ q and φ q ; mark the usage times, frequencies, and operation times of the stop control button as κ t 、γ t and φ t ; mark the usage times, frequencies, and operation times of the mode switch control button as κ h 、γ h and φ h ; and then output the control button value ANZ through the formula y , where ε5, ε6, and ε7 are all preset weight factors, and y = q or t or h; sum ANZ q 、ANZ t and ANZ hThe sum is calculated to obtain the total value ANZZ of the control buttons; then, the total value CKZZ of the joystick and the total value ANZZ of the control buttons are weighted to calculate the total operation value, and the total operation value is used as the operator judgment value. If the operation time of the operator corresponding to the operator judgment value reaches the corresponding operation time threshold, a device rest signal is generated.

[0023] In a second aspect, the present invention provides an excavator safety monitoring and control device, including a remote monitoring server, a real-time monitoring module, a safety analysis module, and a human-machine interaction module;

[0024] The real-time monitoring module collects excavator safety monitoring and control data through acquisition sensors, and the sensors are installed at key parts of the excavator to monitor its working state; the collected excavator safety monitoring and control data is sent to the remote monitoring server and stored in the storage database;

[0025] The safety analysis module analyzes the safety monitoring data and equipment status data, specifically:

[0026] Analyze the safety monitoring data. The real-time position, body tilt angle, traveling speed, and acceleration of the excavator are collected through the corresponding acquisition sensors; the excavator safety value is calculated, and then the excavator safety value WAZ is matched with the preset excavator safety abnormal range. If the excavator safety value WAZ belongs to the preset excavator safety abnormal range, an excavator safety abnormal signal is generated;

[0027] Analyze the equipment status data to generate an engine status abnormal signal; analyze the hydraulic system status to generate a CGN pressure abnormal signal, monitor the hydraulic flow to generate a CGN flow abnormal signal; monitor the hydraulic oil temperature and hydraulic oil quality to generate a hydraulic oil temperature too high signal and a hydraulic oil temperature too low signal;

[0028] Analyze the operator data to obtain the total value of the joystick and the total value of the control buttons; then, the total value of the joystick and the total value of the control buttons are weighted to calculate the total operation value, and the total operation value is used as the operator judgment value. If the operation time of the operator corresponding to the operator judgment value reaches the corresponding operation time threshold, a device rest signal is generated;

[0029] The human-machine interaction module is used for operation, display, alarm, and reminder on the operation page.

[0030] Compared with the prior art, the beneficial effects of the present invention are:

[0031] 1. The present invention comprehensively grasps the working state of the excavator by collecting and analyzing in real time the equipment state, safety monitoring, operator, and remote monitoring data. Specifically, the analysis steps of the safety monitoring data and the equipment state data are detailed. Through a variety of sensing devices such as the Beidou system, acceleration sensors, angular velocity sensors, and angle sensors, the real-time position, tilt angle, traveling speed, and acceleration of the excavator are monitored, and the safety value of the excavator is calculated. This method not only improves the safety of excavator operation but also effectively reduces the accident risk, ensures the safety of the operator and the equipment, and provides a strong guarantee for the smooth implementation of the engineering project.

[0032] 2. The present invention also comprehensively grasps the working state of the excavator by collecting and analyzing in real time the equipment state, safety monitoring, operator, and remote monitoring data of the excavator. Specifically, the load data of each working component is collected through sensors, and the states of the engine and the hydraulic system are analyzed in detail to ensure that the equipment operates in the best state. The state of the engine is monitored through devices such as Hall effect sensors, oil pressure sensors, and thermocouples, generating real-time state values of the engine and performing matching analysis, generating abnormal signals in a timely manner and giving alarm prompts. This method not only improves the safety of excavator operation and the reliability of the equipment but also effectively reduces the risk of faults and accidents, ensures the safety of the operator, and provides a strong guarantee for the smooth implementation of the engineering project.

[0033] 3. The present invention ensures the work efficiency and safety of the operator by comprehensively analyzing the operator data. By operating sensors to collect in detail the usage frequency, usage times, operation duration, and operation force of each joystick and control button, calculating the joystick value and the control button value respectively, then obtaining the total joystick value and the total control button value, and obtaining the total operation value through weighted calculation. The total operation value is used as an index to judge the state of the operator. When the operation time of the operator reaches the set threshold, the system generates an equipment rest signal, which not only improves the work efficiency and operation safety of the operator, effectively prevents potential safety hazards caused by fatigue operation, but also guarantees the long-term stable operation of the equipment, and provides a solid guarantee for the smooth implementation of the engineering project. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] For the convenience of those skilled in the art to understand, the present invention will be further described below in conjunction with the drawings.

[0035] Figure 1 is the method flow chart of the present invention;

[0036] Figure 2 is the principle block diagram of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0037] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0038] It should be understood that the terms "comprising" and "including" used in the specification and claims of this disclosure indicate the presence of the described features, wholes, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components, and / or their combinations.

[0039] It should also be understood that the terms used in this disclosure specification are only for the purpose of describing specific embodiments and are not intended to limit this disclosure. As used in this disclosure specification and claims, unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" are intended to include the plural forms. It should be further understood that the term "and / or" used in this disclosure specification and claims refers to any combination and all possible combinations of one or more of the associated listed items, and includes these combinations.

[0040] Please refer to Figure 1 As shown, on the one hand, a method for excavator safety monitoring and control is provided. The specific embodiments include:

[0041] S1: Collect excavator safety monitoring and control data through acquisition sensors, and install the sensors at key parts of the excavator (such as the boom, bucket, slewing platform, etc.) to monitor its working state; and number several acquisition sensors, with the number being CGN, and N = 0, 1, 2, 3,..., m; the excavator safety monitoring and control data includes but is not limited to equipment status data, safety monitoring data, operator data, and remote monitoring data; and send the collected excavator safety monitoring and control data to a remote monitoring server and store it in a storage database.

[0042] S2: Analyze the safety monitoring data and equipment status data. The specific steps are as follows:

[0043] S21: Analyze the safety monitoring data, and collect the real-time position, body tilt angle, traveling speed, and acceleration of the excavator through the corresponding acquisition sensors; analyze the real-time position, body tilt angle, traveling speed, and traveling acceleration of the excavator; the real-time position is collected by Beidou, the traveling acceleration is collected by an acceleration sensor (such as an accelerometer), and the rotation speed of the slewing platform and the rotation speeds of the boom and bucket are collected by an angular velocity sensor (such as a mechanical gyroscope, MEMS gyroscope, etc.); the body tilt angle is collected by an angle sensor (such as a rotary encoder, gyroscope, etc.); the traveling speed is obtained from the change in the real-time position over time; and through the formula Output the excavator safety value WAZ, where v W 、r W 、a W and ω W respectively represent the traveling speed, body tilt angle, acceleration, and rotation speed of the slewing platform; v W ’、r W ’、a W ’and ω W ’respectively represent the maximum threshold of the traveling speed, the maximum threshold of the body tilt angle, the maximum threshold of the acceleration, and the maximum threshold of the rotation speed of the slewing platform; β1, β2, β3, and β4 are preset weight factors, and the sum of β1, β2, β3, and β4 is 1 (such as β1 is 0.3, β2 is 0.2, β3 is 0.4, β4 is 0.1), and are set by personnel in the relevant technical field; then match the excavator safety value WAZ with the preset excavator safety abnormal interval. If the excavator safety value WAZ belongs to the preset excavator safety abnormal interval, generate an excavator safety abnormal signal and execute the S22 command; receive the safety abnormal signal through the alarm system program and give an alarm. If the operator does not manually turn off the alarm within a certain period of time, connect to the operator through the remote monitoring server;

[0044] S22: Analyze the equipment status data, and collect the load data of each working component through sensors; the load data includes, but is not limited to, engine speed, oil pressure, temperature, and the pressure and flow of the hydraulic system;

[0045] S221: Analyze the engine status. The engine speed is collected by a Hall effect sensor (which calculates the speed by monitoring the pulse signal generated by the magnet on the rotating part, and the sensor is installed on the engine flywheel or gear to ensure that a pulse signal is generated every rotation). The oil pressure is collected by an oil pressure sensor (which measures the oil pressure by using piezoelectric or strain gauge technology, installs the sensor at an appropriate position in the engine oil circuit system, and uses an analog-to-digital converter (ADC) to read the voltage signal output by the sensor and then converts the voltage signal into a pressure value). The temperature is collected by a thermocouple (commonly used for monitoring the engine exhaust and coolant temperatures, installs the thermocouple probe at the part where the temperature needs to be measured, such as in the engine exhaust pipe or coolant system, and uses a thermocouple amplifier (such as MAX31855) and a microcontroller to read the thermocouple output signal and then converts the sensor output voltage into a temperature value). And through the formula Output the engine factory status value FDJZ 初 , ω f 初 , P y 初 , c s 初 and c f 初 respectively represent the engine factory speed, the engine factory oil pressure, the engine factory coolant temperature value, and the engine factory exhaust temperature value; α1 and α2 are preset weight factors; then match the engine factory status value FDJZ 初 with the preset allowable difference interval; and then through the formula Output the engine real-time status value FDJZ 实 , ω f 实 , P y 实 , c s 实 and c f 实 respectively represent the engine real-time speed, the engine real-time oil pressure, the engine real-time coolant temperature value, and the engine real-time exhaust temperature value; α3 is the correction factor for the total engine usage duration; and when ω f 实 is equal to ω f 初 , the startup durations are the same; take the absolute difference between FDJZ 初 and FDJZ 实 , match it with the allowable difference interval. If the absolute difference does not belong to the allowable difference interval, generate an engine status abnormal signal; otherwise, execute S222; receive the engine status abnormal signal through the alarm system program, give an engine status abnormal reminder, and display it on the operation page;

[0046] S222: Analyze the state of the hydraulic system. First, obtain the hydraulic pressure, hydraulic flow rate, hydraulic oil temperature, and hydraulic oil quality. Install hydraulic pressure sensors in the pressure of each hydraulic circuit, including the working circuit, return oil circuit, and pilot circuit, etc. Then, through the serial number CGN of the hydraulic pressure sensor, mark the corresponding hydraulic circuit as circuit CGN, mark the pressure value collected by the hydraulic pressure sensor of circuit CGN as the CGN pressure value, compare the CGN pressure value with the preset corresponding CGN pressure range. If the CGN pressure value does not belong to the preset corresponding CGN pressure range, generate a CGN pressure abnormal signal. Receive the CGN pressure abnormal signal through the alarm system program and display the position of the hydraulic pressure sensor CGN corresponding to the hydraulic system installed in each hydraulic circuit on the operation page.

[0047] Then, monitor the hydraulic flow rate. Similarly, install hydraulic flow sensors in the flow rate of each hydraulic circuit, including the output flow rate of the hydraulic pump and the flow rate of the hydraulic cylinder. Then, through the serial number CGN of the hydraulic flow sensor, mark the corresponding hydraulic flow rate as the output flow rate CGN of the hydraulic pump and the flow rate CGN of the hydraulic cylinder, and mark the flow rate values collected by the hydraulic flow sensor of the output flow rate CGN of the hydraulic pump and the flow rate CGN of the hydraulic cylinder as the CGN output flow rate value and the CGN cylinder flow rate value respectively. Compare the CGN output flow rate value with the corresponding CGN cylinder flow rate value. If the CGN output flow rate value and the corresponding CGN cylinder flow rate value are inconsistent, generate a CGN flow abnormal signal. Receive the CGN flow abnormal signal through the alarm system program and display the position of the hydraulic flow sensor CGN corresponding to the hydraulic system installed in each hydraulic circuit on the operation page.

[0048] Then, monitor the hydraulic oil temperature and hydraulic oil quality. Collect the hydraulic oil temperature with a thermocouple. Based on the serial number CGN of the hydraulic pressure sensor and the pressure of the hydraulic pressure sensor installed in each hydraulic circuit, including the working circuit, return oil circuit, and pilot circuit, etc., mark the temperature value of each hydraulic circuit as the CGN temperature value, match the CGN temperature value with the preset corresponding CGN temperature range. If the CGN temperature value does not belong to the CGN temperature range and the CGN temperature value is less than the minimum value within the CGN temperature range, generate a signal that the hydraulic oil temperature is too low. If the CGN temperature value does not belong to the CGN temperature range and the CGN temperature value is greater than the maximum value within the CGN temperature range, generate a signal that the hydraulic oil temperature is too high. Receive the signal that the hydraulic oil temperature is too low through the alarm system program, give a reminder on the operation page, and display that the hydraulic oil temperature is too low. When the alarm system program receives the signal that the hydraulic oil temperature is too high, give a reminder to the operator on the operation page and display that the hydraulic oil temperature is too high.

[0049] S3: Analyze the operator data, which mainly includes the usage frequency of the joystick, the usage frequency of the control buttons, and the operation time data;

[0050] S31: Analyze the usage frequency of the joystick and the usage frequency of the control buttons. Collect the usage times, frequencies, the duration of each operation, and the operation force of each joystick (such as the control arm, bucket, slewing, etc.) through the operation sensor; mark the usage times, frequencies, the duration of each operation, and the operation force of the first control arm as j1, k1, g1, and f1 respectively, then mark the usage times, frequencies, the duration of each operation, and the operation force of the second control arm as j2, k2, g2, and f2 respectively; mark the usage times, frequencies, the duration of each operation, and the operation force of the bucket as j d , k d , g d , and f d , and mark the usage times, frequencies, the duration of each operation, and the operation force of the slewing as j h , k h , g h , and f h . Then output the joystick value CKZ s through the formula CKZ s = j s × ε1 + k s × ε2 + g s × ε3 + f s × ε4, where ε1, ε2, ε3, and ε4 are all preset weight factors, and s = 1 or 2 or h or d; sum up CKZ1, CKZ2, CKZ d , and CKZ h to obtain the total joystick value CKZZ;

[0051] S32: Then collect the usage times, frequencies, and the number of operations of each function button (such as start, stop, mode switch, etc.) of the control button usage frequency through the operation sensor; mark the usage times, frequencies, and the number of operations of the start control button as κ q , γ q , and φ q ; mark the usage times, frequencies, and the number of operations of the stop control button as κ t , γ t , and φ t ; mark the usage times, frequencies, and the number of operations of the mode switch control button as κ h , γ h , and φ h . Then output the control button value ANZ through the formula y , where ε5, ε6, and ε7 are all preset weight factors, and y = q or t or h; for ANZq and ANZ t and ANZ h Sum them up to get the total value of the control buttons ANZZ; then perform a weighted calculation on the total value of the joystick CKZZ and the total value of the control buttons ANZZ to obtain the total operation value, and use the total operation value as the operator's judgment value. If the operation time of the operator corresponding to the operator's judgment value reaches the corresponding operation time threshold, a device rest signal is generated. The device rest signal is received through the alarm system program, and a reminder is given on the operation page, and it is displayed that the operator needs to rest. If the corresponding operator does not execute, an alarm is given, and the operation of the device is controlled to stop. The sizes of the preset weight factors involved above are all custom settings and are pre-stored in the storage database.

[0052] Please refer to Figure 2 As shown in the figure, on the other hand, a safety monitoring and control device for an excavator is provided, including a remote monitoring server, a real-time monitoring module, a safety analysis module, and a human-machine interaction module;

[0053] The real-time monitoring module collects the safety monitoring and control data of the excavator through the acquisition sensors, and installs the sensors at the key parts of the excavator (such as the boom, bucket, slewing platform, etc.) to monitor its working state; the safety monitoring and control data of the excavator includes but is not limited to equipment status data, safety monitoring data, operator data, and remote monitoring data; and the collected safety monitoring and control data of the excavator is sent into the remote monitoring server and stored by the storage database.

[0054] The safety analysis module analyzes the safety monitoring data and equipment status data. Specifically:

[0055] Analyze the safety monitoring data, and collect the real-time position, body tilt angle, traveling speed, and acceleration of the excavator through the corresponding acquisition sensors; and calculate the excavator safety value, and then match the excavator safety value WAZ with the preset excavator safety abnormal range. If the excavator safety value WAZ belongs to the preset excavator safety abnormal range, an excavator safety abnormal signal is generated.

[0056] Analyze the device status data, and collect the load data of each working component through sensors; the load data includes but is not limited to engine speed, oil pressure, temperature, and the pressure and flow rate of the hydraulic system; analyze the engine status to obtain the engine factory status value and the engine real-time status value; when the engine speed is the same and the startup duration is consistent, subtract the absolute difference between the engine factory status value and the engine real-time status value from the allowable difference range. If the absolute difference does not belong to the allowable difference range, generate an engine status abnormal signal; analyze the hydraulic system status to generate a CGN pressure abnormal signal, and monitor the hydraulic flow rate to generate a CGN flow abnormal signal; monitor the hydraulic oil temperature and the quality of the hydraulic oil to generate a hydraulic oil temperature too high signal and a hydraulic oil temperature too low signal;

[0057] Analyze the operator data, and obtain the total value of the joystick and the total value of the control buttons by analyzing the usage frequency of the joystick and the usage frequency of the control buttons; then calculate the total operation value by weighting the total value of the joystick and the total value of the control buttons, and use the total operation value as the operator judgment value. If the operation time of the operator corresponding to the operator judgment value reaches the corresponding operation time threshold, generate a device rest signal;

[0058] The human-machine interaction module is used for operations, displays, alarms, and reminders on the operation page.

[0059] The above-described preferred embodiments of the present invention disclosed are only used to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to only the specific implementation manners. Obviously, many modifications and changes can be made according to the content of this specification. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the present invention, so that those skilled in the art in the relevant technical field can well understand and utilize the present invention. The present invention is only limited by the claims and their full scope and equivalents.

Claims

1. A safety monitoring and control method for an excavator, characterized in that, Including: S1: Collect the safety monitoring and control data of the excavator, including safety monitoring data and equipment status data, and send them to the remote monitoring server for storage in the storage database; S2: Analyze the safety monitoring data and equipment status data. The specific steps are as follows: S21: Analyze the safety monitoring data to obtain the excavator safety value; S22: Analyze the equipment status data. Collect the load data of each working component through sensors. Specifically: S221: Analyze the engine status to obtain the engine factory status value and the engine real-time status value; S222: Analyze the hydraulic system status. Obtain the hydraulic pressure, hydraulic flow, hydraulic oil temperature, and hydraulic oil quality. Then, through the serial number CGN of the hydraulic pressure sensor, mark the corresponding hydraulic circuit as circuit CGN, mark the pressure value collected by the hydraulic pressure sensor for circuit CGN as the CGN pressure value, compare the CGN pressure value with the preset corresponding CGN pressure range. If the CGN pressure value does not belong to the preset corresponding CGN pressure range, generate a CGN pressure anomaly signal; then monitor the hydraulic flow to generate a CGN flow anomaly signal; monitor the hydraulic oil temperature and hydraulic oil quality to generate a hydraulic oil temperature too high signal and a hydraulic oil temperature too low signal; S3: Analyze the operator data. The operator data mainly includes the operating lever usage frequency, control button usage frequency, and working time data. Specifically: S31: Analyze the operating lever usage frequency and control button usage frequency to obtain the total operating lever value; S32: Then, collect the usage times, frequencies, and operating times of each function button of the control button usage frequency through the operation sensor, and analyze to obtain the control button value.

2. The safety monitoring and control method for an excavator according to claim 1, characterized in that Analyze the safety monitoring data to obtain the excavator safety value. The specific process is as follows: Collect the real-time position, body tilt angle, traveling speed, and acceleration of the excavator through corresponding acquisition sensors; analyze the real-time position, body tilt angle, traveling speed, and traveling acceleration of the excavator; and through the formula Output the excavator safety value WAZ, where v W , r W , a W and ω W represent the traveling speed, body tilt angle, acceleration, and rotational speed of the slewing platform respectively; v W ’, r W ’, a W ’and ω W ’represent the maximum thresholds of the traveling speed, body tilt angle, acceleration, and rotational speed of the slewing platform respectively; β1, β2, β3, and β4 are preset weight factors. Match the excavator safety value WAZ with the preset excavator safety abnormal interval. If the excavator safety value WAZ belongs to the preset excavator safety abnormal interval, then generate an excavator safety abnormal signal and execute the S22 command.

3. A safety monitoring and control method for an excavator according to claim 1, characterized in that, Analyze the engine status to obtain the engine factory status value and the engine real-time status value. The specific process is as follows: The engine speed is collected by a Hall effect sensor, and the oil pressure is collected by an oil pressure sensor; the temperature is collected by a thermocouple; and through the formula Output the engine factory state value FDJZ 初 , ω f 初 , P y 初 , c s 初 and c f 初 respectively represent the engine factory speed, the engine factory oil pressure, the engine factory coolant temperature value and the engine factory exhaust temperature value; α1 and α2 are preset weight factors; then match the engine factory state value FDJZ 初 with the preset allowable difference interval, and then through the formula Output the engine real-time state value FDJZ 实 , ω f 实 , P y 实 , c s 实 and c f 实 respectively represent the engine real-time speed, the engine real-time oil pressure, the engine real-time coolant temperature value and the engine real-time exhaust temperature value; α3 is the correction factor for the total engine usage duration; And set ω f 实 equal to ω f 初 When they are equal, the startup durations are the same; Subtract FDJZ 初 from FDJZ 实 to obtain the absolute difference, and match it with the preset allowable difference range. If the absolute difference does not belong to the preset allowable difference range, an abnormal engine state signal is generated; Otherwise, S222 is executed.

4. A safety monitoring and control method for an excavator according to claim 1, characterized in that, Analyze the operating lever usage frequency and control button usage frequency to obtain the operating lever value. Specifically: Collect the usage times, frequencies, durations of each operation, and operation forces of each joystick by operating the sensors; mark the usage times, frequencies, durations of each operation, and operation forces of the first control arm as j1, k1, g1, and f1 respectively, then mark the usage times, frequencies, durations of each operation, and operation forces of the second control arm as j2, k2, g2, and f2 respectively; mark the usage times, frequencies, durations of each operation, and operation forces of the bucket as j d 、k d 、g d and f d , mark the usage times, frequencies, durations of each operation, and operation forces of the slewing as j h 、k h 、g h and f h , and then output the joystick value CKZ s through the formula CKZ s =j s ×ε1 + k s ×ε2 + g s ×ε3 + f s ×ε4, where ε1, ε2, ε3, and ε4 are all preset weight factors, and s = 1 or 2 or h or d; sum up CKZ1, CKZ2, CKZ d and CKZ h to obtain the total joystick value CKZZ.

5. A safety monitoring and control method for an excavator according to claim 1, characterized in that The specific process of analyzing to obtain the control button value is: Mark the number of uses and frequency of the start control button and the number of operations as κ q , γ q and φ q ; Mark the number of uses and frequency of the stop control button and the number of operations as κ t , γ t and φ t ; Mark the number of uses and frequency of the mode switching control button and the number of operations as κ h , γ h and φ h ; Then, through the formula Output the control button value ANZ y , where ε5, ε6, and ε7 are all preset weight factors, and y = q or t or h; Take ANZ q , ANZ t and ANZ h Sum them up to get the total control button value ANZZ; Then, perform a weighted calculation on the total joystick value CKZZ and the total control button value ANZZ to obtain the total operation value, and use the total operation value as the operator judgment value. If the operation time of the operator corresponding to the operator judgment value reaches the corresponding operation time threshold, a device rest signal is generated.

6. An excavator safety monitoring and control device, characterized in that: Applied to implement an excavator safety monitoring and control method according to any one of claims 1-5, including a remote monitoring server, a real-time monitoring module, a safety analysis module, and a human-computer interaction module; The real-time monitoring module collects the excavator safety monitoring and control data through the acquisition sensor, and monitors its working status by installing the sensor at the key parts of the excavator; send the collected excavator safety monitoring and control data to the remote monitoring server for storage in the storage database; The safety analysis module analyzes the safety monitoring data and equipment status data. Specifically: Analyze the safety monitoring data. Collect the real-time position, body tilt angle, walking speed, and acceleration of the excavator through the corresponding acquisition sensor; calculate to obtain the excavator safety value, and then match the excavator safety value WAZ with the preset excavator safety abnormal range. If the excavator safety value WAZ belongs to the preset excavator safety abnormal range, generate an excavator safety abnormal signal; Analyze the device status data to generate an abnormal engine status signal; analyze the hydraulic system status to generate a CGN pressure abnormal signal, and monitor the hydraulic flow rate to generate a CGN flow rate abnormal signal; Monitor the hydraulic oil temperature and hydraulic oil quality to generate a signal of too high hydraulic oil temperature and a signal of too low hydraulic oil temperature; Analyze the operator data to obtain the total value of the joystick and the total value of the control buttons; then calculate the weighted value by weighting the total value of the joystick and the total value of the control buttons to obtain the total operation value, and use the total operation value as the operator judgment value. If the operation time of the operator corresponding to the operator judgment value reaches the corresponding operation time threshold, generate a device rest signal; The human-machine interaction module is used for operation, display, alarm and reminder on the operation page.

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