Cargo carrying anti-falling control system and control method

Abstract

The invention belongs to the technical field of carrying machinery, and particularly relates to a carried goods anti-falling control system and method, the system is integrated on a fork structure, and the system comprises a position detection unit, a weighing unit and a balance detection unit; the central controller is connected with the position detection unit, the weighing unit and the balance detection unit and executes the steps that (a) whether the goods are located in a safe area or not is judged based on data of the position detection unit; (b) determining whether the weight exceeds a dynamic load threshold based on the data of the weighing unit; (c) determining whether the offset exceeds a dynamic balance threshold based on the data of the balance detection unit; only when (a), (b) and (c) are met at the same time, a carrying permission instruction is output, otherwise, a locking instruction is output; the alarm responds to the locking instruction to trigger sound-light alarm; the executing mechanism responds to the locking instruction and executes hierarchical locking operation; through multi-dimensional dynamic monitoring, self-adaptive threshold value control and graded safety protection, accurate early warning and reliable control of the anti-falling risk in the cargo carrying process are achieved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of handling machinery, and particularly relates to a carrying goods anti-falling control system and a control method. BACKGROUND

[0002] With the upgrading of China's manufacturing industry and the rapid development of intelligent logistics, the safety performance of forklifts and other handling equipment has become the core concern of the industry. According to the China Warehouse Logistics Safety White Paper (2024), cargo slip and overturn accidents account for 68% of total handling accidents, with an annual direct economic loss of over 2.3 billion yuan. The existing anti-falling technology has obvious limitations: For example, Chinese patent CN117585611A discloses a forklift anti-falling fork arm control system and its control method, which solves the problem of fork arm adjustment under side slope working conditions, but lacks a systematic solution to key safety elements such as cargo position detection, weight monitoring, and dynamic balance.

[0003] For example, Chinese patent CN118666215A discloses a cargo anti-falling method, anti-falling device, and program product, which reduces the risk of cargo falling when an AGV forklift takes and places cargo to some extent, but relies excessively on a single monitoring dimension of visual marker positioning, lacks real-time sensing capability for cargo weight changes and balance state, and is difficult to adapt to dynamic and variable logistics operating environments, resulting in limitations in protection effect. SUMMARY

[0004] In view of the above, to overcome the defects of the prior art, the present application provides a carrying goods anti-falling control system and its control method, which realizes precise early warning and reliable control of anti-falling risk in the process of carrying goods through multi-dimensional dynamic monitoring, adaptive threshold control, and hierarchical safety protection.

[0005] To solve the above technical problems, the present application provides the following technical solutions: A control system for preventing cargo from falling during transport is integrated into a fork structure and comprises: a position detection unit configured to detect whether the front and rear boundaries of the cargo exceed a safety zone; a weighing unit configured to detect the weight of the cargo in real time; a balance detection unit configured to detect the left and right offset of the cargo center of gravity; a central controller connected to the position detection unit, the weighing unit and the balance detection unit, and executing: (a) determining whether the cargo is within the safety zone based on data from the position detection unit, wherein the boundary of the safety zone is dynamically calculated according to the length and lifting height of the forks; (b) determining whether the weight exceeds a dynamic load threshold based on data from the weighing unit, wherein the dynamic load threshold decreases as the height of the forks increases; (c) determining whether the offset exceeds a dynamic balance threshold based on data from the balance detection unit, wherein the dynamic balance threshold is related to the real-time weight and height; an instruction to allow transport is output only when (a), (b) and (c) are simultaneously satisfied, otherwise a locking instruction is output; an alarm triggering an audible and visual alarm in response to the locking instruction; and an actuator responding to the locking instruction and executing a graded locking operation.

[0006] The following is a further optimization of the above technical solution by the present invention: The safety area boundary is defined by the front safety line L min and rear safety line L max Define and satisfy: L min =k1×L+Ch,L max =k2×L-Ch, Where: L is the physical length of the fork, k1 is the front safety factor and 0.15≤k1≤0.25, k2 is the posterior safety factor and 0.70≤k2≤0.80, Ch is the height compensation amount and Ch={0, h≤1m; 0.05×(h-1)×L, h>1m}.

[0007] Further optimization: The dynamic load threshold satisfies: W max (h)=W base ×[1-0.01×max(0,h-1)], where: W base It is the rated load when the fork is at the lowest height.

[0008] Further optimization: The dynamic balance threshold satisfies: θ max (W,h)=5°×(1+W / (2×W max (h)))+0.2°×max(0,h-3).

[0009] Further optimization: The central controller is configured to shorten the judgment period to ≤5ms when it is detected that the rate of change of the center of gravity offset exceeds 5° / s.

[0010] Further optimization: The graded locking operation includes: first-level locking: cutting off the power source of the lifting mechanism within ≤50ms; second-level locking: cutting off the power source of the driving mechanism within ≤100ms; third-level locking: triggering mechanical braking within ≤300ms.

[0011] Further optimization: The actuator also includes a status monitoring module, which is configured to: verify whether each level of locking reaches the target state within the target time of the corresponding level; if any level of locking fails to reach the target state, it automatically triggers a higher level locking or retry operation.

[0012] Further optimization: It also includes a wireless communication module, which is configured to: transmit cargo location, weight, balance status and alarm information to the remote terminal in real time; retransmit data at a frequency of ≥3 times / second in the alarm state until confirmation is received.

[0013] The present invention also discloses a control method for a control system for preventing cargo from falling. Based on a control system for preventing cargo from falling, the control method comprises the following steps: S1: Calculate the safety zone boundary based on the fork's physical length L and height h, and calculate the dynamic load threshold W based on the height h max (h), calculate the dynamic balance threshold θ based on the real-time cargo weight W and height h max (W,h); S2: Within a judgment period of ≤20ms, synchronously verify: (i) whether the cargo is located within the safe area; (ii) whether the cargo weight is ≤W max (h); (iii) Is the center of gravity offset ≤ θ? max (W, h); If the rate of change of the center of gravity offset is greater than 5° / s, the judgment period is switched to ≤5ms; S3: When any of the conditions (i), (ii), and (iii) is not met: the central controller outputs a locking instruction; the actuator triggers the locking operation in the order of level 1 → level 2 → level 3; S4: trigger the corresponding alarm mode based on the fault type that triggers the lock; S5: If any level of locking fails to reach the target state within the target time, a higher level of locking or retry operation is triggered.

[0014] The present invention adopts the above technical solution and has the following beneficial effects: The present invention builds a full-operation safety protection system through real-time monitoring of position, weight, and balance status and dynamic threshold calculation, combined with millisecond-level risk response and hierarchical locking mechanism, to significantly reduce the risk of cargo falling.

[0015] The present invention optimizes data accuracy through a fusion filtering algorithm and dynamically adjusts safety standards based on height and weight to ensure that the forklift maintains operational stability under different loads and lifting heights.

[0016] The application integrates real-time fault diagnosis, manual safety reset and historical data optimization functions, and realizes remote state monitoring through encrypted wireless communication, thereby improving equipment maintenance efficiency and management safety. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, a brief introduction will be given below to the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0018] Fig. 1 The system architecture diagram of the embodiment of the present application; Fig. 2 The system logic diagram of the embodiment of the present application. DETAILED DESCRIPTION

[0019] As Figs. 1-2 shown, a carrying goods anti-falling control system integrated in a fork part includes: a position detection unit configured to detect the front and rear boundaries of goods; a weighing unit configured to detect the weight of goods in real time; a balance detection unit configured to detect the left and right offset of the center of gravity of goods; a central controller connected to the position detection unit, the weighing unit and the balance detection unit, and performing: (a) determining whether the goods are in a safe area based on the data of the position detection unit, and the safe area boundary is dynamically calculated according to the fork length and lifting height; (b) determining whether the weight exceeds the dynamic load threshold based on the data of the weighing unit, and the dynamic load threshold decreases with the increase of the fork height; (c) determining whether the offset exceeds the dynamic balance threshold based on the data of the balance detection unit, and the dynamic balance threshold is related to the real-time weight and height; only when (a)(b)(c) are met at the same time, the carrying instruction is output, otherwise the locking instruction is output; an alarm triggered to sound and light alarm in response to the locking instruction; an actuator performing a hierarchical locking operation in response to the locking instruction.

[0020] The safe area is defined by a front safety line (L min ) and a rear safety line (L max ), wherein: L min= k1×L+Ch L max =k2×L-Ch Wherein: L: physical length of the fork (unit: mm).

[0021] k1: front safety coefficient, value range 0.15-0.25 (adjustable, need to be calibrated according to the load characteristics of the fork).

[0022] k2: rear safety factor, value range 0.70-0.80 (adjustable, needs to be calibrated according to the load characteristics of the fork).

[0023] Ch: height compensation factor (unit: mm), used to offset the amount of elastic deformation generated when the fork is lifted, calculated as follows: Ch is the height compensation amount and Ch={0, h≤1m; 0.05×(h-1)×L, h>1m} Where: h: current lifting height of the fork (unit: m).

[0024] Note: The coefficient 0.05 is determined based on finite element analysis and experimental verification.

[0025] The dynamic load threshold is W max (h), which is adjusted according to the fork height h, and the calculation formula is as follows: W max (h)=W base ×[1-0.01×max(0,h-1)] Where: W base : rated load of the fork at the lowest height (h=0m) (kg), determined by the structural strength of the fork (such as the maximum static load specified by the manufacturer).

[0026] W max (h): dynamic allowable load at the current height h (m) (kg), which decreases with increasing height to ensure the stability of the forklift.

[0027] max(0,h-1): take the larger value of 0 and (h-1).

[0028] Note: The dynamic load decrease rate 0.01 is set based on the stability model of the forklift and typical working condition experimental data, to ensure that the stability requirement is met as the height increases.

[0029] The dynamic balance threshold is the maximum threshold θ max (W,h) of the dynamic calculation of the offset angle allowed, and the calculation formula is as follows: θ max (W,h)=5°×(1+W / (2×W max (h)))+0.2°×max(0,h-3) Where: W: real-time detected weight of the goods (kg) (from the weighing unit).

[0030] W max (h): dynamic allowable load at the current height h (m) (kg).

[0031] max(0, h-3): take the larger value of 0 and (h-3).

[0032] Note: The term 0.2°*max(0, h-3) in the formula indicates that after the height exceeds 3 meters, the threshold of the allowed deviation angle increases by 0.2 degrees per meter of height increase.

[0033] The position detection unit includes a front limit sensor installed at the front end of the fork to detect the position of the front end of the cargo relative to the fork in real time, and a rear limit sensor installed at the rear end of the fork to detect the position of the rear end of the cargo relative to the fork in real time.

[0034] The front limit sensor is fixedly installed on the lower surface of the fork 100-150 mm away from the tip, with the detection direction parallel to the fork axis and inclined downward by a first inclination angle a, and the first inclination angle a satisfies 3°≤a≤5° (this angle design mainly avoids interference from ground reflected light).

[0035] The rear limit sensor is installed on the upper surface of the fork 50-80 mm away from the root, with the detection direction parallel to the fork axis and inclined upward by a second inclination angle b, and the second inclination angle b satisfies 5°≤b≤8° (this angle design mainly avoids the gantry structure blocking the sensor's field of view).

[0036] In this embodiment, the front limit sensor and the rear limit sensor can use reflective photoelectric sensors or laser distance measuring sensors (such as Omron E3Z-LS61 or SICK WTT1-L1). The sensors are commercially available products, and their installation methods and working principles (including diffuse reflection / direct detection principles, NPN / PNP output characteristics, etc.) are known to those skilled in the art, so they will not be described here.

[0037] The weighing unit includes a weighing sensor embedded in the fork to detect the weight W (unit: kg) of the cargo in real time. The weighing sensor performs an automatic zeroing operation when powered on and can be calibrated on site using standard weights.

[0038] In this embodiment, the weighing sensor can use a double-shear beam type weighing sensor or a micro pressure sensor (such as HBM Z6FD or Mettler-Toledo PW4AH). The sensors are commercially available products, and their installation methods (including pre-tightening force application methods, overload protection structures, etc.) and working principles (Wheatstone bridge principle, mV / V signal output characteristics, etc.) are known to those skilled in the art, so they will not be described here.

[0039] The balance detection unit includes an inclination sensor installed on the bottom plane of the fork to monitor the left-right deviation angle θ (unit: degrees) of the center of gravity of the cargo on the plane of the fork in real time.

[0040] In this embodiment, the tilt sensor can adopt a MEMS inertial measurement unit or an electrolyte type tilt sensor (such as SICK FDA280 or Bosch BMI160), both of which are commercially available products, and their installation methods (including horizontal calibration methods, shock-absorbing installation structures, etc.) and working principles (horizontal measurement principles based on accelerometers / electrolytes) are known to those skilled in the art, so they will not be described here.

[0041] The central controller, as the core of the system, is responsible for receiving and processing real-time data from various sensors, executing dynamic safety judgment logic, and outputting control instructions. Its key functions are as follows: Multi-source data fusion processing: Position data: Collecting cargo boundary information at a sampling rate of 100Hz, and applying median filtering algorithm to eliminate measurement noise, ensuring the accuracy of position detection.

[0042] Weight data: Using sliding window mean filtering technology to process weighing signals, effectively smoothing fluctuations, and ensuring the stability of the load detection results.

[0043] Tilt angle data: Based on Kalman filter to fuse the raw data of accelerometer and gyroscope, real-time and accurately calculate the left-right offset angle θ of the center of gravity of the goods in the fork plane.

[0044] Dynamic safety state judgment: The controller has a 20ms basic control cycle, and strictly carries out three-level interlock safety verification: (1) Position condition: Verify that the actual boundary position Lactual of the goods is within the dynamically calculated safe area, i.e. L min ≤L 实际 ≤L max .

[0045] (2) Weight condition: Verify that the real-time detected weight of the goods W does not exceed the dynamic allowable load at the current height, i.e. W≤W max (h).

[0046] (3) Balance condition: Verify that the center of gravity offset angle |θ| of the goods does not exceed the dynamic balance threshold at the current weight and height, i.e. |θ|≤θ max (W,h).

[0047] Special response mechanism: When the tilt angle change rate dθ / dt>5° / s (i.e. the goods have a rapid dumping trend), the controller immediately switches the judgment cycle to high-speed mode (≤5ms), achieving millisecond-level risk response.

[0048] Graded instruction output: Allow move instruction: the controller outputs this instruction to allow the handling equipment to continue normal operation when and only when the three safety conditions of position, weight, and balance are met simultaneously within the decision period.

[0049] Lock instruction: the controller immediately outputs this instruction and activates the subsequent protection chain (alarm and actuator locking) when any safety condition triggers the threshold (i.e., not met).

[0050] In this embodiment, the central controller can be implemented using an industrial programmable logic controller (PLC), a safety PLC, or an embedded microcontroller (MCU) (such as Siemens S7-1200, Rockwell GuardLogix, or STM32H7 series), all of which are commercially available general-purpose products. The interface configuration of the controller, the logic programming method, and the fault safety design principles (including multi-sensor data fusion strategy, hardware watchdog mechanism, safety threshold determination process, etc.) are known to those skilled in the art, so they will not be described here.

[0051] The hierarchical locking operation of the actuator includes: Primary locking (≤50ms): cut off the hydraulic lifting oil circuit through a proportional electromagnetic valve, target locking state is hydraulic pressure <0.3MPa; Secondary locking (≤100ms): disconnect the driving motor power supply through a safety relay, target locking state is current <0.5A; Tertiary locking (≤300ms, if configured): apply ≥5kN braking force through a mechanical brake, target locking state is displacement speed <2mm / s.

[0052] In this embodiment, the proportional electromagnetic valve has a double-coil + valve position feedback and can cut off the hydraulic oil circuit within 50ms, for example: Bosch REXROTH 4WRPEH.

[0053] In this embodiment, the safety relay has a double-contact + state monitoring and can disconnect the motor power supply within 100ms, for example: Siemens 3SK1.

[0054] In this embodiment, the mechanical brake implements emergency braking within 300ms, with a braking force ≥5kN, for example: Roper MKE.

[0055] The actuator also includes a state monitoring and fault escalation unit configured to: monitor pressure, current, and displacement speed in real time; if any level of locking does not achieve the target state within the target time, trigger higher-level locking or retry operation.

[0056] If the hydraulic or electrical locking fails (e.g. pressure > 0.3 MPa after 50 ms, current > 0.5 A after 100 ms, or displacement speed > 2 mm / s after 300 ms), the system automatically upgrades the protection measures (e.g. triggers the third level brake).

[0057] All safety-related components and system designs meet the requirements of ISO 13849-1 PLd / SIL3 safety standards. In addition, fault removal requires manual reset and clearing of alarm records.

[0058] In this embodiment, the actuator can use proportional solenoid valve groups or safety relay units (such as Bosch REXROTH 4WRPEH or Siemens 3SK1). The installation method (including hydraulic piping connection specifications, electrical safety spacing requirements, etc.) and working principle (pilot hydraulic control principle, safety relay forced off mechanism, etc.) of the execution element are known to those skilled in the art, so they are not described here.

[0059] The alarm includes a buzzer that distinguishes between position overrun, overweight, or balance abnormalities by frequency difference; LED indicator lights that indicate position abnormalities by red light, overweight by yellow light, and balance abnormalities by flashing red light.

[0060] In this embodiment, the alarm can use industrial-grade multifunctional sound and light alarm devices (such as Peltier PHL-321 or Federal Signal SS2000). The alarm is a commercially available product, and its installation method (including anti-vibration bracket structure, waterproof wiring terminal, etc.) and working principle (programmable sound and light mode control circuit) are known to those skilled in the art, so they are not described here.

[0061] It also includes a wireless communication unit configured to transmit cargo position, weight, balance state data, and alarm information in real time to a remote monitoring terminal.

[0062] In this embodiment, the wireless communication unit usually uses industrial-grade low-power wide-area network communication equipment (such as Siemens Scalance W series, Befora WLAN series, or Huawei 5G industrial module). The communication unit is a commercially available product, and its installation method (must meet the requirements of antenna gain ≥ 5dBi and electromagnetic compatibility) and working principle (data transmission through LoRa / 4G / 5G protocol) are known to those skilled in the art, so they are not described here.

[0063] The data transmission mechanism of the wireless communication unit includes but is not limited to MQTT protocol packaging, TCP / IP data packet splitting, and AES-128 encrypted transmission. Its network topology (star network) and fault diagnosis function (RSSI signal strength monitoring) are general technical solutions for industrial Internet of Things.

[0064] The application further discloses a control method of the cargo carrying anti-falling control system. S1: system initialization Perform sensor self-check calibration: The position detection unit performs distance accuracy verification (±2mm); The weighing unit performs automatic zero clearing (3 seconds of static sampling); The balance detection unit completes zero position calibration (±0.1°).

[0065] Load safety parameters: read fork parameters L and W from the memory base , set default safety coefficients k1=0.2 and k2=0.75.

[0066] S2: real-time data acquisition and processing Multi-sensor data acquisition and execution: Position data: 100Hz sampling rate + median filter processing; Weight data: sliding window mean filter processing is adopted; Inclination data: Kalman filter fusion of accelerometer and gyroscope data is adopted.

[0067] Dynamic calculation of safety threshold: (every control cycle) Calculate the safety region boundary: L min =k1×L+Ch; L max =k2×L-Ch (where Ch is calculated according to the current height h according to the foregoing segmented function).

[0068] Calculate the maximum allowable load: W max (h)=W base ×[1-0.01×max(0,h-1)].

[0069] Calculate the dynamic balance threshold: θ max (W,h)=5°×(1+W / (2×W max (h)))+0.2×max(0,h-3).

[0070] S3: safety state determination In each basic control cycle (20ms), verify the three-level safety conditions: Position condition: L min ≤L 实际 ≤L max ? Weight condition: W≤W max (h)? Balance condition: |θ|≤θ max ? If the rate of change of inclination dθ / dt > 5° / s is detected, switch to the high-speed determination period (≤5 ms) immediately.

[0071] S4: Command output and actuator control If the three conditions in S3 are met simultaneously: output the carrying instruction, maintain the normal operation state of the actuator.

[0072] If any of the conditions in S3 is not met: output the locking instruction.

[0073] Trigger first-level locking (target ≤ 50 ms): control the proportional solenoid valve to cut off the lifting oil circuit.

[0074] Trigger second-level locking (target ≤ 100 ms): control the safety relay to disconnect the main power supply of the motor.

[0075] (If configured) Trigger third-level locking (target ≤ 300 ms): control the mechanical brake to apply braking force.

[0076] Execution state closed-loop verification and fault escalation: real-time monitoring of actuator feedback signals (pressure, current, displacement / speed), verify whether the target locking state is reached within the target time. If not, start the fault escalation process (such as retry locking, activate higher level brake) according to the preset logic.

[0077] S5: Alarm and communication Alarm triggering: according to the locking reason (position, weight, balance), trigger the corresponding differentiated sound and light alarm mode.

[0078] Data communication (if wireless unit is configured): Normal state: send state data at a set period (e.g. 500 ms).

[0079] Alarm state: immediately send alarm information and retransmit at a high frequency (e.g. 3 times / second) until a remote confirmation is received or the local alarm is cleared.

[0080] S6: Safety protection and maintenance mechanism Fault diagnosis: continuously monitor sensor effectiveness (data out of limits, unreasonable jumps) and actuator response performance (timeout without reaching target state).

[0081] Manual reset: after fault locking, the operator must meet the following conditions to reset the system: Press the dedicated reset key for ≥3 seconds.

[0082] Input the preset safety password.

[0083] All safety conditions (three in S3) have currently been restored to meet the requirements.

[0084] Dynamic optimization (optional): The system regularly (e.g., weekly) analyzes historical operation data (parameter ranges for stable operation within safety thresholds), performs fine-tuning within the preset k1 and k2 value ranges using a preset algorithm (e.g., mean shift correction), and records optimization logs.

[0085] Safety standards: All safety-related component design, logic execution, and fault response time meet ISO 13849-1 PLd level requirements (or SIL 3).

[0086] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A cargo anti-drop control system integrated into the fork structure, characterized by: Comprising: a position detection unit configured to detect whether the front and rear boundaries of the cargo exceed a safety zone; a weighing unit configured to detect the weight of the cargo in real time; a balance detection unit configured to detect the left and right offset of the center of gravity of the cargo; a central controller connected to the position detection unit, the weighing unit and the balance detection unit, and performing: (a) determining whether the cargo is within the safety zone based on the data of the position detection unit, the safety zone boundary being dynamically calculated according to the length of the fork and the lifting height; (b) determining whether the weight exceeds a dynamic load threshold based on the data of the weighing unit, the dynamic load threshold decreasing with the increase of the fork height; (c) determining whether the offset exceeds a dynamic balance threshold based on the data of the balance detection unit, the dynamic balance threshold being related to the real-time weight and height; outputting a carrying permission instruction only when (a)(b)(c) are met simultaneously, otherwise outputting a locking instruction; an alarm triggered to sound and light in response to the locking instruction; an actuator responding to the locking instruction and performing a hierarchical locking operation.

2. A cargo anti-falling control system according to claim 1, wherein: The safety zone boundary is delimited by a front safety line L min and a rear safety line L max and satisfies: L min =k1 x L + Ch, L max =k2 x L - Ch, Wherein: L is the physical length of the fork, k1 is the front safety coefficient and 0.15≤k1≤0.25, k2 is the rear safety coefficient and 0.70≤k2≤0.80, Ch is the height compensation amount and Ch={0, h≤1m; 0.05×(h-1)×L, h>1m}.

3. A cargo anti-falling control system according to claim 1, wherein: The dynamic load threshold satisfies: W max (h)=W base ×[1-0.01×max(0,h-1)] wherein: W base is the rated load of the fork at the lowest height.

4. The anti-falling control system for handling cargo according to claim 1, wherein: The dynamic balance threshold satisfies: θ max (W, h) = 5° x (1 + W / (2 x W max (h)) + 0.2° x max(0, h - 3).

5. The anti-falling control system for handling cargo according to claim 1, wherein: The central controller is configured to shorten the determination period to ≤5ms when the center of gravity offset rate of change is detected to exceed 5° / s.

6. A cargo anti-falling control system according to claim 1, wherein: The hierarchical locking operation includes: first-level locking: cutting off the power source of the lifting mechanism within ≤50ms; second-level locking: cutting off the power source of the driving mechanism within ≤100ms; third-level locking: triggering mechanical braking within ≤300ms.

7. A cargo anti-falling control system according to claim 1, wherein: The actuator further includes a state monitoring module configured to verify whether each level of locking achieves the target state within the corresponding target time; If any level of locking does not achieve the target state, higher-level locking or retry operation is automatically triggered.

8. A cargo anti-falling control system according to claim 1, wherein: Further comprising a wireless communication module configured to: transmit the cargo position, weight, balance state and alarm information to a remote terminal in real time; retransmit data at a frequency of ≥3 times / second in the alarm state until an acknowledgement is received.

9. A method of fall control based on the fall control system of any one of claims 1-8, characterized by, Comprising the following steps: S1: Calculate safety zone boundary based on physical length L and height h of forks, calculate dynamic load threshold W based on height h max (h), calculate dynamic balance threshold θ based on real-time weight W and height h of goods max (W, h); S2: within a decision period of <20 ms, verify synchronization that (i) the cargo position is within the safe zone; (ii) the cargo weight is < W max (h); (iii) the center of gravity offset is < θ max (W, h); if the center of gravity offset rate of change is > 5° / s, switch the decision period to < 5 ms; S3: When any one of (i)(ii)(iii) is not met: the central controller outputs a locking instruction; the actuator triggers the locking operation in the order of first level→second level→third level; S4: Trigger the corresponding alarm mode based on the failure type of triggering the locking; S5: If any level of locking does not achieve the target state within the target time, trigger higher-level locking or retry operation.

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