System and method for intelligent inspection of multi-sensor fusion passive wireless pull switch

Abstract

The invention discloses a system and a method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch, and the method comprises the steps: enabling a corresponding module to be activated to enter a working state when an event is triggered due to an abnormal or emergency situation on site; packaging event information triggered by activation into a data frame and sending the data frame to a data receiving control device; the data receiving control device decodes the wireless message after receiving the wireless message of the event information, identifies a sensor number and an instruction type corresponding to a trigger signal, executes a predetermined safety control measure according to an event type, reports the event information to the upper computer monitoring management platform, and sends the event information to the upper computer monitoring management platform; and the data are uploaded to the cloud platform to be stored and analyzed, and field workers are reminded to execute manual reset operation. According to the system and the method of the intelligent inspection multi-sensor fusion passive wireless pull rope switch, the pull rope switch thoroughly gets rid of dependence on external power supply lines or battery power supply, and passive wireless work of the switch device is realized.

Description

Technical Field

[0001] This invention relates to the technical field of power plant equipment inspection and safety monitoring, and in particular to a system and method for intelligent inspection of a multi-sensor fusion passive wireless pull rope switch. Background Technology

[0002] In the transportation system of power plants, pull rope switches are often installed along belt conveyors or hoists for functions such as starting, stopping and emergency stopping of equipment to ensure safe and stable production processes. Traditional pull rope switches are usually connected to the control circuit by wires and rely on external power supply. This wiring method is difficult to install and maintain in the long and complex underground environment, is costly, and the cables are easily worn or damaged.

[0003] With the development of wireless sensing technology, battery-powered wireless pull cord switches have emerged to replace wired solutions. Existing wireless sensors (such as wireless temperature, vibration, tilt, humidity, and door magnetic sensors) are mostly battery-powered, which has the disadvantage of frequent battery replacements in harsh environments. Traditional wired pull cord switches are used for emergency equipment shutdown, but they also have drawbacks such as complex wiring installation, difficult maintenance, and lack of remote monitoring and diagnosis.

[0004] For example, some industrial products use replaceable lithium batteries as power sources, with a battery life of about 3 years. However, battery-powered equipment still has the problem of limited lifespan. Once the power is exhausted, the battery needs to be replaced manually. In gas and dusty environments, frequent battery maintenance is not only inconvenient but also poses safety hazards. Therefore, coal conveying lines urgently need maintenance-free, long-life sensing devices.

[0005] Passive energy harvesting (also known as energy collection) technology offers a possible solution to the above problems. Energy harvesting refers to extracting a small amount of electrical energy from sources such as solar energy, temperature gradients, mechanical vibration, and electromagnetic radiation to power equipment. Sensors with ultra-low power consumption designs can utilize these environmental energy sources to achieve autonomous operation without external power supply. However, the environment of coal conveying lines is dark and has small temperature variations, making the available environmental energy very limited. A pull-rope switch contains a certain amount of mechanical energy at the moment it is manually pulled. If this mechanical energy can be converted into electrical energy and managed properly, it is sufficient to drive a wireless signal transmission. Furthermore, combining it with other micro-energy sources in the environment (such as temperature differences generated by equipment heat dissipation, light generated by underground lighting, or external radio frequency signals) holds promise for further improving the energy self-sufficiency of the sensing device.

[0006] On the other hand, the underground space in mines is vast and structurally complex, requiring wireless communication signals to have long-distance transmission and strong penetration capabilities. LoRa (Long Range) low-power wide-area network technology is very suitable for underground communication. It operates in unlicensed frequency bands, has low power consumption and long propagation distance. In the mining environment, a single LoRa gateway can cover a range of several kilometers, enabling wireless coverage of the entire mining area with minimal infrastructure. Compared to technologies such as Wi-Fi, LoRa signals have less attenuation underground, stronger ability to penetrate rock strata and tunnels, and higher reliability. Therefore, using LoRa as a communication method for the pull rope sensing of coal conveyor lines can remotely transmit alarm signals to the monitoring center the moment personnel pull the rope, achieving timely early warning. Summary of the Invention

[0007] The main technical problem solved by this invention is to provide a system and method for intelligent inspection multi-sensor fusion passive wireless pull-rope switch. It integrates the functions of multiple sensors into the pull-rope switch mechanism, innovatively utilizing the mechanical energy of the pull rope for self-powered operation. It also extracts a small amount of electrical energy from sources such as ambient light, temperature gradient, mechanical vibration, and electromagnetic radiation. Without the need for batteries, the micro-power generation device of the pull-rope switch achieves passive wireless and integrated functionality, completely eliminating the dependence on external power lines or battery power, and realizing passive wireless operation of the switch device.

[0008] To solve the above-mentioned technical problems, one technical solution adopted by the present invention is: to provide a method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch, comprising the following steps: S1: When the wireless pull rope switch module and the multi-type wireless sensor module are in low-power sleep mode, the system is in standby mode; S2: When an abnormality or emergency occurs on site and triggers an event, the corresponding wireless pull rope switch module or multiple types of wireless sensor modules are activated and enter the working state. S3: After the triggered sensor module is woken up, it packages the activation event information into a data frame and sends it to the data receiving and control device through the built-in LoRa wireless transmission unit. S4: After receiving the wireless message containing the event information, the data receiving and control device decodes and analyzes it to identify the sensor number and command type corresponding to the trigger signal. The data receiving and control device then executes predetermined safety control measures based on the event category. S4.1 If the signal is an emergency stop command triggered by the pull rope switch, the relay is remotely controlled through the interface to immediately cut off the control power of the coal conveyor belt drive motor to stop the equipment, and at the same time activate the on-site audible and visual alarm to remind the operators. S4.2 If the signal is an abnormal alarm event from other sensors, the data receiving control device will only send a warning notification or record the alarm information without cutting off the power supply to the equipment, ensuring that the system continues to operate within the safety threshold range; S5: The data receiving and control device reports the event information from step 4 to the host computer monitoring and management platform, and uploads it to the cloud platform for storage and analysis; S6: On-site personnel should first check and confirm the potential fault that caused the incident based on the alarm prompts from the host computer, and then perform a manual reset operation on the triggered device.

[0009] In an embodiment of the present invention, the wireless pull rope switch module includes a passive power harvesting unit, a micro-power generation unit, and a wireless communication unit.

[0010] In embodiments of the present invention, the multi-type wireless sensor module includes a wireless temperature sensor, a wireless vibration sensor, a wireless tilt sensor, a wireless temperature and humidity sensor, a wireless door magnetic sensor, and an Internet of Things data integration server.

[0011] In embodiments of the present invention, event triggering in S2 includes the following cases: S2.1 If someone pulls the rope in an emergency, an alarm signal will be sent immediately; at the same time, pulling the rope will trigger the energy harvesting mechanism and drive the micro-generator to generate electricity instantaneously. S2.2 When the wireless temperature sensor, wireless vibration sensor, wireless tilt sensor, wireless temperature and humidity sensor or wireless door magnetic sensor deployed along the line detects an abnormal signal exceeding the preset threshold, its internal circuit is also triggered, and it obtains power from the energy storage module to complete the autonomous wake-up.

[0012] In an embodiment of the present invention, in step S5, the data receiving and control device sends alarm data containing sensor number, event type, and occurrence time to the power plant industrial control computer or remote monitoring platform via the RS485 MODBUS protocol, thereby realizing centralized recording and display of alarm information.

[0013] In an embodiment of the present invention, the data receiving device can be configured with multiple wireless pull-cord switches, and the data receiving control device can pre-configure the identification code of each device. When reporting, it clearly indicates which sensor is triggered, and the monitoring interface displays the area or number of the accident point, which facilitates managers to quickly locate the source of the fault.

[0014] Another embodiment of the present invention provides a system for intelligent inspection of multi-sensor fusion passive wireless pull-cord switches, including a wireless pull-cord switch module, multiple types of wireless sensor modules, a data receiving and control device, and a host computer monitoring and management platform. When the wireless pull-cord switch module and the multiple types of wireless sensor modules are triggered, they package the activated event information into data frames and send them to the data receiving and control device. The data receiving and control device decodes the received event information wireless messages, executes predetermined safety control measures according to the event category, and reports the event information to the host computer monitoring and management platform and uploads it to a cloud platform for storage. The host computer monitoring and management platform is used to investigate and confirm potential faults that cause the events and issues alarms to prompt personnel to manually reset the switches.

[0015] The beneficial effects of this invention are: (1) The functions of multiple sensors are integrated into the pull rope switch mechanism. The mechanical energy of the pull rope is used to generate its own power. A small amount of electrical energy is extracted from sources such as ambient light, temperature gradient, mechanical vibration and electromagnetic radiation. No battery is required. The micro-power generation device of the pull rope switch realizes the passive wireless and integrated function, completely getting rid of the dependence on external power supply lines or battery power supply. The passive wireless operation of the switch device is realized. The wireless communication method is used to replace the traditional wired connection, realizing the long-distance rapid transmission and interlocking control of emergency stop command. The system installation and modification are greatly simplified, and the flexibility in use is improved. (2) Maintenance-free and long life: The device of the present invention has ultra-low power consumption in standby mode, and no maintenance operations such as replacement of parts are required in daily life. It can operate reliably for a long time, adapt to the harsh environment of mine, and ensure the long life and stability of the device. (3) The ingenious mechanical locking / reset mechanism ensures that the device can remain in the alarm state after the pull rope is triggered. It requires manual intervention to reset and restore the device, preventing potential hazards caused by accidental reset. It is consistent with the safety mechanism of the traditional wired emergency stop button and meets the requirements of industrial safety standards. At the same time, it has been successfully applied to passive wireless devices. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, wherein: Figure 1 A schematic diagram of an intelligent inspection multi-sensor fusion passive wireless pull rope switch system provided by the present invention; Figure 2 This is a flowchart illustrating the operation of the system of the present invention. Figure 3This is a flowchart illustrating the emergency shutdown process based on a passive wireless pull-cord switch. Detailed Implementation

[0017] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Please see Figure 1-3 The present invention includes: a method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch, comprising the following steps: S1: When the wireless pull rope switch module and the multi-type wireless sensor module are in low-power sleep mode, the system is in standby mode; S2: When an abnormality or emergency occurs on site and triggers an event, the corresponding wireless pull rope switch module or multiple types of wireless sensor modules are activated and enter the working state. The event triggering includes the following situations: S2.1 If someone pulls the rope in an emergency, an alarm signal will be sent immediately; at the same time, pulling the rope will trigger the energy harvesting mechanism and drive the micro-generator to generate electricity instantaneously.

[0019] S2.2 When the wireless temperature sensor, wireless vibration sensor, wireless tilt sensor, wireless temperature and humidity sensor or wireless door magnetic sensor deployed along the line detects an abnormal signal exceeding the preset threshold, its internal circuit is also triggered, and it obtains power from the energy storage module to complete the autonomous wake-up.

[0020] S3: After the triggered sensor module is woken up, it packages the activation event information into a data frame and sends it to the data receiving and control device through the built-in LoRa wireless transmission unit. The wireless transmitting unit includes a low-power radio frequency transmitting circuit and an antenna. Its function is to emit a wireless alarm signal when it receives power. Normally, the module is in an ultra-low power mode. When multiple wireless pull-cord switches are deployed at the same time, different devices can be pre-assigned different addresses or frequencies to avoid mutual interference. The operating frequency band of the wireless transmitting module can be selected according to the site environment and regulatory requirements, such as using the 433MHz or 2.4GHz industrial frequency band, and using a dedicated communication protocol to ensure reliable transmission and identification of signals in complex environments such as pipelines and indoor spaces.

[0021] S4: After receiving the wireless message containing the event information, the data receiving and control device decodes and analyzes it to identify the sensor number and command type corresponding to the trigger signal. The data receiving and control device then executes predetermined safety control measures based on the event category. S4.1 If the signal is an emergency stop command triggered by the pull rope switch, the relay is remotely controlled through the interface to immediately cut off the control power of the coal conveyor belt drive motor to stop the equipment, and at the same time activate the on-site audible and visual alarm to remind the operators. S4.2 If the signal is an abnormal alarm event from other sensors, the data receiving control device will only send a warning notification or record the alarm information without cutting off the power supply to the equipment, ensuring that the system continues to operate within the safe threshold range.

[0022] S5: The data receiving and control device reports the event information from step 4 to the host computer monitoring and management platform, and uploads it to the cloud platform for storage and analysis.

[0023] S6: On-site personnel should first check and confirm the potential fault that caused the incident based on the alarm prompts from the host computer, and then perform a manual reset operation on the triggered device.

[0024] Preferably, the wireless pull rope switch module includes a passive energy harvesting unit, a micro-power generation unit, and a wireless communication unit. When manually triggered or when the equipment vibrates, mechanical energy is converted into electrical energy through the micro-power generation unit. The passive energy harvesting mechanism is an intermediate component connecting the pull rope and the micro-power generation device. Its function is to convert the mechanical displacement and tension of the rope into mechanical motion to drive the power generation device when someone pulls the rope. A rotating shaft or slider connected to the pull rope is set in the robust housing of the switch. Normally, it is kept in the initial position by a spring, applying appropriate tension to the pull rope. When the pull rope is pulled, the rotating shaft / slider is driven to generate instantaneous displacement or rotation, quickly moving a distance against the spring force. This mechanical motion is then amplified in speed or torque through gear transmission or cam structure and applied to the micro-power generation device to improve energy conversion efficiency. The mechanical energy harvesting mechanism is preferably a bidirectional trigger design, that is, the rotating shaft or corresponding component can move regardless of whether the rope is pulled to the left or right, thus being suitable for situations where the pull rope is subjected to force at both ends, ensuring that energy can be harvested when the rope is pulled in any direction.

[0025] In addition, the pull-cord switch of the present invention preferably has a self-locking and manual reset function in its mechanical structure. When the pull cord is pulled and the switch is triggered, the internal mechanical energy harvesting mechanism will pass the normal balance position and be locked by the locking component, remaining in the position at the end of the action. Even if the external force is removed at this time (the pull cord is released), due to the locking effect, the mechanical mechanism will not spring back to the initial state on its own, thus keeping the emergency stop state in place. To restore the normal operation of the equipment, the on-site personnel need to perform a reset operation on the switch. Preferably, a manual reset handle or button is provided on the housing of the pull-cord switch. The personnel can rotate or press the reset component to release the locking component. After the lock is released, under the action of the spring reset force, the mechanical energy harvesting mechanism returns to the initial position and re-tightens the pull cord. At this time, the pull-cord switch returns to the standby state, and the receiving control device also detects that the switch state has returned to normal, allowing the relevant equipment to restart. The above-mentioned locking / reset design is consistent with the requirements of the traditional emergency stop button, ensuring that the equipment can only resume operation after the hidden danger has been eliminated and the relevant personnel have confirmed it, avoiding secondary risks caused by accidental reset or premature reset.

[0026] Preferably, the multi-type wireless sensor modules include wireless temperature sensors, wireless vibration sensors, wireless tilt sensors, wireless temperature and humidity sensors, and wireless door magnetic sensors, which do not require external power supplies or battery replacements; the sensor data is transmitted over long distances to the Internet of Things data integration server via LoRa wireless technology to realize real-time remote monitoring and intelligent inspection management of equipment status.

[0027] Preferably, the data receiving and control device sends alarm data containing sensor number, event type, and occurrence time to the power plant's industrial control computer or remote monitoring platform via the RS485 MODBUS protocol, thereby realizing centralized recording and display of alarm information.

[0028] Preferably, the data receiving device can be configured with multiple wireless pull-rope switches, and the data receiving control device can pre-configure the identification code of each device. When reporting, it can clearly indicate which sensor was triggered, and the monitoring interface can display the area or number of the accident point, which can help managers quickly locate the source of the fault.

[0029] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for intelligent inspection of a passive wireless pull-cord switch fused with multiple sensors, characterized in that, Includes the following steps: S1: When the wireless pull rope switch module and the multi-type wireless sensor module are in low-power sleep mode, the system is in standby mode; S2: When an abnormality or emergency occurs on site and triggers an event, the corresponding wireless pull rope switch module or multiple types of wireless sensor modules are activated and enter the working state. S3: After the triggered sensor module is woken up, it packages the activation event information into a data frame and sends it to the data receiving and control device through the built-in LoRa wireless transmission unit. S4: After receiving the wireless message containing the event information, the data receiving and control device decodes and analyzes it to identify the sensor number and command type corresponding to the trigger signal. The data receiving and control device then executes predetermined safety control measures based on the event category. S4.1 If the signal is an emergency stop command triggered by the pull rope switch, the relay is remotely controlled through the interface to immediately cut off the control power of the coal conveyor belt drive motor to stop the equipment, and at the same time activate the on-site audible and visual alarm to remind the operators. S4.2 If the signal is an abnormal alarm event from other sensors, the data receiving control device will only send a warning notification or record the alarm information without cutting off the power supply to the equipment, ensuring that the system continues to operate within the safety threshold range; S5: The data receiving and control device reports the event information from step 4 to the host computer monitoring and management platform, and uploads it to the cloud platform for storage and analysis; S6: On-site personnel should first check and confirm the potential fault that caused the incident based on the alarm prompts from the host computer, and then perform a manual reset operation on the triggered device.

2. The method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch according to claim 1, characterized in that, The wireless pull rope switch module includes a passive power harvesting unit, a micro-power generation unit, and a wireless communication unit.

3. The method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch according to claim 1, characterized in that, The multi-type wireless sensor modules include wireless temperature sensors, wireless vibration sensors, wireless tilt sensors, wireless temperature and humidity sensors, wireless door magnetic sensors, and an IoT data integration server.

4. The method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch according to claim 3, characterized in that, In S2, event triggering includes the following situations: S2.1 If someone pulls the rope in an emergency, an alarm signal will be sent immediately; at the same time, pulling the rope will trigger the energy harvesting mechanism and drive the micro-generator to generate electricity instantaneously. S2.2 When the wireless temperature sensor, wireless vibration sensor, wireless tilt sensor, wireless temperature and humidity sensor or wireless door magnetic sensor deployed along the line detects an abnormal signal exceeding the preset threshold, its internal circuit is also triggered, and it obtains power from the energy storage module to complete the autonomous wake-up.

5. The method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch according to claim 1, characterized in that, In step S5, the data receiving and control device sends alarm data containing sensor number, event type, and occurrence time to the power plant's industrial control computer or remote monitoring platform via the RS485 MODBUS protocol, thereby realizing centralized recording and display of alarm information.

6. The method for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch according to claim 1, characterized in that, The data receiving device can be configured with multiple wireless pull-cord switches, and the data receiving control device can pre-configure the identification code of each device. When reporting, it clearly indicates which sensor location was triggered, and the monitoring interface displays the area or number of the accident point, which facilitates managers to quickly locate the source of the fault.

7. A system for intelligent inspection of a multi-sensor fusion passive wireless pull-cord switch, characterized in that, The system includes a wireless pull rope switch module, multiple types of wireless sensor modules, a data receiving and control device, and a host computer monitoring and management platform. When triggered, the wireless pull rope switch module and the multiple types of wireless sensor modules package the activated event information into data frames and send them to the data receiving and control device. The data receiving and control device decodes the received event information wireless messages, executes predetermined safety control measures according to the event category, and reports the event information to the host computer monitoring and management platform and uploads it to a cloud platform for storage. The host computer monitoring and management platform is used to investigate and confirm potential faults that could cause the event and issues an alarm prompting personnel to manually reset the device.

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