Monitoring device and method for safe fire operation of electric welding / cutting equipment

Abstract

The invention provides an electric welding / cutting equipment safety fire monitoring device, which is arranged between the electric power input end of electric welding / cutting equipment and commercial power, and comprises a protective shell, an information acquisition unit, a local memory, a start-stop control unit, an MCU and a power supply module, the information acquisition unit is used for acquiring electric welding / cutting equipment information and operator information; the start-stop control unit is used for connecting or disconnecting power input of the electric welding / cutting equipment according to an instruction of the MCU; the MCU interacts with the information acquisition unit, the local memory and the supervision and management platform to generate a control instruction to the start-stop control unit and a work log of the fire operation before and after the fire operation; and the MCU and the supervision and management platform synchronously update the interacted record identification information of the operating personnel. The device is easy and convenient to install, the safety supervision efficiency of electric welding / cutting equipment fire operation can be improved, and the supervision load of a supervision management platform is reduced.

Description

Technical Field

[0001] This invention relates to the field of hot work supervision technology, specifically to a monitoring device and method for safe hot work on welding / cutting equipment. Background Technology

[0002] Fires caused by welding or cutting equipment (hereinafter referred to as "welding / cutting equipment") are frequent, endangering human lives. To regulate hot work operations and strengthen safety supervision and management, some measures have been taken, and related products for supervision have emerged. However, many problems still exist in practice, such as: the need for internal installation of the welding / cutting equipment, which is complex, inefficient, and prone to damaging the equipment's structure, causing after-sales problems for the equipment owner; the lack of embodied intelligence in the identification process for operators and equipment leads to low efficiency in information exchange with the cloud-based supervision and management platform, thus affecting the efficiency of supervision and welding / cutting operations. Furthermore, the supervision platform's identification system only supports certificates issued in the emergency field; certificates from other fields require manual review, resulting in a heavy workload for the platform's customer service.

[0003] Therefore, it is of practical significance to design a monitoring method and device for intelligent control of the start and stop of the input power of welding / cutting equipment without interfering with the internal structure of the equipment, and combining automatic control technology, computer technology, and wireless communication technology. Summary of the Invention

[0004] The present invention aims to at least partially solve one of the technical problems existing in the prior art.

[0005] To this end, the present invention proposes a monitoring device and method for safe hot work on welding / cutting equipment. Without intervening in the internal structure of the welding / cutting equipment, it ensures the integrity of the equipment ownership while reducing the installation difficulty of the monitoring device, improves the compatibility with various types of welding / cutting equipment, thereby improving the efficiency of safety supervision of hot work operations on welding / cutting equipment and reducing the supervision load of the supervision and management platform.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: The first aspect of this invention provides a monitoring device for safe hot work on welding / cutting equipment. The monitoring device is installed between the power input terminal and the mains power supply of the welding / cutting equipment. The monitoring device includes a protective housing, an information acquisition unit, a local memory, a start / stop control unit, an MCU, and a power module. The protective housing is installed on the outside of the welding / cutting equipment; The information acquisition unit is used to acquire information about welding / cutting equipment and operators; The local storage is located inside the protective housing and is used to store the work log of hot work, the local information of the monitoring device, the operator information and the welding / cutting equipment information that are not certified by the supervision and management platform, and the local registration information of the monitoring device, the welding / cutting equipment and the operator registration information that are certified by the supervision and management platform. The start / stop control unit is used to connect or disconnect the power input of the welding / cutting equipment according to the instructions of the MCU; The MCU is located inside the protective housing. The MCU interacts with the information acquisition unit, the local memory, and the supervision and management platform to generate control commands for the start / stop control unit before and after the hot work operation, as well as the hot work operation log. The MCU and the supervision and management platform synchronously update the registration identification information of the operators who have interacted with the MCU. The power module is located inside the protective housing and is used to supply power to the various electronic components inside the monitoring device.

[0007] In some embodiments, the protective housing is made of engineering plastics.

[0008] In some embodiments, the information acquisition unit includes a read / write module disposed within the protective housing, the read / write module exchanging data with the MCU via an SPI bus; The on-site registration / supervision personnel interact with the read / write module by using a first storage medium containing welding / cutting equipment information, or the on-site registration / supervision personnel establish a connection with the read / write module using an external information input device to write welding / cutting equipment information to the read / write module; The on-site registration / supervision personnel interact with the read / write module using a second storage medium containing the operator's information, or the on-site registration / supervision personnel establish a connection with the read / write module using the information input device to write the operator's information into the read / write module.

[0009] In some embodiments, the read / write module is selected from RFID read / write modules or NFC read / write modules; the first storage medium and the second storage medium are in the form of IC cards; and the information input device is selected from radio frequency readers.

[0010] In some embodiments, the welding / cutting equipment information includes the owner, name, model, serial number, date of manufacture, rated voltage, rated current, and energy efficiency rating of the welding / cutting equipment; The personnel information includes the personnel's name, gender, age, ID number, and validity period; The local information includes the monitoring device serial number, chip code, device name, and the type of welding / cutting equipment it is bound to.

[0011] In some embodiments, the local memory is divided into a cache area and a main memory area. The cache area is used to store the work log of the hot work operation, as well as the information of the welding / cutting equipment, the operator, and the machine itself that have not been certified by the supervision and management platform. The main memory area is used to store the registration identification information of the welding / cutting equipment, the registration identification information of the operator, and the registration identification information of the machine that have been certified by the supervision and management platform.

[0012] In some embodiments, after receiving the welding / cutting equipment information transmitted by the information acquisition unit, the MCU demodulates the information and combines it with the local information in the local memory, encrypts and modulates it to generate a first electronic tag, and sends the first electronic tag to the supervision and management platform for registration through the communication unit. After the supervision and management platform confirms that the equipment information is compliant, it registers the equipment and transmits the certified welding / cutting equipment registration identification information and the local registration identification information to the MCU through the communication unit for demodulation. The demodulated welding / cutting equipment registration identification information and the local registration identification information are stored in the local memory.

[0013] In some embodiments, after receiving the operator information transmitted by the information acquisition unit, the MCU demodulates it and compares it with the operator information in the local memory: If the local system contains operator registration information that is completely consistent with the operator's information, the MCU generates a first control command. The start / stop control unit responds to the first control command by connecting the power input of the welding / cutting equipment. After the hot work operation is completed, the MCU generates a work log for the hot work operation and sends it to the supervision and management platform for archiving. If the local system does not contain operator registration information that is completely consistent with the operator's information, the MCU will send the welding / cutting equipment information, machine information, and operator information involved in this hot work operation to the supervision and management platform. The supervision and management platform will then determine the compliance of the operator information: if compliant, it will return a "pass" message to the MCU along the original channel. The MCU will store the operator registration information confirmed by the supervision and management platform in its local memory and generate the first control command. The start / stop control unit will respond to the first control command by connecting the power input of the welding / cutting equipment. After the hot work operation is completed, the MCU will generate a work log for this hot work operation and send it to the supervision and management platform for archiving. If non-compliant, it will return a "fail" message to the MCU along the original channel. The MCU will generate a second control command, and the start / stop control unit will respond to the second control command by keeping the power input of the welding / cutting equipment disconnected.

[0014] In some embodiments, the power module is an uninterruptible power supply module with dual power supply. The first power supply is connected in parallel to the power input terminal of the start / stop control unit, and the second power supply is an energy storage element. The dual power supply switches automatically, and the switching signal is transmitted to the MCU via the SPI bus.

[0015] In some embodiments, the start / stop control unit includes a relay, a drive module, a clock circuit, and a current transformer; the MCU is connected to the drive module and the clock circuit via an SPI bus, and the drive module controls the opening and closing of the relay according to the control instructions of the MCU; the initial state of the relay is an open circuit state, the power input terminal of the relay is connected to the mains power, and the power output terminal of the relay is connected to the power input terminal of the welding / cutting equipment; the current transformer is connected between the power output terminal of the relay and the power input terminal of the welding / cutting equipment.

[0016] In some embodiments, the MCU determines the operating status of the welding / cutting equipment by any of the following methods and generates control commands to the start / stop control unit after hot work: Method 1: The current transformer is configured to display a low-level signal when it detects no current output in the line, and a high-level signal when it detects current output in the line. The duration of the low / high-level signals is timed by the clock circuit and processed by the MCU to determine the operating status of the welding / cutting equipment: ① A continuous high-level signal indicates continuous operation; ② Alternating low and high-level signals with a time interval less than a first set time indicate intermittent operation; ③ A low-level signal lasting longer than a second set time indicates paused or stopped operation. When state ③ is detected, the MCU sends a third control command to the drive module. Method 2: When the MCU detects the switching signal of the uninterruptible power supply module, it sends a third control command to the drive module. In response to the third control command, the drive module triggers the relay to return to its initial state, thereby disconnecting the power supply input to the welding / cutting equipment.

[0017] In some embodiments, the shutdown state of the monitoring device is synchronized with the shutdown state of the welding / cutting equipment and the shutdown state of the mains power input.

[0018] In some embodiments, the control device further includes an anti-tamper mechanism installed between the power output terminal of the monitoring device and the insulated wire portion of the power connection terminal of the welding / cutting equipment. The anti-tamper mechanism includes an anti-tamper switch, a signal line, and a clamp. The anti-tamper switch does not contact the housing of the welding / cutting equipment. The clamp is used to connect the anti-tamper switch and the signal line. The detection signal of the anti-tamper switch is transmitted to the I / O port of the MCU through the signal line. When the MCU simultaneously detects a signal interruption of the anti-tamper switch and a lack of current signal at the power output terminal of the monitoring device, it sends an alarm signal to the supervision and management platform.

[0019] The second aspect of this invention provides a method for monitoring safe hot work in welding / cutting equipment, comprising: Step S100: Install the monitoring device according to any embodiment of the first aspect of the present invention at the power input terminal of the welding / cutting equipment that is ready to perform hot work. Step S200: After obtaining the welding / cutting equipment information through the information acquisition unit and binding it with the local information of the monitoring device, the information is uploaded to the supervision and management platform for filing. After confirmation by the supervision and management platform, the welding / cutting equipment filing identification information and the local filing identification information are demodulated by the MCU and stored in the local memory. Step S300: Obtain operator information through the information acquisition unit. The MCU compares and determines whether the operator's registration identification information is present locally. If the operator's registration identification information is not present locally, the monitoring device sends an operator authentication request to the supervision and management platform. If the authentication is successful, proceed to step S400; if the authentication fails, proceed to step S500. If the operator's registration identification information is present locally, proceed to step S400. In step S400, after receiving the "pass" information and operator registration information from the supervision and management platform, the MCU stores the operator registration information in the local memory and generates a first control command. The start / stop control unit responds to the first control command by connecting the mains power to the power input terminal of the welding / cutting equipment. The operator performs hot work. The MCU judges the working status of the welding / cutting equipment until it determines that the welding / cutting equipment is in a suspended or stopped state. Then, it generates a third control command. The start / stop control unit responds to the third control command by disconnecting the mains power from the power input terminal of the welding / cutting equipment. The MCU generates a work log for this hot work operation and temporarily stores it in the local memory. It is then uploaded to the supervision and management platform for archiving in real time or after the network is restored. In step S500, after receiving the "failed" information returned by the supervision and management platform, the MCU generates a second control command. The start / stop control unit responds to the second control command to keep the mains power disconnected from the power input terminal of the welding / cutting equipment.

[0020] Compared with the prior art, the present invention has the following characteristics and beneficial effects: 1. A safety management measure targeting unsafe acts by people and unsafe conditions of equipment. This invention deeply integrates personnel operation authentication and equipment status monitoring, forming a closed-loop safety system that combines hardware and software. The device integrates personnel identity authentication and operation permission management, preventing unauthorized personnel or unapproved operations from starting the equipment, thus eliminating unauthorized hot work at the source. This collaborative control of both "human" and "machine" factors significantly reduces the probability of safety accidents caused by misoperation, equipment aging, and other factors.

[0021] 2. Employing cloud-edge-device collaborative technology, and collaborating in a layered manner with the supervision and management platform to improve supervision efficiency. This invention employs a three-tiered collaborative technology framework of "cloud-edge-device" to improve regulatory efficiency and real-time response. The edge device is responsible for real-time data collection, personnel authentication, and equipment status assessment, ensuring independent and safe operation even in environments without or with unstable networks (such as underground). The supervision and management platform is responsible for aggregating data from multiple terminals, performing macro-analysis, risk warnings, certificate status verification, and file management, providing managers with a comprehensive perspective.

[0022] 3. The device has high adaptability and can adapt to various working conditions, such as underground and other non-networked environments. Designed for special environments with insufficient or no network coverage, such as underground mines and remote areas, this invention's device exhibits exceptional environmental adaptability. The device possesses complete local processing capabilities; all core security authentication and control logic is executed locally, independent of network continuity. Designed to withstand dust, moisture, and vibration, the device can operate stably in various industrial environments, ensuring comprehensive safety monitoring coverage across all regions and operating conditions.

[0023] 4. The device is versatile and suitable for use with all welding / cutting equipment. This invention's device is not a customized product for specific equipment, but rather adopts a standardized interface and modular design, possessing excellent versatility and compatibility. It can be easily integrated into various brands and models of welding / cutting and other hot work equipment through different adapter interfaces, without requiring large-scale modifications to existing equipment. This "plug-and-play" characteristic greatly expands its application scope and facilitates the large-scale promotion and popularization of the technology.

[0024] 5. The device possesses built-in intelligence and has edge authentication and recognition capabilities. The core of this device is the integration of Embodied AI technology, enabling edge terminals not only to perceive but also to understand and make decisions. It supports methods such as QR code scanning and radio frequency identification (RFID) to quickly verify the operator's qualifications and hot work permit status at the device end, achieving unified verification of "human-machine-certificate".

[0025] 6. The device has anti-tampering features to prevent attempts to bypass the monitoring terminal and evade security supervision. Attached Figure Description

[0026] Figure 1 This is a structural block diagram of a monitoring device for safe hot work on welding / cutting equipment provided in the first aspect embodiment of the present invention; Figure 2 yes Figure 1 The diagram shows the structural block diagram of the anti-tamper mechanism in the monitoring device. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this application clearer, the application will be described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely for explaining this application and are not intended to limit this application.

[0028] Conversely, this application covers any alternatives, modifications, equivalent methods, and schemes made within the spirit and scope of this application as defined by the claims. Furthermore, to provide the public with a better understanding of this application, certain specific details are described in detail below. However, this application can be fully understood by those skilled in the art even without these detailed descriptions.

[0029] See Figure 1 The first aspect of this invention provides a monitoring device for safe hot work on welding / cutting equipment, which is installed between the power input terminal of the welding / cutting equipment (hereinafter referred to as "working equipment") and the mains power (380V or 220V). This monitoring device includes a protective housing, an information acquisition unit, a local memory, a start / stop control unit, a microcontroller (MCU), and a power module. Protective housing, installed on the outside of welding / cutting equipment; The information acquisition unit, located inside or outside the protective housing, is used to acquire information about the welding / cutting equipment and the operators. The local storage device, located inside the protective housing, is used to store the work log of hot work operations of the welding / cutting equipment, the local information of the monitoring device that has not been certified by the supervision and management platform, the information of the operator and the welding / cutting equipment, as well as the local registration information of the monitoring device, the registration information of the welding / cutting equipment and the registration information of the operator that have been certified by the supervision and management platform. The start / stop control unit is used to connect or disconnect the power input of the welding / cutting equipment according to the instructions of the MCU; A microcontroller (MCU), housed inside a protective casing, interacts with the supervision and management platform via a communication unit to register the welding / cutting equipment and the monitoring device, obtaining registration identification information for both the welding / cutting equipment and the MCU itself. The MCU compares the personnel information for the current hot work operation with the personnel registration identification information stored in its local memory, and interacts with the supervision and management platform via the communication unit to generate control commands for the start / stop control unit before the hot work operation. The MCU determines the operating status of the welding / cutting equipment and generates control commands for the start / stop control unit after the hot work operation, as well as a work log for the welding / cutting equipment's hot work operation. The MCU and the supervision and management platform synchronously update the registration identification information of the personnel with whom they have interacted. The power module, located inside the protective housing, is used to supply power to the various electronic components within this monitoring device.

[0030] The monitoring device proposed in this embodiment, as an edge device with embodied intelligence, authenticates hot work equipment and personnel, thereby controlling the start and stop of hot work equipment, and realizing communication and data interaction with the supervision and management platform to achieve cloud-edge collaborative management.

[0031] In some embodiments, the protective housing is made of engineering plastic, preferably engineering plastic that meets the IP67 protection rating requirements, to ensure the safety of its internal circuitry.

[0032] In some embodiments, the information acquisition unit includes a read / write module, which exchanges data with the MCU via an SPI bus. Wherein: Regarding the acquisition of information from welding / cutting equipment, an operation is performed when this monitoring device is first installed on the welding / cutting equipment. The on-site registration / supervision personnel (" / " indicates "or") interact with the read / write module using a first storage medium containing information about the welding / cutting equipment to be used for hot work, thus writing the equipment information. Alternatively, the on-site registration / supervision personnel can establish a connection with the read / write module using an external information input device. A first interactive interface for inputting equipment information will pop up on the information input device, and the on-site registration / supervision personnel will write the equipment information to the read / write module through this interface. The read / write module will then exchange the written equipment information with the MCU via the SPI bus. The equipment information includes, but is not limited to, the equipment's ownership unit, name, model, serial number, manufacturing date, rated voltage, rated current, and energy efficiency rating. The energy efficiency rating of the equipment can accurately identify safety hazards in older equipment during subsequent management, enabling tiered management and replacement decisions for equipment. Through data-driven evaluation, the scientific and economical management of older equipment can be improved. For acquiring operator information, on-site registration / supervision personnel interact with the read / write module using a second storage medium containing the operator's information to write the operator's information; alternatively, on-site registration / supervision personnel establish a connection with the read / write module using the aforementioned information input device, and a second interactive interface for inputting operator information pops up on the information input device. The on-site registration / supervision personnel write the operator's information to the read / write module through this second interactive interface. The read / write module exchanges the written operator's information to the MCU via the SPI bus. The operator's information includes, but is not limited to: the operator's name, gender, age, certificate number (the certificates used include welder's operation certificate, special equipment welding certificate, and construction welder's certificate), and validity period.

[0033] It should be noted that obtaining information about the equipment and personnel through storage media or information input devices is particularly suitable for welding / cutting equipment operating in environments without a network (the network must be disconnected during hot work, but can be restored at other times) or when the network signal is poor. In such cases, it is generally not allowed to bring mobile terminals (such as mobile phones, laptops, tablets, etc.) into the work site.

[0034] Furthermore, the read / write module within the information acquisition unit is selected from either a Radio Frequency Identification (RFID) read / write module or a Near Field Communication (NFC) read / write module; the RFID read / write module preferably uses the MFRC-522 chip, and the NFC read / write module preferably uses the PN532 chip. Both the first and second storage media are in the form of IC cards, and the external information input device is an RFID reader / writer. The IC card is used by supervisory personnel / enterprise managers to write electronic tag information through the IC card reader, serving as the information carrier.

[0035] In other embodiments, to ensure compatibility with existing information authentication methods for welding / cutting equipment and operators, and for situations where the welding / cutting equipment operates in a networked environment, it is generally permissible to bring a mobile terminal into the work site. The information acquisition unit includes a mobile terminal externally mounted on the casing of this monitoring device and a QR code affixed to the surface of the casing. On-site registration / supervision personnel use the first mobile terminal to scan the QR code to load an APP or open a WeChat mini-program. Through this APP / WeChat mini-program, they write welding / cutting equipment information and send it to the supervision and management platform for registration. Once the supervision and management platform confirms the equipment information is compliant, it registers the equipment and sends the authenticated welding / cutting equipment registration identification information first to the communication module within this monitoring device, and then transmits it to the MCU via the SPI bus. The MCU demodulates the received welding / cutting equipment registration identification information and stores it in its local memory via the SPI bus. Operators use a second mobile terminal with personal identification information to scan a QR code to download an APP or open a WeChat mini-program. They then enter their personal information as prompted by the APP / WeChat mini-program and send it to the supervision and management platform for verification. Once the supervision and management platform confirms that the operator's information is compliant, it sends the verified operator registration identification information to the communication module in this monitoring device. The information is then transmitted to the MCU via the SPI bus. The MCU demodulates the received operator registration identification information and stores it in the local memory via the SPI bus.

[0036] It should be noted that by obtaining equipment and operator registration information through mobile terminals, this monitoring device is also applicable to existing operator authentication methods, thus expanding the applicable scenarios of this monitoring device to meet the needs of different application scenarios.

[0037] In some embodiments, the local memory is divided into a cache area and a main memory area; the cache area is used to store the work log of hot work of welding / cutting equipment generated by the MCU, as well as the equipment information, operator information and machine information that have not been certified by the supervision and management platform; the main memory area is used to store the equipment registration identification information, operator registration identification information and machine registration identification information that have been certified by the supervision and management platform.

[0038] In some embodiments, the MCU interacts with the information acquisition unit, local memory, and supervision and management platform via the SPI bus to determine whether the hot work application meets the safety start requirements, and generates control commands for the start / stop control unit based on the determination result. Specifically: After receiving the equipment information from the first storage medium (IC card) obtained by the information acquisition unit, the MCU demodulates the equipment information and combines it with the local information of the monitoring device already installed on the welding / cutting equipment (this information is stored in the local memory, including the device serial number, chip code, device name, and the type of welding / cutting equipment bound to it). This information is then encrypted and modulated (using an existing encryption and modulation algorithm) into a first electronic tag. If there is currently no network, it is temporarily stored in the local memory buffer via the SPI bus. Once the network is restored, it is sent to the supervision and management platform for registration via the communication unit. After the supervision and management platform confirms the compliance of the equipment information, it registers the equipment and the local registration information. The authenticated welding / cutting equipment registration identifier and the local registration identifier are first sent to the communication module within the monitoring device, and then transmitted to the MCU via the SPI bus. The MCU demodulates the equipment registration identifier and the local registration identifier and transmits them to the main memory area of ​​the local memory via the SPI bus. It should be noted that the registration and authentication process for the local information and the equipment information generally only needs to be executed once.

[0039] After receiving the operator information from the second storage medium (IC card) obtained by the information acquisition unit, the MCU demodulates it and compares it with the operator information in the local memory. If the local memory contains operator registration identification information that completely matches the operator information, the MCU generates a first control command (i.e., a command to activate the start / stop control unit). The start / stop control unit responds to this first control command. After the hot work operation is completed, the MCU generates a hot work operation log (operator registration identification information, equipment registration identification information, machine registration identification information, operation start time, operation end time) and sends it to the supervision and management platform for archiving, facilitating subsequent traceability. If the local memory does not contain operator registration identification information that completely matches the operator information, the MCU will send the welding / cutting equipment information and monitoring information involved in the hot work operation to the supervision and management platform for archiving. The device's local information and the operator's information are sent to the supervision and management platform via the communication unit. The platform then verifies the operator's information for compliance. If compliant, the platform returns a "pass" message to the MCU along the original channel. The MCU stores the operator's information, confirmed by the platform, as the operator's registration identifier in the main memory of its local storage and generates a first control command. The start / stop control unit responds to this first control command. After the hot work operation is completed, the MCU generates a work log for the hot work operation and sends it to the supervision and management platform for archiving. If non-compliant, the platform returns a "fail" message to the MCU along the original channel. The MCU generates a second control command (i.e., a command to disconnect the start / stop control unit). The start / stop control unit responds to this second control command, keeping the power input of the welding / cutting equipment disconnected, thus preventing the hot work operation.

[0040] Furthermore, to ensure timely updates to the registration status of local information, equipment information, and personnel information (primarily personnel information is used here due to its higher synchronization frequency compared to local and equipment information) that have already been exchanged between the monitoring device and the supervision and management platform, the monitoring device and the supervision and management platform maintain synchronized updates for the exchanged registration information and personnel registration information. If either the monitoring device or the supervision and management platform detects a change in the registration information of the exchanged equipment and / or personnel, it sends a synchronization update message to the other. For example, when a worker's certificate is about to expire, the local device identifies this and sends the information to the supervision and management platform; data synchronization occurs on both sides after the certificate is updated.

[0041] In other embodiments, for authentication via scanning a QR code using a mobile terminal through an APP / WeChat mini-program, if the MCU receives the operator registration identification information confirmed by the supervision and management platform via the communication unit, the MCU stores the operator registration identification information in the main memory area of ​​the local memory and generates a first control command. After the hot work operation is completed, the MCU generates a hot work operation log and sends it to the supervision and management platform for archiving. If the MCU receives the operator registration failure information sent by the supervision and management platform via the communication unit, the MCU generates a second control command. The start / stop control unit responds to the second control command to keep the power supply input side of the welding / cutting equipment disconnected, preventing the hot work operation from being carried out.

[0042] Furthermore, the MCU can be selected from microcontrollers such as M3 / M4, which have rich interfaces and data processing capabilities.

[0043] In some embodiments, the communication unit includes a Bluetooth communication module and a 4G communication module. The configuration of the Bluetooth communication module enables the monitoring device to support short-range data transmission in offline environments.

[0044] In some embodiments, the power module adopts a dual-power uninterruptible power supply module to power the various electronic components in the monitoring device. The first power supply is connected in parallel to the power input terminal of the start / stop control unit, and the second power supply is an energy storage element (such as a supercapacitor or button battery). The dual power supply switches automatically, and the switching signal is transmitted to the MCU via the SPI bus. When the mains power is connected to the welding / cutting equipment, the first power supply is turned on, and the mains power is converted into applicable electrical energy via AC / DC and DC / DC to power the various electronic components in the monitoring device. The second power supply is turned off and is in an energy storage state. When the mains power is disconnected from the welding / cutting equipment, the first power supply is turned off, the second power supply is turned on, and the energy storage element outputs applicable electrical energy to power the various electronic components in the monitoring device.

[0045] In some embodiments, the start / stop control unit includes a relay, a drive module, a clock circuit, and a current transformer. The MCU is connected to the drive module via an SPI bus, and the drive module is connected to the relay. The relay is initially in an open-circuit state. The relay's power input terminal is connected to the mains power, and its power output terminal serves as the power output terminal of this monitoring device, connected to the power input terminal of the welding / cutting equipment. The current transformer is connected between the power output terminal of the monitoring device and the power input terminal of the welding / cutting equipment. The clock circuit is connected to the MCU via an SPI bus and is used to provide the MCU with time information, mainly including timing and time comparison.

[0046] Before hot work begins, when the drive module receives the first control command from the MCU, it sends a first excitation voltage to the relay, causing the relay to change from an open circuit state to a closed state. This connects the mains power to the power input terminal of the welding / cutting equipment, allowing the operator to start the hot work after turning on the equipment's own switch. When the drive module receives the second control command from the MCU, it sends a second excitation voltage to the relay, keeping the relay in an open circuit state. This disconnects the mains power from the power input terminal of the welding / cutting equipment, preventing the start of hot work.

[0047] Once hot work begins, the MCU determines the operating status of the welding / cutting equipment using either of the following two methods and generates control commands for the start / stop control unit after the hot work begins: Method 1: Make a judgment by combining the current signal collected by the current transformer and the time signal of the clock circuit. The current signal from the power output terminal of this monitoring device is collected using a current transformer and transmitted to the MCU via the SPI bus. A low-level signal indicates no current output, while a high-level signal indicates current output. The duration of the low / high level signals is timed by a clock circuit and processed by the MCU to determine the operating status of the welding / cutting equipment: ① A continuous high-level signal indicates continuous operation; ② Alternating low and high level signals with a time interval less than a first set time (e.g., 30 minutes) indicate intermittent operation; ③ A low-level signal lasting longer than a second set time (e.g., 30 minutes) indicates the welding / cutting equipment is paused or stopped (the operator may have already turned off the power switch). When status ③ is detected, the MCU sends a third control command to the drive module, which triggers a relay to return to its initial state, thus disconnecting the mains power from the power input terminal of the welding / cutting equipment. The start / stop control unit waits for control commands from the MCU.

[0048] Method 2: Determine based on the switching signal of the power module. When the operator turns off the mains input switch (referring to the mains switch connected to the site), the MCU detects the switching signal of the uninterruptible power supply module and sends a third control command to the drive module. The drive module triggers the relay to return to its initial state, thereby disconnecting the mains power from the power input terminal of the welding / cutting equipment. The start / stop control unit will then wait for the MCU to send a control command.

[0049] Furthermore, the relay is preferably a 250VAC magnetic latching relay with a current rating of not less than 40A. The drive module provides the excitation voltage for the magnetic latching relay. The clock circuit adopts a standard clock circuit, and the current transformer is a non-contact measuring AC current transformer.

[0050] In some embodiments, see Figure 2 The monitoring device of this invention also includes an anti-tamper mechanism to prevent other personnel from bypassing the monitoring terminal device to evade security supervision. The anti-tamper mechanism includes an anti-tamper switch, a signal line, and a clamp, installed between the insulated wire portion of the power output terminal of the monitoring device and the power connection terminal of the welding / cutting equipment. The anti-tamper switch does not contact the housing of the welding / cutting equipment. The detection distance of the anti-tamper switch is ≤15mm. The detection signal of the anti-tamper switch is transmitted to the I / O port of the MCU via the signal line. When the MCU simultaneously detects an interruption in the anti-tamper switch signal and a low-level signal from the current transformer, it sends an alarm signal to the supervision and management platform via the 4G communication module. The clamp is used to fix the anti-tamper switch and the signal line, ensuring that the anti-tamper switch is installed correctly and the detection distance meets the design requirements.

[0051] Furthermore, the switch adopts a miniature contact limit switch or a miniature non-contact proximity switch. The miniature non-contact proximity switch can be capacitive, inductive, or Hall effect type.

[0052] The shutdown status of this monitoring device is always synchronized with the shutdown status of the welding / cutting equipment and the mains power input (switch cabinet). That is, when either the welding / cutting equipment or the mains power input is in a shutdown state, this monitoring device is in a shutdown state.

[0053] A second aspect of the present invention provides a method for monitoring safe hot work in welding / cutting equipment, comprising the following steps: Step S100: Install the monitoring device provided in the first aspect embodiment of the present invention at the power input terminal of the welding / cutting equipment that is ready to perform hot work; Step S200: The first storage medium interacts with the monitoring device to write the work equipment information and binds it with the local information of the monitoring device. Then, it is uploaded to the supervision and management platform for filing through the communication unit. After the supervision and management platform confirms it, the work equipment filing identification information and the local filing identification information are demodulated by the MCU through the communication unit and stored in the local memory. Step S300: The second storage medium is interactively written to the monitoring device to write the operator's information. The monitoring device compares and determines whether the operator's registration identification information is present locally. If the operator's registration identification information is not present, the monitoring device sends an operator authentication request to the supervision and management platform. If the authentication is successful, proceed to step S400; if the authentication fails, proceed to step S500. If the operator's registration identification information is present, proceed to step S400. In step S400, after receiving the "pass" information and operator registration identification information returned by the supervision and management platform, the MCU stores the operator registration identification information in the local memory and generates a first control command. The start / stop control unit responds to the first control command by connecting the mains power to the power input terminal of the welding / cutting equipment. The operator performs hot work. The MCU determines the working status of the welding / cutting equipment according to the above method one or method two until the MCU determines that the welding / cutting equipment is in a suspended or stopped state. Then, it generates a third control command. The start / stop control unit responds to the third control command by disconnecting the mains power from the power input terminal of the welding / cutting equipment. The MCU generates a work log for this hot work operation and temporarily stores it in the local memory. It is then uploaded to the supervision and management platform for archiving in real time or after the network is restored. In step S500, after receiving the "failed" information returned by the supervision and management platform, the MCU generates a second control command. The start / stop control unit responds to the second control command to keep the mains power disconnected from the power input terminal of the welding / cutting equipment.

[0054] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0055] Although embodiments of this disclosure have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of this disclosure, the scope of which is defined by the claims and their equivalents.

Claims

1. A monitoring device for safe hot work in electric welding / cutting equipment, characterized in that, The monitoring device is installed between the power input terminal and the mains power of the welding / cutting equipment. The monitoring device includes a protective housing, an information acquisition unit, a local memory, a start / stop control unit, an MCU, and a power module. The protective housing is installed on the outside of the welding / cutting equipment; The information acquisition unit is used to acquire information about welding / cutting equipment and operators; The local storage is located inside the protective housing and is used to store the work log of hot work, the local information of the monitoring device, the operator information and the welding / cutting equipment information that are not certified by the supervision and management platform, and the local registration information of the monitoring device, the welding / cutting equipment and the operator registration information that are certified by the supervision and management platform. The start / stop control unit is used to connect or disconnect the power input of the welding / cutting equipment according to the instructions of the MCU; The MCU is located inside the protective housing. The MCU interacts with the information acquisition unit, the local memory, and the supervision and management platform to generate control commands for the start / stop control unit before and after the hot work operation, as well as the hot work operation log. The MCU and the supervision and management platform synchronously update the registration identification information of the operators who have interacted with the MCU. The power module is located inside the protective housing and is used to supply power to the various electronic components inside the monitoring device.

2. The monitoring device according to claim 1, characterized in that, The protective shell is made of engineering plastics.

3. The monitoring device according to claim 1, characterized in that, The information acquisition unit includes a read / write module disposed within the protective housing, and the read / write module exchanges data with the MCU via an SPI bus; The on-site registration / supervision personnel interact with the read / write module by using a first storage medium containing welding / cutting equipment information, or the on-site registration / supervision personnel establish a connection with the read / write module using an external information input device to write welding / cutting equipment information to the read / write module; The on-site registration / supervision personnel interact with the read / write module using a second storage medium containing the operator's information, or the on-site registration / supervision personnel establish a connection with the read / write module using the information input device to write the operator's information into the read / write module.

4. The monitoring device according to claim 3, characterized in that, The read / write module is selected from RFID or NFC; the first and second storage media are in the form of IC cards; the information input device is selected from radio frequency readers.

5. The monitoring device according to claim 1, characterized in that, The information on the welding / cutting equipment includes the owner, name, model, serial number, date of manufacture, rated voltage, rated current, and energy efficiency rating of the welding / cutting equipment. The personnel information includes the personnel's name, gender, age, ID number, and validity period; The local information includes the monitoring device serial number, chip code, device name, and the type of welding / cutting equipment it is bound to.

6. The monitoring device according to claim 1, characterized in that, The local storage is divided into a cache area and a main storage area. The cache area is used to store the work log of the hot work operation, as well as the information of welding / cutting equipment, operators and machine information that have not been certified by the supervision and management platform. The main storage area is used to store the registration identification information of welding / cutting equipment, operators and machine that have been certified by the supervision and management platform.

7. The monitoring device according to claim 1, characterized in that, After receiving the welding / cutting equipment information transmitted by the information acquisition unit, the MCU demodulates it and combines it with the local information in the local memory, encrypts and modulates it to generate a first electronic tag. The first electronic tag is sent to the supervision and management platform for registration through the communication unit. After the supervision and management platform confirms that the equipment information is compliant, it registers the equipment and transmits the certified welding / cutting equipment registration identification information and the local registration identification information to the MCU through the communication unit for demodulation. The demodulated welding / cutting equipment registration identification information and the local registration identification information are stored in the local memory.

8. The monitoring device according to claim 1, characterized in that, After receiving the operator information transmitted by the information acquisition unit, the MCU demodulates it and compares it with the operator information in the local memory. If the local system contains operator registration information that is completely consistent with the operator's information, the MCU generates a first control command. The start / stop control unit responds to the first control command by connecting the power input of the welding / cutting equipment. After the hot work operation is completed, the MCU generates a work log for the hot work operation and sends it to the supervision and management platform for archiving. If the local system does not contain operator registration information that is completely consistent with the operator's information, the MCU will send the welding / cutting equipment information, machine information, and operator information involved in this hot work operation to the supervision and management platform. The supervision and management platform will then determine the compliance of the operator information: if compliant, it will return a "pass" message to the MCU along the original channel. The MCU will store the operator registration information confirmed by the supervision and management platform in its local memory and generate the first control command. The start / stop control unit will respond to the first control command by connecting the power input of the welding / cutting equipment. After the hot work operation is completed, the MCU will generate a work log for this hot work operation and send it to the supervision and management platform for archiving. If non-compliant, it will return a "fail" message to the MCU along the original channel. The MCU will generate a second control command, and the start / stop control unit will respond to the second control command by keeping the power input of the welding / cutting equipment disconnected.

9. The monitoring device according to claim 1, characterized in that, The power module is an uninterruptible power supply module with dual power supply. The first power supply is connected in parallel to the power input terminal of the start / stop control unit, and the second power supply is an energy storage element. The dual power supply switches automatically, and the switching signal is transmitted to the MCU via the SPI bus.

10. The monitoring device according to claim 9, characterized in that, The start / stop control unit includes a relay, a drive module, a clock circuit, and a current transformer; the MCU is connected to the drive module and the clock circuit via an SPI bus, and the drive module controls the opening and closing of the relay according to the control instructions of the MCU; The relay is initially in an open-circuit state. The power input terminal of the relay is connected to the mains power, and the power output terminal of the relay is connected to the power input terminal of the welding / cutting equipment. A current transformer is connected between the power output terminal of the relay and the power input terminal of the welding / cutting equipment.

11. The monitoring device according to claim 10, characterized in that, The MCU determines the operating status of the welding / cutting equipment using any of the following methods and generates control commands for the start / stop control unit after hot work: Method 1: The current transformer is configured to display a low-level signal when it detects no current output in the line, and a high-level signal when it detects current output in the line. The duration of the low / high-level signals is timed by the clock circuit and processed by the MCU to determine the operating status of the welding / cutting equipment: ① A continuous high-level signal indicates continuous operation; ② Alternating low and high-level signals with a time interval less than a first set time indicate intermittent operation; ③ A low-level signal lasting longer than a second set time indicates paused or stopped operation. When state ③ is detected, the MCU sends a third control command to the drive module. Method 2: When the MCU detects the switching signal of the uninterruptible power supply module, it sends a third control command to the drive module. In response to the third control command, the drive module triggers the relay to return to its initial state, thereby disconnecting the power supply input to the welding / cutting equipment.

12. The monitoring device according to claim 1, characterized in that, The shutdown status of the monitoring device is synchronized with the shutdown status of the welding / cutting equipment and the shutdown status of the mains power input.

13. The monitoring device according to any one of claims 1 to 12, characterized in that, The control device also includes an anti-tamper mechanism, installed between the power output terminal of the monitoring device and the insulated wire portion of the power connection terminal of the welding / cutting equipment. The anti-tamper mechanism includes an anti-tamper switch, a signal line, and a clamp. The anti-tamper switch does not contact the housing of the welding / cutting equipment. The clamp is used to connect the anti-tamper switch and the signal line. The detection signal of the anti-tamper switch is transmitted to the I / O port of the MCU through the signal line. When the MCU simultaneously detects an interruption in the signal of the anti-tamper switch and a lack of current signal at the power output terminal of the monitoring device, it sends an alarm signal to the supervision and management platform.

14. A method for monitoring safe hot work in welding / cutting equipment, characterized in that, include: Step S100: Install the monitoring device according to any one of claims 1 to 13 at the power input terminal of the welding / cutting equipment that is ready to perform hot work; Step S200: After obtaining the welding / cutting equipment information through the information acquisition unit and binding it with the local information of the monitoring device, the information is uploaded to the supervision and management platform for filing. After confirmation by the supervision and management platform, the welding / cutting equipment filing identification information and the local filing identification information are demodulated by the MCU and stored in the local memory. Step S300: Obtain operator information through the information acquisition unit. The MCU compares and determines whether the operator's registration identification information is present locally. If the operator's registration identification information is not present locally, the monitoring device sends an operator authentication request to the supervision and management platform. If the authentication is successful, proceed to step S400; if the authentication fails, proceed to step S500. If the operator's registration identification information is present locally, proceed to step S400. In step S400, after receiving the "pass" information and operator registration information from the supervision and management platform, the MCU stores the operator registration information in the local memory and generates a first control command. The start / stop control unit responds to the first control command by connecting the mains power to the power input terminal of the welding / cutting equipment. The operator performs hot work. The MCU judges the working status of the welding / cutting equipment until it determines that the welding / cutting equipment is in a suspended or stopped state. Then, it generates a third control command. The start / stop control unit responds to the third control command by disconnecting the mains power from the power input terminal of the welding / cutting equipment. The MCU generates a work log for this hot work operation and temporarily stores it in the local memory. It is then uploaded to the supervision and management platform for archiving in real time or after the network is restored. In step S500, after receiving the "failed" information returned by the supervision and management platform, the MCU generates a second control command. The start / stop control unit responds to the second control command to keep the mains power disconnected from the power input terminal of the welding / cutting equipment.

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