Device, system and method for preventing sudden stop and false triggering on processing equipment

Abstract

The invention discloses a sudden stop and false triggering prevention device, system and method for machining equipment, belongs to the technical field of safety control of machining equipment, and effectively avoids false triggering caused by unplanned external force interference through design of a compression stroke threshold value of a compression spring of an elastic damping false triggering prevention mechanism. Meanwhile, the emergency stop response reliability is improved by combining an emergency stop line multi-point pull rope linkage triggering mechanism, the double technical advantages of structural mistaken touch prevention and intelligent triggering judgment are achieved, and the technical problems that a traditional emergency stop device is prone to mistaken touch and unreliable in triggering are solved; a pull rope winding module, a data acquisition module, a tension and compression sensor and a control host are arranged on the basis of the structure of the device for preventing sudden stop and false triggering, and the tension and compression sensor is combined with the data acquisition module in a signal transmission mode, so that intelligent upgrading of a sudden stop triggering mechanism of the device for preventing sudden stop and false triggering is realized; the method has the effects of autonomously identifying abnormal working conditions and accurately responding.

Description

Technical Field

[0001] This invention relates to the field of safety control technology for processing equipment, and in particular to a device, system and method for preventing accidental triggering of emergency stops on processing equipment. Background Technology

[0002] In existing designs, emergency stop devices for some processing equipment, such as roller conveyors, generally present a dual safety hazard:

[0003] On the one hand, the emergency stop button of traditional emergency stop devices is fixed in a specific area of ​​the control panel. When the operator is in the equipment working area or far away from the control panel, the emergency stop function cannot be triggered in time, which leads to the expansion of safety accidents.

[0004] On the other hand, exposed emergency stop buttons are prone to unplanned shutdowns due to accidental activation or minor external interference, affecting production continuity. Especially in scenarios involving equipment vibration or accidental personnel collisions, traditional mechanical emergency stop structures lack necessary anti-accidental activation buffer mechanisms, significantly increasing the probability of the emergency stop device being abnormally triggered.

[0005] Furthermore, existing emergency stop devices lack the intelligent recognition capability of triggering force and intent, making it difficult to distinguish between normal operation and abnormal pulling, thus limiting their safety protection effectiveness. To address these issues, existing technologies urgently need improvement. Summary of the Invention

[0006] The purpose of this invention is to provide a device, system, and method for preventing accidental triggering of emergency stops on processing equipment. The device achieves the function of preventing accidental triggering of emergency stops through an elastic damping anti-accidental triggering mechanism, and improves the reliability of emergency stop triggering by linking the emergency stop line with multiple pull ropes, effectively solving the problem of easy accidental triggering of traditional emergency stop devices.

[0007] To achieve the above objectives, the technical solutions of the present invention are as follows:

[0008] As one aspect of this application, a device for preventing accidental triggering of emergency stops on processing equipment includes:

[0009] An emergency stop device, which is used to stop the processing equipment from operating when triggered;

[0010] An emergency stop line is provided with multiple pull ropes. The emergency stop line is configured to pull the pull ropes to pull the emergency stop line and trigger the emergency stop device.

[0011] An elastic damping anti-accidental contact mechanism includes a positioning seat, a connecting rod, and a compression spring. A hollow area is provided on the positioning seat, and the compression spring is disposed in the hollow area. The connecting rod is slidably installed through the positioning seat and the compression spring. An emergency stop device and an emergency stop line are respectively connected to the two ends of the connecting rod. The emergency stop device is triggered only when the restoring force of the compression spring is overcome by pulling the rope, thus preventing accidental contact with the rope in the application environment of the processing equipment.

[0012] A square tube crossbar, on which an elastic damping anti-accidental contact mechanism, an emergency stop line, and a pull rope are installed;

[0013] Pulling one of the ropes to activate the emergency stop line moves the connecting rod, compressing the spring until it is compressed to the set position within the hollow area. At this point, the pull button of the emergency stop device is pulled out, activating the emergency stop function and preventing accidental triggering of the emergency stop.

[0014] Compared with the prior art, the present application provides a device for preventing accidental triggering of emergency stops on processing equipment. Through the compression stroke threshold design of the compression spring of the elastic damping anti-accidental triggering mechanism, it effectively avoids accidental triggering caused by unplanned external force interference. At the same time, it improves the reliability of emergency stop response by combining the multi-point pull rope linkage triggering mechanism of the emergency stop line. It has the dual technical advantages of structural anti-accidental triggering and intelligent trigger judgment, and solves the technical problems of easy accidental triggering and unreliable triggering of traditional emergency stop devices.

[0015] Furthermore, the upper end of the positioning seat has hollow ear loops on both sides, and the hollow area is formed between the two oppositely arranged ear loops. The connecting rod passes through the two ear loops and the hollow area and is installed on the positioning seat.

[0016] A ring is fixedly installed on the connecting rod. After the connecting rod is installed on the positioning seat body, the ring is placed in the hollow area.

[0017] When the connecting rod moves in the direction constrained by the ear and the hollow area, the ring pushes the compression spring to compress or guides the compression spring to return to its original deformation.

[0018] Furthermore, the end of the connecting rod near the emergency stop line is bent upward to form a curved section, and a protrusion is provided on the curved section;

[0019] The emergency stop line is bent at one end near the connecting rod to form a bent section;

[0020] The bent part is fitted onto the curved part to connect the connecting rod to the emergency stop line, and the movement is limited by the protrusion to prevent it from coming off.

[0021] Furthermore, the square tube crossbar is a square tube crossbar with a square cross-section, and the corner of the square tube crossbar has an arc-shaped transition;

[0022] When the emergency stop line is statically stored on the square tube crossbar, the emergency stop line is set at the arc-shaped transition position.

[0023] Furthermore, a cable tie is provided on the square tube crossbar. The cable tie is used to fix the emergency stop line to prevent the emergency stop line from being accidentally triggered by equipment vibration or by the pull rope.

[0024] After the cable tie is installed on the square tube crossbar, an emergency stop line storage area is formed between the cable tie and the arc transition position on the square tube crossbar. When the emergency stop line is statically stored on the square tube crossbar, the emergency stop line is set in this emergency stop line storage area.

[0025] After the cable tie is installed on the square tube crossbar, there is a gap between the cable tie and one side of the square tube crossbar, which serves as a guide path for the movement of the emergency stop line when it is pulled down.

[0026] Furthermore, the device for preventing accidental triggering of emergency stops also includes:

[0027] The mounting bracket clamps and fixes the square tube crossbar, and the emergency stop device is mounted on the mounting bracket.

[0028] As a second aspect of this application, a system for preventing accidental emergency stop triggering on processing equipment, applied to the aforementioned device for preventing accidental emergency stop triggering, includes:

[0029] A pull rope winding module is installed on the pull rope and is used to wind up the pull rope to pull the compression spring in the elastic damping anti-accidental contact mechanism.

[0030] A data acquisition module is installed on a square tube crossbar and is connected to an external control host via a wireless network or a wired network.

[0031] A tension / compression sensor is installed on the pull rope. The tension / compression sensor is used to detect the tension on the pull rope in real time and transmit the detected tension to the control host through the data acquisition module.

[0032] The control host is used to control the rope winding module to wind up the rope when the tension detected by the tension sensor in real time is greater than or equal to a preset threshold. This causes the emergency stop line to drive the connecting rod to move and compress the compression spring. When the compression spring is compressed to a set position in the hollow area, the pull button of the emergency stop device is pulled out, thus enabling the emergency stop device to activate the emergency stop function.

[0033] Compared with existing technologies, this application provides a system for preventing accidental emergency stop triggering on processing equipment. By building upon the device for preventing accidental emergency stop triggering, a multi-level linkage mechanism is constructed to achieve intelligent triggering of the emergency stop function. The control host makes judgments based on preset thresholds. When the detected tension reaches the preset threshold, a control command is output to the rope winding module. This module replaces the traditional manual pulling operation with a mechanical winding action. In the application of the system for preventing accidental emergency stop triggering, the emergency operation characteristics of traditional ropes are retained while intelligent judgment capabilities are introduced, effectively balancing the needs of response speed and accidental triggering protection.

[0034] As a third aspect of this application, a method for preventing accidental emergency stop triggering on a processing device, executed by the aforementioned system for preventing accidental emergency stop triggering, the method comprising:

[0035] The tension force on the rope is detected in real time using a tension / compression sensor.

[0036] The data acquisition module collects data on the real-time detected tensile force.

[0037] The host computer processes the collected tension data and compares the processed tension data with a preset threshold. Based on the comparison result, it outputs an emergency stop signal to the relay of the rope winding module.

[0038] The emergency stop device is activated via a relay on the rope winding module based on an emergency stop signal.

[0039] This application provides a method for preventing accidental emergency stop triggering on processing equipment. Based on the existing method for preventing accidental emergency stop triggering, it incorporates a rope winding module, a data acquisition module, a tension / compression sensor, and a control host on the structural basis of the device. The tension / compression sensor and the data acquisition module are combined via signal transmission. The control host then compares the processed tension data with a preset threshold value and outputs an emergency stop signal based on the result. This emergency stop signal enables the emergency stop function, thus achieving an intelligent upgrade of the emergency stop triggering mechanism of the device. It features the ability to autonomously identify abnormal operating conditions and respond accurately.

[0040] Furthermore, the step of processing the collected tension data through the control host, comparing the processed tension data with a preset threshold, and outputting an emergency stop signal to the relay of the rope winding module based on the judgment result specifically includes:

[0041] Set emergency stop mode and abnormal stop mode;

[0042] A preset critical threshold for tensile force change is established. The host computer processes the collected tensile force data to obtain the rate of change of the detected tensile force. Based on the rate of change of tensile force and the critical threshold, it determines whether to enter emergency stop mode or abnormal stop mode and performs the following operations:

[0043] If the detected rate of change of tension exceeds the critical threshold of tension change, the system enters emergency stop mode. Within a set time window, the system acquires tension data and compares the acquired tension data with a preset peak force threshold. When the conditions of the rate of change of tension exceeding the critical threshold and the acquired tension data exceeding the preset peak force threshold within the set time window are met, an emergency stop signal is output.

[0044] The system enters an abnormal shutdown mode when the rate of change of the detected tensile force is less than or equal to the critical threshold of tensile force change. It continuously monitors the collected tensile force data, and outputs an abnormal shutdown signal when at least one collected tensile force data exceeds the preset peak force threshold within a set time window.

[0045] Furthermore, before the step of processing the collected tension data through the control host and determining whether the processed tension data is greater than or equal to a preset threshold, and if so, outputting an emergency stop signal to the relay of the rope winding module based on the determination result, the method further includes:

[0046] Configure a pull rope sensing module, a pull rope tension state judgment module, and a threshold adjustment module;

[0047] The inherent vibration state of the pull rope is periodically acquired by the pull rope sensing module;

[0048] The tension state of the rope is obtained by extracting data from the natural vibration state of the rope through the rope tension state determination module.

[0049] The threshold adjustment module adjusts the various judgment thresholds for emergency stop mode and abnormal stop mode based on the current tension of the pull rope.

[0050] Compared with existing technologies, the present application provides a device, system, and method for preventing accidental triggering of emergency stops on processing equipment. Through the design of the compression stroke threshold of the compression spring in the elastic damping anti-accidental-trigger mechanism, it effectively avoids accidental triggering caused by unplanned external force interference. Simultaneously, it combines a multi-point pull-rope linkage triggering mechanism for the emergency stop line to improve the reliability of the emergency stop response. It possesses dual technical advantages of structural anti-accidental-triggering and intelligent trigger judgment, solving the technical problems of easy accidental triggering and unreliable triggering in traditional emergency stop devices. Furthermore, in the corresponding system and method, by setting a pull-rope winding module, a data acquisition module, a tension / compression sensor, and a control host on the structural basis of the anti-accidental-triggering device, and by combining the tension / compression sensor and the data acquisition module through signal transmission, it achieves an intelligent upgrade of the emergency stop triggering mechanism of the anti-accidental-triggering device, enabling it to autonomously identify abnormal working conditions and respond accurately.

[0051] To better understand and implement this invention, the following detailed description is provided in conjunction with the accompanying drawings. Attached Figure Description

[0052] Figure 1 This is a schematic diagram of the structure of the device for preventing accidental triggering of emergency stop in this embodiment;

[0053] Figure 2 yes Figure 1 A schematic diagram of the structure at point A in the middle;

[0054] Figure 3 This is a schematic diagram of the structure of the indicator elastic damping anti-accidental-triggering mechanism in the emergency stop mis-triggering device in this embodiment;

[0055] Figure 4 yes Figure 2 A schematic diagram of the structure at point B in the middle;

[0056] Figure 5 This is a schematic diagram of the structure of the emergency stop false triggering system applied to the emergency stop false triggering device in this embodiment;

[0057] Figure 6 This is a structural block diagram of the system for preventing accidental emergency stop triggering in this embodiment;

[0058] Figure 7 This is a flowchart illustrating the method for preventing accidental triggering of emergency stops in this embodiment;

[0059] Figure 8 This is a flowchart illustrating step S3 in the method for preventing accidental triggering of emergency stop in this embodiment;

[0060] Figure 9 This is a flowchart illustrating the steps applied before step S3 in the method for preventing accidental emergency stop triggering in this embodiment.

[0061] Figure label:

[0062] 1. Elastic damping anti-accidental touch mechanism; 11. Positioning seat; 12. Linkage rod; 13. Compression spring; 2. Emergency stop device; 3. Emergency stop line; 5. Pull rope; 4. Square tube crossbar; 111. Ear buckle; 132. Ring; 121. Curved part; 122. Protrusion; 41. Arc transition; 6. Cable tie; 61. Emergency stop line storage area; 62. Interval space; 7. Mounting frame; 100. Pull rope winding module; 200. Data acquisition module; 300. Tension and compression sensor; 400. Control host; 31. Bending part. Detailed Implementation

[0063] To better illustrate the present invention, the invention will now be described in further detail with reference to the accompanying drawings.

[0064] It should be understood that, in order to make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. The components of the embodiments of this disclosure described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this disclosure provided in the accompanying drawings is not intended to limit the scope of the claimed disclosure, but merely represents selected embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without inventive effort are within the scope of protection of this disclosure.

[0065] The following is a specific embodiment for illustration. In this embodiment:

[0066] Firstly, such as Figure 1 As shown, a device for preventing accidental triggering of emergency stops on processing equipment includes:

[0067] Emergency stop device 2, which is used to stop the operation of the processing equipment when triggered, for example, the emergency stop device includes an emergency stop triggering unit and a pull-out button configured to trigger the emergency stop triggering unit;

[0068] Emergency stop line 3, with multiple pull ropes 5 installed on it. The emergency stop line 3 is configured to pull the pull ropes 5 to pull the emergency stop line 3 to pull the emergency stop device and trigger the emergency stop device.

[0069] An elastic damping anti-accidental contact mechanism 1 includes a positioning seat 11, a connecting rod 12, and a compression spring 13. A hollow area is provided on the positioning seat 11, and the compression spring 13 is disposed in the hollow area. The connecting rod 12 is slidably installed through the positioning seat 11 and the compression spring 13. An emergency stop device 2 and an emergency stop line 3 are respectively connected to both ends of the connecting rod 12. The emergency stop device 2 is triggered only when the pull rope 5 overcomes the restoring force of the compression spring 13, thus preventing accidental contact with the pull rope 5 in the application environment of the processing equipment.

[0070] A square tube crossbar 4, on which an elastic damping anti-accidental contact mechanism 1, an emergency stop line 3, and a pull rope 5 are installed;

[0071] Pulling one of the pull ropes 5 to activate the emergency stop line 3 causes the connecting rod 12 to move and compress the compression spring 13. When the compression spring 13 is compressed to the set position in the hollow area, the pull button of the emergency stop device 2 is pulled out, thus enabling the emergency stop device 2 to activate the emergency stop function and thereby prevent the emergency stop from being accidentally triggered.

[0072] The distributed connection structure of the emergency stop line 3 and multiple pull ropes 5 constructs an emergency stop triggering network covering the area surrounding the processing equipment. Operators can trigger the emergency stop function from any position by pulling the emergency stop line 3. Through the linkage design of the compression spring 13 and the connecting rod 12 mechanism, the switch pull action needs to overcome elastic resistance during the triggering process. This mechanical structure not only ensures the reliability of the triggering action, but also effectively prevents false triggering due to vibration or accidental contact through the elastic reset function. This mechanical linkage system expands the triggering method of the emergency stop device 2 from a single fixed button to a multi-point movable triggering structure. At the same time, the elastic damping anti-accidental touch mechanism forms a physical confirmation mechanism for the triggering action, thereby improving the convenience of operation and enhancing the reliability of the system.

[0073] In practical applications, when the operator pulls any of the pull ropes 5, the displacement of the emergency stop line 3 is converted into the elastic deformation of the compression spring 13 through the connecting rod 12. At this time, the limiting ring 132 on the connecting rod 12 will contact the end of the compression spring 13 and push it to compress. Only when the external force overcomes the spring resistance and compresses to the set position will the pull button of the emergency stop device 2 be pulled out and the emergency stop function will be triggered.

[0074] In this embodiment, the device to prevent accidental emergency stop triggering utilizes the synergistic effect of an elastic reset mechanism and a mechanical transmission system. This provides initial reset force while absorbing unexpected minor external forces through elastic deformation, preventing accidental triggering due to vibration or slight collisions. The combined design of the emergency stop line 3 and the pull rope 5 establishes a multi-point triggering mechanism, allowing emergency stop operations to be performed at any designated location on the device, significantly shortening the response time.

[0075] This embodiment describes a device for preventing accidental triggering of emergency stops on processing equipment. Through the compression stroke threshold design of the compression spring 13 of the elastic damping anti-accidental triggering mechanism 1, it effectively avoids accidental triggering caused by unplanned external force interference. At the same time, it improves the reliability of emergency stop response by combining the multi-point pull rope 5 linkage triggering mechanism of the emergency stop line 3. It has the dual technical advantages of structural anti-accidental triggering and intelligent trigger judgment, and solves the technical problems of easy accidental triggering and unreliable triggering of traditional emergency stop devices.

[0076] In this embodiment, as Figure 2 and Figure 3 As shown, the upper end of the positioning seat 11 has hollow ear loops 111 on both sides, and the hollow area is formed between the two oppositely arranged ear loops 111. The connecting rod 12 passes through the two ear loops 111 and the hollow area and is installed on the positioning seat 11.

[0077] A ring 132 is fixedly installed on the connecting rod 12. After the connecting rod 12 is installed on the main body of the positioning seat 11, the ring 132 is placed in the hollow area.

[0078] When the connecting rod 12 moves in the direction constrained by the ear buckle 111 and the hollow area, the ring 132 pushes the compression spring 13 to compress or guides the compression spring 13 to restore its deformation.

[0079] Specifically, the double-ear buckle 111 structure forms a guide frame, and the hollow area therebetween constitutes a directional channel for spring compression. When the connecting rod 12 moves along the direction defined by the ear buckle 111, the engagement of the ring 132 with the hollow area achieves a dual function: during the compression phase, the front end face of the ring 132 forms a surface contact with the end face of the compression spring 13, converting the axial displacement of the connecting rod 12 into the pressure of the compression spring 13; during the reset phase, the ring 132 slides against the compression spring 13, guiding the spring to rebound axially through the ring 132.

[0080] As an example, the positioning seat 11 and its upper two side ear clips 111 are integrally formed by casting, with the distance between the two ear clips 111 being a rectangular hollow area. The ring 132 is welded onto the connecting rod 12 and is fixed perpendicularly to the connecting rod 12. When the emergency stop line 3 is pulled by an external force, the connecting rod 12 drives the ring 132 to move along the axial direction defined by the ear clips 111, and the compression spring 13 undergoes uniform compression deformation under the action of the front end face of the ring 132; when the external force is removed, the annular guide surface on the inner side of the ring 132 contacts the outer periphery of the spring, guiding the spring to rebound and reset along the axial direction.

[0081] In this embodiment, as Figure 2 and Figure 3As shown, the connecting rod 12 is bent upward at one end near the emergency stop line 3 to form a curved section 121, and a protrusion 122 is provided on the curved section 121; the emergency stop line 3 is bent at one end near the connecting rod 12 to form a bent section 31; the bent section 31 is fitted onto the curved section 121 to connect the connecting rod 12 to the emergency stop line 3, and is prevented from dislodging by the movement limit of the protrusion 122.

[0082] The curved section 121 refers to the arc-shaped structure formed by bending one end of the connecting rod 12 upwards. Its purpose is to provide a bearing surface with a certain curvature for the bent section 31 of the emergency stop line 3. The protrusion 122 is arranged on the outside of the curved section 121 as a limiting element. It can be installed by welding, threaded connection or integral molding, etc. Its purpose is to constrain the movement trajectory of the bent section 31 of the emergency stop line 3 through mechanical blocking.

[0083] When the emergency stop line 3 is pulled by the pull rope 5, the bent part 31 of the emergency stop line 3 contacts the curved part 121. The protrusion 122 serves as a limiting structure. After the bent part 31 is sleeved on the curved part 121, its axial displacement along the curved part 121 is limited by the protrusion 122.

[0084] In addition, this structure works in conjunction with the ear buckle 111 of the positioning seat 11 and the compression spring 13. When the emergency stop line 3 is pulled, the connecting rod 12 drives the ring 132 to compress the spring 13, and the bent part 31 of the emergency stop line 3 stops on the curved part 121. The protrusion 122 plays a limiting role in this process.

[0085] In this embodiment, as Figure 4 As shown, the square tube crossbar 4 is a square tube crossbar with a square cross-section, and the corner of the square tube crossbar 4 has an arc transition 41; when the emergency stop line 3 is statically stored on the square tube crossbar 4, the emergency stop line 3 is set at the position of the arc transition 41.

[0086] Among them, the arc transition 41 refers to the transition structure with a continuous smooth curved surface at the corner, which can be achieved by curves with different radii of curvature, such as circular arc chamfers, elliptical arc transitions, or involute surfaces.

[0087] Specifically, the arc-shaped transition area 41 at the corner serves as a sliding channel for the emergency stop line 3, and its radius of curvature matches the diameter of the emergency stop line 3, allowing the emergency stop line 3 to move smoothly along the curved surface during the pulling process. When the emergency stop line 3 is in a static storage state, it naturally embeds itself into the arc-shaped transition area 41 under its own weight, forming a stable positioning state.

[0088] In this embodiment, as Figure 4 As shown, a cable tie 6 is provided on the square tube crossbar 4. The cable tie 6 is used to fix the emergency stop line 3 to prevent the emergency stop line 3 from being accidentally triggered by equipment vibration or by the pull rope.

[0089] After the cable tie 6 is installed on the square tube crossbar 4, an emergency stop line storage area 61 is formed between the cable tie 6 and the arc transition 41 position on the square tube crossbar 4. When the emergency stop line 3 is statically stored on the square tube crossbar 4, the emergency stop line 3 is set in the emergency stop line storage area 61.

[0090] After the cable tie 6 is installed on the square tube crossbar 4, there is a gap space 62 between the cable tie 6 and one side of the square tube crossbar 4. This gap space 62 serves as a movement guide path when the emergency stop line 3 is pulled downward.

[0091] Among them, cable tie 6 refers to the mechanical limiting structure used to constrain the spatial position of emergency stop line 3, which can be implemented in the form of U-shaped buckle, elastic clamping structure, etc.

[0092] Specifically, a dual constraint system is constructed through the structural cooperation of cable ties 6 and square tube crossbars 4. When the emergency stop line 3 is in a static storage state, it is embedded in the emergency stop line storage area 61. The arc-shaped transition surface 41 of this area works together with the inner surface of the cable tie 6 at the upper end to form a circumferential limit on the emergency stop line 3. When the emergency stop line 3 is pulled downward, the space 62 between the inner surface of the cable tie 6 and the square tube crossbar serves as a guide path, and the emergency stop line 3 is restricted by lateral swing and moves downward along the guide path.

[0093] As a concrete example, a square cable tie 6 made of metal is installed in the square cross-section area of ​​the square tube crossbar 4 using threaded fasteners. The square opening of the cable tie 6 and the arc transition 41 of the square tube crossbar 4 form an emergency stop cable storage area 61. A wedge-shaped gap 62 is maintained between the side of the cable tie 6 and the end of the square tube crossbar 4, the minimum spacing of which is slightly smaller than the diameter of the emergency stop cable 3. During installation, the emergency stop cable 3 is embedded in the storage area when not in use, and when pulled by an external force, the emergency stop cable 3 slides smoothly along the wedge-shaped guide surface of the gap 62.

[0094] By setting cable ties 6 on the square tube crossbar 4 to construct an emergency stop line storage area 61, the influence of equipment vibration on the emergency stop line 3 is effectively eliminated. At the same time, the space 62 serves as a guide path to ensure that the movement trajectory of the emergency stop line 3 is controllable when the emergency stop is triggered. Thus, the stability of the non-working state is improved, and the response reliability of the emergency stop function is guaranteed.

[0095] In this embodiment, as Figure 1 As shown, the device for preventing accidental triggering of emergency stops also includes:

[0096] Mounting bracket 7 clamps and fixes the square tube crossbar 4, and the emergency stop device 2 is set on the mounting bracket 7. The emergency stop device 2 is installed and positioned, so that the mounting bracket 7, the square tube crossbar, the elastic damping anti-accidental contact mechanism 1 and the emergency stop device 2 can be used as a whole on various processing equipment.

[0097] Secondly, such as Figure 5 and Figure 6 As shown, a system for preventing accidental emergency stop triggering on a processing equipment is provided, applied to the aforementioned device for preventing accidental emergency stop triggering, comprising:

[0098] A rope winding module 100 is installed on the rope and is used to wind up the rope to pull the compression spring 13 in the elastic damping anti-accidental contact mechanism 1.

[0099] The data acquisition module 200 is installed on the square tube crossbar and is connected to the external control host 400 via a wireless network or a wired network.

[0100] A tension / compression sensor 300 is installed on the pull rope. The tension / compression sensor 300 is used to detect the tension on the pull rope in real time and transmit the detected tension to the control host 400 through the data acquisition module 200.

[0101] The control host 400 is used to control the rope winding module 100 to wind up the rope when the tension detected by the tension sensor in real time is greater than or equal to a preset threshold, thereby causing the emergency stop line 3 to drive the connecting rod 12 to move and compress the compression spring 13. When the compression spring 13 is compressed to a set position in the hollow area, the pull button of the emergency stop device 2 is pulled out, thereby enabling the emergency stop device 2 to activate the emergency stop function.

[0102] In this embodiment, the system for preventing accidental triggering of emergency stops achieves intelligent triggering of the emergency stop function by constructing a multi-level linkage mechanism. The tension sensor 300 monitors the force state of the pull rope in real time, and its detection signal is transmitted to the control host 400 via the data acquisition module 200. This data link design allows changes in physical tension to be instantly converted into digital signal processing. The control host 400 makes judgments based on preset thresholds. When the detected tension reaches the preset threshold, it outputs a control command to the pull rope winding module 100. This module replaces the traditional manual pulling operation with a mechanical winding action, eliminating the delay in human reaction time and filtering out unexpected slight tension disturbances through the threshold judgment mechanism. The mechanical action of the pull rope winding module 100 works in conjunction with the existing elastic damping anti-accidental triggering mechanism, using the tension of the pull rope to convert into the displacement of the compression spring 13, ultimately triggering the emergency stop device 2 through the connecting rod 12.

[0103] This embodiment provides a system for preventing accidental emergency stop triggering on processing equipment. By building upon the device for preventing accidental emergency stop triggering, a multi-level linkage mechanism is constructed to achieve intelligent triggering of the emergency stop function. The control host 400 makes judgments based on preset thresholds. When the detected tension reaches the preset threshold, it outputs a control command to the rope winding module 100. This module replaces the traditional manual pulling operation with a mechanical winding action. In the application of the system for preventing accidental emergency stop triggering, the emergency operation characteristics of the traditional rope are retained, while intelligent judgment capabilities are introduced, effectively balancing the needs of response speed and accidental triggering protection.

[0104] In some of the aforementioned implementations, a mechanism for triggering the emergency stop function based on a tension threshold has been proposed. However, in this process, relying solely on a fixed tension threshold is prone to false triggering due to momentary vibrations of the pull rope or equipment vibrations. When an operator accidentally touches the pull rope in a non-emergency situation, if the tension fluctuation happens to exceed the preset threshold, it will cause unplanned shutdown of the production line, affecting production continuity. In addition, the inherent tension state of the pull rope varies under different operating conditions, and a fixed threshold cannot adapt to dynamically changing usage environments, resulting in an imbalance in trigger sensitivity.

[0105] Therefore, in this embodiment, thirdly, as Figure 7 and Figure 8 As shown, a method for preventing accidental emergency stop triggering on a processing device is provided, executed by the emergency stop prevention system described above. The emergency stop prevention method includes:

[0106] Step S1: Real-time detection of the tension force on the pull rope using a tension / compression sensor;

[0107] Step S2: Collect data on the real-time detected tensile force through the data acquisition module;

[0108] Step S3: The host computer processes the collected tension data and compares the processed tension data with a preset threshold. Based on the comparison result, an emergency stop signal is output to the relay of the rope winding module.

[0109] Step S4: The emergency stop device is activated by controlling the emergency stop function through the relay of the rope winding module according to the emergency stop signal.

[0110] Specifically, step S3 includes:

[0111] Step S31: Set the emergency stop mode and the abnormal stop mode;

[0112] Step S32: Preset the critical threshold for tensile force change. After processing the collected tensile force data by the control host, obtain the rate of change of tensile force corresponding to the detected tensile force data. Based on the rate of change of tensile force and the critical threshold, determine whether to enter the emergency stop mode or the abnormal stop mode, and perform the following operations:

[0113] If the detected rate of change of tensile force exceeds the critical threshold, the system enters emergency stop mode. Within a set time window, it acquires tensile force data and compares the acquired data with a preset peak force threshold. If both the rate of change of tensile force exceeds the critical threshold and the acquired tensile force data within the set time window exceeds the preset peak force threshold, an emergency stop signal is output. Conversely, if the detected rate of change of tensile force is less than or equal to the critical threshold, the system enters abnormal stop mode. It continuously monitors the acquired tensile force data, and if at least one acquired tensile force data exceeds the preset peak force threshold within the set time window, an abnormal stop signal is output.

[0114] Among them, the emergency shutdown mode refers to a high-priority response mechanism triggered when the rate of change of tension exceeds the preset critical threshold of tension change. Its purpose is to quickly respond to sudden and drastic changes in tension, such as the decisive and forceful emergency pulling action taken by operators when facing real danger to processing equipment. The abnormal shutdown mode refers to a response mechanism that continuously monitors slowly changing abnormal tension. Its purpose is to capture cumulative overload risks, such as the response mode when tools or materials are slightly leaning against the pull rope for a long time.

[0115] Specifically, the system periodically collects the tension signal of the pull rope through the tension sensor, judges the tension data obtained by analyzing the tension signal, and selects to enter the emergency stop mode or the abnormal stop mode based on the judgment result, that is, executes two sets of judgment logic.

[0116] For the implementation logic of the emergency stop mode, firstly, the control host 400 continuously monitors the tension data obtained after preprocessing (such as noise reduction processing) through tension and compression sensors, and calculates the current tension change rate and the peak value of the current tension data in real time within a set time window (such as 0.5s). For the calculation of the tension change rate, for example, the tension change rate can be calculated based on the difference in tension values ​​and the time interval between consecutive sampling points. For example, RFC = (F_n - F_{n-1}) / Δt, where F_n is the force value at the current sampling point, RFC indicates the tension change rate, F_{n-1} is the tension value at the previous sampling point, and Δt is the sampling time interval (such as 0.01 seconds). When the tension change rate exceeds a preset tension change threshold (such as 500 Newtons / second), it indicates that the pulling action is sudden and has a strong explosive force. For the peak value of the tension data, the maximum tension value within the current time window is recorded in real time. When this maximum force value exceeds a preset peak force threshold (such as 200 Newtons), it indicates that the pulling force is sufficiently large. In addition, at least one collected tension data point must exceed a preset peak force threshold within the set time window. If the collected tension data remains consistently below the preset peak force threshold within the current time window, it indicates a continuous and stable event, rather than a brief impact. This time window setting helps eliminate instantaneous force fluctuations caused by equipment vibration or brief collisions. The main control unit determines a valid emergency pull only when the tension change rate, peak force magnitude, and duration of the tension force simultaneously meet the requirements—for example, the tension change rate exceeding a critical threshold and the collected tension data exceeding the preset peak force threshold within the set time window. Once the determination is successful, the control host immediately sends an "emergency stop" signal to the equipment's main control system, causing all moving parts of the equipment to stop instantly.

[0117] For the judgment logic of abnormal shutdown mode, firstly, the control host 400 continuously monitors the pre-processed tension data. Through the tension and compression sensors, when the detected tension change rate is less than or equal to the tension change critical threshold (e.g., 5 seconds), it is determined that the abnormal shutdown mode has been entered. If the force corresponding to the tension data continues to increase and eventually meets all the conditions of the tension change critical threshold, the control host 400 will immediately upgrade the response to an abnormal shutdown signal, causing the equipment to stop instantly.

[0118] In this embodiment, the above-described solution can significantly reduce the number of false triggers of the rope-pulling emergency stop device on the processing equipment, thereby reducing production interruptions and economic losses caused by unnecessary shutdowns. Simultaneously, through a tiered response mechanism (combining emergency stop mode and abnormal stop mode), it improves the continuity and efficiency of equipment operation while ensuring operator safety, specifically through the effective application of a single pull in the abnormal stop mode.

[0119] In practical applications, especially on ultra-large, cross-regional processing equipment, such as a material conveyor line exceeding 100 meters in length, the environment along the line is not uniform. A common scenario is that this long line traverses different environmental areas during operation, resulting in significant, localized temperature differences along the rope. For example, some ropes may be located near high-temperature heat treatment furnaces, where temperatures can reach 70 degrees Celsius; while others extend into cooling zones or outdoors, where temperatures may be as low as 5 degrees Celsius. This temperature gradient directly affects the physical properties of the rope itself. The rope is typically made of polymer composite materials, and its elasticity, internal friction characteristics, and coefficient of thermal expansion all change non-linearly with temperature.

[0120] Specifically, in high-temperature zones, the pull rope becomes more flexible and has increased tensile strength; while in low-temperature zones, the pull rope becomes relatively stiff and may even shrink slightly.

[0121] Therefore, this solution needs an application that can accurately distinguish between the operator's true emergency pulling intention and unintentional contact, even when there are significant differences in ambient temperature along the rope causing non-uniform changes in its physical properties.

[0122] Therefore, in this embodiment, as Figure 9 As shown, before the step of processing the collected tension data and determining whether the processed tension data is greater than or equal to a preset threshold, and if so, outputting an emergency stop signal to the relay of the rope winding module based on the determination result, the following steps are also included:

[0123] A1. Configure the pull rope sensing module, the pull rope tension state judgment module, and the threshold adjustment module;

[0124] A2. The inherent vibration state of the pull rope is periodically obtained through the pull rope sensing module;

[0125] A3. The tension state of the pull rope is obtained by extracting data based on the natural vibration state of the pull rope through the pull rope tension state judgment module.

[0126] A4. The threshold adjustment module adjusts the various judgment thresholds for emergency stop mode and abnormal stop mode according to the current tension state of the pull rope.

[0127] Among them, the rope sensing module is used to obtain the vibration characteristics of the rope, and its purpose is to indirectly deduce the tension state by periodically monitoring the change of the natural frequency of the wire rope.

[0128] In this specific implementation, a small excitation device is installed at a fixed end of the pull rope (e.g., the end near the force sensor). Its function is to apply a brief, weak spectral vibration to the pull rope at a specific moment. For example, it can be set to activate the excitation device through the digital output port when the equipment is stopped or during a shift change on the production line, so that it generates a random frequency vibration lasting about 0.5 seconds to excite the inherent vibration of the pull rope.

[0129] The inherent vibration state of the pull rope is extracted from the vibration signal, which can be acquired by the tension sensor 300. The tension sensor 300 can reflect the vibration mode of the pull rope ear by detecting the tension signal.

[0130] In this embodiment, the rope sensing module is used to periodically acquire the inherent vibration state of the rope and determine its current overall tension state. For example, a fast Fourier transform is performed on the vibration signal to obtain vibration spectrum data based on the Fourier transform. One or several peak frequencies with the most concentrated energy are identified in the vibration spectrum data. These peak frequencies represent the dominant inherent vibration frequencies of the rope in the current state. For example, the three frequency peaks with the largest amplitude in the spectrum can be selected, and their average or weighted average can be taken as the characteristic inherent frequency of the current rope. Furthermore, it is known from the prior art that tension is directly proportional to the vibration frequency of the rope, that is, the higher the frequency, the greater the tension and the stiffer the rope; conversely, the lower the frequency, the smaller the tension and the softer the rope.

[0131] Therefore, we get: Tension deviation percentage = (Current characteristic natural frequency - Standard natural frequency) / Standard natural frequency × 100%.

[0132] Using a standard natural frequency of the rope measured at a standard ambient temperature (e.g., 25°C) as a benchmark, the overall tension of the rope is determined by comparing the deviation between the currently measured characteristic natural frequency and the standard natural frequency. This determines whether the tension increases (due to low-temperature contraction) or decreases (due to high-temperature elongation).

[0133] Furthermore, the current tension state is obtained by the tension state judgment module, and the judgment thresholds for emergency stop mode and abnormal stop mode are dynamically adjusted by the threshold adjustment module to adapt to changes in the physical characteristics of the tension rope. This is achieved through the threshold adjustment module.

[0134] For example, when the tension in the draw rope increases (the current frequency is higher than the standard frequency, and the draw rope becomes stiffer):

[0135] The critical threshold for tension change under abnormal shutdown mode should be appropriately increased. For example, the new threshold = original critical threshold for tension change × (1 + tension deviation percentage × adjustment coefficient A). The adjustment coefficient A can be set to 0.5 to prevent slight contact caused by stiffening of the pull rope from being mistakenly judged as abnormal.

[0136] Peak force threshold in emergency stop mode: can be slightly increased, for example, new threshold = original peak force threshold × (1 + tension deviation percentage × adjustment factor B). The adjustment factor B can be set to 0.2 because the tension rope becomes stiffer, the transmission efficiency is improved, and a greater actual pulling force may be needed to achieve the same sensor reading.

[0137] When the tension in the draw rope decreases (the current frequency is lower than the standard frequency, and the draw rope softens):

[0138] Peak force threshold in emergency stop mode: appropriately reduced, for example, new threshold = original peak force threshold × (1 - |tension deviation percentage| × adjustment factor C). The adjustment factor C can be set to 0.8 to compensate for the attenuation of tension transmitted in the rope and ensure that emergency pulls can be reliably identified.

[0139] The tension change rate threshold in emergency stop mode should be appropriately reduced. For example, the new threshold = original change rate threshold × (1 - |tension deviation percentage| × adjustment factor D). The adjustment factor D can be set to 0.6 because the soft rope may appear "sluggish" in response to rapid pulling.

[0140] The adaptive adjustment process of the above thresholds can be set to be executed periodically, for example, automatically every 15 minutes, or perform a self-check before each startup of the device to ensure that the judgment threshold is always consistent with the current physical state of the pull rope.

[0141] Finally, it should be noted that the above-described embodiments are merely specific implementations of this disclosure, used to illustrate the technical solutions of this disclosure, and not to limit them. The protection scope of this disclosure is not limited thereto. Although this disclosure has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some of the technical features within the scope of the technology disclosed in this disclosure. Such modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this disclosure, and should all be covered within the protection scope of this disclosure.

Claims

1. A device for preventing accidental triggering of emergency stops on processing equipment, characterized in that, include: An emergency stop device, which is used to stop the processing equipment from operating when triggered; An emergency stop line is provided with multiple pull ropes. The emergency stop line is configured to pull the pull ropes to pull the emergency stop line and trigger the emergency stop device. An elastic damping anti-accidental contact mechanism includes a positioning seat, a connecting rod, and a compression spring. A hollow area is provided on the positioning seat, and the compression spring is disposed in the hollow area. The connecting rod is slidably installed through the positioning seat and the compression spring. An emergency stop device and an emergency stop line are respectively connected to the two ends of the connecting rod. The emergency stop device is triggered only when the restoring force of the compression spring is overcome by pulling the rope, thus preventing accidental contact with the rope in the application environment of the processing equipment. A square tube crossbar, on which an elastic damping anti-accidental contact mechanism, an emergency stop line, and a pull rope are installed; Pulling one of the ropes to activate the emergency stop line moves the connecting rod, compressing the spring until it is compressed to the set position within the hollow area. At this point, the pull button of the emergency stop device is pulled out, activating the emergency stop function and preventing accidental triggering of the emergency stop.

2. The device for preventing accidental triggering of emergency stops on processing equipment according to claim 1, characterized in that: The upper end of the positioning seat has hollow ear buckles on both sides, and the hollow area is formed between the two oppositely arranged ear buckles. The connecting rod passes through the two ear buckles and the hollow area and is installed on the positioning seat. A ring is fixedly installed on the connecting rod. After the connecting rod is installed on the positioning seat body, the ring is placed in the hollow area. When the connecting rod moves in the direction constrained by the ear and the hollow area, the ring pushes the compression spring to compress or guides the compression spring to return to its original deformation.

3. A device for preventing accidental triggering of emergency stops on processing equipment according to claim 2, characterized in that: The end of the connecting rod near the emergency stop line is bent upward to form a curved section, and a protrusion is provided on the curved section. The emergency stop line is bent at one end near the connecting rod to form a bent section; The bent part is fitted onto the curved part to connect the connecting rod to the emergency stop line, and the movement is limited by the protrusion to prevent it from coming off.

4. A device for preventing accidental triggering of emergency stops on processing equipment according to claim 1, characterized in that: The square tube crossbar is a square tube crossbar with a square cross-section, and the corner of the square tube crossbar has an arc transition; When the emergency stop line is statically stored on the square tube crossbar, the emergency stop line is set at the arc-shaped transition position.

5. A device for preventing accidental triggering of emergency stops on processing equipment according to claim 4, characterized in that: A cable tie is provided on the square tube crossbar. The cable tie is used to fix the emergency stop line to prevent the emergency stop line from being accidentally triggered by equipment vibration or by the pull rope. After the cable tie is installed on the square tube crossbar, an emergency stop line storage area is formed between the cable tie and the arc transition position on the square tube crossbar. When the emergency stop line is statically stored on the square tube crossbar, the emergency stop line is set in this emergency stop line storage area. After the cable tie is installed on the square tube crossbar, there is a gap between the cable tie and one side of the square tube crossbar, which serves as a movement guide path when the emergency stop line is pulled down. After the cable tie is installed on the square tube crossbar, the cable tie is positioned adjacent to the pull rope. The cable tie provides a fulcrum for the corresponding pull rope, so that the emergency stop line around the pull rope or cable tie is locally tightened, reducing the risk of accidental contact with the pull rope by the processing equipment on site, which could lead to accidental emergency stop.

6. A device for preventing accidental triggering of emergency stops on processing equipment according to claim 1, characterized in that, The device for preventing accidental triggering of emergency stops also includes: The mounting bracket clamps and fixes the square tube crossbar, and the emergency stop device is mounted on the mounting bracket.

7. A system for preventing accidental emergency stop triggering on processing equipment, applied to the device for preventing accidental emergency stop triggering as described in any one of claims 1 to 6, characterized in that, include: A pull rope winding module is installed on the pull rope and is used to wind up the pull rope to pull the compression spring in the elastic damping anti-accidental contact mechanism. A data acquisition module is installed on a square tube crossbar and is connected to an external control host via a wireless network or a wired network. A tension / compression sensor is installed on the pull rope. The tension / compression sensor is used to detect the tension on the pull rope in real time and transmit the detected tension to the control host through the data acquisition module. The control host is used to control the rope winding module to wind up the rope when the tension detected by the tension sensor in real time is greater than or equal to a preset threshold. This causes the emergency stop line to drive the connecting rod to move and compress the compression spring. When the compression spring is compressed to a set position in the hollow area, the pull button of the emergency stop device is pulled out, thus enabling the emergency stop device to activate the emergency stop function.

8. A method for preventing accidental emergency stop triggering on processing equipment, executed by the system for preventing accidental emergency stop triggering as described in claim 7, characterized in that, The method for preventing accidental triggering of emergency stops includes: The tension force on the rope is detected in real time using a tension / compression sensor. The data acquisition module collects data on the real-time detected tensile force. The host computer processes the collected tension data and compares the processed tension data with a preset threshold. Based on the comparison result, it outputs an emergency stop signal to the relay of the rope winding module. The emergency stop device is activated via a relay on the rope winding module based on an emergency stop signal.

9. A method for preventing accidental triggering of emergency stops on processing equipment according to claim 8, characterized in that, The steps of processing the collected tension data through the control host, comparing the processed tension data with a preset threshold, and outputting an emergency stop signal to the relay of the rope winding module based on the judgment result, specifically include: Set emergency stop mode and abnormal stop mode; A preset critical threshold for tensile force change is established. The host computer processes the collected tensile force data to obtain the rate of change of the detected tensile force. Based on the rate of change of tensile force and the critical threshold, it determines whether to enter emergency stop mode or abnormal stop mode and performs the following operations: If the detected rate of change of tension exceeds the critical threshold of tension change, the system enters emergency stop mode. Within a set time window, the system acquires tension data and compares the acquired tension data with a preset peak force threshold. When the conditions of the rate of change of tension exceeding the critical threshold and the acquired tension data exceeding the preset peak force threshold within the set time window are met, an emergency stop signal is output. The system enters an abnormal shutdown mode when the rate of change of the detected tensile force is less than or equal to the critical threshold of tensile force change. It continuously monitors the collected tensile force data, and outputs an abnormal shutdown signal when at least one collected tensile force data exceeds the preset peak force threshold within a set time window.

10. A method for preventing accidental triggering of emergency stops on processing equipment according to claim 9, characterized in that, Before the step of processing the collected tension data through the control host and determining whether the processed tension data is greater than or equal to a preset threshold, and outputting an emergency stop signal to the relay of the rope winding module according to the determination result if so, the method further includes: Configure a pull rope sensing module, a pull rope tension state judgment module, and a threshold adjustment module; The inherent vibration state of the pull rope is periodically acquired by the pull rope sensing module; The tension state of the rope is obtained by extracting data from the natural vibration state of the rope through the rope tension state determination module. The threshold adjustment module adjusts the various judgment thresholds for emergency stop mode and abnormal stop mode based on the current tension of the pull rope.

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