Wire crossing protection alarm device for flexible cloth washing

Abstract

The invention discloses a line crossing protection alarm device for flexible cloth washing, and relates to the technical field of safety protection of flexible cloth washing equipment. The device comprises a mounting frame, a human visual identification module, a lifting column, a rope type lifting protective door, an operation indicating lamp, a control module, a sound box and an operation button group, the industrial-grade high-definition AI visual recognition module is used for achieving accurate monitoring of line crossing of personnel, the control module is combined to link the lifting column to drive the rope type lifting protective door to act, sound alarm, operation indicating lamp state switching and washing equipment starting and stopping, and meanwhile the functions of manual and automatic switching, sudden stop and initialized positioning are achieved. The problems that an existing protection device is low in monitoring precision, poor in linkage and weak in working condition adaptability are solved, the safety level and operation flexibility of the flexible cloth washing production line are improved, and the protection device is low in cost, convenient to operate, suitable for 24-hour continuous operation scenes and high in industry popularization value.

Description

Technical Field

[0001] This invention belongs to the field of safety protection technology for flexible fabric washing equipment, and particularly relates to an alarm device for preventing flexible fabric washing equipment from crossing the line. Background Technology

[0002] During the washing process of flexible fabrics, the washing machine needs to operate at high speed continuously, and its internal transmission mechanism, washing rollers, and other components pose safety risks such as mechanical compression and entanglement. To prevent operators from crossing the line and entering the dangerous operating area of ​​the equipment due to misoperation or lack of concentration, existing flexible fabric washing production lines typically employ physical isolation and protection methods.

[0003] In the existing flexible fabric washing production lines in the industry, some companies use ordinary rope-type protective doors with manual control switches. Operators need to manually open / close the protective doors, which is cumbersome and prone to safety accidents due to people forgetting to close the doors. At the same time, most existing protective devices lack manual-automatic switching functions. In special working conditions such as equipment maintenance and fabric docking, the protective doors cannot be controlled by jogging, which reduces the flexibility of operation.

[0004] Existing safety protection devices for flexible fabric washing equipment have the following shortcomings: First, the monitoring method is easily affected by environmental factors such as water vapor and lint in the washing scenario, resulting in low accuracy in identifying personnel crossing the line and an inability to reliably monitor personnel intrusion into dangerous areas. Second, the linkage between the protective mechanism and the alarm system is poor, only achieving physical isolation or sound alarms, failing to form an integrated "monitoring-protection-alarm" protection system, thus limiting the effectiveness of safety protection. Third, there is a lack of manual / automatic switching functions adapted to special working conditions, making it difficult to ensure both safety and operational flexibility. Fourth, there is no customized design for flexible fabric washing scenarios, and the protective structure has poor adaptability to production line space and operational processes, easily affecting normal production efficiency. Therefore, there is an urgent need to design a line-crossing protection alarm device that is accurate in monitoring, highly interconnected, flexible in operation, and adapted to flexible fabric washing scenarios to address the deficiencies of existing technologies. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a protective alarm device for personnel crossing the line in flexible fabric washing production lines. This device enables precise monitoring of personnel crossing the line, flexible automatic / manual control of the protective door, and linkage between audible and visual alarms and equipment start / stop. It improves the safety protection level and operational flexibility of flexible fabric washing production lines and solves the problems in the background technology.

[0006] This invention provides the following technical solution: A flexible fabric water washing line crossing protection alarm device includes a mounting frame, a line crossing monitoring component, a protection execution component, a status indication component, a control module, an alarm component, and an operation control component; The mounting frame is fixed around the hazardous operation area of ​​the flexible cloth washing equipment and is used to support the over-line monitoring component, the protection execution component, the status indication component and the operation control component. The mounting frame is provided with a right upper column and a right lower column on the right side. The line crossing monitoring component is installed on the mounting frame and is used to collect personnel activity information in hazardous work areas in real time, identify personnel crossing behavior and generate a line crossing signal, which is then transmitted to the control module. The protective execution component is connected to the installation frame and operates under the control of the control module to form an openable and closable physical protective barrier to prevent personnel from entering the hazardous work area. The status indicator component is installed on the lower right column of the mounting frame and is electrically connected to the control module. It is driven by the control module to display the device's operating status in different states. The control module is electrically connected to the over-line monitoring component, the protection execution component, the status indication component, the alarm component, and the operation control component, respectively. It receives input signals from each component and outputs control commands to realize the linkage of each component. The alarm component is electrically connected to the control module and emits a warning signal when triggered by the control module to remind personnel to stay away from the danger zone. The operation control component is installed on the upper right column of the installation frame and includes a mode switching unit, an action control unit, an emergency control unit, and a calibration unit. Each unit is electrically connected to the control module and is used to manually control the device's operating mode switching, the action of the protective execution component, emergency shutdown, and position calibration.

[0007] Preferably, the line-crossing monitoring component is a human visual recognition module, including an industrial-grade high-definition camera and an AI visual analysis unit; the industrial-grade high-definition camera is installed on the upper right of the mounting frame and maintains a preset distance from the mounting frame to avoid mechanical interference; the AI ​​visual analysis unit identifies personnel crossing the line by using image information of dangerous work areas collected by the camera, and the industrial-grade high-definition camera has the ability to resist water vapor and lint interference, and is suitable for flexible cloth washing scene environment.

[0008] Preferably, the protective execution component includes a lifting column and a rope-type lifting protective door; the lifting column is a lifting drive component with a built-in drive motor and reduction mechanism, vertically fixed on both sides of the mounting frame, and its output end is connected to both ends of the rope-type lifting protective door; the rope-type lifting protective door is a flexible protective door body, with a high-strength rope as the core and a flexible protective layer on the outside, which rises and falls vertically under the drive of the lifting column to form a physical protective barrier; the drive motor of the lifting column is a DC motor, the lifting speed of the rope-type lifting protective door is 50-150mm / s, and the lifting column has a built-in limit switch for positioning the rope-type lifting protective door in the fully closed and fully open positions.

[0009] Preferably, the high-strength rope of the rope-type lifting safety gate is a stainless steel wire rope with a diameter of 6-10mm and a breaking strength ≥3000N; the flexible protective layer is made of rubber with a thickness of 3-8mm, which can prevent secondary injuries caused by accidental collisions by operators; and the rope-type lifting safety gate is equipped with at least 2 ropes along the height direction of the lifting column, with a rope spacing of 400-700mm to ensure that there are no gaps in the protective coverage area.

[0010] Preferably, the status indicator component is a running indicator light, using an LED light source, installed on the lower right corner of the top surface of the lower right column, and located at a height within the operator's line of sight (1.8-2.5m from the ground); the running indicator light is controlled by the control module and has three working states: off, constantly lit, and flashing, corresponding to three operating conditions: the rope lifting safety door is closed, the rope lifting safety door is open, and the human visual recognition module detects a person crossing the line; and the running indicator light is a dual-color light source, off when the rope lifting safety door is closed, constantly lit in green when it is open, and flashing red when someone crosses the line.

[0011] Preferably, the alarm component is a speaker, electrically connected to the control module. When the human visual recognition module detects a person crossing the line, the control module triggers the speaker to emit a preset voice prompt, the voice message being "Please note, you have entered a dangerous area, please exit immediately." The speaker output volume is adjustable, with an adjustment range of 60-120dB, suitable for the noisy environment of the flexible fabric washing workshop. At the same time, the speaker is linked with the operation indicator light; when the line crossing alarm occurs, the operation indicator light flashes synchronously to enhance the warning effect.

[0012] Preferably, the operation control component is an operation button group, including an open protective door button, a close protective door button, a manual / automatic switch button, an emergency stop button, and an initialization positioning button, all of which are installed on the upper side of the upper right column; The manual / automatic switching button is a mode switching unit, which adopts a button or knob structure to switch the operating mode of the rope lifting safety door, including automatic operation mode and jog operation mode. In automatic operation mode, the rope lifting safety door automatically rises and falls according to the crossing signal of the human visual recognition module or the operating status of the flexible cloth washing equipment. In jog operation mode, the rope lifting safety door only moves when the safety door open button or the safety door close button is continuously pressed, and stops immediately after the button is released. The button to open the protective door and the button to close the protective door are action control units, which are used to trigger the opening and closing actions of the rope-type lifting protective door, respectively. The emergency stop button is an emergency control unit with a mushroom-shaped structure. When pressed, it triggers the control module to cut off the power supply to the drive motor of the lifting column, causing the rope-type lifting safety door to stop moving. At the same time, it triggers a continuous audible alarm, a high-frequency flashing of the operation indicator light, and sends a stop signal to the flexible cloth washing equipment. The initialization positioning button is a calibration unit. When pressed, the control module drives the lifting column to move the rope-type lifting safety door to the preset initial position, which is the fully closed position, thus completing the position calibration.

[0013] Preferably, the control module is a programmable logic controller or an embedded control board, equipped with at least 16 digital input interfaces and 16 digital output interfaces, supporting data interaction with the control system of the flexible fabric washing equipment, and capable of sending speed reduction or shutdown signals to the washing equipment; the control module has built-in over-limit processing logic: upon receiving an over-limit signal from the human visual recognition module, it immediately triggers an audible alarm and flashes the operation indicator light; if the rope-type lifting safety door is in the open state, it synchronously drives the lifting column to close the rope-type lifting safety door; if the over-limit state lasts for more than 3 seconds, the control module sends a shutdown signal to the flexible fabric washing equipment; if the duration is ≤3 seconds, it sends a speed reduction signal.

[0014] Preferably, the mounting frame is made of stainless steel with anti-corrosion and anti-rust treatment. The frame height is 2000-3000mm, and the width is adapted to the width of the hazardous operation area of ​​the flexible cloth washing equipment. The mounting frame is fixed to the ground with expansion bolts, and the fixing point spacing is ≤1500mm to ensure the structural stability of the frame in the humid environment of the washing workshop. The cross-sectional dimensions of the upper right column and the lower right column are 60mm×60mm to 100mm×100mm to meet the installation strength requirements of each component.

[0015] Preferably, the device also includes a power supply module, which is electrically connected to the control module, human vision recognition module, lifting column, running indicator light, audio system, and operation buttons to provide stable power to each electrical component. The power supply module has an input voltage of AC220V and an output voltage of DC24V, and is equipped with overvoltage, overcurrent, and short-circuit protection functions to adapt to the power supply environment of flexible fabric washing workshops. The device also includes a communication module, which is electrically connected to the control module and can transmit the crossing information of the human vision recognition module and the operating status data of the rope lifting safety door to the remote monitoring terminal to realize remote monitoring and data recording.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This invention discloses a line-crossing protection alarm device for flexible fabric washing. It adopts an industrial-grade high-definition AI vision recognition module, which is resistant to water vapor and lint interference. It can accurately identify personnel crossing the line with high reliability. At the same time, it realizes the integrated linkage of "line-crossing recognition → protective door closing → sound alarm → indicator light flashing → equipment shutdown", forming a multi-level protection, significantly reducing the probability of safety accidents and improving the safety protection level of flexible fabric washing production line.

[0017] The system features a manual / automatic switching function. The automatic operation mode caters to the convenience needs of normal production, while the jog operation mode is designed for special working conditions such as equipment maintenance and fabric docking, balancing safety and operational flexibility. The rope-type lifting protective door adopts a high-strength flexible structure, which not only avoids secondary injuries from accidental collisions but also adapts to the spatial layout of flexible fabric washing production lines, making it highly adaptable to various scenarios.

[0018] The operation button group and operation indicator lights are logically laid out and easy to identify, and operators can master the basic operation in just 30 minutes; the emergency stop button adopts a mushroom head design, which can be quickly triggered in case of emergency, reducing the risk of operational errors; the initialization positioning function simplifies the protective door position calibration process and ensures stable operation of the device.

[0019] Each component of the device is resistant to moisture and lint, making it suitable for humid and lint-rich environments where flexible fabrics are washed, and it supports 24-hour continuous operation. The cost is 30% to 40% lower than that of customized protective systems in the industry, and based on production line operating efficiency, the equipment investment cost can be recovered in 3 to 6 months, indicating great potential for industry promotion. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0022] Figure 2 This is a flowchart of the lifting control program for the lifting column of the present invention.

[0023] Figure 3 This is a flowchart of the control logic program for the lifting column slide of the present invention.

[0024] Figure 4 This is a flowchart of the lifting column counter program of the present invention.

[0025] Figure 5 This is a flowchart of the synchronous rising procedure of the lifting column of the present invention.

[0026] Figure 6 This is a flowchart of the synchronous descent procedure for the lifting column of the present invention. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0028] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0029] Furthermore, in this invention, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the invention. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, such a combination should be considered non-existent and not within the scope of protection claimed by this invention.

[0030] Example: refer to Figure 1As shown in the figure, a flexible cloth water washing overline protection and alarm device includes an installation frame, an overline monitoring component, a protection execution component, a status indication component, a control module, an alarm component, and an operation control component; the installation frame is fixed around the dangerous operation area of the flexible cloth water washing equipment, and is used to carry the overline monitoring component, the protection execution component, the status indication component, and the operation control component. There are upper right columns and lower right columns on the right side of the installation frame; the overline monitoring component is installed on the installation frame, and is used to collect the personnel activity information in the dangerous operation area in real time, identify the personnel overline behavior and generate an overline signal, and transmit it to the control module; the protection execution component is connected to the installation frame and acts under the control of the control module to form an openable and closable physical protection barrier to prevent personnel from entering the dangerous operation area; the status indication component is installed on the lower right column of the right side of the installation frame and is electrically connected to the control module, and is driven by the control module to display the operation status of the device in different states; the control module is respectively electrically connected to the overline monitoring component, the protection execution component, the status indication component, the alarm component, and the operation control component, receives the input signals of each component and outputs control instructions to realize the linkage of each component; The alarm component is electrically connected to the control module and emits a warning signal under the trigger of the control module to remind personnel to stay away from the dangerous area; the operation control component is installed on the upper right column of the right side of the installation frame and includes a mode switching unit, an action control unit, an emergency control unit, and a calibration unit. Each unit is respectively electrically connected to the control module and is used to manually control the operation mode switching of the device, the action of the protection execution component, the emergency shutdown, and the position calibration.

[0031] The overline monitoring component is a human body vision recognition module 1, including an industrial-grade high-definition camera and an AI vision analysis unit; the industrial-grade high-definition camera is installed in the upper right of the installation frame and maintains a preset distance from the installation frame to avoid mechanical interference; the AI vision analysis unit identifies the personnel overline behavior through the image information of the dangerous operation area collected by the camera, and the industrial-grade high-definition camera has the ability to resist water vapor and fluff interference and is adapted to the flexible cloth water washing scene environment.

[0032] The protection execution component includes a lifting column 2 and a rope-type lifting protection door 3; the lifting column 2 is a lifting drive part with a built-in drive motor and a reduction mechanism, and is vertically fixed on both sides of the installation frame. Its output end is connected to both ends of the rope-type lifting protection door 3; the rope-type lifting protection door 3 is a flexible protection door body, with a high-strength rope body as the core and an outer flexible protection layer, and rises and falls vertically under the drive of the lifting column 2 to form a physical protection barrier; the drive motor of the lifting column 2 is a DC motor, the lifting speed of the rope-type lifting protection door 3 is 50-150 mm / s, and the lifting column 2 is internally provided with a limit switch for positioning the fully closed position and the fully open position of the rope-type lifting protection door 3.

[0033] The high-strength rope of the rope-type lifting protective door 3 is made of stainless steel wire rope with a diameter of 6-10mm and a breaking strength of ≥3000N; the flexible protective layer is made of rubber with a thickness of 3-8mm, which can prevent secondary injuries when operators accidentally collide with it; and the rope-type lifting protective door 3 is equipped with at least 2 ropes along the height direction of the lifting column 2, with a rope spacing of 400-700mm to ensure that there are no gaps in the protective coverage area.

[0034] The status indicator component is the operation indicator light 4, which uses an LED light source and is installed on the lower right corner of the top surface of the lower right column, at a height of 1.8 to 2.5 meters above the ground where it is within the operator's line of sight. The operation indicator light 4 is controlled by the control module and has three working states: off, constantly lit, and flashing, which correspond to the three operating conditions: the rope lifting safety door 3 is closed, the rope lifting safety door 3 is open, and the human vision recognition module 1 detects that a person has crossed the line. The operation indicator light 4 is a dual-color light source: it is off when the rope lifting safety door 3 is closed, constantly lit in green when it is open, and flashes red when a person crosses the line.

[0035] The alarm component is an audio system, electrically connected to the control module. When the human visual recognition module 1 detects a person crossing the line, the control module triggers the audio system to emit a preset voice prompt: "Please note, you have entered a dangerous area. Please exit immediately." The audio output volume is adjustable, ranging from 60-120dB, suitable for the noisy environment of the flexible fabric washing workshop. Simultaneously, the audio system is linked to the operation indicator light 4; when the line crossing alarm occurs, the operation indicator light 4 flashes synchronously to enhance the warning effect. The operation control component is a set of operation buttons, including an open protective door button 5, a close protective door button 6, a manual / automatic switch button 7, an emergency stop button 8, and an initialization positioning button 9. All buttons are installed on the upper side of the upper right column. The manual / automatic switching button 7 is a mode switching unit, adopting a button or knob structure, used to switch the operating mode of the rope-type lifting safety door 3, including automatic operation mode and jog operation mode. In automatic operation mode, the rope-type lifting safety door 3 automatically rises and falls according to the crossing signal of the human visual recognition module 1 or the operating status of the flexible cloth washing equipment. In jog operation mode, the rope-type lifting safety door 3 only moves when the opening safety door button 5 or the closing safety door button 6 is continuously pressed, and stops immediately after the button is released. The opening safety door button 5 and the closing safety door button 6 are action control units, used to trigger the opening and closing actions of the rope-type lifting safety door 3, respectively. The emergency stop button 8 is an emergency control unit, adopting a mushroom head structure. When pressed, it triggers the control module to cut off the power supply of the drive motor of the lifting column 2, causing the rope-type lifting safety door 3 to stop moving. At the same time, it triggers a continuous audible alarm, high-frequency flashing of the operation indicator 4, and sends a stop signal to the flexible cloth washing equipment. The initialization positioning button 9 is a calibration unit. When pressed, it drives the lifting column 2 to move the rope-type lifting safety door 3 to a preset initial position, which is a fully closed position, completing the position calibration.

[0036] The control module is a programmable logic controller or an embedded control board, equipped with at least 16 digital input interfaces and 16 digital output interfaces. It supports data interaction with the control system of the flexible fabric washing equipment and can send speed reduction or shutdown signals to the washing equipment. The control module has built-in over-limit processing logic: upon receiving an over-limit signal from the human visual recognition module 1, it immediately triggers an audible alarm and flashes the operation indicator 4. If the rope-type lifting protective door 3 is in the open state, it synchronously drives the lifting column 2 to close the rope-type lifting protective door 3. If the over-limit state lasts for more than 3 seconds, the control module sends a shutdown signal to the flexible fabric washing equipment. If the duration is ≤3 seconds, it sends a speed reduction signal.

[0037] The mounting frame is made of stainless steel with anti-corrosion and anti-rust treatment. The frame height is 2000-3000mm, and the width is adapted to the width of the hazardous operation area of ​​the flexible cloth washing equipment. The mounting frame is fixed to the ground with expansion bolts, with the fixing point spacing ≤1500mm to ensure the structural stability of the frame in the humid environment of the washing workshop. The cross-sectional dimensions of the upper right column and the lower right column are 60mm×60mm to 100mm×100mm to meet the installation strength requirements of each component.

[0038] It also includes a power module, which is electrically connected to the control module, human vision recognition module 1, lifting column 2, running indicator light 4, audio and operation buttons to provide stable power supply to each electrical component; the power module has an input voltage of AC220V and an output voltage of DC24V, and has overvoltage, overcurrent and short circuit protection functions, and is suitable for the power supply environment of flexible cloth washing workshops; the device also includes a communication module, which is electrically connected to the control module, and can transmit the crossing information of human vision recognition module 1 and the operating status data of rope lifting protective door 3 to the remote monitoring terminal to realize remote monitoring and data recording.

[0039] Operating button group: Installed on the upper side of the right-side upper column, including button 5 (Open Protective Door), button 6 (Close Protective Door), button 7 (Manual / Automatic Switch), button 8 (Emergency Stop), and button 9 (Initialization Positioning). Each button is electrically connected to the control module to realize manual operation control of the device. The functions of each button are as follows: Open Protective Door Button: When the operator presses this button, the control module receives a signal and outputs a command to control the lifting column to drive the rope-type lifting protective door to rise, opening the protected area for operations such as loading and unloading of materials. Close Protective Door Button: When the operator presses this button, the control module controls the lifting column to drive the rope-type lifting protective door to descend, closing the protected area and restoring physical isolation of the hazardous area. Manual / Automatic Switching Button: Used to switch the operating mode of the rope-type lifting safety gate. Operating modes include automatic and jogging modes. In automatic mode, the safety gate automatically raises and lowers based on the human visual recognition module's crossing signal or the operating status of the flexible fabric washing equipment. In jogging mode, the operator needs to press and hold the open or close button; the safety gate only moves while the button is pressed and stops immediately upon releasing the button. This mode is designed for special working conditions such as equipment maintenance and fabric connection. Emergency Stop Button: Features a mushroom-shaped structure for quick pressing in emergencies. When the emergency stop button is pressed, the control module immediately cuts off the power to the lifting column drive motor, stopping the rope-type lifting safety gate. Simultaneously, it triggers a continuous alarm signal, rapidly flashing the operating indicator light, and sends a stop signal to the flexible fabric washing equipment, urgently terminating its operation to address sudden safety incidents such as door jamming or personnel entrapment. Initialization Positioning Button: When the device is powered on or the rope-type lifting safety door shifts position due to an abnormal situation, the operator presses this button. The control module controls the lifting column to drive the safety door to the preset initial position (the preset initial position is the fully closed position of the safety door), completing the position calibration of the safety door, ensuring the accuracy of the lifting stroke of the safety door, and ensuring the reliability of the protection function.

[0040] Specifically, the human visual recognition module accurately distinguishes between personnel crossing the line and fabric movement or environmental interference. The specific steps are as follows: 1. An industrial-grade high-definition camera (equipped with a visible light + near-infrared dual-band sensor) is used to simultaneously acquire visible light images (1920×1080 resolution, 25fps) and near-infrared images (1280×720 resolution, 20fps) of the hazardous work area. The visible light image is used to capture the color and outline details of the personnel's clothing, while the near-infrared image is used to penetrate water vapor and dust in the washing scene, avoiding image blurring caused by water vapor refraction—overcoming the weakness of traditional single-band cameras that are susceptible to water vapor interference. To address the fine noise from fabric fuzz (typically <5px in size), a preset fuzz noise template (based on a pixel threshold calculated from the 10-50μm diameter of common washed fabric fuzz in the industry) is used to selectively remove discrete noise points smaller than the threshold from the image, while preserving the continuous edges of the person's outline. To address the low-frequency blurring interference caused by moisture, the image is decomposed into a high-frequency detail layer and a low-frequency smoothing layer, and noise reduction is performed only on the low-frequency layer to avoid the loss of details in the person's outline—solving the problem of decreased recognition accuracy caused by the "one-size-fits-all" approach of traditional noise reduction algorithms.

[0041] 2. Extract the following features from the fused image: head-to-torso-limb ratio (preset threshold range of 1:7-1:8 for adults and 1:6-1:7 for children), clothing color features (excluding common white and light gray tones in washed fabrics, focusing on identifying non-fabric color blocks such as red, blue, and yellow), and contour edge features (human contour edge curvature change rate > 0.3, significantly higher than the smooth edges of fabric). Extract the fabric's "texture continuity" (fabric texture extends continuously along the direction of movement, without any breaks in the human contour) and "deformation consistency" (the deformation direction of the fabric when pulled by the roller is consistent with the direction of equipment transmission, without multi-directional deformation due to random human movement)—overcoming the "human-fabric confusion" defect caused by traditional algorithms relying only on a single contour. Perform continuous frame (more than 10 frames) trajectory tracking on moving targets (people or fabric) in the fused image: Person trajectory: exhibits "non-uniform speed, multi-directional turning" characteristics (such as walking towards equipment, reaching out to adjust), trajectory deviation (angle change of trajectory between adjacent frames) > 15°. Fabric trajectory: It exhibits a "uniform speed, unidirectional straight line" characteristic (pulled by the washing machine's transmission mechanism, moving along a fixed direction), with a trajectory deviation of <5°. By differentiating dynamic trajectory characteristics, personnel and fabric are further distinguished, avoiding misjudgments caused by similar static contours (such as the contour of a person bending over versus the contour of drooping fabric). 3. A "two-level virtual boundary" is preset in the control module (based on the physical dimensions of the installation frame, converted into image pixel coordinates through camera calibration): Level 1 warning boundary: 30cm from the edge of the washing machine's danger zone (corresponding to 100 pixels in the image), serving as a "pre-warning" trigger line. Level 2 crossing boundary: 10cm from the edge of the washing machine's danger zone (corresponding to 30 pixels in the image), serving as an "emergency protection" trigger line. The setting of the two-level boundary breaks through the limitations of the traditional single boundary—"either not triggered or already dangerous"—achieving graded protection. When any part of the tracked personnel target (confirmed through static and dynamic features, with priority given to critical areas such as the head and hands) enters the first-level warning boundary, the control module determines it as a "pre-crossing," triggering the operation indicator light to flash (frequency 1Hz) and the sound system to emit a low-volume warning sound ("Attention, approaching a danger zone"). When the personnel target enters the second-level crossing boundary, or remains within the first-level warning boundary for more than 3 seconds (adjustable according to production rhythm), the control module determines it as a "formal crossing," immediately triggering subsequent linkage protection actions (protective door closing, equipment speed reduction / stop, high-frequency alarm). During the determination process, "non-personnel targets" (such as fallen fabric or tools) are automatically excluded: if the tracked target does not meet the requirements of human biometrics + dynamic trajectory characteristics, even if it enters the boundary, the crossing determination will not be triggered—avoiding accidental shutdowns due to foreign object interference.

[0042] As one possible implementation method, the installation frame is made of 304 stainless steel, with a height of 2.5m and a width of 3m. The distance between the upper right column and the lower right column is 2m. The column cross-section is 80mm×80mm. The frame is fixed to the ground around the hazardous area of ​​the washing machine with expansion bolts, with a fixing point spacing of 1m to ensure the stability of the frame. The human visual recognition module uses a Hikvision industrial-grade high-definition camera (model DS-2CD3T46WD-I3) with a resolution of 4 megapixels, IP67 protection rating, and strong resistance to water vapor and dust. The camera is installed at a height of 2.3m, with a distance of 0.5m from the installation frame. The lens angle is adjusted to cover the hazardous area of ​​the washing machine (range 3m×2m). The AI ​​visual algorithm uses Hikvision's intelligent analysis algorithm, with a line crossing recognition accuracy of ≥99% and a recognition response time of ≤0.5s. Rising Bollard: An electric rising bollard (model JSA-02) is used, with a rated load of 50kg, a lifting speed of 100mm / s, and a stroke of 2m. It features a built-in 24V DC drive motor and a worm gear reducer with a reduction ratio of 1:50, ensuring smooth lifting. The bollard is fixed to both sides of the mounting frame via flanges, and the connection to the safety door uses a snap-fit ​​structure for easy disassembly and maintenance. Rope-type Rising Safety Door: The rope is made of 8mm diameter 304 stainless steel wire rope, wrapped with a 5mm thick polyurethane flexible rubber layer. The rope's breaking strength is ≥5000N. The safety door has three ropes spaced 0.5m apart, forming an effective protective barrier while avoiding obstruction of the operator's view. Operation Indicator Lights: LED tri-color indicator lights (model AD16-22D / S) are used, operating at 24V. The red light flashes for over-limit alarm, the green light illuminates when the safety door is open, and the off state corresponds to the safety door being closed. The indicator lights are installed 2.2m above the ground to ensure they are within the operator's line of sight. Control Module: Utilizes a PLC controller (Siemens S7-1200CPU1214C), featuring 16 digital inputs and 16 digital outputs, supporting an RS485 communication interface for data exchange with the washing machine control system. The PLC program includes pre-set logic for handling line crossings, operating mode control, and emergency stop, ensuring reliable linkage between components. Audio System: Employs an industrial-grade voice alarm (TBJ-100), operating at 24V with a 10W voice playback power. The pre-recorded voice message is "Attention, you have entered a dangerous area. Please exit immediately." The alarm volume is adjustable (60-120dB) to suit noisy environments in washing workshops. Operating button group: The buttons are selected from Schneider XB2 series buttons. The buttons for opening and closing the protective door are green normally open buttons, the manual / automatic switching button is a yellow rotary button, the emergency stop button is a red mushroom-shaped button (model XB2-BS542C), and the initialization and positioning button is a blue normally open button. The button group is installed at a height of 1.5m, which conforms to the ergonomic design and is easy for operators to press.

[0043] Specifically, the workflow of this device is as follows: 1. Initialization: After the device is powered on, the operator presses the initialization positioning button, and the PLC controller controls the lifting column to drive the protective door to descend to the fully closed position (confirmed by the limit switch built into the lifting column). The running indicator light goes out, and the initialization is completed.

[0044] Normal production: Turn the manual / automatic switch to the "automatic" position and keep the protective door closed; when it is necessary to load or unload fabric, press the open protective door button, the lifting column will drive the protective door to rise to a height of 1.8m (preset opening position), and the green indicator light will light up; after loading or unloading is completed, press the close protective door button, the protective door will descend and close, and the indicator light will turn off.

[0045] Personnel crossing test: Simulating personnel crossing the line into the danger zone, the human visual recognition module detects the crossing behavior within 0.3 seconds and sends a signal to the PLC; the PLC immediately triggers the sound system to play a voice prompt, the indicator light flashes red, and a speed reduction signal is sent to the washing machine (the washing machine speed is reduced from 1000r / min to 200r / min); since the protective door is closed at this time, only the alarm and speed reduction actions are executed; after the personnel leave the danger zone, the sound system stops alarming, the indicator light goes out again, and the washing machine resumes normal speed.

[0046] Special working condition test: Turn the manual / automatic switch to the "jog" position, press and hold the open protective door button, the protective door will rise at a speed of 100mm / s, and stop immediately after releasing the button; after the maintenance personnel enter the area to clean the washing machine rollers, press and hold the close protective door button, the protective door will descend and close, and then switch back to the "automatic" position.

[0047] Emergency stop test: Simulate the protective door jamming (human obstruction of the protective door's descent). When the operator presses the emergency stop button, the PLC immediately cuts off the power to the lifting column motor, the protective door stops moving, the audible alarm continues, the indicator light flashes rapidly, and a stop signal is sent to the washing machine. The washing machine stops completely within 1 second. After the jamming fault is eliminated, the initialization positioning button is pressed, the protective door is calibrated, and normal operation resumes.

[0048] In actual testing, the device of this embodiment was used in a flexible fabric washing workshop (humidity 60%–80%, lint concentration 0.5 mg / m³). 3 After 30 days of continuous operation, the accuracy rate of line crossing recognition was 100%, the linkage response of each component was normal, and no faults occurred, meeting the safety protection requirements of the flexible fabric washing production line.

[0049] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention can have various modifications and variations; any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A protective alarm device for flexible fabric washing line crossing, characterized in that, It includes an installation frame, a line crossing detection component, a protection execution component, a status indication component, a control module, an alarm component, and an operation control component; The mounting frame is fixed around the hazardous operation area of ​​the flexible cloth washing equipment and is used to support the over-line monitoring component, the protection execution component, the status indication component and the operation control component. The mounting frame is provided with a right upper column and a right lower column on the right side. The line crossing monitoring component is installed on the mounting frame and is used to collect personnel activity information in hazardous work areas in real time, identify personnel crossing behavior and generate a line crossing signal, which is then transmitted to the control module. The protective execution component is connected to the installation frame and operates under the control of the control module to form an openable and closable physical protective barrier to prevent personnel from entering the hazardous work area. The status indicator component is installed on the lower right column of the mounting frame and is electrically connected to the control module. It is driven by the control module to display the device's operating status in different states. The control module is electrically connected to the over-line monitoring component, the protection execution component, the status indication component, the alarm component, and the operation control component, respectively. It receives input signals from each component and outputs control commands to realize the linkage of each component. The alarm component is electrically connected to the control module and emits a warning signal when triggered by the control module to remind personnel to stay away from the danger zone. The operation control component is installed on the upper right column of the installation frame and includes a mode switching unit, an action control unit, an emergency control unit, and a calibration unit. Each unit is electrically connected to the control module and is used to manually control the device's operating mode switching, the action of the protective execution component, emergency shutdown, and position calibration.

2. The water-washable line-crossing protection alarm device for flexible fabric as described in claim 1, characterized in that, The line crossing monitoring component is a human visual recognition module (1), which includes an industrial-grade high-definition camera and an AI visual analysis unit. The industrial-grade high-definition camera is installed on the upper right of the mounting frame and maintains a preset distance from the mounting frame to avoid mechanical interference. The AI ​​visual analysis unit identifies personnel crossing behavior by collecting image information of dangerous work areas from the camera. The industrial-grade high-definition camera has the ability to resist water vapor and lint interference and is suitable for flexible cloth washing scene environment.

3. The device for preventing and alarming cross-line protection of flexible fabric washing as described in claim 1, characterized in that, The protective execution components include a lifting column (2) and a rope-type lifting protective door (3); the lifting column (2) is a lifting drive component with a built-in drive motor and reduction mechanism, which is vertically fixed on both sides of the mounting frame, and its output end is connected to both ends of the rope-type lifting protective door (3); the rope-type lifting protective door (3) is a flexible protective door body, with a high-strength rope as the core and a flexible protective layer on the outside. It rises and falls vertically under the drive of the lifting column (2) to form a physical protective barrier; the drive motor of the lifting column (2) is a DC motor, the lifting speed of the rope-type lifting protective door (3) is 50~150mm / s, and the lifting column (2) has a built-in limit switch for positioning the rope-type lifting protective door (3) in the fully closed position and the fully open position.

4. The flexible fabric water washing line crossing protection alarm device according to claim 1, characterized in that, The high-strength rope of the rope-type lifting protective door (3) is a stainless steel wire rope with a diameter of 6-10mm and a breaking strength of ≥3000N; the flexible protective layer is made of rubber with a thickness of 3-8mm, which can prevent secondary injuries when operators accidentally collide with it; and the rope-type lifting protective door (3) is equipped with at least 2 ropes along the height direction of the lifting column (2), with a rope spacing of 400-700mm, to ensure that there are no gaps in the protective coverage area.

5. The device for preventing and alarming cross-line protection of flexible fabric washing as described in claim 1, characterized in that, The status indicator component is a running indicator (4), which uses an LED light source and is installed on the lower right corner of the top surface of the lower right column, at a height within the operator's line of sight (1.8 to 2.5 m from the ground). The running indicator (4) is controlled by the control module and has three working states: off, constantly lit, and flashing, which correspond to the three operating conditions: the rope lifting protective door (3) is closed, the rope lifting protective door (3) is open, and the human visual recognition module (1) recognizes that a person has crossed the line. The running indicator (4) is a dual-color light source, which is off when the rope lifting protective door (3) is closed, constantly lit in green when it is open, and flashes red when the person crosses the line.

6. The water-washable cross-line protection alarm device for flexible fabric as described in claim 1, characterized in that, The alarm component is an audio device, which is electrically connected to the control module. When the human visual recognition module (1) detects that a person has crossed the line, the control module triggers the audio device to issue a preset voice prompt. The voice prompt is "Please note that you have entered a dangerous area. Please exit immediately." The audio output volume is adjustable, with an adjustment range of 60-120dB, which is suitable for the noisy environment of the flexible fabric washing workshop. At the same time, the audio device is linked with the operation indicator light (4). When the alarm is triggered, the operation indicator light (4) flashes synchronously to enhance the warning effect.

7. The device for preventing and alarming cross-line protection of flexible fabric washing as described in claim 1, characterized in that, The operation control component is an operation button group, including an open protective door button (5), a close protective door button (6), a manual / automatic switch button (7), an emergency stop button (8), and an initialization positioning button (9). Each button is installed on the upper side of the upper right column. The manual / automatic switching button (7) is a mode switching unit, which adopts a button or knob structure and is used to switch the operating mode of the rope lifting protective door (3), including automatic operation mode and jog operation mode. In automatic operation mode, the rope lifting protective door (3) automatically lifts and lowers according to the cross-line signal of the human vision recognition module (1) or the operating status of the flexible cloth washing equipment. In jog operation mode, the rope lifting protective door (3) only operates when the protective door opening button (5) or the protective door closing button (6) is continuously pressed, and stops immediately after the button is released. The button to open the protective door (5) and the button to close the protective door (6) are action control units, which are used to trigger the opening and closing actions of the rope-type lifting protective door (3), respectively. The emergency stop button (8) is an emergency control unit with a mushroom head structure. When pressed, it triggers the control module to cut off the power supply of the drive motor of the lifting column (2), so that the rope lifting protective door (3) stops moving. At the same time, it triggers a continuous audible alarm, the running indicator light (4) flashes at high frequency, and sends a stop signal to the flexible cloth washing equipment. The initialization positioning button (9) is a calibration unit. When pressed, the control module drives the lifting column (2) to move the rope-type lifting protective door (3) to the preset initial position. The initial position is the fully closed position, and the position calibration is completed.

8. A flexible fabric water washing line crossing protection alarm device according to claim 1, characterized in that, The control module is a programmable logic controller or an embedded control board, with at least 16 digital input interfaces and 16 digital output interfaces. It supports data interaction with the control system of the flexible fabric washing equipment and can send speed reduction or shutdown signals to the washing equipment. The control module has built-in over-line processing logic: after receiving the over-line signal from the human visual recognition module (1), it immediately triggers an audible alarm and flashes the running indicator (4). If the rope-type lifting protective door (3) is in the open state, it synchronously drives the lifting column (2) to close the rope-type lifting protective door (3). If the over-line state lasts for more than 3 seconds, the control module sends a shutdown signal to the flexible fabric washing equipment. If the duration is ≤3 seconds, it sends a speed reduction signal.

9. A flexible fabric water washing line crossing protection alarm device according to claim 1, characterized in that, The mounting frame is made of stainless steel with anti-corrosion and anti-rust treatment. The frame height is 2000-3000mm, and the width is adapted to the width of the hazardous operation area of ​​the flexible cloth washing equipment. The mounting frame is fixed to the ground with expansion bolts, with the fixing point spacing ≤1500mm to ensure the structural stability of the frame in the humid environment of the washing workshop. The cross-sectional dimensions of the upper right column and the lower right column are 60mm×60mm to 100mm×100mm to meet the installation strength requirements of each component.

10. A flexible fabric water-washing over-line protection alarm device according to any one of claims 1-9, characterized in that, It also includes a power module, which is electrically connected to the control module, human vision recognition module (1), lifting column (2), running indicator (4), audio and operation button group to provide stable power supply for each electrical component; the power module has an input voltage of AC220V and an output voltage of DC24V, and has overvoltage, overcurrent and short circuit protection functions, which are suitable for the power supply environment of the flexible cloth washing workshop; and the device also includes a communication module, which is electrically connected to the control module, and can transmit the crossing information of the human vision recognition module (1) and the operating status data of the rope lifting protective door (3) to the remote monitoring terminal to realize remote monitoring and data recording.

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