Full-dimension safety protection system and safety protection method for workshop equipment

Abstract

The invention discloses a workshop equipment full-dimension safety protection system and a safety protection method. The workshop equipment full-dimension safety protection system comprises a hardware subsystem, a software subsystem and a control system, the hardware subsystem is used for detecting a dangerous state and executing warning; the software subsystem is used for signal processing, logic judgment and instruction issuing; the control system is used for realizing cooperative interaction between the hardware subsystem and the software subsystem; wherein the hardware subsystem comprises a profiling safety door body which is configured to seal an equipment dangerous gap in a customizable manner; the trigger sensing assembly is arranged on the profiling safety door body and is used for generating a trigger signal when being touched; and the warning execution assembly is in communication connection with the trigger sensing assembly and is used for providing visual warning and / or auditory warning.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of protective engineering, and particularly relates to a workshop equipment full-dimension safety protection system and a workshop equipment full-dimension safety protection method. BACKGROUND

[0002] With the wide application of painting roller beds, elevators and other equipment in modern manufacturing workshops, traditional safety protection relies on fixed guardrails, photoelectric sensors or manual emergency stop buttons, but the gap adaptability is poor and it is difficult to match the gap characteristics of different equipment, which is easy to form a dead angle of protection, and the response lag of manual triggering of the emergency stop button cannot timely prevent damage caused by high-speed equipment. At the same time, the safety circuit lacks redundancy design and is easy to be affected by environmental interference such as dust and oil stains, which may affect the safety protection effect and standardized management of the workshop. Therefore, there is an urgent need for a safety protection technical solution that can realize rapid response and has high reliability. SUMMARY

[0003] The present application aims to at least solve one of the technical problems existing in the prior art. To this end, the present application proposes a workshop equipment full-dimension safety protection system, which can solve the problems of poor gap adaptability, response lag, insufficient reliability and low horizontal expansion efficiency of traditional protection. Through the combination of hardware and software, zero dead angle protection of equipment gap and rapid response to dangerous state are realized, which significantly improves the stability and safety of the protection system. At the same time, it supports rapid standardized deployment across devices and workshops, reduces the cost of repeated design and application, and fully guarantees the safety and operating efficiency of the workshop production.

[0004] To achieve the above-mentioned purpose, the first aspect of the present application proposes a workshop equipment full-dimension safety protection system, comprising a hardware subsystem, a software subsystem and a control system; the hardware subsystem is used for detecting dangerous state and executing warning; the software subsystem is used for signal processing, logic judgment and instruction issuing; the control system is used for realizing the collaborative interaction between the hardware subsystem and the software subsystem; wherein the hardware subsystem comprises: a profiling safety door body configured to customizably block the dangerous gap of the equipment; a trigger sensing component arranged on the profiling safety door body and used for generating a trigger signal when touched; a warning execution component in communication connection with the trigger sensing component and used for providing visual warning and / or audible warning.

[0005] In some embodiments, the profiling safety door body adopts a modular structure, including a main frame and an adjustable secondary plate connected to the main frame through a precision slide rail; the adjustable secondary plate can be continuously adjusted and fixed by a locking mechanism to adapt to the dangerous gap of the equipment; the material of the profiling safety door body is transparent acrylic plate; the profiling safety door body is installed on the equipment rack through a rotatable L-shaped support and an expansion bolt.

[0006] In some embodiments, the trigger sensing component includes a plurality of waterproof contact microswitches, which are distributed and installed on the edge of the contoured safety door body in a fully circumferential triggering manner; the trigger sensing component also includes a signal processing unit, which integrates a signal filtering module and a redundant logic judgment module; the redundant logic judgment module is configured to determine a valid trigger signal when at least two waterproof contact microswitches are triggered simultaneously, or when the triggering time of the same waterproof contact microswitch continuously exceeds a preset triggering threshold.

[0007] In some embodiments, the warning execution component includes a high-brightness tri-color LED warning light and a status indicator panel; the tri-color LED warning light is configured as follows: solid green indicates normal operation of the device, solid yellow indicates standby of the device, and flashing red indicates that the device has been shut down in an emergency; the status indicator panel integrates a status indicator light corresponding to each contoured safety door body, an LCD display for displaying fault information, and a reset button with key lock.

[0008] In some embodiments, the software subsystem includes a PLC control program configured to execute a dual-interlock emergency stop logic, including: upon receiving a valid trigger signal, executing in parallel a hardware power-off command to cut off the main power supply of the equipment and a software stop command to be sent to the original control system of the equipment; wherein the PLC control program sets the valid trigger signal as the highest priority interrupt event.

[0009] In some embodiments, the software subsystem further includes an alarm reset logic module; the alarm reset logic module is configured to trigger alarm reset logic to authorize a reset operation and release the equipment shutdown lock when a preset reset condition is met; wherein, the preset reset condition includes triggering all signals of the sensing components to return to the non-triggered state, the operator confirming authorization through a reset button with a key lock, and confirming that no personnel remain in the equipment's hazardous area through an auxiliary safety sensor installed in the equipment's hazardous area.

[0010] In some embodiments, the software subsystem further includes a parameter configuration module; the parameter configuration module divides the PLC control program into a fixed core control module and an adjustable parameter configuration module; the workshop equipment full-dimensional safety protection system also includes an equipment adaptation database, which pre-stores standardized parameter configuration schemes applicable to different workshops and different types of equipment, which can be called and downloaded with one click through the human-machine interface to configure the adjustable parameter configuration module.

[0011] The workshop equipment full-dimensional safety protection system according to an embodiment of the present invention includes a hardware subsystem, a software subsystem, and a control system. The hardware subsystem is used to detect dangerous conditions and execute warnings; the software subsystem is used for signal processing, logical judgment, and instruction issuance; and the control system is used to realize the collaborative interaction between the hardware subsystem and the software subsystem. The hardware subsystem includes: a contoured safety door body configured to customizablely block dangerous gaps in equipment; a trigger sensing component disposed on the contoured safety door body for generating a trigger signal when touched; and a warning execution component communicatively connected to the trigger sensing component for providing visual and / or auditory warnings. Therefore, this application can solve the problems of poor adaptability, slow response, insufficient reliability, and low lateral efficiency of traditional protective gaps. Through the combination of hardware and software, it achieves zero-dead-angle protection of equipment gaps and rapid response to dangerous conditions, significantly improving the stability and safety of the protection system. It also supports rapid standardized deployment across equipment and workshops, reducing the cost of repetitive design and application, and comprehensively ensuring workshop production safety and operational efficiency.

[0012] To achieve the above objectives, a second aspect of the present invention proposes a method for comprehensive safety protection of workshop equipment, applicable to a comprehensive safety protection system for workshop equipment as described above. The method includes: physically sealing dangerous gaps in the equipment using a contoured safety door; sensing touch behavior using a trigger sensing component and generating a trigger signal; filtering and redundancy logic judgment of the trigger signal using a software subsystem, and executing a double interlocking emergency shutdown logic within a preset execution time after confirming a valid trigger signal; providing visual and / or audible warnings using an alarm execution component and displaying fault information on a status indicator panel; and releasing the equipment shutdown lock by triggering an alarm reset logic to authorize a reset operation after a preset reset condition is met.

[0013] In some embodiments, the trigger signal is filtered and redundant logic is judged by the software subsystem, including: when at least two waterproof contact microswitches are triggered at the same time, or when the trigger time of the same waterproof contact microswitch continues to exceed a preset trigger threshold, it is determined to be a valid trigger signal.

[0014] In some embodiments, the preset reset conditions include: all signals that trigger the sensing components are restored to an untriggered state; the operator confirms authorization via a reset button with a key lock; and an auxiliary safety sensor installed in the hazardous area of ​​the equipment confirms that no personnel remain in the hazardous area.

[0015] According to the workshop equipment full-dimensional safety protection method of the present invention, firstly, dangerous gaps in the equipment are physically sealed by a contour-following safety door; secondly, a trigger sensing component senses touch behavior and generates a trigger signal; further, a software subsystem filters and performs redundant logic judgment on the trigger signal, and after confirming a valid trigger signal, executes a double interlocking emergency shutdown logic within a preset execution time; thirdly, a warning execution component provides visual and / or audible warnings and displays fault information on a status indicator panel; finally, after the preset reset conditions are met, an alarm reset logic is triggered to authorize a reset operation and release the equipment shutdown lock. Therefore, this application can solve the problems of poor adaptability, delayed response, insufficient reliability, and low lateral efficiency of traditional protective gaps. Through the combination of hardware and software, it achieves zero-dead-angle protection of equipment gaps and rapid response to dangerous conditions, significantly improving the stability and safety of the protection system. It also supports rapid standardized deployment across equipment and workshops, reducing the cost of repetitive design and application, and comprehensively ensuring workshop production safety and operational efficiency.

[0016] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0017] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of a workshop equipment all-dimensional safety protection system according to an embodiment of this application; Figure 2 This is a flowchart illustrating a method for comprehensive safety protection of workshop equipment in an embodiment of this application.

[0018] Figure reference numerals: Workshop equipment all-dimensional safety protection system 100, hardware subsystem 101, contour safety door body 1011, trigger sensing component 1012, alarm execution component 1013, software subsystem 102, PLC control program 1021, alarm reset logic module 1022, parameter configuration module 1023, control system 103. Detailed Implementation

[0019] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While some embodiments of this application are shown in the drawings, it should be understood that this application can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of this application. It should be understood that the drawings and embodiments of this application are for illustrative purposes only and are not intended to limit the scope of protection of this application.

[0020] It should be understood that the steps described in the method embodiments of this application may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of this application is not limited in this respect.

[0021] As described in the background section, with the continuous improvement of the automation level of the manufacturing industry and the widespread application of equipment such as painting rollers and elevators in workshops, the prevention and control of mechanical injury risks during equipment operation has become the core demand of production safety management. The requirements of car manufacturers and various manufacturing enterprises for the accuracy, response speed and versatility of equipment protection have increased significantly. In actual production, traditional safety protection relies on fixed metal guardrails, single photoelectric sensors or manual emergency stop buttons, which are difficult to adapt to the gap differences of different equipment, easily creating blind spots and burying the risk of accidental entry. Manually triggered emergency stop response is delayed, and the safety circuit lacks redundant design and is easily affected by environmental interference and failure. Customized protection schemes are made according to the needs of different equipment, resulting in low efficiency and high cost, and it is difficult to achieve standardized safety management.

[0022] Addressing the shortcomings of traditional safety protection, the workshop equipment all-dimensional safety protection system of this invention effectively solves the core problems of poor adaptability, slow response, insufficient reliability and difficulty in horizontal deployment of traditional solutions through the combination of hardware and software. It avoids the protection failure caused by the failure of a single component and the secondary risks caused by unauthorized reset, and achieves zero dead angle protection between equipment, rapid response to dangerous conditions and standardized deployment across workshops, thus ensuring the personal safety of operators.

[0023] The following is for reference. Figure 1 This application describes a comprehensive safety protection system for workshop equipment provided in its embodiments.

[0024] like Figure 1 The diagram shown is a schematic of a workshop equipment all-dimensional safety protection system according to an embodiment of this application. The workshop equipment all-dimensional safety protection system 100 includes a hardware subsystem 101, a software subsystem 102, and a control system 103. The hardware subsystem 101 is used to detect dangerous conditions and execute warnings. The software subsystem 102 is used for signal processing, logical judgment, and instruction issuance. The control system 103 is used to realize the collaborative interaction between the hardware subsystem 101 and the software subsystem 102. The hardware subsystem 101 includes: a contoured safety door body 1011, configured to customizablely block dangerous gaps in the equipment; a trigger sensing component 1012, disposed on the contoured safety door body 1011, used to generate a trigger signal when touched; and a warning execution component 1013, communicatively connected to the trigger sensing component 1012, used to provide visual and / or auditory warnings.

[0025] As an optional embodiment, the contoured safety door body 1011 adopts a modular structure, including a main frame and an adjustable sub-plate connected to the main frame via a precision slide rail; the adjustable sub-plate can be continuously slidably adjusted and fixed by a locking mechanism to adapt to the dangerous gap of the equipment; the contoured safety door body 1011 is made of transparent acrylic sheet; the contoured safety door body 1011 is mounted on the equipment frame by a rotatable L-shaped bracket and expansion bolts.

[0026] Specifically, the contour-following safety door body 1011 includes a main frame and an adjustable sub-plate connected to the main frame via a precision slide rail. The main frame is precision-machined using laser cutting based on the gap reference dimensions of the target equipment (such as a painting roller bed or a lifting machine), and its edges are rounded using CNC technology to effectively avoid the risk of being scratched by sharp edges. The adjustable sub-plate, combined with the precision slide rail, can be continuously slidably adjusted within a preset range of 500mm to 200mm, with adjustment accuracy controlled within ±1mm. After adjustment to completely cover the equipment gap, the sub-plate's position is reliably fixed by tightening the wing bolts on the slide rail. For example, for a lifting machine with a gap of 120mm or a painting roller bed with a gap of 280mm, adaptation can be completed simply by sliding the sub-plate and locking it. No separate door body is required. The contoured safety door body 1011 of this invention uses a transparent acrylic sheet with a thickness of 8mm to 12mm as the main material. The light transmittance of this material is not less than 92%, which can ensure the visual monitoring of equipment operation status by workshop personnel. Its impact resistance is 10 times that of ordinary glass, which can adapt to the complex environment of painting, stamping and other workshops. The contoured safety door body 1011 is installed on the equipment frame by a rotatable L-shaped bracket and expansion bolts. The L-shaped bracket is made of 5mm thick stainless steel with anti-rust treatment. The expansion bolts are embedded in the equipment frame to meet the tensile strength requirements. The bracket and the door body are connected by heavy-duty hinges, which allows the door body to rotate freely from 0 to 90 degrees, which is convenient for quick opening during equipment maintenance.

[0027] As an optional embodiment, the trigger sensing component 1012 includes a plurality of waterproof contact microswitches, which are distributed and installed on the edge of the contoured safety door body 1011 in a fully circumferential triggering manner. The trigger sensing component 1012 also includes a signal processing unit, which integrates a signal filtering module and a redundant logic judgment module. The redundant logic judgment module is configured to determine a valid trigger signal when at least two waterproof contact microswitches are triggered simultaneously, or when the triggering time of the same waterproof contact microswitch continuously exceeds a preset triggering threshold.

[0028] Specifically, the trigger sensing assembly 1012 includes multiple waterproof contact microswitches (such as the Omron D4C-1331 model). These microswitches are installed on the top, bottom, left, and right edges of the contoured safety door body 1011, with the installation position controlled at 10mm-15mm from the edge of the door body. They are fixed by elastic clamps to ensure effective sensing when the door body is touched or squeezed from any direction. Each microswitch is connected to a pluggable terminal block inside the door body through an oil-resistant and high-temperature resistant silicone wire (0.75mm² wire diameter, temperature resistance rating 125℃), facilitating future maintenance and replacement and resisting the corrosion of complex workshop environments. The trigger sensing assembly 1012 also includes an integrated... The signal processing unit consists of a signal filtering module and a redundant logic judgment module. The signal filtering module uses an RC filter circuit to filter out high-frequency electromagnetic interference (frequency range 200kHz-500kHz) generated by equipment such as frequency converters and motors in the workshop, ensuring the purity of the trigger signal. The redundant logic judgment module is based on a high-performance microcontroller. It is only considered a valid trigger signal when at least two waterproof contact microswitches are triggered simultaneously (such as when a person accidentally leans against a door, the switches on the top and bottom sides are synchronously sensed), or when the trigger time of the same waterproof contact microswitch continuously exceeds the preset trigger threshold (such as setting the trigger threshold to 100ms to avoid 80ms instantaneous touch misjudgment caused by equipment vibration).

[0029] As an optional embodiment, the warning execution component 1013 includes a high-brightness tri-color LED warning light and a status indicator panel; the tri-color LED warning light is configured as follows: solid green indicates normal operation of the equipment, solid yellow indicates standby of the equipment, and flashing red indicates that the equipment has been stopped in an emergency; the status indicator panel integrates a status indicator light corresponding to each contoured safety door body 1011, an LCD display for displaying fault information, and a reset button with key lock.

[0030] Specifically, the warning execution component 1013 includes a high-brightness tri-color LED warning light and a status indicator panel. The light body is a cylindrical structure with a diameter of 50mm and a protection rating of IP65, suitable for dusty and humid workshop environments such as painting and stamping. It is installed 1.5 to 2 meters above the contoured safety door to ensure that workshop personnel can clearly observe it within a 10-meter range. A solid green light indicates that the equipment is operating normally and the safety door is closed (e.g., when the roller bed in the final assembly workshop is smoothly conveying workpieces, a solid green light indicates that the operator can operate normally). A solid yellow light indicates that the equipment is in standby or paused state, allowing authorized personnel to open the safety door for maintenance. When red flashes (flash frequency 1Hz-2Hz), a buzzer is triggered simultaneously to indicate that the equipment has been stopped in an emergency. To facilitate rapid hazard detection by personnel at a distance, a status indicator panel is installed on the main control panel of the equipment. The panel integrates a status indicator light corresponding to each contoured safety door body 1011 (for example, if there is one safety door in each of the three hazardous gaps in the workshop, the panel will have three corresponding indicator lights, and the corresponding indicator light will light up simultaneously when a safety door is triggered) and an LCD screen for displaying detailed fault information. The LCD screen can display specific fault codes in real time (such as "microswitch failure", "signal line breakage", etc.) to help maintenance personnel quickly locate the problem. The panel is equipped with a reset button with a key lock. Only authorized maintenance personnel can initiate the reset process after confirming that the on-site hazard has been eliminated, effectively avoiding secondary risks caused by unauthorized personnel's misoperation.

[0031] As an optional embodiment, the software subsystem 102 includes a PLC control program 1021, which is configured to execute a dual-interlock emergency stop logic, including: upon receiving a valid trigger signal, executing in parallel a hardware power-off command to cut off the main power supply of the equipment and a software stop command to be sent to the original control system 103 of the equipment; wherein, the PLC control program 1021 sets the valid trigger signal as the highest priority interrupt event.

[0032] Specifically, the PLC control program 1021 selects a stable PLC (such as the Siemens S7-1200 series model 1214CDC / DC / DC). This PLC has sufficient I / O points and fast response output capability, which can meet the stringent timing requirements of emergency shutdown. The PLC communicates with the original control system 103 of the workshop equipment through the Profinet industrial Ethernet protocol, and the communication delay is controlled within 5ms to ensure the real-time performance of signal interaction. When a valid trigger signal is received from the trigger sensor component 1012 (such as when a person touches the contour safety door, causing two microswitches to trigger synchronously), the program will immediately start the two independent circuits in parallel. The shutdown command has two paths: one directly cuts off the contactor coil circuit of the main power supply of the control equipment through the digital output point, realizing hardware-level forced power-off; the other sends an emergency shutdown signal to the original control system 103 of the equipment through the Profinet network, triggering the internal software safety circuit. In order to maximize the compression of response time, the PLC control program 1021 sets the effective trigger signal as the highest priority interrupt event and forces the PLC user program scan cycle to be within 10ms. Once the trigger signal arrives, the PLC will immediately suspend the current non-critical cycle task and prioritize the execution of the shutdown interrupt service routine, effectively avoiding the risk of mechanical damage caused by high-speed equipment.

[0033] As an optional embodiment, the software subsystem 102 further includes an alarm reset logic module 1022; the alarm reset logic module 1022 is configured to trigger alarm reset logic to authorize a reset operation and release the equipment shutdown lock when a preset reset condition is met; wherein, the preset reset condition includes all signals of the trigger sensing component 1012 returning to the untriggered state, the operator confirming authorization through a reset button with a key lock, and the confirmation by an auxiliary safety sensor installed in the equipment's hazardous area that no personnel remain in the equipment's hazardous area.

[0034] Specifically, the alarm reset logic module 1022 receives feedback signals from the trigger sensing component 1012 in real time. When all microswitch signals are restored to the non-triggered state, the signal processing unit redundancy judgment confirms that there is no residual trigger signal, and the trigger source disappearance condition judgment is completed. The operator must use a special key to unlock and press the reset button on the status indicator panel of the main control panel of the equipment to complete the authorization confirmation condition judgment. Finally, the alarm reset logic module 1022 communicates with the auxiliary safety sensor (such as the Panasonic DL-P1 infrared human presence sensor with a detection accuracy of ±50mm and a coverage range of 0.5m-3m) installed in the dangerous area of ​​the equipment. When it is confirmed that there are no personnel remaining in the area, the area safety confirmation condition judgment is completed. Only when all three conditions are met simultaneously will the PLC release the shutdown lock state.

[0035] As an optional embodiment, the software subsystem 102 also includes a parameter configuration module 1023; the parameter configuration module 1023 divides the PLC control program 1021 into a fixed core control module and an adjustable parameter configuration module 1023; the workshop equipment full-dimensional safety protection system 100 also includes an equipment adaptation database, which pre-stores standardized parameter configuration schemes applicable to different workshops and different types of equipment, and can be called and downloaded with one click through the human-machine interface to configure the adjustable parameter configuration module 1023.

[0036] Specifically, the parameter configuration module 1023 divides the PLC control program 1021 into a fixed core control module and an adjustable parameter configuration module 1023. The core control module (such as the double interlock shutdown logic, alarm recording logic, and reset judgment logic) is fixed once determined, ensuring the consistency and reliability of the system's core safety functions. The parameter configuration module 1023 includes all variables that need to be adapted to specific equipment (such as the number of safety doors installed, the effective trigger threshold of microswitches, the flashing frequency of alarm lights, and the address parameters for communication with the equipment), avoiding the impact of parameter adjustments on the core safety logic. At the same time, the system has a built-in equipment adaptation database. This database pre-stores standardized parameter configuration schemes for different workshops such as painting, stamping, and final assembly, as well as different types of equipment, based on a large number of actual application scenarios. Each scheme has been actually debugged and verified to ensure compatibility and stability. In actual horizontal application, engineers do not need to modify the underlying PLC program code. They only need to select the target equipment type (such as painting workshop - roller bed) in the equipment list. The system will automatically retrieve the corresponding pre-stored parameter scheme from the database and download it to the PLC for execution. The entire configuration process can be completed within 2-4 hours.

[0037] The workshop equipment full-dimensional safety protection system provided in this application can solve the problems of poor adaptability of traditional protection gaps, slow response, insufficient reliability and low lateral efficiency. Through the combination of hardware and software, it realizes zero-dead-angle protection of equipment gaps and rapid response to dangerous conditions, which significantly improves the stability and safety of the protection system. At the same time, it supports rapid standardized deployment across equipment and workshops, reduces the cost of repeated design and application, and comprehensively protects the safety and efficiency of workshop production.

[0038] refer to Figure 2 This is a flowchart illustrating a method for comprehensive safety protection of workshop equipment in an embodiment of this application.

[0039] like Figure 2 As shown, the workshop equipment all-dimensional safety protection method of this invention may include the following steps: Step S201: Physically seal the dangerous gap of the equipment by using the contoured safety door body.

[0040] Step S202: The touch behavior is detected by triggering the sensing component and a trigger signal is generated.

[0041] Specifically, based on the gap characteristics of the target equipment (such as a 2800mm gap between roller beds in a painting workshop and a 150mm gap between elevators), the contoured safety door body is adapted and adjusted until it completely covers the dangerous gap. Then, the touch behavior is sensed by the trigger sensing component and a trigger signal is generated. Multiple waterproof micro-switches of this component are installed on the upper, lower, left, and right edges of the contoured safety door body. When the door is touched, the corresponding micro-switch will immediately generate a trigger signal.

[0042] Step S203: The software subsystem filters and performs redundant logic judgment on the trigger signal. After confirming the valid trigger signal, the double interlock emergency stop logic is executed within the preset execution time.

[0043] As an optional embodiment, the trigger signal is filtered and redundant logic is judged by the software subsystem, including: when at least two waterproof contact microswitches are triggered at the same time, or when the trigger time of the same waterproof contact microswitch continues to exceed the preset trigger threshold, it is determined to be a valid trigger signal.

[0044] Specifically, after the trigger sensing component generates the initial trigger signal, the software subsystem filters and performs redundant logic checks on the trigger signal. A valid trigger signal is determined when at least two waterproof contact microswitches are triggered simultaneously (e.g., when a worker accidentally leans against the contoured safety door, causing the switches on the left and bottom sides of the door to move synchronously), or when the triggering time of the same waterproof contact microswitch continuously exceeds a preset threshold (e.g., a preset trigger threshold of 100ms can filter invalid signals such as 80ms instantaneous touch caused by equipment vibration). Step S204: Provide visual and / or audible alerts through the alert execution component and display fault information on the status indicator panel.

[0045] Specifically, once the software subsystem confirms a valid trigger signal and issues a shutdown command, the high-brightness tri-color LED warning light and buzzer in the warning execution component provide visual and / or audible warnings. At the same time, the LCD screen displays specific fault information in real time.

[0046] Step S205: After the preset reset conditions are met, the alarm reset logic is triggered to authorize the reset operation and release the equipment shutdown lock.

[0047] As an optional embodiment, the preset reset conditions include: all signals triggering the sensing components are restored to the untriggered state; the operator confirms authorization via a reset button with a key lock; and the auxiliary safety sensor installed in the hazardous area of ​​the equipment confirms that no personnel remain in the hazardous area.

[0048] Specifically, first, ensure that all signals of the triggering sensor components are restored to the non-triggered state to confirm that the dangerous trigger source has been eliminated. Next, the operator authorizes the reset button with a key lock. Only authorized maintenance personnel with a special key can unlock the device and press the reset button after checking the equipment status on-site and confirming that there are no abnormalities. This effectively prevents secondary risks caused by unauthorized personnel resetting the device at will. Finally, it is necessary to confirm that there are no personnel in the area by using auxiliary safety sensors (such as infrared human presence sensors with a detection range of 0.5m-3m and an accuracy of ±50mm) installed in the dangerous area of ​​the equipment. Only when all three conditions are met will the alarm reset logic be triggered to perform the authorized reset operation and release the equipment from the shutdown lock state.

[0049] In summary, this application provides a method for comprehensive safety protection of workshop equipment, applicable to any of the aforementioned comprehensive safety protection systems. The method includes: physically sealing dangerous gaps in the equipment using a contoured safety door; sensing touch behavior using a trigger sensor component and generating a trigger signal; filtering and performing redundant logic judgment on the trigger signal using a software subsystem; and, upon confirming a valid trigger signal, executing a dual-interlock emergency shutdown logic within a preset execution time; providing visual and / or audible warnings through an alarm execution component and displaying fault information on a status indicator panel; and, upon meeting preset reset conditions, releasing the equipment shutdown lock by triggering an alarm reset logic and authorizing a reset operation. Therefore, this application solves the problems of poor adaptability, delayed response, insufficient reliability, and low lateral efficiency of traditional protective gaps. Through the combination of hardware and software, it achieves zero-dead-angle protection of equipment gaps and rapid response to dangerous conditions, significantly improving the stability and safety of the protection system. Simultaneously, it supports rapid standardized deployment across equipment and workshops, reducing redundant design and application costs, and comprehensively ensuring workshop production safety and operational efficiency.

[0050] It should be noted that the method of this embodiment can be executed by a single device, such as a computer or server. The method of this embodiment can also be applied to a distributed scenario, where multiple devices cooperate to complete the task. In such a distributed scenario, one of these devices may execute only one or more steps of the method of this embodiment, and the multiple devices will interact with each other to complete the above method.

[0051] It should be noted that the above description describes some embodiments of the present invention. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps described in the claims may be performed in a different order than that shown in the above embodiments and still achieve the desired results. Furthermore, the processes depicted in the drawings do not necessarily require a specific or sequential order to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0052] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0053] From the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of computer software products plus necessary general-purpose hardware platforms, and of course, they can also be implemented by hardware. The computer software product is stored in a storage medium (such as ROM, RAM, magnetic disk, optical disk, etc.) and includes several instructions to cause the terminal or network-side device to execute the methods described in the various embodiments of this application.

[0054] The embodiments of this application have been described above with reference to the accompanying drawings. However, this application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other implementations under the guidance of this application without departing from the spirit and scope of the claims. All of these implementations are within the protection scope of this application.

Claims

1. A full-dimension safety shield system (100) for a plant facility, characterized by, The system comprises a hardware subsystem (101), a software subsystem (102) and a control system (103); The hardware subsystem (101) is configured to detect dangerous states and execute warnings; The software subsystem (102) is configured to perform signal processing, logical judgment and instruction issuing; The control system (103) is configured to realize the cooperative interaction between the hardware subsystem (101) and the software subsystem (102); The hardware subsystem (101) comprises: A profiled safety door body (1011) configured to customizably block a dangerous gap of equipment; A trigger sensing assembly (1012) arranged on the profiled safety door body (1011) and configured to generate a trigger signal when touched; A warning execution assembly (1013) in communication connection with the trigger sensing assembly (1012) and configured to provide visual warning and / or audible warning.

2. The full dimensional safety shield system (100) for a plant facility according to claim 1, characterized in that, The profiled safety door body (1011) adopts a modular structure and comprises a main frame and an adjustable sub-plate connected to the main frame through a precision slide rail; The adjustable sub-plate can be continuously adjusted and fixed through a locking mechanism to adapt to the dangerous gap of equipment; The profiled safety door body (1011) is made of transparent acrylic plate; The profiled safety door body (1011) is installed on the equipment rack through a rotatable L-shaped support and an expansion bolt.

3. The full dimensional safety shield system (100) for a plant facility according to claim 2, characterized in that, The trigger sensing assembly (1012) comprises a plurality of waterproof contact micro switches which are distributedly installed on the edge of the profiled safety door body (1011) in a full-circumferential triggering manner; The trigger sensing assembly (1012) further comprises a signal processing unit integrated with a signal filtering module and a redundant logical judgment module; The redundant logical judgment module is configured to determine an effective trigger signal when at least two waterproof contact micro switches are triggered at the same time or the triggering time of the same waterproof contact micro switch exceeds a preset triggering threshold.

4. The full dimensional safety shield system (100) for a vehicle plant according to claim 3, characterized in that, The warning execution assembly (1013) comprises a high-brightness three-color LED warning light and a state indication panel; The three-color LED warning light is configured to be green all the time to indicate normal operation of the equipment, yellow all the time to indicate standby of the equipment, and red to flash to indicate emergency shutdown of the equipment; The state indication panel is integrated with a state indication light corresponding to each profiled safety door body (1011), an LCD display screen for displaying fault information and a reset button locked by a key.

5. The full dimensional safety shield system (100) for a vehicle plant according to claim 4, characterized in that, The software subsystem (102) comprises a PLC control program (1021) configured to execute a double interlocking emergency shutdown logic, comprising: After receiving an effective trigger signal, a hardware power-off instruction for cutting off the main power supply of the equipment and a software shutdown instruction sent to the original control system (103) of the equipment are executed in parallel; wherein the PLC control program (1021) sets the effective trigger signal as the highest priority interrupt event.

6. The plant equipment omnistage safety shield system (100) of claim 5, characterized in that, The software subsystem (102) further comprises an alarm reset logic module (1022). The alarm reset logic module (1022) is configured to trigger alarm reset logic to authorize the reset operation and release the device shutdown lock when the preset reset condition is met; wherein the preset reset condition includes that all signals of the trigger sensing assembly (1012) return to the untriggered state, the operator authorizes the confirmation through the key-locked reset button, and the auxiliary safety sensor installed in the device dangerous area confirms that there is no personnel staying in the device dangerous area.

7. The plant equipment omnistage safety shield system (100) of claim 5, wherein, The software subsystem (102) further comprises a parameter configuration module (1023); The parameter configuration module (1023) divides the PLC control program (1021) into a solidified core control module and an adjustable parameter configuration module (1023); The full-dimension safety protection system (100) of the plant equipment further comprises an equipment adaptation database, which pre-stores standardized parameter configuration schemes suitable for different plants and different types of equipment, and can be one-key called and downloaded through the man-machine interface to configure the adjustable parameter configuration module (1023).

8. A full-dimension safety protection method for a plant facility, characterized by, The method is applied to the full-dimension safety protection system of the plant equipment according to any one of claims 1-7, and the method comprises: The dangerous gap of the equipment is physically blocked by the profiling safety door body; The trigger sensing assembly senses the touching behavior and generates a trigger signal; After the software subsystem filters and redundantly judges the trigger signal, the double interlocking emergency shutdown logic is executed within the preset execution time after the valid trigger signal is confirmed; The warning execution assembly provides visual and / or audible warnings, and displays fault information on the state indication panel; After the preset reset condition is met, the alarm reset logic is triggered to authorize the reset operation and release the device shutdown lock.

9. The full dimensional safety guarding method for a machine tool according to claim 8, wherein, The filtering and redundant logic judgment of the trigger signal by the software subsystem comprises: When at least two waterproof contact micro switches are triggered at the same time, or the triggering time of the same waterproof contact micro switch lasts more than a preset trigger threshold, it is determined as a valid trigger signal.

10. The full dimensional safety guarding method for a machine tool according to claim 8, wherein, The preset reset condition comprises: All signals of the trigger sensing assembly return to the untriggered state; The operator authorizes the confirmation through the key-locked reset button; The auxiliary safety sensor installed in the device dangerous area confirms that there is no personnel staying in the device dangerous area.

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