Power-off protection device and method based on infrared correlation grating

Abstract

The invention discloses a power-off protection device and method based on an infrared correlation grating, relates to the technical field of safety protection, and solves the problems that existing power-off protection equipment is weak in anti-interference capability in a complex environment, and is difficult to quickly and accurately cut off a power supply of dangerous equipment, and comprises an infrared correlation grating module, a signal processing unit, a power-off execution module and a system control unit, the infrared correlation grating module is composed of a light projector and a light receiver, and the light projector and the light receiver are matched to form a non-blind area monitoring grating in a dangerous area. According to the working principle, when a light beam is shielded, the light receiver converts a light signal into a photoelectric signal, after the photoelectric signal is amplified, filtered and digitalized through the signal processing unit, the system control unit rapidly generates a power-off instruction, and the power-off execution module cuts off a power supply of dangerous equipment within 0.01 second. The method has a good application prospect in the technical field of safety protection of emergency rescue sites and the like.

Description

Technical Field

[0001] This invention relates to the field of safety protection technology, specifically to a power failure protection device and method based on an infrared photoelectric grating. Background Technology

[0002] In complex rescue scenarios, secondary accidents caused by personnel accidentally entering dangerous areas or equipment malfunctions are a major challenge in rescue operations. For example, at fire, high-voltage power outage, or toxic gas leak sites, rescuers may accidentally enter dangerous areas due to obstructed vision or complex environments, leading to increased casualties or reduced rescue efficiency. Rescue sites often involve harsh environmental conditions such as high temperatures, strong vibrations, smoke, and high humidity, placing extremely high demands on the accuracy, rapid response, and environmental adaptability of safety monitoring equipment. Existing safety monitoring methods and equipment are insufficient to meet these requirements.

[0003] Traditional rescue monitoring equipment, such as visible light cameras, physical barriers, or manual power-off devices, has significant shortcomings. Visible light-based monitoring systems are prone to failure in smoke-filled, low-light, or complex obstruction conditions, failing to provide rescuers with real-time intrusion detection and security protection. While physical barriers can temporarily block dangerous areas, they cannot detect or respond to accidental intrusions or malfunctions. Manual power-off devices rely on human judgment, which can easily lead to delayed responses or operational errors in emergencies, hindering optimal rescue efforts and potentially causing further casualties.

[0004] Power outage protection is a crucial measure to ensure the safety of personnel and equipment, but existing equipment struggles to balance high-speed response and environmental adaptability. This is especially true in industrial sites with a high concentration of hazardous equipment, such as high-voltage motors, chemical reactors, and high-power lasers. In the event of an accident, rapidly cutting off the power supply is critical to preventing the escalation of danger. However, most existing equipment is designed as a single-function system, capable of handling only simple power outage scenarios and lacking comprehensive adaptability to complex rescue environments. Therefore, the inefficiency and unreliability of existing equipment severely restrict rescue operations. Thus, developing a power outage protection system capable of adapting to complex rescue environments and possessing real-time monitoring and high-speed response capabilities is of significant practical importance. Summary of the Invention

[0005] To address the technical problems of existing power outage protection devices being weak in anti-interference capabilities, slow response, lack of intelligent linkage and flexible deployment capabilities in complex environments such as smoke, high temperature, and strong vibration, and making it difficult to quickly and accurately cut off the power supply of dangerous equipment to avoid secondary damage, this invention provides a power outage protection device based on an infrared through-beam grating, comprising: an infrared through-beam grating module, a signal processing unit, a power outage execution module, a system control unit, and an environmental parameter acquisition module.

[0006] The infrared beam grating module includes: a projector and a receiver;

[0007] The projector emits a high-density infrared beam, and the receiver works in conjunction with it to form a blind-spot-free monitoring grating in the danger zone to monitor intrusion behavior in real time. When the beam is blocked, the receiver converts the light signal into a photoelectric signal and transmits it to the signal processing unit.

[0008] The signal processing unit is used to amplify, filter, extract features and digitize the photoelectric signal, and transmit the processed occlusion feature signal to the system control unit.

[0009] The system control unit generates a power-off command through high-speed logic judgment and sends it to the power-off execution module;

[0010] The power-off execution module is used to quickly cut off the power supply to dangerous equipment within 0.01 seconds.

[0011] The environmental parameter acquisition module is used to collect on-site environmental parameters in real time, including temperature, humidity, and vibration intensity, and transmit the environmental parameters to the system control unit.

[0012] The system control unit is also configured to execute an environment-adaptive threshold adjustment algorithm and a beam density grading verification mechanism to dynamically adjust the occlusion judgment threshold and respond in grades according to the number, distribution and duration of the occluded beams.

[0013] Furthermore, the projector includes: a high-strength aluminum alloy housing, an infrared light-emitting diode, and an aspherical lens assembly;

[0014] The high-strength aluminum alloy housing is used to protect the light-emitting diode and the aspherical lens group;

[0015] The infrared light beam emitted by the infrared light-emitting diode is focused by the aspherical lens group into a uniformly covered parallel beam.

[0016] The light receiver includes: a polycarbonate housing, a PIN photodiode, and a Fresnel lens;

[0017] The polycarbonate housing serves to protect the internal PIN photodiode and Fresnel lens;

[0018] The Fresnel lens focuses the infrared beam emitted by the projector onto the PIN photodiode, forming a blind-spot-free grating monitoring network in the danger zone. This ensures that when the beam is blocked, the PIN photodiode can quickly capture changes in the light signal and convert them into photoelectric signals.

[0019] Furthermore, the signal processing unit includes: an analog signal conditioning module and a digital signal processing module;

[0020] The analog signal conditioning module amplifies the weak light signal through a differential amplifier, removes high-frequency noise through an anti-aliasing filter, and dynamically adjusts the signal gain in conjunction with a digital potentiometer.

[0021] The digital signal processing module uses a DSP chip to perform high-speed digital processing, generate the occlusion feature signal, and transmit it to the system control unit.

[0022] Furthermore, the power-off execution module includes: a solid-state relay module, an IGBT drive circuit module, and a protection circuit module;

[0023] The solid-state relay module achieves signal isolation through an optocoupler isolation module and drives a power semiconductor switch to complete high-speed circuit disconnection.

[0024] The IGBT drive circuit module is controlled by a high-speed drive chip to adapt to the rapid power-off of high-power devices.

[0025] The protection circuit module includes an overcurrent protection module and an overvoltage protection module, which are used to ensure safe power disconnection in abnormal situations.

[0026] Furthermore, the system control unit includes: a main control chip, a communication interface module, and a display module;

[0027] The main control chip is used to perform high-speed logic judgment on the occlusion feature signal input by the signal processing unit, generate a power-off command, and transmit it to the power-off execution module through the communication interface module.

[0028] The main control chip is also used to execute an environment-adaptive threshold adjustment algorithm and a beam density grading verification mechanism.

[0029] The environmental adaptive threshold adjustment algorithm is as follows: the environmental parameter acquisition module collects the on-site environmental parameters in real time, and after preprocessing, dynamically calculates the occlusion judgment threshold based on the environmental parameters and updates it to the occlusion judgment logic.

[0030] The beam density grading verification mechanism is as follows: the occlusion status of each infrared beam is collected in real time to form an occlusion status matrix, the occlusion level is determined according to the number, distribution and duration of the occluded beams, and a graded response is executed, including alarm prompts or power-off protection.

[0031] The communication interface module includes: an RS485 interface and an Ethernet module;

[0032] The RS485 interface is used for stable and interference-resistant communication with other rescue equipment at close range, and the Ethernet module is used for high-speed data transmission with the monitoring platform remotely. The two work together to ensure the system's remote control and data traceability capabilities.

[0033] The display module presents power failure event information in real time through an LCD screen and status indicator lights, facilitating user operation and monitoring.

[0034] A power failure protection method based on an infrared through-beam grating is also provided, implemented using the power failure protection device described above, including:

[0035] Step 1: Determine the protected area and the installation location of the infrared beam grating module;

[0036] Step 2: Connect the infrared through-beam grating module to the signal processing unit via a signal connection cable, and simultaneously connect the signal processing unit to the system control unit; connect the power-off execution module to the system control unit via a high-speed signal line;

[0037] After completing the device connection, turn on the system power and enter the debugging mode. Check the alignment of the projector and the receiver, adjust the direction of the projector beam and the angle of the photosensitive surface of the receiver to ensure that there are no blind spots in the coverage area of ​​the grating.

[0038] Complete the device self-test, including testing the amplification and filtering functions of the signal processing unit, calibrating the logic judgment function of the system control unit, and testing the trigger response of the power failure execution module, to ensure the normal operation of the system;

[0039] Step 3: After the system self-test is completed, switch to standby mode. The infrared beam grating module starts to emit beams in real time and establish a monitoring area. When the dangerous equipment is in normal operation, the infrared grating is in a continuous and stable monitoring mode. The receiver receives the beam signal and transmits it to the signal processing unit.

[0040] Step 4: Collect environmental parameters in real time, including temperature, humidity, and vibration intensity, and dynamically calculate the current occlusion judgment threshold using an environmental adaptive threshold adjustment algorithm;

[0041] Step 5: When a person accidentally enters the monitored area or a foreign object blocks the infrared grating, the infrared photoelectric grating module quickly transmits the converted photoelectric signal to the signal processing unit.

[0042] After amplifying, filtering, and digitizing the photoelectric signal, the signal processing unit transmits the resulting occlusion feature signal to the system control unit.

[0043] The system control unit determines the occlusion level based on the number, distribution, and duration of the obstructed beams through a beam density grading verification mechanism.

[0044] If the shading level is level three, then confirm that the shading event meets the power-off conditions and immediately generate a power-off command.

[0045] If the occlusion level is level one or level two, an alarm will be triggered, but no power-off command will be generated.

[0046] The system control unit uses a high-speed logic chip to determine signal characteristics. Once it confirms that the occlusion event meets the power-off conditions, it immediately generates a power-off command.

[0047] Step 6: The system control unit transmits the power-off command to the power-off execution module via a high-speed signal line, and quickly cuts off the power supply to the dangerous equipment within 0.01 seconds;

[0048] Step 7: After the power outage is completed, the system records the information of the current power outage event, including the trigger time, duration of obstruction, and power outage status, in the system control unit. Depending on the rescue needs, rescuers can choose manual reset or automatic reset mode to restore the equipment operation.

[0049] Step 8: Complete the power outage protection task. The system saves all power outage trigger information to the built-in storage device in the system control unit. Rescue or operation personnel can replay and analyze the detailed data of the power outage event through the remote monitoring platform to optimize equipment layout and system operating parameters. After the task is completed, the system is switched to standby mode to complete the reset and archiving of the protection device, ensuring that the equipment is ready for the next operation.

[0050] The present invention has the following beneficial effects:

[0051] This invention is applicable to complex and high-risk scenarios such as rescue sites and hazardous industrial areas. It forms a blind-spot-free monitoring network through infrared beam grating modules, coupled with a signal processing unit and system control unit, achieving millisecond-level rapid power-off within 0.01 seconds, effectively solving the problem of slow response in existing equipment. Its anti-interference filter, shock-resistant components, and specially designed housing ensure stable operation in complex environments such as smoke, high temperatures, and strong vibrations, avoiding false triggering or missed triggering. It also supports dual RS485 and Ethernet interfaces, enabling intelligent collaboration with remote monitoring platforms and other rescue equipment to record and trace power-off event data in real time. Its modular structure adapts to various installation methods, and the grating spacing and angle are flexibly adjustable, making deployment convenient and efficient. Combined with overcurrent and overvoltage dual protection mechanisms, it comprehensively improves the reliability, accuracy, and flexibility of power-off protection, significantly reducing the risk of secondary injury caused by personnel accidentally entering the area, and ensuring the safety and efficiency of rescue and production operations. Attached Figure Description

[0052] Figure 1 This is a schematic diagram showing the installation layout and monitoring area of ​​the infrared beam grating module;

[0053] Figure 2 This is a schematic diagram of the projector structure;

[0054] Figure 3 This is a schematic diagram of the light receiver structure;

[0055] Figure 4 This is a schematic diagram of the signal processing unit structure;

[0056] Figure 5 This is a schematic diagram of the power-off execution unit structure;

[0057] Figure 6 This is a schematic diagram of the system control unit structure;

[0058] Figure 7 A flowchart of the environment adaptive threshold adjustment algorithm;

[0059] Figure 8 This is a flowchart of the beam density grading verification mechanism.

[0060] Among them, 1—Infrared through-beam grating module, 1-1—Shine projector, 1-1-1—High-strength aluminum alloy shell, 1-1-2—Infrared light-emitting diode, 1-1-3—Aspherical lens group, 1-2—Shine receiver, 1-2-1—Polycarbonate shell, 1-2-2—PIN photodiode, 1-2-3—Fresnel lens, 2—Signal processing unit, 2-1—Analog signal conditioning module, 2-1-1—Differential amplifier, 2-1-2—Anti-aliasing filter, 2-1-3—Digital potentiometer, 2-2—Digital signal processing module, 2-2-1—DSP chip, 3—Power-off execution module. 3-1—Solid-state relay module, 3-1-1—Optical isolation module, 3-1-2—Power semiconductor switch, 3-2—IGBT drive circuit module, 3-2-1—IGBT module, 3-2-2—High-speed drive chip, 3-3—Protection circuit module, 3-3-1—Overcurrent protection module, 3-3-2—Overvoltage protection module, 4—System control unit, 4-1—Main control chip, 4-2—Communication interface module, 4-2-1—RS485 interface, 4-2-2—Ethernet module, 4-3—Display module, 4-3-1—LCD display screen, 4-3-2—Status indicator light. Detailed Implementation

[0061] The technical solution of the present invention will be further described below with reference to embodiments, but it is not limited thereto. Any modifications or equivalent substitutions to the technical solution of the present invention without departing from the spirit and scope of the technical solution of the present invention should be covered within the protection scope of the present invention. In the following embodiments, the process equipment or apparatus not specifically specified are all conventional equipment or apparatus in the art. Unless otherwise specified, the raw materials used in the embodiments of the present invention are all commercially available; unless otherwise specified, the technical means used in the embodiments of the present invention are all conventional means well known to those skilled in the art.

[0062] Example 1: A power failure protection device based on an infrared through-beam grating, comprising: an infrared through-beam grating module 1, a signal processing unit 2, a power failure execution module 3, a system control unit 4, and an environmental parameter acquisition module;

[0063] The infrared through-beam grating module 1 includes: a projector 1-1 and a receiver 1-2;

[0064] The projector 1-1 emits a high-density infrared beam, and the receiver 1-2 works in conjunction with it to form a blind-spot-free monitoring grating in the danger zone to monitor intrusion behavior in real time. When the beam is blocked, the receiver 1-2 converts the light signal into a photoelectric signal and transmits it to the signal processing unit 2.

[0065] The signal processing unit 2 is used to amplify, filter, extract features and digitize the photoelectric signal, and transmit the occlusion feature signal obtained after processing to the system control unit 4.

[0066] The system control unit 4 generates a power-off command through high-speed logic judgment and sends it to the power-off execution module 3;

[0067] The power-off execution module 3 is used to quickly cut off the power supply to dangerous equipment within 0.01 seconds.

[0068] The environmental parameter acquisition module is used to collect on-site environmental parameters in real time, including temperature, humidity, and vibration intensity, and transmit the environmental parameters to the system control unit 4;

[0069] The system control unit 4 is also configured to execute an environment-adaptive threshold adjustment algorithm and a beam density grading verification mechanism to dynamically adjust the occlusion judgment threshold and respond in grades according to the number, distribution and duration of the occluded beams.

[0070] Specifically, through Figure 1 The deployment and core working logic of the infrared beam grating module 1 are as follows: the projector 1-1 and the receiver 1-2 are mounted opposite each other on the column. The projector 1-1 emits multiple high-density infrared beams to the receiver 1-2, and these beams together form a monitoring grating covering a specific area. The human-shaped symbol in the figure also intuitively reflects its application scenario.

[0071] This invention utilizes the coordinated operation of an infrared beam grating module, a signal processing unit, a system control unit, and a power-off execution module. The projector and receiver work together to form a blind-spot-free infrared monitoring grating in the hazardous area to monitor intrusion behavior in real time. When the beam is blocked, the receiver converts the light signal into a photoelectric signal. After the signal processing unit completes amplification, filtering, feature extraction, and digitization, the system control unit generates a power-off command through high-speed logic judgment. Finally, the power-off execution module quickly cuts off the power supply to the hazardous equipment within 0.01 seconds.

[0072] Furthermore, the projector 1-1 includes: a high-strength aluminum alloy housing 1-1-1, an infrared light-emitting diode 1-1-2, and an aspherical lens group 1-1-3;

[0073] The high-strength aluminum alloy housing 1-1-1 is used to protect the light-emitting diode 1-1-2 and the aspherical lens group 1-1-3;

[0074] The infrared light beam emitted by the infrared light-emitting diode 1-1-2 is focused into a uniformly covered parallel beam by the aspherical lens group 1-1-3.

[0075] The light receiver 1-2 includes: a polycarbonate shell 1-2-1, a PIN photodiode 1-2-2, and a Fresnel lens 1-2-3;

[0076] The polycarbonate housing 1-2-1 is used to protect the internal PIN photodiode 1-2-2 and the Fresnel lens 1-2-3;

[0077] The Fresnel lens 1-2-3 converges the infrared beam emitted by the projector 1-1 to the PIN photodiode 1-2-2, forming a blind-spot-free grating monitoring network in the danger zone, ensuring that the PIN photodiode 1-2-2 can quickly capture changes in the light signal and convert them into photoelectric signals when the beam is blocked.

[0078] Specifically, through Figure 2 and Figure 3 It can be seen that the projector 1-1 is equipped with a high-strength aluminum alloy shell 1-1-1, which serves both as protection and heat dissipation; the top is equipped with vertically arranged infrared light-emitting diodes 1-1-2 as the source of infrared beam emission; and an aspherical lens group 1-1-3 is embedded inside to focus the emitted infrared light into a uniform parallel beam.

[0079] The receiver 1-2 has a polycarbonate shell 1-2-1, which combines protection and light transmission; it is equipped with a high-sensitivity PIN photodiode 1-2-2 to receive the light beam and complete the photoelectric conversion; and it is internally equipped with a Fresnel lens 1-2-3, which can focus the infrared light beam to improve the receiving efficiency.

[0080] Furthermore, combined with Figure 4 It can be seen that the signal processing unit 2 includes: an analog signal conditioning module 2-1 and a digital signal processing module 2-2;

[0081] The analog signal conditioning module 2-1 amplifies the weak light signal through the differential amplifier 2-1-1, removes high-frequency noise through the anti-aliasing filter 2-1-2, and dynamically adjusts the signal gain in conjunction with the digital potentiometer 2-1-3.

[0082] The digital signal processing module 2-2 performs high-speed digital processing using the DSP chip 2-2-1 to generate the occlusion feature signal and transmit it to the system control unit 4.

[0083] Furthermore, the power-off execution module 3 includes: a solid-state relay module 3-1, an IGBT drive circuit module 3-2, and a protection circuit module 3-3;

[0084] The solid-state relay module 3-1 achieves signal isolation through the optocoupler isolation module 3-1-1 and drives the power semiconductor switch 3-1-2 to complete the high-speed circuit cutoff.

[0085] The IGBT drive circuit module 3-2 is controlled by the high-speed drive chip 3-2-2 to control the IGBT module 3-2-1, which is used to adapt to the rapid power-off of high-power devices.

[0086] The protection circuit module 3-3 includes an overcurrent protection module 3-3-1 and an overvoltage protection module 3-3-2. The overcurrent protection module 3-3-1 and the overvoltage protection module 3-3-2 are used to ensure safe power disconnection under abnormal conditions.

[0087] Specifically, the power failure execution module structure diagram is as follows: Figure 5 As shown.

[0088] Furthermore, the system control unit 4 includes: a main control chip 4-1, a communication interface module 4-2, and a display module 4-3;

[0089] The main control chip 4-1 is used to perform high-speed logic judgment on the occlusion feature signal input by the signal processing unit 2, generate a power-off command, and transmit it to the power-off execution module 3 through the communication interface module 4-2;

[0090] The main control chip 4-1 is also used to execute the environment adaptive threshold adjustment algorithm and the beam density classification verification mechanism;

[0091] The environmental adaptive threshold adjustment algorithm is as follows: the environmental parameter acquisition module collects the on-site environmental parameters in real time, and after preprocessing, dynamically calculates the occlusion judgment threshold based on the environmental parameters and updates it to the occlusion judgment logic.

[0092] The beam density grading verification mechanism is as follows: the occlusion status of each infrared beam is collected in real time to form an occlusion status matrix, the occlusion level is determined according to the number, distribution and duration of the occluded beams, and a graded response is executed, including alarm prompts or power-off protection.

[0093] The communication interface module 4-2 includes: an RS485 interface 4-2-1 and an Ethernet module 4-2-2;

[0094] The RS485 interface 4-2-1 is used for stable and interference-resistant linkage communication with other rescue equipment at close range, and the Ethernet module 4-2-2 is used for high-speed data transmission with the monitoring platform remotely. The two work together to ensure the system's remote control and data traceability capabilities.

[0095] The display module 4-3 presents power failure event information in real time through the LCD display screen 4-3-1 and status indicator lights 4-3-2, which facilitates user operation and monitoring.

[0096] Specifically, the system control unit structure is as follows: Figure 6 As shown.

[0097] A power failure protection method based on an infrared through-beam grating is also provided, implemented using the power failure protection device described above, including:

[0098] Step 1: Determine the protected area and the installation location of the infrared beam grating module 1;

[0099] Step 2: Connect the infrared through-beam grating module 1 to the signal processing unit 2 via a signal connection line, and simultaneously connect the signal processing unit 2 to the system control unit 4; connect the power-off execution module 3 to the system control unit 4 via a high-speed signal line;

[0100] After completing the device connection, turn on the system power and enter the debugging mode. Check the alignment of the projector 1-1 and the receiver 1-2, and adjust the direction of the beam of the projector 1-1 and the angle of the photosensitive surface of the receiver 1-2 to ensure that there are no blind spots in the coverage area of ​​the grating.

[0101] Complete the device self-test, including testing the amplification and filtering functions of the signal processing unit 2, calibrating the logic judgment function of the system control unit 4, and testing the trigger response of the power failure execution module 3, to ensure the normal operation of the system;

[0102] Step 3: After the system self-test is completed, switch to standby mode. The infrared beam grating module 1 starts to emit beams in real time and establish a monitoring area. When the dangerous equipment is in normal operation, the infrared grating is in a continuous and stable monitoring mode. The receivers 1-2 receive the beam signals and transmit them to the signal processing unit 2.

[0103] Step 4: Collect environmental parameters in real time, including temperature, humidity, and vibration intensity, and dynamically calculate the current occlusion judgment threshold using an environmental adaptive threshold adjustment algorithm;

[0104] Step 5: When a person accidentally enters the monitored area or a foreign object blocks the infrared grating, the infrared photoelectric grating module 1 quickly transmits the converted photoelectric signal to the signal processing unit 2;

[0105] After amplifying, filtering and digitizing the photoelectric signal, the signal processing unit 2 transmits the processed occlusion feature signal to the system control unit 4.

[0106] The system control unit 4 determines the occlusion level based on the number, distribution and duration of the obstructed beams through a beam density grading verification mechanism.

[0107] If the shading level is level three, then confirm that the shading event meets the power-off conditions and immediately generate a power-off command.

[0108] If the occlusion level is level one or level two, an alarm will be triggered, but no power-off command will be generated.

[0109] The system control unit 4 uses a high-speed logic chip to determine signal characteristics. Once it confirms that the occlusion event meets the power-off conditions, it immediately generates a power-off command.

[0110] Step 6: The system control unit 4 transmits the power-off command to the power-off execution module 3 via a high-speed signal line, and quickly cuts off the power supply to the dangerous equipment within 0.01 seconds;

[0111] Step 7: After the power outage is completed, the system records the information of the current power outage event, including the trigger time, duration of obstruction and power outage status, in the system control unit 4. Depending on the rescue needs, rescuers can choose manual reset or automatic reset mode to restore the equipment operation.

[0112] Step 8: Complete the power outage protection task. The system saves all power outage trigger information to the built-in storage device in the system control unit 4. Rescue or operator personnel can replay and analyze the detailed data of the power outage event through the remote monitoring platform to optimize equipment layout and system operating parameters. After the task is completed, the system is switched to standby mode to complete the reset and archiving of the protection device, ensuring that the equipment is ready for the next operation.

[0113] Specifically, Figure 7 This is a flowchart of the environmental adaptive threshold adjustment algorithm described in this invention. It aims to solve the problem of false triggering or missed triggering caused by the fixed occlusion judgment threshold in traditional infrared beam grating power failure protection devices. Its core logic is to establish a mapping relationship model between environmental parameters and occlusion judgment threshold by collecting environmental parameters such as temperature, humidity and vibration intensity in real time, and dynamically adjust the signal strength judgment threshold of the infrared receiver to ensure accurate differentiation between "effective occlusion (such as human body, large obstacle)" and "ineffective interference (such as dust, water vapor, slight vibration)" under different environmental conditions, thereby improving the adaptability and reliability of the device in complex environments.

[0114] The specific process is as follows: First, initialize the parameters, preset the baseline occlusion threshold T0 (unit: infrared receiver signal strength value, the critical occlusion signal strength measured by experiments in an interference-free environment), environmental parameter weight coefficients that satisfy α+β+γ=1 (temperature weight α, humidity weight β, vibration intensity weight γ), sampling period T of 500ms, and moving average filter window length N of 10 sampling points.

[0115] Subsequently, the original temperature value t, the original humidity value h, and the original vibration intensity value v are collected synchronously according to the sampling period T.

[0116] And note:

[0117]

[0118]

[0119] (in (These are the original data corresponding to the most recent N sampling periods.)

[0120] Preprocessing with moving average filtering;

[0121] Next, using the piecewise linear mapping model calibrated experimentally, the calculation is performed according to the formula: k = α × k_t + β × k_h + γ × k_v.

[0122] Calculate the threshold correction factor k (where k_t is set according to the temperature range: k_t=1.2 when t_filtered < -10℃, k_t=1.0 when -10℃ ≤ t_filtered ≤ 50℃, and k_t=1.1 when t_filtered > 50℃; k_h is set according to the humidity range: k_h=1.3 when h_filtered > 80%RH, and k_h=1.0 when h_filtered ≤ 80%RH; k_v is set according to the vibration intensity range: k_v=1.1 when v_filtered > 2g, and k_v=1.0 when v_filtered ≤ 2g).

[0123] The current occlusion judgment threshold is then dynamically calculated according to T_current=T0×k. At the same time, the upper and lower limits of the thresholds T_min=0.8×T0 and T_max=1.5×T0 are set to avoid over-adjustment (T_min is used when T_current<T_min, and T_max is used when T_current>T_max). Finally, T_current is updated in real time to the occlusion judgment logic of the infrared through-beam grating as the judgment standard for the current period. Then, the above process is repeated in the next sampling period to achieve continuous dynamic adjustment of the threshold.

[0124] This algorithm achieves precise dynamic adjustment of the occlusion threshold through multi-environment parameter fusion analysis. Compared with the fixed threshold scheme, it can effectively avoid false triggering in high temperature, high humidity and strong vibration environments. At the same time, it ensures a low missed trigger rate in signal attenuation scenarios such as low temperature and dryness. Furthermore, the introduction of moving average filtering can filter out instantaneous fluctuations in environmental parameters and ensure the stability of threshold adjustment.

[0125] Figure 8 The flowchart shows the beam density grading verification mechanism. As can be seen from the diagram, this mechanism is based on the multi-beam array layout of infrared through-beam gratings. The core of the mechanism is to accurately distinguish between "ineffective interference blocking (such as dust, debris, and insects)" and "effective hazard blocking (such as human intrusion or large equipment displacement)" by judging the number, distribution, and duration of the blocked beams. This enables "graded response"—only an alarm is triggered when a single or a small number of beams are blocked briefly, while power-off protection is activated only when multiple beams are blocked simultaneously or continuously. This effectively avoids unnecessary power outages caused by environmental interference and significantly improves the practicality and fault tolerance of the device. The mechanism classifies occlusion levels into three levels: Level 1 occlusion (ineffective interference) refers to single beam occlusion for a duration t ≤ t1 (t1 is set to 500ms, configurable via the system control unit), or occlusion of two or fewer adjacent beams for a duration t ≤ t2 (t2 is set to 300ms). Common causes include floating dust, small debris, and flying insects. Level 2 occlusion (early warning) refers to single beam occlusion for a duration t > t1, or occlusion of two or fewer adjacent beams for a duration t2 < t ≤ t3 (t3 is set to 1s). Common causes include small amounts of dust accumulation and slight contamination of the grating surface. Level 3 occlusion (effective hazard) refers to simultaneous occlusion of ≥3 beams (regardless of duration), or continuous occlusion of two or more adjacent beams for a duration t > t3. Common causes include human intrusion, large obstacle occlusion, and equipment displacement / collision. The beam density classification verification and environmental adaptive threshold adjustment algorithm are executed collaboratively, with the specific process as follows:

[0126] First, the beam occlusion status is acquired. The main control module collects the received signal intensity of each infrared beam in real time and compares it with the current occlusion judgment threshold T_current obtained by the environment adaptive algorithm. If the received signal intensity of a beam is less than T_current, it is judged as "occlusion state" (marked as 1); otherwise, it is "normal state" (marked as 0), forming an occlusion status matrix. Next, the occlusion level is determined. The occlusion state matrix S is analyzed, the number of occluded beams M (M=Σs_i) is counted, and the duration t_i of each occluded beam is recorded (starting from the first determination of the occlusion state). If M=1 and max(t_i)≤t1 or M=2 (adjacent) and max(t_i)≤t2, it is determined to be a level 1 occlusion. If M=1 and max(t_i)>t1 or M=2 (adjacent) and t2<max(t_i)≤t3, it is determined to be a level 2 occlusion. If M≥3, M=2 (non-adjacent) and max(t_i)>t3 or M≥2 and non-adjacent beams continuously occlude, it is determined to be a level 3 occlusion.

[0127] Subsequently, a tiered response strategy is implemented. For Level 1 occlusion, the main control module controls the alarm module (e.g., a buzzer) to emit a short tone (e.g., 1 sound / second, lasting 2 seconds), without triggering power-off protection. Simultaneously, the occlusion time and location are recorded for subsequent environmental interference statistics. For Level 2 occlusion, the alarm module emits a continuous buzzer (frequency 2kHz) and controls the status indicator (e.g., a yellow LED) to flash, reminding staff to check the cleanliness of the grating surface or the surrounding environment. If the continuous alarm time t > t4 (t4 is set to 5 seconds), a "light cleaning reminder" is pushed to the staff terminal via the remote communication module, still without triggering power-off. For Level 3 occlusion, the alarm module emits a high-frequency emergency stop buzzer (frequency 4kHz), the status indicator (red LED) remains constantly lit, and the main control module immediately outputs a power-off control signal to trigger the relay, cutting off the power to the protected equipment. Simultaneously, data such as the power-off event, occlusion level, and environmental parameters are uploaded to the monitoring center via RS485 or Ethernet for subsequent traceability.

[0128] Finally, a reset process is performed after the obstruction is removed. When the signal strength of all beams is ≥T_current and the duration t is ≥t5 (t5 is set to 1s), the obstruction state is removed, the main control module controls the alarm module to stop the alarm, and the status indicator returns to normal (such as a green LED that is always on). If the power outage is caused by a level 3 obstruction, the staff needs to manually trigger the reset button or send a reset command remotely through the monitoring center before the device can restore power supply to avoid the safety risks caused by automatic reset.

[0129] To further improve the accuracy of the judgment, the mechanism also includes three optimized designs: First, beam distribution determination, which judges whether the occluded beam is "continuously distributed" by analyzing the continuity of the occlusion state matrix (e.g., ...). and For continuity, and First, it is non-continuous. Non-continuous multi-beam occlusion requires further judgment based on duration to avoid misjudging dangerous states. Second, the time thresholds are configurable. Time thresholds such as t1, t2, t3, t4, and t5 can all be configured through the host computer interface of the main control module, and can be flexibly adapted according to the interference characteristics of different scenarios (e.g., t1 can be appropriately increased in scenarios with more dust, and t3 can be decreased in densely populated areas). Third, it is optimized for anti-vibration interference. Combined with the vibration intensity parameter in the environmental adaptive algorithm, if the vibration intensity v_filtered > 2g, the time thresholds of the first and second level occlusions are automatically extended (e.g., t1 is adjusted to 800ms) to avoid misjudging instantaneous beam occlusion caused by vibration.

Claims

1. An infrared beam-falling protection device based on infrared beam barriers, characterized in that, The application relates to an infrared beam-shooting grating module (1), a signal processing unit (2), a power-off execution module (3), a system control unit (4) and an environmental parameter acquisition module. The infrared beam-shooting grating module (1) comprises a light projector (1-1) and a light receiver (1-2). The light projector (1-1) emits high-density infrared light beams, and the light receiver (1-2) cooperates with the light projector (1-1) to form a blind-area-free monitoring grating in a dangerous area, so that intrusion behavior can be monitored in real time; when the light beams are blocked, the light receiver (1-2) converts the light signals into photoelectric signals and transmits the photoelectric signals to the signal processing unit (2). The signal processing unit (2) is used for amplifying, filtering, feature extracting and digitizing photoelectric signals, and transmits the blocked feature signals obtained after processing to the system control unit (4). The system control unit (4) generates a power-off instruction through high-speed logic judgment and sends the power-off instruction to the power-off execution module (3). The power-off execution module (3) is used for rapidly cutting off the power supply of dangerous equipment within 0.01 seconds. The environmental parameter acquisition module is used for acquiring environmental parameters in real time, including temperature and humidity and vibration intensity, and transmits the environmental parameters to the system control unit (4). The system control unit (4) is further configured to execute an environmental self-adaptive threshold adjustment algorithm and a light beam density grading check mechanism, so as to dynamically adjust the blocking judgment threshold and respond to the number, distribution and duration of the blocked light beams in stages. The light projector (1-1) comprises a high-strength aluminum alloy shell (1-1-1), an infrared light-emitting diode (1-1-2) and an aspheric lens group (1-1-3).

2. The power-off protection device based on infrared transceiver grating according to claim 1, characterized in that, The high-strength aluminum alloy shell (1-1-1) is used for protecting the light-emitting diode (1-1-2) and the aspheric lens group (1-1-3). The infrared light beams emitted by the infrared light-emitting diode (1-1-2) are focused into uniform parallel light beams through the aspheric lens group (1-1-3). The light receiver (1-2) comprises a polycarbonate shell (1-2-1), a PIN photoelectric diode (1-2-2) and a Fresnel lens (1-2-3). The polycarbonate shell (1-2-1) is used for protecting the PIN photoelectric diode (1-2-2) and the Fresnel lens (1-2-3) in the shell. The Fresnel lens (1-2-3) converges the infrared light beams emitted by the light projector (1-1) to the PIN photoelectric diode (1-2-2), forms a blind-area-free grating monitoring network in a dangerous area, and ensures that the PIN photoelectric diode (1-2-2) can quickly capture the change of the light signals and convert the change into photoelectric signals when the light beams are blocked. The signal processing unit (2) comprises an analog signal conditioning module (2-1) and a digital signal processing module (2-2).

3. The power-off protection device based on infrared transceiver grating according to claim 1, characterized in that, The analog signal conditioning module (2-1) amplifies weak light signals through a differential amplifier (2-1-1), removes high-frequency noise through an anti-aliasing filter (2-1-2), and dynamically adjusts the signal gain in combination with a digital potentiometer (2-1-3). ​ The digital signal processing module (2-2) is processed by a DSP chip (2-2-1) to generate the shielding feature signal and transmit it to the system control unit (4).

4. The power-off protection device based on infrared transceiver grating according to claim 1, characterized in that, The power-off execution module (3) comprises a solid-state relay module (3-1), an IGBT drive circuit module (3-2) and a protection circuit module (3-3). The solid-state relay module (3-1) realizes signal isolation through an optical coupling isolation module (3-1-1) and drives a power semiconductor switch (3-1-2) to complete high-speed circuit cutting; The IGBT drive circuit module (3-2) controls an IGBT module (3-2-1) by a high-speed drive chip (3-2-2) to adapt to the fast power-off of high-power equipment; The protection circuit module (3-3) comprises an overcurrent protection module (3-3-1) and an overvoltage protection module (3-3-2) to ensure safe power-off in abnormal conditions.

5. The power-off protection device based on infrared transceiver grating according to claim 1, characterized in that, The system control unit (4) comprises a main control chip (4-1), a communication interface module (4-2) and a display module (4-3). The main control chip (4-1) is used for high-speed logical judgment of the shielding feature signal input by the signal processing unit (2), generates a power-off instruction and transmits it to the power-off execution module (3) through the communication interface module (4-2); The main control chip (4-1) is also used for executing an environment adaptive threshold adjustment algorithm and a light beam density grading verification mechanism; The environment adaptive threshold adjustment algorithm specifically comprises real-time collection of the on-site environment parameters by the environment parameter collection module (5), dynamic calculation of the shielding judgment threshold according to the environment parameters after preprocessing and updating to the shielding judgment logic; The light beam density grading verification mechanism specifically comprises real-time collection of the shielding state of each infrared light, formation of a shielding state matrix, determination of the shielding level according to the number, distribution and duration of the shielding light beams and execution of a grading response including alarm prompt or power-off protection; The communication interface module (4-2) comprises an RS485 interface (4-2-1) and an Ethernet module (4-2-2); The RS485 interface (4-2-1) is used for stable anti-interference linkage communication with other rescue equipment at a short distance, and the Ethernet module (4-2-2) is used for high-speed data transmission with a monitoring platform at a long distance, both of which cooperate to guarantee the remote control and data tracing capability of the system; The display module (4-3) presents the power-off event information in real time through an LCD display screen (4-3-1) and a status indicator light (4-3-2) for user operation and monitoring.

6. A power-off protection method based on infrared transceiver grating, implemented based on the power-off protection device of any one of claims 1-5, characterized in that, It comprises: Step one, determining the protected area and the installation position of the infrared opposite-shooting grating module (1); Step two, connecting the infrared opposite-shooting grating module (1) and the signal processing unit (2) through a signal connection line, connecting the signal processing unit (2) and the system control unit (4) at the same time and connecting the power-off execution module (3) to the system control unit (4) through a high-speed signal line. After the device is connected, the system power is started, the debugging mode is entered, the alignment of the light projector (1-1) and the light receiver (1-2) is checked, the direction of the light beam of the light projector (1-1) and the angle of the light-sensitive surface of the light receiver (1-2) are adjusted, and it is ensured that there is no blind area in the grating coverage range; After the device self-checking is completed, including the amplification and filtering function test of the signal processing unit (2), the logic judgment function calibration of the system control unit (4), and the trigger response test of the power-off execution module (3), it is ensured that the system is normally operated; Step three, after the system self-checking is completed, the standby mode is switched to, the infrared opposite-shooting grating module (1) starts to emit light beams in real time and establishes a monitoring area, the dangerous equipment is in a normal operating state, the infrared grating is in a continuous and stable monitoring mode, the light receiver (1-2) receives the light beam signal and transmits it to the signal processing unit (2); Step four, real-time collection of environmental parameters, including temperature, humidity, vibration intensity, and dynamic calculation of the current shielding judgment threshold value through the environmental self-adaptive threshold adjustment algorithm; Step five, when there is a person or foreign matter shielding the infrared grating in the monitoring area, the infrared opposite-shooting grating module (1) rapidly transmits the converted photoelectric signal to the signal processing unit (2); The signal processing unit (2) amplifies, filters, and digitizes the photoelectric signal, and transmits the shielding feature signal obtained after processing to the system control unit (4); The system control unit (4) determines the shielding level according to the number, distribution, and duration of the shielding light beams through a light beam density grading verification mechanism; If the shielding level is three, it is confirmed that the shielding event meets the power-off condition, and a power-off instruction is immediately generated; If the shielding level is one or two, an alarm prompt is triggered, and no power-off instruction is generated; The system control unit (4) determines the signal characteristics with a high-speed logic chip, and generates a power-off instruction immediately after confirming that the shielding event meets the power-off condition; Step six, the system control unit (4) transmits the power-off instruction to the power-off execution module (3) through a high-speed signal line, and rapidly cuts off the power supply of the dangerous equipment within 0.01 seconds; Step seven, after the power-off action is completed, the system records the information of the current power-off event, including the triggering time, the shielding duration, and the power-off state, in the system control unit (4), and according to the rescue demand, the rescue personnel can choose manual reset or automatic reset mode to restore the equipment operation; Step eight, after the power-off protection task is completed, the system saves all power-off triggering information in the built-in storage device in the system control unit (4), the rescue or operation personnel plays back and analyzes the detailed data of the power-off event through the remote monitoring platform, optimizes the equipment arrangement and system operation parameters, and after the task is completed, the system is switched to the standby mode, the reset and archiving operation of the protection device is completed, and it is ensured that the equipment is prepared for the next operation.

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