Anti-rollover early warning method, device and system for material grabbing machine and material grabbing machine

Abstract

The invention relates to the technical field of engineering machinery safety control, and discloses an anti-rollover early warning method, device and system for a material grabbing machine and the material grabbing machine, and the method comprises the steps that the maximum load weight of the material grabbing machine without rollover is calculated according to the structural parameters of the material grabbing machine and the chassis stabilizing force of the material grabbing machine, and the chassis stabilizing force is the force applied by a chassis of the material grabbing machine to the ground; the maximum load weight is converted into the maximum safety pressure of the movable arm oil cylinder; the actual working pressure of the movable arm oil cylinder is measured; and according to the magnitude relation between the actual working pressure and the maximum safety pressure, tipping early warning is carried out, dynamic and accurate early warning of the tipping risk of the material grabbing machine is achieved, and the operation safety is improved.

Description

Technical Field

[0001] This invention relates to the field of safety control technology for engineering machinery, specifically to a method, device, system, and material grabber for preventing tipping over. Background Technology

[0002] During operation, material handling machines are prone to tipping over due to instability caused by imbalance of the center of gravity or external factors. This tipping can lead to injuries, equipment damage, production interruptions, and economic losses. In most cases, the operator must assess the risk of tipping and immediately stop operation to restore the machine to a safe state. While some technologies have proposed automatic tipping risk detection solutions, these solutions primarily calculate the maximum load weight to prevent tipping, determine the actual weight of the material being handled, and then compare the two. If the actual weight exceeds the maximum load weight, an alarm is triggered. However, because the materials handled by material handling machines are often loose and sticky to the bucket, and the bucket shape is irregular, it's impossible to install weighing sensors for accurate weight measurement. Therefore, the actual weight is calculated based on vehicle structure data, boom operating status data, and the material handling machine's load curve, resulting in complex and inaccurate weight calculations that fail to provide effective tipping warnings. Summary of the Invention

[0003] This invention provides a method, device, system, and material handling machine for preventing tipping over, in order to solve the technical problems of low reliability and poor real-time performance of tipping over warnings caused by reliance on complex and inaccurate calculations of actual cargo weight in related technologies.

[0004] In a first aspect, the present invention provides a method for preventing tipping of a material grabber, the method comprising: calculating the maximum load weight at which the material grabber will not tip over based on the structural parameters of the material grabber and the chassis stabilization force of the material grabber, wherein the chassis stabilization force is the force exerted by the chassis of the material grabber on the ground; converting the maximum load weight into the maximum safe pressure of the boom cylinder; measuring the actual working pressure of the boom cylinder; and issuing a tipping warning based on the relationship between the actual working pressure and the maximum safe pressure.

[0005] In one optional implementation, the maximum load weight that the grabber will not tip over is calculated based on the structural parameters of the grabber and the chassis stabilization force of the grabber. This includes: obtaining the boom angle and stick angle of the grabber, where the boom angle refers to the pitch angle of the boom relative to the vehicle body reference plane, and the stick angle refers to the pitch angle of the stick relative to the vehicle body reference plane; calculating the horizontal lever arm from the load application point to the rotation center under the current posture based on the boom angle and stick angle; calculating the overall machine stabilization torque based on the chassis stabilization force and the rearward horizontal distance from the rotation center to the overturning fulcrum; and calculating the maximum load weight using the ratio of the overall machine stabilization torque to the horizontal lever arm.

[0006] In one optional implementation, the maximum load weight is calculated using the ratio of the overall machine stabilizing torque to the horizontal lever arm, including:

[0007] in, Indicates the maximum load weight. This represents the overall machine stabilizing torque, and K represents the preset safety factor, which satisfies 0. <K<1, Indicates the horizontal lever arm.

[0008] In one optional implementation, the maximum safe pressure of the boom cylinder is calculated by converting the maximum load weight, including: calculating the first overturning moment generated by the maximum load weight; calculating the second overturning moment generated by the weight of the boom itself; calculating the third overturning moment generated by the weight of the stick itself; calculating the fourth overturning moment generated by the weight of the stick cylinder; and calculating the maximum safe pressure based on the total overturning moment, the lever arm of the boom cylinder, and the effective working area of ​​the boom cylinder. The total overturning moment is the sum of the first, second, third, and fourth overturning moments.

[0009] In one optional implementation, the first overturning moment, the second overturning moment, the third overturning moment, and the fourth overturning moment are calculated as follows: the first overturning moment is calculated based on the product of the maximum load weight and the first lever arm, where the first lever arm is the distance from the overturning fulcrum to the load point; the second overturning moment is calculated based on the product of the boom's own weight and the second lever arm, where the second lever arm is the distance from the overturning fulcrum to the boom's center of gravity; the third overturning moment is calculated based on the product of the stick's own weight and the third lever arm, where the third lever arm is the distance from the overturning fulcrum to the stick's center of gravity; and the third overturning moment is calculated based on the product of the stick cylinder's weight and the fourth lever arm, where the fourth lever arm is the distance from the overturning fulcrum to the stick cylinder. In one optional implementation, the maximum safe pressure is calculated by considering the lever arm of the boom cylinder and the effective working area of ​​the boom cylinder, including: distributing the total overturning moment evenly to the two boom cylinders arranged in parallel to obtain the torque component that a single boom cylinder needs to bear; dividing the torque component that a single boom cylinder needs to bear by the lever arm of the boom cylinder to obtain the theoretical thrust that a single boom cylinder needs to output; and dividing the theoretical thrust by the effective working area of ​​the boom cylinder to obtain the maximum safe pressure.

[0010] In one optional implementation, a rollover warning is generated based on the relationship between the actual working pressure and the maximum safe pressure, including: setting a first warning threshold and a second warning threshold based on the maximum safe pressure, wherein the first warning threshold is less than the second warning threshold; outputting a first-level warning signal when the actual working pressure is greater than or equal to the first warning threshold; and outputting a second-level warning signal when the actual working pressure is greater than or equal to the second warning threshold.

[0011] Secondly, the present invention provides an anti-tipping device for a material handling machine, the device comprising: a maximum load weight calculation module, used to calculate the maximum load weight at which the material handling machine will not tip over based on the structural parameters of the material handling machine and the chassis stabilization force of the material handling machine, wherein the chassis stabilization force is the force exerted by the chassis of the material handling machine on the ground; a maximum safety pressure calculation module, used to convert the maximum load weight into the maximum safety pressure of the boom cylinder; an actual working pressure measurement module, used to measure the actual working pressure of the boom cylinder; and a tipping warning module, used to provide a tipping warning based on the relationship between the actual working pressure and the maximum safety pressure.

[0012] Thirdly, a material handling machine anti-tipping early warning system includes: a controller for executing the material handling machine anti-tipping early warning method of the first aspect or any corresponding embodiment; and a sensor group, communicatively connected to the controller, for acquiring the boom angle, stick angle, and actual working pressure of the boom cylinder of the material handling machine. Fourthly, a material handling machine that integrates an anti-tipping early warning system similar to that in the second aspect.

[0013] Based on the above technical means, by combining the structural parameters, chassis stability force and real-time posture of the material grabber, the maximum safe load and corresponding hydraulic pressure threshold under specific working conditions are dynamically calculated. This threshold is then compared with the real-time monitored cylinder working pressure, achieving accurate and dynamic early warning of tipping risk. This changes the limitations of relying on fixed thresholds or operator experience in the traditional method, and can proactively identify and warn of tipping risks caused by excessive load or improper posture, thereby improving operational safety and providing operators with timely and quantitative risk warnings. Attached Figure Description

[0014] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0015] Figure 1 This is a schematic flowchart of the first type of anti-rollover early warning method according to an embodiment of the present invention; Figure 2 This is a structural block diagram of an anti-tipping warning device according to an embodiment of the present invention; Figure 3 This is a structural block diagram of an anti-rollover early warning system according to an embodiment of the present invention; Figure 4 This is a flowchart illustrating the workflow of an anti-rollover early warning system according to an embodiment of the present invention. Figure 5 This is a schematic diagram of the material handling machine structure according to an embodiment of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] It is understood that before using the technical solutions disclosed in the various embodiments of the present invention, users should be informed of the types, scope of use, and usage scenarios of the personal information involved in the present invention and their authorization should be obtained in accordance with relevant laws and regulations through appropriate means.

[0018] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0019] In related technologies, tipping protection for construction machinery such as material handling machines typically relies on operator experience or alarm systems based on fixed thresholds. Experience-based judgment is highly subjective, easily affected by operator condition and environmental factors, and lacks stability. Fixed threshold alarm systems often set uniform alarm limits based on a single operating condition (such as the safe load at maximum extension), and this static setting method has limitations: during actual operation, the boom and stick postures of the material handling machine continuously change, causing the tipping arm of the load to dynamically change accordingly. The tipping effect of the same weight load varies significantly under different postures. If the threshold setting is too conservative, false alarms will frequently occur in operating postures with short arms, limiting equipment efficiency. If the threshold setting is too lenient, timely warnings will not be provided in dangerous postures with long arms, creating a potential tipping hazard. Furthermore, many related technologies do not systematically consider the impact of the weight and changes of the working devices (such as the boom and stick) on overall stability, further reducing the accuracy of risk assessment. Therefore, there is an urgent need for an early warning method that can adapt to changes in operating posture in real time and accurately assess the actual safe load under the current operating conditions, so as to make up for the above-mentioned defects and realize the transformation from experience-based protection and static protection to intelligent dynamic protection.

[0020] According to an embodiment of the present invention, an embodiment of a method for preventing tipping of a material handling machine is provided. It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Furthermore, although a logical order is shown in the flowchart, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0021] This embodiment provides a method for preventing tipping over of a material handling machine, which can be used in the aforementioned material handling machine anti-tipping warning system. Figure 1 This is a flowchart of a material handling machine anti-tipping early warning method according to an embodiment of the present invention, such as... Figure 1 As shown, the process includes the following steps: Step S101: Calculate the maximum load weight that the grabber will not tip over based on the structural parameters of the grabber and the chassis stabilization force of the grabber. The chassis stabilization force is the force exerted by the grabber chassis on the ground.

[0022] Step S102: Calculate the maximum safe pressure of the boom cylinder based on the maximum load weight.

[0023] Step S103: Measure the actual working pressure of the boom cylinder.

[0024] Step S104: Based on the relationship between the actual working pressure and the maximum safe pressure, a rollover warning is issued.

[0025] Specifically, structural parameters include key geometric and mass distribution information such as boom length, chassis dimensions, and center of gravity position. Chassis stabilization force refers to the force exerted by the grabber chassis on the ground, reflecting the overall stability of the equipment during operation. In one example, the chassis stabilization torque is generated by the machine chassis's own weight, the upper vehicle counterweight, and possible ground adhesion. This torque, which counteracts the overturning moment and maintains machine stability, is calculated from the total chassis weight and the horizontal distance from its center of gravity to the overturning axis. This torque characterizes the equipment's inherent anti-overturning capability when there is no external load. When the equipment is in a specific working posture, the boom and stick configuration constitute a lever arm system. The overturning moment generated by the load weight acting on the end of the stick in this posture is calculated using a mechanical model. The maximum safe load weight is the critical value that makes the overturning moment equal to the chassis stabilization torque. Based on the grabber's structural parameters and chassis stabilization force, the maximum load weight that the equipment can withstand without overturning is determined.

[0026] After obtaining the maximum load weight, it needs to be converted into the maximum safe pressure of the boom cylinder. This involves the mechanical relationships of the hydraulic system, as the pressure of the boom cylinder is directly related to the load it bears. For example, through the balance equation between the cylinder piston area and the load torque, the maximum load weight can be mapped to the upper limit of the hydraulic system pressure, i.e., the maximum safe pressure. This represents the critical value of the hydraulic system within its stable operating range. If the pressure exceeds this limit, it means the load has approached or reached the tipping condition.

[0027] It is also necessary to measure the actual working pressure of the boom cylinder in real time, which is achieved through pressure sensors installed on the cylinder. For example, when the grabber performs material grabbing or lifting actions, the sensor will continuously monitor the pressure changes in the hydraulic circuit and feed the data back to the control system.

[0028] Finally, a tipping warning is provided by comparing the actual working pressure with the maximum safe pressure. If the actual pressure approaches or exceeds the maximum safe pressure, the control system will trigger a warning mechanism, such as issuing an audible and visual alarm or automatically limiting the range of motion to prevent the equipment from tipping over. For example, when the material handler is processing overweight materials, if the actual pressure continues to rise and approaches the safety threshold, the warning system will immediately prompt the operator to adjust the load or posture.

[0029] The anti-tipping early warning method for the grabber provided in this embodiment firstly calculates the maximum load weight that the equipment can withstand under the current specific working posture by combining the fixed structural parameters of the grabber (such as boom, stick length, chassis mass distribution) and its inherent chassis stabilizing torque, combined with the boom and stick angles obtained in real time by sensors. Through a mechanical model, the judgment criteria for safe load are adapted to the current mechanical posture in real time.

[0030] Then, the method converts the calculated maximum load weight into the maximum safe pressure of the boom cylinder under the current posture, based on the hydraulic system mechanics principle (the balance relationship between cylinder thrust, lever arm and load torque). The conversion process turns the originally abstract "load weight" safety threshold into a physical quantity that can be directly monitored in the hydraulic system.

[0031] The system measures the actual working pressure of the boom cylinder through a pressure sensor and compares it in real time with the maximum safe pressure calculated dynamically above, reflecting the distance between the mechanical effect generated by the current actual load and the safe limit calculated by the system.

[0032] Therefore, by combining structural parameters, chassis stability, and real-time attitude data for dynamic mechanical calculations, and using hydraulic pressure as a unified monitoring and comparison medium, real-time, accurate, and adaptive early warning of the risk of tipping over the material grabber can be achieved. The hydraulic pressure can be directly measured, changing the traditional method of relying on fixed thresholds, load weight comparisons, or operator experience. It can proactively and quantitatively identify risks and issue timely alarms during continuous load and attitude changes, thereby effectively intervening before tipping accidents occur and improving operational safety.

[0033] In one optional implementation, step S101 includes: Step a1: Obtain the boom angle and stick angle of the grabber. The boom angle refers to the pitch angle of the boom relative to the reference plane of the vehicle body, and the stick angle refers to the pitch angle of the stick relative to the reference plane of the vehicle body.

[0034] Step a2: Based on the boom angle and stick angle, calculate the horizontal lever arm from the load application point to the rotation center under the current posture.

[0035] Step a3: Calculate the overall machine stabilizing torque based on the chassis stabilizing force and the rearward horizontal distance from the center of rotation to the overturning fulcrum.

[0036] Step a4: Calculate the maximum load weight using the ratio of the overall machine stabilizing torque to the horizontal lever arm.

[0037] Specifically, firstly, the real-time angle information of the boom and stick of the grabber is obtained. The boom angle is defined as the pitch angle between the boom and the reference plane of the vehicle body, and the stick angle is defined as the pitch angle between the stick and the same reference plane of the vehicle body. The angle parameters are measured in real time by angle sensors installed on the boom and stick respectively and provided to the system.

[0038] Based on the obtained boom and stick angles, and combined with the structural length parameters of the boom and stick, the horizontal distance from the load application point to the machine's rotation center under the current attitude can be determined by calculation using plane geometry (i.e., trigonometric functions). This distance is the horizontal lever arm required to calculate the overturning moment.

[0039] The calculation of the overall machine stabilizing moment is based on the chassis stabilizing force calculation. This moment is composed of the stabilizing effect of the chassis self-weight on the overturning pivot (usually the track or the grounding wire of the leading edge of the tire). Its value is the product of the chassis self-weight and the horizontal distance from the chassis center of gravity to the overturning pivot. The position of the chassis center of gravity can be predetermined based on the overall machine mass distribution parameters or obtained through calibration.

[0040] After obtaining the overall machine stabilizing torque and the load horizontal lever arm under the current attitude, the maximum safe load weight can be obtained by dividing the overall machine stabilizing torque by the horizontal lever arm.

[0041] The embodiments of the present invention can achieve real-time, accurate, and dynamic calculation of the maximum safe load weight by acquiring the angle between the boom and the stick in real time and calculating the horizontal lever arm.

[0042] Based on the real-time working posture of the material handling machine, the horizontal lever arm of the load is calculated through geometric relationships. Then, it is combined with the inherent stable torque of the whole machine. Based on the torque balance principle, the precise maximum safe load weight under the current posture is directly calculated. This makes the judgment benchmark of safe load-bearing capacity no longer a fixed value, but a dynamic variable that is continuously and synchronously adjusted with every degree change of the working device.

[0043] It provides a highly accurate theoretical safe load limit that is adaptive to the current working conditions for the equipment's tilt safety protection. The dynamically calculated threshold ensures the scientific and accurate judgment criteria on which any subsequent warning or control logic is based, so that the safety protection function can closely match the actual mechanical state of the equipment.

[0044] In one alternative implementation, step a4 includes: Step a41,

[0045] in, Indicates the maximum load weight. This represents the overall machine stabilizing torque, and K represents the preset safety factor, which satisfies 0. <K<1, Indicates the horizontal lever arm.

[0046] Specifically, a safety factor is introduced to correct the calculation of the maximum load weight, providing an additional safety margin. This calculation is expressed as follows: the maximum load weight equals the overall machine stabilizing torque multiplied by a preset safety factor K, then divided by the horizontal lever arm in the current attitude. Here, the safety factor K is a constant greater than 0 and less than 1.

[0047] This invention, by introducing a coefficient less than 1 into the denominator of the torque balance model, essentially uses a design stabilizing torque that is smaller than the actual overall machine stabilizing torque, or a design lever arm that is longer than the actual horizontal lever arm, when calculating the maximum safe load. This reduces the theoretically calculated safe load threshold, thereby compensating for factors such as sensor measurement errors, changes in ground conditions, dynamic impact loads, and uncertainties caused by model simplification. As a result, the final maximum load weight is more conservative and safer, providing a reliable buffer for actual operation and further reducing the risk of overturning.

[0048] In one optional implementation, step S102 includes: Step b1: Calculate the first overturning moment generated by the maximum load weight.

[0049] Step b2: Calculate the second overturning moment generated by the weight of the boom itself.

[0050] Step b3: Calculate the third overturning moment generated by the weight of the boom itself.

[0051] Step b4: Calculate the fourth overturning moment generated by the weight of the boom cylinder.

[0052] Step b5: Calculate the maximum safe pressure based on the total overturning moment, the lever arm of the boom cylinder, and the effective working area of ​​the boom cylinder. The total overturning moment is the sum of the first overturning moment, the second overturning moment, the third overturning moment, and the fourth overturning moment.

[0053] Specifically, the overturning moments generated by the maximum load weight, boom weight, stick weight, and stick cylinder weight about the overall rotation center are determined separately. The moment generated by the weight of each component needs to be calculated based on its current center of gravity position and lever arm.

[0054] Summing these values ​​yields the total overturning moment acting on the entire machine. This total overturning moment must be balanced by the lifting moment generated by the boom cylinder. Based on the principle of torque balance, the output force required by the boom cylinder can be obtained by dividing the total overturning moment by the lever arm of the boom cylinder force about the center of rotation. Finally, according to the mechanical relationship of the hydraulic cylinder, dividing this output force by the effective working area of ​​the boom cylinder piston yields the upper pressure limit that the hydraulic system should maintain under this critical state, i.e., the maximum safe pressure.

[0055] This invention improves the accuracy and completeness of the maximum safe pressure calculation by precisely incorporating the self-weight of the main moving parts of the working device (boom, stick, and stick cylinder). Traditional simplified models may ignore or roughly estimate the torque contribution of these components, but under large-span, heavy-load conditions, the overturning effect caused by their self-weight cannot be ignored. By modeling and synthesizing calculations separately, the mechanical model more closely reflects the actual stress state of the equipment, resulting in a more accurate and reliable pressure safety threshold. This ensures that the pressure benchmark used by the subsequent early warning system can comprehensively reflect all major overturning factors, including self-weight, reducing the risk of early warning deviations caused by model simplification and enhancing the system's protective reliability under different postures and loads.

[0056] In one alternative implementation, the first overturning moment, the second overturning moment, the third overturning moment, and the fourth overturning moment are calculated as follows: Step c1: Calculate the first overturning moment based on the product of the maximum load weight and the first lever arm, where the first lever arm is the distance from the overturning fulcrum to the load point. Step c2: Calculate the second overturning moment based on the product of the boom's own weight and the second lever arm. The second lever arm is the distance from the overturning fulcrum to the boom's center of gravity. Step c3: Calculate the third overturning moment based on the product of the stick's own weight and the third lever arm. The third lever arm is the distance from the overturning fulcrum to the stick's center of gravity. Step c4: Calculate the third overturning moment based on the product of the stick cylinder weight and the fourth lever arm, where the fourth lever arm is the distance from the overturning fulcrum to the stick cylinder.

[0057] Specifically, the first overturning moment is obtained by multiplying the calculated maximum load weight by the horizontal distance (first lever arm) from the load application point to the overturning pivot point. This moment characterizes the direct effect of the external load on the overall overturning tendency. The second overturning moment is obtained by multiplying the weight of the boom itself by the horizontal distance (second lever arm) from its center of gravity to the overturning pivot point in the current posture. This moment reflects the influence of the boom structure's self-weight on the overturning tendency. The third overturning moment is obtained by multiplying the weight of the stick itself by the horizontal distance (third lever arm) from its center of gravity to the overturning pivot point in the current posture. This moment reflects the influence of the stick structure's self-weight on the overturning tendency. The fourth overturning moment is obtained by multiplying the weight of the stick cylinder itself by the horizontal distance (fourth lever arm) from its center of gravity to the overturning pivot point in the current posture. This moment takes into account the overturning effect caused by the self-weight of the stick cylinder accessories.

[0058] This implementation method achieves refined decomposition and synthesis of the overturning moment by establishing independent calculations between the weight of each component and its force arm on the overturning fulcrum, thereby improving the completeness and accuracy of the total overturning moment calculation.

[0059] In one alternative implementation, step b5 includes: Step d1: Distribute the total overturning moment evenly to the two boom cylinders connected in parallel to obtain the torque component that each boom cylinder needs to bear; Step d2: Divide the torque component that a single boom cylinder needs to bear by the lever arm of the boom cylinder to obtain the theoretical thrust that a single boom cylinder needs to output. Step d3: Divide the theoretical thrust by the effective working area of ​​the boom cylinder to obtain the maximum safe pressure.

[0060] Specifically, the calculated total overturning moment is first evenly distributed to the two boom cylinders connected in parallel, yielding the moment component that a single boom cylinder needs to bear to balance the overturning effect. Then, this moment component is divided by the lever arm of the boom cylinder's force relative to the machine's rotation center, thus obtaining the theoretical thrust that cylinder needs to output. Finally, this theoretical thrust is divided by the effective working area of ​​the piston in a single boom cylinder, which converts into the upper pressure limit that the hydraulic system should maintain, i.e., the maximum safe pressure.

[0061] This invention, through a defined calculation logic of torque distribution and step-by-step conversion between two hydraulic cylinders, ensures the mechanical rationality and computational accuracy of the conversion process from the total overturning moment of the system to the pressure threshold of a single hydraulic actuator. It explicitly distributes the total torque evenly to both cylinders, accurately reflecting the symmetrical force characteristics of the parallel dual-cylinder structure; it converts the torque into thrust through lever arm parameters, following the lever principle; and finally, it maps the mechanical thrust into hydraulic pressure through the piston area, conforming to the basic working principle of a hydraulic system. The calculation not only makes the derivation of the maximum safe pressure rigorous, transparent, and verifiable, but also ensures the clear physical meaning of the calculation results, providing the early warning system with a highly reliable safety pressure benchmark that closely matches the actual mechanical and hydraulic structure of the equipment.

[0062] In one optional implementation, step S104 includes: Step e1: Set a first warning threshold and a second warning threshold according to the maximum safe pressure, wherein the first warning threshold is less than the second warning threshold; Step e2: When the actual working pressure is greater than or equal to the first warning threshold, output the first-level warning signal; Step e3: When the actual working pressure is greater than or equal to the second warning threshold, output the second-level warning signal.

[0063] Specifically, the system first sets two warning thresholds based on the calculated maximum safe pressure: a first warning threshold and a second warning threshold, where the first warning threshold is set to a value lower than the second warning threshold. During real-time monitoring, when the actual working pressure of the boom cylinder reaches or exceeds the first warning threshold, the control system determines that a risk has initially emerged and immediately outputs a first-level warning signal. This signal is typically used for alerts, such as triggering a yellow warning light on the instrument panel or emitting a low-frequency warning sound, aiming to remind the operator to pay attention to the load condition and operate cautiously. If the actual working pressure continues to rise and reaches or exceeds the higher second warning threshold, the system determines that the tipping risk is in a high-risk state and immediately outputs a second-level warning signal. This level of signal typically represents a severe alarm, possibly accompanied by a red flashing light, a continuous high-frequency alarm sound, and can automatically trigger the hydraulic system's intervention functions (such as limiting further boom lifting or automatic deceleration) to forcibly reduce the risk.

[0064] This invention introduces a tiered early warning mechanism, refining a single, urgent alarm state into a continuous, graded risk alert process. The first-level warning provides a buffer, allowing operators early warnings before the risk reaches a critical point, giving them time to proactively adjust, such as slowing down movements, reducing load, or adjusting posture, reflecting the preventative and guiding nature of the warning. The second-level warning provides strong intervention when the risk approaches its theoretical limit, ensuring the ultimate safety of the system. This tiered strategy avoids frequent false alarms or alarm delays that might occur with a single threshold setting, improving the user-friendliness of human-computer interaction and operational safety, enabling the early warning system to both preventatively address risks and decisively intervene at critical moments.

[0065] This embodiment also provides a material handling machine anti-tipping early warning device, which is used to implement the above embodiments and preferred embodiments, and will not be repeated as already described. As used below, the term "module" can be a combination of software and / or hardware that implements a predetermined function. Although the device described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0066] This embodiment provides a tipping warning device for a material handling machine, such as... Figure 2 As shown, it includes: The maximum load weight calculation module 201 is used to calculate the maximum load weight of the grabber without tipping over based on the structural parameters of the grabber and the chassis stabilization force of the grabber. The chassis stabilization force is the force exerted by the grabber chassis on the ground.

[0067] The maximum safe pressure calculation module 202 is used to calculate the maximum safe pressure of the boom cylinder based on the maximum load weight.

[0068] The actual working pressure measurement module 203 is used to measure the actual working pressure of the boom cylinder.

[0069] The tilt warning module 204 is used to provide a tilt warning based on the relationship between the actual working pressure and the maximum safe pressure.

[0070] The anti-tipping warning device for the material handling machine provided in this embodiment of the invention can execute the anti-tipping warning method for the material handling machine provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects of the method. Further functional descriptions of the above modules and units are the same as those in the corresponding embodiments above, and will not be repeated here.

[0071] The anti-tipping early warning device for the material handling machine provided in this embodiment achieves automated and real-time monitoring and early warning of the risk of tipping over the material handling machine through a modular combination of hardware and software. Its beneficial effect lies in combining dynamic mechanical calculations with real-time pressure monitoring, enabling it to automatically and accurately calculate the corresponding safe load threshold based on the equipment's current actual operating posture, and convert it into a directly monitorable safe hydraulic pressure range. By continuously comparing the actual working pressure with this dynamic safe pressure, the device issues timely warnings before the risk occurs, thereby effectively improving the safety of the operation process, reducing reliance on operator experience, and providing reliable technical protection against equipment tipping due to overload or improper operation.

[0072] This invention also provides a tipping warning system for a material handling machine, including a controller, a sensor group, and a display unit.

[0073] The controller, as the core processing unit of the system, stores structural parameters of the grabber (such as boom length, stick length, mass and center of gravity coordinates of each component) and inherent data such as chassis stabilizing torque, and presets or calculates parameters such as the safety factor K in real time. The controller establishes a communication connection with the sensor group and the display unit, and is responsible for receiving sensor data and executing the grabber anti-tipping early warning method of this embodiment of the invention.

[0074] Sensor group: Communicates with the controller and is responsible for real-time acquisition of key status parameters of the grabber. It includes at least: Angle sensors: Used to acquire the boom and stick angles of the grabber, installed on the boom and stick respectively, directly measuring their pitch angles relative to the vehicle's reference plane. Pressure sensors: Used to acquire the actual working pressure of the boom cylinder, typically installed in the boom cylinder's inlet or piston chamber pipeline, monitoring pressure changes in the hydraulic system in real time. The sensor group transmits the acquired angle and pressure signals to the controller in real time.

[0075] Display unit: Communicates with the controller and serves as the human-machine interface. It receives warning information (such as normal, level 1 warning, level 2 warning, etc.) output by the controller and performs corresponding prompts.

[0076] In one example, such as Figure 3As shown, the anti-tipping warning system of the material handling machine includes: V-ECU (Vehicle Electronic Control Unit, controller), which detects the actual pressure signal of SE (Sensor Element, boom pressure sensor) in real time, and then calculates the maximum safe pressure of the boom cavity based on the angle signal obtained by IMU (Inertial Measurement Unit, tilt sensor) into a preset algorithm. The maximum safe pressure is then compared with the actual pressure of the boom cavity. When the actual pressure is about to reach the maximum safe pressure, V-ECU transmits an alarm signal to I-ECU (In-Cab Electronic Control Unit, display). I-ECU can be set with a SWITCH function switch. When activated, it displays a tipping alarm information to the driver. The SWITCH function switch is connected to FU (Fuse Unit, fuse), and FU is connected to DC-24V (Direct Current 24 Volts, DC 24 volts power supply). The KEYPAID (electric control handle) is connected to V-ECU.

[0077] In this embodiment of the invention, the SWITCH function switch is first activated on the I-ECU (which automatically melts and cuts off the DC-24V power supply in case of overcurrent, short circuit, or other faults in the circuit, protecting the subsequent SWITCH, V-ECU, and other equipment from damage). The display sends a system activation command to the V-ECU. The V-ECU receives CAN signals from the boom IMU1 and stick IMU2 in real time and converts them into angle data, and receives voltage signals from the SE in real time and converts them into pressure data. The V-ECU inputs the collected angle data into a preset algorithm to calculate the operating pressure of each alarm zone under the current overall machine posture. The V-ECU compares the calculated safe operating pressure of each zone under the current overall machine posture with the collected actual pressure of the boom cavity. When the actual pressure of the boom cavity reaches the pressure of the yellow and red zones, the V-ECU sends a corresponding alarm signal to the I-ECU. The I-ECU receives the alarm signal sent by the V-ECU, displays the alarm, and transmits the alarm to the driver. After seeing the alarm information, the driver should promptly operate the KEYPAID to ensure that the overall machine posture returns to a safe position and prevents rollover.

[0078] As a specific example of the workflow of the system of the present invention, such as Figure 4 As shown: The operator operates the material grabber to grab materials. The sensor array continuously sends data on the boom angle, stick angle, and boom cylinder pressure to the controller. After the function switch on the display is turned on, the controller receives information from the inertial measurement unit and the boom cavity pressure sensor, calculates the current overall machine posture, and calculates the safe operating pressure of the boom cavity in each area based on the current overall machine posture. When the actual pressure is less than the yellow light zone pressure, the display does not alarm; when the actual pressure is greater than the yellow light zone pressure but less than the red light zone pressure, the display shows a yellow alarm; when the actual pressure is greater than the yellow light zone pressure, the display shows a red shutdown alarm.

[0079] This invention also provides a material handling machine that integrates an anti-tipping early warning system according to this invention. For example... Figure 5 The key components of the early warning system shown correspond to the overall structure as follows: Tilting pivot 1: This is usually the theoretical pivot point when the whole machine may tilt forward on the working surface, such as the grounding wire of the leading edge of the track or tire.

[0080] Center of rotation 2: The central axis of the working device (boom, stick) for slewing relative to the upper frame, which is the reference point for calculating the torque of each component.

[0081] Boom cylinder 3: The actuator that drives the boom to perform pitching motion.

[0082] Boom vertex 4: The hinge point between the boom and the stick.

[0083] Controller 5: The core processing unit of the early warning system, usually installed in the cab or electrical control cabinet. It stores data such as the overall structural parameters of the machine (e.g., the size, weight, and center of gravity of each component) and chassis stabilizing torque, and is responsible for performing all calculations and logical judgments, such as calculating the maximum safe pressure based on real-time data and making early warning judgments.

[0084] Electric control handle 6: As an operator input device, it is used to control the operation of the working device and the whole machine.

[0085] Display 7: As a human-machine interface, it is installed in the cab to display working status, warning information (such as pressure, angle, risk level) and issue audible and visual alarms.

[0086] Boom IMU (Inertial Measurement Unit) 8: As an angle sensor, it is installed on the boom to measure the pitch angle (boom angle) of the boom relative to the vehicle body reference plane in real time.

[0087] Boom center of gravity 9: The position of the center of gravity of the boom component itself. Its coordinates change with the boom angle and are used to calculate the overturning moment generated by the boom's own weight.

[0088] 10, the top of the boom cylinder: the hinge point between the boom cylinder and the boom.

[0089] Center of gravity 11 of boom cylinder: The position of the center of gravity of the boom cylinder component, used to calculate the overturning moment generated by its own weight.

[0090] Point 12 where the boom and stick intersect: This is the top of the boom and also the hinge point between the boom and stick.

[0091] Stick IMU (Inertial Measurement Unit) 13: As an angle sensor, it is mounted on the stick to measure the pitch angle (stick angle) of the stick relative to the vehicle body reference plane in real time.

[0092] Stick center of gravity 14: The position of the center of gravity of the stick component itself. Its coordinates change with the stick angle and are used to calculate the overturning moment generated by the stick's own weight.

[0093] 15: The hinge point between the end of the stick and the gripper or load, i.e., the point where the load is applied.

[0094] Boom large chamber pressure sensor 16: Installed in the oil circuit of the large chamber (the oil chamber under pressure when the piston rod extends) of the boom cylinder, it is used to measure the oil pressure when driving the boom to lift in real time. This pressure is the actual working pressure of the boom cylinder.

[0095] As a specific embodiment of the present invention, the safe operating pressure of the boom cavity is calculated as follows: First, the maximum load weight that the gripper can withstand without tipping over must be calculated based on the gripper's structural parameters and chassis stability.

[0096] In this step, the first step is to calculate the horizontal lever arm from the load application point to the center of rotation under the current attitude, i.e. : The horizontal distance from the top of the pole 15 to the center of rotation 2.

[0097] .

[0098] in: The length of the boom apex 4 and the intersection point 12 of the boom and stick. The length of the line connecting the top of the boom 15 and the intersection point 12 of the boom and boom. The horizontal distance between the boom apex 4 and the slewing center 2. The angle between the line connecting the boom apex 4 and the intersection point 12 of the boom and stick and the horizontal plane. The angle between the line connecting the top of the stick 15 and the intersection point 12 of the boom and stick and the horizontal plane.

[0099] The maximum load weight is calculated using the ratio of the overall machine stabilizing torque MStable to the horizontal lever arm. :

[0100] Here, MStable represents the inherent stability capability of the entire machine, independent of the attitude of the working device. It can be understood as: MStable ≈ weight of the entire chassis × rearward horizontal distance from the center of gravity of the chassis to the overturning pivot point. MStable represents the minimum "overturning moment" that needs to be applied in front of it to counteract its own rearward stabilizing moment. K represents the preset safety factor, which satisfies 0. <K<1。

[0101] Then, through the maximum load weight Calculate the maximum safe pressure of the boom cylinder. :include: (1) Calculate the first overturning moment generated by the maximum load weight. :

[0102] in, : The horizontal distance between the tipping fulcrum 1 and the rotation center 2.

[0103] (2) Calculate the second overturning moment generated by the weight of the boom itself. :

[0104] in, Boom weight The length of the line connecting the boom apex 4 and the boom center of gravity 9. This is the distance from the tilting fulcrum to the boom set point.

[0105] (3) Calculate the third overturning moment generated by the weight of the boom itself. :

[0106] in, : pole weight The length of the line connecting the intersection point 12 of the boom and the stick and the center of gravity 14 of the stick. (4) Calculate the fourth overturning moment generated by the weight of the boom cylinder. :

[0107] in, Weight of the boom cylinder The length of the line connecting the boom apex 4 and the stick cylinder apex 10. : The length of the line connecting the top of the boom cylinder 10 and the center of gravity of the boom cylinder 11.

[0108] (5) The first overturning moment Second overturning moment Third overturning moment and the fourth overturning moment The sum of these values ​​is evenly distributed among the two boom cylinders arranged in parallel to obtain the torque component that a single boom cylinder needs to bear. Dividing this torque component by the boom cylinder's lever arm L yields the theoretical thrust that a single boom cylinder needs to output. Dividing this theoretical thrust by the effective working area of ​​the boom cylinder, i.e., the surface area S of the boom's large cavity cross-section, yields the maximum safe pressure P. Max :

[0109] Finally, set the warning pressure thresholds for the red zone (i.e., the second warning value) and the yellow zone (i.e., the first warning value).

[0110] , .

[0111] in, Minimum operating pressure in the red-light district P1: Minimum operating pressure in the yellow zone; P2: Operating pressure range in the red zone.

[0112] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A method for preventing tipping and providing early warning for a material handling machine, characterized in that, The method includes: The maximum load weight that the material grabber will not tip over is calculated based on the structural parameters of the material grabber and the chassis stabilization force of the material grabber. The chassis stabilization force is the force exerted by the chassis of the material grabber on the ground. The maximum safe pressure of the boom cylinder is calculated by converting the maximum load weight. Measure the actual working pressure of the boom cylinder; A rollover warning is issued based on the relationship between the actual working pressure and the maximum safe pressure.

2. The method according to claim 1, characterized in that, The calculation of the maximum load weight that will prevent the material handler from tipping over, based on the structural parameters and chassis stability of the material handler, includes: The boom angle and stick angle of the grabber are obtained. The boom angle refers to the pitch angle of the boom relative to the reference plane of the vehicle body, and the stick angle refers to the pitch angle of the stick relative to the reference plane of the vehicle body. Based on the boom angle and stick angle, calculate the horizontal lever arm from the load application point to the rotation center under the current posture; The overall machine stabilizing moment is calculated based on the chassis stabilizing force and the rearward horizontal distance from the rotation center to the overturning fulcrum. The maximum load weight is calculated using the ratio of the overall machine stabilizing torque to the horizontal lever arm.

3. The method according to claim 2, characterized in that, The calculation of the maximum load weight using the ratio of the overall machine stabilizing torque to the horizontal lever arm includes: in, This indicates the maximum load weight. The value represents the overall machine stabilizing torque, K represents the preset safety factor, and satisfies 0. <K<1, This refers to the horizontal lever arm.

4. The method according to claim 1, characterized in that, The calculation of the maximum safe pressure of the boom cylinder based on the maximum load weight includes: Calculate the first overturning moment generated by the maximum load weight; Calculate the second overturning moment generated by the weight of the boom itself; Calculate the third overturning moment generated by the weight of the boom itself; Calculate the fourth overturning moment generated by the weight of the boom cylinder; The maximum safe pressure is calculated based on the total overturning moment, the lever arm of the boom cylinder, and the effective working area of ​​the boom cylinder. The total overturning moment is the sum of the first overturning moment, the second overturning moment, the third overturning moment, and the fourth overturning moment.

5. The method according to claim 4, characterized in that, The first overturning moment, the second overturning moment, the third overturning moment, and the fourth overturning moment are calculated in the following manner: The first overturning moment is calculated based on the product of the maximum load weight and the first lever arm, where the first lever arm is the distance from the overturning fulcrum to the load point. The second overturning moment is calculated based on the product of the boom's own weight and the second lever arm, where the second lever arm is the distance from the overturning fulcrum to the boom's center of gravity. The third overturning moment is calculated based on the product of the weight of the stick itself and the third lever arm, where the third lever arm is the distance from the overturning fulcrum to the center of gravity of the stick. The third overturning moment is calculated based on the product of the weight of the boom cylinder and the fourth lever arm, where the fourth lever arm is the distance from the overturning fulcrum to the boom cylinder.

6. The method according to claim 5, characterized in that, The calculation of the maximum safe pressure based on the total overturning moment, the lever arm of the boom cylinder, and the effective working area of ​​the boom cylinder includes: The total overturning moment is evenly distributed to the two boom cylinders connected in parallel to obtain the torque component that a single boom cylinder needs to bear; Divide the torque component that the single boom cylinder needs to bear by the lever arm of the boom cylinder to obtain the theoretical thrust that the single boom cylinder needs to output. The maximum safe pressure is obtained by dividing the theoretical thrust by the effective working area of ​​the boom cylinder.

7. The method according to claim 1, characterized in that, The method of providing a rollover warning based on the relationship between the actual working pressure and the maximum safe pressure includes: A first warning threshold and a second warning threshold are set according to the maximum safe pressure, wherein the first warning threshold is less than the second warning threshold; When the actual working pressure is greater than or equal to the first warning threshold, a first-level warning signal is output; When the actual working pressure is greater than or equal to the second warning threshold, a second-level warning signal is output.

8. A tipping warning device for a material handling machine, characterized in that, The device includes: The maximum load weight calculation module is used to calculate the maximum load weight that the grabber will not tip over based on the structural parameters of the grabber and the chassis stabilization force of the grabber. The chassis stabilization force is the force exerted by the grabber chassis on the ground. The maximum safe pressure calculation module is used to calculate the maximum safe pressure of the boom cylinder based on the maximum load weight. The actual working pressure measurement module is used to measure the actual working pressure of the boom cylinder; The tilt warning module is used to provide a tilt warning based on the relationship between the actual working pressure and the maximum safe pressure.

9. A tipping warning system for a material handling machine, characterized in that, include: A controller for performing the method according to any one of claims 1-7; The sensor group, which is communicatively connected to the controller, is used to acquire the boom angle, stick angle, and actual working pressure of the boom cylinder of the grabber. The display unit is communicatively connected to the controller and is used to provide prompts based on the output warning information.

10. A material handling machine, characterized in that, It integrates the anti-tipping early warning system for the material handling machine as described in claim 9.

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