Coupling protection method and intelligent coupling

Abstract

This invention discloses a coupling protection method and an intelligent coupling. The protection method acquires the coupling's operating status signal in real time, and the control unit independently and in parallel executes trend prediction analysis and real-time over-limit monitoring analysis. These two analyses do not wait for each other and trigger protection independently. If either analysis meets the trigger condition, a protection command is executed to cut off or reduce torque transmission. After the overload risk is eliminated, the coupling automatically resets after a delayed confirmation. The intelligent coupling includes a status detection element, a control unit, an execution unit, and a transmission locking mechanism. The transmission locking mechanism can switch to multiple graded protection states such as fully disengaged, slipping, and partially disengaged. It also features adaptive self-learning, fault emergency response, and multi-mode power supply and communication functions. This invention combines overload prediction protection with real-time response, comprehensively covering both gradual and sudden overloads, improving the safety and reliability of the transmission system, and is suitable for various industrial heavy-duty and precision transmission scenarios.

Description

Technical Field

[0001] This invention relates to the field of mechanical transmission protection technology, specifically to a coupling protection method and an intelligent coupling. Background Technology

[0002] Currently, overload protection methods for couplings in mechanical transmission systems are mostly passive response protection, which only triggers protection after an overload actually occurs. They cannot predict overload trends in advance and are ill-suited to avoid equipment impact damage caused by gradual overloads. Existing protection methods generally lack independent and parallel trend prediction and real-time over-limit monitoring mechanisms, resulting in slow response speeds to sudden overloads and significant lag in protection actions. While some couplings possess basic overload protection functions, their protection modes are limited, failing to flexibly switch protection strategies based on overload type, and torque transmission is not completely cut off. Furthermore, current technology lacks an automatic reset mechanism after overload risk is eliminated, resulting in an incomplete protection process and insufficient safety and stability of the transmission system, making it difficult to meet the high-reliability protection requirements of heavy-duty and precision transmission scenarios. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a coupling protection method that can effectively reduce equipment impact damage, flexibly switch protection strategies, and improve the safety and reliability of the transmission system.

[0004] This application provides a method for protecting a coupling, the method comprising:

[0005] S1: Obtain preset warning thresholds and overload thresholds, collect the operating status signals of the coupling in real time and transmit them to the control unit;

[0006] S2: The control unit starts two independent analysis threads that do not wait for each other: a trend prediction analysis thread and a real-time over-limit monitoring analysis thread.

[0007] S3: The trend prediction and analysis thread predicts the load situation within a preset time period based on the changing trend of the running status signal. If the prediction result meets the overload warning conditions, it will independently output the first protection command to control the transmission locking mechanism to cut off or reduce torque transmission.

[0008] S4: The real-time overload monitoring and analysis thread compares the running status signal with the overload threshold in real time. If the current signal value exceeds the overload threshold, it will independently output a second protection command to control the transmission locking mechanism to cut off or reduce torque transmission.

[0009] S5: After the overload risk is eliminated, and after a preset delay time and the detection that the operating status signal is continuously stable within a safe range, a reset operation is performed to restore torque transmission.

[0010] In one aspect, the first protection command and the second protection command cause the transmission locking mechanism to enter at least one of the following protective states: fully disengaged, slipping, or partially disengaged.

[0011] In one aspect, the control unit automatically controls the transmission locking mechanism to switch to the corresponding protection state based on the overload prediction degree or the real-time overload magnitude.

[0012] In one aspect, the operating status signal includes at least one of torque, temperature, vibration, pressure, wear clearance, load fluctuation, position, electrical signal, and electromagnetic signal;

[0013] Trend prediction analysis is achieved based on the rate of change, acceleration of change, or time series prediction model of the state signal. The statistical time series prediction model is trained by collecting historical torque data sequences during normal operation of the coupling to predict the trend of torque values ​​within a preset period in the future; when the predicted value continuously exceeds the warning threshold, the prediction protection is triggered.

[0014] One aspect also includes:

[0015] Record overload event data and adaptively adjust the sensitivity or model parameters of trend prediction analysis based on historical data.

[0016] One aspect also includes a fault response mechanism:

[0017] When a non-core unit fault is detected, the hardware-based real-time over-limit comparison and protection operation functions are retained; when the core control unit software fails, the default safety disengagement action is executed; when an external emergency stop signal is received, it automatically enters the locking or safety disengagement state.

[0018] To address the aforementioned issues, this application also provides an intelligent coupling, comprising a state detection element, a control unit, an execution unit, and a transmission locking mechanism;

[0019] The output of the state detection element is connected to the input of the control unit, the output of the control unit is connected to the input of the execution unit, and the output of the execution unit is connected to the transmission locking mechanism.

[0020] The control unit includes a first analysis module and a second analysis module that are independent of each other. The first analysis module is configured to perform trend prediction analysis, and the second analysis module is configured to perform real-time over-limit monitoring analysis.

[0021] When either the first analysis module or the second analysis module meets the triggering condition, it directly outputs the first protection command or the second protection command to the execution unit, driving the transmission locking mechanism to switch between the connection state and the protection state.

[0022] The protection state is an operating state that reduces or interrupts torque transmission.

[0023] One aspect also includes a reset component and a manual reset structure. The reset component is mechanically connected to the transmission locking mechanism to achieve automatic reset; the manual reset structure is used for manual intervention in reset.

[0024] The transmission locking mechanism can achieve at least one of the following working states: fully released, slipping, and partially released;

[0025] The execution unit employs at least one of the following: electromagnetic drive, mechanical drive, hydraulic drive, pneumatic drive, shape memory alloy drive, and electrofluid drive.

[0026] One aspect also includes coupling units and protective housings;

[0027] The coupling unit includes a contactless electromagnetic induction coupling structure or a wired transmission coupling structure; for the contactless scheme, the coupling unit supplies power to the rotating part through the principle of electromagnetic induction; for the wired scheme, energy and signal transmission are achieved through wired lines.

[0028] The protective housing has at least one of the following functions: explosion protection, vibration reduction, heat dissipation, and prevention of accidental contact.

[0029] In one aspect, the control unit integrates a communication interface, a storage module, and a hardware-level emergency protection circuit;

[0030] The communication interface is linked with the main control system of the equipment, the emergency stop button, or the remote monitoring platform; the storage module is used to record operation and overload data; the hardware-level emergency protection circuit is used to retain real-time over-limit monitoring and protection functions in the event of a software failure in the control unit.

[0031] The beneficial effects of this invention are as follows: By collecting the operating status of the coupling in real time and performing trend prediction analysis and over-limit monitoring analysis in parallel and independently, it effectively solves the defect of existing coupling overload protection that can only respond passively. It achieves early prediction before overload occurs and immediate response after overload occurs, comprehensively covering both gradual and sudden overload conditions. Trend prediction analysis outputs protection commands and cuts off torque transmission before overload occurs, preventing damage to transmission components from overload impact at the source and compensating for the inability of traditional protection methods to provide early protection. Over-limit monitoring analysis can quickly output protection commands when overload occurs in real time, improving the response speed of sudden overloads and eliminating safety hazards caused by delayed protection actions. After the overload risk is eliminated, a reset operation is performed to restore torque transmission, forming a complete and reliable protection closed loop, improving the continuity and stability of coupling operation. The dual analysis mechanisms operate independently and trigger protection collaboratively, making the protection logic more complete, the response faster, and improving the overall safety and reliability of the transmission system. Attached Figure Description

[0032] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0033] Figure 1 This is a schematic diagram of the process steps of the coupling protection method of this application;

[0034] Figure 2 This is a schematic diagram of the intelligent coupling of this application. Detailed Implementation

[0035] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the technical solution of the present invention and are therefore intended to limit the scope of protection of the present invention.

[0036] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application should have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0037] like Figure 1 As shown, this application provides a coupling protection method, the protection method including:

[0038] Step S1: Obtain the preset warning threshold and overload threshold, collect the operating status signal of the coupling in real time and transmit it to the control unit. The control unit performs two independent analyses in parallel and independently on the received operating status parameters, namely trend prediction analysis and over-limit monitoring analysis. The two analyses run in parallel and do not interfere with each other.

[0039] In step S2, the control unit initiates two independent, non-waiting analysis threads: a trend prediction analysis thread and a real-time overload monitoring analysis thread. After receiving the operating status signal from the status detection element, the control unit activates two pre-set sets of analysis threads. These threads start simultaneously within the control unit, operate independently, and do not wait for or interfere with each other. Each thread processes the same set of operating status signals according to its own inherent judgment logic. The trend prediction analysis thread is specifically used to calculate and deduce the changing trend of the operating status signal to predict whether an overload will occur within a preset time period. The real-time overload monitoring analysis thread is specifically used to compare the current operating status signal with a preset overload threshold in real time to determine whether an overload has occurred. The two threads do not have a sequential execution relationship and do not need to wait for the analysis results of the other thread. Either thread can independently output a protection command once it completes its judgment and meets the triggering conditions. This forms a dual parallel overload judgment mechanism, ensuring both the ability to predict gradual overloads in advance and the ability to respond instantly to sudden overloads, making the coupling's protection logic more comprehensive and its response faster.

[0040] Step S3: During trend prediction analysis, if an overload is expected to occur within a preset time period, a protection command is output. Based on this command, the torque transmission of the coupling is cut off or reduced. During the trend prediction analysis, based on the collected rate and trend of change of operating status parameters, the load situation within the preset time period is extrapolated and calculated to determine whether an overload will occur. When the trend prediction analysis determines that there is a high risk of overload within the preset time period, a protection command is immediately generated and output. The protection command is sent directly to the execution unit. Upon receiving the protection command, the execution unit quickly takes action to completely disconnect the torque transmission path of the coupling, preventing the coupling and its associated transmission equipment from being subjected to overload impact in the future period. This prevents component damage and equipment failure caused by overload from the source, effectively addressing gradual overload situations such as slowly increasing load, and improving the foresight of the protection.

[0041] In step S4, during overload monitoring and analysis, if an overload has already occurred, a protection command is output. Based on this command, the torque transmission of the coupling is cut off or reduced. Simultaneously with the trend prediction protection operation, the real-time overload protection process in step S4 is executed concurrently. The currently collected operating status parameters are continuously compared in real-time through overload monitoring and analysis to determine if the current operating status has reached the overload threshold. When the current operating status parameters exceed the preset overload threshold, it is determined that the coupling is in an overloaded operating state. The control unit does not need to wait for the prediction result and directly and quickly outputs a protection command. After the protection command is transmitted to the execution unit, the execution unit immediately responds, forcibly cutting off the current torque transmission of the coupling, preventing the overload state from continuously damaging the transmission system, and quickly responding to sudden overload situations such as instantaneous impacts. This compensates for any potential response blind spots in trend prediction and forms a dual guarantee with trend prediction protection, ensuring that the coupling is effectively protected under various overload scenarios.

[0042] Step S5: After the overload risk is eliminated, a reset operation is performed to restore torque transmission. Once the coupling has completed its complete disengagement protection action, the reset monitoring and recovery process begins. The collected operating status parameters are continuously monitored. When the parameters remain consistently stable within the normal operating range for a preset duration, confirming that the overload risk has been completely eliminated, the control unit automatically triggers a reset control signal. Upon receiving the reset control signal, the reset component drives the coupling's actuator to return to its initial working position, completing the reset operation. After reset, the coupling's torque transmission path is reconnected, restoring normal torque transmission function, and the equipment can continue to operate.

[0043] like Figure 1 As shown, the core of the coupling protection method provided in this application lies in the parallel and independent execution of a trend prediction analysis thread and a real-time over-limit monitoring analysis thread by the control unit 9. The two threads are based on the same real-time acquired operating status signal, but employ different judgment logics to independently trigger protection, forming a complementary protection network.

[0044] The trend prediction and analysis thread focuses on addressing the risk of gradual overload. It analyzes the changing trends of operating status signals (such as torque) to provide early warnings before an overload actually occurs. Specifically, this thread can incorporate a time-series prediction model trained on historical normal data. This model can predict signal trends over a preset time period (e.g., 0.5-5 seconds) based on current and historical data sequences. When the predicted value consistently exceeds the warning threshold, an overload risk is considered, and regardless of whether the actual current value exceeds the limit, predictive protection is immediately triggered, outputting protection commands. This approach prevents slowly accumulating overloads from causing impact damage to the equipment, compensating for the "blind spots" of traditional real-time monitoring.

[0045] The real-time overload monitoring and analysis thread is dedicated to handling sudden overloads. This thread compares the collected operating status signals with a set overload threshold in real time. Once the current signal value exceeds this threshold, regardless of the trend prediction thread's result, real-time protection is immediately triggered, and a protection command is output. This thread responds extremely quickly, aiming to cut off the overload that has already occurred and prevent further damage.

[0046] The two analysis threads described above run independently within the control unit, without waiting for each other. These two independently running, non-waiting analysis threads can be implemented using a hardware-independent dual-microcontroller module or through independent thread scheduling at the software level. The two threads share the same data acquisition buffer, but each executes its own judgment logic independently without blocking the other. When either thread meets the trigger condition, the control unit immediately issues a corresponding instruction (protection instruction) to the execution unit, driving the transmission locking mechanism to cut off or reduce torque transmission. Once the overload risk is eliminated and confirmed after a delay, the system performs a reset operation to restore the connection.

[0047] In one embodiment of this application, the operation of the first protection command and the second protection command causes the transmission locking mechanism to enter at least one of the following protection states: fully disengaged, slipping, and partially disengaged. When the coupling performs a protection operation, it directly acts on the transmission locking mechanism, causing the transmission locking mechanism to switch to the corresponding protection working state according to the control command. This protection state includes three forms: fully disengaged, slipping, and partially disengaged. In actual operation, the transmission locking mechanism can enter any one of these protection states according to the control command, or it can simultaneously enter a combination of multiple protection states according to the working conditions. In the fully disengaged state, the transmission locking mechanism is completely separated, torque transmission is completely interrupted, and torque cannot be transmitted. In the slipping state, the transmission locking mechanism remains in contact but cannot stably transmit torque, allowing only a limited amount of torque to pass through. In the partially disengaged state, the transmission locking mechanism is partially separated, and torque transmission is significantly reduced. By setting the above multiple protection states, the torque transmission can be reliably cut off or reduced after the protection command operation is executed, meeting the protection requirements under different overload scenarios and improving the applicability and reliability of the coupling's protection action. The first protection command is triggered by the trend prediction and analysis thread to prevent gradual overloads in advance; the second protection command is triggered by the real-time overload monitoring and analysis thread to handle sudden overloads that have already occurred. The two commands have completely different triggering sources, triggering times, and applicable scenarios, but both control the transmission locking mechanism to cut off or reduce torque transmission.

[0048] In one embodiment of this application, the driving force for performing the protection operation is generated by the internal actuator of the coupling or provided by an external power source. The control unit automatically controls the transmission locking mechanism to switch to the corresponding protection state based on the predicted overload level or the real-time overload magnitude. When the coupling performs a protection operation, a corresponding driving force is required to drive the relevant mechanisms to complete the action. This driving force can be reliably provided in two ways. The first way is that the driving force is directly generated by the internal actuator of the coupling. The internal actuator is integrated into the coupling body structure and can autonomously generate the corresponding driving force after receiving a control command, completing the protection command action without the need for external equipment, ensuring the independence and timeliness of the protection operation. The second way is that the driving force is provided by an external power source. The external power source maintains a stable connection with the coupling actuator. After the control command is issued, the external power source outputs a matching driving force according to the command requirements and transmits it to the coupling actuator to complete the protection command operation. Both driving force provision methods can be independently selected according to the actual application scenario, and both can stably drive the protection command operation to be executed smoothly, ensuring the reliable completion of the coupling overload protection action.

[0049] In one embodiment of this application, the operating status signal includes at least one of torque, temperature, vibration, pressure, wear clearance, load fluctuation, position, electrical signal, and electromagnetic signal. The operating status signal collected in real time by the coupling includes various parameter types that can reflect the working status and overload risk of the equipment, specifically including torque signal, temperature signal, vibration signal, pressure signal, wear clearance signal, load fluctuation signal, position signal, electrical signal, and electromagnetic signal. During actual operation, any one or more combinations of the above signals can be collected to comprehensively characterize the real-time operating status of the coupling, providing a complete and accurate data foundation for subsequent analysis and judgment. The collected operating status signal is continuously transmitted to the control unit, which uses this type of signal as a basis to conduct trend prediction analysis and over-limit monitoring analysis to ensure the accuracy of protection judgment.

[0050] Trend prediction analysis is achieved based on the rate of change, acceleration of change, or time series prediction models of state signals. The trend prediction analysis performed by the control unit relies on the changing characteristics and analysis models of operating state signals. Specifically, it can be based on the rate of change of state signals, assessing the overload development trend by monitoring the amplitude of signal changes per unit time; it can also be based on the acceleration of change of state signals, predicting the likelihood of overload occurrence by analyzing the degree of change in the signal's rate of change; or it can use time series prediction models to calculate and predict the changing trend of operating state in future periods through modeling and analysis of historical and real-time signal data. These analysis methods can be used individually or in combination to reliably predict overload trends.

[0051] In one embodiment of this application, the protection method further includes: recording overload event data and adaptively adjusting the sensitivity or model parameters of trend prediction analysis based on historical data. After each protection operation is completed, all operational data related to the overload event are fully recorded. The recorded overload event data includes the protection action trigger time, trigger type, corresponding operational status signal value, and protection execution result. All recorded data is stored in chronological order to form a continuous and complete historical operational database. Based on the accumulated historical data, adaptive analysis and optimization processing are automatically performed. According to the overload occurrence pattern and operational status change characteristics under different working conditions, the warning threshold and trigger sensitivity of the trend prediction analysis are dynamically adjusted to make the prediction more consistent with the actual operating scenario and continuously improve the accuracy of coupling overload trend prediction.

[0052] In one embodiment of this application, the protection method further includes a fault emergency mechanism: when a system fault is detected, the real-time over-limit monitoring and protection operation functions are retained; when an external emergency stop signal is received, it automatically enters a locking or safe disengagement state. When a non-core unit fault is detected, the fault emergency handling process is automatically initiated, and the trend prediction analysis related functions are disabled in the fault state, while the basic protection functions of real-time over-limit monitoring and protection operation are fully retained, ensuring that the coupling can still respond to sudden overloads in the event of a system fault, and preventing damage to the transmission system due to loss of protection. When an emergency stop signal is received from an external device, an immediate response is made and an emergency action is executed, controlling the transmission locking mechanism to quickly enter the locking state or directly enter the safe disengagement state. By forcibly stabilizing the transmission structure or completely cutting off torque transmission, the equipment is prevented from unexpected rotation or overload impact during emergency stop, ensuring the safety of the overall equipment and the field operating environment, and improving the safety redundancy of the coupling protection system.

[0053] like Figure 2 As shown, this application also provides an intelligent coupling, including a state detection element 2, a control unit 9, an execution unit, and a transmission locking mechanism. The intelligent coupling also includes a driving shaft 1 and a driven shaft 5. The transmission locking mechanism includes a driving locking mechanism 7 and a driven locking mechanism 6.

[0054] The output of the status detection element 2 is connected to the input of the control unit 9, the output of the control unit 9 is connected to the input of the execution unit, and the output of the execution unit is connected to the transmission locking mechanism. The control unit 9 includes a first analysis module and a second analysis module that are independent of each other. The first analysis module is configured to perform trend prediction analysis, and the second analysis module is configured to perform real-time over-limit monitoring analysis. When either the first analysis module or the second analysis module meets the triggering condition, it directly outputs a first protection command or a second protection command to the execution unit, driving the transmission locking mechanism to switch between the connection state and the protection state. The protection state is a working state that reduces or interrupts torque transmission.

[0055] The first or second protection command generated by the control unit 9 is transmitted to the execution unit. The execution unit drives the transmission locking mechanism to operate according to the command, realizing the switching of the transmission locking mechanism between the connected state and the protected state. The connected state is the normal working state of the transmission locking mechanism. At this time, the coupling can stably transmit torque and ensure the normal operation of the transmission system. The protected state is the abnormal working state after the transmission locking mechanism is switched. The core feature of the abnormal working state is the reduction or interruption of torque transmission. By reducing the torque transmission efficiency or directly interrupting the torque transmission, overload damage to the coupling and surrounding transmission equipment can be effectively avoided, thus achieving safety protection for the coupling.

[0056] In one embodiment of this application, the intelligent coupling further includes a reset element 8 or a manual reset structure; the reset element 8 or the manual reset structure is used to restore the state after the protection action is completed. The reset element 8 directly cooperates with the transmission locking mechanism and can automatically drive the transmission locking mechanism to act after the overload risk is eliminated, so that the transmission locking mechanism returns from the protected state to the normal connection state. The manual reset structure allows the operator to manually operate it under specific working conditions, and complete the reset action of the transmission locking mechanism through manual intervention. The two reset methods can be set individually or in combination according to actual usage needs, ensuring that the coupling can reliably restore the normal working state in various scenarios, improving the flexibility and stability of the protection system. The transmission locking mechanism can achieve at least one working state of complete release, slippage, and partial release; under the drive of the execution unit, the transmission locking mechanism can switch between multiple working states to meet the protection needs under different overload scenarios. The transmission locking mechanism can enter the completely released state, at which time the entire mechanism is separated, the locking effect is completely lost and torque cannot be transmitted. The transmission locking mechanism can enter the slippage state, at which time the mechanism remains in contact but cannot stably transmit torque, only allowing a portion of the torque to pass. The transmission locking mechanism can enter a semi-disengaged state, in which the engaged and disengaged parts of the mechanism are separated, and torque transmission is significantly reduced. The transmission locking mechanism can enter at least one of the above states according to control commands, achieving torque reduction or interruption through diverse operating states, effectively improving the adaptability and reliability of the coupling's overload protection.

[0057] The actuator uses a conventional driving method in the field to achieve power output in order to adapt to different working conditions and structural design requirements.

[0058] In one embodiment of this application, the intelligent coupling further includes a coupling unit 3 and a protective housing 4; the coupling unit 3 and the protective housing 4 provide energy signal transmission protection and external structural protection for the coupling, respectively, thereby improving the overall operational stability and safety of the coupling.

[0059] Coupling unit 3 provides energy and / or transmits signals to the coupling in a contactless or wired manner. Located inside the coupling, coupling unit 3 facilitates energy supply and signal interaction. It can perform energy and signal transmission in a contactless or wired manner. In practical applications, either the contactless or wired method can be used alone, or both can be employed simultaneously. This ensures a stable supply of energy to all components within the coupling and efficient transmission of operating status signals and control commands between components, guaranteeing coordinated operation of all parts of the protection system.

[0060] The protective housing 4 possesses at least one of the following functions: explosion-proof, vibration damping, heat dissipation, and prevention of accidental contact. The protective housing 4 is installed outside the coupling, completely enclosing all internal functional structures and providing comprehensive external protection for the coupling. The protective housing 4 has multiple safety protection functions, and at least one function can be implemented according to the requirements of the operating environment. The protective housing 4 may have an explosion-proof function, preventing contact between the external hazardous environment and the internal structure, and preventing the transmission of explosion risks to the interior. The protective housing 4 may have a vibration damping function, absorbing vibrations generated during the operation of the coupling and reducing the impact of vibration on internal components. The protective housing 4 may have a heat dissipation function, promptly dissipating heat generated during internal operation to prevent high temperatures from affecting the stable operation of the system. The protective housing 4 may have an accidental contact prevention function, preventing unauthorized contact and misoperation, ensuring safe and reliable use.

[0061] In one embodiment of this application, the control unit 9 is equipped with a communication interface 10, which is linked with the main control system of the equipment, the emergency stop button, or a remote monitoring platform, and integrates self-learning and fault emergency response capabilities. As the core component of the coupling protection system, the control unit 9 has its own dedicated communication interface 10, through which it achieves stable connection and information exchange with external systems. The control unit 9 establishes a linkage relationship with the main control system of the equipment through the communication interface 10, receiving operating commands and parameter setting information issued by the main control system, and simultaneously uploading data such as the coupling operating status protection action triggering status to the main control system. The control unit 9 can also be directly linked with the emergency stop button through the communication interface 10, immediately executing emergency protection operations upon receiving a signal from the emergency stop button. The control unit 9 can also establish a connection with the remote monitoring platform through the communication interface 10, realizing remote uploading of operating data and remote reception of protection commands, meeting the needs of remote monitoring and remote control.

[0062] Control unit 9 integrates self-learning and fault emergency response capabilities, further enhancing the intelligence and safety redundancy of the protection system. Its self-learning capability relies on historical operating data and overload event records to continuously optimize the warning thresholds and trigger sensitivity of trend prediction analysis, thereby constantly improving the accuracy of overload judgment and the adaptability of protection actions. Control unit 9's fault emergency response capability can automatically activate preset emergency strategies in the event of an anomaly, preserving critical protection functions and ensuring that the coupling still possesses basic safety protection capabilities even in fault conditions.

[0063] The intelligent coupling uses a drive shaft 1 and a driven shaft 5 as its core transmission carriers. A drive locking mechanism 7 is fixed to the end of the drive shaft 1, and a driven locking mechanism 6 is fixed to the end of the driven shaft 5. Together, they form a transmission locking mechanism, enabling torque transmission between the drive and driven shafts. A status detection element 2 collects operating status signals in real time and transmits them to a control unit 9. The control unit 9 obtains energy through a coupling unit 3 and simultaneously interacts with external systems via a communication interface 10.

[0064] Based on the received signals, the control unit 9 performs parallel trend prediction analysis and over-limit monitoring analysis. When any trigger condition is met, it outputs a corresponding command to the execution unit. The execution unit drives the active locking mechanism 7 and the driven locking mechanism 6 to switch the transmission locking mechanism to the protection state. The protective housing 4 covers all internal components, providing external protection. When the overload risk is eliminated, the control unit 9 outputs a reset command, and the reset component 8 drives the transmission locking mechanism to reset, restoring torque transmission.

[0065] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; those skilled in the art should understand that any modifications or equivalent substitutions made to the technical solutions of the present invention should be covered within the protection scope of the present invention.

Claims

1. A method for protecting a coupling, characterized in that, The protection method includes: S1: Obtain preset warning thresholds and overload thresholds, collect the operating status signals of the coupling in real time and transmit them to the control unit; S2: The control unit starts two independent analysis threads that do not wait for each other: a trend prediction analysis thread and a real-time over-limit monitoring analysis thread. S3: The trend prediction and analysis thread predicts the load situation within a preset time period based on the changing trend of the running status signal. If the prediction result meets the overload warning conditions, it will independently output the first protection command to control the transmission locking mechanism to cut off or reduce torque transmission. S4: The real-time overload monitoring and analysis thread compares the running status signal with the overload threshold in real time. If the current signal value exceeds the overload threshold, it will independently output a second protection command to control the transmission locking mechanism to cut off or reduce torque transmission. S5: After the overload risk is eliminated, and after a preset delay time and the detection that the operating status signal is continuously stable within a safe range, a reset operation is performed to restore torque transmission.

2. The method according to claim 1, characterized in that, The first protection command and the second protection command cause the transmission locking mechanism to enter at least one of the following protection states: fully disengaged, slipping, or partially disengaged.

3. The method according to claim 1, characterized in that, The control unit automatically controls the transmission locking mechanism to switch to the corresponding protection state based on the overload prediction degree or the real-time overload magnitude.

4. The method according to claim 1, characterized in that, The operating status signals include at least one of torque, temperature, vibration, pressure, wear clearance, load fluctuation, position, electrical signals, and electromagnetic signals; the trend prediction analysis is based on the rate of change, acceleration of change, or statistical time series prediction model of the status signals.

5. The method according to claim 1, characterized in that, Also includes: The system records the trigger time, trigger type, and corresponding operating status data of overload events to form a historical database. Based on the historical database, the control unit dynamically adjusts the warning threshold and trigger sensitivity of trend prediction analysis.

6. The method according to claim 1, characterized in that, It also includes a fault emergency response mechanism: When a non-core unit failure is detected in the system, the real-time over-limit monitoring and protection operation functions are retained. When the core control unit fails, the default safety disengagement action is executed; When an external emergency stop signal is received, the control transmission locking mechanism automatically enters the locking or safe disengagement state.

7. An intelligent coupling, characterized in that, Includes status detection elements, control units, execution units, and transmission locking mechanisms; The output of the state detection element is connected to the input of the control unit, the output of the control unit is connected to the input of the execution unit, and the output of the execution unit is connected to the transmission locking mechanism. The control unit includes a first analysis module and a second analysis module that are independent of each other. The first analysis module is configured to perform trend prediction analysis, and the second analysis module is configured to perform real-time over-limit monitoring analysis. When either the first analysis module or the second analysis module meets the triggering condition, it directly outputs the first protection command or the second protection command to the execution unit, driving the transmission locking mechanism to switch between the connection state and the protection state. The protection state is a working state that reduces or interrupts torque transmission.

8. The intelligent coupling according to claim 7, characterized in that, It also includes a reset component and a manual reset structure. The reset component is mechanically connected to the transmission locking mechanism to achieve automatic reset; the manual reset structure is used for manual intervention in reset. The transmission locking mechanism can be switched to at least one graded protection state among fully released, slipping, and partially released.

9. The intelligent coupling according to claim 7, characterized in that, It also includes a coupling unit and a protective housing; The coupling unit is used to provide energy and transmit signals to the coupling, and adopts a non-contact electromagnetic induction coupling method or a wired transmission coupling method. The protective housing has at least one of the following functions: explosion protection, vibration reduction, heat dissipation, and prevention of accidental contact.

10. The intelligent coupling according to claim 7, characterized in that, The control unit integrates a communication interface, a storage module, and a hardware-level emergency protection circuit. The communication interface is linked with the main control system of the equipment, the emergency stop button, or the remote monitoring platform; the storage module is used to record operation and overload data; the hardware-level emergency protection circuit is used to retain real-time over-limit monitoring and protection functions in the event of a software failure in the control unit.

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