A safety early warning and emergency control system for automobile disassembly

Abstract

The application relates to the technical field of engineering machinery control, and discloses a vehicle disassembly safety early warning and emergency control system which comprises a central control unit, a sensing and monitoring module and a hydraulic drive circuit. The circuit comprises an oil inlet proportional servo valve and an oil return proportional back pressure valve; the control unit controls the back pressure valve to establish constant back pressure in the rod cavity and controls the servo valve to output driving pressure of superimposed pulsating excitation signals to the rodless cavity; the system calculates instantaneous net shear impedance and monitors reverse displacement of a wave trough by using a differential hydraulic model; when impedance fluctuation variance exceeds a threshold value, mean value indicates rigid locking or reverse displacement is monitored, a dangerous working condition is determined, oil inlet is immediately closed and back pressure is maintained, and the cylinder is braked by using fluid potential energy of the rod cavity. The application effectively solves the problems of being unable to identify a battery and a high-pressure container and brake response lag by active pulsating detection and normal back pressure damping.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery control technology, specifically to a safety early warning and emergency control system for automobile dismantling. Background Technology

[0002] Vehicle dismantling is a crucial step in resource recycling. With the increasing number of new energy vehicles on the road, dismantling operations are gradually shifting from traditional gasoline-powered vehicles to electric vehicles, which include high-voltage electrical systems and complex pressure-bearing components. During dismantling, hydraulic shears are used to handle the vehicle's frame, chassis components, and parts that may be hidden under the body panels, such as lithium battery modules, high-voltage wiring harnesses, or gas-hydraulic shock absorbers.

[0003] Existing hydraulic shearing equipment primarily focuses on providing enormous shearing force. Its hydraulic circuits are typically designed with an inlet-driven, low-resistance return path directly to the tank to reduce energy consumption and increase operating speed. However, this control method has significant safety limitations when facing complex dismantling conditions. Existing equipment lacks the ability to sense the internal physical properties of the object being sheared, relying mainly on operator visual observation to avoid hazards. However, battery modules or high-pressure containers are often encased in metal shells or located in blind spots, making accurate identification difficult for operators. While some equipment has pressure monitoring capabilities, the pressure changes from shearing high-strength vehicle body steel and the pressure changes from compressing the battery pack casing overlap in amplitude, making it impossible to distinguish between safe and dangerous components simply by relying on pressure thresholds.

[0004] Furthermore, the braking response mechanism of existing hydraulic systems is insufficient to meet the emergency requirements of high-risk components. Because the rod chamber is under low or zero pressure during normal operation, when the system detects an anomaly or a manual emergency stop is triggered, it can only cut off the power source on the oil inlet side. At this time, the relatively heavy cutter head assembly, due to its inertia, cannot stop instantly in the absence of reverse resistance and will still experience a significant forward overshoot. For tightly stacked lithium batteries or pressure vessels under high pressure, this slight braking delay and overshoot can cause the blade to pierce the diaphragm, triggering an internal short circuit and thermal runaway, or damage the container wall, causing high-pressure media ejection, thereby leading to a safety accident. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a safety early warning and emergency control system for automobile dismantling, which solves the problem that existing automobile dismantling equipment lacks material identification and emergency braking methods when handling dangerous components such as batteries and high-pressure containers.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a safety early warning and emergency control system for automobile dismantling, comprising a central control unit, a sensor monitoring module, and a hydraulic drive circuit connected to a hydraulic cylinder. The hydraulic drive circuit includes an inlet proportional servo valve connected to the rodless chamber of the hydraulic cylinder, and a return proportional back pressure valve connected to the rod chamber.

[0007] The central control unit is connected to the hydraulic drive circuit, controlling the return proportional back pressure valve to establish a constant back pressure in the rod chamber, and controlling the inlet proportional servo valve to output a drive pressure superimposed with a pulsating excitation signal to the rodless chamber. Based on the pressure and displacement data collected by the sensing and monitoring module, the central control unit calculates the instantaneous net shear resistance using a differential hydraulic model and monitors the reverse displacement of the cutter head at the trough of the pulsating excitation signal. When the fluctuation variance of the instantaneous net shear resistance exceeds a threshold, or the mean of the instantaneous net shear resistance indicates rigid locking, or the reverse displacement is detected, the central control unit determines a dangerous operating condition, controls the inlet proportional servo valve to close, and controls the return proportional back pressure valve to maintain the constant back pressure, using the fluid potential energy in the rod chamber to brake the hydraulic cylinder.

[0008] Furthermore, the hydraulic drive circuit also includes a safety unloading valve connected in parallel to the oil inlet pipeline; when the central control unit determines the dangerous working condition, it sends an opening command to the safety unloading valve to connect the bypass pressure relief, and cooperates with the pressure holding action of the return oil proportional back pressure valve to form a passive braking state of pressure loss on the oil inlet side and pressure holding on the oil return side.

[0009] Furthermore, the specific calculation logic of the differential hydraulic model is as follows: The product of the driving pressure in the rodless chamber and the first effective force-bearing area is obtained as the driving force; the product of the back pressure in the rod chamber and the second effective force-bearing area is obtained as the damping force; the net driving force is calculated by subtracting the damping force and a preset comprehensive dynamic friction constant from the driving force; and the net driving force is divided by the instantaneous feed speed of the hydraulic cylinder to obtain the instantaneous net shear resistance. The calculation logic includes anti-singularity processing: real-time monitoring of the absolute value of the instantaneous feed speed; when the absolute value is less than or equal to a preset speed dead zone threshold, a hard contact lock-up state is determined, and the instantaneous net shear resistance is set to its saturation maximum value.

[0010] Furthermore, the central control unit combines the data from the acoustic emission sensor to determine the electrochemical hazardous operating condition: if the fluctuation variance of the instantaneous net shear impedance exceeds the threshold, and the count of brittle fracture events detected by the acoustic emission sensor exceeds the frequency threshold within the same time window, then it is confirmed that the current condition involves the electrochemical components.

[0011] Furthermore, the central control unit monitors the displacement change of the cutter head at the trough of the pulsating excitation signal; if the detected displacement change is negative, or if the average value of the instantaneous net shear resistance exceeds the rigid threshold when the displacement is stagnant, it is confirmed that the current situation involves a dangerous working condition of the pressure vessel.

[0012] Furthermore, after braking, the central control unit performs subsequent responses based on the type of hazardous condition: for hazardous conditions involving electrochemical components, it controls the return oil proportional back pressure valve to fully open and drives the hydraulic pump to supply oil to the rod chamber to quickly separate the tool holder; for hazardous conditions involving pressure vessels, it controls the inlet proportional servo valve and the return oil proportional back pressure valve to enter the position closed-loop control mode to maintain the tool holder position unchanged or control the tool holder to retract at a slight speed.

[0013] This invention provides a safety early warning and emergency control system for automobile disassembly. It has the following beneficial effects:

[0014] 1. This invention pre-sets a constant back pressure in the rod chamber of the hydraulic cylinder, maintaining normal resistance during the shearing process. When a dangerous condition is determined, the system cuts off the oil supply and maintains this back pressure, directly utilizing the existing pressure in the rod chamber to counteract the piston's inertia. This method eliminates the time difference required by traditional braking schemes to temporarily establish reverse pressure, shortens the braking distance, and reduces the risk of the cutter head puncturing the battery separator due to inertia.

[0015] 2. This invention controls the superimposed pulsating signal of the inlet oil pressure and monitors the cutter head displacement at the trough. Utilizing the reaction force of the internal medium of the pressure vessel or elastic device to drive the cutter head to produce a reverse displacement during the trough phase of the decreasing driving force, the system can identify dangerous components with internal energy and distinguish their characteristics from those of passive metal components.

[0016] 3. This invention integrates the fluctuation variance of instantaneous net shear impedance with the fracture event count of acoustic emission signals for operating condition determination. By detecting the impedance change pattern during shearing of the internal stacked structure of the battery and the high-frequency stress waves generated by the fracture of brittle materials, the system can eliminate interference caused by friction from corroded metals, thus improving the accuracy of identifying electrochemical components such as lithium batteries. Attached Figure Description

[0017] Figure 1 This is a system architecture diagram of the present invention;

[0018] Figure 2 This is a flowchart of the method of the present invention;

[0019] Figure 3 This is a time-domain waveform diagram of the instantaneous net shear impedance of the present invention;

[0020] Figure 4This is the impedance discrete variance characteristic decision diagram of the present invention;

[0021] Figure 5 This is a waveform diagram of the active flutter pressure excitation of the present invention;

[0022] Figure 6 This is a monitoring diagram of the reverse displacement response of the cutting head in this invention.

[0023] Among them, 100 is the central control unit; 200 is the hydraulic actuator; 210 is the fixed tool holder; 220 is the movable tool holder; 230 is the hydraulic cylinder; 231 is the rodless chamber; 232 is the rod chamber; 300 is the hydraulic drive circuit; 310 is the pressure pump source; 320 is the inlet proportional servo valve; 330 is the return proportional back pressure valve; 340 is the safety unloading valve; 400 is the multi-dimensional sensing and monitoring module; 410 is the inlet pressure sensor; 420 is the return pressure sensor; 430 is the magnetostrictive displacement sensor; and 440 is the acoustic emission sensor. Detailed Implementation

[0024] The technical solutions in 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, and 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.

[0025] See attached document Figure 1 In this embodiment, an adaptive safety disassembly control system is provided. At the hardware level, the system is mainly constructed as a closed-loop control topology consisting of a central control unit 100, a hydraulic actuator 200, a hydraulic drive circuit 300, and a multi-dimensional sensing and monitoring module 400.

[0026] As the execution end of the system, the hydraulic actuator 200 includes a hydraulic shear arm body, which further includes a fixed cutter holder 210, a movable cutter holder 220, and a hydraulic cylinder 230 that drives the movable cutter holder 220 to perform opening and closing movements. The hydraulic cylinder 230 is internally divided by a piston into a rodless chamber 231 and a rod chamber 232. Specifically, the rodless chamber 231 is defined as the drive-side chamber, used to receive high-pressure fluid to generate thrust during the shearing action; the rod chamber 232 is defined as the return-side chamber, used to discharge fluid or establish back pressure damping during the shearing action.

[0027] To precisely control the fluid pressure field within the hydraulic cylinder 230, the hydraulic drive circuit 300 includes a hydraulic pump source 310, an inlet proportional servo valve 320, a return proportional back pressure valve 330, and a safety unloading valve 340. The inlet proportional servo valve 320 connects the hydraulic pump source 310 to the rodless chamber 231 and is configured to regulate the fluid flow rate and pressure entering the rodless chamber 231. The return proportional back pressure valve 330 is located between the rod chamber 232 and the return oil tank and is configured to establish an adjustable fluid back pressure within the rod chamber 232. Notably, this return proportional back pressure valve 330 is configured to have a power-off pressure-maintaining function or be driven by independent control logic to ensure that when the system triggers an emergency stop and cuts off the inlet pressure, the valve can still maintain the predetermined pressure within the rod chamber 232 without directly releasing oil. The safety unloading valve 340 is connected in parallel to the inlet pipeline and is configured to instantly connect to the bypass for pressure relief upon receiving an emergency stop signal.

[0028] The multi-dimensional sensing and monitoring module 400 is used to collect physical state data of the hydraulic actuator 200 during operation to support subsequent intelligent decision-making. Specifically, this module includes: an inlet pressure sensor 410 installed at the inlet of the rodless chamber 231; a return pressure sensor 420 installed at the outlet of the rod chamber 232; a magnetostrictive displacement sensor 430 installed on the piston rod side of the hydraulic cylinder 230; and an acoustic emission sensor 440 magnetically attached to the root of the movable tool holder 220. It should be noted that the acoustic emission sensor 440 establishes a sound wave transmission link with the object being disassembled through the metal structure of the movable tool holder 220, and the sensor is isolated from the external environment by a frequency filtering circuit, collecting only structural stress wave signals in a specific frequency band.

[0029] The central control unit 100 establishes electrical connections with the inlet proportional servo valve 320, the return proportional back pressure valve 330, the safety unloading valve 340, and the multi-dimensional sensing and monitoring module 400. The central control unit 100 is configured to execute an adaptive safety disassembly control method.

[0030] See attached document Figure 2 The method includes the following operational phases:

[0031] S1: Construction and parameter tuning of the differential damping field. When the system enters the exploration mode, the central control unit 100 executes the damping preloading logic. Unlike the traditional hydraulic system's direct return oil to the tank (back pressure close to zero), in this embodiment, the return oil proportional back pressure valve 330 adjusts the valve opening to establish and maintain a constant preset back pressure in the rod chamber 232. .

[0032] The back pressure value is not arbitrarily selected, but determined based on the system's energy conservation and safety requirements. Specifically, The potential energy stored in the rod chamber 232 must be sufficient to overcome the kinetic energy of the movable tool holder 220 at the instant of pressure loss on the oil inlet side. This setting must satisfy the following physical constraints:

[0033] ;

[0034] in, The equivalent kinematic mass of the movable tool holder 220 and the linkage mechanism, The maximum permissible speed during the exploration phase. This represents the effective force-bearing area of ​​the rod cavity 232. A preset safe braking distance (e.g., 1mm to 5mm) is established. The back pressure set by this logic ensures that the system is always physically in a pre-braking state.

[0035] S2: Dynamic balance under low net thrust drive. While maintaining the aforementioned high back pressure damping field, the central control unit 100 controls the oil inlet proportional servo valve 320 to supply oil to the rodless chamber 231. At this time, the system establishes a dynamic force balance model, which aims to eliminate the system's mechanical friction and back pressure resistance, outputting only the small net driving force required to maintain the low-speed creep of the tool holder. Specifically, the dynamic balance of the hydraulic actuator 200 is based on the differential hydraulic principle, that is, the output resultant force of the piston rod is obtained by subtracting the product of the driving pressure and effective area in the rodless chamber 231 from the product of the back pressure and annular area in the rod chamber 232, and then overcoming the mechanical friction resistance.

[0036] In this embodiment, the control algorithm limits the net driving force to an extremely low level (e.g., only 1%-3% of the system's rated thrust), so that although the tool holder moves under the influence of high-pressure hydraulic fluid, its aggression towards external obstacles is extremely low. Once abnormal resistance is encountered, the minimal net driving force is insufficient to produce a destructive cutting depth, thus achieving flexible contact.

[0037] S3: Vector superposition of micro-amplitude pulsating excitation signals. When the displacement sensor confirms that the tool holder has entered the contact area (e.g., the distance between the two cutting edges is less than 50mm), the system switches to active excitation mode. The central control unit 100 superimposes a high-frequency AC component, i.e., a chatter signal, onto the reference DC control signal of the oil inlet proportional servo valve 320. This chatter signal drives the servo valve core to generate a micron-level high-frequency reciprocating displacement near the equilibrium position, causing the hydraulic oil flow rate entering the rodless chamber 231 to fluctuate periodically, thereby modulating a frequency of [missing information] on the pressure in the rodless chamber 231. Pressure ripples.

[0038] For frequency In this embodiment, the frequency is preferably set between 10Hz and 100Hz. This frequency range is chosen based on physical causality considerations: on the one hand, the frequency needs to be lower than the natural frequency of the hydraulic oil column to avoid destructive hydraulic resonance; on the other hand, the frequency needs to be high enough to accumulate sufficient impedance sample points in a short time and to excite the dynamic interlayer friction characteristics of multilayer heterogeneous materials (such as the stacked structure inside a lithium battery). If the frequency is too low, the difference between static and dynamic friction cannot be distinguished; if the frequency is too high, the pressure wave will be significantly attenuated due to the compressibility of the hydraulic oil and cannot be effectively transmitted to the cutting edge.

[0039] See attached document Figure 1 - Appendix Figure 2 This embodiment is not limited to linear reading of data from a single sensor, but instead constructs a heterogeneous data fusion processing model based on microsecond-level time-domain alignment. This model aims to reconstruct the material physical properties of the disassembled object within the first tens of milliseconds of contact by analyzing the dynamic response of hydraulic fluid under unsteady conditions and the acoustic transient response of the metal structure, eliminating environmental interference.

[0040] The specific execution flow of this method is based on the following logical steps:

[0041] S101: Time axis alignment and frequency domain filtering of heterogeneous signals. To eliminate the spatiotemporal difference between the hydraulic transmission delay (millisecond level) and the propagation speed of sound waves in a metallic medium (approximately 5000 m / s), the central control unit 100 adopts an FPGA multi-channel parallel acquisition strategy based on a unified clock source. The system defines a feature extraction time window. In a preferred embodiment, the window is set to the interval from 0ms to 50ms after the displacement sensor detects the contact signal. The reason for selecting this interval is that the object is in the critical stage of transitioning from elastic deformation to plastic deformation at this time, and macroscopic structural damage has not yet occurred, making it the optimal physical window for non-destructive detection.

[0042] Within this window, the analog-to-digital conversion module synchronously locks the sampling clocks for inlet oil pressure, return oil back pressure, piston displacement, and acoustic emission signals. During signal acquisition, to accurately reproduce the high-frequency stress wave characteristics in the acoustic emission signal, the system's analog-to-digital conversion sampling frequency is set to be significantly higher than twice the 440kHz passband upper limit frequency (500kHz) of the acoustic emission sensor. The frequency band is ≥2MHz, strictly adhering to the Nyquist-Shannon theorem to prevent signal distortion caused by spectral aliasing. For acoustic emission signals, the system hardware front-end is equipped with a bandpass filter with a passband range of 100kHz to 500kHz. The technical purpose of this frequency band setting is to effectively filter out low-frequency fluid noise (typically below 5kHz) generated by the hydraulic pump operation and friction noise (typically below 20kHz) generated by the robotic arm movement, thereby ensuring that the system is only sensitive to high-frequency stress waves generated by the propagation of microcracks in the material.

[0043] S102: Calculation of Instantaneous Net Shear Impedance Characteristics. After obtaining the basic physical quantities for synchronization, the signal processing module performs the calculation of instantaneous net shear impedance. The physical essence of this step is to establish an input-output transfer function, where the input is the net effective force acting on the object, and the output is the deformation velocity produced by the object. To obtain realistic material feedback, the preloaded back pressure damping and the inherent mechanical friction of the system must be removed from the total hydraulic thrust. The system calculates the sampling points based on the following differential hydraulic model. Net impedance value :

[0044] ;

[0045] in:

[0046] Sampling time The driving pressure of the rodless chamber 231 and the back pressure of the rod chamber 232;

[0047] , These are the effective force-bearing areas of the rodless cavity 231 and the rod cavity 232, respectively.

[0048] The comprehensive dynamic friction constant is the one calibrated for the system. This constant is obtained in advance by calculating the average pressure difference when the equipment performs a full stroke under no-load conditions.

[0049] The instantaneous feed rate is obtained by differentiating the displacement data and then filtering it using a low-pass filter.

[0050] Represents the absolute value of the instantaneous feed rate;

[0051] This represents the saturation impedance value corresponding to the velocity dead zone.

[0052] Considering the physical phenomenon that the cutting head may momentarily stop during actual contact (at which point the velocity in the denominator approaches zero), the algorithm introduces the above-mentioned anti-singularity processing logic: setting a velocity dead zone threshold. (For example, 0.5 mm / s, this value depends on the resolution and noise floor of the displacement sensor). When the absolute value of the detected velocity meets... Under this condition, the system is determined to be in a hard-contact locked state, and the impedance value is directly set to the system's defined saturation maximum value. This avoids system errors caused by numerical calculation overflow.

[0053] S103: Transient energy feature extraction of acoustic emission signals. Parallel to impedance calculation, the system extracts features from the acoustic emission signals. This embodiment uses a dynamic threshold method to identify burst-type signals, distinguishing them from background noise and material fracture sounds. The signal processing module first calculates the energy count rate of the signal within a time window, with the following determination logic:

[0054] Set floating noise threshold ,in The root mean square value of the ambient background noise collected before step S301 (i.e., the no-load approach phase). For safety reasons, For fixed voltage bias.

[0055] If the signal amplitude exceeds [a certain value] within a single pulse cycle, If the duration is less than the set time, the system marks it as a brittle fracture event. This feature extraction logic utilizes the unique brittle acoustic fingerprint of the ceramic separator inside a lithium battery or the insulation layer of a high-voltage cable under pressure, forming a feature space separation from the continuous acoustic emission signal generated by ordinary ductile metals during plastic rheology.

[0056] S104: Micro-displacement monitoring of passive reverse thrust response. This step utilizes the pressure pulsation applied in S203 as an active excitation source to monitor the kinematic response of the hydraulic cylinder at the moment of force release. During the trough of the pressure pulsation waveform (i.e., when the driving force is at its minimum), the system checks the displacement change. If detected (That is, the cutter head undergoes reverse micro-motion), and at this time, the back pressure in the rod cavity 232 remains constant, indicating that there is active potential energy inside the contacted object. Physically, this corresponds to a pressurized container (such as an unpressurized shock absorber) or a high-elastic modulus object using its stored energy to overcome the hydraulic driving force during a low point, thereby pushing the cutter head back. This characteristic is a unique criterion for identifying pressure vessels with an explosion risk.

[0057] See attached document Figure 1 - Appendix Figure 2 In this embodiment, the central control unit 100 has a built-in intelligent decision-making module, and the specific execution process of this module follows the following steps:

[0058] S201: Statistical quantification of impedance texture characteristics. This involves the instantaneous net shear impedance calculated in the preceding steps. The sequence and decision module performs time-domain statistical analysis to identify the internal structure distribution of the material.

[0059] To quantify this heterogeneity, the system calculates the impedance fluctuation variance within the feature extraction time window. The calculation expression is as follows:

[0060] ;

[0061] in: This represents the total number of sampling points within the feature extraction time window. For the first Instantaneous net shear impedance value at each sampling point This is the arithmetic mean of the impedance sequence within this time window.

[0062] To ensure the objectivity and feasibility of the threshold setting, this embodiment sets a fluctuation threshold. When calculated in real time When the threshold is exceeded, the system determines that the object being cut has the physical characteristics of a layered composite structure and generates a primary danger warning signal.

[0063] S202: Joint Decision for Electrochemical Hazardous Operating Conditions (Condition A). Condition A is defined as involving electrochemical components such as lithium-ion batteries and capacitors that pose a fire and explosion risk. Considering that metal components may also experience impedance fluctuations under severe corrosion, potentially leading to false alarms, this step introduces acoustic emission characteristics for physical-level cross-verification.

[0064] To further improve the accuracy of identification and prevent false alarms caused by corroded metal, this embodiment preferably adopts a combined acoustic and mechanical decision logic: if the system detects impedance variance... At this point, the system can directly trigger a defensive shutdown based on impedance characteristics (corresponding to the basic protection logic in claim 1). Furthermore, if the count of acoustic emission brittle fracture events exceeds the frequency threshold, the system confirms with high confidence that it is currently in operating condition A and executes a targeted, rapid separation strategy.

[0065] S203: Inverse dynamics decision for hazardous operating conditions (condition B) of high-pressure vessels. The system defines condition B as a pressure vessel involving hydraulic cylinder 230, accumulator, shock absorber, etc., which poses a risk of high-pressure jetting. The core physical characteristic of such objects is that the fluid or gas sealed inside possesses active elastic potential energy, which can do work on external loads.

[0066] The decision module makes a judgment based on the micro-displacement monitoring results in step S304 and the impedance calculation results in step S102. The decision logic is set as follows: if a significant reverse displacement is detected (i.e., (negative value and exceeding the noise threshold), or, in the case of displacement stagnation (absolute velocity value) If the mean net impedance exceeds the rigidity threshold that characterizes rigid contact, the system determines that it is currently in operating condition B.

[0067] The physical logic here is quite clear: when ordinary metal components are removed by hydraulic shearing force (pulsating trough), only a slight elastic rebound occurs, without generating significant reverse work; however, the high-pressure medium inside the pressure vessel will actively release energy to drive the cutter head to move in the opposite direction by taking advantage of the gap caused by the decrease in external driving force. Therefore, combining the reverse displacement characteristic is a unique dynamic fingerprint for identifying energetic objects.

[0068] S204: Elimination method confirmation for ordinary metal safety conditions (condition C). When neither the decision conditions for condition A nor condition B are triggered, the system checks the spectral energy distribution of the acoustic emission signal. If the energy of the acoustic emission signal is mainly concentrated in the low-frequency band, and the impedance curve shows a monotonically increasing or stable characteristic, this is consistent with the physical law of plastic flow in ductile metals. The system confirms that the current object is ordinary scrap steel and generates a permissible shearing flag.

[0069] See attached document Figure 1 - Appendix Figure 2 In this mechanism, the technical solution is based on the principle of pre-storage of fluid potential energy and uses the back pressure field pre-established in the rod chamber 232 of the hydraulic cylinder to achieve instantaneous suppression of motion inertia.

[0070] S301: Instantaneous cutoff and unloading pressure maintenance of drive energy. When the central control unit 100 generates a dangerous operating condition judgment signal, the system immediately triggers the emergency shutdown logic. The central control unit 100 simultaneously performs two operations within the same clock cycle: sending a zero-voltage closing command to the oil inlet proportional servo valve 320 and a high-level fully open command to the safety unloading valve 340.

[0071] Under the action of the electromagnetic actuator, the inlet proportional servo valve 320 quickly resets to the neutral closed state, physically cutting off the high-pressure oil source to the rodless chamber 231. At this time, the most critical step is that the central control unit 100 continuously sends a pressure holding command to the return proportional back pressure valve 330, or the valve is designed with a power-off self-locking function, to ensure that while the oil inlet side is depressurized, the damping medium in the rod chamber 232 does not flow back to the oil tank. The technical purpose of this action is to retain the reverse spring required for braking while cutting off the power.

[0072] S302: Passive braking release of differential damping potential energy. With the active driving force... The instantaneous collapse disrupted the force balance of the piston rod in hydraulic cylinder 230. At this moment, the back pressure, pre-established and sealed within the rod cavity 232 in the preceding steps, was disrupted. It immediately transforms from a balancing damping role to a braking force role.

[0073] The physical estimation of braking distance is based on the law of conservation of energy. After the emergency stop action is triggered, the original kinetic energy of the movable tool holder 220 will be entirely converted into work done to overcome the back pressure resistance and mechanical friction of the rod cavity 232. Therefore, the braking distance is directly proportional to the system kinetic energy at the moment of stopping, and inversely proportional to the preset back pressure value in the rod cavity 232. Due to the back pressure... It is a constant positive value, which, from a physical mechanism perspective, ensures that the piston rod will inevitably stop moving within a finite and extremely short distance, thereby effectively preventing the blade from piercing the battery separator or causing the pressure vessel to burst due to excessive inertia.

[0074] S303: Adaptive emergency response based on operating condition classification. After using passive back pressure to complete primary braking and stop the piston rod, the central control unit 100 executes differentiated secondary response strategies based on the identified specific hazard type:

[0075] For the rapid separation response in condition A (electrochemical hazardous materials): the system controls the return oil proportional back pressure valve 330 to be fully open, and simultaneously controls the main hydraulic pump to output maximum flow to the rod chamber 232. At this time, the movable blade holder 220 rapidly retracts from the contact point at maximum return speed. This action aims to cut off the positive and negative electrode short circuit path that may be formed due to blade conduction as quickly as possible, and to reserve physical space for thermal runaway ejection that may occur due to internal chemical reactions of the battery.

[0076] For controlled release response in Condition B (high-pressure vessel): the system executes a position locking or micro-retraction strategy. The central control unit 100 controls the inlet and outlet valves to enter a closed-loop position mode, maintaining the cutter head position or retracting it at an extremely low speed. The hydrodynamic basis of this strategy is that if the cutter head has partially embedded in the vessel wall, causing a perforation, rapid withdrawal may remove the physical seal on the perforation, causing the internal high-pressure medium to form a supersonic jet along the hole, resulting in cutting damage or secondary rupture. By maintaining contact or controlling micro-retraction, using the cutter head body as a temporary plug, valuable time can be gained for subsequent manual depressurization or controlled explosion-proof treatment.

[0077] Specific application examples:

[0078] This embodiment details the application of an intelligent dismantling system based on differential hydraulic impedance feedback in actual operation. Based on the aforementioned hardware topology, this system can perform adaptive identification and safe dismantling of mixed-stack lithium battery modules (condition A) and high-pressure hydraulic shock absorbers (condition B).

[0079] System initialization and parameter tuning

[0080] Before the operation begins, the system first completes the configuration of the hydraulic power unit and sets the rated pressure. =21MPa, sampling frequency =2MHz, feature extraction time window is =0ms~50ms. In exploration mode, the system executes step S1, constructing in the rod cavity 232. A constant back pressure field of 5.0 MPa is applied. This back pressure value is set strictly according to the energy conservation constraint. This ensures that even if the active control circuit fails, passive braking can be achieved solely through the physical back pressure of the hydraulic circuit. Simultaneously, according to step S2, the maximum net thrust is limited to 2% of the rated value (approximately 2000N), allowing the cutter head to engage the target in a flexible contact state, thus avoiding damage during the identification phase.

[0081] Example 1: Identification of the stacked structure of lithium battery modules (Condition A)

[0082] Once the displacement sensor detects that the tool holder has entered the contact area, the system immediately initiates the identification process for heterogeneous stacked structures.

[0083] Based on step S102, the system uses real-time acquired pressure and velocity data to solve the sampling points using a discrete dynamic model to analyze the time-domain characteristics of the instantaneous net shear impedance. Instantaneous net shear resistance:

[0084] ;

[0085] Here Low-pass filtering and anti-singularity dead zone threshold The instantaneous velocity after processing.

[0086] See attached document Figure 3 Within the 0-50ms time window, the measured impedance curve (solid line) exhibits non-homogeneous characteristics: the curve does not show the smooth upward trend of homogeneous metal, but rather shows a large-amplitude periodic sawtooth oscillation between 2000Ns / m and 12000Ns / m.

[0087] Peak characteristics: The hard layer impedance peak marked in the figure corresponds to the moment of high impedance generated when the blade cuts the copper or aluminum foil current collector;

[0088] Valley characteristics: The impedance valleys of the soft layer marked in the figure correspond to the moment of low impedance when the blade cuts into the separator and electrolyte layer. This fluctuating impedance texture accurately maps the physical structure of the alternating stacking of electrodes, separators, and electrolyte inside the lithium battery.

[0089] To quantify the aforementioned oscillation characteristics, the system executes step S1, which calculates the impedance fluctuation variance within the time window, based on the threshold decision of impedance discrete variance:

[0090] ;

[0091] See attached document Figure 4 The gray dashed line in the figure represents the preset composite material judgment threshold. (2.5×10) 5 (Ns / m) 2 .

[0092] Initial stage (0ms to 5ms): The variance curve (solid line) remains at a low level close to zero, indicating that the cutting head has not yet touched the core stacked structure.

[0093] Triggering moment (T≈5ms): As the cutting action occurs, the characteristics of impedance fluctuation instantly appear. As shown by the solid black dot (trigger point) in the figure, the solid line rises sharply at this moment and breaks through the threshold of the dashed line. After the system detects this breakthrough event, it combines the acoustic emission brittle fracture count in step S202 to determine that the target is a dangerous composite material (battery), and then triggers the emergency shutdown logic in S301 to perform safety procedures.

[0094] Example 2: Reverse dynamics identification of high-pressure shock absorbers (condition B)

[0095] For inflatable high-pressure shock absorbers with a homogeneous metal shell, since their impedance variance may not trigger the above criteria, the system instead relies on the inverse dynamic response under active excitation for identification.

[0096] The application of active flutter excitation is based on step S3, whereby the system superimposes a frequency in the oil inlet circuit. =50Hz high-frequency AC component. (See attached image) Figure 5 The sinusoidal drive waveform (normalized display) exhibits periodic driving force troughs (marked by gray squares in the figure). These troughs represent not only low driving pressures but also deliberately constructed defensive weaknesses designed to induce the release of internally stored elastic potential energy from potentially high-pressure vessels.

[0097] The reverse displacement response capture and judgment system executes step S104, which utilizes microsecond-level time-domain alignment technology to focus on monitoring the displacement response of the cutting head at the trough of the driving force wave. .

[0098] See attached document Figure 6 The figure illustrates the key dynamic fingerprint for identifying high-pressure vessels:

[0099] Abnormal springback: In the figure, the solid line represents the real-time displacement of the cutter head, and the dotted line is the zero displacement baseline. At approximately 30ms (corresponding to the trough of the driving force), the displacement curve abnormally drops below the zero line.

[0100] Reverse work: The gray-filled area (reverse displacement area) in the diagram visually represents this. The process. Physically, this indicates that at the instant the hydraulic driving force decays, the rebound force generated by the high-pressure medium (such as 3MPa gas) sealed inside the target overcomes the net thrust of the system, forcing the cutter head to move in the opposite direction.

[0101] According to step S203, the system determines that this reverse work phenomenon is a characteristic of a high-pressure vessel. Once the attached... Figure 6 In the reverse displacement, the system immediately uses the oil cut-off and back pressure holding action executed in S301 to form a hydraulic lock, holding the cutter head to prevent the workpiece from popping out, and maintaining the position or controlling the micro-speed retraction according to the S303 strategy to prevent supersonic jet leakage caused by rapid separation.

Claims

1. A safety early warning and emergency control system for automobile dismantling, characterized in that, It includes a central control unit (100), a sensing and monitoring module (400), and a hydraulic drive circuit (300) connected to a hydraulic cylinder (230); The hydraulic drive circuit (300) includes an inlet proportional servo valve (320) that connects to the rodless chamber (231) of the hydraulic cylinder (230) and a return proportional back pressure valve (330) that connects to the rod chamber (232). The central control unit (100) is connected to the hydraulic drive circuit (300), controls the return oil proportional back pressure valve (330) to establish a constant back pressure in the rod chamber (232), and controls the inlet oil proportional servo valve (320) to output a drive pressure superimposed with a pulsating excitation signal to the rodless chamber (231); The central control unit (100) calculates the instantaneous net shear resistance and monitors the reverse displacement of the cutter head at the trough of the pulsating excitation signal based on the pressure and displacement data collected by the sensing and monitoring module (400). When the fluctuation variance of the instantaneous net shear impedance exceeds the threshold or the mean of the instantaneous net shear impedance indicates rigid lock-up or the reverse displacement is detected, the central control unit (100) determines the dangerous working condition, controls the oil inlet proportional servo valve (320) to close and controls the oil return proportional back pressure valve (330) to maintain the constant back pressure, and uses the fluid potential energy in the rod chamber (232) to brake the hydraulic cylinder (230).

2. The automotive dismantling safety early warning and emergency control system according to claim 1, characterized in that, The hydraulic drive circuit (300) also includes a safety unloading valve (340) connected in parallel to the oil inlet pipeline; when the central control unit (100) determines the dangerous working condition, it sends an opening command to the safety unloading valve (340) to connect the bypass pressure relief, and cooperates with the pressure holding action of the return oil proportional back pressure valve (330) to form a passive braking state of pressure loss on the oil inlet side and pressure holding on the oil return side.

3. The automotive dismantling safety early warning and emergency control system according to claim 1, characterized in that, The sensing and monitoring module (400) includes: an oil inlet pressure sensor (410) installed at the oil inlet of the rodless chamber (231), a return oil pressure sensor (420) installed at the oil outlet of the rod chamber (232), a magnetostrictive displacement sensor (430) installed on the piston rod side of the hydraulic cylinder (230), and an acoustic emission sensor (440) magnetically adsorbed on the movable tool holder (220).

4. The automotive dismantling safety early warning and emergency control system according to claim 3, characterized in that, The specific calculation logic of the differential hydraulic model is as follows: the product of the driving pressure in the rodless chamber (231) and the first effective force-bearing area is obtained as the driving force; the product of the back pressure in the rod chamber (232) and the second effective force-bearing area is obtained as the damping force; the net driving force after subtracting the damping force and the preset comprehensive dynamic friction constant from the driving force is calculated; the net driving force is divided by the instantaneous feed speed of the hydraulic cylinder (230) to obtain the instantaneous net shear resistance.

5. The automotive dismantling safety early warning and emergency control system according to claim 4, characterized in that, The central control unit (100) includes anti-singularity logic when calculating the instantaneous net shear impedance: it monitors the absolute value of the instantaneous feed speed in real time, and when the absolute value is less than or equal to a preset speed dead zone threshold, it determines that the hard contact lock state is in effect and forces the instantaneous net shear impedance to the maximum saturation value.

6. The automotive dismantling safety early warning and emergency control system according to claim 3, characterized in that, The central control unit (100) combines the data from the acoustic emission sensor (440) to determine the electrochemical hazardous operating condition: if the fluctuation variance of the instantaneous net shear impedance exceeds the threshold, and the count of brittle fracture events detected by the acoustic emission sensor (440) exceeds the frequency threshold within the same time window, then it is confirmed that the current condition involves the electrochemical components.

7. The automotive dismantling safety early warning and emergency control system according to claim 6, characterized in that, The central control unit (100) performs bandpass filtering on the signal collected by the acoustic emission sensor (440), with the passband range set to 100kHz to 500kHz, to filter out hydraulic fluid noise and mechanical structure friction noise.

8. The automotive dismantling safety early warning and emergency control system according to claim 1, characterized in that, The central control unit (100) monitors the displacement change of the cutter head at the trough of the pulsating excitation signal; if the displacement change is detected to be negative, or if the mean value of the instantaneous net shear resistance exceeds the rigid threshold in the displacement stagnation state, it is confirmed that the current working condition involves the pressure vessel.

9. The automotive dismantling safety early warning and emergency control system according to claim 1, characterized in that, The setting of the constant back pressure must meet the physical constraint that the product of the constant back pressure and the effective force-bearing area of ​​the rod cavity (232) is greater than or equal to the effective kinetic energy of the hydraulic cylinder (230) and the tool holder assembly divided by the preset safe braking distance.

10. The automotive dismantling safety early warning and emergency control system according to claim 1, characterized in that, After braking, the central control unit (100) performs subsequent responses according to the type of hazardous condition: for hazardous conditions involving electrochemical components, it controls the return oil proportional back pressure valve (330) to be fully open and drives the hydraulic pump to supply oil to the rod chamber (232) to quickly separate the tool holder; for hazardous conditions involving pressure vessels, it controls the inlet proportional servo valve (320) and the return oil proportional back pressure valve (330) to enter the position closed-loop control mode to maintain the tool holder position unchanged or control the tool holder to retract slightly.

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