Modular-based load safety interlock control system and method for hoisting machinery

Abstract

The application relates to the field of hoisting machinery safety control and industrial automation, in particular to a hoisting machinery load safety intelligent interlocking control system and method based on modularization; the system comprises the following steps: acquiring real-time torque current, real-time tension and splicing module configuration information of a hoisting mechanism; according to a connection topological relation, performing series-parallel connection equivalent on inherent stiffness parameters of each splicing module to determine a module system comprehensive stiffness coefficient; calculating a torque current rising rate and a tension rising rate, combining the comprehensive stiffness coefficient to solve a transient load torque coupling gradient, and comparing the transient load torque coupling gradient with a normal hoisting elastic deformation envelope line; when the transient load torque coupling gradient exceeds the envelope line, a torque clamping instruction is generated, and when the transient load torque coupling gradient does not exceed the envelope line, the current hoisting state is maintained; after clamping, the real-time tension and a tension change rate are continuously monitored, an abnormal alarm or a dangerous interlocking hard cut-off instruction is generated; the application can identify abnormal stress transmission in advance and realize low-impact safety interlocking control.

Description

Technical Field

[0001] This invention relates to the field of lifting machinery safety control and industrial automation, specifically to a modular intelligent interlocking control system and method for lifting machinery load safety. Background Technology

[0002] Existing safety control methods for lifting machinery include protection schemes based on hoisting motor current, load sensor tension value, or rated lifting capacity threshold. In related technologies, in order to determine whether there is overload or abnormality during the lifting process, the motor parameters fed back by the frequency converter can be used to monitor the lifting status; or, a tension sensor can be used to detect the load stress and trigger an alarm or brake when a preset threshold is reached; for lifting machinery that uses modular splicing main beams, the equipment can also be managed for routine safety by combining manually entered structural parameters. However, in the initial stage of lifting, when the heavy object has not been completely lifted off the ground, or when there are conditions such as the anchor not being removed, partial jamming, or attachment constraints, the former method is difficult to reflect the abnormality between the structural elastic response and the actual force transmission in a timely manner, while the latter method usually relies on the absolute tensile force exceeding the limit before it takes effect, resulting in a late warning time and difficulty in taking into account the impact of changes in the overall stiffness of the machine under different modular splicing states on the judgment result. Therefore, the crane load safety control methods in related technologies are difficult to take into account the early identification of abnormal working conditions, low-impact intervention, and accurate adaptation to the actual force characteristics of modular structures. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a modular intelligent interlocking control system and method for the load safety of lifting machinery. Specifically, the technical solution of this invention is as follows: A modular intelligent interlocking control method for crane load safety includes: The real-time torque current, real-time tension, and splicing module configuration information of the hoisting mechanism driven by the hoisting motor are obtained. The hoisting mechanism is equipped with a frequency converter and a mechanical brake to control the hoisting motor. The splicing module configuration information includes the inherent stiffness parameters and connection topology of each splicing module. Based on the inherent stiffness parameters and connection topology of each splicing module in the splicing module configuration information, the overall stiffness coefficient of the module system is calculated in series and parallel equivalents. Based on the real-time torque current and the real-time tension, calculate the rate of increase of torque current and the rate of increase of tension, respectively. By combining the overall stiffness coefficient of the module system, the rate of increase of the torque current, and the rate of increase of the tensile force, the transient load torque coupling gradient is calculated. Using the lifting time as the horizontal axis and the transient load torque coupling gradient as the vertical axis, the transient load torque coupling gradient is compared with the preset normal lifting elastic deformation envelope by coordinate mapping. If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, a torque clamping command is generated to limit the motor output torque; if it does not exceed the envelope, the current lifting state is maintained. After generating the torque clamping command, the real-time tension is continuously monitored and the rate of change of tension is calculated within a preset monitoring period; If the real-time tension exceeds the preset absolute tension overload threshold, a dangerous interlock hard cut-off command is generated to trigger the mechanical braking of the hoisting mechanism; If the real-time tension does not exceed the absolute tension overload threshold, the tension change rate is compared with a preset stability judgment threshold: if it is less than the stability judgment threshold, a lifting abnormality alarm command is generated; if it is not less than the threshold, the torque clamping command is maintained and monitoring continues.

[0004] Optionally, the steps of calculating the rate of increase of torque current and the rate of increase of tension based on the real-time torque current and the real-time tension respectively include: Construct a first-in-first-out sliding window of a preset length; The real-time torque current and the real-time tension are collected synchronously and constructed into a time-series data pair; The time-series data pairs are stored in the first-in-first-out sliding window in chronological order. Within each scan cycle, extract the timing data pairs at the beginning and end of the first-in-first-out sliding window; The slope of the change in real-time torque current and real-time tension in the first and last time-series data pairs is calculated using a differential algorithm, and the rate of increase of torque current and the rate of increase of tension are obtained respectively.

[0005] Optionally, the step of calculating the transient load torque coupling gradient by combining the overall stiffness coefficient of the module system, the rate of increase of the torque current, and the rate of increase of the tensile force includes: Calculate the ratio of the rate of increase of the tension to the rate of increase of the torque current to obtain the intermediate transmission efficiency characterization quantity; The intermediate transmission efficiency characterization quantity is multiplied by the module system comprehensive stiffness coefficient to generate the transient load torque coupling gradient. The transient load torque coupling gradient is used to characterize the actual transmission efficiency of the output torque of the hoisting motor into effective pulling force.

[0006] Optionally, if the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, the step of generating a torque clamping command to limit the motor output torque includes: Determine whether the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope within a continuous preset sampling period; If so, it is determined that there is hard resistance in the current lifting state, and the real-time torque current at the current moment is extracted; Obtain a preset torque current limiting ratio, which is a coefficient greater than 1 and close to 1, pre-set according to the hoisting motor nameplate parameters and hoisting safety redundancy. Based on the real-time torque current at the current moment and the preset torque current limit ratio, calculate the target torque current limit upper limit value. The torque clamping command is generated based on the target torque current limit upper limit value, which is used to modify the torque limit upper limit register of the frequency converter controlling the hoisting motor, forcing the hoisting motor to stop accelerating and enter an electrical hovering state; If not, it is determined to be a normal elastic fluctuation, the torque clamping command is not generated, and the current lifting state is maintained.

[0007] Optionally, after generating the torque clamping command, the step of continuously monitoring the real-time tension and calculating the rate of change of tension within a preset monitoring period includes: Extract the real-time tensile force sequence within the preset monitoring period; Calculate the trend characteristics of the real-time tensile force sequence to obtain the tensile force change rate; If the rate of change of tension is less than the stability determination threshold and the real-time tension does not exceed the absolute tension overload threshold, then the lifting abnormality alarm command is generated. If the rate of change of tension is not less than the stability determination threshold and the real-time tension does not exceed the absolute tension overload threshold, then the torque clamping command is maintained and monitoring continues. The real-time tensile force is compared with the absolute tensile force overload threshold. When the real-time tensile force exceeds the absolute tensile force overload threshold, the danger-level interlock hard cut-off command is immediately triggered.

[0008] Optionally, the specific execution steps of the hazard-level interlock hard cutoff command include: A main contactor disconnect signal is generated to control the drive power supply of the hoisting motor, thereby cutting off the drive power supply of the hoisting motor. A mechanical brake closing signal is generated synchronously to close the mechanical brake of the hoisting mechanism and lock the hoisting mechanism.

[0009] Optionally, it also includes: During long-term operation, the transient load torque coupling gradient during historical lifting cycles is continuously collected and stored to construct a historical gradient baseline sequence. Extract the average value of the transient load torque coupling gradient within the current lifting cycle as the current feature value; Calculate the absolute value of the difference between the current feature value and the mean of the historical gradient baseline sequence, as the baseline drift; Determine whether the baseline drift exceeds a preset fatigue warning threshold; If the baseline drift exceeds the fatigue warning threshold, it is determined that the mechanical structure of the hoisting mechanism has undergone fatigue degradation, and an early predictive maintenance prompt is generated. If the baseline drift does not exceed the fatigue warning threshold, the mechanical structure of the lifting mechanism is determined to be in good condition.

[0010] Optionally, it also includes: Real-time monitoring of the slope of the rate of increase of the tensile force; Determine whether the slope of the increase rate of the tensile force is lower than the preset deformation threshold of the extremely flexible load; If the upward slope of the tensile force increase rate is lower than the deformation threshold of the extremely flexible load, then the current hoisting target is determined to be an extremely flexible load, and the transient load torque coupling gradient is determined to have failed. The judgment logic based on transient load torque coupling gradient is disabled, and the system automatically degrades to a backup protection mode based on an absolute weight threshold. If the slope of the increase rate of the tensile force is not lower than the deformation threshold of the extremely flexible load, then the determination logic based on the transient load torque coupling gradient is maintained.

[0011] A modular intelligent interlocking control system for crane machinery load safety includes: The data acquisition module is used to acquire real-time torque current, real-time tension, and splicing module configuration information of the hoisting mechanism driven by the hoisting motor; wherein, the hoisting mechanism is equipped with a frequency converter and a mechanical brake to control the hoisting motor; The core processing module is used to calculate the overall stiffness coefficient of the module system in series and parallel equivalent manner based on the inherent stiffness parameters and connection topology of each splicing module in the splicing module configuration information; calculate the torque current rise rate and the tension rise rate based on the real-time torque current and the real-time tension respectively; and calculate the transient load torque coupling gradient by combining the overall stiffness coefficient of the module system, the torque current rise rate and the tension rise rate. The interlocking determination module is used to compare the transient load torque coupling gradient with a preset normal lifting elastic deformation envelope using the lifting time as the horizontal axis and the transient load torque coupling gradient as the vertical axis. If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, a torque clamping command is generated to limit the motor output torque; if it does not exceed the threshold, the current lifting state is maintained. The closed-loop feedback module is used to continuously monitor the real-time tension and calculate the tension change rate within a preset monitoring period after generating the torque clamping command; if the real-time tension exceeds a preset absolute tension overload threshold, a hazard-level interlock hard cut-off command is generated to trigger the mechanical braking of the hoisting mechanism; if the real-time tension does not exceed the absolute tension overload threshold, the tension change rate is compared with a preset stability judgment threshold: if it is less than the stability judgment threshold, a hoisting abnormality alarm command is generated; if it is not less than the threshold, the torque clamping command is maintained and monitoring continues.

[0012] Compared with existing technologies, this invention obtains the configuration information of the splicing modules and calculates the comprehensive stiffness coefficient of the module system in series and parallel equivalent calculations. It combines this coefficient with the real-time torque current rise rate and tensile force rise rate to calculate the transient load torque coupling gradient, which characterizes the actual transmission efficiency. This mechanism can accurately adapt to the impact of changes in the overall machine stiffness under different module splicing states on the judgment results. By comparing the coordinate mapping with the normal lifting elastic deformation envelope, abnormal resistance conditions can be identified in advance at the beginning of lifting, effectively solving the problem of the traditional absolute weight threshold protection acting too late. When the transient load torque coupling gradient exceeds the envelope, this invention prioritizes generating a torque clamping command. By modifying the torque limit register of the frequency converter, the hoisting motor enters an electrical hovering state, achieving priority low-impact soft intervention and avoiding structural impact caused by direct emergency braking. By monitoring the tension change rate and absolute tension overload threshold within a preset monitoring period through closed-loop monitoring, it intelligently determines whether to generate a hoisting abnormality alarm command or simultaneously generate a main contactor disconnect signal and a mechanical brake closing signal to trigger a dangerous level interlocking hard cut-off when the tension exceeds the limit, ensuring deterministic rigid blocking under extreme dangerous conditions. In calculating the ascent rate, this invention constructs a first-in-first-out sliding window of a preset length to store synchronously acquired time-series data pairs. Within the scanning cycle, the time-series data pairs at the beginning and end of the window are extracted, and the slope of change is calculated using a differential algorithm. This data organization and processing mechanism effectively filters out the accidental jitter errors and noise interference from single-point sampling during hoisting operations, and truly and stably preserves the dynamic evolution process between the motor's applied force and the force on the hoisting point in the initial stage of hoisting, providing highly reliable data support for the accurate calculation of the subsequent coupled gradient. Attached Figure Description

[0013] Figure 1 This is a flowchart of the method of the present invention; Figure 2 This is a structural diagram of the system of the present invention. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0015] Example 1: Please see Figure 1 A modular intelligent interlocking control method for load safety of lifting machinery includes: acquiring real-time torque current, real-time tension and splicing module configuration information of the lifting mechanism driven by the lifting motor, wherein the lifting mechanism is equipped with a frequency converter and a mechanical brake to control the lifting motor, and the splicing module configuration information includes the inherent stiffness parameters and connection topology of each splicing module. Based on the inherent stiffness parameters and connection topology of each splicing module in the splicing module configuration information, the overall stiffness coefficient of the module system is calculated in series and parallel equivalents. Based on real-time torque current and real-time tension, the rate of increase of torque current and the rate of increase of tension are calculated respectively. By combining the overall stiffness coefficient of the modular system, the rate of increase of torque current and the rate of increase of tensile force, the transient load torque coupling gradient is calculated. Using the lifting time as the horizontal axis and the transient load torque coupling gradient as the vertical axis, the transient load torque coupling gradient is compared with the preset normal lifting elastic deformation envelope by coordinate mapping. If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, a torque clamping command is generated to limit the motor output torque; if it does not exceed the envelope, the current lifting state is maintained. After generating the torque clamping command, the real-time tension is continuously monitored and the rate of change of tension is calculated within the preset monitoring period; If the real-time tension exceeds the preset absolute tension overload threshold, a dangerous interlock hard cut-off command is generated to trigger the mechanical braking of the hoisting mechanism; If the real-time tension does not exceed the absolute tension overload threshold, the tension change rate is compared with the preset stability judgment threshold: if it is less than the stability judgment threshold, a lifting abnormality alarm command is generated; if it is not less than the threshold, the torque clamping command is maintained and monitoring continues.

[0016] This embodiment provides a load safety intelligent interlocking control mechanism based on modular lifting machinery. Specifically, the solution is deployed on a double-girder bridge crane with a rated lifting capacity of 32 tons. The main beam of the crane is formed by splicing four standard modules. The application scenario is the hoisting of the reactor base during the equipment installation phase in a petrochemical plant. This embodiment uses this application scenario as an example to illustrate the entire process: the same crane continuously operates during the initial hoisting, abnormal intervention, subsequent maintenance, and special flexible load operations, thereby fully verifying the system reliability and the integrity of the control logic of this solution. The details are as follows: The hoisting mechanism consists of a hoisting motor, a drum, a wire rope assembly, a fixed pulley axle pin sensor, and in this embodiment, a mechanical brake that uses a mechanical brake, and a frequency converter that controls the hoisting motor, to unify terminology and clarify physical correspondence; The controller collects three types of information: first, the real-time torque current that can be directly read from inside the frequency converter; second, the real-time tension output by the axle pin sensor and converted from analog to digital; and third, modular splicing configuration information. The splicing configuration information not only reflects how many standard sections the main beam is composed of, but also reflects the connection position, connection method and corresponding stiffness database entries of each section. Since the modular main beam is not an ideal rigid body, different splicing numbers, flange connection status and span arrangement will change the overall elastic response after being subjected to force. Therefore, the controller first performs engineering series and parallel equivalents on the inherent stiffness parameters of each module based on the connection topology to obtain the comprehensive stiffness coefficient of the module system that matches the current overall structural state. The specific rules for series-parallel equivalent calculation are as follows: when the modular system is spliced ​​end-to-end along the span of the main beam, a series equivalent stiffness model is used, and the reciprocal of the comprehensive stiffness coefficient is equal to the sum of the reciprocals of the inherent stiffness parameters of each spliced ​​module; when the modular system has vertical stacking or parallel connection of stiffeners, a parallel equivalent stiffness model is used, and the comprehensive stiffness coefficient is equal to the sum of the inherent stiffness parameters of each module participating in the parallel connection; furthermore, the calculation process also includes a final correction based on the flange connection status included in the connection topology, multiplied by the corresponding preload stiffness loss coefficient. The significance of this coefficient lies not merely in providing a mathematical constant, but in transforming the overall bending stiffness of the crane's main beam and its elastic potential energy storage characteristics during the initial stage of tensile lifting into a usable structural characteristic quantity. The controller synchronously monitors the changing trends on both the motor side and the load side. During the initial lifting stage, if the load has not yet left the ground, the motor output shows a continuous increase in torque current, while the wire rope and main beam are gradually stretched and deflected. The sensor detects that the tension is established at a slope lower than the first preset rate. For normal lifting, there is a relatively stable mapping relationship between the increase in torque and the establishment of tension. However, when the load is still bound by anchor bolts, tooling clamps, or ground adhesion, the system will exhibit a nonlinear deviation between the load response and the drive output: the motor continues to output an increasing driving force, but the tension establishment speed and the elastic response of the main beam deviate from the normal lifting trajectory. To this end, the controller uses real-time torque current and real-time tension to form the rate of rise, and combines the module system comprehensive stiffness coefficient to calculate the transient load torque coupling gradient. This gradient is used to characterize the efficiency of the motor's current increased output in converting into effective lifting tension. At the judgment level, with the lifting time as the horizontal axis, this gradient is mapped and compared with the pre-established normal lifting elastic deformation envelope. The so-called envelope is a safe elastic boundary formed by measured lifting data of the same type of crane under different conventional loads and different modular splicing states. It reflects the allowable dynamic fluctuation range between the main beam deflection, wire rope elongation, and tension build-up speed under normal working conditions. If the current gradient falls within this boundary, it means that although there is acceleration and elastic deformation in the lifting process, it is still in an acceptable state, and the controller maintains the current lifting state. If the gradient exceeds this boundary, it means that the system has detected abnormal force transmission that exceeds the normal elastic release law. The controller generates a torque clamping command to limit the lifting motor from continuing to increase the output torque, so that the lifting action changes from continuous acceleration to electric hovering. This approach prioritizes eliminating safety hazards through flexible electrical intervention to avoid the impact of directly triggering emergency braking. After implementing soft intervention, the system does not immediately end the judgment but enters a preset monitoring cycle to continue observing the real-time tension. If the tension gradually stabilizes after soft intervention, it indicates that the abnormal source is mainly transient stagnation or local adhesion, and the mechanical system has not continued to deteriorate. At this time, a lifting abnormality alarm is issued and manual handling is awaited. If the tension continues to rise, it means that even if the motor is restricted, dangerous stress is still accumulating within the structure, which may pose risks such as inertial tension, forced detachment of the suspended object, or continuous impact on the wire rope. At this time, torque clamping should be maintained and monitoring should continue. If the real-time tension exceeds the absolute tension overload threshold at this stage, it means that the risk has escalated from being flexibly mitigated to requiring hard blocking. The controller will immediately generate a dangerous level interlock hard cut-off command, triggering the mechanical braking action of the hoisting mechanism. In fault-tolerant processing, if the module splicing information reading fails, the controller can call the most recently manually confirmed configuration file as a temporary parameter and mark the system status as structural parameters to be verified; if the torque current or tension signal is lost, the pre-judgment based on the coupling gradient is paused and the system directly enters the foundation absolute tension protection mode to avoid false release due to incomplete input; if the hoisting time axis mapping has not yet established enough data points, for example, the hoisting command has just been issued and the sampling has not yet covered the minimum judgment window, the abnormal conclusion will not be output for the time being, and only normal operation will be maintained and data collection will continue. During the hoisting of the reactor base in a petrochemical plant, after the operator issues the hoisting command, the motor begins to increase torque, and the four-section spliced ​​main beam enters the initial stress stage. If any anchor bolts on the base are still not removed, the system will detect that the motor output continues to increase, and the tension building process exhibits an abnormal deviation relative to the current structural stiffness of the crane. Based on this, the controller will issue a torque clamp before the load leaves the ground and before the absolute weight reaches the preset absolute tension overload threshold, keeping the hook in a near-ground position. If the tension stabilizes within 200 milliseconds, an alarm command containing hoisting abnormality and anchor connection inspection information will be issued. If the tension continues to increase rapidly and exceeds the absolute tension overload threshold, the drive will be cut off and the mechanical brake will be locked. The purpose of this step is to no longer rely solely on the single trigger condition of exceeding the absolute weight limit, but to identify dangerous working conditions in advance by establishing physical consistency among structural stiffness, motor output and tension in the early stage of lifting, thereby achieving earlier, lower impact and more accurate safety interlock control that conforms to the real elastic behavior of modular cranes. The steps for calculating the rate of increase of torque current and the rate of increase of tension based on real-time torque current and real-time tension include: Construct a first-in-first-out sliding window of a preset length; The real-time torque current and real-time tension collected synchronously are constructed into a time-series data pair; Store time-series data pairs into a first-in-first-out sliding window in chronological order; Within each scan cycle, extract the timing data pairs at the beginning and end of the first-in-first-out sliding window; The slope of the real-time torque current and real-time tension in the first and last time series data pairs is calculated using the differential algorithm, and the rate of increase of torque current and the rate of increase of tension are obtained respectively.

[0017] This embodiment provides a data organization mechanism for obtaining the torque current rise rate and the tension rise rate. Specifically, when the same bridge crane performs the task of lifting the reactor base, reading only the single-point current value and single-point tension value at a certain moment is easily affected by electromagnetic noise, slight vibration of the wire rope and sensor quantization error. Therefore, it is necessary to introduce a timing window processing method that takes into account both real-time performance and anti-interference. The details are as follows: The controller internally constructs a first-in-first-out sliding window of a preset length to store synchronously acquired time-series data pairs; here, synchronization does not require the two sensors to output absolutely simultaneously, but rather requires that the time alignment of the motor side and the load side be completed within the same scan cycle, so that each set of data corresponds to the same stress stage; the window length can be set according to the on-site scan cycle and the response speed of the hoisting system. For example, with a 10-millisecond sampling cycle, a window with a length of 5 can be selected, so that the controller observes the short-term trend within the most recent 50 milliseconds, rather than relying on instantaneous jumps; To further illustrate the processing logic of time-series data, the following logical deduction is provided as an example: Assume that the five data pairs that enter the window consecutively are denoted as P1 to P5, where P1 corresponds to an earlier time and P5 corresponds to the current time; each data pair contains a torque current value and a tension value; the controller does not perform high-order curve fitting on the five data pairs point by point in the current scan cycle, but extracts the first and last two pairs, namely P1 and P5, and observes that the current and tension in this time window generally show an increasing, constant, or decreasing trend; To implement the differential algorithm, the controller calculates the real-time tension difference between time P5 and time P1, and divides it by the time interval between P1 and P5 to obtain the tension rise rate. Similarly, it calculates the real-time torque current difference and divides it by the time interval to obtain the torque current rise rate. If the current continues to rise from P1 to P5, it can be determined that the hoisting motor is continuing to build up output. If the tension also shows a monotonically increasing trend at the same time, it indicates that the force chain between the wire rope and the suspended object is strengthening. The rise rate obtained by using this end-to-end differential method essentially reflects the rate at which the motor applies force and the rate at which the lifting point experiences force in the most recent short period of time. This preserves the dynamic information at the beginning of the hoisting process and reduces the misjudgment caused by occasional jitter of a single sampling point. The reason for using a first-in-first-out window is that risk assessment in lifting operations emphasizes prioritizing the most recent state; once the window is full, newly collected data enters and the oldest data is automatically removed, and the controller always makes judgments based on the most recent force evolution process; this is especially important for hazard identification within tens of milliseconds before liftoff, because lifting anomalies are often not defined by a single instantaneous peak, but by the trends shown by multiple consecutive sampling cycles. In fault-tolerant processing, if the current value is valid but the tension value is missing in a certain sampling period, the data will not enter the formal window, but will be temporarily stored as an incomplete sample and the controller will wait for the next period to complete it; if incomplete samples appear in multiple consecutive periods, the system will judge the window as distorted, suspend the output of the rise rate, and switch to relying only on the basic overload threshold protection; if the window length is not yet full, for example, when the hoisting just starts and there are only 2 or 3 sets of data, the window can be shortened for temporary estimation, but at the same time the judgment level of the anomaly will be reduced to avoid premature triggering of the strong interlock; During the same hoisting task, when the operator first starts lifting, the controller generates a new set of current and tension timing data pairs every 10 milliseconds and writes them into the window in the order of P1, P2, P3, P4, P5. If the current steadily increases from P1 to P5, while the tension only shows slight fluctuations, the system will determine that it is still in the stage of wire rope tensioning and main beam elastic pre-tensioning. If the newly entered P6 replaces P1 and the tension building trend reflected in the window suddenly shows a sharp increase in slope, it indicates that the force chain has changed, providing a more reliable dynamic basis for subsequent coupling gradient determination. The purpose of this step is to replace isolated sampling point judgments with time-series observations of a limited length, thereby achieving stable extraction of the real dynamic process in the early stage of lifting, so that subsequent interlocking judgments are not overly sensitive to noise or falsely triggered, nor lose lead due to excessive smoothing. The steps for calculating the transient load torque coupling gradient by combining the overall stiffness coefficient of the modular system, the rate of increase of torque current, and the rate of increase of tensile force include: Calculate the ratio of the rate of increase of tension to the rate of increase of torque current to obtain the intermediate transmission efficiency characterization quantity; The intermediate transmission efficiency characterization quantity is multiplied by the module system comprehensive stiffness coefficient to generate the transient load torque coupling gradient. Among them, the transient load torque coupling gradient is used to characterize the actual transmission efficiency of the hoisting motor's output torque into effective pulling force.

[0018] This embodiment provides a mechanism for constructing transient load torque coupling gradient. Specifically, although the previous scheme has obtained the changing trends of the motor side and the load side, if these two trends are not linked to the overall elasticity level of the modular structure, it is still difficult to distinguish between normal heavy-load lifting and abnormal sluggish lifting based solely on the current rise rate or the tension rise rate. Therefore, this embodiment further introduces a joint characterization quantity that reflects the true force transmission efficiency. The following is a detailed explanation: The relationship between the rate of increase in tension and the rate of increase in torque current can directly reflect whether the new output of the hoisting motor has been effectively transmitted to the lifting point. If the rate of increase in current is greater than the preset first threshold, while the rate of increase in tension is lower than the preset second threshold, this is commonly seen in the initial stage of wire rope tensioning, the elimination of gaps in flexible connectors, and the slow elastic deformation of the suspended object itself. If, under the current structural stiffness conditions, the rate of increase in tension relative to the rate of increase in current exceeds the allowable range of the normal mapping model, it often means that there is abnormal impedance in the load path, such as the suspended object not being completely freed from ground constraints, the attachment components being stuck, or the guide surface being mechanically jammed. To avoid misinterpretation of the same trend under different splicing structures, the controller combines the above intermediate transmission efficiency characterization quantity with the module system comprehensive stiffness coefficient to obtain the transient load torque coupling gradient. After this structural correction, the same current and tensile force change relationship can obtain a comparable judgment basis in 3-section main beam, 4-section main beam or different connection states. Suppose there are two operations with similar upward trends on the motor side, but one occurs in a splicing state with a smaller span and higher stiffness, while the other occurs in a state with a larger span and more splicing sections. For the former, lower structural elasticity means a relatively smaller delay in the tension build-up response; for the latter, higher structural elasticity absorption will reduce the tension build-up response gradient. Without introducing a comprehensive stiffness coefficient, these two operations may be misjudged as the same stress state. After introducing it, the controller will parametrically compensate for the difference in structural stiffness, so that the coupling gradient accurately represents the physical mapping relationship of the torque increment on the crane in the current structural state into the effective tension. Furthermore, the coupling gradient is used to characterize the actual efficiency of torque to tensile force transmission, rather than to describe the absolute load size. Its technical effect is that most dangerous working conditions occur when the actual weight is not close to the rated value, such as partial adhesion of the suspended object, incomplete release of the footing, or local adhesion between the heavy object and the ground. At this time, the traditional weight threshold protection has not yet been activated, while the coupling gradient can already show abnormal force path. As a fault-tolerance mechanism, if the rate of increase of torque current is close to zero within a short time window, it indicates that the change in motor output is not significant. In this case, it is not advisable to calculate the transmission efficiency, otherwise it will amplify the measurement error within a reasonable range. In this case, the controller can mark the current cycle as a low excitation state, retain only the original trend observation, and not output the effective coupling gradient. If the module system comprehensive stiffness coefficient call fails, the judgment process after structural correction is prohibited, and the operator is prompted to verify the module configuration. During the initial trial lifting of the reactor base, the crane used four standard main beam sections. The controller detected that the motor output was steadily increasing within the last 50 milliseconds, and the rate of tension build-up was significantly higher than the normal stress pattern of the four-section spliced ​​structure. Based on this, the system formed a coupling gradient that exceeded the normal envelope, indicating that the newly added motor torque was not mainly used for smooth lifting as in normal lifting, but was converted into dangerous tension accumulation more quickly under abnormal constraint conditions. The purpose of this step is to unify the motor response, the force on the suspension point, and the elasticity of the modular structure into the same evaluation coordinate, so as to achieve an engineering characterization of the actual force transmission efficiency and provide a criterion for early identification of hard resistance. If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, the steps for generating a torque clamping command to limit the motor output torque include: Determine whether the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope within a continuous preset sampling period; If so, it is determined that there is hard resistance in the current lifting state, and the real-time torque current at the current moment is extracted; Obtain the preset torque current limiting ratio. The preset torque current limiting ratio is a coefficient greater than 1 and close to 1, which is preset based on the hoisting motor nameplate parameters and hoisting safety redundancy. Calculate the target torque current limit upper limit value based on the real-time torque current at the current moment and the preset torque current limit ratio. Based on the target torque current limit upper limit value, a torque clamping command is generated to modify the torque limit upper limit register of the frequency converter controlling the hoisting motor, forcing the hoisting motor to stop accelerating and enter an electrical hovering state; If not, it is determined to be a normal elastic fluctuation, no torque clamping command is generated, and the current lifting state is maintained.

[0019] This embodiment provides a torque clamping triggering mechanism. Specifically, the aforementioned scheme can detect the coupling gradient deviating from the normal envelope. However, in actual lifting operations, main beam micro-vibration, wire rope self-swing, and slight impact of the lifting device may cause single-cycle overruns. If clamping is performed immediately once the overrun occurs, although it is sensitive enough, it may misjudge normal elastic fluctuations as dangerous working conditions. Therefore, a continuous confirmation step is required. The following is a detailed explanation: The controller does not directly change the motor output upon detecting a single out-of-bounds event. Instead, it first determines whether the coupling gradient exceeds the normal lifting elastic deformation envelope within a continuous preset sampling period. This continuous determination essentially distinguishes between occasional fluctuations and persistent anomalies. Occasional fluctuations are usually short in duration and inconsistent in trend, commonly seen in slight swinging of the hook assembly or transition of the drum tooth backlash. Persistent anomalies are characterized by a force transmission that consistently deviates from the normal pattern across multiple adjacent sampling periods, which is more consistent with the characteristics of hard resistance such as heavy object adhesion, bottom jamming, and tooling not being removed. Once a continuous out-of-range condition is confirmed, the controller extracts the real-time torque current at the current moment and uses it as the current output level established by the motor. Based on this level, a preset limiting ratio is applied to generate the target torque current limiting upper limit value, and this value is written to the torque limiting upper limit register of the frequency converter via the communication bus. The key here is not to immediately de-energize the motor, but to prevent it from continuing to climb to a higher torque, so that the drum stops accelerating further, thereby putting the hook system into an electrical hovering state. Because this action preserves the controlled state of the motor, it avoids the impact of sudden mechanical braking and provides a buffer time for subsequent closed-loop observation. As an example of logical deduction: assuming that three coupled gradient states G1, G2, and G3 are obtained in three consecutive sampling cycles, where G1 goes out of bounds while G2 and G3 return to the envelope, the system judges it as normal elastic fluctuation; if G1, G2, and G3 all go out of bounds, it indicates that the anomaly is persistent, and the controller performs clamping. In this way, the system remains sensitive to real resistance without excessively interfering with normal lifting. In fault-tolerant processing, if continuous out-of-bounds is confirmed but the inverter register write fails, the controller should immediately report the soft intervention channel abnormality and switch to a higher level of monitoring; if the current torque current is already near the upper limit of the equipment's allowable limit, the target limit should not be widened further, but should be based on the equipment's safety boundary; if the hoisting motor is in the deceleration or stopping phase, even if a short-term out-of-bounds occurs, clamping can be temporarily suspended to avoid introducing unnecessary control interference in non-acceleration conditions; During the hoisting of the same reactor base, the anchor bolts were not completely removed. The system monitored for several consecutive cycles that the coupling gradient exceeded the normal elastic envelope corresponding to the four spliced ​​main beams. Based on this, the controller determined that it was a continuous hard resistance, rather than an instantaneous high-frequency micro-vibration after the main beam was subjected to force. Therefore, the inverter torque was limited to near the current actual output, causing the drum to stop continuing to wind up the rope. The operator would observe that the hoisting action was stopped by the electrically smooth limiter, rather than by triggering a high-impact mechanical rigid brake. The purpose of this step is to achieve early, low-impact prevention of dangerous lifting by combining continuous overshoot confirmation with register-level torque limiting, while taking into account both identification sensitivity and structural protection requirements. After generating the torque clamping command, the steps of continuously monitoring the real-time tension and calculating the rate of change of tension within a preset monitoring period include: Extract the real-time tensile force sequence within a preset monitoring period; Calculate the changing trend characteristics of the real-time tensile force sequence to obtain the tensile force change rate; If the rate of change of tension is less than the stability judgment threshold and the real-time tension does not exceed the absolute tension overload threshold, a lifting abnormality alarm command is generated. If the rate of change of tension is not less than the stability judgment threshold and the real-time tension does not exceed the absolute tension overload threshold, then maintain the torque clamping command and continue monitoring; The real-time tensile force is compared with the absolute tensile force overload threshold. When the real-time tensile force exceeds the absolute tensile force overload threshold, the dangerous interlock hard cut-off command is immediately triggered.

[0020] This embodiment provides a closed-loop feedback mechanism after soft intervention; specifically, simply performing torque clamping is not enough to guarantee that the risk has been eliminated, because in some working conditions, although the motor no longer continues to apply torque, the tension may still continue to evolve due to the elastic recovery of the wire rope, changes in the attitude of the load, or the inertial migration of the suspension point; therefore, the subsequent trend of the force must be observed after soft intervention. The details are as follows: After the torque clamping takes effect, the controller extracts the real-time tension sequence within the preset monitoring period; the focus here is not on a single tension peak, but on whether the entire short-time sequence stabilizes, continues to rise, or falls back; the preset stability judgment threshold is specifically set as a critical value range of a small rate of change that characterizes the tension tending to static equilibrium. When the absolute value of the rate of change of tension falls within this critical value range, it is considered that the tension no longer produces unidirectional drastic changes. If the rate of change of tension is lower than the stability judgment threshold, it means that the clamp has cut off the further accumulation of dangerous stress, and the system force is transitioning from drastic change to equilibrium. At this time, the soft intervention can be confirmed as successful, and a lifting abnormality alarm will be issued, requiring manual inspection of whether there is any unresolved connection between the lifted object and the foundation, clamp, or surrounding components. If the rate of change of tension is still not less than the stability judgment threshold, but the absolute tension has not exceeded the limit, it means that there is still significant energy release or inertial migration inside the system, and the clamp cannot be directly released. The controller continues to maintain the current electrical hover and extends the monitoring. This design reflects the physical processes of real mechanical systems: after the crane's output torque is limited, it does not instantly reach a stationary state. The elastic system composed of the wire rope, main beam, and suspended load will regain dynamic mechanical equilibrium within tens to hundreds of milliseconds. Only when the tension change truly slows down can it be said that the force chain has stabilized. Conversely, even if the motor output no longer increases, if the tension continues to rise rapidly, it means that the danger is still spreading. As an example of logical deduction: assuming that six tension sampling points L1 to L6 are continuously extracted after clamping; if L1 to L6 are basically flat or slightly decreased, the controller determines that the abnormality has been suppressed; if L1 to L6 still show a significant upward trend, it is determined that the internal inertia or the forced separation trend of the structure has not ended; if any point directly exceeds the absolute tension overload threshold, there is no need to wait for a complete trend conclusion, and hard cut-off is initiated immediately. As a fault-tolerant mechanism, if there are individual distortion points in the tension sequence within the monitoring period, adjacent valid points can be used to make up the trend, but this should not cover up the overload peak value; if the alarm is not confirmed manually for a long time, the system can maintain the locked state that prohibits further lifting; if the tension drops rapidly to a level significantly lower than the normal force level after clamping, it should also prompt to check for reverse anomalies such as hook unloading, wire rope derailment, or unexpected load slippage. During the hoisting of the same reactor base, after the controller issues torque clamping, it continues to observe the tension sequence within 200 milliseconds. If the base is only partially adhered to the ground, the tension will quickly stabilize and slightly decrease after clamping. The system will then confirm that the soft intervention was successful, issue an audible and visual alarm, and request on-site inspection of the remaining connection points. If the base is continuously pulled due to a set of high-strength bolts not being removed, and the tension continues to rise, the system will maintain electrical hovering and prepare to upgrade to hard cut-off if necessary. The purpose of this step is to combine the initial gentle intervention with the subsequent feedback confirmation, thereby achieving a secondary screening after the interlocking, avoiding premature release after soft intervention, and also avoiding unnecessary escalation to emergency braking when the risk has been controlled. The specific execution steps of the hazardous level interlock hard cutoff command include: Generate a main contactor disconnect signal to control the drive power supply of the hoisting motor, which is used to cut off the drive power supply of the hoisting motor. A mechanical brake closing signal is generated synchronously to close the mechanical brake of the hoisting mechanism and lock the hoisting mechanism.

[0021] This embodiment provides a dangerous level interlocking hard cut-off mechanism; specifically, the aforementioned soft intervention prioritizes structural protection and low-impact shutdown, but if the tension has reached the absolute overload level, it indicates that the dangerous state is approaching the bearing limit of the wire rope, main beam, lifting point connector or the suspended object itself, and at this time, a more certain rigid blocking method must be adopted. The details are as follows: After determining that a hard cut-off is necessary, the controller outputs a main contactor disconnect signal, disconnecting the power supply to the hoisting motor drive; simultaneously, it outputs a mechanical brake closing signal, causing the hoisting mechanism's mechanical brake to enter a locked state. The significance of this coordinated action is that a simple power cut-off may not guarantee that the drum will be locked immediately, while a simple mechanical brake operation may introduce a counter-impact while the motor is still powered. Therefore, it is necessary to simultaneously complete the actions of de-driving and locking the mechanism. Through this dual-channel interlocking of electrical and mechanical components, energy input can be quickly cut off and the load can be prevented from continuing to move in extremely dangerous situations. In this embodiment, the mechanical brake is preferably a spring brake, an energized release type brake; during normal operation, the control circuit keeps it released, and once a hard cut-off is triggered, the release circuit is canceled, and the brake closes under the action of the mechanical spring; this method conforms to the power failure braking principle commonly used in the field of lifting safety, and even if the external power supply is abnormal, the braking action can still be reliably realized after the interruption; from an engineering mechanism perspective, hard cut-off is not a daily priority, but a barrier when soft intervention is insufficient to prevent the continuous accumulation of dangerous tension. For example, when the main beam is under severe local tension, the heavy object is about to be forcibly detached from the fixed point, or the wire rope has entered a high-risk stress zone, continuing to maintain electrical hovering may delay the timing of emergency response. In this case, the system must be switched from controlled hovering to rigid locking. As a fault-tolerant mechanism, if the main contactor feedback indicates that it has not actually disconnected, the controller should repeatedly issue a disconnect command and report a fault code. If the mechanical brake closure feedback is abnormal, the system should maintain the contactor in the open state and prohibit any reset action until manual maintenance is completed. If the hoisting position is a special process area where instantaneous locking is not allowed, a graded braking strategy can be set under the premise of meeting relevant specifications and mechanical safety, but the forced blocking after absolute overload triggering must not be canceled. If the abnormal lifting of the reactor base is not suppressed by soft intervention, the tension continues to rise and exceeds the absolute tension overload threshold; the controller immediately disconnects the main lifting contactor and simultaneously closes the mechanical brake, causing the drum to stop winding the rope and lock the current position; on-site maintenance personnel check the anchor bolts that have not been removed and the base jamming points; The purpose of this step is to achieve deterministic extreme risk mitigation by interlocking power failure and braking simultaneously when the danger exceeds the capacity for flexible control, thereby ensuring the basic safety of the hoisting mechanism, slings, personnel, and environment. During long-term operation, the transient load torque coupling gradient during historical lifting cycles is continuously collected and stored to construct a historical gradient baseline sequence. Extract the average value of the transient load torque coupling gradient within the current lifting cycle as the current feature value; Calculate the absolute value of the difference between the current feature value and the mean of the historical gradient baseline sequence, and use it as the baseline drift. Determine whether the baseline drift exceeds the preset fatigue warning threshold; If the baseline drift exceeds the fatigue warning threshold, it is determined that the mechanical structure of the hoisting mechanism has undergone fatigue degradation, and an early predictive maintenance prompt is generated. If the baseline drift does not exceed the fatigue warning threshold, the mechanical structure of the hoisting mechanism is determined to be in good condition.

[0022] This embodiment provides a predictive maintenance mechanism based on a long-term coupled gradient baseline. Specifically, the aforementioned scheme mainly serves the immediate interlocking during a single lifting process. However, during long-term operation, the structural state of the same modular crane will slowly change, such as the accumulation of broken wires inside the wire rope, wear of the drum rope groove, attenuation of flange bolt preload, and local fatigue of the main beam connection nodes. If each lifting is still considered to be independent, important information reflecting the fatigue and performance degradation of the equipment's mechanical structure will be lost. Therefore, this embodiment further extends the maintenance early warning function on the basis of the original interlocking logic. The details are as follows: During long-term operation, the controller continuously collects the transient load torque coupling gradient within each lifting cycle and archives it according to equipment number, module configuration status, typical load range and environmental conditions to form a historical gradient baseline sequence; after each new lifting cycle is completed, the average feature of the coupling gradient within that cycle is extracted and compared with the historical baseline mean to obtain the baseline drift. It is particularly important to note that once the heavy object is completely off the ground and enters the constant-speed lifting phase, the rate of increase in tension enters a stable state approaching zero, causing the dynamic coupling gradient at this time to lose its representational significance for the structural response. If a large amount of invalid zero-value data from this constant-speed phase is mixed into the average calculation of the entire cycle, it will inevitably lead to an abnormal downward shift in the average calculation result for tasks where the single lifting stroke is greater than the reference stroke, thus causing pseudo-baseline drift and fatigue misjudgment. Therefore, the aforementioned extraction of the average value of the transient load torque coupling gradient within the current lifting cycle is explicitly limited in engineering implementation to: extracting only the average value of the transient load torque coupling gradient within the effective force-building stage time window from the start of the hoisting motor until the tension first reaches a steady state, i.e., when the load has just completed elastic tensioning and completely escaped the ground surface constraint, in order to eliminate the interference of differences in different working strokes on the health baseline assessment; this drift does not reflect whether there is an overload at a particular time, but rather whether the overall way in which torque is converted into effective tension has changed slowly during normal daily lifting of this equipment; Its physical meaning is that once a mechanical structure experiences fatigue degradation, the elastic distribution and energy transfer path of the system will slowly change; for example, after a wire breaks inside a steel wire rope, the local equivalent stiffness decreases, and the way it absorbs the motor output in the early stage of lifting is different from that of a new rope; in addition, after the splicing flange of the main beam loosens, there will be an additional slight relative displacement at the connection interface, which will reduce the structural response stiffness in the early stage of stress; these changes may not immediately trigger a one-time interlock, but will be manifested as a continuous shift of the coupling gradient baseline in long-term statistics. Assuming the same crane forms a baseline sequence B1 to B100 in the most recent 100 normal lifting cycles, the current completed cycle yields the current characteristic value C. If C is close to the historical average, it indicates that the structural force transmission characteristics have not changed significantly. If C repeatedly deviates from the historical average and exceeds the fatigue warning threshold, it indicates that the equipment's health status is changing and a maintenance plan should be initiated. Here, the focus is on whether the drift is stable, rather than pursuing instantaneous fluctuations in a single operation. As a fault-tolerance mechanism, if the current cycle belongs to an obviously abnormal working condition, such as having triggered torque clamping or hard shearing, the data of this cycle should not be directly incorporated into the healthy baseline, but should be archived separately as a fault sample; if the modular splicing status changes, such as changing from 4 sections to 5 sections of main beam, it should be switched to the baseline library of the corresponding structural category to prevent data from different stiffness systems from contaminating each other; if the historical sample size is insufficient, only a trend establishment prompt will be output, without directly giving fatigue conclusions. In the months following the completion of the aforementioned reactor base hoisting task, the crane continued to handle multiple batches of equipment hoisting within the plant area. The system detected that, under the same four-section splicing configuration and similar load range, the average characteristics of the coupling gradient had been continuously deviating from the existing healthy baseline over a recent period. On-site inspection revealed that the preload of the high-strength bolts on one side of the main beam splicing flange had decreased, and the hoisting wire rope exhibited early internal wear. The system generated a predictive maintenance prompt, recommending that the wire rope be replaced and the connecting parts be retightened during the planned shutdown window. The purpose of this mechanism is to further transform the dynamic coupling information, which was originally only used for immediate safety assessment, into a basis for equipment life management, thereby enabling early detection of mechanical fatigue degradation and reducing the risk of sudden downtime and catastrophic failure. Also includes: Real-time monitoring of the slope of the rate of increase in tensile force; Determine whether the slope of the increase rate of tensile force is lower than the preset deformation threshold of the extremely flexible load; If the rate of increase of the tension is lower than the deformation threshold of the extremely flexible load, the current hoisting target is determined to be an extremely flexible load, and the transient load torque coupling gradient failure is determined. The judgment logic based on transient load torque coupling gradient is shielded, and it automatically degrades to the backup protection mode based on absolute weight threshold. If the slope of the rate of increase of the tensile force is not lower than the deformation threshold of the extremely flexible load, the judgment logic based on the transient load torque coupling gradient is maintained.

[0023] This embodiment provides a degradation protection mechanism for extremely flexible loads. Specifically, the aforementioned coupling gradient determination is based on an important engineering premise: that after the motor output increases, the tension at the lifting point will be established according to the structural elastic law in a short time. However, this premise does not hold true for some special lifting objects, such as large rubber bags that are not filled with media, ultra-long flexible composite material components, and soft packaging equipment that can deform greatly in some areas. If the coupling gradient determination is still not applicable, the flexible deformation energy absorption may be mistakenly regarded as safe and without abnormality or abnormally delayed. Therefore, it is necessary to set up applicable boundary identification and backup mode switching. The details are as follows: The controller monitors the rise rate of the tension in real time, that is, observes whether the tension has entered the normal stress state. For rigid or conventional semi-rigid loads, as the drum winds up the rope and the wire rope tensions, the tension rise rate will rise quickly and enter the stable force-building zone. However, for extremely flexible loads, a large amount of mechanical energy in the initial stage of motor output will be consumed in the deformation of the load itself, resulting in a significant delay in tension building. The rise rate shows a gradual characteristic of being lower than the preset rate of change. If the controller detects that this characteristic is lower than the preset deformation threshold of extremely flexible loads, it can determine that the current object is not suitable for early risk assessment using coupled gradients. The specific method for obtaining the preset deformation threshold of the extremely flexible load is as follows: based on the trial lifting test of a known typical extremely flexible load or by retrieving its historical trial lifting data, extract the maximum distribution of the natural lifting slope of the tensile force rise rate in the effective force building stage at the beginning of the lifting, and after adding the set safety attenuation tolerance, calibrate it as the lower limit boundary value. It is important to emphasize that the monitoring and judgment mechanism for the rise rate of the aforementioned tension is subject to strict timing constraints of the state machine in the system: its judgment window is only activated during the initial force-building phase after receiving the lifting command and confirming the action; once the lifting process enters the steady-state phase of uniform lifting after the load is completely suspended, even a typical rigid load will naturally have its rise rate return to zero and fall below the deformation threshold because the tension no longer changes drastically; if this pre-condition is not added, the system will misjudge all normal steady-state lifting conditions as extremely flexible loads and incorrectly trigger degradation; Therefore, when the controller detects that the real-time tension no longer increases or exceeds the basic hovering weight and enters a steady state, it actively locks the current load category label and stops executing the degradation judgment action based on slope comparison. Once it is determined to be an extremely flexible load, the system shields the judgment logic based on coupling gradient and automatically degrades to the backup protection mode based on absolute weight threshold. At this time, the safety strategy reverts to traditional overload protection, but this does not mean that the scheme has failed. Instead, it actively adapts to the physical boundary conditions to avoid outputting incorrect conclusions under incorrect premises. When subsequent operations switch back to conventional rigid components, the system can restore the coupling gradient logic. Assuming continuous observation yields three tensile force rise rates, R1, R2, and R3; if R1 to R3 shows only a rise below the deformation threshold of the extremely flexible load and is far lower than the force-building rate of similar rigid loads, it can be inferred that the load itself is deforming rather than the effective force at the lifting point being rapidly established; conversely, if R1 to R3 rises according to the normal pattern, the coupling gradient determination is maintained; as a fault-tolerant mechanism, if the system fails to determine whether the load belongs to the extremely flexible object, dual-channel observation can be maintained first, that is, the coupling gradient is not completely shielded, but its decision weight is reduced and the absolute weight threshold protection is retained simultaneously; if the on-site operator has pre-marked the flexible component hoisting in the work order, the system can also pre-load the backup protection mode before hoisting; after degradation, the current working condition category should be recorded to avoid the subsequent baseline maintenance data from being mixed with inapplicable samples; In a subsequent project after the reactor base installation was completed, the same crane was temporarily used to lift a section of ultra-long flexible fiberglass component. In the early stages of lifting, the controller detected that the motor output had reached the preset load threshold, but the rate of increase in tension was extremely slow, which is consistent with the characteristics of an extremely flexible load absorbing a large amount of initial energy. Based on this, the system shielded the coupling gradient interlock and instead relied solely on the absolute weight threshold and foundation limit protection for operation monitoring. The coupling gradient logic was reactivated when the rigid equipment foundation was lifted again. The purpose of this mechanism is to clarify the applicable boundaries of this scheme and provide an executable degradation path, thereby achieving backup safety protection for special flexible load conditions and avoiding the incorrect application of criteria that should be established for rigid or quasi-rigid lifting scenarios to inapplicable objects. Example 2: Please see Figure 2 A modular intelligent interlocking control system for crane machinery load safety includes: The data acquisition module is used to acquire the real-time torque current, real-time tension, and splicing module configuration information of the hoisting mechanism driven by the hoisting motor; the hoisting mechanism is equipped with a frequency converter and a mechanical brake to control the hoisting motor. The core processing module is used to calculate the comprehensive stiffness coefficient of the module system in series and parallel equivalents based on the inherent stiffness parameters and connection topology of each splicing module in the splicing module configuration information; calculate the torque current rise rate and the tension rise rate based on real-time torque current and real-time tension respectively; and calculate the transient load torque coupling gradient by combining the comprehensive stiffness coefficient of the module system, the torque current rise rate and the tension rise rate. The interlocking determination module is used to compare the transient load torque coupling gradient with the preset normal lifting elastic deformation envelope using the lifting time as the horizontal axis and the transient load torque coupling gradient as the vertical axis. If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, a torque clamping command is generated to limit the motor output torque; if it does not exceed the limit, the current lifting state is maintained. The closed-loop feedback module is used to continuously monitor the real-time tension and calculate the rate of change of tension within a preset monitoring period after generating the torque clamping command. If the real-time tension exceeds the preset absolute tension overload threshold, a dangerous interlock hard cut-off command is generated to trigger the mechanical braking of the hoisting mechanism. If the real-time tension does not exceed the absolute tension overload threshold, the rate of change of tension is compared with the preset stability judgment threshold. If it is less than the stability judgment threshold, a hoisting abnormality alarm command is generated. If it is not less than the threshold, the torque clamping command is maintained and monitoring continues.

[0024] This embodiment provides a load safety intelligent interlocking control system based on modular lifting machinery for implementing the aforementioned method; specifically, the system can be integrated into the electrical control cabinet of the aforementioned 32-ton double girder bridge crane, and is composed of an industrial controller, a frequency conversion drive interface, a sensor acquisition unit, a module configuration identification unit, a human-machine interaction terminal, and a safety execution loop, and completes the entire link control from lifting identification to abnormal handling and maintenance prompts in the same reactor base hoisting project; The details are as follows: In terms of architectural mapping, the frequency conversion drive interface, sensor acquisition unit, module configuration identification unit, human-machine interaction terminal and safety execution loop together constitute the hardware foundation; while the data acquisition module, core processing module, interlocking judgment module and closed-loop feedback module in the embodiment are all deployed as software logic modules within the industrial controller and call the corresponding underlying hardware interface during execution. Specifically, the data acquisition module is used to connect to the frequency converter controlling the hoisting motor through the frequency conversion drive interface, to the axle pin tension sensor through the sensor acquisition unit, and to the module configuration identification device; preferably, the frequency converter side reads the torque current register through the industrial bus, the tension side acquires the axle pin voltage signal through the high-frequency analog-to-digital input module and converts it into real-time tension, and the module configuration side can confirm the current main beam splicing quantity and connection topology through RFID tags, DIP switches, maintenance work order entry or equipment database mapping. The core processing module internally stores a structural stiffness database, sliding window processing logic, and coupled gradient calculation logic to map the acquired raw industrial signals into structured force characteristics that can be used for judgment. The interlocking judgment module is responsible for comparing the lifting time with the normal lifting elastic deformation envelope and generating a torque clamping command that is written to the inverter register when the conditions are met. The closed-loop feedback module continues to monitor the tension trend after clamping and decides whether to output an abnormal alarm, maintain the clamping, or upgrade to a dangerous level hard cut-off. In terms of hardware coordination, the system can use a programmable logic controller as the main control core. Its safety output point is connected to the main contactor control circuit. On the other hand, it connects to the mechanical brake control circuit, so as to simultaneously complete power cut-off and braking in dangerous situations; the human-machine interface terminal is used to display the current module configuration, lifting status, abnormal causes, alarm levels and maintenance suggestions; for historical baseline and fatigue warning functions, a data archive can be established in the host computer or edge industrial control computer to periodically synchronize the coupling gradient characteristics of each lifting. The exemplary module flow logic is as follows: When the data acquisition module calls the underlying sensor to obtain a new set of current value A1, tension value B1 and module configuration M1, the core processing module forms the coupling feature H1 of the current structural state based on this; the interlocking determination module then puts H1 into the envelope comparison. If the result is normal, it outputs state S1 and continues to acquire data. If the result is out of bounds, it outputs state S2 and writes the torque limit to the frequency converter; the closed-loop feedback module outputs state S3, S4 or S5 according to the subsequent tension sequence, corresponding to alarm waiting for manual confirmation, continued clamping monitoring or hard cut-off locking, respectively. In this way, a clear closed loop from input to processing to execution is formed between the various software logics and hardware entities of the system. As a fault tolerance mechanism, if the data acquisition module detects a sensor disconnection, bus communication interruption, or module configuration conflict, the core processing module stops outputting high-order coupling criteria, and the system automatically reverts to the basic overload protection mode. At the same time, the human-machine interface prompts for advanced interlocking degradation operation. If the write feedback between the interlocking judgment module and the execution loop is inconsistent, the closed-loop feedback module must not assume that the command has been successfully executed, but should switch to the fault-safe strategy and prohibit further lifting. If the historical database is unavailable, it will not affect the real-time interlocking process, but will suspend the fatigue warning function. On the day the reactor base was hoisted, the data acquisition module synchronously read the hoisting motor torque current, shaft pin tension, and the configuration of the four spliced ​​main beams at a fixed scanning cycle; the core processing module combined the structural stiffness parameters to form the current coupling gradient; the interlocking judgment module detected that the gradient continued to exceed the limit after the first short time window of hoisting and immediately sent a torque limit register update to the frequency converter; the closed-loop feedback module continuously monitored the tension and issued an on-site alarm after confirming the abnormality; several months later, the same system could also prompt maintenance personnel to check the health status of the main beam connectors and wire ropes based on the long-term accumulated coupling gradient baseline; when the work object was changed to an extremely flexible component, the system could automatically degrade to the backup protection mode to maintain the safety of the foundation; The purpose of this system is to unify structural perception, dynamic judgment, flexible intervention, rigid risk mitigation, and maintenance early warning into a set of engineering-implementable hardware and software architecture, thereby achieving full life-cycle safety interlocking control of modular lifting machinery in complex lifting scenarios.

[0025] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A modular intelligent interlocking control method for the load safety of lifting machinery, characterized in that, include: The real-time torque current, real-time tension, and splicing module configuration information of the hoisting mechanism driven by the hoisting motor are obtained. The hoisting mechanism is equipped with a frequency converter and a mechanical brake to control the hoisting motor. The splicing module configuration information includes the inherent stiffness parameters and connection topology of each splicing module. Based on the inherent stiffness parameters and connection topology of each splicing module in the splicing module configuration information, the overall stiffness coefficient of the module system is calculated in series and parallel equivalents. Based on the real-time torque current and the real-time tension, calculate the rate of increase of torque current and the rate of increase of tension, respectively. By combining the overall stiffness coefficient of the module system, the rate of increase of the torque current, and the rate of increase of the tensile force, the transient load torque coupling gradient is calculated. Using the lifting time as the horizontal axis and the transient load torque coupling gradient as the vertical axis, the transient load torque coupling gradient is compared with the preset normal lifting elastic deformation envelope by coordinate mapping. If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, a torque clamping command is generated to limit the motor output torque; if it does not exceed the envelope, the current lifting state is maintained. After generating the torque clamping command, the real-time tension is continuously monitored and the rate of change of tension is calculated within a preset monitoring period; If the real-time tension exceeds the preset absolute tension overload threshold, a dangerous interlock hard cut-off command is generated to trigger the mechanical braking of the hoisting mechanism; If the real-time tension does not exceed the absolute tension overload threshold, the tension change rate is compared with a preset stability judgment threshold: if it is less than the stability judgment threshold, a lifting abnormality alarm command is generated; if it is not less than the threshold, the torque clamping command is maintained and monitoring continues.

2. The modular-based intelligent interlocking control method for lifting machinery load safety as described in claim 1, characterized in that, The steps for calculating the rate of increase of torque current and the rate of increase of tension based on the real-time torque current and the real-time tension respectively include: Construct a first-in-first-out sliding window of a preset length; The real-time torque current and the real-time tension are collected synchronously and constructed into a time-series data pair; The time-series data pairs are stored in the first-in-first-out sliding window in chronological order. Within each scan cycle, extract the timing data pairs at the beginning and end of the first-in-first-out sliding window; The slope of the change in real-time torque current and real-time tension in the first and last time-series data pairs is calculated using a differential algorithm, and the rate of increase of torque current and the rate of increase of tension are obtained respectively.

3. The modular-based intelligent interlocking control method for lifting machinery load safety as described in claim 1, characterized in that, The steps for calculating the transient load torque coupling gradient by combining the overall stiffness coefficient of the module system, the rate of increase of the torque current, and the rate of increase of the tensile force include: Calculate the ratio of the rate of increase of the tension to the rate of increase of the torque current to obtain the intermediate transmission efficiency characterization quantity; The intermediate transmission efficiency characterization quantity is multiplied by the module system comprehensive stiffness coefficient to generate the transient load torque coupling gradient. The transient load torque coupling gradient is used to characterize the actual transmission efficiency of the output torque of the hoisting motor into effective pulling force.

4. The modular-based intelligent interlocking control method for lifting machinery load safety as described in claim 1, characterized in that, If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, the step of generating a torque clamping command to limit the motor output torque includes: Determine whether the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope within a continuous preset sampling period; If so, it is determined that there is hard resistance in the current lifting state, and the real-time torque current at the current moment is extracted; Obtain a preset torque current limiting ratio, which is a coefficient greater than 1 and close to 1, pre-set according to the hoisting motor nameplate parameters and hoisting safety redundancy. Based on the real-time torque current at the current moment and the preset torque current limit ratio, calculate the target torque current limit upper limit value. The torque clamping command is generated based on the target torque current limit upper limit value, which is used to modify the torque limit upper limit register of the frequency converter controlling the hoisting motor, forcing the hoisting motor to stop accelerating and enter an electrical hovering state; If not, it is determined to be a normal elastic fluctuation, the torque clamping command is not generated, and the current lifting state is maintained.

5. The modular-based intelligent interlocking control method for lifting machinery load safety as described in claim 1, characterized in that, After generating the torque clamping command, the step of continuously monitoring the real-time tension and calculating the rate of change of tension within a preset monitoring period includes: Extract the real-time tensile force sequence within the preset monitoring period; Calculate the trend characteristics of the real-time tensile force sequence to obtain the tensile force change rate; If the rate of change of tension is less than the stability determination threshold and the real-time tension does not exceed the absolute tension overload threshold, then the lifting abnormality alarm command is generated. If the rate of change of tension is not less than the stability determination threshold and the real-time tension does not exceed the absolute tension overload threshold, then the torque clamping command is maintained and monitoring continues. The real-time tensile force is compared with the absolute tensile force overload threshold. When the real-time tensile force exceeds the absolute tensile force overload threshold, the danger-level interlock hard cut-off command is immediately triggered.

6. The modular-based intelligent interlocking control method for lifting machinery load safety as described in claim 1, characterized in that, The specific execution steps of the hazardous level interlock hard cutoff command include: A main contactor disconnect signal is generated to control the drive power supply of the hoisting motor, thereby cutting off the drive power supply of the hoisting motor. A mechanical brake closing signal is generated synchronously to close the mechanical brake of the hoisting mechanism and lock the hoisting mechanism.

7. The modular-based intelligent interlocking control method for lifting machinery load safety as described in claim 1, characterized in that, Also includes: During long-term operation, the transient load torque coupling gradient during historical lifting cycles is continuously collected and stored to construct a historical gradient baseline sequence. Extract the average value of the transient load torque coupling gradient within the current lifting cycle as the current feature value; Calculate the absolute value of the difference between the current feature value and the mean of the historical gradient baseline sequence, as the baseline drift; Determine whether the baseline drift exceeds a preset fatigue warning threshold; If the baseline drift exceeds the fatigue warning threshold, it is determined that the mechanical structure of the hoisting mechanism has undergone fatigue degradation, and an early predictive maintenance prompt is generated. If the baseline drift does not exceed the fatigue warning threshold, the mechanical structure of the lifting mechanism is determined to be in good condition.

8. The modular-based intelligent interlocking control method for lifting machinery load safety as described in claim 1, characterized in that, Also includes: Real-time monitoring of the slope of the rate of increase of the tensile force; Determine whether the slope of the increase rate of the tensile force is lower than the preset deformation threshold of the extremely flexible load; If the upward slope of the tensile force increase rate is lower than the deformation threshold of the extremely flexible load, then the current hoisting target is determined to be an extremely flexible load, and the transient load torque coupling gradient is determined to have failed. The judgment logic based on transient load torque coupling gradient is disabled, and the system automatically degrades to a backup protection mode based on an absolute weight threshold. If the slope of the increase rate of the tensile force is not lower than the deformation threshold of the extremely flexible load, then the determination logic based on the transient load torque coupling gradient is maintained.

9. A modular intelligent interlocking control system for crane load safety, used to implement the modular intelligent interlocking control method for crane load safety as described in any one of claims 1-8, characterized in that, include: The data acquisition module is used to acquire the real-time torque current, real-time tension, and splicing module configuration information of the hoisting mechanism driven by the hoisting motor; wherein, the hoisting mechanism is equipped with a frequency converter and a mechanical brake to control the hoisting motor; The core processing module is used to calculate the overall stiffness coefficient of the module system in series and parallel equivalent manner based on the inherent stiffness parameters and connection topology of each splicing module in the splicing module configuration information; calculate the torque current rise rate and the tension rise rate based on the real-time torque current and the real-time tension respectively; and calculate the transient load torque coupling gradient by combining the overall stiffness coefficient of the module system, the torque current rise rate and the tension rise rate. The interlocking determination module is used to compare the transient load torque coupling gradient with a preset normal lifting elastic deformation envelope using the lifting time as the horizontal axis and the transient load torque coupling gradient as the vertical axis. If the transient load torque coupling gradient exceeds the normal lifting elastic deformation envelope, a torque clamping command is generated to limit the motor output torque; if it does not exceed the threshold, the current lifting state is maintained. The closed-loop feedback module is used to continuously monitor the real-time tension and calculate the tension change rate within a preset monitoring period after generating the torque clamping command; if the real-time tension exceeds a preset absolute tension overload threshold, a hazard-level interlock hard cut-off command is generated to trigger the mechanical braking of the hoisting mechanism; if the real-time tension does not exceed the absolute tension overload threshold, the tension change rate is compared with a preset stability judgment threshold: if it is less than the stability judgment threshold, a hoisting abnormality alarm command is generated; if it is not less than the threshold, the torque clamping command is maintained and monitoring continues.

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