Dual-interlock safety warning system and method for electric industrial vehicles

Abstract

This invention relates to the field of engineering vehicle safety control technology, specifically a dual-interlock safety warning system for electric industrial vehicles. The system includes: a charging compartment door status detection module for detecting the opening and closing status of the vehicle's charging compartment door and outputting a first status signal; a seatbelt status detection module for detecting the driver's seatbelt wearing status and outputting a second status signal; and a main control alarm module electrically connected to the charging compartment door status detection module and the seatbelt status detection module. The dual-interlock safety warning system is equipped with preset interlocking logic. Only when the first status signal indicates that the vehicle's charging compartment door is closed and the second status signal indicates that the seatbelt is fastened will the main control alarm module output a high-voltage power-on enable signal. This advances safety protection before the vehicle is powered on, effectively blocking the high-voltage power-on process at its source, eliminating safety accidents caused by human negligence, and improving safety.

Description

Technical Field

[0001] This invention relates to the field of safety control technology for engineering vehicles, specifically to a dual-interlock safety warning system and method for electric industrial vehicles. Background Technology

[0002] With the deepening of electrification transformation, the number of electric industrial vehicles such as electric loaders and electric forklifts in ports, logistics parks, and other scenarios has surged. Electric industrial vehicles face safety risks during charging and operation: On the one hand, if an electric industrial vehicle is accidentally started while charging (with the charging gun still plugged in), its low operating noise makes it difficult to detect and can easily pull on charging facilities, causing damage to high-value assets (charging piles, cables, vehicle charging interfaces), or even causing personal injury or electrical fires; on the other hand, drivers operating without wearing seat belts also pose serious personal safety hazards in complex working environments.

[0003] Currently, existing technical solutions to the above problems mainly have the following shortcomings: 1. Inadequate charging safety interlocking schemes: Some schemes (such as Chinese patent CN112554674B) achieve interlocking by detecting the physical connection status of the charging gun. However, this method only solves the "gun unplugging" problem and cannot cover the intermediate state where the vehicle charging compartment door is not closed but the charging gun has been unplugged. In this state, foreign objects may be caught in the open vehicle charging compartment door, or the driver may still mistakenly believe that the vehicle is drivable.

[0004] 2. Incomplete Seatbelt Interlocking Strategy: In existing technologies, seatbelt interlocking is mostly associated with the vehicle's gear position or control lever (such as Chinese patent CN107923155A), which falls under the category of "intervention while driving." This design has a logical flaw: the driver can energize the vehicle's high-voltage circuit even without wearing a seatbelt, completing other preparatory work, creating room for opportunistic operation. It fails to prevent disruption at the source of high-voltage energization, resulting in insufficient safety. Summary of the Invention

[0005] The purpose of this invention is to provide a dual-interlock safety warning system and method for electric industrial vehicles, which realizes dual interlock control of the "vehicle charging compartment door status" and "driver's seat belt wearing status" on the "vehicle high-voltage power-on circuit", bringing safety protection forward to the action of vehicle high-voltage power-on, eliminating safety accidents caused by human negligence, and improving safety.

[0006] In a first aspect, the present invention provides a dual-interlock safety warning system for electric industrial vehicles, comprising: The charging compartment door status detection module is used to detect the opening and closing status of the vehicle charging compartment door and output a first status signal. The seat belt status detection module is used to detect the wearing status of the driver's seat belt and output a second status signal; The main control alarm module is electrically connected to the charging compartment door status detection module and the seat belt status detection module. The main control alarm module is configured to receive the first status signal and the second status signal, and output control commands based on preset interlocking logic. The control commands include a first alarm signal, a second alarm signal, and a high-voltage power-on enable signal and a high-voltage power-on prohibit signal that control the on / off of the vehicle's high-voltage power-on circuit. The power module is used to supply power to the various modules of the system; The interlocking logic is as follows: when the first state signal indicates that the vehicle charging compartment door is open, the main control alarm module outputs a first alarm signal and a high-voltage power-on prohibition signal; the second state signal is judged only when the first state signal indicates that the vehicle charging compartment door is closed; if the second state signal indicates that the seat belt is not fastened, the main control alarm module outputs a second alarm signal and a high-voltage power-on prohibition signal; the main control alarm module outputs a high-voltage power-on enable signal only when the first state signal indicates that the vehicle charging compartment door is closed and the second state signal indicates that the seat belt is fastened.

[0007] Based on the above technical solution, the present invention can be further improved as follows: As a further improvement to the above technical solution, the charging compartment door status detection module includes a mechanical limit switch with a protection level of not less than IP65 and an operating temperature range of -20℃ to 70℃.

[0008] As a further improvement to the above technical solution, the seat belt status detection module includes a micro switch disposed in the seat belt buckle, which can detect the insertion status of the seat belt latch.

[0009] As a further improvement to the above technical solution, the main control alarm module includes a logic control unit, an audible and visual alarm unit, and a voice warning unit. The input terminal of the logic control unit is electrically connected to the charging compartment door status detection module and the seat belt status detection module, and the output terminal of the logic control unit is connected to the audible and visual alarm unit and the voice warning unit. The first alarm signal is emitted by the audible and visual alarm unit, including a high-frequency buzzer and flashing lights. The second alarm signal is emitted by the voice warning unit, including a looping voice prompt.

[0010] As a further improvement to the above technical solution, the logic control unit adopts an industrial PLC controller or a combination of high-reliability relays, and the power supply module is an on-board DC power conversion module.

[0011] As a further improvement to the above technical solution, the sound and light alarm unit is installed on the top of the vehicle's driver's side and includes a buzzer and a high-brightness LED strobe light; the voice warning unit is installed in the vehicle's driver's compartment and includes a voice chip and a small speaker.

[0012] In a second aspect, the present invention provides a warning method based on the above system, comprising the following steps: detecting the status of the vehicle charging compartment door; if the vehicle charging compartment door is open, issuing a first alarm signal and prohibiting the vehicle's high-voltage power supply circuit from being powered on; if the vehicle charging compartment door is closed, stopping the alarm and further detecting the seat belt status; if the seat belt is not fastened, issuing a second alarm signal and continuing to prohibit the vehicle's high-voltage power supply.

[0013] The beneficial effects of the present invention are as follows: The above-mentioned dual-interlock safety warning system for electric industrial vehicles, through preset interlocking logic, only outputs a high-voltage power-on enable signal when the first state signal indicates that the vehicle charging compartment door is closed and the second state signal indicates that the seat belt is fastened. This advances safety protection to before the high-voltage power-on action of the vehicle, thereby blocking the high-voltage power-on source and eliminating safety accidents caused by human negligence, thus improving safety. Attached Figure Description

[0014] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0015] Figure 1 This is a structural diagram of a forklift used as an electric industrial vehicle; Figure 2 This is a block diagram of the module configuration of a double-interlock safety warning system for electric industrial vehicles provided in a preferred embodiment of the present invention; Figure 3 This is a logic flowchart of the warning method of the present invention; In the diagram: 1. Charging compartment door status detection module; 11. Limit switch; 2. Seat belt status detection module; 21. Micro switch; 3. Main control alarm module; 31. Logic control unit; 32. Audible and visual alarm unit; 33. Voice warning unit; 4. Power supply module; 5. Vehicle high-voltage power-on circuit; 51. Vehicle high-voltage contactor; 6. Vehicle charging compartment door; 7. Seat belt. Detailed Implementation

[0016] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. These drawings are simplified schematic diagrams, which are only used to illustrate the basic structure of the present invention and therefore only show the components relevant to the present invention.

[0017] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0018] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0019] like Figure 1 , Figure 2 and Figure 3 As shown, a preferred embodiment of the present invention provides a dual-lock safety warning system for electric industrial vehicles, including a charging compartment door status detection module 1, a seat belt status detection module 2, a main control alarm module 3 electrically connected to the charging compartment door status detection module 1 and the seat belt status detection module 2, and a power supply module 4 for supplying power to each module of the system.

[0020] In this embodiment, the electric industrial vehicle is an electric forklift, including a vehicle charging compartment door 6 for connecting the charging gun, a seat belt 7 installed on the seat, a vehicle high-voltage power supply circuit 5, and a vehicle high-voltage contactor 51 connected to the vehicle high-voltage power supply circuit 5.

[0021] The charging compartment door status detection module 1 is used to detect the opening and closing status of the vehicle charging compartment door 6 and output a first status signal. It includes a mechanical limit switch 11 installed inside the vehicle charging compartment door 6. When the vehicle charging compartment door 6 is fully closed, the inner wall of the vehicle charging compartment door 6 presses down the swing arm, and the limit switch 11 closes. The limit switch 11 has a protection rating of not less than IP65 and an operating temperature range of -20℃ to 70℃.

[0022] The seatbelt status detection module 2 is used to detect the wearing status of the driver's seatbelt and output a second status signal. It includes a micro switch 21 (normally closed contact) disposed in the seatbelt 7 buckle. The micro switch 21 can detect the insertion status of the seatbelt 7 latch. When the seatbelt 7 latch is inserted into the buckle, the micro switch 21 is pressed down, and the contact is opened.

[0023] The main control alarm module 3 is configured to receive the first status signal and the second status signal, and output control commands based on preset interlocking logic. The control commands include a first alarm signal, a second alarm signal, and a high-voltage power-on enable signal and a high-voltage power-on prohibit signal that control the on / off of the vehicle's high-voltage power-on circuit 5.

[0024] The main control alarm module 3 includes a logic control unit 31, an audible and visual alarm unit 32, and a voice warning unit 33. The input terminal of the logic control unit 31 is electrically connected to the charging compartment door status detection module 1 and the seat belt status detection module 2 to receive the first status signal and the second status signal. The output terminal of the logic control unit 31 is connected to the audible and visual alarm unit 32 and the voice warning unit 33, and outputs the control command based on a preset interlocking logic. The first alarm signal is emitted by the audible and visual alarm unit 32, including a high-frequency buzzer and flashing lights; the second alarm signal is emitted by the voice warning unit 33, including a looping voice prompt.

[0025] Preferably, the main control alarm module 3 is encapsulated in an engineering plastic box with an IP65 protection rating and installed on the side of the dashboard in the driver's cab. The logic control unit 31 uses an industrial PLC controller or a combination of high-reliability relays to implement the logic. The audible and visual alarm unit 32 is installed on the outer top of the vehicle's driver's cab and includes a high-decibel buzzer and a high-brightness LED strobe light. The voice warning unit 33 is installed inside the vehicle's driver's cab and includes a voice chip and a small speaker.

[0026] The power module 4 is an on-board DC power conversion module, which can convert the on-board 24V power supply into a stable 12V / 5V voltage required by the system, so as to provide a stable operating voltage for the entire system.

[0027] Furthermore, the modules are connected to each other and to the vehicle via waterproof connectors, without accessing the vehicle's CAN bus or modifying the vehicle's original controller software.

[0028] The interlocking logic of the aforementioned dual-interlock safety warning system is as follows: When the first status signal indicates that the vehicle charging compartment door 6 is open, the logic control unit 31 drives the audible and visual alarm unit 32 to issue an audible and visual warning and outputs a high-voltage power-on prohibition signal, thus disconnecting the vehicle's high-voltage power-on circuit 5. Only when the first status signal indicates that the vehicle charging compartment door 6 is closed, the output of the first alarm signal and the high-voltage power-on prohibition signal stops, and the system enters the next judgment stage. If the second status signal indicates that the seat belt 7 is not fastened, the logic control unit 31 drives the voice warning unit 33 to issue voice prompts in a loop and continues to output the high-voltage power-on prohibition signal, keeping the vehicle's high-voltage power-on circuit 5 disconnected. Only when the second status signal indicates that the seat belt 7 is fastened, the voice warning unit 33 stops outputting the second alarm signal, the logic control unit 31 outputs a high-voltage power-on enable signal, turning on the vehicle's high-voltage power-on circuit 5, engaging the vehicle's high-voltage contactor 51, and putting the vehicle into a drivable ready state.

[0029] The present invention also provides a warning method based on the above-mentioned double interlocking safety warning system, comprising the following steps: S1: Vehicle control power is on, system self-test; S2: Real-time monitoring of the vehicle charging compartment door 6 status; S3: If the vehicle charging compartment door 6 is detected to be open, a first alarm signal is issued and the process jumps to S7 to prevent the vehicle from being powered on by high voltage; if the vehicle charging compartment door 6 is closed, the process proceeds to S4. S4: Real-time detection of seatbelt wearing status; S5: If seat belt 7 is detected as unfastened, a second alarm signal is issued and the system jumps to S7 to prevent the vehicle from being powered on; if seat belt 7 is fastened, the system proceeds to S6. S6: Clear the alarm and output a high-voltage power-on enable signal to enable the vehicle's high-voltage power-on circuit 5 to conduct. S7: Maintain the high-voltage power-on prohibition state and continuously or cyclically issue corresponding alarm signals until the conditions for triggering the alarm disappear, then return to the corresponding detection steps.

[0030] Specifically, the system starts working after the vehicle key is turned on (ON position). First, the logic control unit 31 reads the signal from the limit switch 11. If the vehicle charging compartment door 6 is detected to be open, the buzzer will sound continuously and the strobe light will flash. The internal relay will cut off the high-voltage power-on enable signal to the enable terminal of the vehicle high-voltage contactor 51. The vehicle cannot be powered on by high voltage, and the driver must get out of the vehicle and close the vehicle charging compartment door 6.

[0031] Furthermore, when the vehicle charging compartment door 6 is detected to be closed, the limit switch 11 closes, and the audible and visual alarm stops. The system then checks the status of the seat belt 7. If the seat belt 7 latch is not inserted (microswitch 21 is normally closed), the voice warning unit 33 is driven to repeatedly play "Please fasten your seat belt" while maintaining the high-voltage power-on enable signal cut off. Only when the driver inserts the seat belt 7 latch (microswitch 21 is open) will the voice prompt stop, the enable relay inside the logic control unit 31 be activated, the high-voltage power-on enable signal pass through the vehicle high-voltage contactor 51, the vehicle VCU receive the enable signal, the vehicle high-voltage contactor 51 be activated, and the vehicle enters the driving preparation state.

[0032] Any descriptions not covered in the above specific embodiments of the present invention are known technologies in the field and can be implemented with reference to such known technologies.

[0033] Based on the preferred embodiments of the present invention described above, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A double-lock safety warning system for electric industrial vehicles, characterized in that, include: The charging compartment door status detection module is used to detect the opening and closing status of the vehicle charging compartment door and output a first status signal. The seat belt status detection module is used to detect the wearing status of the driver's seat belt and output a second status signal; The main control alarm module is electrically connected to the charging compartment door status detection module and the seat belt status detection module. The main control alarm module is configured to receive the first status signal and the second status signal, and output control commands based on preset interlocking logic. The control commands include a first alarm signal, a second alarm signal, and a high-voltage power-on enable signal and a high-voltage power-on prohibit signal that control the on / off of the vehicle's high-voltage power-on circuit. The power module is used to supply power to the various modules of the system; The interlocking logic is as follows: when the first state signal indicates that the vehicle charging compartment door is open, the main control alarm module outputs a first alarm signal and a high-voltage power-on prohibition signal; the second state signal is judged only when the first state signal indicates that the vehicle charging compartment door is closed; if the second state signal indicates that the seat belt is not fastened, the main control alarm module outputs a second alarm signal and a high-voltage power-on prohibition signal; the main control alarm module outputs a high-voltage power-on enable signal only when the first state signal indicates that the vehicle charging compartment door is closed and the second state signal indicates that the seat belt is fastened.

2. The double-interlock safety warning system for electric industrial vehicles according to claim 1, characterized in that, The charging compartment door status detection module includes a mechanical limit switch with a protection level of not less than IP65 and an operating temperature range of -20℃ to 70℃.

3. The double-lock safety warning system for electric industrial vehicles according to claim 2, characterized in that, The seat belt status detection module includes a micro switch disposed in the seat belt buckle, which can detect the insertion status of the seat belt latch.

4. The dual-interlock safety warning system for electric industrial vehicles according to claim 3, characterized in that, The main control alarm module includes a logic control unit, an audible and visual alarm unit, and a voice warning unit. The input terminal of the logic control unit is electrically connected to the charging compartment door status detection module and the seat belt status detection module, and the output terminal of the logic control unit is connected to the audible and visual alarm unit and the voice warning unit. The first alarm signal is emitted by the audible and visual alarm unit, including a high-frequency buzzer and flashing lights. The second alarm signal is emitted by the voice warning unit, including a looping voice prompt.

5. The dual-interlock safety warning system for electric industrial vehicles according to claim 4, characterized in that, The logic control unit adopts an industrial PLC controller or a combination of high-reliability relays, and the power supply module is an on-board DC power conversion module.

6. The double-interlock safety warning system for electric industrial vehicles according to claim 4, characterized in that, The sound and light alarm unit is installed on the top outside the driver's side of the vehicle and includes a buzzer and a high-brightness LED strobe light; the voice warning unit is installed inside the driver's side of the vehicle and includes a voice chip and a small speaker.

7. A warning method based on the system according to any one of claims 1-6, characterized in that, Includes the following steps: The system detects the status of the vehicle's charging compartment door. If the door is open, a first alarm signal is issued, and the high-voltage power supply circuit to the vehicle is blocked. If the door is closed, the alarm stops, and the seatbelt status is further detected. If the seatbelt is not fastened, a second alarm signal is issued, and the high-voltage power supply to the vehicle is blocked again.

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