Safety interlocking management and control method, system, device and medium for wind power hoisting operation

Abstract

The application discloses a safety interlocking control method, system, equipment and medium for wind power hoisting operation, and relates to the technical field of wind power hoisting safety control.The application collects state data of a crane and a wind power hoisting operation environment in real time, calculates a site change safety evaluation index, and outputs a hydraulic locking signal when the site change is unqualified; after the site change is qualified, target component data is compared, an alarm signal is generated when the target component is unqualified; a hardware ready flag bit is generated and logical verification is performed after the target component acceptance; a dynamic safety envelope is generated based on environmental meteorological data after the verification is passed, and the pilot control oil circuit is cut off when the envelope is exceeded.The application solves the problems of excessive dependence on manual experience, lagging risk control and disconnection between management process and physical control in traditional hoisting through step-by-step forced interlocking control of data collection, site change evaluation, component acceptance, logical verification and dynamic operation, and can be widely applied to wind power hoisting operation scenes in complex environments such as highlands and mountains.

Description

Technical Field

[0001] This invention relates to the field of wind power installation safety control technology, and specifically discloses a method, system, equipment and medium for safety interlocking control of wind power installation operations. Background Technology

[0002] Wind power installation is a high-risk, high-precision system engineering project, especially in high-altitude mountainous environments, where rugged terrain, variable climate, and thin air pose significant challenges to construction safety.

[0003] Traditional wind power hoisting operations rely heavily on a "human-based" safety management model, which has several limitations: During relocation, manual judgment of roadbed flatness and load-bearing capacity is essential, but limitations imposed by on-site perspective and personnel experience can lead to biased assessments and an inability to accurately evaluate the crane's relocation status, posing a risk of crane overturning; acceptance of crane components relies on manual inspection, which is susceptible to errors due to varying standards among inspectors and the influence of fatigue and emotions, often resulting in missed inspections and misjudgments, creating safety hazards for subsequent hoisting operations; dynamic operations only monitor instantaneous wind speed, failing to identify wind speed trends, making the load vulnerable to sudden gusts in high-altitude mountainous areas, causing significant swaying or even falls; furthermore, the wind power hoisting management process is disconnected from the crane's physical control, lacking mandatory interlocking mechanisms. Even if the crane's components fail acceptance, wind speed exceeds limits, or relocation does not meet safety conditions, operators can still forcefully operate the crane, making it difficult to effectively implement safety management systems.

[0004] Therefore, there is an urgent need for a safety interlocking control method, system, equipment, and medium for wind power hoisting operations to solve the problem of low safety in the existing human-based air defense mode. Summary of the Invention

[0005] The purpose of this invention is to provide a safety interlocking control method, system, equipment, and medium for wind power installation operations to solve the aforementioned problems in the prior art; the specific solution is as follows: In a first aspect, the present invention provides a safety interlocking control method for wind power hoisting operations, including: Real-time data collection of the status of the crane and wind power hoisting operation environment; calculation of the crane relocation safety assessment index based on the status data; output of a hydraulic interlock signal to lock the crane traveling mechanism when the relocation safety assessment index does not meet the preset conditions. When the relocation safety assessment index meets the preset conditions, the target component data of the crane in the status data is compared with the preset standard data. When the target component data does not match the preset standard data, an alarm signal is generated. When the target component data matches the preset standard data, a hardware ready flag for the crane is generated. The hardware ready flag is then logically checked. If the check fails, the crane hoisting process is terminated. When the verification is passed, a dynamic safety envelope is generated based on the environmental meteorological data in the status data. When the actual operating parameters of the crane exceed the dynamic safety envelope, the crane pilot control oil circuit is cut off. When the actual operating parameters of the crane are within the dynamic safety envelope, the crane pilot control oil circuit is kept open.

[0006] Preferably, the calculation of the crane's relocation safety assessment index based on the status data includes: The relocation safety assessment index includes longitudinal flatness value, lateral flatness value, and overturning stability coefficient; The longitudinal and lateral flatness values ​​of the crane after it is standing are obtained by a dual-axis tilt sensor. The real-time center of gravity position data of the crane is obtained by calculating the torque limiter data. Combined with the real-time center of gravity position data and the track tension pressure sensor data, the ground pressure distribution of the tracks on both sides of the crane is calculated in reverse. Based on the ground pressure distribution, the overturning stability coefficient of the crane is corrected. If the longitudinal flatness value or the transverse flatness value is greater than the preset flatness limit, or the corrected anti-overturning stability coefficient is less than 1.15, then the transfer safety assessment index is determined to not meet the preset conditions.

[0007] Preferably, comparing the target component data of the crane in the status data with preset standard data includes: The industrial camera is controlled to perform fixed-point scanning of the wire rope arrangement and hook assembly of the crane, and to acquire image data of the wire rope arrangement and hook assembly. The texture contour of the wire rope surface is extracted from the image data using an edge detection algorithm, and the rope spacing of the wire rope is identified based on the texture contour. The consistency coefficient of the rope spacing is then calculated. The grayscale change features of the hook assembly surface are identified from the image data. Based on the grayscale change features, the suspected crack area is located. The aspect ratio of the suspected crack area is geometrically matched with the pre-stored metal fatigue crack feature library to determine whether the suspected crack area is a metal fatigue crack. The target component data is determined to match the preset standard data only when the consistency coefficient of the rope spacing is greater than a preset threshold and the suspected crack area is not a metal fatigue crack.

[0008] Preferably, the logical check of the hardware ready flag includes: Determine whether the three logical verification conditions consisting of the hardware ready flag being valid, the current instantaneous wind speed being less than the lifting threshold, and the torque limiter system having no fault codes are simultaneously met; If both conditions are met, the verification passes; if any one condition is not met, the verification fails.

[0009] Preferably, generating a dynamic safety envelope based on the environmental meteorological data in the state data includes: Establish a time sliding window, collect wind speed sampling values ​​in a continuous time series, calculate the wind speed increment between adjacent sampling points based on the wind speed sampling values, and obtain the first derivative of wind speed change. If the current wind speed is not exceeded, but the first derivative of the wind speed change is continuously positive and exceeds the gust warning threshold, it is determined that there is a risk of exceeding the limit in the future operation window, and the maximum allowable speed of the crane movement is reduced or a hovering and holding command is executed.

[0010] Preferably, it also includes: Different wind speed alarm thresholds and action speed limits are preset for different hoisting objects; The torque limiter detects the current load weight and amplitude, automatically identifies the current lifting object, and calls the corresponding wind speed alarm threshold and action speed limit value based on the identified lifting object.

[0011] Secondly, the present invention also provides a safety interlocking control system for wind power installation operations, used to execute the aforementioned safety interlocking control method for wind power installation operations, including: The perception layer is used to collect real-time status data of the crane and wind turbine hoisting operation environment. The logic control layer is configured to: calculate the relocation safety assessment index of the crane based on the state data; and output a hydraulic locking signal to lock the crane traveling mechanism when the relocation safety assessment index does not meet the preset conditions. When the relocation safety assessment index meets the preset conditions, the target component data of the crane in the status data is compared with the preset standard data. When the target component data does not match the preset standard data, an alarm signal is generated. When the target component data matches the preset standard data, a hardware ready flag for the crane is generated, and a logical check is performed on the hardware ready flag. If the check fails, the crane hoisting process is terminated. When the verification is passed, a dynamic safety envelope is generated based on the environmental meteorological data in the status data. When the actual operating parameters of the crane exceed the dynamic safety envelope, the crane pilot control oil circuit is cut off. When the actual operating parameters of the crane are within the dynamic safety envelope, the crane pilot control oil circuit is kept open. The execution layer includes an electromagnetic shut-off valve and a proportional pressure reducing valve connected in series in the crane's hydraulic system, used to cut off or regulate the hydraulic oil circuit according to the instructions of the logic control layer.

[0012] Preferably, the logic control layer is further configured as follows: Simultaneously record sensor data, logic judgment results, and control commands; When the interlocking action is triggered, the data records within a preset time period before and after the triggering time are automatically locked as an unalterable basis for accident analysis.

[0013] Thirdly, the present invention also provides an electronic device, comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the safety interlocking control method for wind power hoisting operations described in any of the preceding claims.

[0014] Fourthly, the present invention also provides a computer-readable storage medium storing instructions that, when executed on a computer, cause the computer to perform the steps of the safety interlocking control method for wind power hoisting operations described in any of the preceding claims.

[0015] The technical solution of the present invention has at least the following advantages and beneficial effects: The safety interlocking control method for wind power hoisting operations proposed in this application systematically solves the inherent defects of the traditional "human-based" mode through a complete automated and mandatory interlocking control process: First, by collecting data on roadbed flatness and ground pressure using sensors, and combining this data with torque limiter data to calculate the overturning stability coefficient in real time, it replaces manual experience-based judgment and achieves an objective quantitative assessment of the safety of site relocation, reducing the risk of overturning from the source; Second, by employing industrial camera scanning and image recognition algorithms, it automatically completes the status determination of wire rope arrangement and hooks, eliminating the hidden dangers of missed inspections and misjudgments caused by inconsistent standards, fatigue, or emotional influence during manual inspection, and achieving standardization and automation of key component acceptance; Subsequently, by using hardware ready flags and multi-condition logic checks, it ensures that all safety conditions are met before hoisting; Finally, by establishing a wind speed change trend model during dynamic operations, it identifies gust risks in advance and adjusts the operation control strategy, improving the stability of operations under sudden wind conditions. This solution directly links the results of site relocation assessment, component acceptance, and meteorological condition verification with the crane's hydraulic control system. If any condition is not met, the process will be automatically locked or terminated, eliminating the possibility of forced human intervention. At the same time, the full-process data recording and key event locking mechanism provides an objective and complete basis for subsequent accident analysis and liability determination, comprehensively improving the safety and traceability of wind power hoisting operations. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the method flow of the present invention; Figure 2 This is a schematic diagram of the execution flow of the present invention; Figure 3 This is a schematic diagram of the state transition of the present invention; Figure 4 This is a schematic diagram of the hardware components and data flow of the present invention. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] like Figures 1 to 4 As shown, this invention provides a safety interlocking control method for wind power hoisting operations, comprising the following steps: S1: Real-time acquisition of status data of the crane and wind power hoisting operation environment, calculation of the crane relocation safety assessment index based on the status data, and output of hydraulic locking signal for locking the crane traveling mechanism when the relocation safety assessment index does not meet the preset conditions. In this embodiment, the real-time collected status data of the crane and the wind turbine hoisting operation environment serves as the fundamental data source for the entire safety interlocking control method. Specifically, the status data includes two parts: the status data of the crane itself and the status data of the wind turbine hoisting operation environment. The status data of the crane itself includes chassis attitude data, foundation stress data, target component data (such as data related to wire ropes and hook assemblies), lifting weight, boom amplitude, etc.; the status data of the wind turbine hoisting operation environment mainly consists of environmental meteorological data, including parameters such as real-time wind speed and wind direction.

[0020] The aforementioned status data is collected synchronously by various sensors in the perception layer, including dual-axis tilt sensors, track tension pressure sensors, industrial cameras, anemometers, torque limiters, etc. Each sensor collects data at a preset frequency (preferably 10Hz-50Hz, which can be adjusted according to the actual operation accuracy requirements), and transmits the collected analog or digital signals to the logic control layer in real time to ensure the real-time performance of the data.

[0021] The relocation safety assessment index is a core indicator used to judge the safety of crane relocation operations. Its calculation is based on chassis posture data and foundation stress data from the status data. The purpose is to assess the roadbed bearing capacity and overall crane stability during relocation, avoiding safety accidents caused by unstable roadbeds or crane tilting. The specific calculation process will be described in detail in the embodiments corresponding to the subsequent dependent claims.

[0022] The preset conditions for the relocation safety assessment index can be set according to the crane model, lifting weight, and type of work site (such as mountainous areas, plains, wind farm sites, etc.). These conditions typically include flatness thresholds and overturning stability coefficient thresholds. When the calculated relocation safety assessment index is lower than the preset conditions (i.e., it does not meet the preset requirements), the logic control layer immediately outputs a hydraulic interlock signal. This signal is transmitted to the electromagnetic shut-off valve in the execution layer, controlling the electromagnetic shut-off valve to close, thereby locking the crane's traveling mechanism and prohibiting the crane from continuing to relocate until the hidden danger is eliminated and the relocation safety assessment index meets the preset conditions.

[0023] S2: When the relocation safety assessment index meets the preset conditions, the target component data of the crane in the status data is compared with the preset standard data. When the target component data does not match the preset standard data, an alarm signal is generated. In this embodiment, the relocation safety assessment index meets the preset conditions, indicating that the crane relocation environment is safe and can proceed to the subsequent target component acceptance stage. This stage is an important prerequisite for ensuring the safety of hoisting operations, because the integrity of the target components (such as wire ropes and hook assemblies) directly affects the safety of hoisting operations. If the target components are damaged or malfunctioning, it may lead to serious safety accidents such as the load falling.

[0024] The target component data mainly includes the wire rope's arrangement, surface texture contour, rope spacing, surface grayscale changes of the hook assembly, and suspected crack areas. This data is acquired through fixed-point scanning with an industrial camera and converted into image data, which is then transmitted to the logic control layer. The logic control layer processes and analyzes the image data, extracts key features, and compares them with preset acceptance standards to determine whether the target component has any abnormalities.

[0025] The preset conditions for the target component data are set based on industry standards and safety specifications for the crane's target components, such as the consistency coefficient threshold for wire rope spacing and the absence of structural damage (no cracks, no deformation) in the hook assembly. When the target component data is found to be inconsistent with the preset conditions after comparison (such as disordered wire rope arrangement or suspected cracks in the hook), the logic control layer generates an alarm signal. The alarm signal can be output through audible and visual alarms, interface prompts, etc., to remind operators to check and repair critical components in a timely manner, and at the same time suspend the lifting process to avoid safety accidents.

[0026] S3: When the target component data meets the preset conditions, generate the hardware ready flag of the crane, perform a logical check on the hardware ready flag, and terminate the crane hoisting process when the check fails. In this embodiment, the target component data meets the preset conditions, indicating that the target component of the crane is intact. At this time, the logic control layer generates a hardware ready flag, which is a logic signal (preferably a high-level signal, such as "1" indicating ready and "0" indicating not ready), used to identify that the crane hardware has met the basic conditions for hoisting operation.

[0027] The logical verification of the hardware readiness flag is conducted on a "one-lift-one-check" basis. This is the final safety check before lifting operations, aiming to ensure that all relevant hardware, sensors, and control systems of the crane are in normal working order, preventing interlocking control failure due to a single hardware malfunction. The verification includes three core conditions, all of which must be met simultaneously for the verification to pass: First, the hardware readiness flag is valid (i.e., the flag is a preset readiness signal); second, the current instantaneous wind speed is less than the lifting threshold (the lifting threshold is preset based on the type of lifting component and the load weight to avoid lifting in strong winds); and third, the torque limiter system has no fault codes (ensuring that the torque limiter can normally detect the load weight and boom amplitude, providing reliable data for subsequent control).

[0028] If any condition is not met during the logic check (such as an invalid hardware ready flag, excessive instantaneous wind speed, or a fault code appearing in the torque limiter), the check will be deemed unsuccessful. The logic control layer will immediately terminate the crane's hoisting process and output a prompt signal to inform the operator of the specific reason for the failure. The hoisting process can only continue after the operator has troubleshooted the fault and re-checked it successfully.

[0029] S4: When the verification is passed, a dynamic safety envelope is generated based on the environmental meteorological data in the status data. When the actual operating parameters of the crane exceed the dynamic safety envelope, the crane pilot control oil circuit is cut off. When the actual operating parameters of the crane are within the dynamic safety envelope, the crane pilot control oil circuit is kept open.

[0030] In this embodiment, after the logic check is passed, the crane enters the dynamic operation stage. At this time, a dynamic safety envelope needs to be generated based on real-time environmental meteorological data to realize dynamic interlocking control of the hoisting operation. The dynamic safety envelope is the safe operating range of the crane defined based on real-time environmental conditions (mainly wind speed) and hoisting parameters. Its core function is to deal with sudden situations such as gusts and sudden changes in wind speed, and to avoid the hoisting operation from exceeding the safe range due to environmental changes.

[0031] Environmental meteorological data is mainly collected by anemometers, including real-time wind speed and wind speed change trends. Based on this data, the logic control layer combines the current load weight, boom amplitude and other actual operating parameters to generate a dynamic safety envelope through a preset algorithm. This safety envelope is updated in real time with changes in wind speed and load parameters to ensure that it matches the actual operating environment.

[0032] The actual operating parameters of the crane include boom radius, load weight, lifting speed, and luffing speed. These parameters are collected in real time by torque limiters, displacement sensors, etc., and compared with the dynamic safety envelope in real time. When the actual operating parameters exceed the dynamic safety envelope (such as sudden changes in wind speed causing the load to sway beyond the safe range), the logic control layer outputs a cut-off command, controlling the electromagnetic shut-off valve of the execution layer to cut off the crane's pilot control oil circuit, causing the crane to stop all movements and avoid accidents such as load falling or the entire machine overturning. When the actual operating parameters are within the dynamic safety envelope, the pilot control oil circuit remains open, and the crane performs lifting operations normally.

[0033] In one exemplary embodiment of the present invention, calculating the crane relocation safety assessment index based on the status data includes: The relocation safety assessment index includes longitudinal flatness value, lateral flatness value, and overturning stability coefficient; The longitudinal and lateral flatness values ​​of the crane after it is standing are obtained by a dual-axis tilt sensor. The real-time center of gravity position data of the crane is obtained by calculating the torque limiter data. Combined with the real-time center of gravity position data and the track tension pressure sensor data, the ground pressure distribution of the tracks on both sides of the crane is calculated in reverse. Based on the ground pressure distribution, the overturning stability coefficient of the crane is corrected. If the longitudinal flatness value or the transverse flatness value is greater than the preset flatness limit, or the corrected anti-overturning stability coefficient is less than 1.15, then the transfer safety assessment index is determined to not meet the preset conditions.

[0034] In this embodiment, a dual-axis tilt sensor is installed at the center of the crane chassis to detect the longitudinal (crane travel direction) and lateral (perpendicular to the travel direction) tilt angles of the crane in real time after it stands upright, and then converts them into longitudinal and lateral flatness values. The flatness value is in degrees (°), and the smaller the value, the more stable the crane stands and the more uniform the roadbed load. The dual-axis tilt sensor converts the detected tilt angle signal into an electrical signal and transmits it to the logic control layer. The logic control layer converts the tilt angle into the corresponding flatness value through a preset algorithm, providing a basic data source for subsequent calculation of the overturning stability coefficient.

[0035] The torque limiter collects real-time operating data such as the crane's load weight, boom amplitude, and boom angle. The logic control layer calculates the crane's real-time center of gravity position data based on the mechanical model. The center of gravity position offset is directly related to the overall machine's anti-tipping safety margin. Track tension pressure sensors are installed on both sides of the crane's track tensioning mechanism to collect track ground pressure data, which can objectively reflect the differences in the bearing distribution of the working roadbed.

[0036] The ground pressure distribution characterizes the pressure distribution between the crane's tracks and the ground. By combining real-time center of gravity position data and track tension sensor data, it is calculated that when the center of gravity shifts to one side, the ground pressure distribution on that side increases, while the distribution on the opposite side decreases. When the roadbed has uneven hardness or settlement differences, the ground pressure distribution exhibits significant abrupt changes. Correcting the crane's overturning stability coefficient based on the ground pressure distribution can offset assessment biases caused by uneven roadbed bearing capacity and overall center of gravity shift, thus improving the accuracy of the relocation safety assessment index.

[0037] The preset flatness limit is pre-configured based on the crane model and rated load, with a standard value of 1.5°-3°, which can be flexibly adjusted according to the on-site operation scenario; the overturning stability coefficient threshold is set to 1.15, which meets the safety specifications for wind power hoisting operations and ensures that the crane has sufficient overturning safety margin when moving to another location.

[0038] When the longitudinal or lateral flatness values ​​exceed the preset flatness limits, it indicates that the crane tilts excessively in any direction, and the roadbed flatness does not meet the operational requirements. When the corrected overturning stability coefficient is less than 1.15, it indicates that the overall overturning load-bearing capacity of the crane does not meet the safety standards. Based on this, the logic control layer determines that the relocation safety assessment index is substandard, outputs a low-level signal to the brake valve, and locks the crane's traveling mechanism through the brake valve, restricting relocation movements until the attitude is adjusted and the roadbed is repaired, after which the assessment index meets the preset conditions again.

[0039] In one exemplary embodiment of the present invention, comparing the target component data of the crane in the status data with preset standard data includes: The industrial camera is controlled to perform fixed-point scanning of the wire rope arrangement and hook assembly of the crane, and to acquire image data of the wire rope arrangement and hook assembly. The texture contour of the wire rope surface is extracted from the image data using an edge detection algorithm, and the rope spacing of the wire rope is identified based on the texture contour. The consistency coefficient of the rope spacing is then calculated. The grayscale change features of the hook assembly surface are identified from the image data. Based on the grayscale change features, the suspected crack area is located. The aspect ratio of the suspected crack area is geometrically matched with the pre-stored metal fatigue crack feature library to determine whether the suspected crack area is a metal fatigue crack. The target component data is determined to match the preset standard data only when the consistency coefficient of the rope spacing is greater than a preset threshold and the suspected crack area is not a metal fatigue crack. In this embodiment, an industrial camera is installed above the crane boom head and the operator's cab. A high-definition industrial camera (resolution not less than 1080P) is used to perform fixed-point scanning of the wire rope and hook assembly. The wire rope scanning area is the rope section of the wire rope, and the hook assembly scanning area is the hook body, hook neck, and other key parts that are prone to cracking and deformation. The industrial camera performs fixed-point scanning at a preset frequency (preferably 5Hz-10Hz) to capture changes in the state of the target component in a timely manner. The scanned image data is transmitted to the logic control layer in real time for subsequent feature extraction and feature comparison.

[0040] The Canny edge detection algorithm can be used, or conventional edge detection algorithms such as the Sobel algorithm and Laplacian algorithm can be selected without affecting the core functionality of this invention. The edge detection algorithm effectively extracts the texture contour of the wire rope surface, distinguishes the wire rope body from the background area, and accurately identifies the arrangement of the wire ropes. The logic control layer identifies the center position of each wire rope based on the extracted texture contour, thereby obtaining the rope spacing between adjacent wire ropes.

[0041] The consistency coefficient of rope spacing is a core indicator for judging whether wire rope arrangement is orderly. It can be calculated by the average of the ratios of the actual spacing of all adjacent ropes to the standard rope spacing. The closer the consistency coefficient is to 1, the more orderly the rope arrangement; the greater the deviation from 1, the more disordered the rope arrangement. The standard rope spacing is preset according to the wire rope model and specifications to avoid mutual friction and entanglement of the wire ropes during operation, reducing the risk of wear and breakage.

[0042] When fatigue cracks occur in the hook assembly, they cause significant changes in surface grayscale values. The logic control layer uses a grayscale threshold segmentation algorithm to locate suspected crack areas with abnormal grayscale values ​​from the image data. Geometric features such as aspect ratio and contour morphology of the suspected crack areas are extracted and compared geometrically with a pre-stored metal fatigue crack feature library. The feature library contains typical geometric feature parameters for various types of hook fatigue cracks and stress cracks.

[0043] A preset geometric matching similarity threshold can be set, for example, to 80%. When the similarity between the geometric features of the suspected crack area and the crack features in the feature library is greater than or equal to the threshold, the suspected crack area is determined to be a metal fatigue crack. When the similarity is less than the threshold, it is determined not to be a metal fatigue crack.

[0044] The consistency coefficient of the rope spacing can be preset to a threshold of 0.9, which can be adjusted according to the actual wire rope specifications. When the consistency coefficient of the rope spacing is greater than the preset threshold, and the suspected crack area is determined not to be a metal fatigue crack, the wire rope is determined to be free of tangled ropes and the hook is free of structural damage. The acceptance status register is then set to a high-level logic "1". This status signal serves as an important basis for the subsequent generation of the hardware ready flag. If the consistency coefficient of the rope spacing does not meet the standard, or if a metal fatigue crack is determined to exist, the target component data is deemed not to meet the preset conditions, triggering an alarm signal and suspending the hoisting operation.

[0045] In one exemplary embodiment of the present invention, the logical check of the hardware ready flag includes: Determine whether the three logical verification conditions consisting of the hardware ready flag being valid, the current instantaneous wind speed being less than the lifting threshold, and the torque limiter system having no fault codes are simultaneously met; If both conditions are met, the verification passes; if any one condition is not met, the verification fails.

[0046] In this embodiment, all three conditions for logical verification are indispensable and must be met to determine whether the verification passes. Specifically: The hardware readiness flag is generated by the logic control layer after the key components have passed acceptance. Its valid state is a preset high-level signal (i.e., "1"). If the flag is low ("0"), it indicates that the key components have not passed acceptance and the hardware is not ready, thus the verification fails. The lifting threshold is preset according to the type of lifting component (tower, nacelle, blade). For example, the lifting threshold for blade lifting is 8 m / s, and the lifting threshold for tower lifting is 10 m / s. Instantaneous wind speed is collected in real time by an anemometer. If the wind speed is greater than or equal to the lifting threshold, it indicates that the ambient wind force is too strong and unsuitable for lifting operations, thus the verification fails. The torque limiter performs real-time self-testing. When it detects a fault (such as sensor fault or data transmission fault), it generates a corresponding fault code. If a fault code exists, it indicates that the torque limiter cannot work properly and cannot provide reliable lifting data, thus the verification fails.

[0047] The logic control layer performs synchronous judgment on the three conditions. Only when all three conditions are met is the verification considered passed and the subsequent dynamic operation stage allowed. If any one condition is not met, the hoisting process is immediately terminated and the corresponding prompt information is output to facilitate the operator's troubleshooting.

[0048] In one exemplary embodiment of the present invention, generating a dynamic safety envelope based on environmental meteorological data in the state data includes: Establish a time sliding window, collect wind speed sampling values ​​in a continuous time series, calculate the wind speed increment between adjacent sampling points based on the wind speed sampling values, and obtain the first derivative of wind speed change. If the current wind speed is not exceeded, but the first derivative of the wind speed change is continuously positive and exceeds the gust warning threshold, it is determined that there is a risk of exceeding the limit in the future operation window, and the maximum allowable speed of the crane movement is reduced or a hovering and holding command is executed.

[0049] In this embodiment, the length of the time sliding window is preset to 5s-10s (adjustable according to the gust response speed). The window slides forward in 1s increments, collecting wind speed samples in real time over a continuous time series. The wind speed samples are collected by an anemometer at a frequency of 10Hz to ensure that instantaneous changes in wind speed are captured. The wind speed increment between adjacent sampling points, i.e., the wind speed value of the later sampling point minus the wind speed value of the earlier sampling point, is represented by the first derivative of the wind speed change, which is the ratio of the wind speed increment to the sampling time interval (0.1s). This first derivative reflects the rate of change of wind speed; the larger the first derivative, the faster the wind speed changes and the higher the risk of gusts.

[0050] The current wind speed is not exceeded, which means that the current instantaneous wind speed is less than the wind speed threshold corresponding to the dynamic safety envelope, but the first derivative of the wind speed change is continuously positive (indicating that the wind speed is continuously increasing) and exceeds the gust warning threshold (the gust warning threshold is preset to 0.5m / s², which can be adjusted according to the operation scenario). This indicates that the wind speed may exceed the safety threshold in the near future (e.g., 1s-3s), and there is a risk of exceeding the limit.

[0051] To address this risk, the logic control layer outputs control commands, offering two control methods to choose from based on the actual situation: First, reduce the crane's maximum permissible speed (e.g., reduce hoisting and luffing speeds to 50%-70% of their original speeds) to minimize the impact of wind speed changes on the load; second, execute a hovering command to stop all crane movements, keeping the load hovering until the wind speed stabilizes and the risk is eliminated, at which point lifting operations can resume. This method allows for advance prediction of gust risks, preventing sudden wind speed changes from causing actual operating parameters to exceed the dynamic safety envelope.

[0052] An exemplary embodiment of the present invention further includes: Different wind speed alarm thresholds and action speed limits are preset for different hoisting objects; The torque limiter detects the current load weight and amplitude, automatically identifies the current lifting object, and calls the corresponding wind speed alarm threshold and action speed limit value based on the identified lifting object.

[0053] In this embodiment, during wind turbine installation, the tower, nacelle, and blades differ in weight, volume, and windward area, resulting in varying sensitivities to wind speed. Therefore, different tiered safety interlocking parameters need to be preset to ensure the safety of different components during installation. Specific preset parameters are as follows (adjustable according to actual installation requirements): For tower installation, the wind speed alarm threshold is 10 m / s, with operating speed limits of ≤0.5 m / s for lifting speed and ≤1 m / s for luffing speed; for nacelle installation, the wind speed alarm threshold is 9 m / s, with operating speed limits of ≤0.4 m / s for lifting speed and ≤0.8 m / s for luffing speed; and for blade installation, the wind speed alarm threshold is 8 m / s, with operating speed limits of ≤0.3 m / s for lifting speed and ≤0.6 m / s for luffing speed. These parameters are preset in the logic control layer as the basis for tiered interlocking control.

[0054] The torque limiter monitors the current load weight and boom radius in real time. The logic control layer compares the detected load weight and boom radius with the preset weight-radius correspondences for different lifting components to automatically identify the current lifting object. For example, the load weight of a tower is typically 80t-120t, corresponding to a boom radius of 15m-25m; the load weight of a blade is typically 20t-30t, corresponding to a boom radius of 25m-35m. Through the dual comparison of weight and radius, the lifting object can be accurately identified, avoiding identification errors.

[0055] After the logic control layer identifies the current lifting object, it automatically retrieves the corresponding wind speed alarm threshold and motion speed limit from preset parameters to monitor the lifting operation in real time. For example, when the lifting object is identified as a blade, the corresponding wind speed alarm threshold (8m / s) and motion speed limit are retrieved. When the instantaneous wind speed reaches 8m / s, an alarm signal is generated. When the crane's motion speed exceeds the limit, the speed is automatically reduced to within the limit range to ensure the operational safety of different lifting components and improve the pertinence and reliability of interlocking control.

[0056] Secondly, the present invention also provides a wind turbine hoisting safety interlock control system, comprising: The perception layer is used to collect real-time status data of the crane and wind turbine hoisting operation environment. The logic control layer is configured to: calculate the relocation safety assessment index of the crane based on the state data; and output a hydraulic locking signal to lock the crane traveling mechanism when the relocation safety assessment index does not meet the preset conditions. When the relocation safety assessment index meets the preset conditions, the target component data of the crane in the status data is compared with the preset standard data. When the target component data does not match the preset standard data, an alarm signal is generated. When the target component data matches the preset standard data, a hardware ready flag for the crane is generated, and a logical check is performed on the hardware ready flag. If the check fails, the crane hoisting process is terminated. When the verification is passed, a dynamic safety envelope is generated based on the environmental meteorological data in the status data. When the actual operating parameters of the crane exceed the dynamic safety envelope, the crane pilot control oil circuit is cut off. When the actual operating parameters of the crane are within the dynamic safety envelope, the crane pilot control oil circuit is kept open. The execution layer includes an electromagnetic shut-off valve and a proportional pressure reducing valve connected in series in the crane's hydraulic system, used to cut off or regulate the hydraulic oil circuit according to the instructions of the logic control layer.

[0057] In this embodiment, the sensing layer includes tilt sensors, pressure sensors, industrial cameras, anemometers, and torque limiters. It is the core of the system's data acquisition, and the various sensors work together to ensure the comprehensiveness, real-time performance, and accuracy of the status data. Among them, the dual-axis tilt sensor is installed at the center of the crane chassis to collect the longitudinal and lateral tilt angles of the crane after it is standing upright, converting them into flatness values ​​to provide data for calculating the relocation safety assessment index; the track tension pressure sensor is installed on the track tensioning mechanism on both sides of the crane to collect the contact pressure data between the track and the ground to assist in calculating the ground pressure distribution; the high-definition industrial camera is installed above the boom head and the cab to perform fixed-point scanning of the wire rope and hook assembly, collecting image data to provide support for target component comparison; the anemometer is installed on the top of the crane boom to collect real-time meteorological data such as instantaneous wind speed and wind speed change trends in the working environment, providing data for dynamic safety envelope generation and hierarchical interlocking control; the torque limiter is installed at the root of the crane boom to collect real-time data such as the load weight, boom amplitude, and boom angle, providing data for center of gravity position calculation, lifting object identification, and logic verification, and also has its own fault detection function to generate fault codes. All sensors in the perception layer are industrial-grade sensors, which are anti-interference, waterproof, dustproof, and resistant to high and low temperatures. They are suitable for the complex working environment of wind power installation and ensure that data can be stably collected and transmitted to the logic control layer even in harsh environments.

[0058] The logic control layer is the core control unit of the system. In a preferred implementation, the logic control layer can employ a programmable logic controller (PLC), a microcontroller, an industrial computer, or a dedicated control chip. It internally stores control programs that implement the aforementioned functions, receives status data transmitted from the sensing layer, executes corresponding control logic, and outputs control commands to the execution layer. The implementation process of the core functions of the logic control layer corresponds one-to-one with the steps of the aforementioned wind power hoisting safety interlocking control method. Specifically: after receiving status data from the sensing layer, it first calculates the relocation safety assessment index to determine the relocation safety; after the relocation is safe, it compares the target component data with preset standard data to determine the integrity of the target component; after the target component is qualified, it generates a hardware ready flag and performs a logic check; after the check passes, it generates a dynamic safety envelope to achieve dynamic interlocking control, ensuring the safety of the entire hoisting operation process. In addition, the logic control layer also has auxiliary functions such as data processing, parameter storage, and fault diagnosis. It can store preset safety thresholds, hierarchical interlocking parameters, metal fatigue crack feature library, etc. At the same time, it performs noise reduction and filtering on the data transmitted by the sensor to ensure the accuracy of the data. When a fault is detected (such as sensor fault or data transmission fault), a fault prompt is generated to facilitate the operator's troubleshooting.

[0059] The execution layer is the core of the system's action execution. It receives control commands from the logic control layer and achieves interlocked control of the crane by controlling the opening and closing of the hydraulic circuit and adjusting the pressure. Specifically, an electromagnetic shut-off valve is connected in series in the crane's pilot control oil circuit. When it receives a hydraulic interlock signal or a circuit cut-off command from the logic control layer, the electromagnetic shut-off valve closes, cutting off the pilot control oil circuit and stopping the crane's travel, lifting, and luffing actions. When it receives a circuit-keeping command, the electromagnetic shut-off valve opens, allowing the pilot control oil circuit to operate normally, and the crane to operate normally. A proportional pressure reducing valve is connected in series in the crane's hydraulic system. When it receives a speed adjustment command from the logic control layer (such as reducing the crane's operating speed), the proportional pressure reducing valve adjusts the hydraulic oil pressure, thereby regulating the crane's operating speed and achieving precise speed control to avoid safety hazards caused by excessive speed. Both the electromagnetic shut-off valve and the proportional pressure reducing valve in the execution layer use industrial-grade hydraulic components, featuring fast response speed, high control accuracy, and high reliability, ensuring timely and accurate execution of the logic control layer's commands and guaranteeing the effectiveness of the interlocked control. In one exemplary embodiment of the invention, the logic control layer is further configured as follows: Simultaneously record sensor data, logic judgment results, and control commands; When the interlocking action is triggered, the data records within a preset time period before and after the triggering time are automatically locked as an unalterable basis for accident analysis. In this embodiment, the logic control layer has a data recording function, recording three types of data in real time: first, all sensor data transmitted by the perception layer (such as wind speed, load weight, and flatness value); second, logic judgment results (such as whether the relocation safety assessment index meets the standard, whether key components are qualified, and whether the logic check passes); and third, all control commands output by the logic control layer (such as hydraulic interlock signals, alarm signals, and oil circuit cut-off commands). The data recording frequency is consistent with the sensor acquisition frequency to ensure the continuity and integrity of the data.

[0060] When a locking action is triggered (e.g., a site relocation safety assessment fails to meet standards, or actual operating parameters exceed the dynamic safety envelope), the logic control layer automatically locks data records within a preset time period before and after the trigger (preferably 10-20 seconds, i.e., 5-10 seconds before and 5-10 seconds after triggering), and encrypts and stores the data to ensure it cannot be tampered with. This data can serve as a basis for accident analysis. In the event of a safety accident or abnormal situation, operators can retrieve the locked data to analyze the cause of the accident (e.g., sudden changes in wind speed, failure of critical components, etc.), providing reliable data support for subsequent accident investigation and solution optimization.

[0061] Thirdly, the present invention also provides an electronic device, comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of a wind power hoisting safety interlock control method as described in any of the preceding claims; In this embodiment, the electronic device can serve as a concrete implementation carrier for the logic control layer, including but not limited to industrial computers, PLCs, and microcontrollers. The memory stores computer programs, preset parameters (such as safety thresholds and hierarchical interlocking parameters), sensor data, and logic judgment results. The memory can utilize various storage media such as ROM, RAM, hard disks, and USB flash drives to ensure the security and stability of data storage. The processor executes the computer programs stored in the memory, calls preset parameters, receives sensor data, executes all steps of the wind power hoisting safety interlocking control method, and outputs control commands to achieve full-process interlocking control of the hoisting operation.

[0062] The electronic device may also include a communication interface for data transmission and command interaction with various sensors in the sensing layer and hydraulic components in the execution layer. The communication interface can use various methods such as RS485, Ethernet, and wireless communication to ensure the real-time performance and reliability of data transmission. It may also include a display interface for connecting to a display device to display sensor data, logic judgment results, control commands, and other information in real time, so that operators can monitor the operation status in real time.

[0063] Fourthly, the present invention also provides a computer-readable storage medium, characterized in that the computer-readable storage medium stores instructions that, when the instructions are executed on a computer, cause the computer to perform the steps of a wind power hoisting safety interlock control method as described in any of the preceding claims; In this embodiment, the computer-readable storage medium can be a USB flash drive, portable hard drive, ROM, RAM, optical disc, or other media capable of storing instructions. The stored instructions are computer program instructions for implementing the wind power hoisting safety interlocking control method. When these instructions are executed on a computer (such as the processor of the aforementioned electronic device), the computer can perform all the steps of the above method, including data acquisition, site relocation safety assessment, key component comparison, logic verification, dynamic safety envelope generation, and hierarchical interlocking control, thereby achieving safety interlocking control for hoisting operations.

[0064] The advantage of this computer-readable storage medium is that it can store and propagate the instructions for implementing the method of the present invention, which can be easily called by different electronic devices without the need to repeatedly write programs, thus reducing the cost of system deployment. At the same time, it ensures that the method steps executed by different devices are consistent, thus guaranteeing the uniformity and reliability of interlocking control.

[0065] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A safety interlocking control method for wind turbine hoisting operations, characterized in that, include: Real-time data collection of the status of the crane and wind power hoisting operation environment; calculation of the crane relocation safety assessment index based on the status data; output of a hydraulic interlock signal to lock the crane traveling mechanism when the relocation safety assessment index does not meet the preset conditions. When the relocation safety assessment index meets the preset conditions, the target component data of the crane in the status data is compared with the preset standard data. When the target component data does not match the preset standard data, an alarm signal is generated. When the target component data matches the preset standard data, a hardware ready flag for the crane is generated. The hardware ready flag is then logically checked. If the check fails, the crane hoisting process is terminated. When the verification is passed, a dynamic safety envelope is generated based on the environmental meteorological data in the status data. When the actual operating parameters of the crane exceed the dynamic safety envelope, the crane pilot control oil circuit is cut off. When the actual operating parameters of the crane are within the dynamic safety envelope, the crane pilot control oil circuit is kept open.

2. The safety interlocking control method for wind power hoisting operations according to claim 1, characterized in that, The calculation of the crane relocation safety assessment index based on the status data includes: The relocation safety assessment index includes longitudinal flatness value, lateral flatness value, and overturning stability coefficient; The longitudinal and lateral flatness values ​​of the crane after it is standing are obtained by a dual-axis tilt sensor. The real-time center of gravity position data of the crane is obtained by calculating the torque limiter data. Combined with the real-time center of gravity position data and the track tension pressure sensor data, the ground pressure distribution of the tracks on both sides of the crane is calculated in reverse. Based on the ground pressure distribution, the overturning stability coefficient of the crane is corrected. If the longitudinal flatness value or the transverse flatness value is greater than the preset flatness limit, or the corrected anti-overturning stability coefficient is less than 1.15, then the transfer safety assessment index is determined to not meet the preset conditions.

3. The safety interlocking control method for wind power hoisting operations according to claim 1, characterized in that, The comparison of the target component data of the crane in the status data with the preset standard data includes: The industrial camera is controlled to perform fixed-point scanning of the wire rope arrangement and hook assembly of the crane, and to acquire image data of the wire rope arrangement and hook assembly. The texture contour of the wire rope surface is extracted from the image data using an edge detection algorithm, and the rope spacing of the wire rope is identified based on the texture contour. The consistency coefficient of the rope spacing is then calculated. The grayscale change features of the hook assembly surface are identified from the image data. Based on the grayscale change features, the suspected crack area is located. The aspect ratio of the suspected crack area is geometrically matched with the pre-stored metal fatigue crack feature library to determine whether the suspected crack area is a metal fatigue crack. The target component data is determined to match the preset standard data only when the consistency coefficient of the rope spacing is greater than a preset threshold and the suspected crack area is not a metal fatigue crack.

4. The safety interlocking control method for wind power hoisting operations according to claim 1, characterized in that, The logical check of the hardware ready flag includes: Determine whether the three logical verification conditions consisting of the hardware ready flag being valid, the current instantaneous wind speed being less than the lifting threshold, and the torque limiter system having no fault codes are simultaneously met; If both conditions are met, the verification passes; if any one condition is not met, the verification fails.

5. The safety interlocking control method for wind power hoisting operations according to claim 1, characterized in that, The generation of the dynamic security envelope based on the environmental meteorological data in the state data includes: Establish a time sliding window, collect wind speed sampling values ​​in a continuous time series, calculate the wind speed increment between adjacent sampling points based on the wind speed sampling values, and obtain the first derivative of wind speed change. If the current wind speed is not exceeded, but the first derivative of the wind speed change is continuously positive and exceeds the gust warning threshold, it is determined that there is a risk of exceeding the limit in the future operation window, and the maximum allowable speed of the crane movement is reduced or a hovering and holding command is executed.

6. The safety interlocking control method for wind power hoisting operations according to claim 1, characterized in that, Also includes: Different wind speed alarm thresholds and action speed limits are preset for different hoisting objects; The torque limiter detects the current load weight and amplitude, automatically identifies the current lifting object, and calls the corresponding wind speed alarm threshold and action speed limit value based on the identified lifting object.

7. A safety interlocking control system for wind turbine hoisting operations, characterized in that, The safety interlocking control method for performing wind power hoisting operations according to any one of claims 1-6 includes: The perception layer is used to collect real-time status data of the crane and wind turbine hoisting operation environment. The logic control layer is configured to: calculate the relocation safety assessment index of the crane based on the state data; and output a hydraulic locking signal to lock the crane traveling mechanism when the relocation safety assessment index does not meet the preset conditions. When the relocation safety assessment index meets the preset conditions, the target component data of the crane in the status data is compared with the preset standard data. When the target component data does not match the preset standard data, an alarm signal is generated. When the target component data matches the preset standard data, a hardware ready flag for the crane is generated, and a logical check is performed on the hardware ready flag. If the check fails, the crane hoisting process is terminated. When the verification is passed, a dynamic safety envelope is generated based on the environmental meteorological data in the status data. When the actual operating parameters of the crane exceed the dynamic safety envelope, the crane pilot control oil circuit is cut off. When the actual operating parameters of the crane are within the dynamic safety envelope, the crane pilot control oil circuit is kept open. The execution layer includes an electromagnetic shut-off valve and a proportional pressure reducing valve connected in series in the crane's hydraulic system, used to cut off or regulate the hydraulic oil circuit according to the instructions of the logic control layer.

8. The safety interlocking control system for wind power hoisting operations according to claim 7, characterized in that, The logic control layer is also configured to: Simultaneously record sensor data, logic judgment results, and control commands; When the interlocking action is triggered, the data records within a preset time period before and after the triggering time are automatically locked as an unalterable basis for accident analysis.

9. An electronic device, characterized in that, include: The memory, the processor, and the computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the safety interlocking control method for wind power hoisting operations as described in any one of claims 1 to 6.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores instructions that, when executed on a computer, cause the computer to perform the steps of the safety interlocking control method for wind power hoisting operations as described in any one of claims 1 to 6.

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