Insulation sub-string live working robot unexpected power failure guarantee system and method

Abstract

The application discloses an unexpected power-off guarantee system and method for an insulator string live-line working robot, relates to the technical field of power transmission, and comprises an environment and power supply state sensing unit, a power-off risk discrimination and grading early warning unit, an emergency braking and mechanical locking unit, a multi-stage redundant anti-falling and buffering unit, an emergency power supply quick switching and bottom guarantee endurance unit and a safety linkage control unit. The power-off risk discrimination and grading early warning unit is used for determining the system warning level. The emergency braking and mechanical locking unit is used for executing a first-stage protection action of a normally closed brake lock and a mechanical locking claw pop-up self-locking, and confirming the locking state. The multi-stage redundant anti-falling and buffering unit is used for executing a second-stage anti-falling action to limit and stop the robot and buffer energy absorption. The application can significantly improve the safety and engineering application reliability of the high-altitude insulator string working robot.

Description

Technical Field

[0001] This application relates to the field of power transmission technology, and in particular to an accidental power outage protection system and method for live-line working robots for insulator strings. Background Technology

[0002] In live-line insulator replacement, defect detection, and high-altitude maintenance operations on transmission lines, robots typically need to move along the surface of insulator strings or along motion support structures located near the insulator strings, performing tasks such as clamping, positioning, disassembly, and inspection in high-altitude environments. Due to the high altitude of the insulator strings, significant wind disturbances, and complex attitude changes at the work site, any abnormal main power supply, momentary power outage, battery management failure, or power circuit contact failure during robot operation can easily lead to risks such as drive instability, reduced clamping force, braking failure, and overall robot slippage. This is especially true for robots operating on insulator strings, whose work surfaces are characterized by series distribution, local undulations, and significant wind load and vibration coupling effects. The ability to maintain safety after a power outage directly impacts equipment safety and the safety of on-site personnel.

[0003] Currently, methods for handling the risk of power outages in aerial work robots mainly include manual remote emergency stops, single electromagnetic braking, backup batteries for short-term power supply, and additional safety rope protection. Some solutions can maintain communication and control through backup power after a power outage, while others install brakes on the drive motor shaft to reduce slippage in abnormal conditions. However, most of these solutions are designed for ground-based mobile platforms, track-mounted inspection platforms, or ordinary lifting machinery, lacking a systematic power outage fall prevention linkage design for insulator string operating environments. This makes it difficult to simultaneously address risk warning speed, clamping and locking reliability, redundant fall prevention capabilities, and continuous control capabilities after a power outage. Summary of the Invention

[0004] The purpose of this application is to provide an accidental power outage protection system and method for robots working on live insulator strings, which significantly improves the safety and engineering application reliability of robots working on live insulator strings at heights.

[0005] To achieve the above objectives, this application provides the following solution: In the first aspect, this application provides an accidental power outage protection system for a robot working on live insulator strings, including: an environment and power supply status sensing unit, a power outage risk judgment and graded early warning unit, an emergency braking and mechanical locking unit, a multi-level redundant anti-fall buffer unit, an emergency power supply rapid switching and backup power supply unit, and a safety linkage control unit.

[0006] The environment and power supply status sensing unit is used to collect multi-source status data of the robot working on the insulator string.

[0007] The power outage risk assessment and graded early warning unit is used to receive multi-source status data, calculate the power outage risk index and power outage probability estimate based on the multi-source status data, and determine the system early warning level.

[0008] The emergency braking and mechanical locking unit is used to perform a first-level protection action of locking the normally closed brake and releasing the mechanical locking claw to lock itself when the system warning level reaches the preset condition or the main power supply is lost, and to confirm the locking status.

[0009] The multi-level redundant fall protection buffer unit is used to perform secondary fall protection actions to limit and stop the robot and absorb energy when the locking state confirmation fails or the robot has a tendency to slip.

[0010] The emergency power quick switch and backup power unit is used to switch the system from the main power supply to the emergency power supply when the main power supply drops below a set threshold.

[0011] The safety linkage control unit is used to uniformly schedule the above-mentioned units.

[0012] Secondly, this application provides a method for protecting against unexpected power outages for robots working on live insulator strings, including: Multi-source status data of the robot working on live insulator strings are collected.

[0013] The power outage risk index and power outage probability estimate are calculated based on multi-source status data to determine the system early warning level.

[0014] When the system warning level reaches the preset condition or a loss of main power supply is detected, the first-level protection action of locking the normally closed brake and self-locking the mechanical locking claw is executed, and the locking status is confirmed.

[0015] If the locking status fails to be confirmed or the robot shows a tendency to slip, a secondary anti-fall action is executed to limit and stop the robot and absorb energy.

[0016] When the main power supply drops below a set threshold, the system will switch from the main power supply to the emergency power supply.

[0017] Based on the system's early warning level and the execution results of Level 1 protection actions and Level 2 fall prevention actions, multi-source status data are collected and transmitted back.

[0018] According to the specific embodiments provided in this application, the following technical effects are disclosed: This application provides an accidental power outage protection system and method for live-line working robots for insulator strings. An environmental and power supply status sensing unit collects multi-source status data from the live-line working robot for real-time input to a subsequent power outage risk assessment and graded early warning unit. The power outage risk assessment and graded early warning unit calculates a power outage risk index and an estimated power outage probability based on the multi-source status data, determines the system's early warning level, and achieves early warning and graded handling of power outage risks. When the system's early warning level reaches a preset condition or a main power supply loss is detected, the emergency braking and mechanical locking unit engages the normally closed brake and activates the mechanical locking claws. The system initiates a primary protection action based on the locking mechanism and confirms the locking status, thus establishing a primary active fall protection capability. A multi-level redundant fall protection buffer unit executes a secondary fall protection action to limit and stop the robot and absorb energy when the locking status confirmation fails or the robot shows a tendency to slip. This provides secondary fall protection and impact mitigation capabilities in addition to primary protection, improving the overall safety redundancy of high-altitude operations with insulator strings. An emergency power rapid switching and backup power unit can switch the system from main power to emergency power, ensuring the robot's safe linkage actions can continue to execute after a power outage. The safety linkage control unit uniformly schedules all units, ensuring the system's safety and reliability. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the overall structure of an accidental power outage protection system for a robot working on live insulator strings, provided as an embodiment of this application.

[0021] Figure 2 A flowchart of multi-source state perception and power outage risk judgment provided in an embodiment of this application.

[0022] Figure 3 This is a timing flowchart for a security linkage control provided in an embodiment of this application.

[0023] Figure 4 The graph shows the variation of key parameters under simulated power outage conditions, as provided in an embodiment of this application. Detailed Implementation

[0024] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0026] Specifically, the relevant solutions have the following shortcomings: ① The identification of power outage risks is based on a single dimension, usually only monitoring whether the main voltage is below the threshold. It lacks joint discrimination of multiple source signals such as voltage drop rate, attitude change, vibration and shock, wind speed disturbance and clamping status, resulting in delayed early warning.

[0027] ② The power failure protection chain is incomplete. Most related solutions rely on a single electromagnetic brake or a single clamping action. If the brake response is too slow or the clamping mechanism is loosened by impact, the robot may still slip along the insulator string.

[0028] ③ There is a lack of self-holding locking structures suitable for insulator string operation. Ordinary power failure protection mechanisms are usually characterized by energized control and power failure, and cannot maintain effective clamping and mechanical locking when the main power supply is completely lost.

[0029] ④ There is a lack of coordination between the backup power supply and the safety actuator. Even if the relevant system is equipped with a backup battery, it is often only used to keep the controller powered on, and it fails to form a unified control closed loop with the warning, braking, locking, buffering and alarm modules.

[0030] ⑤ The system lacks buffer protection design for high-altitude wind loads, vibrations, and the tilting posture of insulator strings. When the first-level braking or first-level locking fails, it is difficult to absorb and limit the impact energy, resulting in insufficient overall safety redundancy of the system.

[0031] Therefore, there is an urgent need for an accidental power outage prevention and safety assurance system and method for robots operating insulator strings. By constructing an integrated chain safety system of "multi-source perception - risk judgment - power outage linkage - redundant fall prevention - emergency endurance", the robot can achieve rapid early warning, stable locking and safe maintenance in the event of abnormal main power supply or accidental power outage.

[0032] To address the issues of slow early warning, delayed locking, insufficient redundancy, and poor continuous control capability after power outages in the event of main power supply anomalies or unexpected power failures for insulator string operation robots, this application designs and implements a power outage fall prevention early warning and safety assurance system and method for insulator string operation environments (i.e., an accidental power outage protection system and method for live-line insulator string operation robots). This scheme is based on multi-source state perception, with power outage risk index discrimination as its core, and emergency braking and mechanical locking as key execution means, supplemented by multi-level redundant fall prevention buffer mechanisms and a rapid emergency power switching mechanism, forming a complete chain-like safety closed loop.

[0033] The entire system consists of an environmental and power supply status sensing unit, a power outage risk assessment and graded early warning unit, an emergency braking and mechanical locking unit, a multi-level redundant fall protection buffer unit, an emergency power rapid switching and backup power unit, and a safety linkage control unit. Each unit works collaboratively around the specific scenario of high-altitude insulator string operations, considering both the electrical failure process of main power supply falling and the mechanical safety processes of wind load, vibration, tilt angle, and slippage trend. This allows the robot to provide early warning before a power outage, quickly lock in place at the moment of power failure, and maintain necessary control and alarm capabilities after a power outage.

[0034] The overall solution has advantages such as clear structure, complete protection chain, strong self-holding ability after power failure, high redundancy level and adaptability to complex working conditions of insulator strings, which can significantly improve the safety and engineering application reliability of high-altitude insulator string operation robots.

[0035] like Figure 1 As shown, an accidental power outage protection system for robots working on live insulator strings is provided, including: an environment and power supply status sensing unit, a power outage risk judgment and graded early warning unit, an emergency braking and mechanical locking unit, a multi-level redundant anti-fall buffer unit, an emergency power rapid switching and backup power unit, and a safety linkage control unit.

[0036] The environment and power supply status sensing unit is used to collect multi-source status data of the robot working on the insulator string.

[0037] The power outage risk assessment and graded early warning unit is used to receive multi-source status data, calculate the power outage risk index and power outage probability estimate based on the multi-source status data, and determine the system early warning level.

[0038] In another exemplary embodiment of this application, the power outage risk identification and classification early warning unit includes: a power outage risk index calculation and power outage probability estimation unit, and a risk level classification unit.

[0039] The power outage risk index calculation and power outage probability estimation unit is used to calculate the power outage risk index and power outage probability estimate based on multi-source state data.

[0040] The risk level classification unit is used to determine the risk level and probability level based on the power outage risk index and the estimated power outage probability value using a preset warning threshold. The maximum value between the risk level and the probability level is taken as the system warning level.

[0041] The emergency braking and mechanical locking unit is used to perform a first-level protection action of locking the normally closed brake and releasing the mechanical locking claw to lock itself when the system warning level reaches the preset condition or the main power supply is lost, and to confirm the locking status.

[0042] The multi-level redundant fall protection buffer unit is used to perform secondary fall protection actions to limit and stop the robot and absorb energy when the locking state confirmation fails or the robot has a tendency to slip.

[0043] In another exemplary embodiment of this application, the multi-level redundant fall arrestor unit includes: a two-level redundant fall arrestor mechanism and a buffer energy absorption mechanism.

[0044] The secondary redundant fall protection mechanism is used to limit and stop the robot.

[0045] The buffer energy absorption mechanism is used for buffer energy absorption.

[0046] In another exemplary embodiment of this application, the secondary redundant fall arrestor adopts a pawl-type limiting component, a wedge-type self-locking component, or a flexible limiting belt component.

[0047] In another exemplary embodiment of this application, the buffer energy absorption mechanism adopts a spring-damping composite structure.

[0048] The emergency power quick switch and backup power unit is used to switch the system from the main power supply to the emergency power supply when the main power supply drops below a set threshold.

[0049] In another exemplary embodiment of this application, the emergency power rapid switching and backup power unit includes a backup battery pack, a supercapacitor module, a power switching controller, and a minimum power consumption task management module.

[0050] The safety linkage control unit is used to uniformly schedule the above-mentioned units.

[0051] The environmental and power supply status sensing unit of this application collects multi-source status data from the insulator string live-line working robot, providing real-time status input for the subsequent power outage risk assessment and graded early warning unit. The power outage risk assessment and graded early warning unit calculates the power outage risk index and power outage probability estimate based on the multi-source status data, determines the system early warning level, and achieves early warning and graded handling of power outage risks. When the system early warning level reaches a preset condition or a main power supply loss is detected, the emergency braking and mechanical locking unit executes a first-level protection action of locking the normally closed brake and self-locking the mechanical locking claw, and locks the device. The system confirms the status, establishing a primary active fall protection capability. When the locking status confirmation fails or the robot shows a tendency to slip, the multi-level redundant fall protection buffer unit executes a secondary fall protection action to limit and stop the robot and absorb energy, providing secondary fall protection and impact mitigation capabilities in addition to primary protection, thus improving the overall safety redundancy of high-altitude operations with insulator strings. The emergency power rapid switching and backup power unit can switch the system from main power supply to emergency power supply, ensuring the robot's safe linkage actions can continue to execute after a power outage. The safety linkage control unit uniformly schedules all units, ensuring the system's safety and reliability.

[0052] The accidental power outage prevention and safety assurance system for insulator string operation robots (i.e., an accidental power outage protection system for live-line insulator string operation robots) of this application consists of six core functional modules connected in series: an environmental and power supply status perception unit, a power outage risk judgment and graded early warning unit, an emergency braking and mechanical locking unit, a multi-level redundant anti-fall buffer unit, an emergency power supply rapid switching and backup power supply unit, and a safety linkage control unit. These six modules transmit status information and execution commands step by step during on-site operations, ultimately achieving safety maintenance under abnormal power outage conditions. The working steps, key formulas, and variable definitions of each module are described in detail below.

[0053] (1) Environment and power supply status sensing unit.

[0054] During high-altitude operations involving insulator strings, the robot is simultaneously affected by power supply fluctuations, body vibration, attitude changes, and wind load disturbances. To avoid missed or false alarms caused by relying solely on a single voltage threshold to determine power outage risk, this unit unifies the modeling of main power supply, motor, attitude, vibration, wind speed, and clamping status signals, generating a state vector. (i.e., multi-source state data), serving as input for subsequent risk assessment. Inputs include main power supply voltage, current, drive motor encoder information, IMU data, wind speed sensor data, temperature information, and clamping status feedback; the output is a fused state vector. (i.e., multi-source state data). For example... Figure 2 The diagram shown is a flowchart of multi-source state perception and power outage risk assessment.

[0055] (a) State vector construction.

[0056] The state vector is constructed as follows: .

[0057] in, for The main power supply voltage at any given time, for The main power supply current at any given time, for The rate of voltage drop at any given moment. for The root mean square value of the body vibration acceleration at time t. for The tilt angle of the machine body relative to the axis of the insulator string at any given moment. for The angular velocity of the driving component at any given moment. for At any given time, the ambient wind speed for The ambient temperature at any given time for The state of charge of the backup power supply at any given time. for The clamping or locking state at any given moment.

[0058] (b) Multi-source normalization.

[0059] To eliminate the direct superposition error of data with different dimensions, each state variable is normalized: .

[0060] in, for The first moment One original state variable, for The first moment A normalized state quantity and These are the minimum and maximum values ​​of the variable within the safe operating range, respectively.

[0061] To enable the insulator string handling robot to proactively identify the risk of unexpected power outages, the environmental and power supply status sensing unit synchronously collects data on the main power supply voltage, current, voltage drop rate, drive motor speed, robot attitude angle, vibration acceleration, ambient wind speed, temperature, and the status of the gripping and execution parts, forming a multi-source status vector. Considering the characteristics of insulator string handling, such as wind-induced swaying, local tilt angle changes, and fluctuations in the force on the gripping claws, this unit improves the stability of anomaly identification through multi-sensor fusion and temporal filtering, avoiding false triggering by a single signal.

[0062] The function of this environment and power supply status sensing unit is to provide real-time status input for the subsequent power outage risk assessment and graded early warning unit, so as to realize the early judgment from "whether there is a power outage" to "whether there is an imminent power loss and that will cause slippage".

[0063] (2) Power outage risk assessment and graded early warning unit.

[0064] The power outage risk assessment and hierarchical early warning unit performs weighted fusion of normalized state variables to establish a power outage risk index. Considering the increased risk of insulator string failure due to a combination of voltage anomalies, mechanical disturbances, and clamping fluctuations, electrical failure symptoms and mechanical instability symptoms are incorporated into the evaluation model. The input to this unit is... The result of its normalization is output as a power outage risk index. Risk level And corresponding warning instructions.

[0065] (a) Calculation of power outage risk index.

[0066] The power outage risk index is defined as follows: .

[0067] in, For the first The weight coefficients of each state variable satisfy the following conditions: , The number of state variables involved in the evaluation. By setting higher weights for voltage drop rate, clamping state, and attitude disturbance, the system's sensitivity to power outage precursors and slip precursors can be improved.

[0068] (b) Power outage probability estimation.

[0069] To enhance the predictive capability for short-term voltage drops and unstable contact conditions, a power outage probability estimation model can be further established: .

[0070] in, for The estimated probability of power outage at any given time. Main power supply early warning threshold, These are empirical coefficients or calibration coefficients.

[0071] (c) Risk level classification.

[0072] according to and The combined results are used to establish a tiered early warning system. Firstly, based on the power outage risk index... Calculate risk level Implement tiered early warning systems. .

[0073] in, , , These are the power outage risk indices. The corresponding Level 1, Level 2, and Level 3 warning thresholds.

[0074] Then based on the power outage probability estimate Calculate probability level : .

[0075] in, , , These are the power outage risk indices. The corresponding Level 1, Level 2, and Level 3 warning thresholds.

[0076] The final system warning level is taken as follows and Higher levels: .

[0077] in, Indicates a normal state; This indicates a Level 1 warning, triggering local audio-visual alerts and background notifications. This indicates a Level 2 warning, triggering brake pre-charging, locking mechanism standby, and backup power self-test. This indicates a Level 3 warning, which directly triggers emergency braking, mechanical locking, and emergency power supply switching. Through this combined judgment method, it can be ensured that the system can promptly enter the corresponding safety protection level when the overall risk increases or the probability of power outage significantly increases.

[0078] The power outage risk assessment and tiered early warning unit establishes a power outage risk index model based on multi-source status data input from the environmental and power supply status sensing unit. It comprehensively assesses main power supply anomalies, loose connectors, instantaneous voltage drops, sudden attitude changes, and external wind-induced vibration disturbances, triggering Level 1, Level 2, and Level 3 safety actions according to the risk level. This unit not only outputs audible and visual alarm signals and remote communication alarms, but also pre-charges the braking actuator, activates the lock-up standby state, and initiates backup power supply self-checks in high-risk conditions.

[0079] The function of this power outage risk assessment and tiered early warning unit is to provide early warning and tiered handling of power outage risks, thereby buying time for emergency braking and mechanical locking.

[0080] (3) Emergency braking and mechanical locking unit.

[0081] when When a Level 3 warning is reached or the main power supply is lost, this unit executes a combined protection action of "normally closed brake locking + mechanical locking claw ejection and self-locking". Because the insulator string handling robot is at risk of slipping along the string direction, relying solely on motor power failure cannot guarantee a stable stop; mechanical locking is also required to create self-holding capability. The unit's inputs are the linkage control command and the robot's motion status; its outputs are the braking response, locking status, and estimated slip distance.

[0082] (a) Determination of safety retention capacity.

[0083] The safety maintenance condition for the robot along the tangential direction of the insulator string can be expressed as: .

[0084] in, To maintain force for safety, The equivalent friction coefficient of the clamping interface, To hold the normal force, Additional locking force provided to the mechanical locking pawl. For robot gravity, The local tilt angle of the insulator string where the robot is located. This is the equivalent component of the wind load along the slip direction. When When the value is greater than 0, the system can remain stationary and not slip.

[0085] (b) Braking deceleration and braking distance.

[0086] The theoretical braking deceleration and braking distance at the instant of power failure can be written as: .

[0087] .

[0088] in, For braking and deceleration, The braking force provided to the normally closed brake, For the total mass of the robot, The initial velocity of the robot along the insulator string at the instant of power failure. This is the braking distance.

[0089] (c) Locking determination logic.

[0090] To ensure the locking action is truly completed, the emergency braking and mechanical locking unit confirms the locking status through locking position sensors and clamping strain feedback. If locking confirmation fails, the linkage control unit forces the system into a secondary redundant fall protection mode.

[0091] To address the robot's motion-maintaining requirements on insulator strings, the emergency braking and mechanical locking unit employs a composite structure of "motor braking + normally closed brake + spring-preloaded mechanical locking pawl." During normal operation, the drive system controls the robot's movement along the insulator string. When the main power supply fails or the power outage signal reaches the trigger threshold, the normally closed brake automatically engages under power loss conditions, and the mechanical locking pawl, under spring preload, forms a self-locking mechanism on the corresponding load-bearing portion of the insulator string, thus maintaining braking capability even without external power supply.

[0092] The function of this emergency braking and mechanical locking unit is to quickly stop the robot's tendency to slide along the insulator string after the main power supply is abnormal or completely cut off, thus forming a primary active fall prevention capability.

[0093] (4) Multi-level redundant fall protection buffer unit.

[0094] This unit provides secondary redundant fall protection and impact buffering functions on top of primary braking and primary locking. When the robot experiences minor slippage or a large impact during locking under extreme conditions, secondary stopping is achieved through pawl limiting, wedge self-locking, or flexible limiting structures, and kinetic energy is absorbed through a spring-damped buffer structure to reduce the impact on the contact points between the robot body and the insulator string.

[0095] (a) Kinetic energy calculation.

[0096] The formula for calculating kinetic energy is: .

[0097] in, This represents the instantaneous kinetic energy of the robot along the sliding direction before locking.

[0098] (b) Buffer energy absorption model.

[0099] The buffer energy absorption model is as follows: .

[0100] in, The total energy absorbed by the buffer mechanism. For the equivalent stiffness of the buffer spring, For maximum compression, The damping coefficient is... This refers to the compression speed during the buffering process. For buffer duration. When This indicates that the buffer mechanism can theoretically absorb the robot's remaining impact energy.

[0101] (c) Peak impact force estimation.

[0102] .

[0103] in, To buffer the peak impact force during the process, For the maximum compressive displacement, This represents the compression rate at its peak.

[0104] To prevent the primary braking or locking mechanism from failing under extreme impacts, the multi-stage redundant fall arrestor unit is equipped with a secondary redundant fall arrestor mechanism and a buffer energy absorption mechanism. The secondary redundant fall arrestor mechanism can employ a pawl-type limiting assembly, a wedge-type self-locking assembly, or a high-strength flexible limiting band assembly; the buffer energy absorption mechanism adopts a spring-damping composite structure to absorb the impact energy generated at the moment of locking or when the sliding is stopped, thereby reducing the peak impact load on the body and stress concentration at the clamping points.

[0105] The function of this multi-level redundant fall protection buffer unit is to provide secondary fall protection and impact mitigation capabilities in addition to primary protection, thereby improving the overall safety redundancy of insulator string high-altitude operations.

[0106] (5) Emergency power supply quick switching and backup power unit.

[0107] The emergency power rapid switching and backup power unit is used to keep safety-related equipment online after a main power supply failure, ensuring the continuous execution of functions such as alarms, status feedback, lockout confirmation, and emergency rescue waiting. Inputs include main power supply status, backup power supply status, and linkage control commands; outputs include a switching completion flag, backup power supply output status, and remaining safe operating time.

[0108] (a) Power switching time.

[0109] .

[0110] in, Total switching time For power outage detection time, To switch control decision time, This refers to the actual switching time of the relay or electronic switch. Through optimization... , and This allows for the control of safe power supply interruption time within a relatively small range.

[0111] (b) Estimated minimum battery life.

[0112] .

[0113] in, This is the minimum safe operating time that a backup power source can maintain. For power conversion efficiency, Available energy for backup power. This is the minimum sustaining power in safe mode.

[0114] (c) Minimum charge state constraint for safe mode.

[0115] .

[0116] in, The minimum state of charge required to perform the predetermined safe waiting time, To preset the waiting time for rescue, Rated energy for backup power.

[0117] The emergency power rapid switching and backup power unit consists of a backup battery pack, a supercapacitor module, a power switching controller, and a minimum power consumption task management module. When the main power supply is detected to drop below a threshold, the switching controller switches the system from the main power supply to the emergency power supply according to the set logic, allowing the controller, alarm module, status feedback module, attitude monitoring module, and lockout status detection module to continue operating. Through hierarchical load management, priority is given to ensuring that safety-related equipment remains online, reducing unnecessary load power consumption.

[0118] The function of this emergency power supply quick switching and backup power unit is to ensure that the robot can continue to perform safe linkage actions after a power outage, and to maintain the necessary alarm, communication and rescue waiting capabilities.

[0119] (6) Safety linkage control unit.

[0120] This safety linkage control unit performs unified timing scheduling of each protection action and determines whether to proceed to the next protection level based on execution feedback. The linkage logic is based on the power outage risk level; when... As the system is progressively upgraded from Level 1 to Level 3, it sequentially enters the warning, standby, braking and locking, Level 2 fall protection, and emergency power supply modes. The sequence of actions can be summarized as follows: ① Normal state: Continuously collect state data and update the risk index.

[0121] ② Level 1 warning: Audio and visual alerts are provided and the data is transmitted back to the backend.

[0122] ③ Level 2 warning: The brake enters standby mode, the locking mechanism is preloaded, and the backup power supply performs a self-test.

[0123] ④ Level 3 warning or confirmed power failure: normally closed brake locks, mechanical lock pawl self-locks, backup power supply switches.

[0124] ⑤ If locking confirmation fails: immediately activate the secondary redundant fall protection buffer unit.

[0125] ⑥ Maintain safe mode: continuously transmit location, attitude, locking status and remaining battery power, waiting for manual intervention or rescue recovery.

[0126] like Figure 3The diagram shows the safety linkage control sequence flow. The safety linkage control unit uniformly schedules the above functional units, establishing a linkage sequence of "early warning - braking - locking - fall prevention - switching - feedback," and performs closed-loop confirmation of the execution results. When the first-level action fails to reach the set state, the second-level action is automatically triggered; when the locking state confirmation fails, the backup power output is immediately maintained and a high-priority alarm signal is repeatedly sent.

[0127] This safety linkage control unit elevates the protection units from simple stacking to a collaborative safety system with controllable timing and verifiable status.

[0128] The present application will now be described with reference to specific embodiments.

[0129] I. Implementation process of the environmental and power supply status sensing unit.

[0130] This embodiment designs a maintenance robot for moving along insulator strings. The robot weighs 32kg, has a rated operating voltage of 48V, a rated moving speed of 0.16m / s along the insulator string direction, and consists of four sets of gripping claws (two on each side), one normally closed brake, two sets of spring-preloaded mechanical locking claws, one set of secondary redundant fall protection limit components, and a buffer stroke of 22mm. The sensor configuration is as follows: Main power supply voltage and current sampling frequency: 1000Hz.

[0131] IMU attitude and vibration sampling frequency: 200Hz.

[0132] Wind speed sensor sampling frequency: 20Hz.

[0133] The sampling frequency of the clamping status and locking position sensor is 200Hz.

[0134] Backup power status sampling frequency: 10Hz.

[0135] This step involves synchronously collecting the robot's operating status on the insulator string using the aforementioned sensors, and constructing S(t) according to the aforementioned state vector model. Under normal operating conditions, the main power supply voltage is stable at around 48.2V, the root mean square value of the robot's vibration is approximately 0.18g, the local tilt angle is approximately 7.5°, and the ambient wind speed is 4.2m / s.

[0136] II. Implementation process of power outage risk assessment and graded early warning unit.

[0137] After normalizing the collected state variables, risk calculation is performed using the calibrated weighting coefficients. In this embodiment, voltage, voltage drop rate, vibration acceleration, attitude angle, wind speed, and clamping state are selected as core evaluation variables, with corresponding weights set as follows: .

[0138] .

[0139] The risk level threshold is set as follows: .

[0140] In the test simulating a loose main power supply connector coupled with gust wind disturbance, the main power supply voltage dropped from 48.0V to 34.6V within 75ms, with a peak voltage drop rate of -178.7V / s. The wind speed increased from 4.5m / s to 8.3m / s, and the root mean square value of vibration increased to 0.61g. Based on the risk model calculations, the following results were obtained: .

[0141] Therefore, the system directly enters a level three warning state, triggering emergency braking, mechanical locking, and emergency power switching.

[0142] III. Implementation process of emergency braking and mechanical locking unit.

[0143] In this embodiment, the rated power of the normally closed brake is 420N, and the locking pawl spring, after pre-tensioning, can provide an additional locking force F. l =180N, the equivalent friction coefficient of the clamping interface is taken as... The clamping normal N = 1050 N, and the local tilt angle of the insulator string where the robot is located. Wind load equivalent component F w =22N. Substituting this into the safety maintenance condition, we get: .

[0144] Therefore, under the parameters of this embodiment, the robot possesses sufficient self-holding capability after power failure. Further substituting into the braking distance formula, under the condition that the initial velocity v0 = 0.16 m / s at the moment of power failure, the theoretical braking distance is less than 6 mm. In actual experiments, the normally closed brake response time was 46 ms, the mechanical locking pawl completed self-locking in 79 ms, and the measured maximum sliding displacement was 5.4 mm.

[0145] IV. Implementation process of multi-level redundant fall protection buffer unit.

[0146] To verify the secondary fall protection and buffering capabilities, a simulation test was conducted under the condition of a single-sided delayed action of the locking pawl. In the test, the secondary redundant fall protection component intervened within 11ms, the maximum compression displacement of the buffer component was 14.8mm, and the peak impact force was controlled below 612N. Based on a robot mass of 32kg and an equivalent sliding speed of 0.21m / s before stopping, the robot's instantaneous kinetic energy is approximately: .

[0147] The equivalent stiffness of the buffer component is taken as k = 4200 N / m, and the damping coefficient is taken as... Calculations and actual measurements show that the buffer mechanism can absorb the remaining kinetic energy and significantly reduce the impact of the stop, thus avoiding excessive concentrated loads at the contact points between the body and the insulator string.

[0148] V. Implementation process of emergency power rapid switching and backup power unit.

[0149] In this embodiment, the backup power supply uses a 48V, 6Ah lithium iron phosphate battery pack, and is equipped with a supercapacitor module to ensure continuous power supply to the controller during switching. Power outage detection time t d =18ms, control decision time t c =27ms, switch execution time t r =61ms, therefore the total switching time is: .

[0150] After power switching is complete, the system automatically enters safety mode, retaining only the controller, communication module, alarm module, attitude monitoring module, lock status detection module, and emergency lighting module, with a minimum sustaining power of approximately 32W. Based on a backup power supply of 240Wh and a conversion efficiency of 0.88, the guaranteed minimum operating time is as follows: .

[0151] In practical engineering applications, a portion of the battery life margin can be reserved for low-temperature correction, aging correction, and communication peak power consumption correction, depending on project requirements, while still meeting the needs of long-term waiting for rescue or remote recovery.

[0152] VI. Implementation process of the safety linkage control unit.

[0153] In 30 simulated power outage tests, the safety linkage control unit executed the following sequence: "Level 3 warning trigger - normally closed brake locking - mechanical locking pawl self-locking - backup power supply switching - locking status confirmation - continuous alarm and feedback." The key time points are as follows: Level 1 anomaly detection time: approximately 22ms.

[0154] Level 3 warning output time: approximately 34ms.

[0155] Brake lock-up time: approximately 46ms.

[0156] Locking claw completes self-locking time: approximately 79ms.

[0157] Backup power switching completion time: approximately 106ms.

[0158] The first transmission time for high-priority alarms is approximately 132ms.

[0159] like Figure 4 The figure shown is a graph illustrating the changes in key parameters under simulated power outage conditions.

[0160] The above experiments demonstrate that this application has the following advantages: ① It can identify main power supply anomalies in advance when insulator strings are working at height, significantly shortening the risk detection time.

[0161] ② It can achieve self-holding without power loss by relying on normally closed brake and spring pre-tightening locking pawl under complete power failure conditions, thus avoiding the failure of protection action due to power loss.

[0162] ③ Through the two-stage redundant fall protection and buffer energy absorption structure, the slip displacement can be controlled within a small range, and the stopping impact can be effectively reduced.

[0163] ④ The backup power supply has a short switching time, which can continuously ensure that alarm, communication and status monitoring functions are online.

[0164] ⑤ No falling or unstable detachment occurred in any of the 30 simulated power outage tests, demonstrating its good engineering application value.

[0165] The chain-like processing flow constructed in this application, consisting of "multi-source perception and early warning + power failure self-holding braking and locking + redundant fall protection and buffering + emergency power supply," provides a clear causal path for improving the safety of insulator string operation robots in the event of an unexpected power outage: enhanced multi-source state perception → early identification of power failure risks → shortened linkage response time → rapid activation of normally closed braking and mechanical locking → reduced sliding distance → secondary redundancy and buffering further absorb the impact → backup power supply maintains alarm and feedback → significantly improved overall fall protection reliability.

[0166] The beneficial effects of this application are as follows.

[0167] 1. Multi-source sensing and risk assessment improve the timeliness of power outage early warning.

[0168] This application does not solely rely on whether the voltage is below a threshold to determine risk. Instead, it constructs a risk index model by integrating multi-source information such as voltage, voltage drop rate, wind speed, attitude angle, vibration acceleration, and clamping status. Because it incorporates both electrical failure precursors and mechanical instability precursors into the judgment process, it can identify anomalies before a complete power outage, significantly shortening the warning lag time. This effect corresponds to the first part of the causal chain: "Enhanced multi-source state perception → Early identification of power outage risks → Shortened linkage response time."

[0169] 2. Normally closed braking and mechanical locking work together to improve self-holding capability after power failure.

[0170] This application introduces a normally closed brake and a spring-preloaded mechanical locking pawl into the actuator structure for the robot's movement along an insulator string. The normally closed brake possesses an "automatic locking upon power failure" characteristic, while the mechanical locking pawl possesses a "self-holding locking upon power failure" characteristic. The combination of these two features creates a primary fall protection capability that remains effective even after power failure. Compared to traditional solutions that rely solely on electric braking or solely on clamping friction, this application significantly reduces slippage displacement and improves stability during power failure. This effect corresponds to the middle segment of the causal chain: "rapid activation of normally closed braking and mechanical locking → reduced slippage distance."

[0171] 3. Redundancy buffering and emergency power supply enhance the overall safety and reliability of the system.

[0172] Building upon primary braking and locking, this application further incorporates a secondary redundant fall arrest mechanism and an emergency power supply rapid switching module. Even if the primary mechanism exhibits response deviations under extreme impact or complex wind-induced vibration environments, the secondary mechanism can continue to limit and absorb impact energy. Simultaneously, the emergency power supply ensures continuous online operation of alarms, communication, and status monitoring, providing a time window for manual intervention and rescue recovery. This elevates the system from "preventing slippage" to "preventing falls and maintaining a rescueable state." This effect corresponds to the latter part of the causal chain: "Secondary redundancy and buffering further absorb impact → backup power maintains alarms and feedback → overall fall arrest reliability is significantly improved."

[0173] Based on the same inventive concept, this application also provides a method for ensuring the protection against unexpected power outages of a robot working on live insulator strings, in order to implement the aforementioned system for protecting against unexpected power outages of a robot working on live insulator strings. The solution provided by this method is similar to the implementation described in the above system. Therefore, the specific limitations in one or more embodiments of the method for ensuring the protection against unexpected power outages of a robot working on live insulator strings provided below can be found in the limitations of the system for protecting against unexpected power outages of a robot working on live insulator strings described above, and will not be repeated here.

[0174] In one exemplary embodiment, a method for protecting against accidental power outages for robots working on live insulator strings is provided, comprising: Multi-source status data of the robot working on live insulator strings are collected.

[0175] The power outage risk index and power outage probability estimate are calculated based on multi-source status data to determine the system early warning level.

[0176] When the system warning level reaches the preset condition or a loss of main power supply is detected, the first-level protection action of locking the normally closed brake and self-locking the mechanical locking claw is executed, and the locking status is confirmed.

[0177] If the locking status fails to be confirmed or the robot shows a tendency to slip, a secondary anti-fall action is executed to limit and stop the robot and absorb energy.

[0178] When the main power supply drops below a set threshold, the system will switch from the main power supply to the emergency power supply.

[0179] Based on the system's early warning level and the execution results of Level 1 protection actions and Level 2 fall prevention actions, multi-source status data are collected and transmitted back.

[0180] In one exemplary embodiment, the system early warning level is determined by calculating a power outage risk index and an estimated power outage probability based on multi-source state data, specifically including: Based on multi-source state data, the power outage risk index and the power outage probability estimate are calculated respectively.

[0181] The risk level and probability level are determined by a preset warning threshold based on the power outage risk index and the estimated power outage probability. The maximum value between the risk level and the probability level is taken as the system warning level.

[0182] In one exemplary embodiment, the formula for calculating the power outage risk index is: .

[0183] .

[0184] in, for The risk index of power outage at any given moment. The number of state variables participating in the evaluation. For the first The weighting coefficients of each state variable for The first moment A normalized state quantity for The first moment One original state variable, For the first The minimum value of each original state variable within the safe operating range. For the first The maximum value of each original state variable within the safe operating range.

[0185] In an exemplary embodiment, the formula for calculating the power outage probability estimate is as follows: .

[0186] in, for The estimated probability of power outage at any given time. Main power supply early warning threshold, All are empirical coefficients or calibration coefficients. for The main power supply voltage at any given time, for The rate of voltage drop at any given moment. for The root mean square value of the body vibration acceleration at time t. for The tilt angle of the machine body relative to the axis of the insulator string at any given moment. for The ambient wind speed at any given time.

[0187] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0188] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. An accidental power outage protection system for robots operating live-lined insulator strings, characterized in that, include: The environment and power supply status sensing unit is used to collect multi-source status data of the robot working on the insulator string. The power outage risk assessment and graded early warning unit is used to receive multi-source status data, calculate the power outage risk index and power outage probability estimate based on the multi-source status data, and determine the system early warning level. The emergency braking and mechanical locking unit is used to perform a first-level protection action of locking the normally closed brake and popping out the mechanical locking claw when the system warning level reaches the preset condition or the main power supply is lost, and to confirm the locking status. The multi-level redundant fall protection buffer unit is used to perform secondary fall protection actions to limit and stop the robot and absorb energy when the locking state confirmation fails or the robot has a tendency to slip. The emergency power quick switching and backup power unit is used to switch the system from the main power supply to the emergency power supply when the main power supply drops below a set threshold. The safety linkage control unit is used to uniformly schedule the above-mentioned units.

2. The accidental power outage protection system for live-line working robots for insulator strings according to claim 1, characterized in that, The power outage risk identification and classification early warning unit includes: a power outage risk index calculation and power outage probability estimation unit, and a risk level classification unit; The power outage risk index calculation and power outage probability estimation unit is used to calculate the power outage risk index and power outage probability estimate based on multi-source status data. The risk level classification unit is used to determine the risk level and probability level based on the power outage risk index and the estimated power outage probability value using a preset warning threshold. The maximum value between the risk level and the probability level is taken as the system warning level.

3. The accidental power outage protection system for live-line working robots for insulator strings according to claim 1, characterized in that, The multi-level redundant fall protection buffer unit includes: a two-level redundant fall protection mechanism and a buffer energy absorption mechanism; The secondary redundant fall protection mechanism is used to limit and stop the robot. The buffer energy absorption mechanism is used for buffer energy absorption.

4. The accidental power outage protection system for live-line working robots for insulator strings according to claim 3, characterized in that, The secondary redundant fall arrest mechanism adopts a pawl-type limiting component, a wedge-type self-locking component, or a flexible limiting belt component.

5. The accidental power outage protection system for live-line working robots for insulator strings according to claim 3, characterized in that, The buffer energy absorption mechanism adopts a spring-damping composite structure.

6. The accidental power outage protection system for live-line working robots for insulator strings according to claim 1, characterized in that, The emergency power rapid switching and backup power unit includes a backup battery pack, a supercapacitor module, a power switching controller, and a minimum power consumption task management module.

7. A method for ensuring protection against accidental power outages for robots working on live insulator strings, characterized in that, include: Collect multi-source status data of the robot working on live insulator strings; The power outage risk index and power outage probability estimate are calculated based on multi-source status data to determine the system early warning level. When the system warning level reaches the preset condition or the main power supply is lost, the first-level protection action of locking the normally closed brake and self-locking the mechanical locking claw is executed, and the locking status is confirmed. If the locking status fails to be confirmed or the robot shows a tendency to slip, a secondary anti-fall action is executed to limit and stop the robot and absorb energy. When the main power supply drops below a set threshold, the system will switch from the main power supply to the emergency power supply. Based on the system's early warning level and the execution results of Level 1 protection actions and Level 2 fall prevention actions, multi-source status data are collected and transmitted back.

8. The method for ensuring protection against accidental power outages for robots operating live insulator strings according to claim 7, characterized in that, Based on multi-source status data, a power outage risk index and an estimated power outage probability are calculated to determine the system warning level, specifically including: Based on multi-source state data, calculate the power outage risk index and the power outage probability estimate respectively; The risk level and probability level are determined by a preset warning threshold based on the power outage risk index and the estimated power outage probability. The maximum value between the risk level and the probability level is taken as the system warning level.

9. The method for ensuring protection against accidental power outages for robots operating live insulator strings according to claim 7 or 8, characterized in that, The formula for calculating the power outage risk index is as follows: ； ； in, for The risk index of power outage at any given moment. The number of state variables participating in the evaluation. For the first The weighting coefficients of each state variable for The first moment A normalized state quantity for The first moment One original state variable, For the first The minimum value of each original state variable within the safe operating range. For the first The maximum value of each original state variable within the safe operating range.

10. The method for ensuring protection against accidental power outages for robots operating live insulator strings according to claim 7 or 8, characterized in that, The formula for calculating the power outage probability estimate is as follows: ； in, for The estimated probability of power outage at any given time. Main power supply early warning threshold, All are empirical coefficients or calibration coefficients. for The main power supply voltage at any given time, for The rate of voltage drop at any given moment. for The root mean square value of the body vibration acceleration at time t. for The tilt angle of the machine body relative to the axis of the insulator string at any given moment. for The ambient wind speed at any given time.

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