Electrical panel transfer and hoisting device and hoisting method

Abstract

The application provides an electrical panel transfer and hoisting device and a hoisting method, and belongs to the technical field of electrical equipment installation and construction. The device comprises a walking chassis, a clamping mechanism, a synchronous lifting mechanism, a horizontal moving mechanism and a control unit. The method comprises the following steps: transferring to a target work station through the walking chassis; applying a symmetrical clamping force to the panel through the clamping mechanism and performing force closed-loop control to maintain the holding state; vertically lifting to a target height through the synchronous lifting mechanism and performing synchronous error monitoring; performing precise translation to meet the accuracy requirement of alignment deviation through the horizontal moving mechanism combined with a position detection device; and coordinating and scheduling each mechanism through the control unit and implementing multi-stage safety interlocking. The application integrates the functions of transfer, clamping, lifting and positioning in a unified framework, realizes full-process automation through multi-sensor closed-loop control, can be completed by a single person, and has the characteristics of high positioning accuracy, strong safety protection capability and adaptation to narrow spaces.

Description

Technical Field

[0001] This invention relates to the field of electrical equipment installation and construction technology, specifically to an electrical panel transfer and hoisting device and hoisting method. Background Technology

[0002] Electrical control panels, as the core carrier of power distribution systems, are widely used in power engineering, data centers, and industrial plants. During construction, the installation of electrical control panels requires multiple processes, including horizontal transport from the storage yard to the installation site, vertical lifting, and precise positioning and docking.

[0003] Current construction methods typically involve using forklifts or overhead cranes for transport, hydraulic trolleys or chain hoists for lifting, and finally, manual pushing and visual calibration for positioning and docking. These devices operate independently, lacking interaction and closed-loop coordination of control signals. In the clamping stage, manual binding or unidirectional pushing is commonly used to secure the cabinets, lacking real-time monitoring and feedback control of the clamping force. In the lifting stage, the hydraulic lifting mechanism cannot actively adjust the synchronization of multiple support points. In the horizontal positioning stage, it relies on the operator's experience and repeated fine-tuning.

[0004] The above-mentioned separate operation mode has the following technical problems: Firstly, the lack of a unified safety interlocking mechanism among the various devices means that abnormal states such as clamping loosening, lifting and tilting cannot be detected in real time and automatically intervened, resulting in uncontrollable safety risks. Secondly, horizontal positioning relies entirely on human experience and judgment, lacks closed-loop feedback correction capability, and has large positioning deviation and poor consistency. Third, multiple processes require multiple independent machines and multiple operators to complete, and the process connection relies on manual coordination, which limits efficiency and makes equipment scheduling difficult in narrow passage environments. Summary of the Invention

[0005] This invention provides an electrical panel transfer and hoisting device and method to solve the technical problems in existing electrical panel installation operations where the transfer equipment, clamping equipment and positioning equipment are independent of each other, lack closed-loop collaborative control, resulting in uncontrollable safety risks, insufficient positioning accuracy and the need for multiple people to cooperate in operation.

[0006] The first aspect of the present invention provides an electrical panel transfer and hoisting device, including a traveling chassis, a clamping mechanism, a synchronous lifting mechanism, a horizontal moving mechanism and a control unit, wherein the control unit is communicatively connected to each mechanism and performs coordinated scheduling and multi-level safety interlocking.

[0007] The second aspect of this invention provides a method for transferring and hoisting an electrical control panel, comprising: transferring the device to the target workstation where the electrical control panel is located via a mobile chassis; applying a symmetrical clamping force to the electrical control panel via a clamping mechanism, and performing force closed-loop control by real-time feedback of the clamping force through a force detection element, and entering a holding state after reaching the set clamping force; vertically lifting the clamped electrical control panel to the target height via a synchronous lifting mechanism, and performing synchronous error monitoring by real-time feedback of the height of each support point through a height detection element during the lifting process; performing precise translation via a horizontal moving mechanism, and performing position closed-loop control by acquiring the horizontal deviation through a position detection device during the translation process until the alignment deviation meets the preset accuracy requirements; and performing coordinated scheduling of each mechanism through a control unit and implementing multi-level safety interlocks.

[0008] The beneficial effects of this invention include: 1. By integrating the walking, clamping, lifting and horizontal movement mechanisms into a unified frame and coordinating them with the control unit, a single operator can complete all the installation procedures of the electrical panel cabinet remotely, without the need for multiple people to cooperate.

[0009] 2. The clamping force is fed back in real time by force detection element and closed-loop control is executed. Force decay is automatically compensated during the holding phase, eliminating the safety hazard of clamping loosening under manual binding method.

[0010] 3. The height of each support point is monitored synchronously by multiple height detection elements. When a synchronization error occurs during the lifting process, the system will automatically pause and compensate to prevent the lifting platform from tilting and causing load shift.

[0011] 4. By acquiring the horizontal deviation through the position detection device and executing closed-loop position control, the uncertainty of human experience judgment is eliminated, and the horizontal positioning accuracy is improved from millimeter-level fluctuations in experience operation to a repeatable and controllable accuracy range.

[0012] 5. Through multi-level safety interlocks covering all processes of walking, clamping, lifting and translating, the corresponding mechanism automatically enters a safe state when any interlock condition is triggered, realizing active safety protection throughout the entire process. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of the electrical panel transfer and hoisting device provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of the walking cart in an embodiment of the present invention; Figure 3 This is a schematic diagram of the clamping system in an embodiment of the present invention; Figure 4 This is a schematic diagram of the lifting system in an embodiment of the present invention; Figure 5This is a schematic diagram of the structure of the horizontal movement system in an embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of the electronic control system in an embodiment of the present invention; Figure 7 This is a general flowchart of the electrical panel transfer and hoisting method provided in the embodiments of the present invention; Figure 8 This is a graph showing the lifting synchronization error monitoring in an embodiment of the present invention.

[0014] In the diagram, 1. Trolley; 11. Steering wheel; 12. Trolley frame; 13. Battery; 14. Weighing sensor; 15. Remote control; 2. Clamping system; 21. Support frame; 22. Bearing seat; 23. Guide post; 24. Nut; 25. Spring; 26. Clamping plate; 27. First lead screw; 28. Stop block; 29. ​​Pressure sensor; 210. First reducer; 211. First servo motor; 3. Electrical control system; 31. PLC; 32. 7-inch PLC touch screen; 33. 10-inch industrial computer display screen; 34. Second industrial computer; 35. Servo drive unit; 36. 4. Power supply unit; 4. Lifting system; 41. Vertical lifting frame; 42. Lifting assembly; 43. Connecting rod; 44. Lifting power; 45. Synchronous belt; 46. Lifting machine; 47. Laser rangefinder sensor; 48. Guide wheel; 5. Horizontal movement system; 51. Linear guide rail; 52. Joint; 53. Second lead screw; 54. Second reducer; 55. Second servo motor; 56. Linear bearing; 57. Main frame; 58. Movable bracket; 59. Spring connecting rope; 510. Movable hanger; 511. Adjusting handwheel; 512. Camera; 513. Special lifting tool. Detailed Implementation

[0015] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with the accompanying drawings and specific embodiments. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0016] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0017] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0018] like Figure 1 As shown, the present invention provides an electrical panel transfer and hoisting device, which mainly consists of five parts: a traveling trolley 1, a clamping system 2, an electrical control system 3, a lifting system 4, and a horizontal movement system 5. The traveling trolley 1 is responsible for the flexible transfer of the device on the construction site; the clamping system 2 is responsible for applying symmetrical clamping force to the electrical panel and maintaining a constant holding position; the lifting system 4 vertically lifts the clamped panel to the target height; the horizontal movement system 5 performs precise horizontal alignment after being lifted into place; and the electrical control system 3, as the control core of the device, performs coordinated scheduling of the various systems and implements multi-level safety interlocks.

[0019] like Figure 2 As shown, the traveling trolley 1 is responsible for the movement of the device during equipment transfer, and mainly consists of five parts: steering wheel 11, trolley frame 12, battery 13, weighing sensor 14, and remote controller 15.

[0020] The steering wheel 11 is used to control the forward movement and direction of the trolley; the trolley frame 12 integrates the steering wheel 11, battery 13, load cell 14 and DC servo driver into one unit, and integrates the lifting system 4, clamping system 2, horizontal movement system 5 and electronic control system 3 into one unit; the battery 13 is used to power the trolley; the load cell 14 is used to sense the weight borne by the trolley 1; the remote controller 15 is used to send commands such as walking and turning to the trolley.

[0021] The walking principle of the walking trolley 1 is as follows: The user can issue basic walking commands such as forward and backward via remote control 15. Upon receiving the forward or backward command, the walking servo driver drives the corresponding walking motor. The left and right front walking motors enter a synchronous speed closed-loop control state to ensure the smoothness of the equipment's straight-line movement. During the execution of the action, the laser rangefinder 47 is simultaneously activated, collecting real-time data on the distance to obstacles ahead and transmitting it back to the industrial control computer and PLC31, achieving real-time obstacle detection and collision protection. The equipment uses a differential steering control method: After the user issues left or right turn commands via remote control 15, PLC31 controls the speed difference between the left and right walking motors, driving the independent steering wheels to complete the corresponding steering action, achieving smooth equipment steering. During the steering process, PLC31 and the walking servo driver collect real-time status data such as motor speed, encoder position, and steering angle, performing closed-loop monitoring of the steering action throughout the entire process. If the relevant data exceeds the safety threshold or an abnormality occurs, the system will immediately trigger a light and sound alarm, issuing a real-time alarm prompt, and triggering emergency stop protection if necessary.

[0022] like Figure 3As shown, the clamping system 2 is the core positioning and clamping mechanism of the electrical panel handling equipment, mainly composed of left and right support frames 21, bearing seats 22, guide columns 23, nuts 24, springs 25, clamping plates 26, first lead screw 27, stop blocks 28, pressure sensors 29, first reducers 210, and first servo motors 211.

[0023] The support frame 21 is made of thick steel plate welded or high-strength aluminum alloy cast, used to fix the bearing seat 22, guide post 23 and lead screw 53, and to reliably install the entire clamping system 2 on the frame of the traveling trolley 1. The bearing seat 22 supports both ends of the bidirectional ball screw 53 and uses a sealed deep groove ball bearing to reduce the rotational resistance of the first lead screw 27 and prevent dust from entering the bearing. The guide post 23 has been hardened by quenching, resulting in high hardness and good wear resistance, providing micron-level linear guidance for the clamping plate 26 and preventing the clamping plate 26 from deflecting or jamming during clamping. The first lead screw 27 adopts an integrated left- and right-hand thread design, which can drive the two clamping plates 26 to clamp synchronously towards the center or to release synchronously to both sides when rotating, with a large clamping stroke and no backlash. The nut 24 cooperates with the bidirectional ball screw (i.e., the first lead screw 27) to efficiently convert the rotational motion of the first lead screw 27 into the linear motion of the clamping plate 26. The spring 25 plays a crucial role in buffering and absorbing shocks, preventing damage to the electrical cabinet surface from rigid clamping impacts, while also enabling the pressure sensor 29 to stably and linearly detect the clamping force. A 5mm thick anti-slip rubber pad is attached to the surface of the clamping plate 26 that contacts the electrical cabinet, increasing friction, preventing slippage, and protecting the paint surface from scratches. The stop block 28 moves with the ball nut 24, directly pushing the pressure sensor 29 during clamping, accurately transmitting the clamping force to the sensor. The pressure sensor 29 is a high-precision strain gauge pressure sensor with a measurement accuracy of ±1%, detecting the clamping force in real time and providing a closed-loop feedback signal for the servo system. The first reducer 210 reduces the output speed of the first servo motor 211 while significantly amplifying the output torque to meet the power requirements of clamping heavy electrical cabinets. The first servo motor 211 serves as the precise power source for the clamping system 2, accurately controlling the clamping stroke and clamping force to achieve rapid clamping, precise pressure holding, and overload protection.

[0024] The clamping system 2 adopts a control scheme of first servo motor 211-bidirectional lead screw-pressure closed-loop feedback. The workflow is as follows: After the electrical panel is lifted by the lifting device and accurately moved to the clamping position, the user sends a clamping command to the first servo motor 211 via the touch screen and industrial computer. The first servo motor 211 drives the first reducer 210 and the bidirectional lead screw to rotate, and the two ball bearing nuts 24 drive the left and right clamping plates 26 to move towards the center simultaneously. When the rubber pads of the clamping plates 26 contact the side wall of the electrical panel, the first lead screw 27 continues to rotate, and the nuts 24 drive the stop block 28 to move towards the clamping plate 26, starting to compress the buffer spring 25 mounted on the guide post 23. The stop block 28 is in close contact with the pressure sensor 29 installed on the clamping plate 26, and the pressure sensor 29 starts to detect the clamping force in real time and feeds back the analog signal. When the clamping force reaches the system's preset rated value, the PLC 31 immediately issues a stop command, the first servo motor 211 is powered off and locked, maintaining a stable clamping state. Throughout the entire process of moving, lifting, and leveling the electrical control panel, the pressure sensor 29 continuously monitors the clamping force. If the clamping force drops below 90% of the set value due to vibration, bumps, or other reasons, the system automatically starts the first servo motor 211 to replenish the pressure, ensuring that the electrical control panel is always firmly clamped. When the electrical control panel reaches the designated installation position, the user sends a release command to the first servo motor 211 via the touch screen or industrial computer. The first servo motor 211 drives the bidirectional ball screw to rotate, and the two clamping plates 26 simultaneously and rapidly release to both sides, returning to the initial standby position.

[0025] like Figure 4 As shown, the lifting system 4 is the core vertical actuator of the electrical panel handling equipment, mainly composed of a vertical lifting frame 41, a lifting assembly 42, a connecting rod 43, a lifting power 44, a synchronous belt 45, a lifting machine 46, a laser rangefinder sensor 47, and four sets of guide wheels 48.

[0026] The lifting frame adopts a rectangular box-type structure welded from thick-walled square steel. Its bottom is rigidly fixed to the weighing sensor 14 of the traveling trolley 1 with bolts, serving as the load-bearing and installation benchmark for the entire lifting system 4. The lifting assembly 42 uses a high-precision heavy-duty lead screw 53, which has strong load-bearing capacity and no backlash. Four sets of synchronous drives ensure absolute levelness and stability during the lifting process. The connecting rod 43 rigidly connects to the first lead screw 27, maintaining complete synchronous movement with it to prevent the lifting platform from tilting due to transmission errors or uneven loads, thus avoiding the electrical control panel tipping over. The lifting power 44 consists of a high-torque first servo motor 211 and a reducer, which can precisely control the lifting speed and displacement, achieving smooth start and stop under heavy loads. The synchronous belt 45 uses a high-strength flexible synchronous belt 45, with accurate transmission ratio, no slippage, and low noise, simultaneously and evenly transmitting the power of the first servo motor 211 to the first lead screw 27, ensuring complete consistency in speed and direction. The lifting machine 46 is welded from high-strength steel plates, with a smooth surface and good rigidity, serving as the installation foundation for the horizontal movement system 5. The laser rangefinder 47 enables non-contact measurement with high accuracy, providing real-time feedback of the electrical control cabinet distance to the electrical control system 3 for precise positioning, soft limit protection, and low-speed approach control. The guide wheels 48 eliminate forward, backward, left, and right swaying during lifting, ensuring the verticality and stability of the lifting platform, while also bearing the horizontal lateral forces generated during the handling of the electrical control cabinet.

[0027] The lifting system 4 adopts a control scheme of first servo motor 211 - synchronous drive - laser ranging closed-loop feedback. The workflow is as follows: After the traveling trolley 1 moves directly below the electrical control panel and completes the hoisting, the user sends a lifting command to the first servo motor 211 via the touch screen and industrial control computer. The first servo motor 211 drives the reducer to rotate, which in turn drives the first lead screw 27 to rotate synchronously at the same speed via the synchronous transmission belt, and the lifting platform 46 begins to move upward. During the lifting process, four sets of vertical guide wheels 48 roll along the guide rail surface of the lifting frame column, strictly limiting the horizontal displacement of the lifting platform and ensuring the verticality of the lifting movement.

[0028] like Figure 5 As shown, the horizontal moving system 5 is the core actuator of the automated handling / adjustment equipment for electrical control panels. It mainly consists of a linear guide rail 51, a connector 52, a second lead screw 53, a second reducer 54, a second servo motor 55, a linear bearing 56, a main frame 57, a movable bracket 58, a spring 25 connecting rope, a movable hanger 510, an adjusting handwheel 511, a camera 512, and a special lifting tool 513.

[0029] The guide rail provides millimeter-level linear motion guidance, ensuring the straightness and repeatability of the main frame 57's movement, while also bearing the weight of the entire system and electrical cabinet. The connector 52 reliably connects the ball screw (second screw 53) to the fixed end of the lifting device, eliminating additional stress caused by installation errors and smoothly converting rotational motion into linear motion. The second screw 53 efficiently converts the rotational motion of the second servo motor 55 into linear motion, featuring high precision, low friction, and zero backlash. The reducer lowers the output speed of the second servo motor 55 while significantly amplifying the output torque, meeting the power requirements for the horizontal movement of the heavy electrical cabinet. The second servo motor 55 is the system's precise power source, accurately controlling the speed, direction, and translational displacement of the second screw 53, achieving ±0.5mm level horizontal positioning accuracy for the electrical cabinet. The linear bearing 56 employs a rolling friction structure, greatly reducing the motion resistance between the main frame 57 and the guide rail, ensuring smooth high-speed movement and low noise. The main frame 57 is the load-bearing base of the horizontal movement system 5, welded from high-strength aluminum alloy or steel, and integrates all moving and actuating components. The movable bracket 58 is coarsely adjusted in the Y-axis direction via the adjusting handwheel 511 to adapt to electrical cabinets of different widths and adjust the lateral spacing of the lifting device. The spring connecting rope has a built-in buffer spring to absorb impact loads during the lifting and movement of the electrical cabinet, while also allowing the lifting device to adapt to angular deviations, facilitating quick and easy attachment of the electrical cabinet lifting lugs. The movable hanger 510 is coarsely adjusted in the X-axis direction via the adjusting handwheel 511 to adapt to electrical cabinets of different lengths and adjust the longitudinal spacing of the lifting device. The adjusting handwheel 511 is used to manually adjust the longitudinal and lateral spacing of the lifting device. The camera 512 captures real-time image information of the electrical cabinet below, automatically identifying the precise position and posture of the electrical cabinet through machine vision algorithms, providing visual feedback for the automatic positioning of the servo system. The lifting device adopts a self-locking hook design, automatically locking after attachment to prevent the electrical cabinet from falling off during transport and ensure operational safety.

[0030] The horizontal movement system 5 operates as follows: After power-on, the electrical control system 3 first performs a comprehensive self-test on the second servo motor 55, the second reducer 54, the visual positioning camera 512, the travel limit sensor, and the second servo motor 55 to confirm that all components communicate normally, limit triggering is effective, and the servo brake function is intact. Then, the operator manually rotates the adjusting handwheel 511 according to the width specifications of the electrical cabinet to be moved, causing the movable horizontal support to slide along the Y-axis, adjusting the lateral spacing of the two movable longitudinal hangers to match the center distance of the top lifting lugs of the electrical cabinet. Simultaneously, the tension of the connecting rope of the spring 25 and the self-locking mechanism of the lifting device are checked to ensure there is no jamming or loosening. After the system switches to automatic operation mode, the visual positioning camera 512, installed on the main frame 57, collects high-definition images of the work area in real time. The built-in machine vision algorithm extracts the feature points of the electrical cabinet lifting lugs, calculating the X-axis offset, Y-axis offset, and planar angle deviation of the electrical cabinet relative to the system's reference coordinate system. The electronic control system 3 converts these deviation values ​​into pulse control commands for the second servo motor 55. The second servo motor 55, acting as a precise power source, outputs rotational power, which, after being reduced in speed and increased in torque by the second reducer 54, drives the ball screw 53 to rotate. The ball screw 53 (i.e., the second screw) is reliably connected to the fixed end of the main frame 57 via a connecting joint 52. The joint 52 eliminates the additional stress caused by installation errors, smoothly converting the rotational motion of the second screw 53 into the linear motion of the main frame 57. The main frame 57 rolls on the linear guide rails 51 on both sides via linear bearings 56. The rolling friction structure of the linear bearings 56 greatly reduces motion resistance, ensuring smooth high-speed movement and low noise. The guide rails simultaneously provide guidance and load-bearing functions, offering millimeter-level linear motion accuracy, ensuring the straightness and repeatability of the main frame 57's movement, and bearing the entire weight of the system and electrical cabinet, ultimately driving the main frame 57 to quickly move to the coarse positioning position directly above the electrical cabinet. After the main frame 57 is roughly positioned, the operator or the supporting vertical lifting system attaches the four self-locking lifting devices to the four lifting lugs of the electrical panel cabinet, mechanically eliminating the risk of the electrical panel cabinet falling off during transportation. The spring 25 connecting rope plays a crucial adaptive role in this stage. The built-in buffer spring 25 absorbs the impact load during attachment and subsequent lifting, preventing rigid damage to the electrical panel cabinet, lifting lugs, and system structure caused by the hard connection. Simultaneously, it allows the lifting devices to swing freely within a certain range, automatically adapting to minor positional and angular deviations of the electrical panel cabinet lifting lugs, eliminating the need for repeated manual fine-tuning of the lifting device position and significantly improving attachment efficiency. After the lifting devices are attached and confirmed to be safe, the supporting vertical lifting system lifts the electrical panel cabinet off the ground to a safe handling height. During this process, the system forms a dual closed-loop control, with the encoder of the second servo motor 55 providing real-time feedback on speed and angle information, precisely controlling the rotation of the lead screw 53 to ensure theoretical displacement accuracy.

[0031] The horizontal moving system 5 integrates multiple safety protection mechanisms: hard and soft limits are set at both ends of the guide rail, and the main frame 57 automatically stops when it moves to the limit position; the second servo motor 55 monitors the output torque in real time, and immediately stops and alarms when the weight being transported exceeds the rated load or an obstacle is encountered; in the event of an accidental power failure, the servo brake and the self-locking characteristics of the lead screw 53 work together to prevent the main frame 57 and the electrical cabinet from sliding due to gravity; at the same time, the system monitors the locking status of the lifting device in real time, and lifting and moving are prohibited when it is not fully locked.

[0032] like Figure 6 As shown, the electronic control system 3 undertakes the core functions of instruction parsing, logic operation, motion control, status monitoring, safety interlocking and human-machine interaction for the entire equipment. It consists of six major modules: core control unit (PLC31), human-machine interaction terminal, servo drive unit 35, power supply unit 36, safety protection and alarm unit, and communication / interface unit.

[0033] The core control unit (PLC31) consists of a programmable logic controller host and expansion modules such as digital input / output modules, analog input / output modules, high-speed counting modules, and communication modules. After power-on initialization, it synchronously sends heartbeat signals to all servo drives and sensors to establish communication links. During the execution of actions, it corrects control commands in real time based on sensor feedback.

[0034] The human-machine interface terminal includes a 7-inch PLC31 touchscreen, a 10-inch industrial computer display screen 33, and an industrial-grade industrial computer. The touchscreen and display screen are used for visual display of equipment operating status, parameter configuration, manual single-step control, fault display and reset, and communicate with the PLC31 in real time via RS485 / Ethernet. The industrial computer is used for machine vision positioning, multi-axis synchronous control calculation, remote monitoring and debugging, batch task management and data export, and communicates with the PLC31 and vision camera 512 via Ethernet.

[0035] The servo drive unit 35 includes two walking servo drives, one clamping servo drive, one lifting servo drive, and one horizontal movement servo drive. Its function is to receive control commands from the PLC31 to drive the corresponding servo motors to operate, collect motor encoder speed, angle, current, and torque data in real time and send them back to the PLC31 to form a closed-loop control, and has self-protection functions against overcurrent, overvoltage, overload, overheating, and encoder failure.

[0036] The power supply unit 36 ​​includes a main power switch, a main circuit breaker, a servo power module, a control power module, a DC switching power supply, a lithium battery pack, and a battery management system (BMS). It provides stable power to all modules of the equipment. The BMS monitors the battery level in real time, and automatically enters a protection program when the level falls below a threshold. The safety protection and alarm unit includes an audible and visual alarm, an emergency stop button, a safety relay, and a fault indicator light. It executes safety protection commands from the PLC31. When the emergency stop button is pressed, it cuts off all servo power and triggers the servo brake. The fault indicator light uses different colors and flashing frequencies to indicate the fault type. The communication / interface unit consists of an industrial Ethernet module, an RS485 communication module, a digital / analog signal interface, a safety loop interface, and a terminal block. As the data interaction hub of the electrical control system 3, it enables stable communication between the PLC31 and the servo driver, the human-machine interface terminal, and external actuators. It provides unified access to various control signals and feedback signals, and features signal isolation, anti-interference protection, and line detection functions to ensure accurate and reliable command transmission and data interaction throughout the system.

[0037] The complete workflow of the electrical control system 3 is as follows: During the power-on initialization phase, the main power switch is turned on, and the power module starts to supply power to the PLC31, human-machine interface terminal, and sensors. The PLC31 performs a full system self-test, checking hardware communication, actuator posture, sensor signals, and the integrity of safety circuits. The servo driver completes its self-test and sends back its status. If no abnormalities are found, the system enters standby mode. During the instruction receiving and parsing phase, the user sends operation instructions such as moving, clamping, lifting, and translating via the touchscreen, industrial computer, or remote control 15. The instructions are transmitted to the PLC31 and parsed into corresponding actuator control codes, activating the safety interlock logic. During the execution drive and collaborative control phase, the PLC31 sends the control codes to the target servo driver, which drives the corresponding servo motor to operate, thus driving the mechanical system to perform actions. During the feedback correction and closed-loop control phase, during action execution, the sensors and servo encoders send data back to the PLC31 in real time. The PLC31 compares the set value with the actual value and dynamically adjusts the output to achieve closed-loop control such as automatic clamping force compensation and precise correction of lifting height.

[0038] The electronic control system 3 has multiple safety interlocking logics: emergency stop interlock, pressing any emergency stop button cuts off all servo power, locks the servo brake, triggers a light and sound alarm, and invalidates all commands; load interlock, when the load sensor 14 detects that the load exceeds the rated value, it prohibits walking, lifting, and lateral movement, and the touch screen displays an overload alarm; clamping interlock, if the clamping force does not reach the set value, it prohibits walking and lifting, and automatically compensates for pressure when the clamping force is lower than 90% of the set value during operation, and stops the machine in an emergency if the compensation fails; limit interlock, all moving mechanisms are equipped with soft and hard limits, the soft limit automatically decelerates and stops, and the hard limit cuts off the power supply; communication interlock, if the communication between PLC31 and the servo driver and sensor is interrupted, it immediately stops the machine in an emergency, and the touch screen displays a communication fault alarm.

[0039] like Figure 7 As shown, the overall process of this method sequentially executes the following steps: system initialization and self-test, walking and transport, servo clamping and pressure holding, four-axis synchronous lifting, vision-guided precision translation, clamp release and return to position, and orderly power-off. Each step is sequentially connected through the interlocking gate conditions of the electronic control system, and the completion of the previous step constitutes a prerequisite for starting the next step.

[0040] S000, System Initialization and Self-Test After power-on, the control unit first loads its own firmware and initializes its internal registers. Then, the control unit sequentially sends heartbeat detection messages to all servo drives to establish communication links. In this embodiment, the device is equipped with five servo drives, corresponding to the left wheel, right wheel, clamping, lifting, and horizontal movement axes, respectively. The control unit uses a fixed heartbeat cycle. A request message is sent to each servo driver, and each driver sends back a response message within a specified time window after receiving it. The control unit internally maintains a heartbeat counter for each driver. The counter increments by 1 for each request sent and resets to zero upon receiving a response. The heartbeat counter reaches the continuous loss threshold. If this occurs, the slave station is deemed to have a communication failure.

[0041] In this embodiment, the heartbeat cycle Set as The continuous loss threshold Set to 3 times, corresponding to the timeout judgment period. This parameter setting strikes a balance between communication load control and fault detection response speed. Below Increased load on the communication bus may lead to a higher message loss rate and thus more false alarms. Exceed Communication interruption detection delay exceeds It does not meet the safety response requirements.

[0042] After the communication link is confirmed, the control unit sequentially writes parameters to each servo drive: first, it writes the motor nameplate parameters (rated current, rated speed, number of pole pairs); then, it writes the control mode configuration (speed mode), acceleration / deceleration time parameters, and limiting parameters (maximum speed, maximum current); finally, it activates the drive's enable state. After each drive is successfully enabled, it reports the current position value of the absolute encoder. The control unit compares this value with the position value saved before the last power outage. If the deviation exceeds... The system prompts the operator to confirm whether the equipment has been moved. The encoder is a 17-bit single-turn absolute encoder with a resolution of 131072 pulses / revolution, and is paired with a lead screw. It is achievable The theoretical positional resolution. Multi-turn information is stored via a battery-powered turn counter with a battery life of at least 5 years. The touchscreen provides a 6-month advance warning to replace the battery when its voltage drops below a threshold.

[0043] After the communication link is established, the control unit enters the sensor zero-point calibration stage. Under confirmed no-load conditions, continuous sampling is performed on the weighing sensor and pressure sensor. The arithmetic mean of the two original readings is taken as the zero-point offset. : Subtract this offset from all subsequent measurements to obtain the true physical quantity. The criteria for passing the zero-point drift test are as follows: ,in This is the sensor's full-scale value. This is the pass / fail coefficient. In this embodiment... Set to 100 times, sampling frequency is Calibration time ; The value is set to 0.005, meaning the zero-point drift does not exceed 0.5% of the full scale. If... This indicates that the sensor may be damaged or the wiring is faulty. The system refuses to enter the operation mode and displays a calibration failure message on the touch screen.

[0044] After sensor calibration, the control unit reads the feedback signal from the safety loop terminal via the digital input module. The safety loop adopts a normally closed series design; under normal conditions, the feedback signal is high when the loop is closed, and it becomes low when any node is open. The safety loop qualification criteria are as follows: in For the first The status of each safe node This represents the total number of secure nodes. In this embodiment... This includes two emergency stop buttons, two safety relays, four travel limit switches, and two door switches. After all nodes are confirmed closed, the control unit will display a system ready flag. When set to true, the touchscreen displays the system ready status, and the device enters standby mode to await operation commands.

[0045] Optionally, the control unit also performs reference distance calibration on the laser rangefinder during the self-test process. A standard reflector is fixed at a known distance, and the control unit reads the laser sensor's measurement of the standard reflector and compares it with the known distance. If the deviation exceeds... The sensor linearity coefficient is automatically corrected in real time. This calibration ensures the accuracy of distance measurement data upon which subsequent walking collision avoidance and elevation positioning depend. The total time for the self-test does not exceed [a certain amount]. Firmware loading approximately Heart rate monitoring (5 drivers for serial detection), sensor calibration approximately (6 channels each) ), safety loop scan and reference calibration approximately After all self-tests pass, the control unit records the power-on timestamp and self-test result summary in the retention data block for subsequent maintenance queries. During the self-test, the touchscreen displays the pass status of each sub-item in real time as a progress bar. If any sub-item fails, the progress bar stops and the name of the failed item and fault code are highlighted in red. The operator can troubleshoot the corresponding hardware based on the prompts.

[0046] S100, Intelligent Walking and Transfer The system ready flag In standby mode (true), the operator sends walking commands via a wireless remote control. The control unit receives the remote control's radio frequency signal and decodes it into direction commands and target speed settings.

[0047] The chassis employs a differential steering structure with independent two-wheel drive. A steering wheel is positioned on each of the left and right front sides, and a swivel wheel is positioned on the rear side. When a forward or reverse command is received, the control unit sends the same speed command to the left and right travel servo drives to achieve straight-line travel. When a steering command is received, the control unit calculates the target speed difference between the left and right wheels according to the differential steering kinematic model and sends the commands separately.

[0048] The relationship between the speed of the two wheels and the turning radius is as follows: in The track width between the left and right drive wheels. and These are the linear velocities of the left and right wheels, respectively. The relationship between the linear velocities of the two wheels and the motor speed is as follows: , ,in Let be the radius of the drive wheels. The linear velocity and angular velocity of the vehicle's centerline are respectively: The target wheel speed is deduced from the remote control command: In this embodiment, the wheel track Set as The radius of the drive wheel Set as Polyurethane-coated wheels are used to balance load-bearing capacity and maneuverability. When traveling in a straight line... The turning radius approaches infinity. When rotating in place... The turning radius is zero. This design allows the chassis to operate within a minimum width. It allows for flexible maneuvering within the passageway, eliminating the need for the space required by traditional forklifts. The above refers to the turning space. The minimum turning radius is limited by the chassis outline dimensions and the width of the passage. In this embodiment, the chassis outline dimensions are... ,exist Minimum can be achieved in wide channels A 90-degree turn with a turning radius. The control unit limits the maximum vehicle angular velocity under load conditions. To prevent the risk of the control unit tilting due to excessive centrifugal force, when turning under load, the control unit experiences a lateral overturning moment due to centrifugal force. The control unit calculates the anti-rollover safety factor in real time based on the current vehicle speed and turning radius. ,when It automatically limits the upper limit of angular velocity to ensure that the anti-rollover safety factor is not less than 2 under any working condition; among which, The anti-overturning moment generated by gravity is the moment generated by the weight of the cabinet and chassis itself around the overturning fulcrum (the contact point of the outer wheel) that makes the vehicle body upright. This refers to the lateral overturning moment generated by centrifugal force during turning, that is, the moment generated by centrifugal force around the same overturning fulcrum that causes the vehicle to overturn outwards. When the restoring torque is less than twice the overturning torque, the control unit automatically limits the upper limit of the angular velocity to ensure a safety margin.

[0049] During the journey, a laser rangefinder installed at the front of the vehicle continuously measures the distance to obstacles ahead. The control unit adjusts the speed based on the current vehicle speed. The system's braking capacity is used to calculate the three-level distance threshold in real time. The emergency stopping distance threshold is: Deceleration distance threshold Warning distance threshold .in For maximum braking deceleration, For system response time, For safety margin. In this embodiment... Set as , Set as , Set as .

[0050] The hierarchical response logic is: when Normal driving without any movement; when When an audible and visual warning is triggered; The vehicle speed will automatically decrease. ;when Emergency braking is executed to stop the vehicle. If the sensor fails, the most dangerous situation is handled, and an immediate emergency stop is initiated. The raw data from the laser rangefinder sensor undergoes triple median filtering to eliminate flying-point noise.

[0051] During the movement, four load cells continuously monitor the total load. The total load is calculated as follows: in For the first The road's calibration coefficient. The two-level overload protection logic is: when... Normal operation at times; when An alarm is triggered and new actions are prevented from starting; when An emergency stop is triggered when the rated load is present. In this embodiment, the rated load... Set as The weighing data were filtered using a 10-fold moving average to eliminate vibration interference.

[0052] After the device reaches the target workstation, the operator sends a stop command, and the control unit brakes both walking motors and activates the brake lock. At this time, the walking status indicator... Updated to "In place," the load value confirmed by the weighing sensor is recorded as follows: The remote control signal was lost for more than [time period missing]. The system will automatically activate braking and stopping protection.

[0053] The chassis is powered by a 48V lithium iron phosphate battery pack with a rated capacity of [missing information]. It can support continuous walking for at least 4 hours under full load. The battery management system monitors the total voltage of the battery pack, the voltage of each individual cell, the charging and discharging current, and the temperature in real time. When the remaining power is below 20%, a low power warning is triggered and a yellow indicator is displayed on the touchscreen. When it is below 10%, new walking commands are prohibited to reserve power for returning to the starting position. The battery pack is designed to support fast charging mode, using a dedicated charger. It can be charged from 20% to 90%. The battery compartment is designed with a side-pull quick-change structure, allowing for easy replacement in emergencies. The battery pack replacement was completed within the specified time.

[0054] The remote control uses Spread spectrum communication technology, transmit power The effective remote control distance is not less than It supports frequency hopping for interference suppression. The remote control panel features dual joysticks (left for direction and speed control, right for fine-tuning and steering), an emergency stop button, and a mode switching dial. Signal loss detection is based on... No new command window appears; once triggered, the controlled brake is immediately brought to zero speed and the holding brake is activated. The operator can switch between three speed levels via the touchscreen: low speed and maximum linear speed. Suitable for precise positioning, medium speed range with maximum linear speed Suitable for short-distance transport, high-speed gear with maximum linear speed Suitable for long-distance unloaded transport. Load exceeding... The system automatically locks the high-speed gear, allowing only medium and low speed operation.

[0055] During straight-line driving, the control unit also detects yaw trends caused by uneven ground or uneven tire wear in real time through the speed difference between the encoders on both sides. When the actual speed difference between the left and right wheels continuously exceeds the target speed... At that time, the control unit automatically decelerates the fast-side wheel. To maintain a straight trajectory, the correction process is completely transparent to the operator. The drive wheels feature a polyurethane-coated structure with a Shore A hardness of 85, balancing load-bearing capacity, wear resistance, and ground adhesion. The omnidirectional driven wheels employ a heavy-duty double-row ball bearing structure, with a load-bearing capacity of no less than [missing information]. Chassis ground clearance It can span no more than High ground joints or cable trays.

[0056] S200, Servo Clamping and Pressure Holding The walking status indicator Once the position is established, the operator sends a clamping command and inputs the target clamping force via the touchscreen. The system is based on the confirmed load values. Automatically recommends the default clamping force.

[0057] The clamping mechanism's execution flow is divided into four sequential stages: a fast advance stage, a slow advance stage, a force-closed-loop force application stage, and a pressure-holding monitoring stage. The clamping mechanism includes a clamping servo motor, a planetary reducer, a bidirectional ball screw, two ball nuts on each side, guide posts, linear bearings, two clamping plates on each side, an elastic buffer, and a force detection element. The clamping servo motor drives the bidirectional ball screw to rotate via the planetary reducer. Because the threads on both sides of the screw rotate in opposite directions, the two ball nuts on both sides move axially in opposite directions, causing the two clamping plates to synchronously align and close along the guide posts.

[0058] The relationship between the axial thrust of the lead screw and the torque of the motor is as follows: in For the servo motor output torque, The reduction ratio of the speed reducer. For the lead screw, This refers to the lead screw drive efficiency. In this embodiment, the rated torque of the clamping servo motor is... Peak torque is Equipped with a 17-bit absolute encoder; the reduction ratio The lead of the lead screw is set to 10. Set as Lead screw diameter C5 accuracy grade; the transmission efficiency The value is 0.9. The two sides of the bidirectional ball screw have left-hand and right-hand threads respectively. Both ball nuts adopt a pre-tightened backlash-eliminating structure, and the axial clearance is controlled within... Within this range, the clamping plate is designed to operate without dead zones during reversal. The lead screw is supported at both ends by sealed deep groove ball bearings on the left and right support frames. The bearing housings are filled with high-temperature grease, with a design life of no less than 10,000 hours.

[0059] The guide posts of the clamping mechanism are hardened with HRC58 quenching agent and chrome-plated, and are equipped with self-lubricating, maintenance-free linear bearings to ensure minimal sliding friction between the clamping plate and the guide posts, eliminating the need for periodic grease application. The parallelism of the two guide posts is controlled within... Within this range, ensure that the mating surfaces of the clamping plates on both sides remain parallel, and that the symmetrical clamping force is evenly distributed on both sides of the cabinet to prevent excessive force on one side from causing cabinet deformation. The inner side of the clamping plates is attached with... Thick anti-slip rubber pads with a Shore A hardness of 60 increase the coefficient of friction to prevent longitudinal slippage of the cabinet and provide local deformation to adapt to unevenness on the cabinet surface.

[0060] A force detection element is provided between the elastic buffer and the clamping plate. The elastic buffer is a compression spring, installed between the ball nut stop and the force detection element. The actual clamping force applied by the clamping plate to the electrical control cabinet is equal to the lead screw thrust minus the reaction force generated by the spring compression. in For spring stiffness, This represents the current compression of the spring. The spring stiffness described in this embodiment... Set as Free length Maximum allowable compression At the instant the clamping plate initially contacts the control panel, the spring compression absorbs the impact kinetic energy. The contact force increases gradually according to a linear relationship between spring force and displacement, rather than a rigid abrupt change, protecting the control panel surface from damage. The half-cycle of the impact force increase is approximately... ,in This is the equivalent mass of the clamping plate. In this embodiment... Pick (Including clamping plate, rubber pad, and sensor mounting base), spring stiffness converted to SI units. ,but The impact force is approximately The spring compression smoothly rises from zero to its peak value and then falls back, remaining within the spring's elastic recovery range. The maximum allowable compression must not be exceeded. Corresponding to the maximum spring force .

[0061] The clamping process employs a two-stage speed switching strategy (fast and slow). The control unit calculates the distance between the clamping plate and the cabinet surface based on the real-time position of the encoder. The distance is greater than... At fast forward speed Run, distance less than or equal to Automatically switches to slow forward speed Switching is achieved by modifying the servo driver speed limit register. The motor speed during the fast traverse is... The motor speed in the slow advance section is .

[0062] After the clamping plate contacts the control panel and establishes a valid force signal, the control unit initiates pressure closed-loop control. An incremental PID controller is used to set the clamping force. The force detection element provides real-time feedback for the target value. This is a process variable, and the output is a motor speed increment command. The controller cycles... Sample and calculate the deviation: The incremental PID output is: Motor speed command updated to and limited to To prevent overshoot and motor overload. In this embodiment, the proportional gain... Set as Integral gain Set as Differential gain Set to 0.02, control cycle Set as Position force tolerance Set as ,when Furthermore, the system is determined to be in the correct position and clamped when the system maintains this position for 10 consecutive control cycles. Switching to voltage holding mode. The reason for choosing incremental PID instead of positional PID is that incremental output is speed increment, which naturally has integral limiting characteristics and will not cause motor stall and overheating due to integral saturation; and when power is off and restored, the previous cycle instruction is the safe stop speed, so no additional reset logic is needed.

[0063] When the force step response exceeds 0.1, an overshoot of more than 10% occurs, which may cause local deformation to the thin-walled panel of the cabinet. When the value exceeds 0.01, force oscillations occur in the system, and the clamping force fluctuates around the target value, affecting the stability of the pressure holding. When the temperature suddenly drops to zero, instead of performing PID integral accumulation, the system switches to emergency stop mode within one control cycle.

[0064] After entering the pressure holding state, the servo motor is powered off and the brake locking is activated, with the lead screw's self-locking characteristic providing basic holding force. The control unit initiates an independent pressure holding monitoring background task to... Periodic continuous reading The raw data from the force detection element is filtered using a 10-fold moving average to eliminate vibration noise. The pressure compensation trigger condition is: After triggering, the control unit restarts the PID force control loop to perform pressure compensation, and the target remains the same. Each pressurization is applied. time window Successful pressurization is determined as follows: If continuous If the pressure replenishment fails to meet the target, an emergency shutdown is triggered. In this embodiment... The setting is 3 times. The main reason for the decrease in clamping force during the holding pressure stage is the slight creep of the rubber pad on the surface of the clamping plate (approximately...). (Deformation), during pressure compensation, the lead screw only needs to be pushed forward by a small displacement to restore the original force.

[0065] In addition, to prevent catastrophic failures such as sudden cabinet slippage, the control unit adds sudden drop detection logic to the force signal: when And the single-cycle force drop At this time, instead of entering the pressurization process, an emergency stop is triggered directly, and the lifting system and the walking system are locked simultaneously.

[0066] The physical mechanism of clamping force attenuation during the pressure holding stage is: the surface of the clamping plate Thick rubber pads undergo creep under continuous compressive stress; creep displacement... The relationship with time approximately follows a logarithmic law. ,in The creep coefficient depends on the rubber formulation and initial compression ratio. This is the relaxation time constant. In this embodiment, the initial compression ratio of the rubber pad is approximately... ( (deformation), at room temperature Under these conditions, the creep displacement within 30 minutes is approximately The decrease in clamping force is caused by the release of the spring compression. Ambient temperature affects the creep rate of rubber. When the temperature at the construction site exceeds [a certain threshold], [the creep rate increases]. The creep rate increases by approximately The control unit can dynamically adjust the pressure compensation trigger threshold based on the temperature sensor reading (tightening to [value] at high temperatures). The permanent deformation of the rubber pad may exceed [a certain value] after more than 5000 compression cycles. It is recommended to replace it every six months.

[0067] In another embodiment, the elastic buffer can be a disc spring instead of a compression coil spring. Disc springs are characterized by high stiffness and short stroke; the compression stroke of a single disc spring is only... But it's bearable. The above loads can be adjusted by stacking multiple disc springs to adjust the equivalent stiffness and stroke. The disc spring solution is suitable for applications requiring higher clamping forces (exceeding...). It is suitable for heavy-duty cabinet applications, but its elastic buffer stroke is shorter and its impact absorption capacity is weaker than that of the helical spring solution.

[0068] The clamping servo motor employs a dual braking strategy, prioritizing electrical braking and using a mechanical brake as a backup. During normal stopping, the control unit issues a zero-speed command, and the servo driver decelerates the motor to zero via electrical regenerative braking before activating the mechanical brake for locking. In case of emergency stopping, both electrical braking and the mechanical brake operate simultaneously, with the braking time not exceeding [a certain value]. The mechanical brake is a normally closed spring brake. When power is off, the spring force locks the brake disc, and when power is on, the electromagnetic force releases the brake disc, ensuring that the motor shaft is immediately locked in the event of an accidental power failure.

[0069] The clamping range of the clamping mechanism can be adapted to different specifications of electrical control panels by changing the length of the lead screw or adjusting the initial position of the nut. In this embodiment, the effective stroke of the standard lead screw is [missing information]. (unilateral) ), clamping width For extra-wide panel cabinets ( ), can be replaced An extended lead screw with an effective stroke. The clamping plate is connected to the nut seat via a quick-release pin, allowing for easy replacement of the clamping plate or adjustment of the plate surface spacing. Completed within minutes. The parallelism requirement for the clamping plates is the same for cabinets of different widths. Therefore, recalibration is not required after each replacement.

[0070] By target clamping force Calculate the required motor torque: in This represents the steady-state spring compression. In a specific operating scenario, the clamping width... ,weight When setting up the cabinet , hour Much less than the rated torque The clamping force setting range is... When the value automatically recommended by the system based on the load weight exceeds It automatically limits the amplitude and prompts the operator for confirmation.

[0071] After the clamping operation is completed, the control unit outputs a clamping interlock enable signal. If true, subsequent lifting operations are allowed. The clamping mechanism communicates with the control unit via an industrial Ethernet (EtherCAT) bus, employing a periodic speed mode with an update cycle. The force detection element is a strain gauge pressure sensor with a range of [missing information]. Precision Output The analog signal is converted into a digital quantity by the AI ​​module's 16-bit ADC, and the sampling frequency is... .

[0072] S300, four-axis synchronous lifting In the clamping state To maintain pressure and enable clamping interlock signal When the condition is true, the operator inputs the target lifting height via the touchscreen. Alternatively, it can be manually controlled by sending up / down commands via a remote control. The control unit activates the lifting servo motor after verifying that the interlocking conditions are met.

[0073] The synchronous lifting mechanism includes a lifting servo motor, a planetary reducer, a high-strength synchronous belt, synchronous pulleys, four heavy-duty ball screws, four ball nuts, a vertical lifting frame, a lifting platform, four sets of guide wheel groups, and four height detection elements. The lifting servo motor drives the active synchronous pulley to rotate via the planetary reducer. The active pulley transmits power synchronously to the four driven pulleys via four HTD 8M toothed synchronous belts. The four driven pulleys are coaxially fixed to the four screws, thus achieving uniform rotation of the four screws. The lifting platform is connected to the four screws via four flange-mounted ball nuts and rises and falls vertically as the screws rotate.

[0074] Four sets of guide wheels clamp the four columns of the lifting frame, each set containing four polyurethane rollers that constrain the lifting platform along all four sides of the column, limiting horizontal displacement and allowing only vertical movement. The guide wheels are mounted with eccentric shafts to adjust the preload clearance. The eccentricity of the eccentric shaft is... The gap between the guide wheel and the column surface can be infinitely adjusted by rotating the hex wrench. Within the specified range. Adjust the gap to the specified range during initial installation. Ensure the lifting platform moves smoothly and that the horizontal sway does not exceed [a certain value]. The guide rollers have a Shore A92 surface hardness, ensuring wear resistance while preventing scratches on the chrome-plated surface of the column. Each group of four rollers uses sealed deep groove ball bearings with a maintenance-free design life of no less than 20,000 hours. The column surface is hard chrome plated and then precision ground to achieve a surface roughness of [missing information]. This ensures that the rollers have minimal friction and produce no metal shavings during operation.

[0075] The lifting servo motor described in this embodiment is a high-torque type with a rated torque of [missing information]. Peak torque It is equipped with a 17-bit absolute encoder. The planetary reducer has a reduction ratio of 5:1 and an output torque of not less than... The synchronization band width is The diameter of the four lead screws , guide C5 accuracy class, static rated load Not less than The lifting stroke is .

[0076] Four height detection elements are installed on the top of the lifting frame, illuminating the four corners of the lifting platform downwards, measuring the range. Precision The absolute height of each angle is calculated as follows: in The known distance constant from the installation position of the height detection element to the lowest point of the lifting platform. For the first Measured distance of the road. Average platform height: The maximum synchronization error is: when Exceeding the synchronization error threshold At this time, the control unit pauses the lifting movement and triggers an alarm. In this embodiment... Set as .exist On a diagonal span lifting platform, The height difference corresponds to the tilt angle only The offset of the cabinet's center of gravity is negligible, and the structural safety margin is sufficient. If Continue to exceed If three attempts to pause and compensate still fail to restore the system, the system determines that there is a serious malfunction in the lifting system, executes emergency braking, and locks all shafts. The four-channel height data undergoes five rounds of median filtering to eliminate fly-point interference.

[0077] The lifting process employs a three-stage speed planning mechanism to achieve a balance between rapid arrival and precise stopping. Remaining distance is... The speed is planned as follows: The conditions for determining the arrival of goods are as follows: and In this embodiment, the speed of the rapid ascent section under no-load conditions is: When fully loaded Crawling speed Set as ; Starting distance of deceleration phase Set as ; crawling segment starting distance Set as Height tolerance Set as Speed ​​arrival determination threshold Set as The maximum acceleration / deceleration limit is... To prevent load inertial impact.

[0078] Braking distance verification under full load: Much smaller than the starting distance of the deceleration phase Sufficient redundancy. If the height detection element fails (reading changes abruptly exceeding...) If the speed exceeds the range, the system will immediately brake to a stop at maximum deceleration.

[0079] Uniaxial load distribution and lead screw strength verification ensure structural safety. The uniaxial load is: In this embodiment, the lifting platform's own weight Set as Fully loaded Uniaxial load Static safety factor The requirements are met. Under eccentric loading conditions, the total load that the lead screw may bear in the most unfavorable situation is... ,Right now Verification It meets the requirements of the off-center load safety factor.

[0080] The motor torque requirement is: in The efficiency of the lead screw drive is taken as 0.9. The efficiency of the synchronous belt drive is taken as 0.97. Add frictional torque to the guide wheel and seals When fully loaded The available torque on the output side of the reducer is... greater than The driving capability is satisfied.

[0081] The safety anti-fall design of the synchronous lifting mechanism includes triple protection: the servo motor brake immediately locks the rotor when power is off; the lead screw self-locking characteristic reverses and locks when the lead angle is less than the friction angle; and the travel hard limit switch has a pair of normally closed contacts at the upper and lower ends, which directly cut off the servo power circuit when triggered. In this embodiment, the lead screw lead angle... The equivalent friction angle of the ball screw is approximately Because the lead angle is greater than the friction angle, the ball screw itself does not have complete self-locking capability and must rely on the motor brake to provide the main anti-fall force. The brake is a power-off braking type electromagnetic brake, with a holding torque of not less than... Braking response time After the power was suddenly cut off The brake lock is completed within the time limit.

[0082] During descent, the load's gravity direction is the same as the motion direction, and the lead screw is in a passively driven state. The control unit reduces the speed loop gain to the level during ascent in descent mode. Furthermore, braking torque feedforward compensation is added to ensure a smooth and controllable descent speed without stalling or overspeeding. If the actual speed exceeds the set speed during descent... Emergency braking will be triggered immediately.

[0083] Optionally, the operator can control the lifting in manual mode via remote control. In manual mode, the operator holds down the up or down button while the platform is raised. The movement is uniform and stops when the button is released. Manual mode is suitable for fine height adjustments and equipment debugging. In manual mode, synchronous error monitoring and all safety interlocks remain active.

[0084] The hard limit protection at both ends of the lifting stroke adopts a dual redundancy design. Each end is equipped with an upper limit switch and a final limit switch, spaced at intervals. Installation. When the upper limit is triggered, the control unit executes a software shutdown (controlled deceleration stop); if the software shutdown fails and the platform continues to move... Touching the limit switch will directly cut off the servo power supply via the hardware circuit. The limit switch is a mechanically forced disconnect type (forward switch) to ensure reliable disconnection even in the event of a switch malfunction (such as soldered contacts).

[0085] After the lifting position is reached, the control unit will display the lifting status indicator. Updated to "in place" and output lifting interlock enable signal. If true, subsequent horizontal movement operations are allowed. The synchronous lifting mechanism communicates with the control unit via an EtherCAT bus, employing a periodic speed mode with an update cycle. The four height detection elements communicate with the control unit via an RS485 serial port using the Modbus RTU protocol. All four sensors are connected to the same bus and poll for a total refresh cycle of [missing information]. .

[0086] The preload of the synchronous belt in the synchronous lifting mechanism is adjusted via a tensioning pulley. The tensioning pulley is an eccentric shaft mounting structure; rotating the eccentric shaft changes the wrap angle and preload of the synchronous belt. Insufficient preload on the synchronous belt results in slack on the transmission side, causing the driven pulley to lag behind the driving pulley, potentially leading to cumulative displacement errors exceeding a threshold during sudden stops under full load. In this embodiment, the synchronous belt preload is set to 60% of the belt's allowable tension and is verified using a spring-loaded tension indicator during initial assembly and periodic maintenance. The synchronous belt material is a neoprene rubber matrix with a glass fiber core, and its operating temperature range is [not specified]. It is adapted to the environmental conditions of electrical construction sites. The vertical lifting frame is welded from thick-walled square steel, and the cross-sectional dimensions of the four columns are... The overall rigidity ensures that the frame deflection does not exceed [a certain value] during full-load lifting. .

[0087] For lead screw life calculation, the lead screw speed under full load is used. Calculation of dynamic rated load Select Then the rated life Converted to usage time Hours. Based on the time consumed per lifting / lowering operation. Based on 20 operations per day, the daily running time is approximately... The lead screw is designed to last for over 10 years.

[0088] In a real-world verification case, the device uses constant speed The cabinet was lifted from its lowest position to Throughout the entire lifting process, four height detection elements continuously record the height at each angle, with the maximum measured synchronization error... Maintain at Fluctuations within the range, far lower than The alarm threshold. In Near the height, due to the shift in the center of gravity of the cabinet, approximately This resulted in an excessively high load on the No. 3 lead screw. Briefly rose to It then continued to rise and fall automatically. The elastic deformation of the timing belt self-equalizes during continuous operation. (Reaching the target height.) The crawling phase takes approximately [time missing] Final positioning accuracy The positioning has been verified. Figure 8 As shown, the synchronization error curve during the lifting process exhibits a slight increase in the early stage and convergence in the later stage, verifying the engineering feasibility of the single motor plus synchronous belt scheme meeting the synchronization accuracy requirements under reasonable preload conditions. The mean of the synchronization error during the entire lifting process is... The standard deviation is Furthermore, no alarm threshold was triggered at any height, proving that the solution has stable and reliable synchronization performance under continuous full-load operation conditions.

[0089] S400, Vision-guided precision translation The lifting status flag The signal indicating that the elevator is in position and the lifting interlock is enabled is present. When the setting is true, the operator selects between automatic alignment mode and manual fine-tuning mode via the touchscreen. In automatic alignment mode, the control unit automatically performs visually guided closed-loop translation until alignment is complete; in manual fine-tuning mode, the operator manually controls the translation direction and speed via remote control.

[0090] The horizontal movement mechanism includes a translation servo motor, a ball screw, a ball nut, a linear guide, a slider, a position detection device, and an encoder. The translation servo motor drives the ball screw to rotate, and the ball nut is fixed to the horizontal sliding plate of the lifting platform, converting the rotational motion into horizontal linear motion along the linear guide. The translation stroke is... The maximum translation speed is limited to .

[0091] The position detection device includes an image acquisition unit, which in this embodiment is an industrial area array camera, installed at the front end of the lifting platform facing the mounting reference surface of the electrical control panel. The image acquisition unit acquires images of positioning feature points on the side of the electrical control panel. The positioning feature points are crosshairs pre-attached to the mounting reference position or the control panel's own lifting lugs / mounting holes are used as identification targets.

[0092] The visual feature extraction and deviation calculation process is as follows: The image acquisition unit acquires grayscale images at a fixed frame rate; the control unit performs adaptive threshold segmentation on the image to extract feature point regions; and calculates the centroid coordinates of the extracted regions. As pixel-level feature point locations, sub-pixel interpolation is used to improve the positioning accuracy to [missing information]. Pixel.

[0093] The transformation from image coordinates to world coordinates is established through camera calibration. The calibration process is completed offline, obtaining the camera intrinsic parameter matrix. and extrinsic parameter matrix For a target point on a known Z-coordinate plane, the pixel coordinates... Reverse physical coordinates The transformation is: in The homography matrix is ​​calculated from corresponding point pairs of the calibration plate on a known plane. The physical deviation is the difference between the world coordinates and the installation reference coordinates of the target feature point. In this embodiment, the pixel resolution of the image acquisition unit is no less than […]. Visual recognition accuracy reaches The condition for determining the position is the deviation of three consecutive samples. All less than .

[0094] The position closed-loop control adopts a dual-closed-loop cascade control structure with an outer loop for position and an inner loop for velocity. The outer loop uses the physical deviation... The setpoint is the speed command output via a proportional controller: The inner ring uses the encoder to provide position feedback. The corresponding speed is a process variable, and it is tracked by the PI controller according to the speed command given by the outer loop. Among them, speed deviation , Obtained by encoder position differential. The outer loop control cycle is synchronized with the visual frame rate (in this embodiment). The inner loop control cycle is It is consistent with the servo driver update cycle.

[0095] In this embodiment, the position loop proportional gain Set as ,Right now Deviation correspondence Speed ​​command. Speed ​​loop proportional gain. Set to 2.0, velocity loop integral gain Set to 0.1. Outer loop output limit is... When visual deviation hour, The system enters a micro-motion crawling state for precise approximation.

[0096] The velocity planning for the translation process employs a seven-segment S-curve design to eliminate start-stop shocks. The seven segments are: acceleration, uniform acceleration, deceleration, constant velocity, acceleration-deceleration, uniform deceleration, and deceleration-deceleration. The duration of each segment is determined by the maximum acceleration. And maximum jerk. Common constraints: Accelerate for a period of time The duration of uniform acceleration is determined by the target speed and acceleration capability. In this embodiment... Set as , Set as ,but For short distances (less than...) The system adaptively reduces the peak speed to overlap acceleration and deceleration segments, ensuring smooth motion. S-curve planning ensures that speed, acceleration, and jerk are all continuous, minimizing the impact force transmitted to the lead screw and nut.

[0097] The complete process of vision-guided translation is as follows: image acquisition, feature extraction, coordinate transformation, deviation calculation → outer loop position control, inner loop speed control, motor drive screw, platform movement, encoder feedback, waiting for the next frame of vision update; this process is continuously executed in a loop until the deviation meets the accuracy requirements.

[0098] After alignment is completed, the control unit will move the status flag. Updated to aligned, final position and alignment deviation The data is recorded in the control unit data block and pushed to the touch screen display. The directional deviation is simultaneously displayed on the touchscreen for operator reference. If the set threshold is exceeded, the touchscreen prompts the operator to fine-tune the Y-direction position using the walking chassis.

[0099] The horizontal moving mechanism communicates with the control unit via the EtherCAT bus, adopts a periodic speed mode, and the update period . The image acquisition unit communicates with the industrial personal computer connected to the control unit via the industrial Ethernet GigE Vision protocol, and the frame rate . After the industrial personal computer completes the calculation of the vision algorithm, it transmits the deviation value to the control unit via Modbus TCP, and the communication delay is less than .

[0100] In an actual construction scenario, the cross target on the installation reference surface is pre-attached by a magnetic attraction method, and the target size is a black-and-white high-contrast pattern. The working distance of the image acquisition unit is set to , and the field of view covers the area within this distance range, with a pixel resolution better than . The influence of ambient illumination changes on recognition accuracy is eliminated by an adaptive threshold segmentation algorithm — this algorithm dynamically calculates the segmentation threshold according to the global grayscale histogram of the image, and can stably extract feature points within the illuminance range of . When the ambient illumination is insufficient, the annular LED fill light matched with the image acquisition unit is automatically activated, the color temperature of the fill light is , and the illuminance is not less than .

[0101] Camera calibration is performed once when the device is used for the first time or after the camera is replaced. A standard chessboard calibration board of is used to collect no less than 15 groups of image pairs at multiple angles and distances, the intrinsic parameter matrix and distortion coefficient are solved by Zhang Zhengyou's calibration method, and the reprojection error is controlled within pixels. After calibration is completed, the parameters are solidified and stored in the configuration file of the industrial personal computer. Optionally, when the operating environment temperature changes by more than , the system prompts the operator to re-perform calibration to compensate for the focal length drift caused by thermal deformation.

[0102] The sub-pixel interpolation is implemented by the grayscale centroid method. After obtaining the integer-pixel level feature point coordinates through coarse positioning, a neighborhood window centered on this point with the size of is adopted, and the accurate centroid position is calculated by weighting each pixel in the window according to the grayscale value: where is the pixel grayscale value, and the summation range is . This method improves the positioning accuracy from the integer-pixel level ( ) to pixels ( To suppress the impact of image noise on centroid calculation, the neighborhood window is processed before subpixel interpolation. Gaussian smoothing filter.

[0103] Mechanical vibrations of the lifting platform during translation may cause image blurring or jitter in the position of feature points. The control unit pauses the translation movement before each visual sampling. Image acquisition is triggered only after vibration has decayed, ensuring the platform is stationary during acquisition. This strategy slightly increases the single closed-loop cycle (from...). Increase to approximately However, this comes at the cost of more stable visual measurement accuracy. Optionally, for the micro-motion crawling stage ( With extremely small vibration amplitude, it can skip the pause and wait and directly collect data continuously to speed up the convergence speed.

[0104] The abnormal handling logic of the vision system includes: when no feature points are detected for 5 consecutive frames, it is determined that the target is lost, the control unit pauses the translation and prompts the operator to check the target status on the touch screen; when the image acquisition unit communication is interrupted, it switches to the pure encoder feedback open-loop positioning mode as a degradation scheme, and the operator manually confirms the alignment result in the open-loop mode.

[0105] The alignment completion determination adopts a three-continuous confirmation mechanism: the control unit continuously confirms 3 frames of images (interval) ,common The deviation calculation results all satisfy The alignment is considered successful upon confirmation. This mechanism prevents false positives caused by noise or vibration in a single frame of the image. In a typical operation, the total time from visual guidance initiation to alignment completion is... This depends on the magnitude of the initial deviation. The initial deviation is... Within this range, the peak speed of the S-curve is approximately... ,about After completing the main body displacement, it enters the micro-motion crawling stage, and then... Alignment confirmed. Initial deviation reached... Peak speed can reach The main body displacement is approximately After completion, decelerate to the crawling zone. The lead of the translation screw is selected. To achieve higher displacement resolution, each motor revolution corresponds to a translation. When used with a 17-bit absolute encoder, it can achieve The theoretical position resolution is approximately [value missing], but the actual repeatability is limited by the lead screw backlash and mechanical stiffness. Far superior The system positioning accuracy requirements.

[0106] S500, Electronic Control Coordination and Safety Interlocking The control unit runs through the entire operation process and is responsible for coordinating the operation of the walking chassis, the clamping mechanism, the synchronous lifting mechanism and the horizontal moving mechanism, and implementing multi-level safety interlocks.

[0107] The control unit internally operates a finite state machine scheduling model, dividing the overall operating state of the device into eight mutually exclusive states: initialization state, standby state, walking state, clamping state, lifting state, translation state, fault state, and emergency stop state. Transitions between states are controlled by interlocking gating conditions. The state transition rules are as follows: the initialization state transitions to the standby state after all self-tests pass; the standby state transitions to the walking state after receiving a walking command; the walking state transitions to the standby state (waiting for a clamping command) or directly to the clamping state after position confirmation; the clamping state transitions to the pre-lifting state waiting phase after pressure holding confirmation; the lifting state transitions to the pre-translation state waiting phase after position confirmation; the translation state transitions to the standby state waiting for a return command after alignment is completed. If a fault condition is detected in any state, the device can jump to the fault state or the emergency stop state.

[0108] The mutual exclusion of states in the finite state machine is ensured through atomic operations. Only one state transition is allowed per scan cycle, and all precondition gating checks must be passed before each transition. The state register uses double-word redundant storage—the main state word and the mirror state word are written synchronously with each update. The consistency between the two is checked at the start of the main loop scan; if they are inconsistent, a memory anomaly is detected, triggering a shutdown protection mechanism. The control unit maintains a linked list of timestamp records for state transition events. The timestamps and triggering conditions of the most recent 100 transition events are persistently stored in a persistent data block for later analysis.

[0109] The recovery process from a fault state to normal operation requires a complete recovery procedure: After the operator confirms that the fault has been resolved, they press the reset button on the touchscreen. The control unit then performs a simplified self-test (checking only the fault-related sensors and drivers). After the self-test passes, the state machine reverts to the most recent safe state before the fault occurred (from walking mode to standby mode, from lifting mode to clamping and pressure-holding mode). The operator must confirm before proceeding with subsequent operations. Recovery from an emergency stop state requires an additional physical reset of the emergency stop button and a full self-test.

[0110] Interlocking door control conditions ensure that none of the mechanisms will be activated under unsafe conditions. The activation prerequisite for the lifting mechanism is... Equal to holding pressure and The condition for starting the horizontal moving mechanism is true; It is equivalent to being in place and If true, the walking mechanism is prohibited from starting when the lifting height is not zero. The control unit refreshes the AND gate determination results of all interlocking conditions in each scanning cycle.

[0111] The multi-level safety interlocking system comprises five levels, ordered from highest to lowest priority: emergency stop interlocking, load interlocking, clamping interlocking, limit interlocking, and communication interlocking. The triggering conditions and response actions for each level are as follows: The emergency stop interlock is a highest-priority hardware-level protection. When any emergency stop button is pressed, the safety relay directly cuts off the power supply circuit to all servo drives, and the brakes of all motors are simultaneously activated and locked. This path does not pass through the software logic of the control unit, and the response time from pressing the button to the complete power cut-off does not exceed [time missing]. To restore normal operation, manually rotate the emergency stop button and confirm.

[0112] The load interlock remains active during travel and lifting. When the load cell detects... When this occurs, the control unit immediately stops the current moving axis and activates the brake, while simultaneously prohibiting any new actions from starting. This interlock does not automatically disengage after the load returns to the normal range; it requires manual confirmation and reset by the operator.

[0113] The clamping interlock remains active during lifting, lowering, and translation. The clamping force is detected by the force detection element. Fall to If the pressure replenishment fails three times, the control unit will immediately brake the lifting and translating shafts to prevent the cabinet from shifting or falling due to insufficient clamping force.

[0114] Limit interlocking is achieved through hardware travel limit switches. A pair of normally closed limit switches are installed at each end of the lifting stroke, and a pair at each end of the translational stroke. When a limit switch is triggered, the control unit stops the corresponding axis movement and prohibits further action in that direction, allowing only reverse retraction. Simultaneously, the limit switches directly disconnect the corresponding driver enable signal via a hardware circuit, forming hardware redundancy protection beyond the software.

[0115] The communication interlock is based on a heartbeat detection mechanism. The control unit communicates with each servo driver via... Periodically exchange heartbeat messages. Three consecutive times ( If no response is received from a slave station, the slave station is determined to be in communication failure. The control unit then suspends all motion axes and waits for communication to be restored or for manual intervention.

[0116] When multiple interlocking levels are triggered simultaneously, the control unit executes the highest priority response action in descending order of priority. After a high-priority response action is executed, independent responses of lower priority are automatically suppressed to avoid control command conflicts. All interlocking statuses are displayed in real-time on the touchscreen using a matrix of indicator lights—five interlocking levels correspond to five rows of indicator lights: green for normal, yellow for warning, and red for triggered. Each interlocking trigger event records the trigger time, triggering level, current system status, and snapshots of instantaneous sensor values, stored in a cyclically overwritten log area (the most recent 200 records). The log can be exported to an external storage device via USB for professional accident analysis.

[0117] The design of the multi-level safety interlock follows the layered protection concept of the IEC 62061 functional safety standard. The hardware-level protection (emergency stop, limit hard-wired) operates independently of the software logic. Even if the control unit program crashes abnormally, the hardware protection circuit can still independently cut off the power supply to ensure the equipment stops.

[0118] The fault classification response of the control unit categorizes all abnormal events into three levels.

[0119] Warning level (yellow): Sensor data is abnormal but does not affect safety. Only a prompt message is displayed on the touch screen and a yellow indicator light flashes. It does not interrupt the current operation.

[0120] Stop level (orange): Affects the safety of the current process but does not pose an immediate danger. The control unit smoothly brakes the current motion axis and locks it, waiting for the operator to confirm that the fault has been eliminated before manually resuming operation.

[0121] Emergency Stop Level (Red): This poses an immediate threat to personal safety or equipment safety. All axes are simultaneously locked in an emergency braking manner, and the audible and visual alarms remain activated. Manual reset is required after a complete troubleshooting process.

[0122] The control unit maintains a 16-bit fault code. The high 4 bits represent the fault level identifier, and the low 12 bits represent the fault source number, supporting a unique identifier for up to 4096 fault types. Each time a fault is triggered, the control unit writes the fault code, timestamp, and a snapshot of the system state before the trigger to the log storage area (PLC retainable data block) for maintenance personnel to analyze later.

[0123] The hardware foundation of the control unit is an industrial-grade PLC host, and the scanning cycle does not exceed [a certain value]. It connects to each servo drive via an EtherCAT industrial real-time Ethernet bus, with a communication cycle of... It communicates with the touchscreen via an RS485 interface using the Modbus RTU protocol, with a baud rate of... The system communicates with the industrial control computer via TCP / IP Ethernet using the Modbus TCP protocol. The signal decoded by the remote control's RF receiver module is connected to the control unit via a digital input module.

[0124] S600, release clamp and power off After the panel cabinet is installed and aligned, the operator secures it to the installation foundation using external fixing measures (anchor bolts, channel steel brackets, etc.). Once secured, the operator presses the "Confirm Secured" button on the touchscreen. This confirmation signal is the sole prerequisite for initiating the release operation—the control unit is prohibited from performing the release operation until it receives this manual confirmation signal, preventing the panel cabinet from being released without external securing.

[0125] The reset and power-off processes are executed in a strict and orderly sequence, consisting of five stages completed sequentially.

[0126] The first stage is the release of the clamp. The servo motor of the clamping mechanism reverses to drive the bidirectional lead screw, and the clamping plates on both sides synchronously retract outward. The release speed is limited to the slow advance speed. Ensure a smooth release. Force detection element monitors... After gradually lowering to zero, confirm that the clamp release is complete. The servo motor stops once the clamping plate retracts to the initial spacing. Updated to "Release".

[0127] The second stage is the lifting and returning to the starting position. The synchronous lifting mechanism drives the lifting platform to descend back to its lowest position. The returning speed is limited to 50% of the maximum unloaded speed, i.e. Four height detection elements continuously monitor the height at each corner, and when it reaches the lowest position ( Confirm that the repositioning is complete. Synchronization error monitoring is also performed during the descent process.

[0128] The third stage is horizontal repositioning. The horizontal movement mechanism drives the slide plate back to its zero point. A rapid return combined with precise calibration using an origin sensor is employed: first... Quickly return to the area near the origin, and decelerate to the point after touching the origin proximity switch. The crawling mechanism stops after touching the origin precision switch and the encoder position is zeroed.

[0129] The return sequence is executed in reverse order—first, return to horizontal position, then to vertical position, and finally, the clamp release is completed in the first step. This reverse design ensures that the lifting platform has returned to the horizontal zero position before descent, avoiding interference between the platform and the lifting frame when descending from an offset position.

[0130] The fourth stage is the confirmation of each axis's return to its original position. The control unit verifies, axis by axis, that each actuator has returned to its initial position. Within the scope. After all verifications pass. Set the flag to true.

[0131] The fifth stage is orderly power-down. The power-down sequence is strictly as follows: First, stop the enable signals of all motion actuators (at this time, the motor is already in the brake-locked state); then disconnect the power supply (AC bus) of each servo drive; next, disconnect the control power supply (DC 24V auxiliary circuit); finally, disconnect the main power switch. The stages are set with intervals between them. The delay ensures that the preceding actions are fully effective. If any stage during the power-down process times out (exceeds...) If the expected state transition is not completed, the control unit triggers an alarm and suspends the power-down process, awaiting manual intervention.

[0132] The power-down sequence is irreversible—do not disconnect the control power supply while the servo power is still on (otherwise the servo driver may lose control commands and execute unknown actions); do not disconnect the main power supply while the control power supply is still on (otherwise the PLC may lose data blocks due to power failure).

[0133] After all power is off When the flag is set to true, the touchscreen displays "Safely powered off," and all sound and light indicators turn off.

[0134] The control unit operates throughout the entire operation. The main loop program is executed continuously during the scan cycle. Within each scan cycle, the following tasks are completed sequentially: reading all digital and analog inputs, executing state machine transition logic, refreshing all interlocking conditions via AND gate operations, calculating motion control commands for each axis, sending commands to the corresponding drivers via the EtherCAT bus, and updating the touchscreen display data. The determinism of the scan cycle is guaranteed by the PLC operating system's real-time task scheduling mechanism; the highest priority safety interlock scan task cannot be preempted by other tasks.

[0135] The touchscreen serves as a human-machine interface, providing three levels of access permissions: Level 1 is for operators, who can perform daily operations, view real-time status, and respond to alarms; Level 2 is for maintenance engineers, who can modify process parameters (such as default clamping force and speed limit), view fault logs, and perform sensor calibration; Level 3 is for system administrators, who can modify safety parameters (such as interlock thresholds and timeout periods), update PLC programs, and export full operational data. Permission switching is achieved through digital password verification. The touchscreen interface includes five main screens: a main screen (system status overview), an operation screen (start / stop buttons for each step), a parameter screen (process parameter settings), an alarm screen (historical alarm records and real-time alarm stack), and a maintenance screen (fault logs and sensor calibration entry). Operators can switch between these screens via a side tab bar.

[0136] The electrical system of the device is powered by a centralized distribution cabinet. The main power supply is three-phase AC. The voltage is stepped down to AC by a transformer. The servo driver is supplied with power, and the control loop uses a switching power supply to convert DC power. It supplies PLCs, sensors, and touch screens. The distribution cabinet is equipped with a main circuit breaker, branch circuit breakers for each circuit, and residual current devices (RCDs). The EtherCAT communication cable uses industrial-grade shielded twisted-pair cable, and the connectors are M12-D coded, with electromagnetic interference immunity meeting industrial site requirements.

[0137] In a typical complete construction cycle, the total time from the operator switching on the main power supply to the completion of the panel installation and alignment is approximately Minutes, of which system initialization takes approximately Walking transfer approx. Minutes (depending on transfer distance and channel complexity), clamping approximately Lifting Approximately ( Itinerary (Full load speed calculation), precise translation approximation Return to position and power off Compared to traditional manual methods, it requires... The device can be completed in minutes and requires at least 3 people to work together. The construction efficiency is increased by about 3 to 5 times, and the manpower requirement is reduced to single-person operation. At the same time, the entire process is under multi-level safety interlock protection.

[0138] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit described above can be implemented in hardware.

[0139] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An electrical control panel transfer and hoisting device, characterized in that, include: The mobile chassis is used to transport the equipment to the target workstation where the electrical control panel is located; A clamping mechanism is used to apply symmetrical clamping force to the electrical panel and maintain the set clamping force through force closed-loop control; The synchronous lifting mechanism is used to vertically lift the clamped electrical panel to the target height, and to monitor and compensate for synchronous errors through a height detection element; A horizontal moving mechanism is used to perform precise translation of the electrical control panel after it has been lifted into place, and to perform closed-loop position control through a position detection device; The control unit is communicatively connected to the walking chassis, the clamping mechanism, the synchronous lifting mechanism, and the horizontal moving mechanism, and is used to perform coordinated scheduling and implement multi-level safety interlocks.

2. The apparatus according to claim 1, characterized in that, The chassis includes a differential steering drive wheel assembly and a collision avoidance detection element. The differential steering drive wheel assembly achieves steering through the speed difference between the left and right drive wheels, and the collision avoidance detection element implements graded braking based on the distance to the obstacle.

3. The apparatus according to claim 1, characterized in that, The control unit includes a state machine scheduling module and a fault classification response module. The state machine scheduling module manages the switching of the device between multiple working states, and the fault classification response module executes the corresponding protection strategy according to the fault level.

4. A method for transferring and hoisting electrical control panels, characterized in that, The electrical panel transfer and hoisting device according to any one of claims 1-3 includes: The equipment is transported to the target workstation where the electrical control panel is located using a mobile chassis. The electrical panel is subjected to symmetrical clamping force by the clamping mechanism, and the clamping force is fed back in real time by the force detection element to perform closed-loop force control. When the real-time clamping force reaches the set clamping force, it enters the holding state. The clamped electrical panel is vertically lifted to the target height by a synchronous lifting mechanism. During the lifting process, the height of each support point is fed back in real time by a height detection element and synchronous error is monitored. When the synchronous error exceeds a preset threshold, the lifting is paused and compensation is performed. The electrical control panel is precisely moved into place by a horizontal moving mechanism. During the movement, the horizontal deviation is obtained by a position detection device and the position is closed-loop controlled until the alignment deviation meets the preset accuracy requirements. The control unit performs coordinated scheduling of the walking chassis, the clamping mechanism, the synchronous lifting mechanism and the horizontal moving mechanism, and implements multi-level safety interlocks; when any interlock condition is triggered, the corresponding mechanism is controlled to enter a safe state.

5. The method according to claim 4, characterized in that, The clamping mechanism includes a symmetrical clamping drive component, which drives the clamping plates on both sides to synchronously center and close; the force closed-loop control also includes an automatic pressure compensation strategy, which automatically starts pressure compensation when the real-time clamping force drops below the preset ratio of the set clamping force in the holding state, and triggers shutdown protection when the pressure compensation fails to meet the standard after multiple consecutive attempts.

6. The method according to claim 5, characterized in that, The clamping mechanism further includes an elastic buffer disposed between the symmetrical clamping drive and the clamping plate. The elastic buffer absorbs impact energy when the clamping plate initially contacts the electrical cabinet, causing the contact force to increase according to a preset gradient.

7. The method according to claim 4, characterized in that, The synchronous lifting mechanism adopts a multi-segment speed planning, including: a fast segment, which operates at a first speed when the distance to the target is greater than a first distance threshold; a deceleration segment, which decelerates linearly when the distance to the target is between the first distance threshold and a second distance threshold; and a crawling segment, which approaches the target at a second speed when the distance to the target is less than or equal to the second distance threshold, wherein the second speed is less than the first speed.

8. The method according to claim 4, characterized in that, The position detection device includes an image acquisition unit, which acquires images of the positioning feature points of the electrical control panel and converts the image coordinates into physical deviations through coordinate transformation.

9. The method according to claim 5, characterized in that, The position closed-loop control adopts a dual closed-loop cascade control structure with an outer loop position and an inner loop speed. The outer loop uses the physical deviation as the set value, and the inner loop uses the encoder feedback position as the process variable.

10. The method according to claim 4, characterized in that, The method further includes: Before the transfer, the control unit performs heartbeat detection on each slave station and zero-point calibration on the sensors. After all self-tests pass, it outputs a system ready flag.

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