A cable anti-breaking intelligent protection system and method for a trailing electric excavator

Abstract

The application discloses a kind of intelligent protection system and method of cable of drag excavator is prevented from being broken, it is related to electrical safety protection technical field, multiple turns absolute value encoder is installed in reel shaft end, the rotation number of reel is collected, drum controller obtains rotation number, is transmitted to excavator controller by first communication module and second communication module, and excavator controller determines cable winding number according to rotation number, and then calculates cable remaining length, whole process relies on equipment quantitative operation, subjective bias caused by manual visual estimation is discarded, and the accuracy of cable surplus judgment is improved.Excavator controller compares the cable remaining length calculated with set threshold, and controls audible and visual annunciator to issue early warning according to comparison result, and driver does not need to observe cable, and can stop moving away from power supply in time, to avoid cable being forcibly pulled, effectively prevent cable break, leakage, equipment damage and other accidents, avoid electric shock hidden danger, and guarantee the personal safety of on-site operator.

Description

Technical Field

[0001] This application relates to the field of electrical safety protection technology, and in particular to an intelligent protection system and method for preventing cable breakage in trolley excavators. Background Technology

[0002] Electric-powered excavators obtain power from a fixed power source or a mobile battery vehicle via a tail cable. During operation, the excavator moves frequently, and the cable is automatically retracted and extended by a drum mounted on the chassis. As the excavator moves away from the power source, the cable is gradually released from the drum. When the remaining cable is almost completely released, if the operator fails to notice in time and stop moving away, the cable will be pulled directly, leading to serious accidents such as breakage, leakage, or even equipment damage. Current methods rely solely on the operator's subjective judgment of the remaining cable length based on personal experience, which has large errors and insufficient accuracy. At the same time, the complex conditions at construction sites make it difficult to ensure the personal safety of on-site workers by relying solely on manual observation.

[0003] Therefore, improving the accuracy of cable allowance assessment and ensuring the personal safety of on-site workers are problems that need to be solved by those skilled in the art. Summary of the Invention

[0004] The purpose of this application is to provide an intelligent protection system and method for preventing cable breakage in electric excavators, which solves the following problems: existing methods rely solely on operators' subjective judgment of the remaining cable length based on their personal experience, resulting in large errors and insufficient accuracy in judging cable slack. At the same time, the working conditions at construction sites are complex, and relying solely on manual observation is insufficient to guarantee the personal safety of on-site workers.

[0005] To solve the above-mentioned technical problems, this application provides an intelligent protection system for preventing cable breakage in electric excavators, including: a drum controller, a multi-turn absolute encoder, a first communication module, an audible and visual alarm, a second communication module, and an excavator controller; The drum controller, the first communication module, and the audible and visual alarm are mounted on the drum bracket. The multi-turn absolute encoder is mounted on the drum shaft end. The drum controller is connected to the multi-turn absolute encoder, the first communication module, and the audible and visual alarm. The first communication module is connected to the excavator controller via the second communication module. The excavator controller is connected to the forward cut-off actuator. The drum controller is used to obtain the number of rotations detected by the multi-turn absolute encoder and send the number of rotations to the excavator controller via the first and second communication modules. The excavator controller is used to determine the current number of cable turns on the drum based on the number of rotations, determine the remaining length of the cable on the drum based on the current number of turns, and control the audible and visual alarm to issue a warning based on the remaining cable length and a set threshold.

[0006] In one optional embodiment, the device further includes a DC-to-DC power supply module, which is connected to the cable, the roller controller, the multi-turn absolute encoder, the first communication module, and the audible and visual alarm.

[0007] In an optional embodiment, a travel pilot pressure sensor is also included. If the excavator is a hydraulically piloted main valve excavator, the forward cut-off actuator is a normally closed two-position three-way solenoid valve. The normally closed two-position three-way solenoid valve is installed on the left and right travel forward pilot oil lines of the excavator. The travel pilot pressure sensor is installed in the forward pilot oil line downstream of each normally closed two-position three-way solenoid valve. The travel pilot pressure sensor is used to detect the oil pressure in the forward pilot oil line.

[0008] This application also provides an intelligent protection method for preventing cable breakage in electric excavators, applied to the aforementioned intelligent protection system for preventing cable breakage in electric excavators, comprising: Obtain the number of rotations detected by the multi-turn absolute encoder; The current number of cable turns on the drum is determined based on the number of rotations. The remaining length of the cable wound on the drum is determined based on the current number of winding turns; The audible and visual alarm is controlled to issue an early warning based on the remaining length of the cable and a set threshold.

[0009] In one optional embodiment, determining the remaining cable length wound on the drum based on the current number of turns includes: Determine the total number of cable winding layers and the number of outermost cable winding turns on the drum based on the current number of winding turns. The maximum number of cable turns per layer is determined based on the effective cable width of the drum and the outer diameter of the cable. The circumference of each turn of the cable is determined based on the drum diameter, the cable outer diameter, and the layer number of each layer of cable. The remaining length of cable wound on the drum is calculated based on the total number of winding layers, the maximum number of winding turns, the circumference of a single turn of each layer, and the number of turns of the outermost cable winding layer.

[0010] In one optional embodiment, determining the remaining cable length wound on the drum based on the current number of turns includes: Call the preset mapping table and determine the remaining cable length corresponding to the current number of winding turns according to the preset mapping table; The preset mapping table includes the correspondence between the number of cable turns on the reel and the remaining cable length.

[0011] In an optional embodiment, before invoking the preset mapping table, the following steps are further included: Calculate the length of the first cable wound on the drum corresponding to each number of turns of the cable on the drum; Measure the length of the second cable that has been released corresponding to the target number of turns of cable on the reel, and subtract the length of the second cable from the total cable length to obtain the length of the third cable; The deviation is determined based on the first and third cable lengths corresponding to the target number of winding turns, and the first cable length corresponding to each number of winding turns is calibrated based on the deviation to obtain the remaining cable length corresponding to each number of winding turns on the drum, so as to establish the preset mapping table.

[0012] In one optional embodiment, controlling the audible and visual alarm to issue a warning based on the remaining cable length and a set threshold includes: If the remaining length is less than or equal to the first set threshold, control the yellow light of the sound and light alarm to flash and the buzzer to sound, and control the display to show a prompt message indicating that walking is normal. If the remaining length is less than or equal to the second set threshold, control the red light of the sound and light alarm to flash and the buzzer to sound, control the display to show a prompt message that the walking is normal, and adjust the pump displacement to limit the walking speed to a preset low speed. If the remaining length is less than or equal to the third set threshold, control the red light of the sound and light alarm to stay on and the buzzer to sound, control the display to show a prompt message containing "prohibit forward movement" and "please retreat and retract the cable", and control the forward cut-off actuator to cut off the forward movement power. Wherein, the second set threshold is greater than the first set threshold and less than the third set threshold.

[0013] In one optional embodiment, after controlling the forward cut-off actuator to cut off the forward travel power, the method further includes: In response to the user's temporary permission to move forward, the excavator's forward movement function is restored; If the recovery time of the forward travel function exceeds the preset duration and / or the cable pull-out length after the forward travel function is restored is greater than the preset length, the excavator will be prohibited from moving forward again.

[0014] In one optional embodiment, controlling the audible and visual alarm to issue a warning based on the remaining cable length and a set threshold includes: Subtract the set length from the remaining cable length to obtain the displayed remaining length; The sound and light alarm is controlled to issue a warning based on the displayed remaining length and the set threshold.

[0015] This application provides an intelligent protection system for cable breakage prevention in electric excavators, comprising: a drum controller, a multi-turn absolute encoder, a first communication module, an audible and visual alarm, a second communication module, and an excavator controller. The drum controller, the first communication module, and the audible and visual alarm are mounted on a drum bracket. The multi-turn absolute encoder is mounted on the drum shaft end. The drum controller is connected to the multi-turn absolute encoder, the first communication module, and the audible and visual alarm. The first communication module is connected to the excavator controller via the second communication module. The excavator controller is connected to a forward cut-off actuator. The drum controller is used to acquire the number of rotations detected by the multi-turn absolute encoder and send the number of rotations to the excavator controller via the first and second communication modules. The excavator controller is used to determine the current number of cable turns on the drum based on the number of rotations, determine the remaining length of the cable on the drum based on the current number of turns, and control the audible and visual alarm to issue a warning based on the remaining cable length and a set threshold. A multi-turn absolute encoder is installed at the end of the drum shaft to collect the number of drum rotations. The drum controller obtains the number of rotations and transmits it to the excavator controller via the first and second communication modules. The excavator controller determines the number of cable windings based on the number of rotations and then calculates the remaining cable length. The entire process relies on equipment-based quantitative calculations, eliminating subjective biases caused by manual visual estimation and improving the accuracy of cable length assessment. The excavator controller compares the calculated remaining cable length with a set threshold and, based on the comparison result, controls an audible and visual alarm to issue a warning. The operator does not need to be distracted by observing the cable and can promptly stop moving away from the power source, preventing the cable from being forcibly pulled. This effectively prevents accidents such as cable breakage, leakage, and equipment damage, avoids the risk of electric shock, and ensures the personal safety of on-site personnel.

[0016] The beneficial effects of the intelligent protection method for preventing cable breakage in a trolley excavator provided in this application correspond to the system, as described above. Attached Figure Description

[0017] To more clearly illustrate the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A structural diagram of an intelligent protection system for preventing cable breakage in an electric excavator provided in this application embodiment; Figure 2 A flowchart illustrating an intelligent protection method for preventing cable breakage in an electric excavator, provided in an embodiment of this application; Figure 3 A structural diagram of an intelligent protection device for preventing cable breakage in an electric excavator provided in this application embodiment; Figure 4 A structural diagram of another intelligent protection device for preventing cable breakage in a tractor-mounted excavator provided in this application embodiment.

[0019] The attached diagram is labeled as follows: 1-Drum controller, 2-Multi-turn absolute encoder, 3-First communication module, 4-Audio and visual alarm, 5-Excavator controller, 6-Second communication module, 7-DC to DC power supply module, 8-Travel pilot pressure sensor. Detailed Implementation

[0020] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this application.

[0021] The core of this application is to provide an intelligent protection system and method for preventing cable breakage in electric excavators, which improves the accuracy of cable slack assessment and ensures the personal safety of on-site workers.

[0022] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] Figure 1 A structural diagram of an intelligent protection system for preventing cable breakage in an electric excavator, as provided in this application embodiment, is shown below. Figure 1 As shown, an intelligent protection system for preventing cable breakage in a trolley excavator includes: a drum controller 1, a multi-turn absolute encoder 2, a first communication module 3, an audible and visual alarm 4, a second communication module 6, and an excavator controller 5. The drum controller 1, the first communication module 3, and the audible and visual alarm 4 are mounted on the drum bracket. The multi-turn absolute encoder 2 is mounted on the drum shaft end. The drum controller 1 is connected to the multi-turn absolute encoder 2, the first communication module 3, and the audible and visual alarm 4. The first communication module 3 is connected to the excavator controller 5 through the second communication module 6. The excavator controller 5 is connected to a forward cutting actuator. The drum controller 1 is used to acquire the number of rotations detected by the multi-turn absolute encoder 2 and send the number of rotations to the excavator controller 5 through the first communication module 3 and the second communication module 6. The excavator controller 5 is used to determine the current number of turns of the cable wound on the drum based on the number of rotations, determine the remaining length of the cable wound on the drum based on the current number of turns, and control the audible and visual alarm 4 to issue an early warning based on the remaining cable length and a set threshold.

[0024] In this embodiment, the drum support is equipped with a control box, and the drum controller 1, the first communication module 3, and the audible and visual alarm 4 are assembled inside the control box.

[0025] The roller controller 1 is connected to the multi-turn absolute encoder 2, the first communication module 3, and the audible and visual alarm 4. It is responsible for collecting the number of rotations detected by the multi-turn absolute encoder 2 and sending the rotation count data through the first communication module 3. Of course, the roller controller 1 can also determine the current number of cable turns on the drum based on the rotation count, and determine the remaining length of cable wound on the drum based on the current number of turns.

[0026] The multi-turn absolute encoder 2 is installed on the end of the drum shaft, providing angle information within a single turn and recording the number of rotations through an internal gear mechanism. The multi-turn absolute encoder 2 ensures that the position is not lost after power failure, and that the current number of winding turns can be obtained directly without recalibration after the system restarts, greatly improving the reliability and ease of use of the system.

[0027] The first communication module 3 can use a 2.4GHz wireless communication module with a latency of less than 20ms.

[0028] The audible and visual alarm 4 is mounted on the roller bracket and controlled by the roller controller 1. It has at least three modes (slow flash, fast flash, and constant light) and different beeping frequencies.

[0029] The second communication module 6 can also use a 2.4GHz wireless communication module with a latency of less than 20ms. The second communication module 6 is installed on the roof of the cab and connects to the excavator controller 5 via a Controller Area Network (CAN) bus. The second communication module 6 and the first communication module 3 can achieve bidirectional data transmission via the CAN bus. The second communication module 6 draws power from the original vehicle's 24V system.

[0030] The excavator controller 5 receives wireless data from the drum controller 1, combines it with the travel handle signal to determine the driver's forward or reverse intention, and executes actions such as prohibiting forward movement, limiting speed, displaying pop-up alarms, and managing emergency release functions. It can also determine the current number of cable turns on the drum based on the number of rotations, determine the remaining cable length on the drum based on the current number of turns, and control the audible and visual alarm 4 to issue a warning based on the remaining cable length and a set threshold. Alternatively, the excavator controller 5 can obtain the remaining cable length calculated by the drum controller 1, determine the warning information based on the remaining cable length, and send the warning information to the drum controller 1. The drum controller 1 then controls the audible and visual alarm 4 to issue a warning based on the warning information.

[0031] The forward cut-off actuator is implemented differently depending on the excavator type. For excavators with a hydraulically piloted main valve, the forward cut-off actuator is a normally closed two-position three-way solenoid valve. This valve is installed on the left and right travel forward pilot oil lines of the excavator. A travel pilot pressure sensor 8 is installed downstream of each normally closed two-position three-way solenoid valve in the forward pilot oil line. The travel pilot pressure sensor 8 detects the forward pilot oil pressure after the normally closed two-position three-way solenoid valve is shut off. The normally closed two-position three-way solenoid valve is controlled by the excavator controller 5. When energized, it allows the forward pilot oil to flow; when de-energized, it shuts off the forward pilot oil line, thus prohibiting the excavator from traveling in the forward direction. For fully electronically controlled main valve excavators, the forward cut-off actuator is a proportional valve. It can set the output drive signal of the proportional valve in the forward travel direction to zero, directly cutting off the forward travel control command. The output command of the proportional valve in the reverse direction is unrestricted.

[0032] It also includes a DC-to-DC power supply module 7, which is connected to the cable, roller controller 1, multi-turn absolute encoder 2, first communication module 3, and audible and visual alarm 4. The DC-to-DC power supply module 7 can draw power from a fixed power source through the cable and convert it into a stable 24V DC power to power the roller controller 1, multi-turn absolute encoder 2, first communication module 3, and audible and visual alarm 4; when the power source is cut off, it automatically loses power, and forward movement is prohibited, automatically entering a safety state.

[0033] It also includes a travel pilot pressure sensor 8. If the excavator is a hydraulically piloted main valve excavator, the forward cut-off actuator is a normally closed two-position three-way solenoid valve. The normally closed two-position three-way solenoid valve is installed on the left and right travel forward pilot oil lines of the excavator. The travel pilot pressure sensor 8 is installed downstream of each normally closed two-position three-way solenoid valve (on the oil outlet side of the solenoid valve) in the forward pilot oil line. The travel pilot pressure sensor 8 is used to detect the oil pressure in the forward pilot oil line. The normally closed two-position three-way solenoid valve is electrically connected to the excavator controller 5, and the excavator controller 5 outputs an electrical signal to control the opening and closing of the solenoid valve. The travel pilot pressure sensor 8 is also connected to the excavator controller 5, and transmits the real-time collected forward pilot oil pressure signal back to the excavator controller 5. The normally closed two-position three-way solenoid valve remains open under normal conditions; when the remaining cable length is less than or equal to the third set threshold, the controller controls the normally closed two-position three-way solenoid valve to close due to de-energization, cutting off the forward pilot oil line and blocking the excavator's forward movement. The reverse oil line is not affected. The travel pilot pressure sensor 8 continuously monitors the oil pressure in the forward pilot oil circuit downstream of the solenoid valve to verify whether the solenoid valve has completed the shut-off action. If the travel pilot pressure sensor 8 still detects normal oil pressure after the excavator controller 5 issues a shut-off command, it is determined that the solenoid valve is faulty and the shut-off protection has failed. The system will automatically trigger the secondary protection, that is, adjust the pump displacement to limit the travel speed to a preset low speed, which can be less than 1.5 km / h.

[0034] This application provides an intelligent protection system for preventing cable breakage in a trolley excavator, comprising: a drum controller, a multi-turn absolute encoder, a first communication module, an audible and visual alarm, a second communication module, and an excavator controller. The drum controller, the first communication module, and the audible and visual alarm are mounted on a drum bracket. The multi-turn absolute encoder is mounted on the drum shaft end. The drum controller is connected to the multi-turn absolute encoder, the first communication module, and the audible and visual alarm. The first communication module is connected to the excavator controller via the second communication module. The excavator controller is connected to a forward cutting actuator. The drum controller is used to acquire the number of rotations detected by the multi-turn absolute encoder and send the number of rotations to the excavator controller via the first and second communication modules. The excavator controller is used to determine the current number of turns of the cable wound on the drum based on the number of rotations, determine the remaining length of the cable wound on the drum based on the current number of turns, and control the audible and visual alarm to issue a warning based on the remaining cable length and a set threshold. A multi-turn absolute encoder is installed at the end of the drum shaft to collect the number of drum rotations. The drum controller obtains the number of rotations and transmits it to the excavator controller via the first and second communication modules. The excavator controller determines the number of cable windings based on the number of rotations and then calculates the remaining cable length. The entire process relies on equipment-based quantitative calculations, eliminating subjective biases caused by manual visual estimation and improving the accuracy of cable length assessment. The excavator controller compares the calculated remaining cable length with a set threshold and, based on the comparison result, controls an audible and visual alarm to issue a warning. The operator does not need to be distracted by observing the cable and can promptly stop moving away from the power source, preventing the cable from being forcibly pulled. This effectively prevents accidents such as cable breakage, leakage, and equipment damage, avoids the risk of electric shock, and ensures the personal safety of on-site personnel.

[0035] Figure 2 A flowchart illustrating an intelligent protection method for preventing cable breakage in an electric excavator, as provided in this application embodiment, is shown below. Figure 2 As shown, a method for intelligent protection against cable breakage in an electric excavator, applied to the aforementioned intelligent protection system for cable breakage in an electric excavator, includes: S10: Obtain the number of rotations detected by the multi-turn absolute encoder.

[0036] S11: Determine the current number of cable turns on the drum based on the number of rotations.

[0037] S12: Determine the remaining length of cable wound on the drum based on the current number of turns.

[0038] S13: Control the audible and visual alarm to issue a warning based on the remaining cable length and the set threshold.

[0039] In step S10, the number of rotations is not necessarily an integer and may include a decimal part. The decimal part can be converted into the corresponding number of rotations based on the angle information within a single rotation range. For example, if you rotate 180° within a single rotation range (360°), then the number of rotations corresponding to 180° is 0.5 rotations.

[0040] In step S11, when the cable is fully wound on the drum, the number of rotations output by the multi-turn absolute encoder is the total number of rotations of the cable wound on the drum. When the drum releases all the cable, the number of rotations output by the multi-turn absolute encoder is zero. Under this setting, the number of rotations detected by the multi-turn absolute encoder is the current number of cable rotations on the drum.

[0041] When the cable is fully wound on the drum, the number of rotations output by the multi-turn absolute encoder is zero. When the drum unwinds all the cable, the number of rotations output by the multi-turn absolute encoder is the total number of turns of the cable wound on the drum. Under this setting, the current number of turns of the cable on the drum is obtained by subtracting the number of rotations detected by the multi-turn absolute encoder from the total number of turns of the cable wound on the drum.

[0042] Alternatively, calibration can be performed at the factory. The cable is fully retracted to the mechanical limit position on the drum, and the total reference number of encoder turns is recorded. This total reference number of turns corresponds to the fully wound state of the cable on the drum. Then, the cable is released to the safety zero position, and the encoder zero-position turns are recorded. This establishes a one-to-one mapping data table between the encoder's rotation count and the current number of cable turns on the drum, which is stored in the excavator controller and drum controller. Subsequently, the current number of cable turns on the drum corresponding to the number of rotation counts can be determined based on the mapping data table.

[0043] In step S12, determining the remaining length of the cable wound on the drum based on the current number of winding turns includes: determining the total number of cable winding layers and the number of outermost cable winding turns on the drum based on the current number of winding turns; determining the maximum number of winding turns for each layer of cable based on the effective cable routing width of the drum and the outer diameter of the cable; determining the circumference of a single turn of each layer of cable based on the drum diameter, the outer diameter of the cable, and the layer number of each layer of cable; and calculating the remaining length of the cable wound on the drum based on the total number of winding layers, the maximum number of winding turns, the circumference of a single turn of each layer, and the number of outermost cable winding turns.

[0044] The drum body is a cylindrical cylinder, and there is an effective length in the axial direction of the cylinder for neatly winding cables. This length is the effective cable width of the drum.

[0045] To facilitate understanding, an example is given below. Known parameters: drum diameter 800mm, effective cable width on the drum 1000mm, cable outer diameter 60mm; after equipment calibration, the total number of winding layers when the cable is fully wound is 4, with a maximum of 16 turns per layer; the current total number of cable winding turns is calculated to be 38. The formula for the center diameter of each layer is: Di=Db+(2i-1)d, and the circumference of a single turn is Li=πDi; where Di is the center diameter of each layer; Db is the drum diameter; i is the layer number, with the layer closest to the drum being the first layer, and the layer numbers gradually increasing from the closest to the drum to the furthest away; d is the cable outer diameter; and Li is the circumference of a single turn in the i-th layer.

[0046] A single layer can have a maximum of 16 turns. The first layer has 16 turns, the second layer has 16 turns, and the two layers together have a total of 16 + 16 = 32 turns. The current total number of turns is 38. The outermost layer of cable has 38 - 32 = 6 turns. The total number of layers is 3. The first two layers are completely full, and the third layer has 6 turns.

[0047] Let π = 3.14. For the first layer (i = 1), D1 = 800 + (2 × 1 - 1) × 60 = 800 + 60 = 860 mm, L1 = 3.14 × 860 = 2700.4 mm. For the second layer (i = 2), D2 = 800 + (2 × 2 - 1) × 60 = 800 + 180 = 980 mm, L2 = 3.14 × 980 = 3077.2 mm. For the third layer (i = 3), D3 = 800 + (2 × 3 - 1) × 60 = 800 + 300 = 1100 mm, L3 = 3.14 × 1100 = 3454 mm.

[0048] The total length of the first full layer is 16 × 2700.4 = 43206.4 mm.

[0049] The total length of the second full layer is 16 × 3077.2 = 49235.2 mm.

[0050] The total length of the 6 rings in the 3rd layer is 6 × 3454 = 20724 mm.

[0051] Remaining cable length: 43206.4 + 49235.2 + 20724 = 113165.6 mm = 113.1656 m.

[0052] In step S12, the remaining length of the cable wound on the drum is determined based on the current number of winding turns, including calling a preset mapping table and determining the remaining cable length corresponding to the current number of winding turns according to the preset mapping table; wherein, the preset mapping table includes the correspondence between the number of cable winding turns on the drum and the remaining cable length.

[0053] Before calling the preset mapping table, the process includes: calculating the length of the first cable wound on the drum corresponding to each number of turns of the cable on the drum; measuring the length of the second cable that has been released corresponding to the target number of turns of the cable on the drum, and subtracting the second cable length from the total cable length to obtain the third cable length; determining the deviation based on the first and third cable lengths corresponding to the target number of turns, and calibrating the first cable length corresponding to each number of turns based on the deviation to obtain the remaining cable length corresponding to each number of turns of the cable on the drum, thus establishing the preset mapping table. The calculation of the length of the first cable wound on the drum corresponding to each number of turns of the cable on the drum refers to the method described above for determining the remaining cable length wound on the drum based on the current number of turns. The target number of turns can be any two numbers, for example: 20 turns and 38 turns.

[0054] In step S13, the audible and visual alarm is controlled to issue a warning based on the remaining cable length and a set threshold, including: if the remaining length is less than or equal to the first set threshold, the yellow light of the audible and visual alarm flashes and the buzzer sounds, and the display shows a message indicating normal movement; if the remaining length is less than or equal to the second set threshold, the red light of the audible and visual alarm flashes and the buzzer sounds, the display shows a message indicating normal movement, and the pump displacement is adjusted to limit the walking speed to a preset low speed; if the remaining length is less than or equal to the third set threshold, the red light of the audible and visual alarm remains on and the buzzer sounds, the display shows a message indicating "prohibit forward movement" and "please retreat and retract the cable," and the forward cut-off actuator cuts off the forward movement power; wherein the second set threshold is greater than the first set threshold and less than the third set threshold.

[0055] The three threshold settings are as follows: the first threshold is 7 meters, the second is 5 meters, and the third is 3.2 meters. Remaining length ≤ 7 meters: Level 1 warning, the audible and visual alarm flashes yellow slowly and beeps intermittently, the display shows yellow text, and movement is normal; Remaining length ≤ 5 meters: Level 2 warning, the audible and visual alarm flashes red quickly and beeps rapidly, the display shows a red warning bar, movement is normal, and controller A limits the movement speed to a low speed (less than 1.5 km / h) by adjusting the pump displacement; Remaining length ≤ 3.2 meters: Level 3 prohibition, the audible and visual alarm stays red and sounds continuously; When the driver's intention to move forward is detected, a full-screen pop-up window "Prohibited from moving forward! Please reverse and retract the cable" appears on the display, and the forward movement power is immediately cut off. Reverse movement and all other actions are normal. When the intention to move forward disappears, the pop-up window disappears but the top warning bar remains. The condition for resuming the prohibition is: the remaining length increases to more than 3.5 meters, and the movement handle returns to the neutral position with a 0.5-second delay.

[0056] The excavator controller acquires the forward and reverse opening signals of the left and right travel handles via CAN bus or hardwire. If the forward opening on either side exceeds a preset threshold (e.g., 10%), it is interpreted as a forward intention. For hydraulically piloted main valve excavators, the controller de-energizes two normally closed two-position three-way solenoid valves to cut off the forward pilot oil; for fully electronically controlled main valve excavators, the controller forcibly resets the travel forward proportional valve command to zero. The travel pilot pressure sensor monitors the effectiveness of the prohibition; if it fails, it triggers secondary protection, adjusting the pump displacement to limit the travel speed to a preset low speed setting.

[0057] Furthermore, after the forward cut-off actuator cuts off the forward travel power, the system also includes: in response to the user's temporary forward permission operation, restoring the excavator's forward travel function; and if the restoration time of the forward travel function exceeds a preset duration and / or the cable pull-out length after the forward travel function is restored is greater than a preset length, then the excavator's forward movement is prohibited again.

[0058] A password-protected temporary forward movement permission function is configured within the monitor's maintenance menu. After activation by the user entering a password, forward movement can be temporarily restored, but the system has two automatic termination conditions: Condition 1, the cumulative restoration time exceeds n seconds (default 30 seconds); Condition 2, the cable extension length exceeds 1.5 meters from the activation time. If either condition is met, forward movement is automatically disabled again, and the operation log is recorded. The software-based emergency deactivation of password protection replaces the physical switch, preventing accidental activation and providing a controlled escape method in extreme situations.

[0059] It should be noted that the excavator controller monitors the wireless signal strength in real time and issues an early warning when the signal strength falls below a threshold; if no wireless signal is received within a preset time, forward movement is prohibited. When the drum controller passes its power-on self-test, the audible and visual alarm flashes twice; if the sensor malfunctions, the audible and visual alarm remains constantly lit.

[0060] Furthermore, the system controls an audible and visual alarm to issue a warning based on the remaining cable length and a set threshold. This includes: subtracting the set length from the remaining cable length to obtain the displayed remaining length; and controlling the audible and visual alarm to issue a warning based on the displayed remaining length and the set threshold. The set length can be the length of two turns of cable, ensuring sufficient buffer cable to prevent breakage even if the displayed remaining length is zero meters.

[0061] This application provides an intelligent protection method for preventing cable breakage in electric excavators, applied to the aforementioned intelligent protection system for electric excavator cables. The method includes: acquiring the number of rotations detected by a multi-turn absolute encoder; determining the current number of cable turns on the drum based on the number of rotations; determining the remaining cable length on the drum based on the current number of turns; and controlling an audible and visual alarm to issue a warning based on the remaining cable length and a set threshold. Determining the number of cable turns based on the number of rotations, and then calculating the remaining cable length, relies entirely on equipment-based quantitative calculations, eliminating subjective biases caused by manual visual estimation and improving the accuracy of cable length assessment. The calculated remaining cable length is compared with a set threshold, and the audible and visual alarm is activated based on the comparison result. The driver does not need to focus on the cable and can promptly stop moving away from the power source, preventing the cable from being forcibly pulled, effectively preventing accidents such as cable breakage, leakage, and equipment damage, avoiding the risk of electric shock, and ensuring the personal safety of on-site personnel.

[0062] The above embodiments have described in detail the intelligent protection method for preventing cable breakage in electric scooter excavators. This application also provides embodiments corresponding to the intelligent protection device for preventing cable breakage in electric scooter excavators. It should be noted that this application describes the embodiments of the device from two perspectives: one based on functional modules and the other based on hardware.

[0063] Figure 3 A structural diagram of an intelligent protection device for preventing cable breakage in an electric excavator, as provided in this application embodiment, is shown below. Figure 3 As shown, a smart protection device for preventing cable breakage in an electric excavator includes: The acquisition module is used to acquire the number of rotations detected by the multi-turn absolute encoder.

[0064] The first determining module is used to determine the current number of cable turns on the drum based on the number of rotations.

[0065] The second determining module is used to determine the remaining length of the cable wound on the drum based on the current number of winding turns; The early warning module is used to control the audible and visual alarm to issue early warnings based on the remaining cable length and a set threshold.

[0066] Since the embodiments of the apparatus and the embodiments of the method correspond to each other, please refer to the description of the embodiments of the method for the embodiments of the apparatus, which will not be repeated here.

[0067] Figure 4 A structural diagram of another intelligent protection device for preventing cable breakage in a tractor-trailer excavator provided in this application embodiment is shown below. Figure 4 As shown, the intelligent protection device for preventing cable breakage in electric excavators includes: a memory 20 for storing computer programs; The processor 21 is used to execute computer programs to implement the steps of the intelligent protection method for preventing cable breakage of electric excavators as described in the above embodiments.

[0068] The intelligent protection device for preventing cable breakage of the electric excavator provided in this embodiment can include, but is not limited to, smartphones, tablets, laptops, or desktop computers.

[0069] The processor 21 may include one or more processing cores, such as a quad-core processor or an octa-core processor. The processor 21 may be implemented using at least one of the following hardware forms: Digital Signal Processor (DSP), Field-Programmable Gate Array (FPGA), or Programmable Logic Array (PLA). The processor 21 may also include a main processor and a coprocessor. The main processor, also known as the Central Processing Unit (CPU), is used to process data in the wake-up state; the coprocessor is a low-power processor used to process data in the standby state. In some embodiments, the processor 21 may integrate a Graphics Processing Unit (GPU), which is responsible for rendering and drawing the content to be displayed on the screen. In some embodiments, the processor 21 may also include an Artificial Intelligence (AI) processor, which handles computational operations related to machine learning.

[0070] The memory 20 may include one or more computer-readable storage media, which may be non-transitory. The memory 20 may also include high-speed random access memory and non-volatile memory, such as one or more disk storage devices or flash memory devices. In this embodiment, the memory 20 is used to store at least the following computer program 201, which, after being loaded and executed by the processor 21, is capable of implementing the relevant steps of the intelligent protection method for preventing cable breakage in electric excavators disclosed in any of the foregoing embodiments. In addition, the resources stored in the memory 20 may also include an operating system 202 and data 203, and the storage method may be temporary or permanent storage. The operating system 202 may include Windows, Unix, Linux, etc. The data 203 may include, but is not limited to, the number of rotations.

[0071] In some embodiments, the intelligent protection device for preventing cable breakage of electric excavators may further include a display screen 22, an input / output interface 23, a communication interface 24, a power supply 25, and a communication bus 26.

[0072] Those skilled in the art will understand that Figure 4 The structure shown does not constitute a limitation on the intelligent protection device for preventing cable breakage in electric excavators and may include more or fewer components than shown.

[0073] The intelligent protection device for preventing cable breakage in trolley excavators provided in this application includes a memory and a processor. When the processor executes the program stored in the memory, it can perform the following methods: obtain the number of rotations detected by the multi-turn absolute encoder; determine the current number of cable windings on the drum based on the number of rotations; determine the remaining length of the cable wound on the drum based on the current number of windings; and control the audible and visual alarm to issue a warning based on the remaining cable length and a set threshold.

[0074] Finally, this application also provides an embodiment corresponding to a computer-readable storage medium. The computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps described in the above-described method embodiment for intelligent protection against cable breakage in electric excavators.

[0075] It is understood that if the methods in the above embodiments are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and executes all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0076] The above provides a detailed description of an intelligent protection system and method for preventing cable breakage in electric excavators. The various embodiments in the specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to in the method section. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

[0077] It should also be noted that, in this specification, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A smart protection system for preventing cable breakage in electric excavators, characterized in that, include: The system includes a drum controller, a multi-turn absolute encoder, a first communication module, an audible and visual alarm, a second communication module, and an excavator controller. The drum controller, the first communication module, and the audible and visual alarm are mounted on the drum bracket. The multi-turn absolute encoder is mounted on the drum shaft end. The drum controller is connected to the multi-turn absolute encoder, the first communication module, and the audible and visual alarm. The first communication module is connected to the excavator controller via the second communication module. The excavator controller is connected to the forward cut-off actuator. The drum controller is used to obtain the number of rotations detected by the multi-turn absolute encoder and send the number of rotations to the excavator controller via the first and second communication modules. The excavator controller is used to determine the current number of cable turns on the drum based on the number of rotations, determine the remaining length of the cable on the drum based on the current number of turns, and control the audible and visual alarm to issue a warning based on the remaining cable length and a set threshold.

2. The intelligent protection system for preventing cable breakage in electric excavators according to claim 1, characterized in that, It also includes a DC-to-DC power supply module, which is connected to the cable, the roller controller, the multi-turn absolute encoder, the first communication module, and the audible and visual alarm.

3. The intelligent protection system for preventing cable breakage in electric excavators according to claim 1, characterized in that, It also includes a travel pilot pressure sensor. If the excavator is a hydraulically piloted main valve excavator, the forward cut-off actuator is a normally closed two-position three-way solenoid valve. The normally closed two-position three-way solenoid valve is installed on the left and right travel forward pilot oil lines of the excavator. The travel pilot pressure sensor is installed on the forward pilot oil line downstream of each normally closed two-position three-way solenoid valve. The travel pilot pressure sensor is used to detect the oil pressure in the forward pilot oil line.

4. A method for intelligent protection against cable breakage in electric excavators, characterized in that, The intelligent protection system for preventing cable breakage in electric excavators according to any one of claims 1 to 3 includes: Obtain the number of rotations detected by the multi-turn absolute encoder; The current number of cable turns on the drum is determined based on the number of rotations. The remaining length of the cable wound on the drum is determined based on the current number of winding turns; The audible and visual alarm is controlled to issue an early warning based on the remaining length of the cable and a set threshold.

5. The intelligent protection method for preventing cable breakage in electric excavators according to claim 4, characterized in that, Determining the remaining cable length wound on the drum based on the current number of turns includes: Determine the total number of cable winding layers and the number of outermost cable winding turns on the drum based on the current number of winding turns. The maximum number of cable turns per layer is determined based on the effective cable width of the drum and the outer diameter of the cable. The circumference of each turn of the cable is determined based on the drum diameter, the cable outer diameter, and the layer number of each layer of cable. The remaining length of cable wound on the drum is calculated based on the total number of winding layers, the maximum number of winding turns, the circumference of a single turn of each layer, and the number of turns of the outermost cable winding layer.

6. The intelligent protection method for preventing cable breakage in electric excavators according to claim 4, characterized in that, Determining the remaining cable length wound on the drum based on the current number of turns includes: Call the preset mapping table and determine the remaining cable length corresponding to the current number of winding turns according to the preset mapping table; The preset mapping table includes the correspondence between the number of cable turns on the reel and the remaining cable length.

7. The intelligent protection method for preventing cable breakage in electric excavators according to claim 6, characterized in that, Before calling the preset mapping table, the following is also included: Calculate the length of the first cable wound on the drum corresponding to each number of turns of the cable on the drum; Measure the length of the second cable that has been released corresponding to the target number of turns of cable on the reel, and subtract the length of the second cable from the total cable length to obtain the length of the third cable; The deviation is determined based on the first and third cable lengths corresponding to the target number of winding turns, and the first cable length corresponding to each number of winding turns is calibrated based on the deviation to obtain the remaining cable length corresponding to each number of winding turns on the drum, so as to establish the preset mapping table.

8. The intelligent protection method for preventing cable breakage in electric excavators according to claim 4, characterized in that, The audible and visual alarm is controlled to issue a warning based on the remaining cable length and a set threshold, including: If the remaining length is less than or equal to the first set threshold, control the yellow light of the sound and light alarm to flash and the buzzer to sound, and control the display to show a prompt message indicating that walking is normal. If the remaining length is less than or equal to the second set threshold, control the red light of the sound and light alarm to flash and the buzzer to sound, control the display to show a prompt message that the walking is normal, and adjust the pump displacement to limit the walking speed to a preset low speed. If the remaining length is less than or equal to the third set threshold, control the red light of the sound and light alarm to stay on and the buzzer to sound, control the display to show a prompt message containing "prohibit forward movement" and "please retreat and retract the cable", and control the forward cut-off actuator to cut off the forward movement power. Wherein, the second set threshold is greater than the first set threshold and less than the third set threshold.

9. The intelligent protection method for preventing cable breakage in electric excavators according to claim 8, characterized in that, After controlling the forward cut-off actuator to cut off the forward travel power, it also includes: In response to the user's temporary permission to move forward, the excavator's forward movement function is restored; If the recovery time of the forward travel function exceeds the preset duration and / or the cable pull-out length after the forward travel function is restored is greater than the preset length, the excavator will be prohibited from moving forward again.

10. The intelligent protection method for preventing cable breakage in electric excavators according to claim 4, characterized in that, The audible and visual alarm is controlled to issue a warning based on the remaining cable length and a set threshold, including: Subtract the set length from the remaining cable length to obtain the displayed remaining length; The sound and light alarm is controlled to issue a warning based on the displayed remaining length and the set threshold.

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