A rotating equipment start-up safety control system based on multi-sensor fusion

Abstract

This invention provides a multi-sensor fusion-based safety control system for starting rotating equipment. It includes: a start signal receiving module for receiving the equipment's start signal; a multi-sensor fusion sensing module for real-time acquisition of environmental data surrounding the equipment; a risk assessment module for generating a risk assessment result based on the environmental data; an intelligent voice broadcasting device for playing a safety warning voice when the risk assessment result does not meet the safety start conditions; and an equipment start execution module for starting the rotating equipment when the risk assessment result meets the safety start conditions. This application prevents personnel injury caused by accidental starting of rotating equipment from the source, improves the safety and reliability of equipment start-up, and has strong versatility, adaptable to the start-up control of various industrial rotating equipment.

Description

Technical Field

[0001] This invention relates to the field of industrial safety control technology, specifically to a safety control system for starting rotating equipment based on multi-sensor fusion. Background Technology

[0002] In industrial production, rotating equipment such as belt conveyors, fans, and water pumps are widely used. These devices typically employ remote start-up for convenient and quick operation when needed. However, while this method offers operational convenience, it also harbors serious safety hazards. Specifically, when personnel are engaged in cleaning, temporary operations, or other close-range work, the sudden start-up of the equipment can easily cause mechanical injuries, posing a serious threat to the lives of workers.

[0003] While some safety measures are applied in industrial production, such as setting up safety warning signs and strengthening employee safety training, these measures often rely on personnel's proactive compliance and reaction speed, and cannot fundamentally solve the problem of personal injury caused by sudden equipment startup. Especially in emergency or negligent situations, personnel may not be able to detect and avoid the starting equipment in time, leading to tragedy.

[0004] Therefore, there is an urgent need for a device start-up safety control system with environmental perception, intelligent decision-making, and dynamic response capabilities. Summary of the Invention

[0005] This invention provides a multi-sensor fusion-based safety control system for starting rotating equipment, which addresses the shortcomings of existing technologies where on-site personnel may suffer mechanical injuries due to failure to detect equipment startup in time when rotating equipment is started remotely, and where existing safety measures rely on personnel's active compliance, failing to fundamentally solve the problem of personnel injury caused by sudden equipment startup.

[0006] A safety control system for starting rotating equipment based on multi-sensor fusion, comprising: A start signal receiving module is used to receive the device's start signal; A multi-sensor fusion sensing module is used to collect environmental data around the device in real time, and the environmental data includes at least personnel location information; The risk assessment module is connected to the multi-sensor fusion perception module of the start signal receiving module and the multi-sensor fusion perception module, and has a built-in security strategy model for generating risk assessment results based on the environmental data. An intelligent voice broadcasting device, connected to the risk assessment, is used to play a safety prompt voice when the risk assessment result does not meet the safety start conditions; The equipment startup execution module is connected to the risk assessment and is used to start the rotating equipment when the risk assessment result meets the safe startup conditions.

[0007] Furthermore, in the system described above, the multi-sensor fusion sensing module includes at least two of the following sensors: an infrared sensor, a millimeter-wave radar, a camera, and a microphone array; the system also includes an edge computing unit connected to the multi-sensor fusion sensing module, which is used to perform real-time fusion and analysis of the data collected by the sensors.

[0008] Furthermore, in the system described above, the risk assessment also includes a model training and update unit; The model training and update unit is used to dynamically optimize the security strategy model based on historical data, device type, working environment, or personnel behavior patterns.

[0009] Furthermore, in the system described above, the intelligent voice broadcasting device supports customized voice content, multi-language switching, and adaptive volume adjustment; The system also includes an environmental noise monitoring module, which is connected to the intelligent voice broadcasting device and is used to monitor the environmental noise level in real time and trigger automatic volume adjustment.

[0010] Furthermore, as described above, the system also includes a remote monitoring and management platform, which is communicatively connected to the risk assessment module and used to display equipment status, personnel distribution, alarm records, and operation logs in real time.

[0011] Furthermore, in the system described above, the risk assessment module is also used to dynamically adjust the equipment startup delay time based on personnel location, movement speed, or equipment startup risk level, wherein the delay time is not fixed.

[0012] Furthermore, as described above, the system also includes a personnel identification module connected to the multi-sensor fusion perception module and the risk assessment module, used to distinguish authorized personnel from visitors through facial recognition or ID card recognition; The risk assessment module is also used to set different security policies based on the identified identity information.

[0013] Furthermore, as described above, the system also includes an external system linkage interface connected to the risk assessment module for data interaction and coordinated response with the factory access control system, fire protection system, or emergency broadcast system.

[0014] Furthermore, as described above, the system also includes a self-diagnosis and fault warning module, which is connected to the multi-sensor fusion perception module, the risk assessment module, and the intelligent voice broadcasting device, for real-time monitoring of the operating status of each module and issuing an alarm signal when an anomaly is detected.

[0015] The rotating equipment start-up safety control system provided in this application uses multi-sensor fusion to sense environmental data such as the location of personnel around the equipment. After the risk assessment module determines the safety status, the equipment start-up execution module executes the start-up command. If the safety conditions are not met, a voice prompt is given. This system avoids personnel injury caused by accidental start-up of rotating equipment from the source, improves the safety and reliability of equipment start-up, and has strong versatility, which can be adapted to the start-up control of various industrial rotating equipment. Attached Figure Description

[0016] Figure 1 A schematic diagram of the structure of the rotating equipment start-up safety control system based on multi-sensor fusion provided in this application. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0018] In current industrial settings, rotating equipment such as belt conveyors, fans, and pumps widely employ remote start-up. While convenient, this method poses a significant risk of mechanical injury when personnel are engaged in close-range tasks such as cleaning or temporary operations. Existing safety warning signs and employee safety training rely heavily on personnel's proactive compliance and reaction speed. In emergencies or due to negligence, personnel may not be able to detect and avoid starting equipment in time, failing to effectively prevent such accidents. This system, through multi-sensor fusion technology, can more comprehensively and accurately perceive the situation of personnel on-site, providing effective safety warnings before equipment startup and enabling delayed startup, fundamentally reducing the risk of injury due to sudden equipment startup.

[0019] This system mainly consists of a start signal receiving module, a multi-sensor fusion sensing module, a risk assessment module, an intelligent voice broadcasting device, an equipment start execution module, an edge computing unit, an environmental noise monitoring module, a remote monitoring and management platform, a personnel identification module, an external system linkage interface, and a self-diagnosis and fault early warning module. The modules are connected via wired or wireless means to achieve real-time data transmission and interaction.

[0020] Figure 1 This is a schematic diagram of the multi-sensor fusion-based rotating equipment start-up safety control system provided in this application, as shown below. Figure 1 As shown, the system includes: a start signal receiving module 101, a multi-sensor fusion perception module 102, a risk assessment module 103, an intelligent voice broadcasting device 104, and a device start execution module 105.

[0021] The start signal receiving module 101 is used to receive start signals from the rotating equipment. These start signals can originate from sources such as field control cabinet buttons, remote start commands from the host computer, automatic scheduling commands from the DCS / PLC system, and timed start signals.

[0022] The start signal receiving module 101 has signal isolation and anti-interference capabilities, and supports digital / analog / network communication access. After receiving a valid start signal, it does not directly execute the start, but instead transmits the signal synchronously to the risk assessment module and waits for the safety assessment to be completed.

[0023] The multi-sensor fusion sensing module 102 is used to collect data on the surrounding environment of the equipment in real time and continuously, and to identify whether there are personnel, obstacles and abnormal conditions in the dangerous area of ​​the equipment.

[0024] In this embodiment, the multi-sensor fusion sensing module 102 employs at least two sensor combinations, preferably: Millimeter-wave radar: Used for all-weather, long-distance, high-precision detection of the position, distance, and speed of people / objects, unaffected by dust, smoke, or light.

[0025] Infrared sensor array: used to supplement the detection of human body heat sources in dangerous areas, to achieve area coverage monitoring; Industrial cameras: used for video image acquisition, combined with visual algorithms to achieve personnel recognition, behavior analysis, and area intrusion detection; Microphone array: Used to collect on-site sound signals and assist in identifying personnel work sounds, shouts, and abnormal noises.

[0026] The rotating equipment start-up safety control system provided in this application, based on multi-sensor fusion, collects real-time environmental data around the equipment through a multi-sensor fusion sensing module. It can automatically identify the presence of personnel in hazardous areas before equipment start-up, eliminating reliance on personnel to actively avoid hazards. This fundamentally solves the risk of mechanical injury caused by personnel negligence or failure to evacuate during remote / automatic start-up, significantly improving the inherent safety of rotating equipment operation. Furthermore, the multi-sensor fusion approach to environmental information collection offers stronger environmental adaptability and identification accuracy compared to single detection methods. It can stably and reliably acquire key safety data such as personnel location, providing a true and effective basis for risk assessment, significantly reducing the probability of misjudgment and missed detection, and improving system operational reliability.

[0027] Furthermore, after receiving the start command through the start signal receiving module, the start is not executed immediately. Instead, the risk assessment module judges the environmental risk based on the preset security strategy model, forming a closed-loop control logic of "start request - security assessment - allow / disallow start". This eliminates the possibility of the device starting suddenly without warning from the control architecture, and the security is far higher than the traditional direct start method.

[0028] Furthermore, the system also includes an edge computing unit, which is directly connected to the multi-sensor fusion sensing module 102. This unit is used to perform real-time preprocessing, noise reduction, and feature extraction on raw data from multiple sensors. The system employs a data layer / decision layer fusion algorithm to comprehensively judge information from different sensors, thereby reducing the probability of false alarms and missed alarms from a single sensor. This results in the output of stable and reliable environmental data such as personnel location, movement trajectory, and occupation status of dangerous areas, which is then uploaded to the risk assessment module.

[0029] The risk assessment module 103 is connected to the start signal receiving module 101 and the multi-sensor fusion perception module 102 respectively. Its internally pre-built security strategy model is the decision-making core of the entire system.

[0030] The specific implementation steps for this risk assessment module 103 are as follows: Receive device start request signal; receive environmental fusion data output by edge computing unit, including: whether there are people in the danger zone, the distance of people, their movement speed, and their dwell time; call the safety policy model and perform risk assessment according to preset safety rules: if there are no people or obstacles in the danger zone of the device, it is determined that the safe start conditions are met; if there are people or obstacles in the danger zone of the device, it is determined that the safe start conditions are not met and start is prohibited.

[0031] The rotating equipment start-up safety control system provided in this application, based on multi-sensor fusion, can quickly generate assessment results based on real-time environmental data through a risk assessment module. When safety conditions are not met, a timely prompt is issued through an intelligent voice broadcast device. When safety conditions are met, the equipment start-up execution module starts normally, realizing an integrated and automated safety response of perception, judgment, prompting and execution, thereby improving emergency response efficiency.

[0032] Furthermore, the risk assessment module also includes a model training and update unit, which can access historical alarm data, equipment operation logs, parameters of different equipment types, on-site environment layout, personnel daily work paths, and other data; it can iteratively train and dynamically optimize the safety strategy model to adapt to different working conditions, different equipment, and different shifts, thereby improving the accuracy of risk identification and the rationality of response.

[0033] Meanwhile, the risk assessment module 103 supports a dynamic delay start strategy, classifying different risk levels based on the distance between personnel and equipment, the direction of movement, and the speed of movement; and setting corresponding non-fixed, adjustable start delay times: the closer the personnel are and the higher the risk, the longer the delay; if personnel evacuate quickly, the delay can be shortened or start can be allowed earlier; environmental monitoring is continuously carried out during the delay period, and if the safety conditions are still not met after the delay ends, the system will remain locked and an alarm will be triggered.

[0034] The intelligent voice broadcasting device 104 is connected to the risk assessment module 103 and is used to provide on-site audio-visual / voice prompts when the risk assessment does not meet the safe start-up conditions.

[0035] In this embodiment, the intelligent voice broadcasting device 104 has the following functions: It supports customized voice content, allowing users to record prompts based on on-site needs, such as: "The equipment is about to start up. Personnel in the danger zone, please evacuate immediately!" or "Person detected in the danger zone. Equipment startup is now locked!"

[0036] In addition, the intelligent voice broadcasting device 104 supports multi-language switching, allowing users to switch between Chinese, English, or their local language; it also supports adaptive volume adjustment. Furthermore, the system is equipped with an environmental noise monitoring module that collects real-time noise levels in decibels, automatically increasing the broadcast volume when noise is high and decreasing it when noise is low, ensuring clear and audible prompts without causing noise pollution.

[0037] The startup execution module 105 is connected to the risk assessment module 103 and is used to execute the final startup command.

[0038] When the risk assessment module 103 outputs a start-allow signal, the equipment start-up execution module 101 outputs a closing / start command to the control cabinet / PLC of the rotating equipment, and the equipment starts normally. When the risk assessment module 103 outputs a start-prohibit signal, the equipment start-up execution module remains locked, cutting off the equipment start-up circuit. It cannot be forcibly started, whether on-site or remotely, until the danger is eliminated and the reassessment is passed.

[0039] Furthermore, the system also includes a personnel identification module, which is connected to the multi-sensor fusion perception module 102 and the risk assessment module 103. This personnel identification module uses a camera for facial recognition or a card reader / RFID for employee badge recognition; it distinguishes between authorized maintenance personnel, on-site workers, visitors, and unauthorized personnel. The risk assessment module 103 implements differentiated strategies based on identity: authorized personnel can work within a specified area, allowing low-speed / jog-type equipment adjustments; visitors or unauthorized personnel entering the danger zone trigger a high-level alarm and lockout activation.

[0040] Furthermore, the system includes a remote monitoring and management platform, which communicates with the risk assessment module 103 via Ethernet, 4G / 5G, LoRa, and other methods. This platform displays the current status of the equipment, startup command records, sensor status, personnel distribution in hazardous areas, alarm information, and operation logs in real time. It supports historical data querying, report export, and alarm statistical analysis. Administrators can remotely view the safety status and, when necessary, remotely lock the equipment.

[0041] Furthermore, the system is equipped with external system linkage interfaces to connect with factory access control systems, fire protection systems, emergency broadcast systems, MES systems, etc. When a high risk is detected, it can link with the access control system to lock the entrance to the dangerous area; link with the emergency broadcast system to provide voice prompts throughout the plant / zones; and link with the fire protection system to coordinate actions in situations such as fires and emergency shutdowns, thereby improving the overall safety level of the plant.

[0042] Furthermore, the system also includes a self-diagnosis and fault early warning module, which is connected to the multi-sensor fusion sensing module 102, the risk assessment module 103, and the intelligent voice broadcasting device 104. It monitors the power supply, communication, and algorithm operation status of each module in real time; automatically detects sensor obstruction, disconnection, communication interruption, and module failure; and provides local audible and visual alarms in case of faults, uploading the information to a remote platform to prompt maintenance personnel for timely repairs and prevent system failure.

[0043] The following is an overview of the system's workflow, which includes the following steps: 1. The operator or automatic system sends a start signal to the rotating equipment; 2. Activate the signal receiving module to send the signal to the risk assessment module; 3. The risk assessment module triggers the multi-sensor fusion perception module to operate; 4. Environmental data is collected by millimeter-wave radar, cameras, infrared sensors, etc., and then fused and processed by the edge computing unit to determine whether there are people in the dangerous area; 5. The risk assessment module performs assessments based on fused data and a security strategy model: 6. Unmanned / Safe: Startup countdown begins, with a voice prompt "Device is about to start safely." After the countdown ends, the device startup execution module will begin the startup process. 7. Personnel / Unsafe: Immediately lock the start-up circuit, the intelligent voice broadcast device will repeatedly prompt evacuation, and the alarm will be uploaded to the remote platform at the same time; 8. If personnel evacuate, the system will re-detect, and once the conditions are met, the lockout will be released, allowing startup; 9. The system records the entire process of startup time, evaluation results, alarm information, operators, etc., and supports traceability and model optimization.

[0044] The rotating equipment start-up safety control system based on multi-sensor fusion provided in this application can achieve: 1. Shift from "human management" to inherently safe control that features intelligent sensing, proactive protection, and mandatory interlocking; 2. Multi-sensor fusion significantly reduces false alarm rate and adapts to complex industrial environments such as dust, noise, and low light; 3. Combining dynamic risk assessment with voice prompts improves on-site personnel response speed and evacuation efficiency; 4. It can be expanded to include identity recognition, remote monitoring, and multi-system linkage to meet the intelligent security management needs of modern factories.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A safety control system for starting rotating equipment based on multi-sensor fusion, characterized in that, include: A start signal receiving module is used to receive the device's start signal; A multi-sensor fusion sensing module is used to collect environmental data around the device in real time, and the environmental data includes at least personnel location information; The risk assessment module is connected to the multi-sensor fusion perception module of the start signal receiving module and the multi-sensor fusion perception module, and has a built-in security strategy model for generating risk assessment results based on the environmental data. An intelligent voice broadcasting device, connected to the risk assessment, is used to play a safety prompt voice when the risk assessment result does not meet the safety start conditions; The equipment startup execution module is connected to the risk assessment and is used to start the rotating equipment when the risk assessment result meets the safe startup conditions.

2. The system according to claim 1, characterized in that, The multi-sensor fusion sensing module includes at least two of the following sensors: infrared sensor, millimeter-wave radar, camera, and microphone array; the system also includes an edge computing unit connected to the multi-sensor fusion sensing module, which is used to perform real-time fusion and analysis of the data collected by the sensors.

3. The system according to claim 1, characterized in that, The risk assessment also includes a model training and update unit; The model training and update unit is used to dynamically optimize the security strategy model based on historical data, device type, working environment, or personnel behavior patterns.

4. The system according to claim 1, characterized in that, The intelligent voice broadcasting device supports customized voice content, multi-language switching, and adaptive volume adjustment. The system also includes an environmental noise monitoring module, which is connected to the intelligent voice broadcasting device and is used to monitor the environmental noise level in real time and trigger automatic volume adjustment.

5. The system according to claim 1, characterized in that, The system also includes a remote monitoring and management platform, which is connected to the risk assessment module to display equipment status, personnel distribution, alarm records, and operation logs in real time.

6. The system according to claim 1, characterized in that, The risk assessment module is also used to dynamically adjust the equipment startup delay time based on personnel location, movement speed, or equipment startup risk level. The delay time is not fixed.

7. The system according to claim 1, characterized in that, The system also includes a personnel identification module, which is connected to the multi-sensor fusion perception module and the risk assessment module, and is used to distinguish between authorized personnel and visitors through facial recognition or ID card recognition; The risk assessment module is also used to set different security policies based on the identified identity information.

8. The system according to claim 1, characterized in that, The system also includes an external system linkage interface, which is connected to the risk assessment module and used for data interaction and collaborative response with the factory access control system, fire protection system or emergency broadcast system.

9. The system according to claim 1, characterized in that, The system also includes a self-diagnosis and fault early warning module, which is connected to the multi-sensor fusion perception module, the risk assessment module and the intelligent voice broadcasting device, for real-time monitoring of the operating status of each module and issuing an alarm signal when an abnormality is detected.

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