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CN-121978990-A - Load control system with multi-level security protection

CN121978990ACN 121978990 ACN121978990 ACN 121978990ACN-121978990-A

Abstract

The invention provides a loading control system with multi-level security protection, which constructs a multi-level security control system through a collaborative processing architecture integrating data acquisition and fusion, digital twin synchronization, intelligent decision and independent hardware security arbitration. The intelligent risk assessment and prejudgement strategy generation method based on multi-source data fusion and virtual model comparison can be used for carrying out intelligent risk assessment and prejudgement strategy generation, and a hardware-level safety execution loop which directly monitors an original signal and is independent of main decision software is set up, so that the rapid emergency protection of the highest priority can be triggered under the condition of any software layer fault or delay, the single point failure risk and response delay problems of a traditional centralized safety control system are fundamentally overcome, and the omnibearing and high-reliability safety protection of a structural test loading process is realized.

Inventors

  • TANG DAOYU
  • WANG XIAODONG
  • LI ZHUFENG

Assignees

  • 北京品创联拓科技有限公司

Dates

Publication Date
20260505
Application Date
20251210

Claims (10)

  1. 1. A load control system with multi-level security protection, comprising: the data acquisition and fusion unit is used for acquiring, aligning and fusing state signals of all loading actuators in the physical loading system and generating a multichannel state vector containing load, displacement measured by the displacement sensor and instantaneous following error signals generated by control feedback; The digital twin synchronization unit is used for receiving the multichannel state vector and driving the high-fidelity virtual model, and calculating real-time synchronization deviation between key monitoring points of the physical entity and corresponding points of the virtual model; The intelligent decision unit is used for carrying out multi-scale risk assessment through a preset rule and a prediction model based on the multi-channel state vector and the real-time synchronization deviation and generating a coping strategy containing strategy types; The system comprises a safety execution and arbitration unit, a safety state management module and a control unit, wherein the safety execution and arbitration unit is used for analyzing the coping strategy and generating a coordination control instruction, and simultaneously directly monitoring an original signal to execute hardware-level protection with the highest priority, and comprises an adaptive controller for adjusting actuator control parameters; And the man-machine interaction and recording unit is used for providing a three-dimensional visual interface, a parameter configuration interface and recording the whole system operation event.
  2. 2. The system of claim 1, wherein the data acquisition and fusion unit comprises a distributed sensing network and a real-time fusion processor; the distributed sensing network comprises a strain sensor for measuring load, a grating ruler for measuring global displacement and a dual-redundancy magnetostrictive displacement sensor which is used for collecting the position of a piston rod of an actuator and is used as one of the displacement sensors; The real-time fusion processor fuses the multi-source signals based on Kalman filtering and a dynamic time warping algorithm.
  3. 3. The system of claim 1, wherein the high-fidelity virtual model comprises a parameterized geometric model and a real-time finite element simulation kernel; And the digital twin synchronization unit performs space pose calibration through pre-scanned mounting point cloud data, and outputs the real-time synchronization deviation of each key monitoring point, wherein the real-time synchronization deviation is the Euclidean distance between a physical point and a virtual point.
  4. 4. The system of claim 1, wherein the intelligent decision unit comprises a configurable multi-level rule base and a long and short term memory network based prediction engine; the types of the coping strategies comprise flexible adjustment, gradient unloading and emergency braking; The intelligent decision unit triggers strategy generation by calculating global comprehensive risk indexes; The configurable multi-level rule base stores protection threshold values of load, following error and synchronous deviation.
  5. 5. The system of claim 4, wherein the intelligent decision unit calculates the global integrated risk index by: the real-time load measurement value, the real-time following error evaluation value and the real-time synchronous deviation absolute value from the monitoring node are obtained in parallel, and each type of real-time data and the corresponding preset safety threshold value are subjected to benchmark processing to generate a group of dimensionless relative deviation data; Carrying out nonlinear intensity mapping on the load relative deviation data, the following error evaluation value relative deviation data and the synchronous deviation relative deviation data to respectively obtain load risk intensity, tracking risk intensity and deviation risk intensity; Distributing a first class weight for the load risk intensity and the tracking risk intensity of each channel and carrying out intra-channel aggregation to obtain channel execution risk indexes, introducing a time risk factor for the deviation risk intensity of each monitoring node and distributing a second class weight and carrying out intra-node aggregation to obtain node model risk indexes; And carrying out standardization processing on the intermediate value of the global comprehensive risk index, and outputting the final global comprehensive risk index.
  6. 6. The system of claim 5, wherein the real-time following error assessment value is obtained by: Acquiring an instruction position signal and an actual feedback position signal of a loading actuator in real time, and calculating to obtain an instantaneous following error signal; Extracting from said instantaneous following error signal, within an evaluation time window, a first characteristic characterizing its average energy, a second characteristic characterizing its extreme amplitude and a third characteristic characterizing its fluctuation stability; And fusing the first feature, the second feature and the third feature according to a preset contribution ratio to generate the real-time following error evaluation value.
  7. 7. The system of claim 5, wherein the temporal risk factor is obtained by: calculating the average trend level of the absolute value of the real-time synchronous deviation generated by the designated monitoring node in a sliding time window; Comparing the trend average level with a preset tolerance threshold value of the node to obtain a benchmarked recent deviation level index; And carrying out nonlinear saturation mapping on the recent deviation level index to generate a time risk factor which is not smaller than a reference value and is used for representing the statistical severity of the recent model synchronous deviation of the node.
  8. 8. The system of claim 1, wherein the system further comprises a controller configured to control the controller, The safety execution and arbitration unit comprises a strategy analyzer, the self-adaptive controller, an independent safety logic processor and the safety state management module; the strategy analyzer converts the coping strategy into a control instruction sequence with sequential logic; the adaptive controller receives the instantaneous following error signal to calculate and output a control quantity; the independent safety logic processor directly receives the original signal from the data acquisition and fusion unit, and directly starts an emergency unloading loop beyond the intelligent decision unit when triggering a hard protection threshold or an emergency stop signal.
  9. 9. The system of claim 8, wherein the emergency unloading circuit comprises a super capacitor energy storage module and a mechanical locking mechanism; When emergency unloading is triggered, the super capacitor energy storage module provides independent electric energy to drive all loading actuators to retract to a mechanical zero point according to a preset exponential decay speed curve, and then the mechanical locking mechanism fixes the piston rods of the actuators.
  10. 10. The system of claim 1, wherein the system further comprises a controller configured to control the controller, The three-dimensional visual interface is obtained by rendering the high-fidelity virtual model based on a WebGL engine, and a stress field cloud image is displayed in a superposition mode in a color mapping mode, wherein the stress field cloud image is obtained by calculation of the real-time finite element simulation kernel; the parameter configuration interface supports modification of the protection threshold value through a voice instruction, and the modification operation is authenticated through preset multiple authorities and determines whether the modification operation passes or not.

Description

Load control system with multi-level security protection Technical Field The invention relates to the technical field of structural engineering tests, in particular to a loading control system with multistage safety protection. Background The structure loading test is a key means for evaluating the mechanical properties of large structures such as civil construction and mechanical equipment or parts thereof, and the whole process from stress and deformation to damage is observed by applying static or dynamic load simulating real working conditions on a test piece. As test subjects become increasingly complex and the loading scale continues to expand, safety control of the test process becomes critical. The traditional loading safety control system mostly adopts a centralized monitoring architecture based on a central processing unit, and the safety protection logic thereof seriously depends on the single main control software to judge and decide the collected and processed state data. The architecture has a fundamental defect that when a central processing unit fails due to software abnormality, computational overload or communication interruption and other faults, the whole safety protection chain is broken immediately, and the system loses the response capability to the emergency danger. Meanwhile, unavoidable time delay exists in the process from sensor signal acquisition and software algorithm processing to final instruction issuing, and under the extreme working condition that the load or deformation is out of control rapidly, the delay possibly causes delay of protection action, and immediate intervention cannot be realized at the most critical moment, so that sudden damage of a test piece, damage of loading equipment and even safety accidents are caused. Disclosure of Invention In view of the above, the present invention provides a load control system with multi-level security protection to solve the technical drawbacks of the prior art. Specifically, the present invention provides a load control system with multi-level security protection, comprising: the data acquisition and fusion unit is used for acquiring, aligning and fusing state signals of all loading actuators in the physical loading system and generating a multichannel state vector containing load, displacement measured by the displacement sensor and instantaneous following error signals generated by control feedback; The digital twin synchronization unit is used for receiving the multichannel state vector and driving the high-fidelity virtual model, and calculating the real-time synchronization deviation between the key monitoring points of the physical entity and the corresponding points of the virtual model; the intelligent decision unit is used for carrying out multi-scale risk assessment through a preset rule and a prediction model based on the multi-channel state vector and the real-time synchronous deviation, and generating a coping strategy containing strategy types; the system comprises a safety execution and arbitration unit, a safety state management module, a control unit and a control unit, wherein the safety execution and arbitration unit is used for analyzing a coping strategy and generating a coordination control instruction, and simultaneously directly monitoring an original signal to execute hardware-level protection with the highest priority; And the man-machine interaction and recording unit is used for providing a three-dimensional visual interface, a parameter configuration interface and recording the whole system operation event. In some embodiments, the data acquisition and fusion unit comprises a distributed sensing network and a real-time fusion processor, wherein the distributed sensing network comprises a strain sensor for measuring load, a grating ruler for measuring global displacement and a dual-redundancy magnetostrictive displacement sensor which is used for acquiring the position of a piston rod of an actuator and is used as one of displacement sensors, and the real-time fusion processor fuses multiple source signals based on Kalman filtering and a dynamic time warping algorithm. In some embodiments, the high-fidelity virtual model comprises a parameterized geometric model and a real-time finite element simulation kernel, the digital twin synchronization unit performs space pose calibration through pre-scanned mounting point cloud data and outputs real-time synchronization deviation of each key monitoring point, and the real-time synchronization deviation is Euclidean distance between a physical point and a virtual point. In some embodiments, the intelligent decision unit comprises a configurable multi-level rule base and a prediction engine based on a long-term and short-term memory network, types of coping strategies comprise flexible adjustment, gradient unloading and emergency braking, the intelligent decision unit triggers strategy generation by calculating a global comprehensive risk index, and the co