CN-122017547-A - Contactor function detection method and system based on multi-parameter fusion

CN122017547ACN 122017547 ACN122017547 ACN 122017547ACN-122017547-A

Abstract

The application discloses a contactor function detection method and system based on multi-parameter fusion, and belongs to the technical field of contactor detection. The method comprises the steps of collecting voltage signals, current signals and temperature signals of a contactor in real time, dynamically correcting a voltage sampling comparison threshold and a voltage-current change rate ratio threshold according to the current collected temperature signals and current signals based on a pre-established dynamic threshold correction model, calculating a voltage-current change rate ratio based on the voltage signals and the current signals, comparing the voltage-current change rate ratio with the corrected voltage-current change rate ratio threshold to obtain a first comparison result, sampling and comparing voltage signals at two ends of the contactor to obtain a voltage sampling comparison value, comparing the voltage sampling comparison value with the corrected voltage sampling comparison threshold to obtain a second comparison result, and carrying out fusion judgment according to the first comparison result and the second comparison result to determine whether the contactor is normal.

Inventors

WANG MENGHANG
ZHANG FAN
LI FEI
YAO XIN

Assignees

河南嘉晨智能控制股份有限公司

Dates

Publication Date: 20260512
Application Date: 20260209

Claims (10)

1. The contactor function detection method based on multi-parameter fusion is characterized by comprising the following steps of: Collecting voltage signals, current signals and temperature signals of the contactor in real time; Based on a pre-established dynamic threshold correction model, dynamically correcting a voltage sampling comparison threshold and a voltage-current change rate ratio threshold according to a currently acquired temperature signal and current signal; Calculating a voltage-current change rate ratio based on the voltage signal and the current signal, and comparing the voltage-current change rate ratio with a corrected voltage-current change rate ratio threshold value to obtain a first comparison result; Sampling and comparing voltage signals at two ends of the contactor to obtain a voltage sampling comparison value, and comparing the voltage sampling comparison value with a corrected voltage sampling comparison threshold value to obtain a second comparison result; And carrying out fusion judgment according to the first comparison result and the second comparison result to determine whether the contactor is normal.
2. The method of claim 1, wherein the dynamic threshold correction model is obtained by: obtaining calibration data of the contactor under different temperature and different current working conditions; Based on the calibration data, establishing a correlation model reflecting the change of the voltage sampling comparison threshold and the voltage-current change rate ratio threshold along with the temperature and current.
3. The method of claim 2, wherein the obtaining calibration data comprises: Collecting voltage response data of the contactor under different working voltages and current disturbance at a plurality of temperature points; and constructing a multidimensional calibration model representing the relation between the electrical characteristics of the contactor and the temperature and the current based on the voltage response data.
4. The method of claim 1, wherein the calculating the voltage-to-current rate of change ratio comprises: respectively performing differential operation on the voltage signal and the current signal to obtain a voltage change rate and a current change rate; And calculating the ratio of the voltage change rate to the current change rate to obtain the ratio of the voltage change rate to the current change rate.
5. The method of claim 1, wherein the performing a fusion determination based on the first comparison result and the second comparison result comprises: and when the first comparison result indicates that the voltage-current change rate ratio exceeds the corresponding threshold value, and the second comparison result indicates that the voltage sampling comparison value exceeds the corresponding threshold value, judging that the contactor is abnormal in function.
6. The method of claim 1 or 5, further comprising, after determining that the contactor is malfunctioning: triggering linkage response of the whole forklift safety control system, wherein the linkage response comprises at least one of fault alarm, power cut-off or scram protection.
7. The method of claim 2, wherein the calibration data is obtained by laboratory calibration or by historical health data learning during operation of the apparatus.
8. A method according to claim 3, wherein the multi-dimensional calibration model is implemented by a look-up table or a polynomial regression model.
9. A contactor function detection system based on multi-parameter fusion for implementing the method according to any of claims 1-8, comprising the following modules: The signal acquisition module is used for acquiring voltage signals, current signals and temperature signals of the contactor in real time; The dynamic threshold correction module is used for outputting a voltage sampling comparison threshold value and a voltage-current change rate ratio threshold value after dynamic correction based on a pre-established dynamic threshold correction model according to the currently acquired temperature signal and current signal; the first comparison module is used for calculating the voltage-current change rate ratio, comparing the voltage-current change rate ratio with the corrected voltage-current change rate ratio threshold value and outputting a first comparison result; The second comparison module is used for sampling and comparing voltage signals at two ends of the contactor to obtain a voltage sampling comparison value, comparing the voltage sampling comparison value with a corrected voltage sampling comparison threshold value and outputting a second comparison result; and the fusion judging module is used for outputting a judging result of whether the contactor function is normal or not according to the first comparison result and the second comparison result.
10. The system of claim 9, further comprising a calibration modeling module and a safety execution module, wherein the calibration modeling module is configured to establish the dynamic threshold correction model according to calibration data of the contactor, the safety execution module is configured to execute a linkage response with a forklift whole safety control system when the fusion judgment module outputs a judgment result of the contactor function abnormality, and the linkage response comprises at least one of a fault alarm, a power cut-off or a scram protection.

Description

Contactor function detection method and system based on multi-parameter fusion Technical Field The application relates to the technical field of contactor detection, in particular to a contactor function detection method and system based on multi-parameter fusion. Background In the industrial production and logistics transportation scene, the fork truck is used as core transportation equipment, and the operation safety of the fork truck is directly related to personnel safety and production efficiency. The power output and operation control of the forklift are dependent on a direct current contactor in a motor controller, and the component drives the contact to be attracted or disconnected by controlling the on-off of a coil, so that the connection, the disconnection and the switching of a circuit between a direct current power supply and a load are realized, and the direct current contactor is a key electrical element for guaranteeing the stable operation of a power system. When the forklift works, the functional faults (adhesion, poor contact and the like) of the contactor of the motor controller can directly cause potential safety hazards such as out-of-control, abnormal operation and the like of a forklift power system, and seriously threaten the safety of personnel and equipment. The detection method for the forklift contactor in the industry has obvious limitations that the detection method generally depends on single parameters such as voltage or current to judge, misjudgment is extremely easy to generate under the complex and changeable working conditions (such as abrupt load change and system voltage fluctuation) of the forklift, real contactor faults and normal working condition interference cannot be distinguished, and due to the fact that the physical characteristics that the internal resistance and the contact state of the direct-current contactor can change obviously along with the working temperature and the passing current are ignored, the traditional method adopts fixed and uncompensated judgment thresholds, so that under the extreme working conditions such as high temperature and high current, the detection system cannot accurately identify early faults or potential anomalies (such as slight adhesion and contact resistance increase) of the contactor to cause missed detection or misinformation, in addition, the traditional detection scheme does not form effective linkage with the whole forklift safety system, even if the faults are detected, safety measures such as emergency stop and power cut off cannot be triggered timely, active safety protection cannot be realized only passively, and finally safety requirements of forklift operation cannot be met. Therefore, research and development of a contactor function detection scheme with working condition self-adaptation capability, high detection precision and capability of realizing active safety protection becomes a key requirement for solving the pain point of the prior art and improving the operation safety of a forklift. Disclosure of Invention Accordingly, the present application has been made keeping in mind the above problems and needs occurring in the prior art. The application aims to construct a multi-dimensional and high-reliability detection system, combines dynamic self-adaptive correction of a detection threshold value, solves the problems of poor anti-interference capability, insufficient detection precision and lack of working condition self-adaptive capability in the prior art, realizes active safety protection of a forklift electrical system, and finally provides an active safety solution based on predictive diagnosis for a forklift. The application aims at realizing the following technical scheme: in a first aspect, an embodiment of the present application provides a contactor function detection method based on multi-parameter fusion, including the following steps: Collecting voltage signals, current signals and temperature signals of the contactor in real time; Based on a pre-established dynamic threshold correction model, dynamically correcting a voltage sampling comparison threshold and a voltage-current change rate ratio threshold according to a currently acquired temperature signal and current signal; Calculating a voltage-current change rate ratio based on the voltage signal and the current signal, and comparing the voltage-current change rate ratio with a corrected voltage-current change rate ratio threshold value to obtain a first comparison result; Sampling and comparing voltage signals at two ends of the contactor to obtain a voltage sampling comparison value, and comparing the voltage sampling comparison value with a corrected voltage sampling comparison threshold value to obtain a second comparison result; And carrying out fusion judgment according to the first comparison result and the second comparison result to determine whether the contactor is normal. In the above method for detecting a contactor function bas