DE102016224459A1 - Mobile visual assistance in metallurgical, rolling, forging and tube works - Google Patents

Abstract

The invention relates to a visual assistance system, comprising mobile devices for a maintenance person in a system to be maintained, stationary computers and a network, via which the stationary computers are connected to the mobile devices. To support on-site maintenance activities of the maintenance worker, the visual assistance system also includes: a graphical output device, an asset information system with maintenance-related documents for remedying damage, and technical devices for identifying relevant components at maintenance and inspection control points of the equipment.

Description

Summary

• – Bereitstellung, Darstellung (Visualisierung) und Editierbarkeit von relevanten Informationen zu jederzeit und an jedem Ort zur Unterstützung der jeweiligen Arbeitsprozesse.
• – Effizienz- und Effektivitätssteigerung, z. B. im Bereich der Instandhaltung, durch zielgerichtetem und damit schnellem Finden von gesuchten Anlagenkomponenten sowie der Möglichkeit sich schnellen und übersichtlichen Gesamtüberblick zu verschaffen.

Mobile visual assistance for the operation of metallurgical and rolling mill plants as well as forging and tube technology plants using mobile portable information and communication technologies (ICT) and Industry 4.0 technologies as well as model-based approaches with the goals:

• - Provision, presentation (visualization) and editability of relevant information to anytime and anywhere to support the respective work processes.
• - efficiency and effectiveness increase, z. As in the field of maintenance, by targeted and thus quickly finding sought-after plant components and the ability to get a quick and clear overview.

Relevant operating areas are, for example, production, quality management, maintenance and new building planning
(Model = geometry models and simulation models, as well as their couplings)

Components of the Mobile Visual Assistance

• • Mobile Information and Communication Technologies (ICT)
• • Industry 4.0 technologies
• • Establishment or access to a plant information system (eg BDIS) as well as to other database systems such as IBFS, QMS, ....
• • model-based approaches: model = geometry models and simulation models, as well as their couplings

• – global, lokal, drahtgebunden und Funknetze
• – Unternehmensübergreifend (WWW, WWW mit VPN, ...)
• – Unternehmensintern: Werkübergreifend
• – Unternehmensintern: Werksintern

seinThe characteristics of the access technologies used can be:

• - global, local, wired and wireless networks
• - Cross-company (WWW, WWW with VPN, ...)
• - Internal: Cross-plant
• - Company internal: factory internal

be

introduction

The automotive industry is characterized by shorter product life cycles, increasing number of variants, high quality standards and increasing product complexity. The metal producing and processing industries as a supplier industry must meet these requirements. A crucial competitive factor is the availability of (general) production-relevant information, which should be available at any time, in any place and for any employee.

This is a challenge within the individual production areas of, for example, steel mills today; Although the information is generally available, but the traditional paper-based information provision z. B. by means of drawings significant disadvantages. More advantageous may be the use of digital information, but access is often restricted to stationary PCs (office workplaces) that are only available at certain stationary workplaces (control rooms, control rooms) in the workplace (heat, steam, dusts, hazardous working environment).

concept

The idea relates to devices and methods for performing on-site work activities in metallurgical and rolling mill plants as well as in press, forge and tube plants using a scalable system for mobile visual assistance in production.

Relevant operating areas are, for example, production, quality management, maintenance as well as reconstruction measures by the new building planning departments, as well as materials management.

Subsequently, the scalable visual assistance system will be demonstrated using the example of "mobile visual assistance in maintenance".

The maintenance of the functional safety and energy efficiency of facilities in the field of metal production and primary shaping also require regular inspections from the point of view of environmental protection. These energy-intensive industrial plants incorporate function-relevant components with a limited lifespan. Permanently reliable operation of the system is only guaranteed with proper maintenance. Against this background and taking into account the guidelines and regulations to be observed (eg safety and environmental protection), a large number of inspection and maintenance work must be carried out.

Definition of terms maintenance

The following definitions of terms are used below:
Maintenance (IH) is divided into maintenance and restoration measures.

• • Inspektionen (Tätigkeiten beschränken sich auf die Feststellung des IST-Zustandes), d. h. bei einer Inspektion wird festgestellt, ob eine Wartungsarbeiten erforderlich ist
• • Wartungen (Tätigkeiten zur Erhaltung des SOLL-Zustandes)

Conservation measures include:

• • Inspections (activities are limited to the determination of the actual condition), ie an inspection determines whether maintenance is required
• • Maintenance (activities to maintain the required state)

• • Instandsetzung (Tätigkeit zur Wiederherstellung des SOLL-Zustandes).

The recovery measures include:

• • Repair (activity to restore the TARGET state).

During inspection and maintenance work, the condition of wearing parts must be checked; if necessary, wear parts are replaced. During maintenance, function-relevant components (spare parts) may be exchanged to restore the TARGET function.

The scope of inspection and maintenance depends on the type of equipment, the components of the system, the environmental influences, the user habits and the manufacturer's information. The replacement of wear and spare parts can be carried out as part of the maintenance or a repair order. Self-diagnostic devices are only to be considered with regard to the extension of the inspection intervals if all inspection-relevant functions are self-monitoring.

Typical inspection activities are z. B. a general condition check, visual and functional check of all claimed parts including the safety and control devices, checking gas, steam and water bearing system parts for leaks, visible signs of corrosion and aging as well as a final inspection of the inspection work by measuring and documentation of the measuring and test results. Examples of typical maintenance work include the replacement of consumables, the refilling of consumables (lubricating oil, greases, cooling water) and final inspection of maintenance work by measuring and documenting the results.

The maintenance strategy, z. B. at what time is used, it may be failure-oriented or prevention-oriented or condition-oriented, z. B. determined with self-diagnostic facilities (predictive IH) be. Accordingly, you can maintenance processes u. a. after scheduled maintenance over maintenance request and order, after maintenance (not planable, immediate on-site readiness, shortest system reaction times required) as well as after scheduled maintenance (maintenance and inspection according to maintenance plans).

Economic significance - maintenance

Improved and faster information transfer leads to faster results and quality improvements in maintenance (fault management, fault prevention / optimization). The consequences are cost reductions by minimizing downtimes and avoiding unplanned downtimes and thus potential production losses. The quality and efficiency of maintenance in the current state of the art depends very much on the personal experience of the respective maintenance personnel. Increase of responsibility in the context of personnel savings due to high cost pressure, leads to a worsening of this problem (formerly: responsible for the converter plant, now: additionally the continuous casting plant)

Maintenance-relevant information

• • Montage-, Demontage- und Betriebsanleitung; Sicherheitsanweisungen, Hinweisen zur Wartung und Pflege (z. B. Wartungsvorschriften und -hinweise der Hersteller, Wartungsplan, Pflegeanleitung), Teilelisten der Gerätehersteller (Auflistung von Ersatzteile, Verschleißteile und erforderliches Hilfsmaterial), Störungshilfe (Informationen zur Störungssuche und -behebung)
• • Kenntnis der Störfallhistorie (Schadens-/Alarmmeldungen, Instandhaltungstätigkeiten, etc.) zur Rückverfolgung und Ursachenanalyse bei der Störungsbewältigung
• • Kenntnis über den Aufbau und Gesamtüberblick über die relevanten installierte Medienversorgung und deren Anbindung an die Funktionssysteme: Medium A fließ durch Rohrleitung B mit dem erforderlichen Betriebsdruck p; elektrische Versorgung (Strom-/Signal- und Steuerkabel).

In the above-mentioned maintenance tasks in industrial plants, a variety of maintenance-related information must be available, such. B .:

• • assembly, disassembly and operating instructions; Safety instructions, maintenance and service instructions (eg manufacturer's maintenance instructions and instructions, maintenance plan, care instructions), parts lists of the device manufacturers (listing of spare parts, wearing parts and required auxiliary material), troubleshooting (troubleshooting information)
• • Knowledge of the accident history (damage / alarm messages, maintenance activities, etc.) for traceability and root cause analysis during fault management
• • Knowledge of the structure and overall overview of the relevant installed media supply and their connection to the functional systems: Medium A flows through pipeline B with the required operating pressure p; electrical supply (power / signal and control cables).

Special features in the maintenance of large systems z. As the metallurgical and rolling mill industry

• • Hoher Komplexitätsgrad aufgrund der Vernetzung einer Vielzahl von Teilsystemen
• • Produktionsanlagen mit weitläufigen Hallenflächen und starker räumlicher Werksgeländeausdehnung. Damit verbunden sind einer sehr hohen Anzahl an Wartungs- und Kontrollstellen
• • Gewachsene, heterogener Systemlandschaft: die verwendeten (Teil-)Systeme sind komplex und bestehen aus einer Vielzahl verschiedener Komponenten mit ihrer individuellen Funktionalität, dabei werden Geräte unterschiedlicher Hersteller verwendet, mit häufig unterschiedlicher Technikgenerationen
• • Anwendung vielfältiger Inspektionstechnologien; dabei ist eine Vielzahl von ablaufenden Vorgängen und Anlagenteilen nicht sichtbar
• • Vielzahl von verschleißbehafteter Komponenten und kritischen Maschinenteilen (z. B. Führungseinrichtungen, Werkzeuge, Motoren, Getriebe, Lager, etc.) innerhalb der Anlage, welche die Qualität des Anlagenproduktes beeinflussen oder für die Lebensdauer der Maschinen und Anlagenkomponenten wesentlich sind
• • Teilweise gefährliche Arbeitsbedingungen während Prüfung und Wartung
• • Instandhaltungsarbeiten werden dezentral (nicht in einer Werkstattumgebung) vor Ort in der Anlage durchgeführt („im Feld”). In der Regel ist an diesem temporärer Arbeitsplatz kein Zugang zu Informationssystemen (BDIS oder IBFS) möglich.

In addition to the traditional maintenance and inspection tasks of every industrial company, large-scale industrial plants in the area of metal production and primary shaping have additional specific problems:

• • High degree of complexity due to the networking of a large number of subsystems
• • Production facilities with extensive hall areas and a strong spatial extent of the factory premises. This is associated with a very high number of maintenance and inspection bodies
• • Grown, heterogeneous system landscape: the (sub-) systems used are complex and consist of a large number of different components with their individual functionality, using devices from different manufacturers, often with different generations of technology
• • application of various inspection technologies; In doing so, a large number of running processes and plant components are not visible
• • Variety of components subject to wear and critical machine parts (eg guide mechanisms, tools, motors, gearboxes, bearings, etc.) within the plant, which influence the quality of the plant product or are essential for the life of the machinery and plant components
• • Partly hazardous working conditions during testing and maintenance
• • Maintenance work is carried out locally (not in a workshop environment) on site in the plant ("in the field"). As a rule, access to information systems (BDIS or IBFS) is not possible at this temporary workplace.

State of the art - disadvantages of previous solutions

• a) schlechte Lichtverhältnisse oder Schattenzonen vor Ort an der Anlage (z. B. die Kühlkammer einer Stranggußanlage)
• b) umständliches Handhaben: u. U. begrenzter Platz, unbequeme Haltungen, begrenzte Bewegungen. Beispielweise ist kein ausreichender Platz zur Ablage vorhanden, so dass mindestens eine Hand gebraucht wird, oder die Platzverhältnisse sind so eingeschränkt; dass der Instandhalter den Ort wechseln muss zwischen dem Ort an dem die Zeichnung aufgehängt wurde und dem Arbeitsraum der Montage
• c) die erforderliche Blickverschiebung (Bewegung der Augen, die ausgeführt wird um den Blick von der Zeichnung auf den Arbeitsraum der Montage zu lenken); Informationen zur Montage oder Bedienung werden nicht direkt in den Arbeitsbereich projiziert. Besonders hinderlich bei unbequemer Haltung oder begrenzten Bewegungsraum
• d) widrige Umgebungsbedingungen, wie Wasser, Dampf, Staub, Hitze und korrosiven Betriebsmitteln
• e) sowie die geringe Flexibilität (während der Tätigkeit werden weitere Informationen erforderlich, keine vollständige Information).

The traditional paper-based information provision by drawings and descriptions as well as handwritten montage reports have disadvantages, such. B .:

• a) poor lighting conditions or shadow zones on site at the plant (eg the cooling chamber of a continuous casting plant)
• b) cumbersome handling: u. Limited space, uncomfortable postures, limited movements. For example, there is not enough space to deposit, so that at least one hand is needed, or the space is limited so; that the maintenance person must change the place between the place where the drawing was hung up and the working space of the assembly
• c) the required visual shift (movement of the eyes, which is carried out to direct the view from the drawing to the working space of the assembly); Information about installation or operation is not projected directly into the workspace. Particularly inconvenient in uncomfortable posture or limited range of motion
• d) adverse environmental conditions, such as water, steam, dust, heat and corrosive equipment
• e) and the lack of flexibility (additional information is required during the activity, not complete information).

Point (e) contains another major weakness of the traditional way of working: a common problem in practice is the indication of an unclear fault description by the production. Messages such. For example, "equipment failure" or "failure of the equipment" does not allow maintenance to be clearly formulated so that there is no actionable information, what needs to be done, what information is required?

Digital work aids such as industrial PCs or industrial notebooks can not be set up or used effectively in temporary workplaces - especially in hazardous work areas and due to the harsh operating environment (dusts, heat, water or steam). Mobile devices such as the PDA systems primarily used are too unergonomic to operate. The depiction of a complex maintenance protocol consisting of several DIN A4 pages or complex drawings is only possible with great effort for the maintenance personnel. Furthermore, it is necessary for the maintenance engineer to interrupt his primary work task (eg disassembly of interchangeable parts) as the operating principle (interaction paradigm) of mobile computing is based on user interfaces used in classic desktop applications (WIMP: = "window icon, menu, pointing "). The user can either operate the mobile terminal or perform his actual task. Both at the same time is almost impossible. A hands-free operation (hands-free interaction), such. For example, controlling, moving 3D data models of a component (3D CAD model) through the head movement of the user enable new techniques of human-computer interaction (HCI). Examples of such new interaction techniques and paradigms include virtual reality (VR) technology, augmented reality, and wearable computing technology. Since VR technology is by definition limited to representing a virtual space and only a small proportion of real-world environmental objects are included, it is unsuitable for supporting mobile workers on site in the field. Wearable computer systems as well as Augmented Reality (AR) technology have the night parts of a too small and impractical display (data glasses, PDA) already mentioned in the PDA-supported solutions.

Another traditional communication channel for obtaining information is the communication of the maintenance engineer on site in the system with the plant control room or various control rooms (= central collection point all relevant plant and process information and measured values) by means of a radio. The verbal communication is efficient when asked (which display value can be seen?), But ineffective with extensive information (how is the cable history?).

aim

The invention has for its object to provide a flexible solution for the design of a mobile information system for technicians or general. for operators in the shop-floor area, as a visual assistance system, to support on-site work on metallurgical and rolling mill plants, as well as in press, forging and tube plants (hereafter referred to as "factory floor") as a "mobile visual assistance system").

The goal is to provide and display (visualize) relevant information anytime, anywhere for each employee to be available to support their respective work processes. Furthermore, the use as a mobile, interactive documentation system. The visual assistance system should increase the efficiency and effectiveness of the work in the direct production environment (no office environment!). For example, in the field of maintenance through targeted - and therefore faster - finding of sought-after plant components (rapid error detection) as well as through rapid troubleshooting. This requires z. For example, you have the opportunity to get a quick and clear overall overview as well as the mobile provision of data and relevant documents.

solution

According to the invention, the object is achieved by using the possibilities modern technologies of mobile information and communication technology (ICT), such as the use of augmented reality technology, wearable computing and mobile devices and the use of special asset information systems (as a database), or enabled and combined.

Furthermore, hybrid approaches are used by combining devices or the technology used in the area of the displays used, in the area of localization and location (where is the maintenance engineer ?, where is the sought-after component?), As well as in the area of the access technology used for data transmission.

The combinations are used specifically to compensate for weaknesses of the one by strengthening the other system. The goal of this effort is to increase the accuracy, reliability and robustness of the various system components.

• – Grundsätzliche Typen: globale, lokale und Ad-hoc Netzwerke (drahtgebunden und/oder Funk)
• – Unternehmensübergreifend: mittels WWW, WWW mit VPN oder eine eigene (Daten-)Standleitungen (z. B. ohne öffentliche IP-Adress-Zuweisung)
• – Unternehmensintern: Werkübergreifend
• – Unternehmensintern: Werksintern (z. B. werkseigenes Funknetz, WLAN)
• – persönlichem Netzwerk (Personal Area Network, PAN), z. B. drahtloses persönliches Netzwerk (Wireless Personal Area Network, WPAN)

As an example of the possible characteristics of the access technology used for the mobile access to data sources away from the office workplace, the following technologies are listed:

• - Basic types: global, local and ad-hoc networks (wired and / or wireless)
• - Cross-company: via WWW, WWW with VPN or a dedicated (data) leased lines (eg without public IP address assignment)
• - Internal: Cross-plant
• - in-house: factory-internal (eg factory-owned radio network, WLAN)
• Personal network (PAN), e.g. B. Wireless Personal Area Network (WPAN)

The devices of the PAN, d. H. the wearable computers (portable computing devices) are integrated into a LAN. For example, the user of a PAN device can match his stored data with a database on a network server. Furthermore, an intranet or Internet access for the PAN device can be created by integrating with the LAN.

Furthermore, Industry 4.0 technologies are to be used, such as: B. New machine-to-machine communication required in the application of the "Internet of Things (IoT)" to production. Specific examples include machines equipped with cyber-physical systems (CPS) or plant components and their spare parts (smart objects) as well as suitably equipped plant products, such as eg. As slabs, wound coils, sheets (smart products), which are networked together (communication via wireless sensor network).

In addition, special data models are to be used (virtual prototypes of the plant), which are expanded (enriched data), for. B. maintenance-related information, which are located on the geometry model of the system (or the machine and its components) and can be found quickly.

1

Aus Arbeitszeitstudien ist bekannt, dass der Instandhalter im Schnitt 10% seiner täglichen Arbeitszeit damit verwendet, passende Ersatzteile zu identifizieren und sie im Lager auch vorzufinden [Biedermann 2008].

ermöglicht. Üblicherweise findet die Suche des korrekten Maschinenteile über (i) Materialnummern und (ii) Struktur-/Stücklisten (z. B. die Teilelisten der Gerätehersteller (Auflistung von Ersatzteile) sowie (ii) mittels abstrahierten Strukturgrafiken (Explosionszeichnung der Maschine oder 2D-Zeichnung) statt. Die nötigen Informationen sind in umfangreichen Reparatur-, Wartungsanleitungen, Zeichnungen, Aufstellanweisungen, etc., und, bei papiergebundener Archivierung, in unhandlichen und unübersichtlichen Ordnern.With the help of these special data models a new possibility and mode of operation for fast and safe finding of maintenance-relevant information, such as the identification of machine or spare parts 1

1

From working hours studies it is known that the maintenance worker uses on average 10% of his daily working time to identify suitable spare parts and to find them in the warehouse [Biedermann 2008].

allows. Usually, the search for the correct machine parts is based on (i) material numbers and (ii) structure / parts lists (eg parts lists of device manufacturers (list of spare parts) and (ii) abstracted structure graphics (exploded view of the machine or 2D). Drawing). The necessary information is in extensive repair, maintenance manuals, drawings, installation instructions, etc., and, in paper-based archiving, in cumbersome and confusing folders.

In order to find components with these special data models, it is possible, for example, to work according to the "rough to detailed" philosophy. The maintenance engineer can find relevant machine or spare parts via the navigation within the data model of the plant, the installation location of the main assembly and the subsequent interactive search for the relevant component. During the planning of maintenance work. Furthermore, the subsystems for calculating the current field of view of the maintenance person on site in the plant (position determination by means of outdoor / indoor systems, detection of the viewing direction / orientation by means of electronic compass, etc.) can be coupled to the special data model. The result is a tracked 3D plant model in which the current position and viewing direction of the maintenance person within the real plant is identical to the position within the virtual plant (data model). For example, the user can find components by subsequent interactive search.

In addition to effective navigation methods, such as B. the o. G. Direct transfer of user orientation to the orientation of the virtual camera within the 3D plant model, or navigation through previously stored views, filter, detail and context techniques such. For example, filtered views of the plant, filtered according to the type of fault message or according to the user group (maintenance electrician) used.

The flexibility of the "mobile visual assistance system" is achieved, for example, by the fact that the system allows and combines different types of displays (smart glasses, arm-mounted display, industrial tablet PC) (multi-display environment of the mobile assistance system) , The combination with different display devices of different display sizes makes sense, because detailed data can hardly be displayed on data glasses due to the limited readability.

Use:

This invention encompasses all production, quality assurance and maintenance workplaces, as well as new or re-planning operations for metallurgical plants and rolling mills, as well as in press, forging and tube plants, where the work is carried out directly on site at the plants. It does not include activities in technical offices or in the control rooms of the facilities where z. As the acquisition of information takes place on conventional PC workstations, with mouse and keyboard as input devices, designed for the typical office operation ("office environments").

Technical Instructions

A so-described mobile visual assistance system consists at least of the components robot, safety sensor system, safe control and human machine interface (manual control, voice control)

• • leistungsfähiger Rechner mit einer leistungsfähigen Graphikkarte, auf dem entsprechende Software-Anwendung laufen. Es kann ein Wearable Computer und/oder ein robuster Industrie Tablet-PC für extreme Arbeitsumgebungen (z. B. nach Schutzklasse IP54) und stationäre Rechner (Server, ...), die über ein Netzwerk (z. B. WLAN) mit den zu vor genannten mobilen Geräten verbunden ist Alternativ kann beim Einsatz von verteilten Anwendungen oder der Verwendung von Cloud-basierten Lösungen (s. unter Punkt Software im weiteren Text) auf leistungsfähige Rechner verzichtet werden.
• • graphisches Ausgabegerät. Ein solches Anzeigesystem (Display) kann eine AR-Datenbrille sein (Kopfbasierte Anzeige, Head Mounted Display; HMD), vorzugsweise als optisches See Through System (OST-HMD) ausgeführt, und/oder ein Arm-Mounted Display bzw. Wrist-Mounted Display (am Handgelenk befestigte Anzeige) und/oder das Display des Industrie-Tablet-PCs sein.
• • Subsysteme zur zuverlässigen und exakten Bestimmung, wie z. B.:
• – von Position und Bewegungen sowie Blickrichtung (Orientierung) des Nutzers (mobiles Tracking), z. B. • die Kombination einem GPS-Subsystem in Form eines industrietauglichen Standalone-GPS-Moduls zur Positionsbestimmung und einem Kreiselkompass (Gyroskop) oder einem elektronischen Kompass (Magnetfeldsensor) für die Bestimmung der Blickrichtung
• – von Position und Ausrichtung (Orientierung) aller relevanten Objekte in der Benutzer-Umgebung; diese Ortung gibt Hinweise auf die räumliche Positionen von Bauteilen (z. B. zur Komponentenerkennung von Maschinenteile) oder von Montageorten • Kamera zur Erfassung der realen Umgebung, bzw. zur Erfassung von Piktogrammen (Markern) • Verschiedene Sensoren

über unterschiedlich große Distanzen und unter wechselnden Umgebungsbedingungen, z. B. der Einsatz außerhalb oder innerhalb von Gebäuden (Outdoor Lokalisierung und Indoor Lokalisierung).A so-described mobile visual assistance system consists at least of the components:

• • powerful calculator with a powerful graphics card running on the appropriate software application. It can be a wearable computer and / or a rugged industrial tablet PC for extreme work environments (eg IP54) and stationary computers (servers, ...) connected to the network via a network (eg WLAN) Alternatively, when using distributed applications or the use of cloud-based solutions (see Software section below), powerful computers can be dispensed with.
• • graphic output device. Such a display system (display) may be an AR data goggles (head-mounted display, HMD), preferably as a See See Through Optical System (OST-HMD), and / or an Arm-Mounted Display or Wrist-Mounted Display (wrist-mounted display) and / or the display of the industrial tablet PC.
• • Subsystems for reliable and accurate determination, such as: B .:
• - of position and movements as well as viewing direction (orientation) of the user (mobile tracking), z. B. • The combination of a GPS subsystem in the form of an industry-standard standalone GPS module for position determination and a gyroscope (gyroscope) or an electronic compass (magnetic field sensor) for determining the viewing direction
• - of position and orientation of all relevant objects in the user environment; This location provides information on the spatial positions of components (eg for component identification of machine parts) or on mounting locations • Camera for capturing the real environment or for capturing pictograms (markers) • Various sensors

over different distances and under changing environmental conditions, eg. B. the use outside or inside buildings (outdoor localization and indoor localization).

For this purpose, different tracking methods (optical, video-based tracking, inertial tracking methods / inertial navigation systems, RFID tracking, ...) and their combinations, cf. z. B. Köppe 2014 ] are used.

3

Positionsbestimmung auf Basis von Funkstandards wie WLAN, RFID, Bluetooth, Zigbee, GSM und UMTS

). Neuste Lokalisierungstechnologien und deren Weiterentwicklung reichen von der Satellitenortung über kombinierte Ortungslösungen wie awiloc (WLAN, GPS, INS) für z. B. Gebäude, drahtlose Sensornetzen wie s-net und flexibel einsetzbare Ortungstechnologien wie BlackFIR bis hin zu hochpräzisen Lokalisierungsverfahren wie RedFIR, vgl. [2014-Fh-IIS_CPS_NOP_Broschuere].

• • Technische Geräte zur Komponentenerkennung (Leseeinrichtungen für Auto-ID Systeme, Scanfunktion), wie z. B.: Barcode-Reader oder RFID-Lesegerät

For this an outdoor and indoor position and orientation system is used, such as the GPS localization (eg WAAS, RTG-GPS, mmGPS for the outdoor area) or for the indoor area (eg Cricket System of the WITH or MagicMap 3

3

Position determination based on wireless standards such as WLAN, RFID, Bluetooth, Zigbee, GSM and UMTS

). Recent localization technologies and their further development range from satellite positioning via combined positioning solutions such as awiloc (WLAN, GPS, INS) for z. As buildings, wireless sensor networks such as s-net and flexible positioning technologies such as BlackFIR to high-precision localization methods such as RedFIR, see. [2014 Fh-IIS_CPS_NOP_Broschuere].

• • Technical devices for component recognition (reading devices for Auto-ID systems, scan function), such as: Eg: barcode reader or RFID reader

• • Hardware zur Kommunikation mit stationären Servern (Content-Server) und anderen mobilen Geräten, wie z. B. WPAN, WLAN oder UMTS
• • Hardware zur online-Kommunikation zwischen dem Instandhalter „vor Ort” und weiteren interne Experten (betriebs-/unternehmensintern) oder externen Experten (Teleservice mit Maschinenbau-Unternehmen). Die Kommunikation kann textbasiert, mit Video-/Audioübertragung (Experte sieht z. B. das Schadenbild Vorort) sowie mit Übertragung relevanter Sensordaten sein (Multimediale Unterstützung zur Störungsfindung und -beseitigung bei Einbindung von „entfernten Experten”).
• • AR-Anwendungen und andere relevante Anwendungen, wie z. B.: Magic Map, virtuelles Anlageninformationssystem, digitale Handbücher (mit/ohne Interaktion für 3D-Modelle)
• • Software: die beim mobilen, visuellen Assistenzsystem eingesetzten Software-Anwendungen können monolithische als auch verteilte Anwendungen sein, d. h. sie laufen nicht nur auf dem mobilen Gerät, sondern bestimmte Teilsysteme der Anwendung laufen auf stationären Servern, die über Netzwerke mit dem mobilen Gerät verbunden sind. Beispiele sind Datenbanken, die für die Ausführung der Anwendung notwendige Daten aufbereiten und bereitstellen, wie z. B. Lagepläne eines Gebäudes, Handbücher, etc. Ebenfalls ist es denkbar, die erforderliche grafische Berechnung bei der Darstellung von 3D-Modellen der Anlage auf stationären Rechnern ablaufen zu lassen, das mobile System dient in diesem Fall nur noch dazu, Videobilder von einer Kamera zu aufzunehmen, an einen Server zu schicken, die angereicherten Bilder (augmentierten Bilder) wieder vom Server zu empfangen und darzustellen. Hierzu können auch Cloud-basierte Lösungen eingesetzt werden.

The relevant plant and machine components at the maintenance and inspection control points of the plants are used with z. For example, additional installed hardware components pictograms (markers) for marker-based tracking (eg QR code) equipped, or by means of coordinates (stationary tracking of the AR system) or based on "Markerless-3D" tracking of the AR system. When used in heavily polluted environments, RFID tags are a good marker.

• • Hardware for communication with stationary servers (content servers) and other mobile devices, such as: B. WPAN, WLAN or UMTS
• • Hardware for online communication between the on-site maintenance engineer and other internal experts (company / company-internal) or external experts (teleservice with mechanical engineering companies). The communication can be text-based, with video / audio transmission (expert sees, for example, the damage image on-site) as well as transmission of relevant sensor data (multimedia support for fault finding and elimination with the involvement of "remote experts").
• • AR applications and other relevant applications, such as: Eg: Magic Map, virtual asset information system, digital manuals (with / without interaction for 3D models)
• • Software: the software applications used in the mobile visual assistance system can be monolithic as well as distributed applications, ie they not only run on the mobile device, but certain subsystems of the application run on stationary servers connected to the mobile device via networks , Examples are databases that prepare and provide necessary data for the execution of the application, such as: Also, it is conceivable to run the required graphical calculation when displaying 3D models of the system on stationary computers, the mobile system is in this case only to video images from a camera to send to a server, to receive the enriched images (augmented images) back from the server and represent. Cloud-based solutions can also be used for this.

For controlling or interacting with the connected computers of the mobile visual assistance system, in addition to the input via the camera (eg the data glasses or the helmet camera), data can also be input via pen / handwriting recognition (pen operation) or possibly by means of speech recognition. Furthermore, various mobile peripherals such as keyboard can be connected, the z. B. via Bluetooth (Bluetooth Keyboard) are coupled.

The solution according to the invention is illustrated in the attached figure.

Specific operating example: fault-related maintenance processing - Comparison: with and without assistance system

Example scenario with and without a visual assistance system for the maintenance engineer: In the control station of the continuous casting plant, the level indicator for the hydraulic systems of the strand guide segments drops from 90% to 30%. This incident occurs during the casting process. There is no standstill for a repair. Possible causes of malfunction could be: a sensor error of the level gauge or a leak in the hydraulic system. The plant operator in the control room instructs employees in mechanical and electrical maintenance to troubleshoot and repair them. The cause clarification by the two maintenance engineers takes place during full plant operation.

The personal equipment of the maintenance personnel is:
According to method (A) "visual assistance system": the usual work equipment consisting of radio with battery for the exchange of information with the central control station and helmet with helmet lamp as well as the relevant tools, extended to the Components of the previously described visual assistance system. The relevant information is available digitally through appropriate access to the asset information system and model-based information; or
By method (B) "traditional type": the usual working equipment (radio, hard hat with helmet lamp, relevant tools). Furthermore, paper-based information which is carried along by the maintenance department due to the fault report by the production department. Here, the weak point of the traditional way of working already discussed in the section "state of the art" appears directly: the direct interaction between unclear fault description and ineffective fault resolution.

The relevant tool is carried along to the maintenance due to the fault report of the production, in this case, for example, repair case with voltage testers.

The troubleshooting and rectification is done either by processing points within a fault manual or on the basis of personal experience (diagnostic skills), the work is ideally carried out systematically, z. B. on the principle of groping search for error limitation or the fault correction according to the U-method. The basic steps are illustrated below by way of example. By means of new Industry 4.0 technologies, such as system components equipped with sensors and embedded systems with their own IP address (eg a motor), an error code can be transmitted, for example, if the engine fails via radio (or another interface) Fault reporting triggers in ERP systems or IPS solutions.

In the following, these different cases are to be considered: with error code-based troubleshooting and without troubleshooting (own diagnostic competence).

Case: with error code based troubleshooting

For example, the hydraulic systems of the strand guide segments have Industry 4.0 technologies, such as: B. via integrated communication-capable sensors for latent monitoring. This system becomes active when sensors register the sharp drop in the level indicator. A fault message is triggered automatically. To a relevant IT system of maintenance, such as a Maintenance Planning and Control (IPS) system such as SAP PM. Additionally - in this example - an error code is given.

By method (A): The error message appears with error code in the IPS system, eg. On the workstation of the maintenance master. Due to the urgency, a maintenance job is triggered directly with the IPS. The maintenance technician "in the field" can send this message directly as a message to the handhelds. Not only can the error code be transmitted, but also the malfunction and malfunction help can be sent in digital form. The maintenance engineer calls up the necessary maintenance-relevant documents for carrying out the damage repair via the system information system.

According to method (B): The maintenance engineer "in the field" receives the fault message via the radio. Under certain circumstances the error code and a description of the malfunction will be communicated verbally. A provision of technical drawings and maintenance documents on site is not possible! The relevant documents must now be procured by the maintenance engineer, eg. B. from the maintenance workshop. With the large systems considered here, with the large spatial distances of the systems, only the required long travel times lead to an extension of fault times.

Conclusion - Case: with error code based troubleshooting method B:

• • hohe Wegezeitanteil (Beschaffen und Transfer von Arbeitspapieren)
• • Informationslücken
• • mangehafte Datenqualität

und führt somit zu Verlängerung von Störungszeiten, zu Produktions- und Qualitätseinbußen.The traditional way of working has the following disadvantages:

• • high proportion of travel time (procurement and transfer of working papers)
• • Information gaps
• • manageable data quality

and thus leads to prolongation of disruption times, to production and quality losses.

Case: without troubleshooting (own diagnostic competence required)

1st step: verification of the alarm message; here: Checking the tank contents by means of oil dipstick. This requires orientation at the location of the incident as well as the localization and correct identification of the relevant system components and parts. The required information is z. B. Location information to "which tanks are eligible?", "Where is the tank or tanks?" And "where is the measuring tube and dipstick".

By method (A): Query by display to the asset information system and possibly with additional information component detection by means of the data glasses. This could be z. B be the display of the component name, which virtually in addition to the current field of view (the real working environment) of the maintenance person is displayed. Alternatively, the display of the relevant locations or components based on digital maps and drawings on the additional, mobile displays (wrist-mounted display or industrial tablet PC) can be done. The current position and / or gaze position of the maintenance engineer is tracked (tracked) by means of the indoor systems and displayed on the display (data goggles or additional displays) (eg level: Hüttenflur, plant area: hydraulic space XY of the continuous casting plant Z).

Furthermore, the current position can also be displayed, for example, within the dynamic 2D site plan (plan of the plant) or with the 3D plant information model (eg for orientation within the central hydraulic system or a ventilation center).

According to method (B), the maintenance personnel must have carried these relevant paper-based documents to the location of the incident due to the production fault report.

The orientation within the system ("where am I in the system?", "What do I see?") Must be ensured by the maintenance engineer based on his experience.

Another required information may be the question "What is the current level reading?".
According to method (A), the maintenance engineer has access to the system information system, here the operating data information system, with the help of the additional wearable computer and the radio network. He can display the corresponding display (display of signals within the HMI of the automation level 1) on the additional displays. When using Industry 4.0 technologies, such as wireless sensors that communicate via wireless radio technologies, it is possible to display the wirelessly transmitted information on the additional displays and assign them to the spatially related components.

According to method (B), call the maintenance engineer at the control center or in the computer room and ask the corresponding inquiry ("please read off the display value of tank filling measurement xy").

2nd step: Limitation by error diagnosis to clarify sensor or process errors. In the case of sensor errors, the casting process can be continued. In the case of a process error, it is necessary to a) weigh up whether the casting process can be safely continued and b) identify the affected components. For example, is it an electrical / electronic problem or a hydraulic one? Possible test measures are, for example, the measurement of electrical voltage conditions at certain measuring points or checking the hydraulic system for leaks. For this purpose z. For example, the following information is available: At which measuring points can electrical voltage states be tapped? What are the cable names? Where are the relevant piping and components (filters, ...) of the hydraulic system (pressure and tank lines, control oil lines, hydraulic units, control blocks, etc.)? The relevant sources of information (documents) are z. B. Circuit diagrams and cable plans with the numbering of cables and hydraulic circuit diagram with numbered pipe outlets z. B. of the aggregate.

By method (A): Localization of the relevant components (electrical or hydraulic) either automatically by means of tracked goggles and display in the glasses display or by information access to the asset information system, for example by means of a tracked 3D plant model and automatic specification.

Method (B) requires maintenance personnel to have (or had anticipated) this relevant information in paper-based form due to the production fault report to maintenance at the location of the failure. Another possibility is the oral communication via two-way radios, in which the maintenance staff missing information, such. For example, the maintenance manager or other experts.

3rd step: Maintaining a basic functionality for the operation of the system, here: refill tank. For this purpose z. B. information for filling and possibly bleeding the tank and the specification of the hydraulic oil to be known. Relevant sources of information (documents) are the maintenance documents of the hydraulic system with safety instructions.

By method (A): By information access to the asset information system. The risk of filling in a wrong hydraulic oil is thereby eliminated.

According to method (B), the maintenance personnel must have carried this relevant information (see step 2).

4th step: the damage can be localized exactly; burst hydraulic hose in a difficult to reach and difficult to see place. The affected machine component (segment of the strand guide) is secured to the current setting position (so that the component can also be operated without a hydraulic system). For this, the corresponding information must be available to the maintenance personnel.

By method (A): By information access to the asset information system, eg. On electronic document (e-book) or on video files of an interactive instructional film (utility film) with a step-by-step guide.

According to method (B), the maintenance personnel must have carried this relevant information (see step 2).

Both methods would require an oral request from the on-duty shift master to obtain approval for the change to the facility. According to method (A), a corresponding message could be sent by the maintenance engineer to the control center using the system information system.

Furthermore, handling of the leaked hydraulic oil must be clarified, such. B. there is a risk of fire or explosion. Eventually, the company fire brigade must be notified, for. B. when leaving large amounts of oil (the volume of the hydraulic tank can be several hundred liters of hydraulic oil).
By method (A): By information access to the asset information system. By concrete information on the type of oil could z. B. the factory fire brigade carry the appropriate binder directly.
According to method (B), the maintenance personnel must have carried this relevant information (see step 2).

5th step: another casting operation with fixed segment; Clarification, whether a damage correction at the next pouring break is possible. For this, the pouring pause (normal value approx. 30 min) must be extended in coordination with the upstream converter or melting operation. The necessary spare parts must be identified quickly and correctly (hose type, nominal diameter, maximum working pressure, ...). Furthermore, it must be agreed with the in-house central warehouse, whether the spare part is available until the next casting break. The correct identification of the hydraulic hose by reading the marking on the hydraulic hose and on the compression sleeve can cause difficulties. For example, the hydraulic hose can be located in a difficult to reach and difficult to see place, or the hose name is wiped or abraded.

By method (A): By information access to the asset information system, eg. B. with the help of the relevant hydraulic schemes or operating instructions of the hydraulic system and by means of parts list for hydraulic hose lines.

According to method (B), the maintenance personnel must have carried this relevant information (see step 2). If necessary, the dimensions (hose length) must be measured manually by tape measure at hard to reach places.

Step 6: By means of the correct identification of the required spare part (hydraulic hose), a request can be made to the in-house central material store and it can be clarified whether it is possible to repair the damage at the next pouring break.

By method (A): By information access to the asset information system, eg. For example, via a connection to the warehouse, a program checks whether all materials are available or whether it has to be ordered. All data could then be automatically transferred to the central warehouse by means of an operating order, with information to the production (control center). The actions take place via the additional handhelds. Afterwards it can be finally decided whether the production plan can be kept. Cheapest If a short-term repair could be carried out without a delay in the operation, so that neither quality and production losses occur.

According to method (B), the information exchange between maintenance personnel, central warehouse and production (control center) takes place purely on the basis of an oral communication by means of a radio. Due to the loss of time in the communication between the various information carriers and decision makers and the need for explanation, then a repair is not possible in the short term. This results in quality losses (eg no soft reduction) or production losses.

Conclusion:

• • A variety of maintenance-related information was required, such as Troubleshooting Guide, Function Diagrams, Wiring Diagrams, Hydraulic Schemes, Isometric Drawings, and Machine / System Design Drawing, as well as Floor Plans and Floor Plans as an inventory
• • The maintenance engineer binds other resources to method B by repeatedly asking him / her and verbally procuring information from the control center ("what is the display value now", "is the error message gone now") or other experts, eg. B. Maintenance Manager ("we had the error before ...")
• • Instead of a thick manual or (paper) collection of technical documentation, the maintenance engineer has access to a "digital tool box" at the location of the supposed incident
• • by improving the navigation and orientation of maintenance personnel within the complex plant and its systems ( Piping systems, media equipment, ...), as well as the improved localization of the machine parts and components by the visual assistant, can locate potential sources of interference quickly and reliably and appropriate measures are initiated immediately by the maintenance engineer
• • The spare part for the function or assembly is identified quickly, easily and correctly using Method A.
• • In the scenario shown, the production plan can be adapted on-line so that it could be complied with and no quality and production losses took place
• • Method A allows a single maintenance engineer to maintain a larger machine park with the same plant availability than conventional method B.

In 1 (Digital production - the combination of virtual and real production, device pool: scalable solution from the mobile information system to the wearable computing platform) the reference signs have the following meaning:

LIST OF REFERENCE NUMBERS

1

Subsystems for localization and orientation z. B. GPS subsystem: with industry-standard standalone GPS module - Operating data information system (BDIS), if applicable, connection to higher-level management systems (PPS, PAM, IBFS, QMS) - Connection to central DB d. Plant documentation ("Central Archive") - Connection to digital plant prototypes with simulation service

2

Handheld display (Wrist-Mounted or Arm-Mounted Display, wrist-mounted display)

3

AR system

4

Industrial Tablet PC

5

Additional helmet camera

6

Additional audio system

7

System information system, Ethernet, Wireless LAN if necessary LAN, "Internet cloud" IoS & IoD (optional) (open)

8th

Indoor navigation (possibly digital map)

9

Gyroscope, localization

10

Reading function for Auto ID system, QR code, RFID tags Component recognition occurs z. B. by marker or localized

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited non-patent literature

• Köppe 2014 [0040]

Claims (20)

Visual assistance system, comprising: mobile devices for a maintenance person in a system to be maintained; stationary computers, a network via which the stationary computers are connected to the mobile devices, a graphical output device; a system information system with maintenance-relevant information sources, in particular documents, for carrying out a damage repair; and technical devices for the detection of relevant components at maintenance and inspection control points of the plant. A visual assistance system according to claim 1, characterized in that the network is a personal area network PAN, a wireless PAN, a WLAN or a UMTS network, wherein the network can be formed across companies or within the company; and wherein the network may be wireline or wireless based. Visual assistance system according to one of the preceding claims, characterized in that it is in the graphic output device to an augmented reality AR-data glasses, z. B. in the form of a head-based display or a head-mounted display HMD, preferably designed as See Through System OST-HMD, and / or is an arm / wrist-mounted display and / or the display of an industrial tablet PC. Visual assistance system according to one of the preceding claims, characterized by a subsystem for the reliable and accurate determination of the position, the movements and the line of sight of the maintenance person, comprising a combination of a Global Positioning System GPS subsystem in the form of an industry-standard standalone GPS module for position determination and from a gyro compass or an electronic compass for determining the line of vision. Visual assistance system according to one of the preceding claims, characterized by a subsystem for determining the position and orientation of all relevant objects in the environment of the maintenance person, comprising a camera for detecting the real environment or for detecting pictograms and various sensors. Visual assistance system according to one of the preceding claims, characterized in that the technical devices for the detection of relevant components are reading devices for auto-ID systems or scanners, such as barcode or pictogram readers or RFID readers for reading of barcodes or pictograms or to read out markers or RFID tags that identify the components. Visual assistance system according to one of the preceding claims, characterized by hardware for online communication between the maintenance engineer on site and other internal or external experts. Visual assistance system according to one of the preceding claims, characterized in that the assistance system is scalable. Visual assistance system according to one of the preceding claims, characterized in that the assistance system has an outdoor or indoor position and orientation system. Use of the visual assistance system for locating and locating a maintenance person or a sought-after component. Use the visual assistance system to support on-site work on metallurgical and rolling mill facilities, as well as in press, forge and tube plants by providing and presenting relevant information at any time and place for each employee, especially the maintenance engineer. Using the visual assistance system as a mobile interactive documentation system. A method of performing damage repair using the visual assistance system of any of claims 1 to 9; comprising the steps of: registering a drop of a level indicator of a hydraulic system of a strand guide segment by a communicable sensor; Automatic triggering of a fault message and transmission of the fault message by the communication-capable sensor to a relevant information technology IT system of the maintenance, preferably together with an error code; Depending on the urgency: Automatic triggering of a maintenance order by the IT system, the fault message is sent directly to the mobile device, in particular a handheld of a maintenance engineer on site, the fault message preferably not only the error code, but also the malfunction and a fault help in digital form; and Calling up necessary maintenance-relevant documents for carrying out the damage repair via the asset information system. A method according to claim 13, characterized in that for the orientation of the maintenance person at the location of the accident and for localization and specific identification of the relevant plant components a query is directed to the asset information system, possibly with additional information component detection; and that the display of the relevant locations or components on the basis of digital maps and drawings on additional mobile devices, the current position and / or gaze of the maintenance tracked by the indoor position and orientation system and on the data glasses or on the additional displays the mobile device is displayed. A method according to claim 13 or 14, characterized in that to clarify whether there is a sensor error or a process error, a localization of the relevant electrical or hydraulic components to be tested either automatically by means of tracked goggles and display in the glasses display or by accessing the system information system and automatic indication he follows. Method according to one of claims 13 to 15, characterized in that for information for filling and possibly venting a tank, for the specification of hydraulic oil, to detect an explosion hazard and possibly to notify the plant fire department access to the system information system. Method according to one of claims 13 to 16, characterized in that after a localization of the damage, a step-by-step instructions is retrieved by the asset information system to secure the affected equipment component at a current parking position. A method according to claim 17, characterized in that with the aid of the system information system, a request to the control center of the system is discontinued with the request for release for a change in the system in the form of securing the system component on the current parking position. Method according to one of claims 13 to 18, characterized in that with the aid of the system information system an identification of a necessary spare part takes place, for example by providing relevant hydraulic schemes or operating instructions of the hydraulic system and by means of parts lists for hydraulic hose lines. A method according to claim 19, characterized in that by information access to the asset information system, for example via a connection to the warehouse, a program checks whether all materials are available or whether they must be ordered, and - in the latter case - then automated operating order to the Zentralmateriager, preferably with information to the control room.

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