WO2014127978A2

WO2014127978A2 - Camera-based monitoring of the equipment of a technical system

Info

Publication number: WO2014127978A2
Application number: PCT/EP2014/052003
Authority: WO
Inventors: Martin LEHOFER
Original assignee: Siemens Aktiengesellschaft
Priority date: 2013-02-21
Filing date: 2014-02-03
Publication date: 2014-08-28
Also published as: WO2014127978A3

Abstract

The invention relates to a method for monitoring the equipment (1) of a technical system. The invention further relates to a system, a controller (13), a computer program (14), and a computer program product (15) for monitoring the equipment (1) of a technical system. The aim of the invention is to ensure a reliable detection of relevant data in the event of a fault of the equipment (1). This is achieved in that at least one camera (2) detects optical data of at least one part of the equipment (1). If the monitored equipment (1) transitions into a specified fault state, a notification is generated, and the at least one camera (2) is operated using settings (21) defined in advance when the monitored equipment (1) is in the specified fault state.

Description

description

Camera monitoring of equipment of a technical installation The invention relates to a method for monitoring equipment of a technical installation. Furthermore, the invention relates to a system, a controller, a computer program and a computer program product for monitoring equipment of a technical facility.

Such a method is used, for example, in industrial plants, which are frequently equipped with camera systems and condition monitoring systems, camera systems being used, inter alia, to perform visual inspections from the control center, for example to make a visual initial assessment Among other things, these visual inspections are also carried out on the basis of reports from a condition monitoring system, whereby messages from a condition monitoring system are generally related to a specific component or component of a system.

To switch or control the cameras, physical switches can be labeled with the corresponding designations, for example the system component in the field of view of the camera. In particular, if the camera system offers a software control surface, images or graphics of the system can be provided with the positions of the camera in the system and the cameras can be labeled accordingly. If the operator in the control room is made aware of a problem situation by an alarm of an automation system, condition monitoring system or a message from an employee, he can activate a picture by manually operating the camera system. The invention has for its object to ensure reliable detection of relevant data in the presence of a fault of the equipment. This object is achieved by a method of the aforementioned type in that at least one camera captures optical data of at least part of the equipment, wherein, if the monitored equipment passes into a predetermined error state, a message is generated, wherein the at least one camera with advance defined settings is operated when the monitored equipment is in the predetermined error state, wherein the optical data of the at least one camera are continuously stored in a memory and wherein at least a part of that optical data, which passes during the monitored equipment in the predetermined error state, are detected by the at least one camera, and at least a part of those optical data which within a predeterminable time interval before and / or after the monitored equipment passes into the predetermined error state, are detected by the at least one camera in ei stored in an archive.

Furthermore, this object is achieved by a system which has at least one camera for acquiring optical data of at least part of the equipment, an alarm module for generating a message if the monitored equipment changes to a predetermined error state, a computing unit and a working memory on which predefined Can be stored settings with which the at least one camera is operable when the monitored equipment in the predetermined error state passes, at least partially integrated into the camera and / or connected to the actuator actuator, which is connected to the computing unit and by means of which the at least one camera can be operated with the predefined settings if the monitored equipment is in the predetermined error state, and a memory in which the optical data of the at least one camera can be continuously stored, wherein at least part of the optical data which, while the monitored equipment passes into the predetermined error state by which at least one camera can be detected, and at least part of that optical data which within a predeterminable time interval before and / or after the monitored equipment in the predetermined error state passes through which at least one camera can be detected, can be stored in an archive. Finally, this object is also achieved by a controller according to claim 9, a computer program according to claim 10 and a computer program product according to claim 11.

If the monitored equipment changes to the specified fault condition, a message is generated and the at least one camera is operated with the previously defined settings. The message can be executed, for example, as a hint, error message or alarm or the like. Thus, meaningful settings for the operation of the at least one camera must be defined in advance for the given error state and, if appropriate, further error states.

As a result, the reliability of the monitoring of the equipment can be increased or ensured, for example, the monitoring is no longer dependent on operating personnel in the control room. When the predetermined error state is present, it is thus no longer necessary for the operating personnel to select the camera (s) assigned to the respective error state, and in particular the assigned settings of the camera (s).

The at least one camera can be embodied, in particular, as a camera system, which comprises a plurality of cameras, wherein each individual camera and / or groups of cameras of the camera system can be actuated and operated respectively with the previously defined settings or individually assigned, pre-defined settings are operated. The inventive system can, for example, as a

Alarm system in particular a basic automation, process automation, another automation or IT system to be executed. It can also be provided to execute the system according to the invention as a condition monitoring system or a subsystem of a condition monitoring system, which is connected in particular to at least one of said automation or IT systems.

In particular, the predetermined error state and, if appropriate, further predetermined error states can be combined into alarm classes. In this case, actions of the at least one camera can be assigned to the predetermined error state or the alarm classes. For example, the technical system can be designed as a rolling mill with multiple rolling stands and with a motor. As soon as it has been determined that the engine is starting to vibrate and thus changes into the predetermined error state, in particular overview images of the entire rolling train, detailed images of the individual rolling stands and / or detailed images of the engine can be acquired at the time of leaving the normal vibration range. The memory may in particular be embodied as a ring memory, which continuously records the optical data of the at least one camera and in each case overwrites the oldest optical data stored in the ring memory. If the memory has a certain data capacity, which corresponds, for example, to the collected optical data over a period of 30 minutes, then the optical data of the last 30 minutes are always available in the memory.

Furthermore, an archive is provided which, for example, can be designed as long-term storage and which initially no longer overwrites the optical data once stored in the archive. The memory and / or the archive can be embodied, for example, as a tape or hard disk storage or a storage system (cloud storage) connected via a computer network.

If it is provided that the amount of data which accumulates before the monitored equipment changes into the predetermined error state is also stored in the archive, the data capacity of both the memory and the archive is usefully chosen to be at least as large as this amount of data.

In the case of the rolling train, for example, video recordings of the camera responsible for the motor can be stored in the archive, for example, 1 minute before and / or after the transition when the error state occurs.

If it is further provided to examine the optical data stored in the memory and / or in the archive by means of an analysis function, which in particular requires a longer time, such as a few minutes, it can be determined beforehand how much time the analysis function will take , This determined time can in turn be used to predetermine the data capacity of the memory and / or the archive or the length of the predeterminable time interval.

According to an alternative, it may be provided to store only a part of the optical data in the archive which, while the monitored equipment passes into the predetermined error state, is detected by the at least one camera. Optionally, it may also be provided to store only a portion of those optical data which are recorded within a predefinable time interval before and / or after the monitored equipment changes into the predetermined error state by the at least one camera. In an advantageous embodiment of the invention, the predefined settings comprise a lens focal length, an angle of view, an aperture width, an exposure time, a frequency band and / or a specific orientation of the at least one camera.

Due to the specified, predefined settings, it is possible to obtain the relevant optical data for every conceivable fault condition, adapted to the monitored equipment or technical system. They make it possible to examine in more detail the part of the equipment which is relevant for the given error state, for example by focusing on this part or by detecting a predetermined optical frequency band, such as infrared radiation. In this case, the frequency band, the exposure time and / or the aperture width can be chosen such that the data obtained allow a good resolution and oversteering during processing of the detected optical data is reliably avoided. Selecting the orientation of the at least one camera allows the relevant part of the monitored

To visually record equipment or to make detailed or enlarged views of the monitored equipment. The predefined settings can also be such that, when changing over to the predetermined error state, it is also possible to deposit a plurality of positions or camera settings, so that e.g. Overview images and multiple magnifications can be recorded.

In a further advantageous embodiment of the invention, at least the optical data stored in the archive are linked with information on the predetermined error state, the information being stored at least in the archive.

The information can be, for example, such that the predefined error state can be identified directly from it. In particular, it can therefore contain the generated message. Furthermore, the information may contain information about the time of the transition to the predetermined error state, for example in the form of a timestamp, and / or how long the default error condition has existed. Thus, the optical data of the predetermined error state can also be retrieved later by means of the time stamp. In addition, additional context information can be included in the stored information, such as the operating mode of the monitored equipment and / or the technical system, further information of the above condition monitoring system, automation or IT system or the like.

The optical data resulting from different scenarios are thus stored in the archive and provided with meaningful context information, which allows a very effective monitoring of the equipment or the technical system, in particular thanks to the linking of the optical data with the context information.

For example, the optical data stored in the archive are linked to the original message or the original alarm, such as by adding a URI / URL or unique ID, so that the optical data directly from the information stored in the archive to the default error state out are callable.

In a further advantageous embodiment of the invention, a report is generated if the monitored equipment changes into a predetermined error state, the report comprising at least the optical data stored in the archive and the information on the predetermined error state.

The report accordingly comprises the optical data, which are present for example as video recordings, as well as the information, which in particular includes the message, an identification of the predetermined error state, a time stamp or the like. Thus, the report allows to call the optical data directly from the report. It can report in particular in PDF format with embedded as images or video recordings of executed optical data which are integrated, for example, via PDF multimedia functionalities in the report. The format of the report can in particular be adapted to specific output media, for example the printout on paper, the display on a screen of a PC or mobile device or the sending by email or via SMS and the like. For example, the report may be accessed "remotely" over a computer network, ie, remotely, for example, over the Internet and / or using mobile devices.

In particular, it can be provided that the transition to the predetermined error state and the creation of the report are time-separated processes. It is also conceivable that the report can be created later, for example, when the report is called by a user or software that routinely queries and documents error conditions.

In a further advantageous embodiment of the invention, access authorization information is stored, wherein a user and / or software can access the optical data and / or the report only if it is defined in the access authorization information that the user and / or or the software is authorized to access the optical data and / or the report.

The authorization and / or the optical information can be effectively protected against unauthorized access by means of the access authorization information. Furthermore, approval workflows can be linked, which can be used in particular for the revision or updating of the access authorization information.

It can also be provided that the access authorization, regardless of the preparation of a report only is checked for access to the optical data and / or the information on the predetermined error condition.

In a further advantageous embodiment of the invention, the archive is arranged in a network which is protected by means of a firewall and is accessible by means of a web server from outside the network.

The archive can, for example, in a DMZ

In this case, the archive set up in the DMZ is shielded by one or more firewalls against other networks, such as the Internet or LAN, for example Separation allows access to publicly available services such as bastion hosts, WWW, etc., while protecting the internal network from unauthorized access from the outside by protecting a DMZ by isolating one system from two or more networks ,

The firewall provides security for the network and reduces the risk of attacks from outside the network. In general, firewalls are designed to block network traffic that is not authorized to access one or more areas of the network. Typically, firewalls contain one or more rule sets that filter unauthorized communication from various other network devices or network locations, using two general categories of rule sets that include policy-based and signature-based rule sets.

In particular, the network can be separated from other networks, for example the above-mentioned condition monitoring system, automation or IT system or the like, or can only be reached via the firewall and the web server. It can be established that the ar- chiv is available remotely for employees of the plant operator or for employees of a company specializing in condition monitoring, for example, via a PC, notebook or any mobile device such as mobile phones or tablets.

The network is protected against unauthorized access and attacks, as stated above. The system can be set so that the stored optical data and optionally additionally stored information, such as in particular the message, an identification of the predetermined error state, a time stamp or the like, only after release of one or more persons for the external access of mobile devices from and / or external staff. In addition, all accesses can be logged.

Such access control to the network and thus to the archive can also be used to take account of legal regulations and restrictions of some countries with regard to the recording of video images and with regard to the access to the recordings. However, access control can also be desirable for reasons of know-how protection.

For example, due to legal conditions, it may have been necessary to regulate the integration of camera systems and the access to data through internal work instructions, a data protection officer or the works council. This often stood in the way of quick resolution to problems and increased the implementation effort of condition monitoring systems. The legally compliant transmission of recordings was also cumbersome in terms of documentation and ensuring the destruction of recordings. In particular, with such framework conditions, advantages can therefore be achieved by the proposed monitoring method. For if legal or other restrictions exist which restrict real-time access or access to archived video recordings or allow only certain users, this can be stored in the system according to the invention. The access to the optical data and possibly to the further context information is then only after prior release of one or more users, such as the works council or the data protection officer, possible. In this case, the system can be configured so that the release for certain users, especially in an emergency situation or inaccessibility of persons responsible, for example, during the night shift or on weekends, if necessary and exceptionally bypassable and the actual beneficiaries are informed, for example by e-mail , In addition, all accesses can be logged, for example, on video data, which record who what when and where has viewed.

In a further advantageous embodiment of the invention, the stored in the memory and / or in the archive optical data are synchronized with a time variable size and reproduced.

Thus, the optical data, along with the time-varying size, can be used for error analysis. At the same time, this allows you to slow down or accelerate, stop, pause, or jump to freely selectable locations. Furthermore, in a camera system with a plurality of cameras, various camera shots can also be viewed synchronously in parallel in order to facilitate an interpretation or analysis of the error.

The time-variable variable may be a measured value, for example an electrical current or an electrical voltage, a temperature, the nature or the viscosity of a fluid, a force or a torque or the like. It is also conceivable that the time-variable variable is the result of a simulation or calculation or generally a numerical value, which is taken over by a basic automation, a process automation, another automation or IT system. In particular, the reproduction of the optical data can be synchronized in time with the reproduction of protocols and be played back with a freely definable sequence speed, for example 0.5x, 10x. In this case, the optical data, for example in the form of video images, and the temporally variable size, for example as a diagram with a time axis, are displayed synchronously. For example, so the pressure profile of a line in the inlet of nozzles for water cooling can be displayed and reproduced together with a video image of the water cooling.

In general, it is possible to integrate the alarm module into the arithmetic unit or vice versa, wherein it is furthermore conceivable for the arithmetic unit to be part of a condition

Monitoring System or another automation or IT system.

In the following, the invention will be described and explained in more detail with reference to the embodiment shown in the figure. It shows:

1 shows an embodiment of a system according to the invention for monitoring an equipment.

1 shows an exemplary embodiment of a system according to the invention for monitoring equipment 1. A camera 2 is directed towards the equipment 1 and records optical data of at least part of the equipment 1. The camera 2 transmits the optical data to a computing unit 10, which stores a main memory 11 and is connected to a controller 13 and to an alarm module 9. In this case, the controller 13 can be supplied with a computer program product 15, for example a CD or another data carrier, which includes a computer program 14 for carrying out the method Sequence in the controller 13 contains. The controller 13 is in turn connected to a condition monitoring system 16, a basic automation 17, a process automation 18 and a further automation or IT system 19.

At the transition of the monitored equipment 1 in a predetermined error condition, a message is generated by the alarm module 9. It can be provided that the condition

Monitoring system 16 detects the default error condition and causes the alarm module 9 to generate the message. Furthermore, the alarm module 9 can be used as part of the condition

Monitoring Systems 16 be executed. It is also conceivable that the arithmetic unit 10, the controller 13 and / or one of the automation systems 17, 18 or 19 instructs the alarm module 9 to output the message.

As soon as the message has been generated and the monitored equipment 1 is in the predetermined error state, the camera 2 is operated with predefined settings 21, which are stored in the main memory 11 of the arithmetic unit 10. This can be achieved, for example, by sending the message to the controller 13, which outputs a command via the arithmetic unit 10 to an actuator 12 connected to the camera 2. If the actuator 12 has received the command, it ensures that the camera 2 is operated with the previously defined settings 21.

The acquired optical data are stored in a memory 3 connected to the arithmetic unit 11, wherein the memory 3 is furthermore connected to a network 5, which has a web server 8 and an archive 4. In this case, the archive 4 is connected from the memory 3 via an internal firewall 7, which prevents unauthorized data traffic. The memory 3 is designed, for example, as a ring memory, which continuously records the optical data of the camera 2 and in each case overwrites the oldest optical data stored in the ring memory. In addition to the memory 3, a part of the optical data is also stored in the archive 4. In particular, that part of the optical data stored in the archive 4, which passes while the monitored equipment 1 in the predetermined error state passes through the camera 2. In addition, it is also possible to store those optical data in the archive 4 which are detected by the camera 2 within a predefinable time interval before and / or after the monitored equipment 1 changes into the predetermined error state.

In the archive 4, in addition to the aforementioned optical data, information about the predetermined error state can be stored. The information can be, for example, such that the predefined error state can be identified directly from it. In particular, it can therefore contain the generated message. Furthermore, the information may include information about the time of the transition to the predetermined error state, for example in the form of a time stamp, and / or how long the predetermined error state has been present. Thus, the optical data of the predetermined error state can also be retrieved later by means of the time stamp. In addition, further context information can be included in the stored information, such as a meaningful context information on the operating mode of the monitored equipment 1 and / or the technical system, further information of the condition monitoring system 16 and / or the aforementioned automation systems 17, 18 or 19.

The network 5 with the archive 4 and the web server 8 is still accessible via an external firewall 6 from outside the network 5. For example, the archive 4 can be accessed by means of a PC 22, a tablet 23 or a smartphone 24. Appropriate authorizations must be available for such access and, if necessary, identification and authentication procedures must be run through. In a transition of the monitored equipment 1 in the predetermined error state, a report can be created, which includes the said information together with the optical data, which were detected in a transition to the predetermined error state.

Likewise, it can be provided to synchronize and reproduce the optical data stored in the memory 3 and / or in the archive 4 with a time-variable size.

In addition, it is possible to provide not only a camera 2, but a camera system which comprises a plurality of cameras 2, wherein each individual camera 2 and / or groups of cameras 2 of the camera system can be controlled and respectively operated with the previously defined settings 21 can be.

In summary, the invention relates to a method for monitoring equipment of a technical facility. Furthermore, the invention relates to a system, a controller, a computer program and a computer program product for monitoring a technical equipment. In order to ensure a reliable collection of relevant data in the event of equipment failure, it is proposed that at least one camera acquire optical data of at least a portion of the equipment, and if the monitored equipment transitions to a predetermined fault condition, a message is generated wherein the at least one camera is operated with pre-defined settings when the monitored equipment is in the predetermined fault condition.

Other aspects of the present invention are that in a single automation / IT system of a plant are often not all the data necessary for the interpretation of an alarm or error message. Visual information from surveillance cameras may be present during interpretation provide valuable information. The operation of the camera system and (if controllable) the control of the cameras are eliminated in the control room. If the interpretation of the data is not directly in the control room (eg at the manufacturer of the plant, a

Service providers) or after the occurrence of the event (e.g., after a shift change), camera images provide important additional information that is not available through automation systems (and thus reports). In the process, filming surveillance screens in the control room with high-resolution cameras can be a less expensive method of making data available for error analysis, since accessing the data and integrating the systems are usually very costly. It may therefore be possible to avoid costly software integrations.

By archiving the image and video data on a separate system without direct access to the camera system can be accessed via VPN employees or external companies access, without making internal networks vulnerable or access to real-time images to provide information enable sensitive information and are unrelated to the cause of the problem.

By mapping internal policies or privacy and employee monitoring laws, legal concerns about the system's storage and access can be ruled out. The integration of the camera system in the automation makes it possible to access camera data synchronously during the error correction. Due to the careful consideration of data protection and know-how protection, it is easier to install such systems as a system builder at customers and to get the necessary access to such systems.

Claims

claims

1. Method for monitoring equipment (1) of a technical installation,

wherein at least one camera (2) captures optical data of at least part of the equipment (1),

wherein, if the monitored equipment (1) transitions to a predetermined fault condition, a message is generated,

- Wherein the at least one camera (2) is operated with predefined settings (21) when the monitored

Equipment (1) is in the predetermined fault condition,

- Wherein the optical data of the at least one camera (2) are stored continuously in a memory (3) and

- Wherein at least a portion of that optical data, which during the monitored equipment (1) in the predetermined error state passes, are detected by the at least one camera (2), and at least a part of those optical data which within a predetermined time interval before and / or after the monitored equipment (1) passes into the predetermined error state by which at least one camera (2) is detected, are stored in an archive (4).

2. The method according to claim 1,

wherein the predefined settings (21) comprise a lens focal length, an angle of view, an aperture width, an exposure time, a frequency band and / or a specific orientation of the at least one camera (2).

3. The method according to any one of the preceding claims, wherein at least the in the archive (4) stored optical data are linked to an information on the default error state and

wherein the information on the predetermined error state is stored at least in the archive (4).

4. The method according to claim one of the preceding claims, wherein a report is generated if the monitored equipment (1) transitions to a predetermined error state, the report comprising at least the optical data stored in the archive (4) and the information on the predetermined error state.

5. The method according to claim 4,

wherein access authorization information is stored and wherein a user and / or software can access the optical data and / or the report only if it is defined in the access authorization information that the user and / or the software is authorized to access the optical data and / or the report.

6. The method according to any one of the preceding claims, wherein the archive (4) in a network (5) is arranged, which by means of a firewall (6, 7) is protected and accessible by means of a web server (8) from outside the network (5) is.

7. The method according to any one of the preceding claims, wherein the stored in the memory (3) and / or in the archive (4) optical data synchronized with a time variable size and reproduced.

8. System for monitoring equipment (1) of a technical installation comprising

at least one camera (2) for acquiring optical data of at least part of the equipment (1),

an alarm module (9) for generating a message if the monitored equipment (1) changes to a predetermined error state,

a computing unit (10) and a main memory (11) on which pre-defined settings (21) can be stored with which the at least one camera (2) is operable when the monitored equipment (1) changes into the predetermined error state, an actuator (12) at least partially integrated and / or connected to the camera, which is connected to the arithmetic unit (10) and by means of which the at least one camera (2) with the previously defined settings ( 21) is operable when the monitored equipment (1) is in the predetermined fault condition, and

- A memory (3) in which the optical data of the at least one camera (2) are continuously stored, wherein at least a portion of that optical data, which during the monitored equipment (1) in the predetermined error state passes through the at least one camera (2) can be detected, as well as at least a part of those optical data which within a predefinable time interval before and / or after the monitored equipment (1) passes into the predetermined error state by which at least one camera (2) can be detected, in an archive (4) can be stored.

9. Control (13) for a system according to claim 8 for carrying out a method according to one of claims 1-7.

10. Computer program (14) for carrying out a method according to one of claims 1 - 7 when running in a controller (13) according to claim 9.

11. Computer program product (15) on which a computer program (14) according to claim 10 is stored.