EP1984795A1 - Procede et dispositif de surveillance d'une ligne de production - Google Patents

Procede et dispositif de surveillance d'une ligne de production

Info

Publication number
EP1984795A1
EP1984795A1 EP06819009A EP06819009A EP1984795A1 EP 1984795 A1 EP1984795 A1 EP 1984795A1 EP 06819009 A EP06819009 A EP 06819009A EP 06819009 A EP06819009 A EP 06819009A EP 1984795 A1 EP1984795 A1 EP 1984795A1
Authority
EP
European Patent Office
Prior art keywords
image sequence
determined
test image
objects
deviation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP06819009A
Other languages
German (de)
English (en)
Inventor
Martin KÄSEMANN
Stefan Strathmann
Helmut Herrmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Henkel AG and Co KGaA
Original Assignee
Henkel AG and Co KGaA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Henkel AG and Co KGaA filed Critical Henkel AG and Co KGaA
Publication of EP1984795A1 publication Critical patent/EP1984795A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00Testing or monitoring of control systems or parts thereof
    • G05B23/02Electric testing or monitoring
    • G05B23/0205Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0218Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
    • G05B23/0224Process history based detection method, e.g. whereby history implies the availability of large amounts of data
    • G05B23/0227Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions
    • G05B23/0235Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold

Definitions

  • the invention relates to a method and a device for monitoring a production line.
  • the individual steps of filling, closing, labeling and further packaging are usually carried out in a production line by several machines.
  • the containers are transported from one machine to the next.
  • Transport belts, screw conveyors or similar devices are used for the transport, with which the containers or products are transported individually from one machine to the next.
  • the solid or liquid products are filled into the containers at the highest possible cycle rate.
  • several hundred containers are filled, labeled and packed per minute and, accordingly, transported quickly between the individual machines.
  • trouble-free transport of the products or containers is essential. If, for example, containers are transported to a machine by means of a conveyor belt and if one of the containers is not delivered to the machine in a position from which the machine can further process the container, the machine and thus the production line can be blocked by this container.
  • Typical malfunctions when transporting the containers or products between the machines are, for example, placement outside the permissible limits on the conveyor belt or twisting or tilting or overturning on a conveyor belt Conveyor belt.
  • the causes of such faults can be, for example, unexpectedly high tolerances in the geometric dimensions of the objects to be transported, incorrect setting of transport or handling systems or causes that change over time, such as vibrations, fluctuating climatic conditions or signs of wear.
  • WO01 / 50204 describes a method and system for monitoring a production line, in which sensors on the production line to be monitored record production data and deliver it to a computer system which compares the supplied data with preset limit values and, in the event of deviations, in a suitable manner on a screen for these displays the monitored production line.
  • the system records, for example, the quantity of goods ejected from a machine or a conveyor belt and reports this to the computer system.
  • KR 2003053731 describes a device for monitoring a conveyor belt on which objects are transported. To monitor the conveyor belt, it has a current measuring device on its electric drive. A deviation in the current strength is interpreted as an indicator of a fault.
  • the methods and systems for monitoring a production line known from the prior art thus already detect the effects of a malfunction, for example a reduction in the output of a conveyor belt or a change in the operating parameters of a machine. Although this information is helpful for determining the cause, it is only possible to draw a limited conclusion about the cause of the fault.
  • the object of the invention is therefore to propose a method and a device with which the causes of a fault in a production line can be detected.
  • a reference image sequence is first generated, which maps at least one area of a transport path to be monitored between the machines of a production line.
  • This reference image sequence shows the trouble-free operation of the part of a production line to be monitored in a period of suitable length.
  • the reference image sequence not only captures a period of time in which the production line to be monitored is operated without problems, but in which the area to be monitored is operated with ideal parameters, so that it is ensured that the system is not operated at the limit of an operating parameter becomes.
  • a digital camera with a CCD or CMOS chip can be used to generate the reference image sequence, with which the desired part of a production line is captured in an image-generating manner and from which the individual images of an image sequence are supplied to a connected computer via a connection will.
  • an image sequence could initially also be generated with a conventional analog camera, the images being digitized in a later method step.
  • An image sequence could furthermore be composed of several partial sequences that cover different areas of a production line at a time in order to be subsequently processed as a whole. In this way, a production line could be completely recorded and monitored.
  • the reference image sequence generated in this way is first stored on the computer and evaluated in a subsequent method step.
  • This evaluation in a later method step includes the determination of a statistical parameter derived from the movement of the objects, for example the speeds of the objects transported between the machines, that is to say the products to be packaged or the packagings or the packaged and further processed products.
  • the statistical parameter derived from the movement of an object is the speed of an object.
  • the acceleration as occurs, for example, when the direction of a movement of an object changes, can be determined and processed as a statistical parameter derived from the movement of an object.
  • the speed of an object is assumed below as the statistical parameter derived from the movement of the object.
  • the statistical parameter for example the speed of a moving object in one direction, is determined using known algorithms by first determining corresponding pixels in successive images, for example on the basis of their color or gray value. Since the time period between the successive images is known, the speed of the imaged object can be determined by moving the image points. The determined speeds of the transported objects are then saved for further use. In this way, for each place the whole in the Transport image shown in the reference image sequence determines the speed of a transported product.
  • the statistical parameter of an object is advantageously determined for each location on the transport route, so that the entire length of the transport route is monitored without gaps.
  • the reference image sequence must record a sufficiently long period of trouble-free operation so that a sufficiently large amount of data is available for the determination of the speeds in order to be able to calculate temporal averages of the speeds.
  • a test pattern sequence is generated.
  • the camera delivers the generated images to the computer, which summarizes them in test image sequences of a predetermined length.
  • the test pattern sequence starts the operation of the production line within a period of time, which may have a situation that can be recognized as different below. This divides the entire monitoring time into sections.
  • a test pattern sequence is generated for each time period, which is further processed in the further steps of the test method.
  • the test image sequence Since the method compares information from the test image sequence with corresponding information from the reference image sequence in a later method step in order to determine a deviation of the test image sequence from the ideal state or fault-free state, the test image sequence must map the same machines and conveyor belts as the reference image sequence.
  • the image sections when generating the reference and test image sequence and the image repetition rates of the camera are advantageously identical.
  • the speeds of the objects in the test pattern sequence are now determined in a further method step analogous to the determination of the speeds in the reference image sequence.
  • the speed at the current location of the object is determined.
  • the same algorithm is preferably used as was used to determine the speeds in the reference image sequence.
  • the determined speeds of the objects in the test image sequence are compared in a further method step with the speed values determined for the reference image sequence. If deviations between the speeds are determined in this comparison, this indicates a possible cause of a fault.
  • a deviation in the speed of an object can be, for example, a jam of objects in front of a machine that takes the objects off the belt.
  • the method determines those locations where the actual speed of an object deviates from that which the object had at this location during the trouble-free reference operation, namely during the generation of the reference image sequence.
  • the process thus enables permanent automatic monitoring of a production line.
  • a deviation is only evaluated as a deviation in the comparison if the size of the deviation exceeds a preset limit value. A detected deviation that is below the preset limit value is therefore not considered a relevant deviation.
  • a tolerance range is defined for the speeds, so that only the speed deviations that are known from experience are evaluated as relevant and treated accordingly.
  • Speed deviations are advantageously marked in the test pattern sequence in such a way that each location of a test pattern sequence is marked at which a deviation in the speed between objects of the test sequence and the reference image sequence was determined.
  • the location can, for example, by specifying the X and Y coordinates in the Image can be given.
  • the location of a deviation on a display screen can also be marked in color by the location of the deviation being highlighted in a striking color. If, for example, the image area in which no deviation was found is highlighted in green, this area can be highlighted in red to indicate a detected speed deviation.
  • the ascertained speed deviation can advantageously be displayed by specifying the direction and the amount of the determined deviation and / or by specifying the speed components in the X and Y axis directions, the X and Y axes of the generated images being used as a coordinate system for display serve the speed deviations.
  • test pattern sequence for which a relevant speed deviation has been determined is then saved. If several test pattern sequences with relevant speed deviations are determined in quick succession, the last determined test pattern sequence can always be shown on a display. Older test pattern sequences can, however, also be displayed, if desired, so that the information is available for a later error analysis over several test pattern sequences. Test pattern sequences for which no relevant speed deviations have been determined can, however, be deleted or are not saved.
  • the method can advantageously have the method step that, after the generation of the reference image sequence, the largest contiguous moving image area is determined therein and subsequent method steps are carried out exclusively for this image area.
  • the camera typically cannot only record only those areas in which objects are transported from one machine to another.
  • the largest contiguous area in which objects are moved is determined after the generation of the reference image sequence. This is the area of the conveyor belt to be monitored. Other areas where, for example, machine parts are moving and people move are not considered any further. On the one hand, this results in a reduction in the amount of data to be processed, and on the other hand, the method is thus insensitive to movements that do not take place in the area to be checked, that is to say in the area of the conveyor belt.
  • the temporal variance of the color or gray value is determined for each pixel of all images in an image sequence by measuring the color or gray value. Only if this is significantly above the statistical noise level is this regarded as the movement of objects and the area is treated accordingly. Image areas in which the temporal variance of color or gray values of pixels lies below the statistical noise level are masked for the subsequent method steps and are not taken into account.
  • the largest coherent moving image area determined can be marked in the reference and test image sequences, in particular highlighted in color. When the image sequences are displayed, this enables a simple and quick check as to whether the image section determined as relevant has been correctly determined.
  • those image areas in which the color values of individual pixels fluctuate considerably over time can advantageously be marked as not relevant and thus be disregarded in subsequent method steps.
  • image areas it is only possible with a disproportionately high amount of computation and thus time to determine the movement of an object and thus its speed of movement.
  • the monitoring system should process the evaluation of the generated test image sequences as quickly and as quickly as possible, so that a display or other reaction to a determined speed deviation can occur as soon as possible, complex algorithms for determining the speed of an object in a region of strongly changing colors are unsuitable here .
  • Such image areas are therefore advantageously marked as irrelevant for subsequent process steps.
  • such areas are caused by light reflections on the transported objects or by moving surfaces of liquids in transparent containers.
  • a device which has at least one camera for generating the images and a computer connected to the camera.
  • the camera can be controlled via the connection to the computer in such a way that the generation of the images is triggered and controlled by the computer and the images are then transferred to the computer. All further processing steps are carried out on the computer.
  • the method can be represented in a computer program which can carry out all method steps of the method, trigger the generation of the images in the camera and control the image settings.
  • the generated images or image sequences as well as determined speed deviations can be displayed on a screen. You can manually intervene in the program at any time. For example, the evaluation of the reference image sequence, in particular the determination of the largest contiguous moving area, can be checked by one person.
  • the computer program can be designed in such a way that the images for the next test pattern sequence are already generated and transmitted to the computer during the processing of a test pattern sequence, so that continuous monitoring is possible.
  • a portable computer for example a laptop
  • a portable black and white CCD camera which can be used together as a mobile system without a time-consuming installation, has proven itself as a computer.
  • this mobile system enables monitoring of machines or conveyor belts that have not yet been monitored or for which a permanently installed monitoring system is too complex and whose economic benefits are therefore questionable.
  • the method according to the invention is described in more detail below using an exemplary embodiment. Show it:
  • Fig. 1 is a schematic representation of a production line
  • Monitoring device Fig. 2 is a schematic representation of the largest contiguous moving
  • Fig. 1 shows a schematic representation of a production line 1 with the monitoring system.
  • the production line has a first machine 2 and a second machine 3, which in this exemplary embodiment are a filling machine 2 and a labeling machine 3.
  • the filling machine 2 fills the bottles 5 with a liquid.
  • a conveyor belt 4 transports objects 5, here transparent bottles 5, in the direction indicated by arrow 6 first to the filling machine 2, then to the labeling machine 3.
  • the monitoring system has a camera 7 for generating the reference and test image sequences, which is connected to a computer 8.
  • the camera 7 is positioned such that it captures the section of the conveyor belt 4 to be monitored from a position elevated relative to the conveyor belt 4.
  • the generated image sequences thus show a supervision of the part of the production line 1 to be monitored or the part of the conveyor belt 4 to be monitored.
  • the camera 7 records the area delimited by the frame 9 drawn in broken lines, which comprises a piece of the conveyor belt 4 which transports bottles 5 from the filling machine 2 to the labeling machine 3.
  • the image sequences generated by the camera 7 thus represent the section of the conveyor belt 4 to be monitored between the machines 2, 3.
  • the camera 7 At the beginning of the method, the camera 7 generates the images for the reference image sequence, which reproduces the trouble-free and ideally possible transportation of the bottles 5.
  • the reference image sequence usually has a duration of a few seconds to a few minutes, typically 60 seconds. For this period of time is through Manual checking ensures that the transport of the bottles 5 by means of the conveyor belt 4 runs smoothly and with ideal parameters.
  • the camera 7 is set so that it generates the images for the reference image sequence with a sufficiently high image frequency so that the movement of the bottles 5, which are the objects of interest here, can be clearly tracked on the conveyor belt 4 to be monitored using the images .
  • the image frequency should preferably be set so that an object moves by a maximum of 4 pixels between two images.
  • the camera should generate the image sequences with more than 50 images per second.
  • the images of the reference image sequence are transmitted from the camera 7 to the computer 8, which takes over the entire further processing of the images.
  • the computer first determines the areas in which any movement takes place. On the one hand, this is the area in which the bottles 5 are moved by means of the conveyor belt 4. On the other hand, moving machine parts or a moving person can be depicted in the image sequences. The image sections recognized as moving image areas can be displayed on the screen of the computer 8 so that they can be checked so that they can be checked.
  • FIG. 2 shows the image section delimited by the dashed frame 9, which the camera 7 records from its position.
  • the computer 8 has determined the largest contiguous moving image area 10 for all images and thus all image sequences that are generated from this position of the camera 7.
  • This image area 10 is marked visibly on the screen of the computer 8, for example by the background being colored.
  • the largest contiguous moving image area 10 is marked by hatching.
  • the marking of this image section which the computer 8 has determined as the largest contiguous moving area 10, applies to all images of the reference image sequence and the test image sequences, so that the determination of this area only has to be carried out once at the beginning of the method using the reference image sequence.
  • FIG. 3 shows a graphic representation of the determined speeds of the transported bottles 5 in the horizontal direction of the image and along the transport path.
  • the X axis of the coordinate system indicates the location in the X direction along the conveyor belt 4.
  • the value of the speed in the X direction that is to say the speed component Vx, is indicated on the Y axis of the graphic.
  • the hatched line 11 indicates the speeds Vx of the bottles 6, which were determined on the basis of the reference image sequence.
  • the entire length of the conveyor belt 4 shown in the pictures is divided into sections 4a to 4e by the curves 12a to 12d.
  • the speeds of the bottles 5 are greatest and almost the same in the reference image sequence.
  • the magnitude of the speed in the X direction decreases sharply.
  • the speeds of the bottles 5 are considerably lower, but not zero, since the camera captures an oblique view of these route sections.
  • the speeds are also determined in the transport direction perpendicular thereto, which runs into the paper plane in the representations and is not shown here.
  • the speeds are averaged over time.
  • a spatial averaging is also conceivable, in which the averaging or the determination of a statistical parameter takes place over an image area defined around a pixel to be considered.
  • a spatio-temporal averaging could be carried out in which a plurality of successive images of a sequence and of these an image area around a pixel to be considered are used to determine the statistical parameter.
  • a first-order statistical parameter i.e. a temporal averaging of the speed value
  • statistical parameters of a higher order for example the standard deviation or variance, or statistical parameters of a third or even higher order can be used as a reference value for determining a deviation from the ideal case.
  • the invention is explained below on the basis of speed deviations.
  • the speeds determined in this way on the basis of the reference image sequence are stored and serve as reference values for the test image sequences to be subsequently generated.
  • test image sequences can subsequently be generated and evaluated.
  • test image sequences are now generated which show the conveyor belt during normal operation. The faults should be recognized early on using the test pattern sequences.
  • test image sequences are generated with the same camera settings and from the same position as the reference sequence, so that the test image sequences can be compared with the reference image sequence.
  • a test pattern sequence has a duration of a few seconds to a few minutes, the duration of the test pattern sequence being able to deviate from the duration of the reference pattern sequence.
  • the Test image sequences are contiguous to one another so that the area to be monitored is monitored without interruption during monitoring.
  • the speeds of the bottles 5 along the transport path are then determined on the basis of the test image sequences.
  • the speeds or the speed components are preferably determined using the same algorithm that was used for the evaluation of the reference image sequence, so that deviations in speed values due to different determination methods can be excluded.
  • the speeds determined for a test image sequence are then compared with those of the reference image sequence in order to reveal deviations.
  • a determined speed deviation is shown in FIG. 3 as a solid line 13. This indicates that the speed of the bottles 5 in the X direction in front of the curve 12d and on the subsequent conveyor belt section 4e is lower than the reference speed. This means that the bottles 5 are transported from the location before the change of direction 12d to the labeling machine 2 more slowly than in the reference image sequence. However, since bottles 5 are transported at the reference speed to the location from which the transport speed is lower in the route sections lying in front of them, the bottles jam before the direction change 12d of the conveyor belt 4. As a further consequence of such a jam of bottles 5, they can jam or fall over, for example, and thereby trigger a fault in production line 1.
  • a transfer station that places the objects from a first to a second conveyor belt.
  • a station can, for example, essentially be designed as a rotating disk on which the objects are placed and are transported in a rotating manner to be placed on the second conveyor belt. If the rotational speed of the disc deviates from the ideal value, the bottles are thereby placed, for example, on an edge of the second conveyor belt.
  • This position of a bottle 5 on a conveyor belt 4 which deviates from the ideal state can, for example, cause a guide rail to touch, which could brake the bottle or not match the position of the bottle 5 expected by a further processing machine, so that this would cause malfunctions.
  • the non-ideal position of the bottle on the second conveyor belt can therefore be a result of a speed deviation on the one hand, and can also trigger a - further - speed deviation on the other.
  • the comparison of the speeds of the bottles 5 from the test image sequences with those from the reference image sequence over the observed transport route thus enables the exact determination of all locations at which the speeds differ from one another.
  • the location at which the speed of an object deviates from the reference speed for the first time and at which the chain of subsequent deviations and faults begins can thus be determined.
  • Test pattern sequences that have a deviation of the speeds from the reference speeds are permanently stored on a data carrier so that they are permanently available. Those test pattern sequences in which no speed deviation was found are deleted or not saved, since these only show the trouble-free operation and therefore do not provide any relevant information. Since a test pattern sequence lasts from a few seconds to a few minutes, the data volume to be saved is limited. Stored reference image sequences can be reloaded into the computer at a later time and can be used as a comparison for further test image sequences, which may be generated considerably later. However, the prerequisite for this is that the test image sequences are created with the camera settings with which the reference image sequence was created.
  • a reference image sequence can again serve as a reference after a longer time, for example a few days, weeks or months, in order, for example, to determine the changes in the speed values of a production line 1 between two points in time that are relatively long apart. For example, it can thus be determined for an uninterrupted production line 1 whether and, if so, which speed changes can be determined if it is operated over a long period of time.
  • the method thus enables permanent monitoring of a production line or a section thereof, the time and location of the first deviation being ascertained and stored as an image sequence. Furthermore, further measures can be triggered in the event of a detected fault.
  • the computer can be connected to a control system that controls production line 1, so that an alarm can be triggered in it or the machines of the production line can be influenced directly.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Automation & Control Theory (AREA)
  • Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
  • Length Measuring Devices By Optical Means (AREA)

Abstract

L'invention concerne un procédé et un dispositif de surveillance d'une ligne de production dans laquelle des objets (5) sont transportés entre des machines (2, 3) sur des parcours de transport (4). Pour détecter précocement et de manière précise des perturbations, ledit procédé comporte les étapes qui consistent (a) à produire une séquence d'images de référence qui représente au moins un parcours de transport (4) à surveiller entre des machines (2, 3), (b) à déterminer une grandeur statistique caractéristique dérivée du déplacement des objets (5) transportés entre les machines (2, 3), (c) à produire une séquence d'images de test qui représente le même parcours de transport (4) entre les machines (2, 3), (d) à déterminer une grandeur statistique caractéristique, dérivée du déplacement d'un objet (5), pour chacun des objets (5) représentéset (e) à comparer les grandeurs statistiques caractéristiques déterminées pour la séquence d'images de test aux grandeurs statistiques caractéristiques déterminées pour la séquence d'images de référence.
EP06819009A 2006-01-19 2006-12-08 Procede et dispositif de surveillance d'une ligne de production Withdrawn EP1984795A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102006002704A DE102006002704A1 (de) 2006-01-19 2006-01-19 Verfahren und Vorrichtung zur Überwachung einer Produktionslinie
PCT/EP2006/011821 WO2007082575A1 (fr) 2006-01-19 2006-12-08 Procede et dispositif de surveillance d'une ligne de production

Publications (1)

Publication Number Publication Date
EP1984795A1 true EP1984795A1 (fr) 2008-10-29

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Country Link
US (1) US20110019877A1 (fr)
EP (1) EP1984795A1 (fr)
DE (1) DE102006002704A1 (fr)
WO (1) WO2007082575A1 (fr)

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WO2007082575A9 (fr) 2007-11-15
WO2007082575A1 (fr) 2007-07-26
DE102006002704A1 (de) 2007-08-02
US20110019877A1 (en) 2011-01-27

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