JP2018128729A - Process monitoring apparatus, and control method and program for process monitoring apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process monitoring apparatus capable of efficiently maintaining information necessary for verifying the status of abnormality in a production process by a simple method.SOLUTION: A process monitoring apparatus comprises: video information acquiring means for acquiring video information obtained by taking video of a production process including a plurality of processes by a photographing device; abnormality information acquiring means for acquiring abnormality information in the production process; region setting means for setting a specific region from the entire photographing region to be photographed by the photographing device on the basis of the abnormality information acquired by the abnormality information acquiring means; extracting means for extracting specific video information in the specific region set by the region setting means out of the video information acquired by the video information acquiring means; and storage means for storing the specific video information extracted by the extracting means.SELECTED DRAWING: Figure 1

Description

  The present technology relates to a process monitoring apparatus, and more particularly to a process monitoring apparatus used in a production process in which a product is produced through a plurality of processes.

  In many production sites, a short stoppage of production equipment, a so-called chocolate stop, occurs on a daily basis. A chocolate stop is a short stop. It was restarted when the work was reset or the device was restarted, and it suddenly occurred and the reproducibility was low, so the cause of the occurrence was not fully verified.

  However, although the one stop time is short, the occurrence frequency is high, and the total time may be long, and the influence of the production loss due to the line stop may become large.

  In order to solve the above problem, there has been known an imaging apparatus for attaching a camera to an apparatus and recording an abnormality signal output from the apparatus as a trigger so as to record the state when the abnormality occurs and analyze the cause.

  On the other hand, it is difficult to predict in advance in which part of the apparatus an abnormality will occur. It is also conceivable that an abnormality occurs over a plurality of processes. Therefore, it is conceivable to shoot a plurality of areas using a plurality of cameras in order to record a state of a plurality of areas, or to shoot a plurality of steps using a high resolution camera.

  However, when shooting is performed assuming an operation for identifying the cause of the occurrence of abnormality, image data for a plurality of cameras or high-resolution image data needs to be recorded for a long time and must be retained. .

  Therefore, the necessary storage capacity is enormous, and the cost of the storage device may be high.

  Japanese Patent Application Laid-Open No. 2015-55990 (Patent Document 1) describes an image of only a time during which work is performed in a process when a continuous process is divided by a specified work time for each process and an abnormality occurs in the process A method for reducing data capacity by recording data is disclosed.

Japanese Patent Laying-Open No. 2015-55990

  However, in the above method, not only the process in which an abnormality has occurred but also the image data of the entire process is recorded, which is insufficient as an effect of reducing the data capacity.

  An object of the present technology is to provide a process monitoring apparatus that can efficiently hold information necessary for verification of an abnormal state of a production process by a simple method.

  A process monitoring device according to a certain aspect includes a moving image information acquiring unit that acquires moving image information obtained by photographing a production process including a plurality of steps with an imaging device, an abnormal information acquiring unit that acquires abnormal information in the production process, and an abnormal information acquiring unit. Based on the acquired abnormality information, area setting means for setting a specific area from all shooting areas to be imaged by the imaging device, and specific moving picture information in the specific area set by the area setting means among the moving picture information acquired by the moving picture information acquisition means Extraction means for extracting the image data, and storage means for storing the specific moving image information extracted by the extraction means.

  Preferably, the abnormality information includes assembly abnormality information generated in the assembly work, and the region setting means selects a specific region from among regions including a plurality of abnormality detection locations among all photographing regions based on the assembly abnormality information. Set.

  Preferably, the plurality of processes include a work process and an inspection process for the work process. The abnormality information acquisition means acquires abnormality information for the work process in the inspection process. The area setting means sets, as a specific area, work processes related to the inspection process in a plurality of processes from all imaging areas based on the abnormality information.

  Preferably, the production process is provided with a plurality of sensors respectively associated with the plurality of processes. The abnormality information includes information on sensor values exceeding a specified value. The area setting means sets, as a specific area, an area including a process related to a corresponding sensor among a plurality of processes from all imaging areas based on information on sensor values exceeding a specified value.

  Preferably, the abnormality information includes information regarding the worker. The area setting means sets an area including the worker as a specific area from all the imaging areas based on the abnormality information.

  Preferably, the abnormality information acquisition unit acquires a plurality of abnormality information at the same time. The area setting means sets a plurality of specific areas from the entire imaging area based on the plurality of abnormality information. The extracting means extracts a plurality of specific moving image information in a plurality of set specific areas from the moving image information. The storage unit stores the extracted plurality of specific moving image information in association with each other.

  Preferably, the region setting means sets a specific region having a size corresponding to the type of abnormality based on the abnormality information with reference to the center position of the abnormal part.

  Preferably, the entire photographing area is divided into a plurality of areas in a lattice shape. The area setting means sets one area as a specific area from among the divided areas based on the abnormality information.

  A method for controlling a process monitoring apparatus according to a certain aspect, comprising: obtaining video information for photographing a production process including a plurality of processes with a photographing apparatus; obtaining abnormal information in the production process; and based on the obtained abnormality information The step of setting a specific region from all the shooting regions photographed by the photographing device, the step of extracting the specific video information in the specific region set by the region setting means from the acquired video information, and storing the extracted specific video information And a step of performing.

  A program executed by a computer of a process monitoring apparatus according to a certain aspect, wherein the program is a moving picture information acquisition means for acquiring moving picture information in which a production process including a plurality of processes is photographed by a photographing apparatus, and abnormality information in the production process. Information acquisition means for acquiring image information, area setting means for setting a specific area from all shooting areas photographed by the imaging device based on the abnormality information acquired by the abnormality information acquisition means, and moving picture information acquired by the moving picture information acquisition means Among them, the extraction means for extracting the specific moving image information in the specific area set by the area setting means, and the storage means for storing the specific moving image information extracted by the extraction means.

  It is possible to efficiently hold information necessary for verification of the abnormal situation of the production process by a simple method.

1 is an overall configuration diagram illustrating a process monitoring system 1 based on Embodiment 1. FIG. It is a figure which illustrates notionally the flow of a process of the process monitoring system 1 based on Embodiment 1. FIG. It is a flowchart explaining the control method of the process monitoring apparatus based on Embodiment 1. FIG. It is a figure which illustrates notionally the flow of a process of the process monitoring system 1 based on the modification of Embodiment 1. FIG. It is a figure which illustrates notionally the flow of a process of the process monitoring system 1 based on Embodiment 2. FIG. It is a figure which illustrates notionally the flow of a process of the process monitoring system 1 based on Embodiment 3. FIG. It is a figure which illustrates notionally the flow of a process of the process monitoring system 1 based on Embodiment 4. FIG. It is a figure which illustrates notionally the flow of a process of the process monitoring system 1 based on the modification 1 of Embodiment 4. FIG. It is a figure which illustrates notionally the flow of a process of the process monitoring system 1 based on the modification 2 of Embodiment 4. FIG. It is a figure which illustrates notionally the process of the process monitoring system 1 based on Embodiment 5. FIG. It is a figure which illustrates notionally the process of the process monitoring system 1 based on Embodiment 6. FIG. It is a figure which illustrates notionally the process of the process monitoring system 1 based on the modification of Embodiment 6. FIG.

  Embodiments of the present invention will be described in detail with reference to the drawings. In addition, about the same or equivalent part in a figure, the same code | symbol is attached | subjected and the description is not repeated.

(Embodiment 1)
FIG. 1 is an overall configuration diagram illustrating a process monitoring system 1 based on the first embodiment.

  As shown in FIG. 1, the process monitoring system 1 includes an imaging device 40 provided for the production line 5, switches SW <b> 1 to SW <b> 3 that output abnormal signals, and a process monitoring device 10.

  The production line 5 is provided with a plurality of processes. In this example, the case where work is performed in the order of process A, process B, and process C is shown as an example. Further, an abnormality detection device is provided corresponding to each of the processes A, B, and C. In this example, switches SW1 to SW3 (generally referred to as switches SW) for outputting an abnormality signal are provided as an example of the abnormality detection device. For example, when the inspector operates the switch SW, an abnormal signal is output to the process monitoring apparatus 10. Further, the process of the production line 5 may be interrupted by operating the switch SW.

  When the inspector operates the switch SW1, an abnormal signal related to the process A is output to the process monitoring apparatus 10. When the switch SW2 is operated, an abnormal signal related to the process B is output to the process monitoring apparatus 10. When the switch SW3 is operated, an abnormal signal related to the process C is output to the process monitoring apparatus 10.

  The photographing device 40 is disposed at a position where the process A, the process B, and the process C of the production line 5 can be photographed. The imaging area of the imaging device 40 includes image data relating to the operations of the process A, the process B, and the process C.

  The imaging device 40 outputs moving image data (moving image information) taken for the production line 5 to the process monitoring device 10. Note that the moving image data may be a plurality of still image data arranged in time series.

  The process monitoring apparatus 10 in this example receives the moving image data from the imaging apparatus 40 and efficiently stores information necessary for verifying the abnormal state of the production line 5. Specifically, a part of the moving image data of the moving image data from the imaging device 40 is stored. Specifically, an area to be extracted from all the shooting areas is specified, and moving image data of the specified area (specific area) is stored.

  Therefore, it is possible to store information necessary for efficiently storing moving image data in a specific area, instead of storing all moving image data.

  In this example, a configuration in which the imaging device 40 and the abnormality detection device are provided separately from the process monitoring device 10 will be described. However, the present invention is not limited to this, and at least one of the imaging device 40 and the abnormality detection device is a process monitoring device. It may be incorporated as part of

  The process monitoring device 10 includes a CPU (Central Processing Unit) 11, a storage device 30, and a temporary storage device 32. As an example, the storage device 30 can use an HDD (Hard Disc Drive). As an example, the temporary storage device 32 can use a RAM (Random Access Memory).

  The CPU 11 can realize a plurality of functional blocks by executing a program stored in the storage device 30. Specifically, the CPU 11 includes a reproduction unit 12, an area setting unit 14, an abnormality information acquisition unit 16, an extraction unit 18, a storage unit 20, and a moving image information acquisition unit 22. Although not shown, it is possible to realize a configuration in which the functional block is realized in cooperation with an external server.

  The playback unit 12 plays back the moving image information stored in the storage device 30. As an example, it is reproduced and displayed on a display unit (not shown).

  The moving image information acquisition unit 22 acquires moving image data shot by the shooting device 40. The moving image information acquisition unit 22 stores the acquired moving image data in the temporary storage device 32. The temporary storage device 32 is provided with an area for storing moving image data for a predetermined period, and can be overwritten and updated at any time.

The abnormality information acquisition unit 16 receives input of abnormality signals from the switches SW1 to SW3.
The area setting unit 14 specifies an area to be extracted from the imaging area of the imaging device 40 based on the input of the abnormality signal from the abnormality information acquisition unit 16 and sets the specific area.

  The extraction unit 18 extracts the specific moving image data of the set specific area from the moving image data acquired by the moving image information acquisition unit 22 stored in the temporary storage device 32.

  FIG. 2 is a diagram conceptually illustrating a process flow of the process monitoring system 1 based on the first embodiment.

  As shown in FIG. 2, in this example, a case where an abnormality has occurred in process B is shown.

  Specifically, the case where the inspector operates the switch SW2 is shown. In this case, the abnormality information acquisition unit 16 receives an input of an abnormality signal from the switch SW2. Accordingly, the abnormality information acquisition unit 16 notifies the region setting unit 14 that there is an abnormality signal from the switch SW2. The area setting unit 14 sets a specific area based on the notification of the abnormal signal from the switch SW2.

  Of the imaging areas to be imaged by the imaging device 40, the areas to be extracted with respect to the processes A, B, and C are set in advance. In this example, the area setting unit 14 sets the area related to the process B as the specific area in accordance with the notification of the abnormal signal from the switch SW2.

  The extraction unit 18 extracts specific moving image data of a specific region including the process B set by the region setting unit 14 with respect to the moving image data stored in the temporary storage device 32.

The storage unit 20 stores the extracted specific moving image data in the storage device 30.
FIG. 3 is a flowchart for explaining the control method of the process monitoring apparatus according to the first embodiment.

  As shown in FIG. 3, the CPU 11 acquires moving image information (step S2). Specifically, the moving image information acquisition unit 22 receives input of moving image data from the imaging device 40. The moving image information acquisition unit 22 stores the acquired moving image data in the temporary storage device 32 as needed.

  Next, the CPU 11 determines whether there is abnormality information (step S4). Specifically, the abnormality information acquisition unit 16 determines whether or not an abnormality signal is input from the switch SW.

  In step S4, if the CPU 11 determines that there is no abnormality information (NO in step S4), the CPU 11 returns to step S2 and continues to acquire moving image information.

  On the other hand, if the CPU 11 determines in step S4 that there is abnormality information (YES in step S4), it sets a specific area (step S6). Specifically, when the abnormality information acquisition unit 16 receives an input of an abnormality signal, the abnormality information acquisition unit 16 notifies the region setting unit 14 that there is an abnormality signal. The area setting unit 14 sets a specific area to be extracted from the imaging area based on the notification of the abnormal signal. The area setting unit 14 outputs information regarding the set specific area to the extraction unit 18.

  Next, the CPU 11 extracts specific moving image information (step S8). Specifically, the extraction unit 18 is set out of the moving image data acquired by the moving image information acquisition unit 22 stored in the temporary storage device 32 based on the information related to the specific region set by the region setting unit 14. Extract specific video data in a specific area. The extraction unit 18 outputs the extracted specific image data to the storage unit 20.

  Next, the CPU 11 stores the extracted specific moving image information (step S10). Specifically, the storage unit 20 stores the extracted specific moving image data in the storage device 30.

Then, the process ends (END).
By this processing, it is possible to store information necessary for efficiently storing moving image data in a specific area in the storage device 30 instead of storing all moving image data.

  In this example, the case where the switches SW1 to SW3 are provided as an abnormality detection device has been described as an example. However, the present invention is not limited to this, and a sensor (abnormality detection sensor) that detects an abnormality may be used. For example, a proximity sensor, an area sensor, or the like can be used. It is also possible to input the abnormality signal of the sensor to the abnormality information acquisition unit 16 and execute the same processing as described above.

  Further, the abnormality information acquisition unit 16 receives not only input from the abnormality detection device but also sensor value data of a sensor that detects the rotation speed, current value, and the like of the motor as input, and performs each process based on the input value. It is also possible to acquire the abnormal information. Specifically, the abnormality information acquisition unit 16 can acquire abnormality information when the input value exceeds a specified value.

  Alternatively, the abnormality information acquisition unit 16 may acquire abnormality information using captured moving image data. Specifically, it may be determined whether there is an abnormality in the image data captured by the image analysis process, and the abnormality information may be acquired.

  FIG. 4 is a diagram conceptually illustrating a process flow of the process monitoring system 1 based on the modification of the first embodiment.

  As shown in FIG. 4A, a case where each process is divided into a grid by a cell production method or the like is shown. Specifically, the case where the process A to the process I are allocated corresponding to each of the nine areas R1 to R9 is shown. In this case, a setting area is set in advance corresponding to each area.

  As shown in FIG. 4B, in this example, it is assumed that the abnormality information acquisition unit 16 has detected an abnormality in the process F. The area setting unit 14 sets the area of the area R6 corresponding to the process F as a specific area.

  The extraction unit 18 extracts the specific moving image data of the specific region of the area R6 set by the region setting unit 14 with respect to the moving image data stored in the temporary storage device 32.

The storage unit 20 stores the extracted specific moving image data in the storage device 30.
With this method, it is possible to manage the status of occurrence of abnormality for each area, and it is possible to easily acquire information necessary for verification of the status of abnormality in the production process. Thereby, subsequent data management and statistical processing can be simplified.

(Embodiment 2)
FIG. 5 is a diagram conceptually illustrating a process flow of the process monitoring system 1 based on the second embodiment.

  As shown in FIG. 5, in this example, the case where the process A, the process B, and the process C are respectively a cleaning process, a filling process, and a packing process is shown as an example.

  In this example, the case where the toner bottle TB is sequentially conveyed to each process via the conveyor CB is shown.

  In this example, the cleaning process of the toner bottle TB is executed in the cleaning process. In the filling process, an operation of filling the toner bottle TB with toner is performed. In the packing process, an operation for packing the toner bottle TB is performed.

  In this example, line sensors are arranged at both ends of the process, and the passing time of the toner bottle TB by the conveyor CB is measured. Specifically, line sensors LS0 to LS2 (also collectively referred to as line sensors LS) are arranged. A line sensor LS0 is disposed at the tip of the cleaning process. A line sensor LS1 is disposed at the tip of the filling process. A line sensor LS2 is disposed at the tip of the packing process.

  Each line sensor LS is connected to the process monitoring device 10. The abnormality information acquisition unit 16 of the process monitoring device 10 receives an input of a detection signal from the line sensor LS. Then, the abnormality information acquisition unit 16 measures the passing pitch time of the toner bottle TB that passes between the line sensors LS. Specifically, a passing pitch time PT1 from passing through the line sensor LS0 to passing through the line sensor LS1 and a passing pitch time PT2 from passing through the line sensor LS1 to passing through the line sensor LS2 are measured. To do.

  Each passage pitch time is provided with an upper limit time in advance. The upper limit time of the passage pitch time PT1 is set to 50 sec. The upper limit time of the passing pitch time PT2 is set to 57 seconds.

  In this example, the abnormality information acquisition unit 16 detects whether or not the passing pitch time in each step of the toner bottle continuously exceeds the upper limit time. Judge that an abnormality has occurred.

  As a specific example, in this example, the passing pitch time when the toner bottle passes the line sensor LS four times in each step is shown.

  In this example, in the cleaning process, it is shown that the passage pitch time PT1 is within the upper limit time in all four times.

  On the other hand, in the filling process, the case where it is detected that the passage pitch time PT2 in the third and fourth times continuously exceeds the upper limit time is shown.

In this case, it is determined that an abnormality has occurred in the filling process.
The abnormality information acquisition unit 16 notifies the region setting unit 14 that there is an abnormality in the filling process based on the measured passing pitch time according to the input of the line sensor LS.

  The area setting unit 14 sets a specific area based on the notification of abnormality in the filling process. Specifically, an area related to the filling process is set as a specific area in the imaging area captured by the imaging device 40.

  The extraction unit 18 extracts specific moving image data of a specific region including the filling process set by the region setting unit 14 with respect to the moving image data stored in the temporary storage device 32.

The storage unit 20 stores the extracted specific moving image data in the storage device 30.
By this processing, not all moving image data is stored, but a process that causes an abnormality is specified, and information necessary for efficiently storing moving image data in a specific area can be stored in the storage device 30. Is possible.

  In this example, the method of determining whether or not an abnormality has occurred based on whether or not the upper limit time is exceeded twice in succession has been described. However, the number of times can be appropriately changed in design.

(Embodiment 3)
In the first embodiment, the method of extracting the moving image data at the position where the abnormality is detected as the specific image data when the abnormality is detected has been described.

  On the other hand, the production line 5 may be divided into a work process and an inspection process for the work process. If an abnormality is detected in the inspection process, even if the inspection process area is set as the specific area and the specific image data is extracted, the information may not be a necessary part for the abnormal situation verification. is there.

  FIG. 6 is a diagram conceptually illustrating a process flow of the process monitoring system 1 based on the third embodiment.

  As shown in FIG. 6, in this example, the case where the process A, the process B, and the process C are an assembly process, a labeling process, and an inspection process is shown as an example.

  In this example, the toner bottle TB is assembled in the assembly process. In the label attaching process, a label is attached to the toner bottle TB assembled in the assembly process.

  In the inspection process, it is inspected whether the assembled toner bottle TB is assembled by mistake.

  Further, the case where the toner bottle TB is sequentially conveyed to the next process by the conveyor CB is shown.

  In this example, a switch SWP is provided in the inspection process, and an abnormal signal is output to the process monitoring device 10 by operating the switch SWP.

  In this case, it is the inspection process that finds a destination error. However, it is the assembly process that exists at a remote location that is the cause of the misdirection.

  In this example, the switch SWP is provided corresponding to the inspection process, but the abnormal signal of the switch SWP is assumed to be associated with the assembly process.

  The abnormality information acquisition unit 16 notifies the region setting unit 14 that there is an abnormality signal in accordance with the input of the abnormality signal from the switch SWP.

  The area setting unit 14 sets a specific area based on the notification of the abnormal signal from the switch SWP. Specifically, an area related to the assembly process of the assembly process, the labeling process, and the inspection process is set as the specific area in the imaging area captured by the imaging device 40.

  The extraction unit 18 extracts specific moving image data of a specific region including the assembly process set by the region setting unit 14 with respect to the moving image data stored in the temporary storage device 32.

The storage unit 20 stores the extracted specific moving image data in the storage device 30.
By this process, the process that caused the abnormality is identified, and the area including the relevant process is saved as a specific area, so that only the process that caused the abnormality is identified, not the position where the abnormality was detected. It can be saved as image data.

(Embodiment 4)
In the first embodiment, the case where the area corresponding to a part of the production line 5 is set as the specific area and the moving image data of the specific area is stored has been described. In the fourth embodiment, a case where a more detailed part is set as the specific area will be described.

  FIG. 7 is a diagram conceptually illustrating the flow of processing of the process monitoring system 1 based on the fourth embodiment.

  As shown in FIG. 7, in this example, a case where an abnormality has occurred in the process B is shown as an example.

As an example of the process B, in this example, a screwing process of the bottom plate is shown.
In this example, an abnormality in the screw tightening process is detected by image analysis.

  Specifically, an image of the bottom plate that has been correctly screwed is used as a reference image, and compared with the reference image, it is detected whether or not there is a forgotten screw tightening.

  In this example, the case where the location where screw tightening is performed, that is, the abnormality detection locations P1 to P13 for detecting whether or not there is an abnormality in forgetting screw tightening is set in advance.

  The abnormality information acquisition unit 16 determines the presence or absence of abnormality based on the comparison with the reference image by image analysis processing based on the moving image data acquired by the moving image information acquisition unit 22. In this example, the case where a case where there is an abnormality in the abnormality detection points P4 and P6 is detected is shown.

  The abnormality information acquisition unit 16 outputs the detection results of the abnormality detection points P4 and P6 to the region setting unit 14.

A region to be extracted is set in advance in each of the abnormality detection points P1 to P13.
The region setting unit 14 sets a region including a preset abnormality detection location as a specific region based on the abnormality presence information of the abnormality detection locations P4 and P6 acquired by the abnormality information acquisition unit 16.

  Based on the information regarding the specific area set by the area setting unit 14, the extraction unit 18 specifies the specific moving image of the specific area set in the moving image data acquired by the moving image information acquisition unit 22 stored in the temporary storage device 32. Extract data.

The extraction unit 18 outputs the extracted specific image data to the storage unit 20.
The storage unit 20 stores the extracted specific moving image data in the storage device 30.

  By storing the specific image data of a more detailed location by this method, it is possible to efficiently store necessary information in the storage device 30.

  In the above, the case where the abnormality information acquisition unit 16 executes the image analysis process to detect an abnormality in forgetting screw tightening has been described, but the present invention can be similarly applied to the case where an abnormality in the screw tightening process is detected. .

  Specifically, the abnormality information acquisition unit 16 acquires the driver torque value of the driver that executes the screw tightening process at the abnormality detection points P1 to P13. Then, it is determined whether or not the acquired driver torque value is outside the specified torque. If the acquired driver torque value is outside the specified torque, it is possible to determine that the screw tightening process is abnormal. The abnormality information acquisition unit 16 outputs the abnormality detection location to the region setting unit 14 based on the above determination, so that the specific moving image data regarding the abnormality of the screw tightening process can be extracted and stored in the storage device 30.

  FIG. 8 is a diagram conceptually illustrating a process flow of the process monitoring system 1 based on the first modification of the fourth embodiment.

  As shown in FIG. 8, in this example, a case where an abnormality has occurred in the process B is shown as an example. As an example of the process B, in this example, a screwing process of the bottom plate is shown.

In this example, the abnormality of the screw tightening process is detected based on the driver torque value.
Specifically, the driver torque value is acquired from the Z-axis actuator that presses the driver bit DB.

  In this example, the driver torque values at the abnormality detection points P1, P2 for each workpiece W are shown as an example. The case where the specified value is set to 40 to 50 N is shown.

  This example shows a case where the teaching position of the screw tightening position is deviated due to a lot change of the workpiece W and the torque is out of the specified torque at the abnormality detection point P2 from the workpiece W34.

  In this example, when the abnormality information acquisition unit 16 detects a location where the outside of the predetermined torque is continuously generated, and detects that the torque is continuously exceeded, an abnormality has occurred at the abnormality detection location. to decide.

The abnormality information acquisition unit 16 outputs the detection result of the abnormality detection location P2 to the region setting unit 14.
As described above, a region to be extracted is set in advance in each of the abnormality detection points P1 to P13.

  The region setting unit 14 sets a region including a preset abnormality detection location as a specific region based on information indicating that there is an abnormality in the abnormality detection location P2 acquired by the abnormality information acquisition unit 16.

  Based on the information regarding the specific area set by the area setting unit 14, the extraction unit 18 specifies the specific moving image of the specific area set in the moving image data acquired by the moving image information acquisition unit 22 stored in the temporary storage device 32. Extract data.

The extraction unit 18 outputs the extracted specific image data to the storage unit 20.
The storage unit 20 stores the extracted specific moving image data in the storage device 30.

  By storing the specific image data of a more detailed location by this method, it is possible to efficiently store necessary information in the storage device 30.

  FIG. 9 is a diagram conceptually illustrating a process flow of the process monitoring system 1 based on the second modification of the fourth embodiment.

  As shown in FIG. 9, the abnormality information acquisition unit 16 shows a case where the presence of abnormality in a plurality of abnormality detection locations is detected in the same workpiece W. Specifically, a case is shown in which an abnormality (error) is detected at three locations of abnormality detection locations P4, P6, and P13.

  By the same method as described above, the region setting unit 14 selects a region including a preset abnormality detection location based on the abnormality presence information of the abnormality detection locations P4, P6, and P13 acquired by the abnormality information acquisition unit 16. Set to a specific area.

  Based on the information regarding the specific area set by the area setting unit 14, the extraction unit 18 specifies the specific moving image of the specific area set in the moving image data acquired by the moving image information acquisition unit 22 stored in the temporary storage device 32. Extract data.

The extraction unit 18 outputs the extracted specific image data to the storage unit 20.
The storage unit 20 stores the extracted specific moving image data in the storage device 30.

  In this case, when an abnormality is detected in the same workpiece W at the same time, a plurality of specific areas are set, so that a plurality of files are stored.

  In the second modification, the storage unit 20 does not store the extracted specific image data, but stores the extracted specific image data in the storage device 30 in a format including a plurality of extracted specific moving image data in one file.

  By this method, a plurality of specific moving image data in which an abnormality is detected in the same work W is stored in one file, so that it is possible to easily acquire information necessary for verifying the abnormal state of the production process. .

  In the above description, the method of storing a plurality of specific moving image data in one file has been described. However, a plurality of specific moving image data are individually stored, and information indicating the association of each data is stored in a database. It may be.

  Specifically, the specific moving image data of each specific area is stored as an individual file, and the generation date and time, the device XXX, the work YYY, the file name, and the error name are associated and stored in a separately prepared moving image file database. Thus, the relationship between each file may be clarified and stored.

(Embodiment 5)
In the fifth embodiment, a case will be described in which an operator involved in the production line is also recorded.

  FIG. 10 is a diagram conceptually illustrating the process of the process monitoring system 1 based on the fifth embodiment.

  As shown in FIG. 10 (A), when the worker sets the work W on a work desk or the like to a part assembly or cradle, and then the automatic assembly process is started in the automatic assembly apparatus, Even if there is a mistake in the direction of setting the workpiece W, the abnormality is detected in the automatic assembly device. If only the automatic assembly device is extracted as a specific area, the information on the worker who causes it is recorded. Not.

  Therefore, in the fourth embodiment, as shown in FIG. 10B, the worker and the work area that are closest to the automatic assembly apparatus are stored as a specific area.

  The specific area may be set in advance as an area where an operator exists.

  As another method, the abnormality information acquisition unit 16 may acquire information on the worker included in the abnormality information using the captured moving image data. Specifically, an object that moves in a region other than the automatic assembly apparatus in the image data captured by the image analysis process is specified, and the moving object is determined as an operator.

  The area setting unit 14 sets an area including the worker as a specific area based on information on the worker acquired by the abnormality information acquisition unit 16.

  The extraction unit 18 extracts specific moving image data of a specific region including the worker set by the region setting unit 14 with respect to the moving image data stored in the temporary storage device 32.

The storage unit 20 stores the extracted specific moving image data in the storage device 30.
By this processing, it is possible to record information including the worker who causes it and easily acquire information necessary for verifying the abnormal state of the production process.

  Instead of saving all moving image data, it is possible to specify a process that causes an abnormality and efficiently store necessary information in the storage device 30 to save moving image data in a specific area.

  Also, the worker is allowed to carry the RFID, the abnormality information acquisition unit 16 identifies the position of the worker based on the information of the RFID, and the region setting unit 14 identifies the region including the identified position as the specific region. It is also possible to set to. Note that the position of the worker can be specified using an area sensor or the like without being limited to the RFID.

(Embodiment 6)
FIG. 11 is a diagram conceptually illustrating the process of the process monitoring system 1 based on the sixth embodiment.

  FIG. 11A shows a case where an abnormality has occurred in process B. And the case where the area | region setting part 14 sets the area | region regarding the process B as a specific area is shown.

  In this example, a case where an abnormal pattern A is detected among a plurality of abnormal patterns is shown as an occurrence of an abnormality.

  FIG. 11B is a correspondence table illustrating pixel sizes that define specific areas respectively associated with a plurality of abnormal patterns. The correspondence table is assumed to be stored in advance in the storage device 30 as an example.

  Specifically, a pixel size of 480 × 640 is associated with the abnormal pattern A. In addition, a pixel size of 960 × 1280 is associated with the abnormal pattern B.

  In FIG. 11A, the region setting unit 14 refers to the correspondence table stored in the storage device 30 and sets a specific region having a pixel size of 480 × 640 corresponding to the abnormal pattern A. It is shown.

  The extraction unit 18 extracts specific moving image data of a specific region having a pixel size set by the region setting unit 14 with respect to the moving image data stored in the temporary storage device 32.

The storage unit 20 stores the extracted specific moving image data in the storage device 30.
As a specific example, for example, in the process of assembling components, if the abnormal pattern A is a screw idle due to a torque abnormality at the time of screw tightening, the abnormal pattern B is assumed to be in the wrong assembly order of components.

  In the case of the abnormal pattern A, the state of the actual abnormality can be observed and analyzed by recording only the image near the corresponding screw. On the other hand, if the abnormal pattern B is in the wrong assembly order of parts, it is necessary to record how parts are assembled at multiple locations in the workpiece, so it is necessary to expand and save a specific area so that each location can be accommodated. It becomes.

  Therefore, even if an abnormality is detected at the same abnormality detection location, it is possible to easily acquire information necessary for verification of the abnormality status of the production process by adjusting the size of the specific area according to the type of abnormality. .

  In this example, two types of abnormal patterns have been described. However, the number of abnormal patterns is not limited to two, and pixel sizes corresponding to a plurality of abnormal patterns may be provided.

  The abnormality information acquisition unit 16 can determine an abnormality pattern using the captured moving image data. Specifically, an abnormal pattern such as a component missing item, an assembly order difference, or a component type difference that is abnormal is determined based on a comparison with a reference image by image analysis processing.

  Alternatively, the abnormality information acquisition unit 16 can determine an abnormal pattern such as a tightening torque abnormality or a driver pressing force abnormality based on a sensor value from a sensor attached to the apparatus in the case of screw tightening.

  In the above description, the case where the specific area is set based on the reference position (for example, an abnormality detection location) has been described. However, the specific area may be set using coordinates.

  FIG. 12 is a diagram conceptually illustrating the process of the process monitoring system 1 based on the modification of the sixth embodiment.

FIG. 12A shows an assembly process for fixing driving.
In the assembling process, a case where a component L gear type difference is detected as an abnormal pattern is shown. The detection of the abnormal pattern is determined based on the image analysis process described above or the input sensor value.

  FIG. 12B shows a correspondence table for a plurality of abnormal patterns. The correspondence table is stored in the storage device 30 in advance.

  Specifically, a correspondence table in which the abnormality number, the abnormality pattern name, and the coordinates Q1 and Q2 in the XY coordinates for setting the specific area are associated is shown.

  Specifically, the part K missing item, the coordinate Q1 (−30, −10), and the coordinate Q2 (50, 30) are set corresponding to the abnormality number 1.

  Corresponding to the abnormality number 2, a part L missing item, coordinates Q1 (10, -15), and coordinates Q2 (60, 40) are set.

  Corresponding to the abnormality number 3, the part L gear type difference, coordinates Q1 (5, 10), and coordinates Q2 (60, 40) are set.

  The coordinates Q1 and Q2 are coordinates for setting a specific area in the XY coordinate system, and the coordinate Q1 indicates a lower left coordinate when the specific area is a rectangular area. The coordinate Q2 indicates the upper right coordinate when the specific area is a rectangular area. The specific area can be set by the coordinates of the two points.

  In FIG. 11A, the area setting unit 14 refers to the correspondence table stored in the storage device 30, reads out information on the abnormality number 3 corresponding to the part L gear type difference, and coordinates Q1 (5 10), Q2 (60, 40), a case where a specific area is set is shown.

  The extraction unit 18 extracts the specific moving image data of the specific area set by the area setting unit 14 with respect to the moving image data stored in the temporary storage device 32.

The storage unit 20 stores the extracted specific moving image data in the storage device 30.
By adjusting the size of the specific area according to the type of abnormality by this method, it is possible to easily acquire information necessary for verifying the abnormal state of the production process.

  This apparatus uses an image recording apparatus such as a high-resolution camera to photograph the entire process / apparatus. For a large amount of captured image data, by identifying only the area where the abnormality occurred based on the difference information of the image and information from various sensors attached to the process and storing only that area, the situation of the abnormality Only the parts necessary for verification can be extracted and stored simply and appropriately with an appropriate data amount without omission.

  Moreover, you may provide the application which can be performed with the computer of a process drying apparatus as a program in this embodiment. At this time, the program according to the present embodiment may be incorporated as a partial function of various applications executed on the personal computer.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  DESCRIPTION OF SYMBOLS 1 Process monitoring system, 5 Production line, 10 Process monitoring apparatus, 12 Reproduction | regeneration part, 14 Area | region setting part, 16 Abnormal information acquisition part, 18 Extraction part, 20 Storage part, 22 Movie information acquisition part, 30 Storage device, 32 Temporary storage Device, 40 photographic device.

Claims (10)

Movie information acquisition means for acquiring movie information obtained by imaging a production process including a plurality of processes with an imaging device;
Abnormality information acquisition means for acquiring abnormality information in the production process;
Based on the abnormality information acquired by the abnormality information acquisition means, an area setting means for setting a specific area from all imaging areas imaged by the imaging device;
Extraction means for extracting specific video information in a specific area set by the area setting means from the video information acquired by the video information acquisition means;
A process monitoring apparatus comprising: a storage unit that stores the specific moving image information extracted by the extraction unit. The abnormality information includes assembly abnormality information that occurs during assembly work,
The process monitoring apparatus according to claim 1, wherein the area setting unit sets a specific area from areas including a plurality of abnormality detection locations in the entire imaging area based on the assembly abnormality information. The plurality of processes include a work process and an inspection process for the work process,
The abnormality information acquisition means acquires abnormality information for the work process in the inspection process,
The process monitoring apparatus according to claim 1, wherein the area setting unit sets a work process related to the inspection process in the plurality of processes as a specific area from the entire imaging area based on the abnormality information. The production process is provided with a plurality of sensors respectively associated with a plurality of processes.
The abnormality information includes sensor value information exceeding a specified value,
The area setting means sets, as a specific area, an area including a process related to a corresponding sensor among the plurality of processes from the entire imaging area based on information on a sensor value exceeding the specified value. The process monitoring apparatus described. The abnormality information includes information on the worker,
The process monitoring apparatus according to claim 1, wherein the area setting unit sets, as a specific area, an area including the worker from the entire imaging area based on the abnormality information. The abnormality information acquisition means acquires a plurality of abnormality information at the same time,
The area setting means sets a plurality of specific areas from the entire imaging area based on a plurality of abnormality information,
The extraction means extracts a plurality of specific video information in a plurality of specific areas set out of the video information,
The process monitoring apparatus according to claim 1, wherein the storage unit stores the extracted plurality of pieces of specific moving image information in association with each other.   The process monitoring apparatus according to claim 1, wherein the area setting unit sets a specific area having a size corresponding to the type of abnormality based on the abnormality information based on the center position of the abnormal part. The entire shooting area is divided into a plurality of areas in a lattice pattern,
The process monitoring apparatus according to claim 1, wherein the area setting unit sets one area as a specific area from among the plurality of divided areas based on the abnormality information. A method for controlling a process monitoring device,
Acquiring video information for photographing a production process including a plurality of processes with a photographing device;
Obtaining abnormal information in the production process;
Based on the acquired abnormality information, a step of setting a specific area from all the imaging areas imaged by the imaging device;
Extracting the specific video information in the specific area set by the area setting means from the acquired video information;
And a step of storing the extracted specific moving image information. A program executed by a computer of a process monitoring device,
The program causes the computer to
Movie information acquisition means for acquiring movie information for imaging a production process including a plurality of processes with an imaging device;
Abnormality information acquisition means for acquiring abnormality information in the production process;
Based on the abnormality information acquired by the abnormality information acquisition means, an area setting means for setting a specific area from all imaging areas imaged by the imaging device;
Extraction means for extracting specific video information in a specific area set by the area setting means from the video information acquired by the video information acquisition means;
A program that functions as a storage unit that stores the specific moving image information extracted by the extraction unit.

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