JP3360969B2 - Plant inspection support device - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plant inspection support apparatus and method, and more particularly to a plant inspection support for remotely recognizing the position of an inspection device (inspection work vehicle) in a plant and remotely controlling attitude and operation. apparatus about the.

[0002]

2. Description of the Related Art In conventional plant inspection equipment, ITV
(Industrial television) The inspection device is operated remotely depending only on the monitor image of the camera, and the inspection of the inspection object was mainly visual inspection by the monitor image of the ITV camera mounted on the inspection device. Furthermore, the operator confirms the inspection data by referring to the books and documents.

[0003]

However, in the conventional plant inspection device as described above, the position of the inspection device and the remote control of the area near the inspection object are performed only by the monitor image of the ITV camera. , This will be operated remotely depending on the experience and intuition of the operator. In particular, there is a problem in remote control of a portion outside the monitor image of the ITV camera, that is, a portion that the operator cannot see, and it is difficult to operate the inspection device and control the posture of steps, protrusions and the like.

Further, since the inspection work by remote control is controlled by the skill of the operator using only the monitor image of the ITV camera, no guidance other than visual inspection can be obtained through the monitor image of the ITV camera. However, there was a problem that the work efficiency was low and the work was not accurate.

Furthermore, since there is no method other than visual inspection through the monitor image of the ITV camera for abnormality prediction,
It has been difficult to predict abnormalities for minute deformation that exceeds the operator's recognition limit and missing minute parts.

The present invention has been made in consideration of the above circumstances, and reproduces the position and orientation of the inspection device on a three-dimensional model composed of three-dimensional CAD data in the same space as the inspection object. , A plant inspection support apparatus and method are provided in which information other than the monitor image of the ITV camera is obtained and the operability of the inspection device is improved.

Another object of the present invention is to:
An object of the present invention is to provide a plant inspection support device and method in which inspection simulation of an inspection object is performed in advance on a three-dimensional model, and the result is used as guidance to improve inspection workability.

Furthermore, the monitor image of the ITV camera and 3
Providing a plant inspection support device and method that can perform highly accurate inspection work by performing image processing with a dimensional model and predicting abnormalities such as minute deformations and loss of minute parts that the operator cannot identify with the naked eye To do.

[0009]

In order to solve the above-mentioned problems, the plant inspection support device according to claim 1 of the present invention comprises:
It is equipped with an ITV camera that confirms the inspection target in the plant and a distance sensor that measures the distance to a preset target, and supports the plant inspection that remotely operates an inspection device that is self-propellable and self-propelled. A first storage device for storing three-dimensional CAD data, a second storage device for storing design data and inspection data of the inspection object, distance information from the distance sensor, and the first storage device. -Dimensional CAD stored in the storage device of
An arithmetic processing unit that calculates the optimum access route to the inspection object and the position information of the inspection device based on the three-dimensional model information created from the data, and a display device that displays the calculation result are provided. Characterize.

[0010]

The plant inspection support apparatus according to claim 2 is equipped with an ITV camera for confirming an inspection object in the plant and a distance sensor for measuring a distance to a preset target, and is capable of self-attitude control and self-propelled. A plant inspection support device for remotely operating the inspection device configured as described above, comprising: a first storage device for storing three-dimensional CAD data;
Three-dimensional model information created from a second storage device that stores design data and inspection data of the inspection object, a monitor image of the ITV camera, and three-dimensional CAD data stored in the first storage device. And an arithmetic processing unit for retrieving a defect event based on the abnormality prediction information that identifies the difference in shape and position from the above, and the past inspection information stored in the second storage unit, and a display unit that displays the retrieval result. It is characterized by having and.

[0012]

[0013]

[0014]

[0015]

In the plant inspection support apparatus according to claim 1 and the plant inspection support method according to claim 4 of the present invention, the distance information obtained from the distance sensor mounted on the inspection device is stored in the first storage device. The 3D model information created from the existing 3D CAD data is collated, and the obtained position information and posture information of the inspection device are calculated, and the above 3
The optimum access route to the inspection object and the position information of the inspection device are calculated based on the dimensional model information and the position information and attitude information of the inspection device, and the calculation result is displayed to create a space near the inspection object. The position and orientation of the inspection device was reproduced on a three-dimensional model composed of three-dimensional CAD data in the exact same space so that information other than the monitor image of the ITV camera could be obtained.

[0016]

Further, in the plant inspection support apparatus according to claim 2, the monitor image from the ITV camera of the inspection device and the three-dimensional CA stored in the first storage device.
Image processing is performed with the three-dimensional model information created from the D data, the design data and the inspection data of the inspection object stored in the second storage device, and the difference in the minute deformation of the inspection object and the lack of minute parts By identifying and displaying the identification result, image processing of the monitor image of the ITV camera and the three-dimensional model is performed, and the operator can predict abnormalities such as minute deformation and missing of minute parts that cannot be identified by the naked eye. It is possible to perform highly accurate inspection work.

[0018]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing an embodiment of a plant inspection support device according to the present invention. As shown in FIG. 1, the inspection device 1 includes a posture / motion control unit 2 for self-propelled and self-propelled by remote wireless operation, and an ITV camera for photographing and confirming an inspection target in a plant. 3, a distance sensor 4 for measuring a distance to a target (reference point) preset in the plant, a data input / output unit 5 for inputting / outputting data between an inspection support device described later, and an inspection target. A tool (not shown) for inspecting an object with a manipulator or the like is mounted.

Further, the plant inspection support device 1 of this embodiment
Reference numeral 0 denotes a display device 11 for displaying a three-dimensional model image and characters created from a three-dimensional CAD (computer-aided design), an image processing device 12, and a first storage for three-dimensional CAD data. Storage device 13 as a storage device, a storage device 14 as a second storage device for storing design data / inspection data of the inspection object, operation instructions of the inspection device 1, instruction of the inspection object / data selection An input device 15 such as a keyboard, a tablet or a mouse for inputting to the system, and a control device 16 for controlling the inspection device 1 are provided.

Further, the inspection support device 10 has an arithmetic processing unit 17, and the arithmetic processing unit 17 executes a sequential arithmetic operation, a sequential arithmetic operation unit 17a, a processing procedure memory unit 17b in which a processing procedure is stored, and an input device. An input unit 17c for obtaining an input signal from the input / output unit 15, an input / output unit 17d for performing input / output with the storage device 13 for storing the three-dimensional CAD data, and design data.
An input / output unit 17e that performs input / output with the storage device 14 that stores inspection data and the like, an output unit 7f that outputs to the image processing device 12, and a data input unit 17g from the inspection device 1.
And the intermediate data memory 17h, and the procedure stored in the processing procedure memory unit 17b is read by the sequential operation unit 17a and sequentially executed.

Next, the operation of this embodiment will be described.

FIG. 2 is a flow chart showing a procedure of the attitude control of the inspection device 1 in the processing procedure executed by the arithmetic processing unit 17. As shown in FIG. 2, step S1
~ S5 is a position calculation step, which measures the distance between the target and the inspection device 1 preset in the plant by the distance sensor 4 mounted on the inspection device 1 and corresponds to a crid (cell) containing the target. The three-dimensional CAD data of the space to be loaded is loaded (read out) from the storage device 13 to form a three-dimensional model, and the distance data measured by the distance sensor 4 of the inspection device 1 and the three-dimensional model are referred to, and the display device is displayed. The position of the inspection device 1 is displayed on 11 three-dimensional model.

Then, step S6 and step S7
Is an attitude control step, and the accurate current position / orientation information of the inspection device 1 calculated in steps S1 to S5 and 3
The optimum posture control data is calculated with reference to the three-dimensional model, a control command signal is transmitted from the control device 16, and the control command signal is received by the input / output unit 5 of the inspection device 1, and the posture / motion control unit 2 The optimum posture control of the inspection device 1 is performed by. Then, in step S8, it is determined whether or not the position and orientation of the inspection device 1 are accurate, and if they are correct, the process proceeds to the next step.

FIG. 3 is a flow chart showing a procedure for calculating and executing the optimum access route and posture of the inspection device 1 traveling to the inspection object and the inspection method in the processing procedure executed by the arithmetic processing unit 17. Steps S9 to S12
Is an access route calculation step, in which an inspection object is selected from the monitor image from the ITV camera 3 displayed on the display device 11 or the three-dimensional model image displayed on the display device 11 at the same time, and the selected inspection is performed. Based on the position information of the three-dimensional model of the object and the position / orientation information of the inspection device 1 calculated in steps S1 to S5, the optimum access route and attitude to the inspection object are calculated.

Then, step S13 and step S
Reference numeral 14 is an inspection method calculation step, in which the design data and inspection data of the selected inspection object are read from the storage device 14, and the inspection device 1 calculated in steps S1 to S5.
The optimum inspection method is calculated based on the accurate current position, posture information, and three-dimensional model data of the inspection object.

Further, step S15 and step S
Reference numeral 16 is an inspection execution step, which is steps S9 to S12.
The optimum access route and posture to the inspection object calculated in step S3 and the optimum inspection method calculated in steps S13 and S14 are displayed on the three-dimensional model image of the display device 11, and the information is displayed from the control device 16. The control command signal is transmitted, and the control command signal is received by the input / output unit 5 of the inspection device 1, and the posture / motion control unit 2 executes optimum inspection support of the inspection device 1. Then, in step S17, it is determined whether or not the next inspection object is to be accessed, and if it is not accessed, the processing ends.

FIG. 4 is a flow chart showing a procedure in which the inspection device 1 predicts an abnormality among the processing procedures executed by the arithmetic processing unit 17. Steps S20 to S25 are abnormality prediction steps, in which image processing of the monitor image from the ITV camera 3 and the three-dimensional model data is performed to detect a minute defect in shape / position, and the abnormal portion is displayed on the display device 11. indicate.

Next, steps S26 to S28 are abnormality analogy steps, in which the corresponding abnormal situation is compared with the inspection data such as past trouble cases stored in the storage device 14, and an event expected to be applicable is determined. If found, the case is displayed on the display device 11.

FIG. 5 shows an example in which the present position of the inspection device 1 calculated by the flow chart shown in FIG. 2 and the optimum access route to the inspection object calculated by the flow chart shown in FIG. 3 are displayed on the display device 11. ing.

FIG. 6 shows an example of displaying on the display device 11 inspection data such as abnormal points and past trouble cases calculated by the flowchart shown in FIG. In this way, the abnormality prediction is executed and displayed.

[0032]

As described above, according to the first aspect of the present invention.
According to the plant inspection support device, the distance information obtained from the distance sensor mounted on the inspection device is compared with the three-dimensional model information created from the three-dimensional CAD data stored in the first storage device. The calculated position information and attitude information of the inspection device are calculated, and the optimum access route to the inspection object and the position information of the inspection device are calculated based on the three-dimensional model information and the position information and attitude information of the inspection device. , By displaying the calculation result, the same space as the space near the inspection object can be displayed in the three-dimensional C
It is possible to improve the operability of the inspection device by reproducing the position and orientation of the inspection device on a three-dimensional model composed of AD data so that information other than the monitor image of the ITV camera can be obtained.

[0033]

Further, according to the plant inspection support apparatus of claim 2, the monitor image from the ITV camera of the inspection device and the three-dimensional CAD stored in the first storage device.
Image processing is performed with the three-dimensional model information created from the data, the design data and the inspection data of the inspection object stored in the second storage device, and the difference in minute deformation of the inspection object or lack of minute parts is detected. By performing identification and displaying the identification result, image processing of the monitor image of the ITV camera and the three-dimensional model is performed, and the operator predicts abnormalities such as minute deformation and missing of minute parts that cannot be identified by the naked eye. Highly accurate inspection work can be performed.

[Brief description of drawings]

FIG. 1 is a block diagram showing an embodiment of a plant inspection support device according to the present invention.

FIG. 2 is a flowchart showing a procedure in which the inspection device performs attitude control, out of the processing procedures executed by the arithmetic processing unit in FIG.

FIG. 3 is a flowchart showing a procedure for calculating and executing an optimum access route and posture of an inspection device traveling to an inspection object and an inspection method among the processing procedures executed by the arithmetic processing unit of FIG.

FIG. 4 is a flowchart showing a procedure in which the inspection device predicts an abnormality among the processing procedures executed by the arithmetic processing unit in FIG. 1.

FIG. 5 is a diagram showing an example in which the present position of the inspection device and the optimum access route to the inspection object are displayed on the display device.

FIG. 6 is a diagram showing an example in which when a predicted search event is found from inspection data such as an abnormal place and a past defect case, the case is displayed on a display device.

[Explanation of symbols]

1 Inspection device 2 Posture / motion control unit 3 ITV camera 4 distance sensor 5 Data input / output section 10 Plant inspection support device 11 Display 12 Image processing device 13 Storage device (first storage device) 14 Storage device (second storage device) 15 Input device 16 Control device 17 Processor 17a Sequential calculation unit 17b Processing procedure memory unit 17c Input section 17d Input / output section 17e Input / output section 17f Output section 17g Data input section 17h Intermediate data memory

Continuation of the front page (56) Reference JP-A-6-187355 (JP, A) JP-A-3-12783 (JP, A) JP-A-6-317090 (JP, A) JP-A-4-357488 (JP , A) JP 2-136793 (JP, A) JP 4-101791 (JP, A) JP 6-168246 (JP, A) JP 8-262179 (JP, A) JP 7-281753 (JP, A) JP-A-8-105991 (JP, A) JP-A-62-174878 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) G21C 17/00

Claims (2)

(57) [Claims] 1. An IT for confirming an inspection target in a plant
A plant inspection support device that is equipped with a V camera and a distance sensor that measures the distance to a preset target, and remotely operates an inspection device that is self-propellable and self-propelled, and is three-dimensional CAD data. , A second storage device for storing design data and inspection data of the inspection object, distance information from the distance sensor, and 3 stored in the first storage device. An arithmetic processing unit that calculates the optimum access route to the inspection object and the position information of the inspection device based on the three-dimensional model information created from the three-dimensional CAD data, and a display device that displays the calculation result are provided. A plant inspection support device characterized in that 2. IT for confirming an inspection target in a plant
A plant inspection support device that is equipped with a V camera and a distance sensor that measures the distance to a preset target, and remotely operates an inspection device that is self-propellable and self-propelled, and is three-dimensional CAD data. Storage device, a second storage device for storing design data and inspection data of the inspection object, a monitor image of the ITV camera, and a three-dimensional image stored in the first storage device. Arithmetic processing device for retrieving a defective event based on abnormality prediction information that identifies a difference in shape and position from three-dimensional model information created from CAD data and past inspection information stored in a second storage device And a display device for displaying the search result, a plant inspection support device.