KR101476909B1 - Real-time Process Monitoring System using Block Image - Google Patents

Real-time Process Monitoring System using Block Image Download PDF

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KR101476909B1
KR101476909B1 KR1020130061548A KR20130061548A KR101476909B1 KR 101476909 B1 KR101476909 B1 KR 101476909B1 KR 1020130061548 A KR1020130061548 A KR 1020130061548A KR 20130061548 A KR20130061548 A KR 20130061548A KR 101476909 B1 KR101476909 B1 KR 101476909B1
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image
block
progress
video
information
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KR20140140763A (en
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최우성
김병철
강태선
임래수
김호경
허주호
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에스티엑스조선해양 주식회사
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30—Computing systems specially adapted for manufacturing

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Abstract

The present invention relates to a real-time process monitoring system using a block image, and more particularly, to a process monitoring system using a block image, which automatically grasps the progress status (progress) of a block production process To a display, and to a system for monitoring a part requiring correction of a layout plan or input of additional manpower by using the obtained result.

Description

{Real-time Process Monitoring System using Block Image}

The present invention relates to a real-time process monitoring system using a block image, and more particularly, to a system and method for real-time process monitoring using a block image, more specifically, And to a system for monitoring a portion requiring correction of a layout plan or input of additional manpower by using the obtained result.

Generally, a large shipyard is equipped with several docks, and a plurality of blocks different in ship type and linear type are simultaneously being produced, and each ship is divided into blocks of a predetermined size. The divided blocks are enlarged by assembling process, design process, coating process, and mounting process, and each process area is scattered all over the yard because the required equipment is different.

In order to control the amount of goods to be shipped and the amount of goods to be delivered between distributed lines, the administrator must know the progress of the block production process in advance. In this case, external influences such as weather, It is a major factor in causing disruption to progress.

The general management method is to record the block production process of the field directly by the manager at least once a day, and the form to be used differs according to the management purpose. FIG. 1 is an example of a status table that displays and manages the position and progress of an assembly block in a turning factory.

Among the above-mentioned processes, the area where the arrangement of blocks and the production schedule are most strictly managed is the assembling process inside the factory (see FIG. 2). Since it is directly related to the productivity where the steel and the member that have been cut and machined in the limited working area are placed and how long to assemble the block, the placement plan is made about one month different from the other process and the progress is checked and managed. The design process and coating process are relatively less important because of the shorter working period than the assembly process.

The ship factory where the assembly process is performed is divided into a flat block area having a planar abacus and a curved block area having an angular abacus. In the case of a flat block, it moves sequentially along the conveyor, so it is possible to estimate the progress by grasping the relative position. However, in the case of the curved block, since the abacus is raised on the pin jig using a crane, There is no sex. In the assembling process, it is common to set the abacus of the block in accordance with a previously set layout plan, and when the block is completed, it is generally taken out through a passage and moved to a post-process using a transporter.

However, there are several problems here.

1. Visual Inspection and Handling Status Report

The schedule and the layout plan of the block to be put in accordance with the middle class are prepared by the manager in charge for the next two rounds (approx. 10-15 days for one round), and it changes organically according to the production results. As a result, the managers must check and adjust the progress of the block production process in the field from time to time. However, the on-site confirmation work that takes more than 5 hours per day to perform the production instruction and the layout plan is a burden to the managers.

Actually, each manager is responsible for 1 to 1.5 bases, and the progress of the block production process arranged on the whole bases is checked again, and the status table (see FIG. 1) is created and distributed by hand. Although there is a process of building a block repeatedly, there is a difference between the process of confirming the progress and the process of creating the status table. Thus, there is a time difference between the production time and the confirmation time of the block, It is difficult to do.

2. Schedule changes based on administrator experience

In the current management system, production scheduling, layout planning, and progress are delivered to the manager, but nothing is systematically related. It is difficult to expect a certain adjustment result because it is purely the responsibility of the manager to identify and adjust the associations among the elements that exist as separate data, and the calculations that accompany them depend on experience.

3. Deployment planning vs. block shape interlocking constraint

Although there is a block shape necessary to make the layout plan according to the production schedule, it is not linked with the production style, and the manager prepares the shape corresponding to the ratio directly and arranges it on the plaque of the plaid pattern 1). As the layout plan and management status are all produced in separate document format (EXCEL), excessive time is spent.

4. Limitations of analysis due to individual file management

In the case of a handwritten document, the document file is the minimum management unit because it does not use a specialized storage structure such as a database, and thus it is difficult to have an association between the produced status tables as a result. If a block list is required to be imported / exported on a monthly basis, it is necessary to take a considerable amount of time to obtain the required results because the management system as described above compiles each document file.

1. Monitoring system for monitoring the status of ship block (Patent Application No. 10-2011-0018586) (FIG. 10) 2. Block production real-time monitoring and process management system (Patent Application No. 10-2009-0084875) (Figure 11) 3. Detection of welding line position of welding member using image image (Patent Application No. 10-2006-0103078) (Fig. 12) 4. Block making system using IGPS and block making method using the same (Patent Application No. 10-2010-0105407) (Fig. 13) 5. Block management system and its ship block transporter job allocation method (Patent Application No. 10-2010-0124097) (Fig. 14) 6. Ship block arranging device and method (Patent Application No. 10-2008-0124210) (Figure 15) 7. Movement of ship block and method of managing the ship block (Patent Application No. 10-2008-0092752) (Figure 16) 8. MANUFACTURING METHOD FOR MANUFACTURING BLOCKS (Patent Application No. 10-2003-0062107) (FIG. 17)

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above problems, and it is an object of the present invention to automatically detect the progress of a block production process, The purpose of this system is to provide a system that monitors the parts requiring revision of the layout plan or the addition of additional manpower using the obtained results.

According to an aspect of the present invention,

An image collecting system comprising an image collecting unit, an image storing unit, and an image transmitting unit, collecting a video image of a block disposed on a base plate in real time and transmitting the same to a video management system;

A video management system for receiving and storing a video image transmitted from an image collection system every time and selectively transmitting a desired video image to a server system;

A design support system for storing design models of blocks;

A data extraction system for selectively extracting only the shape information and attribute information of a design model necessary for grasping the progress of the server system from the design support system and transmitting the extracted shape information and attribute information to the server system;

In order to store and manage layout information, block information, and layout planning information, it stores some of the data obtained from the server system and the data extracted from the design support system. The planning management table, the configuration management table, the progress management table, A database consisting of four information tables of a table; And

The progress of the block production process is calculated by comparing the image of the block received from the video management system with the design model of the block received from the data extraction system, and the progress of the block production process is monitored, A server system comprising a base station monitoring status monitoring unit and a base station layout plan adjustment unit;

And a real-time process monitoring system using the block image.

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According to the present invention, the progress of the block production process that is performed by the frontal factory at the frontal factory is automatically detected using the block image, and the parts requiring correction of the layout plan or the addition of the additional personnel are monitored in real time .

FIG. 1 is an example of a status table that displays and manages the position and progress of an assembly block in a hinged factory.
Fig. 2 shows the assembling process of the inside of the hull factory.
3 is a block diagram of a real-time process monitoring system using a block image according to the present invention.
Figs. 4 to 7 illustrate exemplary table attributes and example data of a database according to an embodiment of the present invention. Fig.
Figure 8 is an embodiment of the present invention, an example of a video image and its design model used to search for placed assembly blocks;
Figure 9 is an embodiment of the present invention, showing block layout and progress, and visualization of a design model.
10 to 17 are prior art documents.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear.

The present invention relates to a real-time process monitoring system using a block image, more specifically, a process of automatically monitoring the progress of a block production process, In addition, it provides a system that monitors the parts needed to revise the layout plan or to input additional manpower using the obtained results.

The application of the present invention is mainly a block drying in a shipyard. The reason for this is that in the case of building blocks in the shipyard, different products have to be produced each time according to the shipowner's requirements, and the operation is continued for a long time in a fixed position. The longer the work period, the wider the work area, and the greater the number of products produced, the greater the impact of the layout plan and its utilization. Conversely, in the case of the line production system, since the same product is produced on the conveyor, the production amount becomes a main concern rather than the monitoring of the batch status or the progress, and thus it is not suitable to be applied to the present invention.

FIG. 3 shows the construction of a real-time process monitoring system using a block image according to the present invention.

The present invention comprises an image acquisition system 10, a video management system 20, a design support system 30, a data extraction system 40, a database 50, and a server system 60. Hereinafter, functions and functions of the constituent elements of the present invention will be described in detail.

Image acquisition system

The image collection system 10 collects the image of the block arranged on the surface of the table in real time and transmits it to the image management system 20.

More specifically, the image capturing system 10 includes an image capturing unit 11 that converts a video image of a block input in real time via a camera lens into a digital signal, An image storing unit 12 for temporarily storing a video image of a block converted into an image stored in the image storing unit 12 and an image storing unit 12 for storing the image of the block temporarily stored in the image storing unit 12, And a transfer unit 13.

Video management system

The image management system 20 receives and stores the image image transmitted from the image collection system 10 every time. Assuming that the image acquisition system 10 (more specifically, the image storage 12) is a small capacity storage, the image management system 20 may be referred to as a large capacity storage.

Since the image management system 20 has not only storage of image images but also management functions, it is possible to inquire, delete, and update image images through the image management system 20. Also, the block ID, the image image collection date and time may be managed through the image management system 20.

Meanwhile, the video management system 20 has a function of selectively transmitting a desired video image to a server system 60 that performs a main operation. The server system 60 compares the video image received from the video management system 20 with the design model transmitted from the data extraction system 40 to determine the progress of the block production process In this case, the closer the video image is to the design model, the higher the degree of progress, and vice versa.

Design Support System

The design support system 30 stores the design model of the block. Here, the design model refers to an object having shape information and attribute information of the completed block, and the design model is a structure model for the server system 60 to understand the progress of the block production process .

The design support system 30 is a part of a CAD system used in designing products in various industries, and in the present invention, indicates a shipyard CAD system as a target industry. The design support system 30 stores a plurality of model types / linear design models, and has its own database so that a plurality of users can simultaneously access and work on them. There are Tribon, Aveva Marine, and GS CAD as representative design support systems 30 used in the shipyard. Although there are various types and data types to be stored for each of these design support systems 30, It should be equipped with a function to retrieve data such as drawings and members.

Data extraction system

The data extraction system 40 selectively extracts only the shape information and attribute information of the design model necessary for grasping the progress in the server system 60 from the design support system 30 and transmits the extracted shape information and attribute information to the server system 60, In this case, the data extraction system 40 simplifies and processes the shape information of the design model as much as possible in order to increase the visualization and operation speed in the server system 60.

Generally, in order to increase the accuracy of the curved surface in the CAD system, the data capacity increases considerably. In general, since the design data processed by the server per operation is several tens per designation, the shape information of the design model is simplified, . On the other hand, in order to efficiently extract the data required by the server system 60 for performing the main operation, it is necessary to provide an interface type data extraction system 40.

Database

The database 50 stores and manages surface information, block information, and layout plan information. For this purpose, the database 50 stores the result data of the server system 60 and some of the data extracted by the design support system 30 . The database 50 is made up of four types of information tables such as a plan management table 51, a configuration management table 52, a progress management table 53, and an assembly member management table 54.

The plan management table 51 has attributes such as the block ID and the block name, the date of receipt, the date of the release, the placement position, and the placement angle of the block, and stores information for comparing the progress plan and the placement plan (See Fig. 4). The shape management table 52 stores the block ID, the file name including the shape information of the block, and the attributes such as the storage path, for the main purpose of storing the shape information of the block outputted in the form specified by the data extraction system 40 (See Fig. 5). The progress degree management table 53 stores information on which block is currently disposed and the progress thereof based on the progress degree obtained by the server system 60. The progress degree management table 53 includes a block ID, Location, placement planning progress, block building progress, update time, and the like (see FIG. 6). Finally, the assembly member management table 54 stores the block lower member information for generating the design model image used in the block progress comparison. The block member ID management table 54 includes a block ID and a lower member ID, a member level (Level) And the like (see FIG. 7).

Server system

The server system 60 in which the main operation is performed compares the image of the block received from the image management system 20 with the design model of the block received from the data extraction system 40 to calculate the progress of the block production process, Monitor the status of the deployment and coordinate the deployment plan. The server system 60 includes a progress degree inference unit 61, a base placement status monitoring unit 62, and a base placement plan adjustment unit 63.

The progress degree inference unit 61 calculates the progress of the block production process. For this, the progress inferring unit 61 compares the image image received from the image management system 20 with the design model transmitted from the data extraction system 40 (the design model is a 3D image while the image image is a projected 2D image (See FIG. 8), and the progress of the block manufacturing process that has been performed so far is calculated by dividing the members input into the block production into a predetermined unit (see FIG. 8) .

In this case, the progress inferring unit 61 calculates the progress of the image as the closer to the design model, and the lower the progress of the image, the more the progress image is calculated. More specifically, And the value calculated through the ratio of the members stored in the database 50 is updated to the progress degree.

The placement status monitoring unit 62 displays the position and progress of the block through the monitoring interface. As shown in FIG. 9, the block shape is automatically arranged on the base and the progress degree calculated by the progress degree inference unit 61 Display. The main function of the base placement monitoring unit 62 is to display a delayed or fluctuating operation as compared with the layout plan, which indicates a part where the user (manager) should adjust the schedule or the input staff. In the embodiment of FIG. 9, the layout layout is divided into three levels of normal, delay, and warning on the monitoring interface, and is displayed in different colors.

The layout layout plan adjustment unit 63 adjusts the layout plan of the blocks in operation, and this function of the layout layout plan adjustment unit 63 can also be utilized for creating a schedule before the user (manager) arranges the blocks . The base placement plan adjustment unit 63 generates schedule information to be compared with monitoring, and adjusts the schedule information when a problem occurs.

As described above, according to the present invention, it is possible to automatically grasp the progress of a block manufacturing process that is performed by a front end factory, and to modify a block layout plan or to monitor a portion requiring additional manpower in real time .

It will be apparent to those skilled in the art that various modifications, substitutions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. will be. Therefore, the embodiments disclosed in the present invention and the accompanying drawings are intended to illustrate and not to limit the technical spirit of the present invention, and the scope of the technical idea of the present invention is not limited by these embodiments and accompanying drawings. The scope of protection of the present invention should be construed according to the following claims, and all technical ideas within the scope of equivalents should be construed as falling within the scope of the present invention.

10: image collecting system 11: image collecting unit
12: Image storage unit 13: Image transmission unit
20: video management system 30: design support system
40: Data extraction system 50: Database
51: plan management table 52: configuration management table
53: progress management table 54: assembly member management table
60: server system 61: progress degree inference unit
62: Platemaking Monitoring Unit 63: Platemaking Plan Adjustment Unit

Claims (20)

An image collecting unit 11 for converting a video image of a block inputted in real time through a camera lens into a digital signal for collecting a video image of a block arranged on a base in real time and transmitting the same to a video management system 20, An image storage unit 12 for temporarily storing a video image of a block converted into a digital signal by the image collection unit 11, and a storage unit 12 for storing a video image of a block temporarily stored in the image storage unit 12, An image capturing system (10) comprising an image transmitting unit (13) for transmitting the image data to the image management system (20)
A video management system 20 for receiving and storing video images transmitted from the video capture system 10 and selectively transmitting video images desired by the user to the server system 60;
A design support system (30) for storing a design model of a block;
A data extraction system 40 for selectively extracting only the shape information and attribute information of the design model necessary for grasping the progress of the server system 60 from the design support system 30 and transmitting it to the server system 60;
And stores the result data of the server system 60 and some of the data extracted by the design support system 30 in order to store and manage the surface information, the block information, and the layout plan information, A database 50 composed of a table 52, a progress degree management table 53, and an assembly member management table 54; And
The image of the block received from the image management system 20 is compared with the design model of the block received from the data extraction system 40 to calculate the progress of the block production process and monitor the layout of the block, A server system 60 including a progress degree inference unit 61, a base placement status monitoring unit 62, and a base placement plan adjustment unit 63;
A real time process monitoring system using a block image. delete delete delete The method according to claim 1,
The image management system 20 has not only a storage of a video image but also a management function. The video management system 20 is capable of inquiring, deleting, and updating a video image through the video management system 20, system. 6. The method of claim 5,
Wherein the image management system (20) manages the block ID, the image acquisition date and time separately. The method according to claim 1,
The design support system 30 stores various design models of a ship type and a linear type and has its own database for allowing a plurality of users to simultaneously access and work on the data. And a real-time process monitoring system using the block image. The method according to claim 1,
Wherein the data extraction system (40) simplifies and processes the shape information of the design model to increase visualization and operation speed in the server system (60). The method according to claim 1,
Wherein the data extraction system (40) is provided in an interface form for efficiently extracting data required by the server system (60). The method according to claim 1,
The plan management table 51 stores information for comparing the progress plan and the layout plan by searching for the block with the block ID. The plan management table 51 stores the information such as the block ID, the block date, the date of receipt, the date of export, And a real-time process monitoring system using the block image. The method according to claim 1,
The shape management table 52 stores shape information of a block output in a format specified by the data extraction system 40 and has attributes such as a file name and a storage path including a block ID and shape information of the block Real time process monitoring system using block image. The method according to claim 1,
The progress management table 53 stores information on which block is currently located and the progress of the block based on the progress information obtained by the server system 60. The block ID, , The progress of the batch planning, the progress of the block production, and the update time. The method according to claim 1,
The assembly member management table 54 stores the block lower member information for generating a design model image used in the block progress comparison, and has the attributes such as the block ID, the lower member ID of the corresponding block, the member level, and the number of block members Wherein the real-time process monitoring system uses the block image. The method according to claim 1,
The progress degree inferring unit 61 compares the video image received from the video management system 20 with the design model transmitted from the data extraction system 40 for the progress of the block production process, And the progress of the block production process that has been performed so far is calculated based on the block image. 15. The method of claim 14,
In comparing the image of the image with the design model, the progression inference unit 61 compares the image of the design model with the image of the image and maps the image according to the change of the design model since the design model is a 3D image while the image is a projected 2D image And a real-time process monitoring system using the block image. 15. The method of claim 14,
The progress degree inferring unit 61 calculates the progression degree as the image image approaches the design model, and calculates the progression degree as low if the image is in the opposite direction. The difference between the image image and the design model is detected, , And updates the value calculated through the ratio of the members stored in the database (50) to the progress degree. The method according to claim 1,
The base placement status monitoring unit 62 displays the position and progress of the block through the monitoring interface so that the block shape is automatically arranged on the base and the progress degree calculated by the progress degree inference unit 61 is displayed together Real time process monitoring system using block image. 18. The method of claim 17,
The basic layout monitoring unit 62 displays the delayed or changed work as compared with the layout plan, and displays the different layouts of the basic layout in three stages of normal, delay, and warning on the monitoring interface Real - time process monitoring system using block image. The method according to claim 1,
The real-time placement plan adjustment unit (63) adjusts the layout plan of a block in operation, and generates schedule information to be compared with monitoring, and adjusts the schedule information when a problem occurs. Monitoring system. delete
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