RU2756347C1 - Robotic complex for production process management, product and raw materials resources control - Google Patents

Abstract

FIELD: production process robotic control.

SUBSTANCE: claimed invention is a complex of control of production processes, control of products, raw materials, which is intended for the organization of objective robotic control of production processes of enterprises using raw materials in the form of bulk materials, storing finished products in open areas. The complex consists of a central server with software, a video surveillance system, a weight control system, an active monitoring system, and the central server is connected via a cable communication channel to an automatic helicopter maintenance complex, while the server performs the functions of receiving, accumulating and storing information, provides constant analysis of the information received, sends out a newsletter containing analytics information to employees and responsible persons, forms a summary report on the results of monitoring and analysis of incidents and the condition of controlled objects, equipment, raw materials, supplies, finished products, provides employees with access to archives and databases.

EFFECT: complex monitors all processes on the territory of the production enterprise, from the import of materials and equipment to the sale of finished products, determines the volume and weight of imported and exported materials and finished products in the form of bulk cargo, giving results with an error of 0.01%, controls the arrival of goods, the directions of their movement on the territory of the enterprise and the place of their shipment, determines the volume by which the mass of the total dump has increased, and compares with the planned receipt, when releasing materials for production and receiving finished products, an automatic analysis of the results takes place and the actual result is determined, a comparison is made with the planned indicators.

1 cl, 5 dwg

Description

The claimed invention is a complex for managing production processes, control of products, raw materials, which is designed to organize objective robotic control of production processes of enterprises using raw materials in the form of bulk materials, storing finished products in open areas.

It is effective for enterprises in whose production processes it is necessary to measure the volume of raw materials or finished products sold by weight or volume. Organizes control over the receipt of raw materials or components at the manufacturing enterprise, controls the receipt of materials and equipment at the warehouse and storage areas. Controls the shipment of materials from the warehouse to production. Controls the exit of finished products from production to the finished product warehouse. Controls the shipment of finished products to consumers, customers.

An analogue of the claimed invention is, selected as a prototype, is a telematic control complex containing a central dispatching point (CDC) connected through an available communication channel with at least one peripheral object containing a video server and a control module connected to a local area network (LAN), and at least one video camera is connected to the video server, at least one sensor is connected to the control module, and the LAN is connected to the communication unit, which is configured to interact with the central control unit communication unit connected to at least one operator's server, and the peripheral object contains the connected with a LAN, a video conferencing terminal (VCS), and the DCC contains a LAN connected to its communication unit, to which at least one operator's server is connected, and a switch, a video multiplexer and at least one distributed archive module connected to the DCS LAN, and the switch is connected to, at least one of those by the videoconferencing terminal of the central control center, connected in turn with the registration module, and the total number of distributed archive modules is equal to the sum of the number of video conferencing terminals of the central control center and the number of operator's servers (patent for utility model No. 81358, publication date: 10.03.2009).

The main significant disadvantages of the prototype are low efficiency in functionality, since for example, it does not allow you to track all processes on the territory of a production enterprise, from the import of materials and equipment into the territory, to the sale of finished products, and there is no possibility of interaction with narrowly focused systems, for the formation of analytics for making decisions on the operation of the enterprise as a whole in connection with the presence of " human factor ".

The objective of the claimed invention is to eliminate the shortcomings of the prototype, and the technical result is that this complex monitors all processes on the territory of the production enterprise, from the import into the territory of materials and equipment, to the sale of finished products, the complex determines the volume and weight of imported and exported materials and finished products in the form of bulk cargo, giving out the results with an error of 0.01%, controls the arrival of goods, the directions of their movement across the territory of the enterprise and the place of their shipment, the complex determines the volume by which the mass of the total dump has increased and compares it with the planned receipt, when materials are released into production and the output of finished products, an automatic analysis of the results takes place and the actual result is determined, comparisons are made with the planned indicators, has the ability to interact with narrowly focused systems, to form analytics for making decisions on the operation of the enterprise as a whole, monitors the actual use monitoring of processes, reveals a violation of technological processes at the enterprise, the control complex performs all of the above without human intervention, and notifies the responsible persons about the violation of technological processes, providing facts for decision-making and notifying the senior manager about the incident, decisions and results.

The achieved technical result is ensured due to the fact that a robotic complex for managing production processes, control of products, raw materials, consisting of a central server with software, a video surveillance system, a weight control system, an active monitoring system, characterized in that the central server is configured to be located in any place convenient for work, subject to the availability of a stable cable communication channel with an automatic helicopter service complex, while the server performs the functions of receiving, accumulating and storing information, provides constant analytics of the information received, sends out analytics containing information to employees and responsible persons, forms a consolidated a certificate on the results of monitoring and analyzing incidents and the state of controlled objects, equipment, raw materials, materials, finished products, provides employees with access to archives and databases;

video surveillance system, consists of a group of video cameras for entry and exit from the territory of the enterprise, a group of video cameras for monitoring cargo flows across the territory, a group of video cameras for controlling workshops, production volumes, a group of video cameras for controlling warehouse areas, while the system uses two types of video cameras, stationary observation cameras and stationary rotary video cameras with a varifocal lens, while the video cameras are installed in places where cargo flows, loading and unloading points, while the system is combined by means of a computer program, with a helicopter;

weight control system, is a group of truck scales connected to a central server, scales are installed at the entrance, exit from the territory, at the entrance to the exit from workshops, entrance, exit from warehouse areas, the weight control system actively interacts, when weighing, the video surveillance system forms a video archive of the moment weighing, determining the mode of transport and the nature of the load, information from the weighing system and the video surveillance system enters the analytical program, which forms a database of events and archives them, with a video surveillance system and active monitoring, while at each place where the scales are installed, a remote workplace is arranged, all information received by the equipment are transmitted and processed on a central server;

active monitoring system, consists of two all-weather helicopters, a communication and information transmission system, an automated service complex.

The claimed invention is illustrated by drawings.

FIG. 1 shows the central server.

FIG. 2-4 show the cameras of the surveillance system.

FIG. 5 shows the active monitoring system.

The complex consists of:

1) Central server with software.

2) CCTV system

3) Weight control system.

4) Active monitoring systems (helicopter).

Central server - can be located in any place convenient for work, provided there is a stable cable communication channel with an automatic helicopter service complex. The server carries out the functions of receiving, accumulating and storing information. Provides constant analytics of the information received. Carries out a mailing containing analytic information to employees and responsible persons, in accordance with the appointment. Generates a summary report on the results of monitoring and analyzing incidents and the state of controlled objects, equipment, raw materials, materials, finished products. Provides employee access to archives and databases.

Specifications

1) Intel Xeon Silver 4214R processor (12-core (24-thread), 16.5M Cache, 2.40 GHz, 100W) x 2

2) Cooling system Supermicro SNK-P0070APS4 4U active cooler for Socket P x 2

3) RAM 64GB PC4-23400 2933MHz DDR4 ECC Registered DIMM x 4

4) Expansion slots 4x PCI-E x16; 2x PCI-E x8;

5) Integrated RAID Intel C621 10-port SATA3 (6Gb / s) software RAID 0, 1, 5, 10

6) Hard drives 1 Seagate 1TB SATA3 6Gb / s 7.2krpm 128Mb Exos 7E2 3.5 "HDD (512n) ST1000NM0008 x 2

7) Hard drives 2 Seagate 16TB SATA3 6Gb / s 7.2krpm 256Mb Exos X16 3.5 "HDD (512e / 4Kn) ST16000NM001G x 8

8) Integrated network card 2-port 1Gbps (2x RJ-45)

9) IPMI Integrated IPMI 2.0 + KVM-over-LAN with dedicated LAN port

10) Integrated video Aspeed AST2500 (1x VGA)

11) GPU PNY NVIDIA GeForce GTX 1070 Blower 8Gb GDDR5 (1xDVI, 1xHDMI, 3xDP) x 1

12) Operating system Microsoft Windows Server 2016 Standard (24-core) Rus DSP OEI DVD

13) Warranty plan Standard 3-year warranty with service center

14) Platform specifications:

15) Main Applications Workstation for rendering, prototyping, animation, design, CAD

16) Supported processors Up to two Intel Xeon Scalable series processors

17) Features of IPMI 2.0 + KVM with dedicated LAN port

18) Server motherboard

19) board / chipset

20) SuperMicro X11DAi-N

21) Intel C621 Chipset

22) RAM Up to 1TB 2666MHz Reg ECC DDR4 Load Reduced DIMM in 16 DIMM slots

23) Expansion slots 4x PCI-Express 3.0 x16 for GPU

24) 2x PCI-Express 3.0 x8

25) Integrated

26) raid controller

27) Intel C621 for 8 SATA3 (6Gb / s) ports; RAID 0,1,5,10

28) Network / Video / Audio 2x 1Gbps network ports (2x RJ-45)

29) Integrated video AST2500 (1x VGA)

30) IPMI 2.0 Management + KVM with dedicated LAN port

31) Intel Node Manager, SUM, SPM, SSM

32) SuperDoctor 5, Watchdog

33) Baskets for railway 8x 3.5 "Hot-Swap SAS3 / SATA3 baskets

34) Peripheral equipment Optional DVD-ROM drive

35) 3x 5.25 "drive bays

36) Power supply unit High efficiency PSU 1200W

37) Cooling system 5 fans with speed control

38) 4U Form Factor Rackmountable / Tower 452 x 178 x 648mm (17.8 "x 7" x 25.5 ")

The software will represent a single array, including the management and interaction of all equipment of the facility and interaction with warehouse logistics and accounting programs. The information received from all devices will be consolidated into file databases that provide continuous analysis of the situation. The archive will allow you to get information about the general movement of vehicles and persons, sections by day, time and events - receipt, movement, output of finished products.

Video surveillance system:

Comprises:

1. groups of video cameras entering and leaving the territory of the enterprise.

2. Groups of video cameras for monitoring the flow of goods across the territory.

3. Groups of video cameras for control of workshops, production volumes.

4. Groups of video cameras monitoring warehouse areas.

The system uses two types of video cameras, stationary survey cameras and stationary PTZ cameras with a varifocal lens. Video cameras are installed in places of movement of cargo flows, places of loading and unloading. The system is combined with a helicopter. The system takes the territory under constant video control (or uses it, if there is video from the security complex) Tracks the movement of material assets across the territory and movement between the workshops of the enterprise. Forms reports on the location of material assets.

Specifications

Maximum resolution: 5MP: 2592x1944, 25-30 frames / sec.

Sensor: 6MP 1 / 1.8 "SONY IMX178 Starvis CMOS progressive scan.

Lens: default 3.6-11mm varifocal motorized.

Video encoding: up to 3 streams H.264 (BP, MP, HP) / H.264 + (BP, MP,

HP) /H.265 / H.265 + / MJPG.

Functionality in short: WDR ~ 120Db, motion detection, anti-sabotage,

Private masks, BLC, HLC, anti-fog, LDC, 2 / 3DNR, ROI 4 zones, corridor

mode, network break detector, line crossing, area intrusion,

abandoned items, visitor counting, face detection, lens cover, network disconnection.

Specifications:

Maximum resolution: 5MP: 2592x1944, 25-30 frames / sec.

Sensor: 6MP 1 / 1.8 "SONY IMX178 Starvis CMOS progressive scan.

Lens: default 3.6-11mm varifocal motorized.

Video encoding: up to 3 streams H.264 (BP, MP, HP) / H.264 + (BP, MP,

HP) /H.265 / H.265 + / MJPG.

Functionality in short: WDR ~ 80Db, motion detection, anti-sabotage,

Private masks, BLC, HLC, anti-fog, LDC, 2 / 3DNR, ROI 4 zones, corridor

mode, network break detector, line crossing, area intrusion,

abandoned items, visitor counting, face detection, closure

lens, power outage.

Specifications.

High-speed outdoor PTZ camera with IR illumination

(optional laser illumination or thermal imager).

Janitor lens cleaner.

360 ° horizontal rotation, 90 ° + 15 ° vertical rotation,

automatic vertical turn.

3D positioning 1 to 128 presets.

Power supply: AC24V / 2500 mA.

Interfaces: Audio In / Out, Alarm

In / Out, RS-485, RESET, RJ45, AC24V, BNC.

Working range: -40 ° C ~ + 60 ° C.

Built-in heater for outdoor use.

Increased resolution up to 5MP, 1 / 1.8 "CMOS SONY IMX178 Starvis sensor.

Resolution: 2065 * 1553 up to 30 frames / sec., 3072 * 1728 up to 30 frames / sec.

Sensitivity: 0.005 Lux / 0.001 Lux

A group of video cameras for monitoring the import and export of materials and products.

Video cameras for control of entry and exit are installed in order to determine the type of vehicle, determine the nature of the load, comparing the current images with the reference images uploaded to the central server. When interacting with the weight control system, it determines the compliance of the declared cargo and its volumes in the accompanying documents, with those actually imported or exported.

Group of video cameras for monitoring the movement of goods across the territory

To control the movement of goods across the territory, standard routes for the movement of goods across the territory have been determined in accordance with their type and purpose in production processes. The system monitors the consistency of cargo volumes from the moment of weighing and determining the volume of cargo, to arrival at the warehouse or transfer to production. Violations of routes, or an unscheduled stop, are regarded as an emergency situation, the possibility of a violation of technology. The violation is recorded, the responsible persons are notified. An active monitoring tool is connected to event monitoring. When the cargo arrives at its destination, the weight and volume of the cargo is checked additionally.

Group of control cameras for production workshops and storage areas

Upon receipt of materials in the workshop (production area), its control is carried out by analogy of entry and exit. Its weight and volume are determined. The central server is loaded with the rates of material consumption in accordance with the production technology, indicating the volumes of incoming raw materials and the output of finished products, which are taken under control during analytics.

In addition to controlling the turnover of materials and the output of finished products, the shop control system monitors the stages of production in order to provide information on the nature of the technology violation and monitors the observance of safety measures by the shop workers. In case of violations, the responsible persons are informed, in the event of threats to life and health, the equipment can be stopped and de-energized, and then the responsible persons are informed.

Group of warehouse control cameras

When materials or finished products arrive at the warehouse territories, they are checked by analogy with checking goods at the entrance and exit to the territory. In addition, the places of storage of various materials, bulk cargo, finished products are determined. Violation of the established storage procedure is automatically recorded and the responsible persons are notified. Any change in the order of using warehouse space is preceded by uploading a storage plan for materials on the server through a remote warehouse workplace. In addition to control of areas by video surveillance and weight control, the volumes of stored goods are controlled by an active monitoring system.

Weight control system

It is a group of truck scales connected to a central server. Scales are installed at the entrance, exit from the territory, at the entrance to the exit from the workshops, entrance, exit from the warehouse territories. The weight control system actively interacts with the video surveillance and active monitoring system. A remote workplace is arranged at each place where the scales are installed. All information received by the equipment is transmitted and processed on a central server. This allows real-time analysis and comparison of readings in different areas of production.

Active monitoring system:

It consists of two all-weather helicopters, a communication and information transmission system, and an automated service complex.

Specifications:

Flight time (battery LiPo 6S 16000) 60+ minutes Maximum speed 90+ km / h Vertical speed: lifting 6 mps Vertical speed: decrease 4.5 m / s Point holding accuracy (GPS mode), horizon ± 2.5 m Point hold accuracy (GPS mode), vertical ± 0.8 m Maximum tilt angle 35 ° Maximum swing speed 150 ° / s Max. permissible wind speed 12 m / s Operating temperature range -20 ... + 45 ° C

The helicopter carries a suspension of up to five kilograms, the possible flight distance in one flight is up to fifty kilometers, a speed of 90 km / h, or hovering in one place for forty-five minutes. With these characteristics, the device can move the suspended equipment, automatically patrolling the object along a given route, while hovering in place, observe the entire territory using a wide-angle camera. A high-resolution video camera suspension will allow you to control the movement of vehicles and persons across the territory with the recognition of the transported, transported cargo. The third video camera is specialized for determining the volume of material values in open storage areas, determines the number of products, packages or the volume of bulk cargo, records changes in the volume of raw materials. At any point on the route, he can receive unscheduled, additional commands and, after their execution, he will proceed to perform a planned flight. In case of emergency situations, the helicopter hovers over the place of the event and, using a high-resolution video camera, gives a detailed picture of the events. The video camera of the helicopter is a part of the face recognition system, and therefore, in the event of an emergency situation, the helicopter will display information on the basis of friend or foe, and if his, then who exactly. One of the helicopters is always on observation with a change on the spot, the same change will take place in case of emergency, ensuring continuous observation of the scene of the event.

The communication and information transmission system consists of sets of autonomous equipment installed at the facility, forming a seamless wi fi field along the entire flight route. The sets are interconnected by radio bridges and provide information transfer at a speed of at least 100 Mb. This is enough to control and monitor the operation of the helicopter and receive information from three gimbal devices in real time.

An automatic service complex is installed in a place inaccessible for free visits. The complex provides helicopter reception, technical condition analysis, and additional charging. Downloads the information accumulated during the flight to internal media. Provides helicopter departure according to the flight schedule. Transfers information to a central server. The complex has final equipment for radio bridges and a transition to cable communication channels. The complex operates autonomously and is serviced in accordance with the regulations.

All systems are designed for an ordinary user; deep knowledge of the system by the user is not required. The complex is independent and does not need to attract additional, specially trained personnel.

In 2019, the complex was tested at a plant producing asphalt, reinforced concrete structures. The complex made it possible to identify violations of the production technology of products, as a result of which the quality of asphalt and concrete structures significantly decreased and allowed the formation of unaccounted for surplus in storage areas, from which products were subsequently manufactured for illegal sale.

Claims (4)

A robotic complex for managing production processes, controlling products, raw materials, consisting of a central server with software, a video surveillance system, a weight control system, an active monitoring system, characterized in that the central server is configured to be located in any convenient place for work, subject to availability stable cable communication channel with an automatic helicopter maintenance complex, while the server performs the functions of receiving, accumulating and storing information, provides constant analytics of the information received, sends out a mailing containing analytics information to employees and responsible persons, generates a summary report on the results of monitoring and analyzing incidents and the state of controlled objects, equipment, raw materials, materials, finished products, provides employees with access to archives and databases; the video surveillance system consists of a group of video cameras for entry and exit from the territory of the enterprise, a group of video cameras for monitoring cargo flows through the territory, a group of video cameras for controlling workshops, production volumes, a group of video cameras that control warehouse areas, while the system uses two types of video cameras, stationary observation cameras and stationary rotary video cameras with a varifocal lens, while the video cameras are installed in places where cargo flows, places of loading and unloading, while the system is combined, by means of a computer program, with a helicopter; the weight control system is a group of truck scales connected to a central server, the scales are installed at the entrance, exit from the territory, at the entrance, exit from the workshops, entrance, exit from the warehouse areas, the weight control system actively interacts, when weighing, the video surveillance system forms a video archive of the moment weighing, determining the mode of transport and the nature of the load, information from the weighing system and the video surveillance system is fed into the analytical program, which forms a database of events and archives them, with a video surveillance system and active monitoring, while at each place where the scales are installed, a remote workplace is arranged, all information received by the equipment are transmitted and processed on a central server; the active monitoring system consists of two all-weather helicopters, a communication and information transmission system, and an automated service complex.

Images