WO2020215475A1 - 一种监控设备内部运行情况的方法及装置 - Google Patents

一种监控设备内部运行情况的方法及装置 Download PDF

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Publication number
WO2020215475A1
WO2020215475A1 PCT/CN2019/092515 CN2019092515W WO2020215475A1 WO 2020215475 A1 WO2020215475 A1 WO 2020215475A1 CN 2019092515 W CN2019092515 W CN 2019092515W WO 2020215475 A1 WO2020215475 A1 WO 2020215475A1
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equipment
layer
dimensional
event
data
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French (fr)
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唐敦兵
潘俊峰
宋家烨
张泽群
周通
王仕存
伍健民
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Nanjing University of Aeronautics and Astronautics
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Nanjing University of Aeronautics and Astronautics
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01DMEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D21/00Measuring or testing not otherwise provided for
    • G01D21/02Measuring two or more variables by means not covered by a single other subclass
    • HELECTRICITY
    • H04ELECTRIC COMMUNICATION TECHNIQUE
    • H04NPICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N7/00Television systems
    • H04N7/18Closed-circuit television [CCTV] systems, i.e. systems in which the video signal is not broadcast
    • H04N7/181Closed-circuit television [CCTV] systems, i.e. systems in which the video signal is not broadcast for receiving images from a plurality of remote sources

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  • the present invention relates to the technical field of intelligent manufacturing, in particular to a method and device for monitoring the internal operation of equipment.
  • the means to understand the real-time status of the workshop mainly include two parts: video monitoring and real-time collection of equipment operating parameters.
  • video monitoring in a surveillance solution that collects workshop video through a camera, multiple video sources are collected, and the surveillance video data is merged according to comprehensive weights.
  • the disadvantage of this design is that the video monitoring method can only see the equipment shell, and cannot detect the internal faults of the equipment.
  • the host computer is used to read and analyze the data in the programmable controller, and the related data is generated into histogram and data pie chart, or displayed in the pre-designed system topology diagram (such as the current high-speed rail and subway operation master control center Graphical display mode).
  • the data charting technology only converts text data into chart data, and cannot intuitively find problems in the production environment, especially the internal failures of the equipment, especially in the experience of technicians. When it is not very abundant, it is often easy to ignore the changes of some parameters, thus missing the hidden danger of equipment failure.
  • the embodiments of the present invention provide a method and device for monitoring the internal operating conditions of equipment, which can intuitively reflect changes in equipment operating parameters, thereby reducing the possibility that operation and maintenance personnel miss the hidden trouble of equipment failure.
  • a method to monitor the internal operation of equipment :
  • the relevant sensors include at least: built-in sensors, programmable controllers, and external sensors of the monitored device, and the peripheral auxiliary equipment includes at least: Video equipment for monitoring equipment;
  • the equipment unit model is used to simulate the equipment in the plant: each monitored equipment, Sensors related to each monitored device and peripheral auxiliary equipment related to each monitored device;
  • the equipment operation events that have occurred are displayed in the 3D model.
  • a device for monitoring the internal operation of equipment comprising: an equipment unit model, a data interface layer, a data fusion layer, an event perception layer and a three-dimensional simulation monitoring layer;
  • the equipment unit model is used to simulate each monitored device in the factory building, sensors related to each monitored device, and peripheral auxiliary equipment related to each monitored device, wherein the related sensors include at least: the monitored device
  • the built-in sensors, programmable controllers, and external sensors of, the peripheral auxiliary equipment includes at least: video equipment for monitoring the monitored equipment;
  • the data interface layer is used to collect operating data of the monitored device in real time from the related sensors and the peripheral auxiliary device, and transmit it to the data fusion layer;
  • the data fusion layer is used for fusing the operating data transmitted by the data interface layer into the equipment unit model, so as to refresh the sensor data in the equipment unit model in real time;
  • the event perception layer is used to analyze the state change of the device unit model, determine the device operation event that has occurred, and generate an event notification, and then transmit the generated event notification to the three-dimensional simulation monitoring layer;
  • the three-dimensional simulation monitoring layer is used to display the equipment operation events that have occurred on the three-dimensional model of the monitoring interface.
  • the method can be applied to the scene of monitoring the operation of the equipment on the factory floor.
  • the method can see the internal operation of the equipment through simulation, which is equivalent to the realization of In order to detect and observe through the machine shell, in order to locate the fault and analyze the equipment load.
  • this method can more intuitively view the operating conditions of machine tools, so that the staff can check the workshop conditions at any time.
  • Figure 1 is a schematic structural diagram of a lathe equipment unit provided by an embodiment of the present invention.
  • FIG. 2 is a schematic structural diagram of a milling machine equipment unit provided by an embodiment of the present invention.
  • Figure 3 is a schematic structural diagram of a logistics equipment unit provided by an embodiment of the present invention.
  • Figure 4 is a schematic diagram of the overall structure of a monitoring solution provided by an embodiment of the present invention.
  • the embodiment of the present invention provides a method for monitoring the internal operation of a device.
  • the process of the method can be applied to the monitoring system as shown in FIG. 4.
  • the monitoring system includes a data interface layer, a data fusion layer, an event perception layer, and a three-dimensional simulation monitoring layer. .
  • the data interface layer is responsible for collecting and sorting data from three lathe equipment unit models, three milling machine equipment unit models, and one logistics equipment unit model, and send them to the data fusion layer.
  • the data fusion layer receives the cleaned and repaired data from the data interface layer, performs fusion, establishes the data structure of each device unit model in the system, and is responsible for updating the data in real time.
  • the event perception layer analyzes the status changes of each device unit model, senses the occurrence of events, processes the events, and sends notifications to the 3D simulation monitoring layer.
  • the 3D simulation monitoring layer receives event notifications from the event perception layer and performs corresponding actions on the 3D model to realize real-time monitoring.
  • the method process includes:
  • the relevant sensors include at least: built-in sensors, programmable controllers, and external sensors of the monitored equipment
  • the peripheral auxiliary equipment includes at least: video equipment for monitoring the monitored equipment.
  • the equipment unit model as a whole includes: equipment that completes a certain function, various sensors, peripheral auxiliary equipment, etc. related to it to form an overall model.
  • the function of the data interface layer is to collect real-time data for the built-in sensors and programmable controllers of the factory processing equipment, external sensors, and video equipment.
  • the data interface layer is compatible with various sensor types and multiple sensor data formats. Clean and pack the acquired data; use linear interpolation to compensate for missing and misread data; for various types of data, parse them and pack them into a unified data format for processing at the data fusion layer.
  • the operating data includes: the temperature of the machine tool, the current coordinates of the spindle and tool position, cutting parameters (spindle speed, feed rate), fixture status and other operating parameters; the pose data of each axis of the manipulator, fixture status, etc. Data of operating parameters; data of operating parameters such as the current position, speed, acceleration of the AGV.
  • built-in sensors refer to sensors that are necessary for the operation of the device, and the device itself integrates these sensors. The lack of these sensors will cause the equipment to fail to work normally, including programmable controllers, encoders, grating scales, displacement sensors, and grating scales.
  • the built-in sensors of the machine tool include: spindle encoder, grating ruler, and air pressure sensor.
  • the built-in sensors of AGV include: navigation sensors (magnetic navigation, infrared navigation, laser navigation, etc.), encoder (speed control).
  • the built-in sensors of the manipulator include: encoder (controlling the attitude of multiple axes). In practical applications, the built-in sensor is controlled by a programmable controller (PLC). Obtain the data value of the built-in sensor by reading the officially defined PLC register address or rewriting the PLC program.
  • PLC programmable controller
  • the external sensor means that it is not necessary for the operation of the equipment, but can assist the operation of the equipment.
  • General equipment is not integrated and needs to be additionally purchased, installed or modified by itself, including RFID card readers, material sensors, vision detection sensors, temperature sensors, vibration sensors, air pressure sensors, etc.
  • the external sensors of the machine tool include: temperature sensor, vibration sensor, tool state detection sensor.
  • the external sensors of AGV include: RFID sensor (read IC chip and other information), visual sensor (identify goods two-dimensional code).
  • the equipment unit model includes the plant: each monitored device, sensors related to each monitored device, and peripheral auxiliary equipment related to each monitored device .
  • the function of the data fusion layer is to fuse various types of information received in the data interface layer into each device unit model, so that the sensor data in each device unit model is updated in real time for the event perception layer to analyze and process.
  • multiple event templates are encapsulated in the event perception layer.
  • the event is triggered to notify the upper three-dimensional simulation monitoring layer that an event has occurred.
  • the event template uses computer program code. Save in the form. For example: posture change event, if the current posture status information of the device has changed from the previous posture status information, the upper three analog monitoring layer is notified that a device movement event has occurred; abnormal status events, the current status information parameters of the device are not When the parameters of the normal operation state are met, the event perception layer sends an event notification upward; for a fault warning event, the current state information parameters of the equipment are at the edge of the normal operation state parameter range and belong to the normal state. With the normal operation of the equipment, it is very likely to trigger abnormal state events.
  • This embodiment can be applied to the scene of monitoring the operation of the equipment on the factory floor. Compared with the traditional video monitoring method, this method can see the internal operation of the equipment by means of simulation, which is equivalent to the realization of Test and observe through the machine shell to locate faults and analyze equipment load conditions. Compared with data charting technology, this method can more intuitively view the operating conditions of machine tools, so that the staff can check the workshop conditions at any time.
  • the isometric three-dimensional model is driven by collecting various sensor data in the factory to realize real-time simulation of the on-site environment.
  • Its advantage lies in the fact that the internal state of the device can be directly viewed through the device casing, which effectively solves the problem of the blind spot of traditional video surveillance technology.
  • the naked eye can visually find the location of the fault in the factory and the cause of the fault, which effectively solves the shortcomings of data charting technology that is not intuitive.
  • Parallel to S3 is optional, or can be executed simultaneously, this embodiment also includes:
  • the upcoming equipment operation events are displayed in the three-dimensional model. That is, to perceive upcoming events and preprocess. And display these events on the 3D simulation monitoring layer.
  • the equipment unit model establish a three-dimensional model of the same scale as the plant, and display the established three-dimensional model on the monitoring interface;
  • the three-dimensional model includes each monitored device in the workshop and a three-dimensional internal structure diagram of each monitored device.
  • Step S4 displaying equipment operation events in the three-dimensional model, which specifically includes:
  • the event perception layer sends out event notifications based on the device operation event; the three-dimensional simulation monitoring layer triggers the three-dimensional model displayed in the monitoring interface to take actions based on the obtained event notifications, where the taken actions correspond to the event notifications.
  • the three-dimensional simulation monitoring layer triggers the three-dimensional model displayed in the monitoring interface to take actions based on the obtained event notifications, where the taken actions correspond to the event notifications.
  • the 3D model in the monitoring interface will refresh the current posture position to keep it consistent with the actual device state.
  • the 3D model in the monitoring interface displays a striking color (such as red), and displays the corresponding status parameters and fault names. It is convenient for technicians to inspect and maintain in time.
  • the 3D model in the monitoring interface displays the warning color (such as yellow), and displays the corresponding status parameters, as well as possible failure conditions.
  • the three-dimensional simulation monitoring layer can display a three-dimensional model of the same scale as the factory. Its function is to receive event notifications from the event perception layer to make the three-dimensional model act to simulate changes in the real factory environment.
  • These three-dimensional models are supported by the data in the equipment unit model, and can perceive changes in internal conditions through the equipment housing.
  • the monitored equipment is a lathe equipment
  • the lathe equipment is composed of a lathe part, a manipulator part, and a work station part;
  • the lathe part is provided with a programmable controller, a visual detection sensor, an encoder, a grating ruler, a temperature sensor, a vibration sensor, and an air pressure sensor;
  • the manipulator part is provided with a displacement sensor and an encoder
  • the station part is provided with an RFID card reader and a material sensor.
  • the monitored equipment is a milling machine equipment
  • the milling machine equipment consists of a milling machine part, a manipulator part and a station part;
  • the milling machine part is provided with a programmable controller, a visual detection sensor, an encoder, a grating ruler, a temperature sensor, a vibration sensor, and an air pressure sensor.
  • the manipulator part is provided with a displacement sensor and an encoder.
  • the station part is provided with an RFID card reader and a material sensor.
  • the built-in sensors used in common lathes and milling machines are integrated by the equipment itself to provide data required for equipment operation. External sensors used in lathes and milling machines provide additional data to assist in improving equipment processing capabilities or provide monitoring means. There are no specific models of sensors. Generally, the sensors used in lathes and milling machines are the same, and the difference between them is the processing capabilities of the two machine tools.
  • the lathe is used to turn the rotating body, and the milling machine can perform surface milling.
  • the monitored equipment is a logistics equipment
  • the logistics equipment is composed of a three-dimensional warehouse part, a manipulator part and an automatic guided car part;
  • Programmable controllers, material detection sensors, RFID card readers, and encoders are provided in the three-dimensional warehouse part;
  • the manipulator part is provided with a displacement sensor and an encoder
  • the part of the automatic guided car is provided with an RFID card reader and a programmable controller.
  • the function of the three-dimensional warehouse is to provide the storage capacity of the goods. Compared with lathes and milling machines, there are no sensors for auxiliary machining such as grating scales, visual detection sensors, temperature sensors, vibration sensors, and air pressure sensors. An RFID reader and material detection sensor are added to identify the goods.
  • the device includes: a device unit model, a data interface layer, a data fusion layer, an event perception layer, and a three-dimensional simulation monitoring layer.
  • the equipment unit model is used to simulate each monitored device in the factory building, sensors related to each monitored device, and peripheral auxiliary equipment related to each monitored device, wherein the related sensors include at least: the monitored device
  • the built-in sensors, programmable controllers, and external sensors of, and the peripheral auxiliary equipment includes at least: video equipment for monitoring the monitored equipment.
  • the data interface layer is used to collect operating data of the monitored device in real time from the related sensors and the peripheral auxiliary device, and transmit it to the data fusion layer.
  • the data fusion layer is used to merge the operating data transmitted by the data interface layer into the equipment unit model, so as to refresh the sensor data in the equipment unit model in real time.
  • the event perception layer is used to analyze the state change of the equipment unit model, determine the equipment operation event that has occurred, and generate an event notification, and then transmit the generated event notification to the three-dimensional simulation monitoring layer.
  • the three-dimensional simulation monitoring layer is used to display the equipment operation events that have occurred on the three-dimensional model of the monitoring interface.
  • the overall structure of the monitoring method includes a device unit model, a data interface layer, a data fusion layer, an event perception layer, and a three-dimensional simulation monitoring layer.
  • the equipment unit model as a whole includes: equipment that completes a certain function, various sensors, peripheral auxiliary equipment, etc. related to the equipment to form an overall model.
  • the function of the data interface layer is to collect real-time data for the built-in sensors and programmable controllers of the factory processing equipment, external sensors, and video equipment.
  • the data interface layer is compatible with various sensor types and multiple sensor data formats. Clean and pack the acquired data. Use linear interpolation to compensate for missing or misread data. For various types of data, it is parsed and packaged into a unified data format for processing at the data fusion layer.
  • the function of the data fusion layer is to fuse various types of information received in the data interface layer into each device unit model, so that the sensor data in each device unit model is updated in real time for the event perception layer to analyze and process.
  • the function of the event perception layer is to analyze the state changes of each device unit model, sense the events that have occurred, and process them. Or perceive upcoming events and perform preprocessing. And display these events on the 3D simulation monitoring layer.
  • the three-dimensional simulation monitoring layer is characterized by: a three-dimensional model of the same scale as the factory. Its function is to receive event notifications from the event perception layer to make the three-dimensional model act to simulate changes in the real factory environment. These three-dimensional models are supported by the data in the equipment unit model, and can perceive changes in internal conditions through the equipment housing.
  • the event perception layer is also used to predict the upcoming equipment operation event based on the state change of the equipment unit model.
  • the three-dimensional simulation monitoring layer is used to display the upcoming equipment operation event on the three-dimensional model of the monitoring interface.
  • the three-dimensional simulation monitoring layer is also used to establish a three-dimensional model of the same scale as the plant according to the equipment unit model, and display the established three-dimensional model on the monitoring interface.
  • the three-dimensional model includes each monitored device in the workshop and a three-dimensional internal structure diagram of each monitored device.
  • the event perception layer is also used to send event notifications based on device operation events.
  • the three-dimensional simulation monitoring layer is also used to trigger an action on the three-dimensional model displayed in the monitoring interface according to the obtained event notification, wherein the action that occurs corresponds to the event notification.
  • the monitored equipment is a lathe equipment, which is composed of a lathe part, a manipulator part and a work station part.
  • a programmable controller and a visual detection sensor are arranged in the lathe part.
  • the manipulator part is provided with a displacement sensor.
  • the station part is provided with an RFID card reader and a material sensor.
  • the monitored equipment is a milling machine equipment
  • the milling machine equipment consists of a milling machine part, a manipulator part and a work station part.
  • a programmable controller and a visual detection sensor are arranged in the milling machine part.
  • the manipulator part is provided with a displacement sensor.
  • the station part is provided with an RFID card reader and a material sensor.
  • the monitored equipment is a logistics equipment
  • the lathe equipment is composed of a three-dimensional warehouse part, a manipulator part and an automatic guided car part.
  • a programmable controller is provided in the three-dimensional warehouse part.
  • the manipulator part is provided with a displacement sensor.
  • the part of the automatic guided car is provided with an RFID card reader and a programmable controller.

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Abstract

一种监控设备内部运行情况的方法及装置,涉及智能制造技术领域,包括:S1.通过数据接口层,实时采集被监控设备的运行数据;S2.将经过数据接口层传输的数据,导入设备单元模型中,以便于设备单元模型内实时刷新传感数据;S3.根据设备单元模型的状态变化,确定已发生的设备运行事件;S4.将已发生的设备运行事件,显示在三维模型中。

Description

一种监控设备内部运行情况的方法及装置 技术领域
本发明涉及智能制造技术领域,尤其涉及一种监控设备内部运行情况的方法及装置。
背景技术
近年来,国家对于智能制造领域的投入越来越大,智能制造技术中很重要的一环,就是在实现车间无人化生产的同时,运维人员可以远程查看车间状态。通过各类传感器收集车间、工厂的实时数据发送至服务器或是云端,技术人员不必亲自前往加工现场便可以了解车间实时状态,用户也可以通过工厂开放的数据来了解自己的订单当前状况。
目前了解车间实时状态的手段主要包括了视频监控和设备运行参数的实时采集这两部分。例如:通过摄像头采集车间视频的监控方案中,会采集多个视频源,根据综合权重融合监控视频数据。这种设计的不足之处是:视频监控方法只能看到设备外壳,无法探知设备内部故障。
同时,利用上位计算机读取分析可编程控制器内的数据,将相关数据生成柱状图和数据饼图,或者显示在预先设计好的系统拓扑图中(比如目前高铁、地铁运行的总控中心的图形化显示方式)。这种设计的不足之处是:数据图表化技术只是将文字数据转换成图表数据,无法直观地发现生产环境中出现的问题,尤其是无法直观得探知设备内部故障,尤其是在技术人员的经验不是很丰富时,往往很容易忽略一些参数的变化,从而遗漏设备的故障隐患。
发明内容
本发明的实施例提供一种监控设备内部运行情况的方法及装置,能够直观 得体现设备运行参数的变化,从而降低运维人员遗漏设备的故障隐患的可能性。
为达到上述目的,本发明的实施例采用如下技术方案:
一种监控设备内部运行情况的方法:
通过数据接口层,实时采集被监控设备的运行数据,所述相关的传感器至少包括:被监控设备的内置传感器、可编程控制器、外置传感器,所述外围辅助设备至少包括:用于监控被监控设备的视频设备;
将经过所述数据接口层传输的数据,导入设备单元模型中,以便于所述设备单元模型内实时刷新传感数据,其中,所述设备单元模型用于仿真厂房内的:各个被监控设备、与各个被监控设备相关的传感器和与各个被监控设备相关的外围辅助设备;
根据所述设备单元模型的状态变化,确定已发生的设备运行事件;
将已发生的设备运行事件,显示在三维模型中。
一种监控设备内部运行情况的装置,所述装置包括:设备单元模型、数据接口层、数据融合层、事件感知层和三维模拟监控层;
所述设备单元模型,用于仿真厂房内的各个被监控设备、与各个被监控设备相关的传感器和与各个被监控设备相关的外围辅助设备,其中,所述相关的传感器至少包括:被监控设备的内置传感器、可编程控制器、外置传感器,所述外围辅助设备至少包括:用于监控被监控设备的视频设备;
所述数据接口层,用于从所述相关的传感器和所述外围辅助设备,实时采集被监控设备的运行数据,并向数据融合层传输;
所述数据融合层,用于将所述数据接口层传输的运行数据,融合到所述设备单元模型中,以便于所述设备单元模型内实时刷新传感数据;
所述事件感知层,用于分析所述设备单元模型的状态变化,确定已发生的设备运行事件,并生成事件通知,之后将所生成的事件通知向所述三维模拟监控层传输;
所述三维模拟监控层,用于将已发生的设备运行事件,显示在监控界面的三维模型。
本实施例中,可以应用在监控工厂车间的设备运行情况的场景中,相比传统视频监控方法,该方法可以通过模拟仿真的方式看到设备内部运行情况,对于技术人员来说,相当于实现了穿过机器外壳进行检测观察,以便定位故障以及分析设备负载情况。相比数据图表化技术,该方法可以更加直观的查看机床设备的运行情况,以便于工作人员随时检查车间情况。
附图说明
为了更清楚地说明本发明实施例中的技术方案,下面将对实施例中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其它的附图。
图1为本发明实施例提供的车床设备单元的结构示意图;
图2为本发明实施例提供的铣床设备单元的结构示意图;
图3为本发明实施例提供的物流设备单元的结构示意图;
图4为本发明实施例提供的监控方案整体结构的示意图。
具体实施方式
为使本领域技术人员更好地理解本发明的技术方案,下面结合附图和具体实施方式对本发明作进一步详细描述。下文中将详细描述本发明的实施方式,所述实施方式的示例在附图中示出,其中自始至终相同或类似的标号表示相同 或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施方式是示例性的,仅用于解释本发明,而不能解释为对本发明的限制。本技术领域技术人员可以理解,除非特意声明,这里使用的单数形式“一”、“一个”、“所述”和“该”也可包括复数形式。应该进一步理解的是,本发明的说明书中使用的措辞“包括”是指存在所述特征、整数、步骤、操作、元件和/或组件,但是并不排除存在或添加一个或多个其他特征、整数、步骤、操作、元件、组件和/或它们的组。应该理解,当我们称元件被“连接”或“耦接”到另一元件时,它可以直接连接或耦接到其他元件,或者也可以存在中间元件。此外,这里使用的“连接”或“耦接”可以包括无线连接或耦接。这里使用的措辞“和/或”包括一个或更多个相关联的列出项的任一单元和全部组合。本技术领域技术人员可以理解,除非另外定义,这里使用的所有术语(包括技术术语和科学术语)具有与本发明所属领域中的普通技术人员的一般理解相同的意义。还应该理解的是,诸如通用字典中定义的那些术语应该被理解为具有与现有技术的上下文中的意义一致的意义,并且除非像这里一样定义,不会用理想化或过于正式的含义来解释。
本发明实施例提供一种监控设备内部运行情况的方法,该方法流程可以应用在如图4所示的监控系统上,监控系统包括数据接口层、数据融合层、事件感知层和三维模拟监控层。
数据接口层负责从三个车床设备单元模型和三个铣床设备单元模型和一个物流设备单元模型中采集整理数据,发送给数据融合层。
数据融合层接收来自数据接口层清洗、修复后的数据,进行融合,在系统中建立各个设备单元模型的数据结构,并负责实时更新数据。
事件感知层通过分析各个设备单元模型的状态变化,感知事件发生,处理事件,并向三维模拟监控层发出通知。
三维模拟监控层接收来自事件感知层的事件通知,对三维模型进行相应动作,以实现实时监控。
其中,该方法流程包括:
S1、通过数据接口层,实时采集被监控设备的运行数据。
其中,所述相关的传感器至少包括:被监控设备的内置传感器、可编程控制器、外置传感器,所述外围辅助设备至少包括:用于监控被监控设备的视频设备。具体的,所述设备单元模型,其整体包括:完成一定功能的设备以及与之相关的各类传感器、外围辅助设备等构建成为一个整体模型。所述数据接口层,其功能是负责针对工厂加工设备内置传感器与可编程控制器、外置传感器、视频设备等进行实时数据采集。数据接口层兼容各种传感器类型以及多种传感器数据格式。对于获取的数据进行清洗、包装;针对缺失、错读的数据使用线性插值弥补;针对各种类型数据,将其解析后包装成统一的数据格式,供数据融合层处理。
具体的,运行数据包括了:机床的温度、主轴及刀具位置当前坐标、切削参数(主轴转速、进给速率)、夹具状态等运行参数的数据;机械手的各个轴的位姿数据、夹具状态等运行参数的数据;AGV的当前位置、速度、加速度等运行参数的数据。
本实施例中,内置传感器指的是,设备运行必备的传感器,设备自身集成这些传感器。缺少这些传感器将导致设备无法正常工作,具体包括了可编程控制器、编码器、光栅尺、位移传感器、光栅尺等。例如:机床的内置传感器包括:主轴编码器、光栅尺,气压传感器。AGV的内置传感器包括:导航传感器(磁 导航、红外导航、激光导航等),编码器(速度控制)。机械手的内置传感器包括:编码器(控制多个轴的姿态)。在实际应用中,内置传感器使用可编程控制器(PLC)进行控制。通过读取官方定义的PLC寄存器地址,或是改写PLC程序,来获取内置传感器的数据值。
本实施例中,外置传感器指的是,非设备运行所必须,但可以辅助设备运行。一般设备没有集成,需要自行额外购买、安装或改造,具体包括了RFID读卡器、物料传感器、视觉检测传感器、温度传感器、震动传感器、气压传感器等。例如:机床的外置传感器包括:温度传感器、震动传感器、刀具状态检测传感器。AGV的外置传感器包括:RFID传感器(读取IC芯片等信息)、视觉传感器(识别货物二维码)。
S2、将经过所述数据接口层传输的数据,导入设备单元模型中。
以便于所述设备单元模型内实时刷新传感数据,其中,所述设备单元模型包括厂房内的:各个被监控设备、与各个被监控设备相关的传感器和与各个被监控设备相关的外围辅助设备。所述数据融合层,其功能是将数据接口层中接收到的各类信息融合到各个设备单元模型中,使每个设备单元模型内的传感数据实时更新,供事件感知层分析处理。
S3、根据所述设备单元模型的状态变化,确定已发生的设备运行事件。
具体的,在事件感知层封装了多个事件模板,根据设备状态参数的变化,符合事件模板内容,则触发该事件,通知上层三维模拟监控层某事件已发生,其中,事件模板以计算机程序代码的形式保存。例如:姿态变更事件,设备当前的位姿状态信息与前一时刻位姿状态信息发生了变化,则通知上层三位模拟监控层,发生了设备移动事件;状态异常事件,设备当前状态信息参数不符合正常运行状态参数时,事件感知层向上发出事件通知;故障预警事件,设备当 前状态信息参数处于正常运行状态参数范围的边缘,属于正常状态。随着设备的正常运行,极有可能触发状态异常事件。
S4、将已发生的设备运行事件,显示在三维模型中。
本实施例,可以应用在监控工厂车间的设备运行情况的场景中,相比传统视频监控方法,该方法可以通过模拟仿真的方式看到设备内部运行情况,对于技术人员来说,相当于实现了穿过机器外壳进行检测观察,以便定位故障以及分析设备负载情况。相比数据图表化技术,该方法可以更加直观的查看机床设备的运行情况,以便于工作人员随时检查车间情况。
具体的,本实施例中通过采集工厂内各类传感器数据来驱动等比例三维模型,以实现实时模拟现场环境。其优势在于:可以透过设备外壳直接查看设备内部状态,有效解决了传统视频监控技术的监控盲区问题。肉眼可直观发现工厂内故障所在位置,以及故障原因,有效解决了数据图表化技术不够直观的缺点。
与S3并列可选的,或者可以同时执行的,本实施例中还包括:
根据所述设备单元模型的状态变化,预测即将发生的设备运行事件;
将即将发生的设备运行事件,显示在所述三维模型中。即感知即将发生的事件,进行预处理。并将这些事件显示在三维模拟监控层。
进一步的,还包括:
根据所述设备单元模型,建立与所述厂房等比例的三维模型,并将所建立的三维模型显示在监控界面;
其中,所述三维模型包括了厂房内的各个被监控设备,和各个被监控设备的三维的内部结构图。
步骤S4,将设备运行事件显示在三维模型中,具体包括:
所述事件感知层中根据设备运行事件,发出事件通知;三维模拟监控层根据获取到的事件通知,触发所述监控界面中显示的三维模型发生动作,其中所发生的动作对应所述事件通知。例如:
当三维模拟监控层捕获姿态变更事件,监控界面中的三维模型会刷新当前姿态位置,保持与实际设备状态一致。
当三维模拟监控层捕获状态异常事件,监控界面中的三维模型显示出醒目颜色(如红色),并显示相应状态参数、故障名称。便于技术人员及时检修维护。
当三维模拟监控层捕获异常预警事件,监控界面中的三维模型显示预警颜色(如黄色),并显示相应的状态参数,以及可能发生故障情况。
其中,三维模拟监控层,可以显示与工厂等比例的三维模型。其功能是接受来自事件感知层的事件通知,使三维模型发生动作,以模拟真实工厂环境的情况变化。这些三维模型由设备单元模型内的数据支撑,可以透过设备外壳感知内部情况变化。
下面列举本实施例的几种可能的实际应用场景:
以车床设备的场景为例:如图1所示,所述被监控设备为车床设备,所述车床设备由车床部分、机械手部分和工位台部分组成;
所述车床部分中设置有可编程控制器、视觉检测传感器、编码器、光栅尺、温度传感器、震动传感器、气压传感器;
所述机械手部分中设置有包含位移传感器和编码器;
所述工位台部分中设置有包含RFID读卡器和物料传感器。
以铣床设备的场景为例:如图2所示,所述被监控设备为铣床设备,所述铣 床设备由铣床部分、机械手部分和工位台部分;
所述铣床部分中设置有可编程控制器、视觉检测传感器、编码器、光栅尺、温度传感器、震动传感器、气压传感器。
所述机械手部分中设置有包含位移传感器和编码器。
所述工位台部分中设置有包含RFID读卡器和物料传感器。
通常的车床和铣床使用的内置传感器由设备自身集成,提供设备运行所需数据。车床和铣床使用的外置传感器提供额外数据,辅助提升设备加工能力或者是提供监控手段。没有限定具体型号的传感器。通常的,车床和铣床使用的传感器是一样的,它们的区别是这两种机床的加工能力不同。车床用于车削回转体,铣床可以进行曲面铣削。
以物流设备的场景为例:如图3所示,所述被监控设备为物流设备,所述物流设备由立体仓库部分、机械手部分和自动引导小车部分组成;
所述立体仓库部分中设置有可编程控制器、物料检测传感器、RFID读卡器,编码器;
所述机械手部分中设置有包含位移传感器和编码器;
所述自动引导小车部分中设置有包含RFID读卡器和可编程控制器。立体仓库的功能是提供货物的存储能力。与车床铣床相比,没有光栅尺、视觉检测传感器、温度传感器、震动传感器、气压传感器等辅助机加工的传感器。而增加了RFID读卡器、物料检测传感器用于识别货物。
本实施例中还提供一种监控设备内部运行情况的装置,如图4所示的,所述装置包括:设备单元模型、数据接口层、数据融合层、事件感知层和三维模拟监控层。
所述设备单元模型,用于仿真厂房内的各个被监控设备、与各个被监控设备相关的传感器和与各个被监控设备相关的外围辅助设备,其中,所述相关的传感器至少包括:被监控设备的内置传感器、可编程控制器、外置传感器,所述外围辅助设备至少包括:用于监控被监控设备的视频设备。
所述数据接口层,用于从所述相关的传感器和所述外围辅助设备,实时采集被监控设备的运行数据,并向数据融合层传输。
所述数据融合层,用于将所述数据接口层传输的运行数据,融合到所述设备单元模型中,以便于所述设备单元模型内实时刷新传感数据。
所述事件感知层,用于分析所述设备单元模型的状态变化,确定已发生的设备运行事件,并生成事件通知,之后将所生成的事件通知向所述三维模拟监控层传输。
所述三维模拟监控层,用于将已发生的设备运行事件,显示在监控界面的三维模型。
具体的,所述监控方法的整体结构包括设备单元模型、数据接口层、数据融合层、事件感知层、三维模拟监控层。所述设备单元模型,其整体包括:完成一定功能的设备以及与之相关的各类传感器、外围辅助设备等构建成为一个整体模型。所述数据接口层,其功能是负责针对工厂加工设备内置传感器与可编程控制器、外置传感器、视频设备等进行实时数据采集。数据接口层兼容各种传感器类型以及多种传感器数据格式。对于获取的数据进行清洗、包装。针对缺失、错读的数据使用线性插值弥补。针对各种类型数据,将其解析后包装成统一的数据格式,供数据融合层处理。所述数据融合层,其功能是将数据接口层中接收到的各类信息融合到各个设备单元模型中,使每个设备单元模型内的传感数据实时更新,供事件感知层分析处理。所述事件感知层,其功能是分析各个设备单元模型的状态变化,感知已发生的事件,进行处理。或感知即将 发生的事件,进行预处理。并将这些事件显示在三维模拟监控层。所述三维模拟监控层,其特征在于:与工厂等比例的三维模型。其功能是接受来自事件感知层的事件通知,使三维模型发生动作,以模拟真实工厂环境的情况变化。这些三维模型由设备单元模型内的数据支撑,可以透过设备外壳感知内部情况变化。
本实施例中,所述事件感知层,还用于根据所述设备单元模型的状态变化,预测即将发生的设备运行事件。
所述三维模拟监控层,用于将即将发生的设备运行事件,显示在监控界面的三维模型。
本实施例中,所述三维模拟监控层,还用于根据所述设备单元模型,建立与所述厂房等比例的三维模型,并将所建立的三维模型显示在监控界面。其中,所述三维模型包括了厂房内的各个被监控设备,和各个被监控设备的三维的内部结构图。
本实施例中,所述事件感知层中,还用于根据设备运行事件,发出事件通知。所述三维模拟监控层,还用于根据获取到的事件通知,触发所述监控界面中显示的三维模型发生动作,其中所发生的动作对应所述事件通知。
举例来说:
其一,所述被监控设备为车床设备,所述车床设备由车床部分、机械手部分和工位台部分组成。所述车床部分中设置有可编程控制器和视觉检测传感器。所述机械手部分中设置有包含位移传感器。所述工位台部分中设置有包含RFID读卡器和物料传感器。
其二,所述被监控设备为铣床设备,所述铣床设备由铣床部分、机械手部分和工位台部分。所述铣床部分中设置有可编程控制器和视觉检测传感器。所述机械手部分中设置有包含位移传感器。所述工位台部分中设置有包含RFID读卡器和物料传感器。
其三,所述被监控设备为物流设备,所述车床设备由立体仓库部分、机械手部分和自动引导小车部分组成。所述立体仓库部分中设置有可编程控制器。所述机械手部分中设置有包含位移传感器。所述自动引导小车部分中设置有包含RFID读卡器和可编程控制器。
本说明书中的各个实施例均采用递进的方式描述,各个实施例之间相同相似的部分互相参见即可,每个实施例重点说明的都是与其他实施例的不同之处。尤其,对于设备实施例而言,由于其基本相似于方法实施例,所以描述得比较简单,相关之处参见方法实施例的部分说明即可。以上所述,仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到的变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应该以权利要求的保护范围为准。

Claims (14)

  1. 一种监控设备内部运行情况的方法,其特征在于,包括:
    通过数据接口层,实时采集被监控设备的运行数据,所述相关的传感器至少包括:被监控设备的内置传感器、可编程控制器、外置传感器,所述外围辅助设备至少包括:用于监控被监控设备的视频设备;
    将经过所述数据接口层传输的数据,导入设备单元模型中,以便于所述设备单元模型内实时刷新传感数据,其中,所述设备单元模型包括厂房内的:各个被监控设备、与各个被监控设备相关的传感器和与各个被监控设备相关的外围辅助设备;
    根据所述设备单元模型的状态变化,确定已发生的设备运行事件;
    将已发生的设备运行事件,显示在三维模型中。
  2. 根据权利要求1所述的方法,其特征在于,还包括:
    根据所述设备单元模型的状态变化,预测即将发生的设备运行事件;
    将即将发生的设备运行事件,显示在所述三维模型中。
  3. 根据权利要求1或2所述的方法,其特征在于,还包括:
    根据所述设备单元模型,建立与所述厂房等比例的三维模型,并将所建立的三维模型显示在监控界面;
    其中,所述三维模型包括了厂房内的各个被监控设备,和各个被监控设备的三维的内部结构图。
  4. 根据权利要求3所述的方法,其特征在于,将设备运行事件显示在三维模型中,包括:
    所述事件感知层中根据设备运行事件,发出事件通知;
    三维模拟监控层根据获取到的事件通知,触发所述监控界面中显示的三维模型发生动作,其中所发生的动作对应所述事件通知。
  5. 根据权利要求3所述的方法,其特征在于,所述被监控设备为车床设备,所述车床设备由车床部分、机械手部分和工位台部分组成;
    所述车床部分中设置有可编程控制器、视觉检测传感器、编码器、光栅尺、温度传感器、震动传感器、气压传感器;
    所述机械手部分中设置有包含位移传感器和编码器;
    所述工位台部分中设置有包含RFID读卡器和物料传感器。
  6. 根据权利要求3所述的方法,其特征在于,所述被监控设备为铣床设备,所述铣床设备由铣床部分、机械手部分和工位台部分;
    所述铣床部分中设置有可编程控制器、视觉检测传感器、编码器、光栅尺、温度传感器、震动传感器、气压传感器;
    所述机械手部分中设置有包含位移传感器和编码器;
    所述工位台部分中设置有包含RFID读卡器和物料传感器。
  7. 根据权利要求3所述的方法,其特征在于,所述被监控设备为物流设备,所述物流设备由立体仓库部分、机械手部分和自动引导小车部分组成;
    所述立体仓库部分中设置有可编程控制器、物料检测传感器、RFID读卡器,编码器;
    所述机械手部分中设置有包含位移传感器和编码器;
    所述自动引导小车部分中设置有包含RFID读卡器和可编程控制器。
  8. 一种监控设备内部运行情况的装置,其特征在于,所述装置包括:设备单元模型、数据接口层、数据融合层、事件感知层和三维模拟监控层;
    所述设备单元模型,用于仿真厂房内的各个被监控设备、与各个被监控设备相关的传感器和与各个被监控设备相关的外围辅助设备,其中,所述相关的传感器至少包括:被监控设备的内置传感器、可编程控制器、外置传感器,所 述外围辅助设备至少包括:用于监控被监控设备的视频设备;
    所述数据接口层,用于从所述相关的传感器和所述外围辅助设备,实时采集被监控设备的运行数据,并向数据融合层传输;
    所述数据融合层,用于将所述数据接口层传输的运行数据,融合到所述设备单元模型中,以便于所述设备单元模型内实时刷新传感数据;
    所述事件感知层,用于分析所述设备单元模型的状态变化,确定已发生的设备运行事件,并生成事件通知,之后将所生成的事件通知向所述三维模拟监控层传输;
    所述三维模拟监控层,用于将已发生的设备运行事件,显示在监控界面的三维模型。
  9. 根据权利要求8所述的装置,其特征在于,所述事件感知层,还用于根据所述设备单元模型的状态变化,预测即将发生的设备运行事件;
    所述三维模拟监控层,用于将即将发生的设备运行事件,显示在监控界面的三维模型。
  10. 根据权利要求8或9所述的装置,其特征在于,所述三维模拟监控层,还用于根据所述设备单元模型,建立与所述厂房等比例的三维模型,并将所建立的三维模型显示在监控界面;
    其中,所述三维模型包括了厂房内的各个被监控设备,和各个被监控设备的三维的内部结构图。
  11. 根据权利要求10所述的装置,其特征在于,所述事件感知层中,还用于根据设备运行事件,发出事件通知;
    所述三维模拟监控层,还用于根据获取到的事件通知,触发所述监控界面中显示的三维模型发生动作,其中所发生的动作对应所述事件通知。
  12. 根据权利要求10所述的装置,其特征在于,所述被监控设备为车床设备,所述车床设备由车床部分、机械手部分和工位台部分组成;
    所述车床部分中设置有可编程控制器和视觉检测传感器;
    所述机械手部分中设置有包含位移传感器;
    所述工位台部分中设置有包含RFID读卡器和物料传感器。
  13. 根据权利要求10所述的装置,其特征在于,所述被监控设备为铣床设备,所述铣床设备由铣床部分、机械手部分和工位台部分;
    所述铣床部分中设置有可编程控制器和视觉检测传感器;
    所述机械手部分中设置有包含位移传感器;
    所述工位台部分中设置有包含RFID读卡器和物料传感器。
  14. 根据权利要求10所述的装置,其特征在于,所述被监控设备为物流设备,所述车床设备由立体仓库部分、机械手部分和自动引导小车部分组成;
    所述立体仓库部分中设置有可编程控制器;
    所述机械手部分中设置有包含位移传感器;
    所述自动引导小车部分中设置有包含RFID读卡器和可编程控制器。
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