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 PDFInfo
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- 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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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING 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
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
- H04N7/00—Television systems
- H04N7/18—Closed-circuit television [CCTV] systems, i.e. systems in which the video signal is not broadcast
- H04N7/181—Closed-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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Claims (14)
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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。
- 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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| CN201910332794.4 | 2019-04-24 | ||
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| US11630005B1 (en) * | 2022-01-13 | 2023-04-18 | Eli Yudkevich | Machining monitor and a method for monitoring a machining of an object |
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| CN110687806B (zh) * | 2019-09-30 | 2023-04-07 | 万翼科技有限公司 | 一种设备控制方法及相关装置 |
| CN113362571B (zh) * | 2020-03-06 | 2023-03-21 | 华晨宝马汽车有限公司 | 工厂监控系统及方法 |
| CN112180888A (zh) * | 2020-11-02 | 2021-01-05 | 中海石油(中国)有限公司 | 一种水下生产监控系统和方法 |
| CN120101844B (zh) * | 2025-05-08 | 2025-07-11 | 广东力创信息技术有限公司 | 基于光纤光栅传感器的设备环境的检测方法以及系统 |
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