Safety monitoring method for container general assembly line
By collecting image information on the container assembly line and using image recognition algorithms to determine obstacles, the problem of inaccurate identification of operators wearing protective clothing and arc light in the prior art is solved, fast and accurate safety monitoring is achieved, and factory safety is improved.
Patent Information
- Application Number
- CN202510540694.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-27
- Publication Date
- 2025-08-08
AI Technical Summary
The human visual monitoring system of the existing container assembly line has low accuracy in identifying operators and arcs in factory environments, slow recognition speed, and identification delay and false alarm rates.
By collecting image information of the processing station, using an image recognition algorithm to determine whether there are obstacles, and determining whether the obstacles are in the judgment area, sending control signals to control the conveying of the container, and establishing a parameter database to identify the operator wearing protective clothing and arc light.
It improves the safety monitoring accuracy and identification speed of the container assembly line, reduces identification delay, and ensures the safety of operators.
Smart Images
Figure CN120451902A_ABST
Abstract
Description
Technical Field
[0001] The present application generally relates to the technical field of platform-type container structures, and more particularly to a safety monitoring method for a container assembly line. Background Art
[0002] In a container production workshop, there is a container assembly production line for assembling the various components of the container into a whole. N processing stations are set up on the assembly production line, and each processing station is equipped with a number of workers to complete the work tasks at the processing station. After the work tasks at all processing stations are completed, the containers located on each processing station are transferred to the next station as a whole. During the transfer, it is necessary to monitor whether there are workers in each work to avoid colliding with the workers during the transfer. However, the existing human visual monitoring system is a general design that only monitors personnel and is not suitable for the identification of personnel in full protective clothing in a factory environment. Therefore, the existing monitoring method has low accuracy, slow recognition speed, high recognition delay and a certain false alarm rate.
[0003] Therefore, it is necessary to provide a safety monitoring method for a container assembly line to at least partially solve the above problems. Summary of the Invention
[0004] The Summary of the Invention introduces a series of simplified concepts that will be further described in the Detailed Description of the Invention. The Summary of the Invention of this application is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.
[0005] To at least partially address the above-mentioned problems, the present application provides a safety monitoring method for a container assembly line, wherein the container assembly line includes at least two processing stations and a control module. The safety monitoring method includes:
[0006] Collecting image information of the processing station;
[0007] Determining whether there is an obstacle in the image based on the image information; and
[0008] Determine whether the obstacle of at least one of the processing stations is in a determination area. If the obstacle is in the determination area, send a prohibition start signal to the control module; if the obstacle is not in the determination area, and it is determined that each of the processing stations has completed the corresponding processing task, send a start signal to the control module to transport the container of the previous processing station to the next processing station.
[0009] Optionally, the safety monitoring method further includes:
[0010] The corresponding determination area is determined according to the obstacle.
[0011] Optionally, the obstacle is an operator wearing protective clothing or an arc light.
[0012] Optionally, before executing the step of collecting image information of the processing station, the safety monitoring method further includes:
[0013] Collect operator data at each processing station and perform parameter screening on the data;
[0014] defining the determination area; and
[0015] Define the decision logic for determining whether an operator exists in the decision area.
[0016] Optionally, the identified obstacles are marked with a marking box.
[0017] Optionally, the marking frame for marking the operator is a first marking frame with a first color, and the marking frame for marking the arc light is a second marking frame with a second color.
[0018] Optionally, when executing the step of determining whether there is an obstacle in the image based on the image information, the determination logic includes: if the marking box overlaps with the determination area, it indicates that the obstacle exists in the determination area.
[0019] Optionally, the container assembly line further includes at least two conveyor lines; when the obstacle is an operator wearing protective clothing, the determination area is an area enclosed between the at least two conveyor lines.
[0020] Optionally, the decision logic further includes:
[0021] If the lower end of the first mark frame overlaps with the determination area, it indicates that there is an operator wearing protective clothing in the determination area.
[0022] Optionally, the decision logic further includes:
[0023] If the second mark box appears in the determination area, it indicates that the arc light exists in the determination area.
[0024] Compared with the existing technology, the safety monitoring method of the container assembly line of the present application has the following beneficial effects:
[0025] The safety monitoring method for the container assembly line of the present application collects image information of the processing stations, and then determines whether there are obstacles in the image based on the collected image information. It determines whether the obstacle of at least one processing station is in the judgment area. If the obstacle is in the judgment area, a prohibition start signal is sent to the control module. If the obstacle is not in the judgment area, and it is determined that each processing station has completed the corresponding processing task, a start signal is sent to the control module to transport the container of the previous processing station to the next processing station. The safety monitoring method of the present application can more accurately identify whether the obstacle is in the judgment area, effectively improving the safety during monitoring, and has the advantages of fast recognition speed and reduced recognition delay. At the same time, by collecting parameters of operators wearing protective clothing to form a parameter database, it is convenient to quickly identify operators later, thereby improving recognition speed and accuracy. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The following drawings of the embodiments of the present application are hereby incorporated as part of the present application for understanding the present application. The drawings show the embodiments of the present application and their descriptions, and are used to explain the principles of the present application. In the drawings,
[0027] Figure 1 This is a schematic flow chart of the steps of a safety monitoring method for a container assembly line according to a preferred embodiment of the present application;
[0028] Figure 2 This is a logic block diagram of a safety monitoring method for a container assembly line according to a preferred embodiment of the present application;
[0029] Figure 3 This is a structural diagram of a container bus applicable to a safety monitoring method for a container assembly line according to a preferred embodiment of the present application;
[0030] Figure 4 A schematic structural diagram of a safety monitoring system applicable to a safety monitoring method for a container assembly line according to a preferred embodiment of the present application; and
[0031] Figure 5 This is a schematic diagram of the position structure of the determination area, the first marking frame and the second marking frame of the container assembly line safety monitoring method according to a preferred embodiment of the present application.
[0032] Reference numerals:
[0033] 10: Conveyor line; 200: Container; DW: Width direction; DL: Length direction; 300: Processing station; 201: Safety detection system; 201a: Acquisition module; 201b: Control module; 201c: Communication module; 201d: Display module; 400: Judgment area; 500: First marking box; 600: Second marking box. DETAILED DESCRIPTION
[0034] In the following description, a large number of specific details are provided to provide a more thorough understanding of the present application. However, it will be apparent to those skilled in the art that the present application embodiments can be implemented without one or more of these details. In other examples, some technical features well known in the art are not described to avoid confusion with the present application embodiments.
[0035] In order to fully understand the embodiments of the present application, a detailed structure will be presented in the following description. Obviously, the implementation of the embodiments of the present application is not limited to the specific details familiar to those skilled in the art.
[0036] like Figures 1 to 5 As shown, the present application provides a safety monitoring method for a container assembly line, wherein the container assembly line includes at least two conveyor lines 10 and a control module 201b for controlling the start and stop of at least two conveyor lines 10, wherein the conveyor lines 10 extend along the width direction DW of the container 200, and at least two conveyor lines 10 are spaced apart along the length direction DL of the container 200, and at least two conveyor lines 10 are spaced apart along the width direction DW of the container 200 and provided with at least two processing stations 300, each processing station 300 is used to carry, process and transport the container 200, and the container 200 is arranged on the upper surface of the conveyor line 10.
[0037] It should be noted that in order to ensure the smooth transportation of the container 200 on the conveyor line 10 and to prevent the container 200 from falling or shaking violently during the movement of the conveyor line 10, a locking structure (not shown in the figure) can be installed on the bottom wall of the container 200, that is, the conveyor line 10 on the corresponding side can be locked to ensure the smooth transportation of the container 200 as a whole. In order to save space, the locking structure will not be described in detail here.
[0038] The container assembly line of this application is along Figure 3There are N processing stations 300 set in the conveying direction indicated by the arrow in , where N ≥ 2, that is, the container assembly line of the present application has at least two processing stations 300, and the N processing stations 300 are arranged at intervals along the conveying direction, and the spacing between adjacent processing stations 300 is equal. The conveying direction is parallel to the width direction DW of the container 200. The container assembly line is arranged in a straight line, that is, the container 200 moves along the straight line direction to realize the transfer between different processing stations 300, that is, to complete the assembly of the container 200, it is necessary to pass through the above-mentioned N processing stations 300 in sequence. Relevant staff are arranged at each processing station 300 to complete the work tasks at the processing station 300. For example, the operator realizes the welding between the box body and the chassis of the container 200 in a certain processing station 300.
[0039] The above-mentioned container assembly line is provided with a conveying mechanism (not shown in the figure) to realize the transfer of the container 200 between different processing stations 300. The conveying mechanism includes at least two conveying lines 10, each of which includes a plurality of spliced conveying rods, which are arranged at intervals along the length direction DL of the container 200 and extend along the width direction DW of the container 200. The above-mentioned processing stations 300 are distributed at intervals along the extension direction of the conveying rods, and the container 200 is supported on the conveying rods. During transportation, after the work tasks at each processing station 300 are completed, the conveying mechanism transports forward, and the container 200 located at the previous processing station 300 is transferred to the next processing station 300 under the transportation of the conveying mechanism to complete the final assembly of the container 200. The prerequisites for the conveying mechanism to start the transportation work are as follows:
[0040] like Figures 1 to 3 As shown, the safety monitoring method of the container assembly line according to the present application includes:
[0041] Step S10 , collecting image information of the processing station 300 .
[0042] Step S20: determining whether there is an obstacle in the image based on the image information.
[0043] Step S30 determines whether an obstacle at at least one processing station 300 is within the determination area 400. If so, a disable start signal is sent to the control module 201b. If the obstacle is not within the determination area 400, and it is determined that each processing station 300 has completed its corresponding processing task, a start signal is sent to the control module 201b to transport the container 200 from the previous processing station 300 to the next processing station 300. The safety monitoring method for a container assembly line of the present application collects image information of the processing stations 300 and then, based on the collected image information, determines whether an obstacle exists in the image. The method then determines whether an obstacle at at least one processing station 300 is within the determination area 400. If so, a disable start signal is sent to the control module 201b. If the obstacle is not within the determination area 400 and it is determined that each processing station 300 has completed its corresponding processing task, a start signal is sent to the control module 201b to transport the container 200 from the previous processing station 300 to the next processing station 300. The safety monitoring method of the present application can more accurately identify whether the obstacle is within the determination area 400, effectively improving safety during monitoring and having the advantages of fast recognition speed and reduced recognition delay. At the same time, by collecting parameters of operators wearing protective clothing to form a parameter database, it facilitates the rapid identification of operators later, improving recognition speed and accuracy.
[0044] The prerequisites for the conveying mechanism to start conveying work are as follows:
[0045] A: Each processing station 300 has completed the work task at the processing station 300.
[0046] B: Each of the 300 processing stations has passed safety monitoring.
[0047] The above-mentioned condition A is triggered by the operator at each processing station 300. For example, a trigger switch is provided at each processing station 300. After completing the work task at the processing station 300, the operator at the processing station 300 actively triggers the switch to issue a notification that the work at the processing station 300 has been completed. When the trigger switches at all the processing stations 300 on the entire container assembly line are triggered, it means that the above-mentioned condition A is met.
[0048] The above-mentioned condition B is monitored by a safety monitoring method. Specifically, the safety monitoring method monitors each processing station 300 separately. After the safety monitoring on each processing station 300 is passed, it is indicated that the above-mentioned condition B is met.
[0049] The above determination work is performed in real time, that is, after the conveying condition A is met, the conveying mechanism is automatically started after the conveying condition B is met to realize the transfer of the container 200 between different processing stations 300.
[0050] If any processing station 300 outputs a prohibit signal, the PLC system in the conveyor mechanism locks the conveyor mechanism and prohibits its operation. If all processing stations 300 in the entire container assembly line output an enable signal, the PLC in the conveyor mechanism controls the conveyor mechanism to achieve the conversion between different processing stations 300.
[0051] like Figure 5 As shown, in some preferred embodiments of the present application, the safety monitoring method of the present application further includes: determining a corresponding determination area 400 according to the obstacle. In other words, the specific determination area 400 is determined by determining whether the obstacle is an operator wearing protective clothing as described below or an arc.
[0052] like Figure 5 As shown, in some preferred embodiments of the present application, the aforementioned obstacles are operators wearing protective clothing or arc light, thereby proving the presence of operators within the determination area 400. Furthermore, by increasing monitoring of arc light, monitoring accuracy is improved. Specifically, by collecting data from on-site operators, i.e., operators wearing full protective clothing, a new database is formed to ensure the accuracy of subsequent data recognition and, at the same time, improve recognition speed. The aforementioned obstacle parameters utilize small model parameters to increase computational speed, reduce recognition latency, and improve deployment efficiency.
[0053] It should be noted that the arc light may be the arc light generated when welding the container 200 .
[0054] like Figure 4 As shown, in some preferred embodiments of the present application, before executing the step of collecting image information of the processing station 300, the safety monitoring method further includes:
[0055] The operator data of each processing station 300 is collected and parameter screening is performed on the data.
[0056] A determination area 400 is defined.
[0057] Define the decision logic for determining whether an operator exists in the area 400 .
[0058] It should be noted that the aforementioned determination area 400 is the area through which the conveyor mechanism passes when transporting the containers 200 from the various processing stations 300, i.e., the area through which the containers 200 pass when transferring from one processing station 300 to the next. It can also be a conveying area to prevent the containers 200 from striking operators during transport, thereby ensuring operator safety. Specifically, if the obstacle is an operator, the determination area 400 is preferably the area between the two outermost conveyor rods of the conveyor mechanism in the displayed image, i.e., the area between the two conveyor rods farthest apart on the conveyor mechanism. If the obstacle is arc light generated during welding, the determination area 400 is the entire area displayed in the image.
[0059] In some preferred embodiments of the present application, when executing the step of determining whether there is an obstacle in the image based on the image information, an AI algorithm is used to automatically identify the obstacle, and the obstacle is framed with a marking frame to highlight the obstacle in the image, so as to facilitate subsequent comparison with the judgment area 400.
[0060] It should be noted that the so-called "AI algorithm" is well known to those skilled in the art. The security monitoring method of this application only uses this set of algorithms. In order to save space, it will not be described in detail here.
[0061] In some preferred embodiments of the present application, the identified obstacles are marked with a marking frame.
[0062] like Figure 5 As shown, in some preferred embodiments of the present application, the marking frame for marking the operator is a first marking frame 500 having a first color, and the marking frame for marking the arc is a second marking frame 600 having a second color. Specifically, the operator appearing in the image is marked with the first marking frame 500, wherein the first marking frame 500 includes a worker, and the arc area appearing in the image is marked with the second marking frame 600, wherein the first marking frame 500 includes the area where the arc is generated, wherein the first marking frame 500 and the second marking frame 600 are marked with different colors and styles. At the same time, the first marking frame 500 and the second marking frame 600 are framed by square frames, and the operator is entirely or mostly contained within the first marking frame 500; the arc generated during welding is completely contained within the second marking frame 600.
[0063] In some preferred embodiments of the present application, when executing the step of determining whether there is an obstacle in the image based on image information, the determination logic includes: if the marking box overlaps with the determination area 400, it indicates that there is an obstacle in the determination area 400.
[0064] The above-mentioned determination logic is as follows: whether the aforementioned marking frame exists within the determination area 400. If the marking frame exists within the determination area 400, it indicates that there is an obstacle within the determination area 400. Specifically, it is determined whether the marking frame overlaps with the determination area 400. If so, it indicates that there is an obstacle; if not, it indicates that there is no obstacle. More specifically, a third marking frame is used to display the scope of the determination area 400 to identify whether there is an operator within the determination area 400. At the same time, the entire image display area is marked with the first marking frame 500 or the second marking frame 600 to identify whether there is an operator within the first marking frame 500 or whether there is arc light generated by welding within the second marking frame 600.
[0065] The first marking frame 500 , the second marking frame 600 and the third marking frame are marked with different colors respectively.
[0066] like Figure 3 and Figure 5 As shown, in some preferred embodiments of the present application, the container assembly line further includes at least two conveyor lines 10 . When the above-mentioned obstacle is an operator wearing protective clothing, the determination area 400 is the area enclosed between the at least two conveyor lines 10 .
[0067] In some preferred embodiments of the present application, the decision logic further includes:
[0068] If the lower end of the first marking frame 500 overlaps with the determination area 400, it indicates that an operator wearing protective clothing is present in the determination area 400. Specifically, if the lower end of the first marking frame 500 within the determination area 400 overlaps with the determination area 400, it indicates that an operator is present in the determination area 400. If the lower end of the first marking frame 500 within the determination area 400 does not overlap with the determination area 400, it indicates that an operator is not present in the determination area 400. When determining whether there is an arc light within the determination area 400, the entire image is identified to determine whether the second marking frame 600 appears. If so, it indicates that there is an arc light within the determination area 400. If not, it indicates that there is no arc light within the determination area 400.
[0069] In some preferred embodiments of the present application, the decision logic further includes:
[0070] If a second marking box 600 appears in the determination area 400, it indicates that there is an arc in the determination area 400, which means that there is also an operator in the area. At this time, it is necessary to send a signal prohibiting startup to the control module 201b to ensure the safety of the operators in the area and avoid accidents.
[0071] like Figure 4As shown, the safety detection system for executing the above safety monitoring method includes an acquisition module 201a, a control module 201b, a communication module 201c and a display module 201d.
[0072] like Figure 4 As shown, the acquisition module 201a is a camera, facing the processing station 300, capturing images within the processing station 300. The control module 201b is used to automatically identify images within the image. Simultaneously, based on the aforementioned determination logic, it determines whether there are obstacles within the determination area 400 and obtains a corresponding result. The communication module 201c transmits the result in real time to the PLC system of the conveying mechanism. The display module 201d is used to display the images and video data collected by the acquisition module 201a, and also displays the results of safety monitoring in real time, facilitating manual intervention by monitoring personnel and further improving operator safety.
[0073] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art in the technical field of this application. The terms used herein are only for describing specific implementation purposes and are not intended to limit this application. Terms such as "setting" appearing in this document can mean that one component is directly attached to another component, or that one component is attached to another component through an intermediate component. Features described in this document in one embodiment may be applied to another embodiment alone or in combination with other features, unless the feature is not applicable in the other embodiment or otherwise specified.
[0074] The present application has been described through the above embodiments, but it should be understood that the above embodiments are for illustrative and illustrative purposes only and are not intended to limit the present application to the described embodiments. Those skilled in the art will appreciate that many more variations and modifications may be made based on the teachings of this application, and all of these variations and modifications fall within the scope of protection claimed in this application.
Claims
1. A safety monitoring method for a container assembly line, wherein the container assembly line includes at least two processing stations and a control module, characterized in that: The safety monitoring method comprises: Collecting image information of the processing station; Determining whether there is an obstacle in the image based on the image information; and Determine whether the obstacle of at least one of the processing stations is in a determination area. If the obstacle is in the determination area, send a prohibition start signal to the control module; if the obstacle is not in the determination area, and it is determined that each of the processing stations has completed the corresponding processing task, send a start signal to the control module to transport the container of the previous processing station to the next processing station.
2. The method for safety monitoring of a container assembly line according to claim 1, characterized in that: The safety monitoring method further includes: The corresponding determination area is determined according to the obstacle.
3. The method for safety monitoring of a container assembly line according to claim 1, characterized in that: The obstacles are operators wearing protective clothing or arc light.
4. The method for safety monitoring of a container assembly line according to claim 1, characterized in that: Before executing the step of collecting image information of the processing station, the safety monitoring method further includes: Collect operator data at each processing station and perform parameter screening on the data; defining the determination area; and Define the decision logic for determining whether an operator exists in the decision area.
5. The method for safety monitoring of a container assembly line according to claim 1, characterized in that: Identified obstacles are marked with a mark box.
6. The method for safety monitoring of a container assembly line according to claim 5, characterized in that: The marking frame for marking the operator is a first marking frame with a first color, and the marking frame for marking the arc light is a second marking frame with a second color.
7. The method for safety monitoring of a container assembly line according to claim 5, characterized in that: When executing the step of determining whether there is an obstacle in the image based on the image information, the determination logic includes: if the marking box overlaps with the determination area, it indicates that the obstacle exists in the determination area.
8. The method for safety monitoring of a container assembly line according to claim 6, characterized in that: The container assembly line also includes at least two conveyor lines; When the obstacle is an operator wearing protective clothing, the determination area is an area surrounded by at least two of the conveying lines.
9. The method for safety monitoring of a container assembly line according to claim 6, characterized in that: The decision logic also includes: If the lower end of the first mark frame overlaps with the determination area, it indicates that there is an operator wearing protective clothing in the determination area.
10. The method for safety monitoring of a container assembly line according to claim 6, characterized in that: The decision logic also includes: If the second mark box appears in the determination area, it indicates that the arc light exists in the determination area.