Method for inspecting and monitoring a heating device using a sensor-generated image

Description

[0001] The invention relates to a method for inspecting and monitoring a heating device using a sensor-generated image.

[0002] A heating appliance is usually inspected at regular intervals by a person familiar with the system. For an inspection and the associated visual inspection, the heater's housing must be opened, thus shutting down the heater. During an inspection, changes within the heater, such as dirt or moisture, and the associated incipient damage can be identified by a specialist's assessment. Disadvantages include the high level of effort, particularly the cost and time lost for the specialist's visit, as well as the fact that the heater must be turned off for the inspection and the associated loss of comfort.

[0003] CN 208 567 105 U discloses a device for heating water, in which the accumulation of impurities in a transparent pipe can be detected by an image recording device arranged in the housing. The captured image can be transmitted to a mobile device via a transmission device connected to the image recording device. If an accumulation in the pipe is detected, manual cleaning of the pipe can be initiated.

[0004] Based on this, the object of the invention is to propose a method for inspecting and monitoring a heater that at least partially overcomes the described problems of the prior art. In particular, the method should facilitate early detection of damage and, if possible, be feasible without shutting down the heater.

[0005] In addition, the method proposed here should be simple, cost-effective and, if possible, also feasible on existing systems, and should not increase the complexity of a heating device or should only increase it insignificantly.

[0006] These objects are achieved by the features of the independent patent claims. Further advantageous embodiments of the solution proposed here are specified in the independent patent claims. It should be noted that the features listed in the dependent patent claims can be combined with one another in any technologically expedient manner and define further embodiments of the invention. Furthermore, the features specified in the patent claims are further specified and explained in the description, with further preferred embodiments of the invention being presented.

[0007] A method for the automatic inspection and / or monitoring of a heating device, comprising at least one optical device, contributes to this, which comprises at least the following steps: a) capturing at least one image of at least one component within a housing of the heater by means of at least one optical device, b) automatically evaluating the image captured in step a).

[0008] Steps a) and b) can be performed at least once in the specified order. In particular, step a) can be repeated several times before step b) is performed.

[0009] The invention can be used in particular for an automatic inspection and / or monitoring of a heater. An inspection or monitoring serves to check the heater, similar to a visual inspection by a specialist with system knowledge, in particular with regard to optical and / or thermal changes, moisture, noise and / or vibrations, and enables conclusions to be drawn about the technical condition of the heater. If a fault condition is detected, an appropriate automatic response can be the subject of a method proposed here, for example, an automatic emergency shutdown of the heater. According to an advantageous embodiment, the method can be carried out regularly; for example, a possibly prescribed regular visual inspection by a specialist in person can be replaced by a (repeated) execution of a method proposed here.If carried out at relatively short intervals, for example every minute or hour, a method proposed here can also be used for automated monitoring of a heating device.

[0010] In principle, the method can be used or implemented with any type or design of heating device, in particular with oil or gas heating devices and heating devices comprising a heat pump or circulating water heaters. The heating device can have any installation position, for example floor-standing or wall-mounted. The heating device is in particular a gas heating device that is designed to burn a fuel gas, such as natural gas and / or hydrogen, with the supply of ambient air and to generate thermal energy, for example to heat a heat transfer medium of a heating circuit and / or to provide a hot water supply. In particular, the heating device can be a condensing boiler. The heating device generally has a combustion chamber and a conveying device that can convey a mixture of fuel gas and combustion air into a combustion chamber.The combustion products can then be discharged through an exhaust system.

[0011] An optical device can consist of multiple parts or assemblies, which can include at least one imaging sensor. The imaging sensor can be arranged inside and / or outside a housing of the heater. Advantageously, multiple imaging sensors can also be arranged inside and / or outside the housing of the heater in such a way that the most complete image possible of relevant components inside the housing of the heater can be captured. In particular, multiple (different) imaging sensors can be arranged in such a way that multiple (different) images can be captured, for example, with different wavelength ranges of the electromagnetic spectrum.

[0012] Step a) can be triggered or initiated by a counter at a specified time. Alternatively or cumulatively, step a) can be triggered by a control unit, for example, when an operating parameter of the heater reaches a threshold. Of course, step a) can also be started "manually," for example, upon a specific instruction from an inspector. Step a) can, in particular, be initiated "remotely," i.e., via an instruction sent via a cloud, a radio unit, or the like.

[0013] Within the scope of step a), a single (overview) image and / or multiple (detail) images can be captured. It is possible that a series of images (video) is captured. It is possible that an image captured in this way essentially relates to a (single) component and / or a housing interior area attributable to a (single) component. It is possible that multiple images, possibly capturing different housing interior areas and / or components, are created when performing step a).

[0014] It is possible for an optical device to be stationary during the execution of step a) or all executions of steps a) and thus always capture the same image. Alternatively or cumulatively, it is possible for a (possibly different) optical device to be movable during the execution of step a) or during the execution of several steps a), for example, with regard to the viewing direction, a zoom, etc. It is possible for multiple optical devices to generate or capture detailed images relating to adjacent areas of components and / or housing interior areas.

[0015] Once at least some or all of the images from step a) have been captured, step b) can be initiated automatically. This step b) can include image processing as a preparatory process, e.g., by composing, (partially) superimposing, adjusting, etc. captured images. The at least one image is then checked, in particular, for changes and / or deviations from a predefined state and / or a previous image capture. This can be done automatically and / or using (computer) image analysis.

[0016] If necessary, it is possible that, based on the evaluation in step b), step a) is (immediately) carried out again, whereby the setting of the optical device may be changed or adjusted during the repeated execution of step a).

[0017] The at least one optical device can comprise at least one device for beam focusing. The beam focusing device can comprise at least one optical converging lens, so that, similar to a wide-angle lens, a large angle of view within the housing of the heater can be captured by an imaging sensor. Advantageously, the largest possible image area within the housing of the heater can thus be captured by an imaging sensor.

[0018] The at least one optical device can be a magnification device, similar to a telescopic lens. This advantageously allows a magnified image of a component or a relevant region thereof to be captured from a remote position.

[0019] A device for beam focusing can be arranged on and / or within a housing, in particular integrated into a wall of the housing. The device for beam focusing can be arranged and aligned such that an image from a position outside the housing with an imaging sensor can be captured by the device for beam focusing with a large angle of view and thus of as many areas or components of the heater relevant for an inspection as possible. Advantageously, the device for beam focusing can also have a spacing device, in particular with a contact surface for a recording device comprising an imaging sensor, by means of which simple handling combined with comparable image quality and a consistent image section can be ensured.The recording device can be, for example, a camera or an IR camera, in particular a (network-capable) mobile terminal having such a camera.

[0020] An optical device with a beam-focusing facility in or on the housing can provide a very simple and cost-effective way of conducting an inspection, in particular. For example, a system operator can use a mobile device to capture analyzable images of the interior of the heater at regular intervals or when problems arise, without having to shut it down. Advantageously, a mobile network-capable device could transmit the captured image(s) via the network to perform step b). It would also be conceivable for the mobile device to be configured to perform a method proposed here.

[0021] At least one imaging sensor can be arranged in the housing of a heating device and in step a) the at least one image can be captured by means of the at least one imaging sensor arranged within the housing.

[0022] Relevant components can be, in particular, components that have a high potential for damage and / or are subject to wear. Relevant components can include, for example, a combustion chamber or burner and its gas supply, a heating circuit pump, a gas valve, a heat exchanger, an air supply, and / or a conveying device (blower).

[0023] The optical device can comprise at least one imaging sensor, which can be a light sensor, an infrared (IR) radiation sensor, a lidar, and / or a radar sensor. A light sensor can, for example, be an optical sensor (CCD or CMOS) that can detect the part of the electromagnetic spectrum visible to the human eye. An IR sensor can be a thermal imaging sensor, which advantageously makes it possible to detect thermal changes in components of the heater. A lidar and / or radar sensor can measure distances and thus detect physical changes within the heater, such as deformations.

[0024] The optical device may (additionally) comprise a light source to sufficiently illuminate (possibly at predeterminable times) relevant areas within the housing for capturing a (light) image. The light source may, for example, be an illumination device known from photography, in particular an LED light source.

[0025] An image captured in step a) can be (temporarily) stored on an (electronic) storage medium. The storage medium can, for example, be a memory of a control and regulation device of the heater.

[0026] An image captured in step a) can be transmitted via a (data) network, in particular the Internet, or provided via an interface. Automated execution of a method proposed here can be realized, particularly in conjunction with at least one imaging sensor arranged within the housing.

[0027] The evaluation in step b) can be performed using suitable algorithms for detecting error states, or using so-called artificial intelligence and / or by executing a computer program designed for this purpose. The computer program could, for example, be executed by a control unit of the heater or a mobile (network-capable) device.

[0028] The evaluation may include a comparison with a reference image. The reference image may represent an image acquired at an earlier time and / or a reference state of the heater. Advantageously, a reference image may have been acquired by the same sensor as the image acquired in step a) to ensure good comparability. A comparison with a reference image may be performed as part of an automated implementation of a method proposed here.

[0029] An evaluation according to step b) can involve superimposing images from different sensor types, in other words, identifying relevant components in different images, particularly from different imaging sensors. For example, evaluating a light image, a thermal image, and / or a radar image of a component can enable a very comprehensive assessment of the component's condition. By linking the images from different imaging sensors and identifying relevant components, various sensor data for a component can advantageously be combined and evaluated. This embodiment of evaluating a captured image according to step b) can also be easily carried out automatically, for example by executing a computer program.

[0030] Time series of images captured in step a) can be evaluated in step b). For example, the speed of changes in the heater can be determined, which in turn can be used to estimate the probability or time of failure.

[0031] As part of the evaluation according to step b), (determined and / or stored) operating data of the heater can also be used. The operating data can in particular be operating parameters such as the output of the heater and / or the conveyor device and / or data from temperature or other sensors, in particular a flame monitor. For example, the performance data of the heater, data from temperature sensors and / or a flame monitor at the time the image is captured can be used in an evaluation of a thermal image of a combustion chamber or burner. The inclusion of operating data can enable comprehensive insight into the technical condition of a component of the heater and, associated with this, in particular more precise estimates of failure times.

[0032] An image captured in step a) may contain a reference code arranged in the image area, which is included in an evaluation in step b). The reference code may in particular be a 2D code, for example a DataMatrix code. The reference code may be arranged at a position in the heater that is detected by an imaging sensor. Contamination of the sensor can advantageously be detected using reference codes. The reference code may be arranged, for example, glued, on at least one relevant component, thus enabling verification of the image captured in step a).

[0033] In step a), additional data can be recorded by at least one detector, which can then also be taken into account in the evaluation. The at least one detector can, in particular, be a sound, structure-borne sound, gyro, humidity, temperature, dust, and / or vibration sensor. Advantageously, additional data that provide a more comprehensive picture of the technical condition of the heating device can thus be fed into an evaluation in step b). For example, a heating circuit pump in a critical state of wear can often be identified by a change in the operating noise and / or vibrations, which were recorded, for example, using a structure-borne sound sensor. Advantageously, a structure-borne sound sensor can allay concerns of users or residents regarding data security compared to a sound sensor (microphone).

[0034] An image captured in step a) and / or a result of an evaluation according to step b) can be made available for retrieval in step c) via an interface to a network, sent via a network, in particular the Internet, and / or displayed via a visual and / or acoustic display device of the heater. This allows a specialist with system knowledge to inspect an operating heater using one or more images captured in step a) without having to be on site. Providing results of an evaluation according to step b) can include estimated failure times of relevant components and offer guidance for planning maintenance work by a person with system knowledge.Step c) can be performed after an evaluation, i.e., following step b), but after the execution of step a), particularly if images captured in step a) are to be provided or transmitted. In this case, an evaluation can be performed by evaluating an image captured in step a) that was provided via an interface and / or sent via a network following step a) in accordance with step c).

[0035] According to a further aspect, a computer program according to claim 11 is also proposed.

[0036] According to a further aspect, a heating device according to claim 10 is also proposed.

[0037] The details, features and advantageous embodiments discussed in connection with the method can occur correspondingly in the computer program proposed here and the heating device, the invention being defined by the claims.

[0038] This therefore provides a method for the automatic inspection and monitoring of a heater and a computer program which at least partially solve the problems described with reference to the state of the art. In particular, they each at least contribute to enabling a comprehensive inspection of a heater without the presence of a specialist and without taking the heater out of operation. Furthermore, an automated inspection using a computer program set up for this purpose can significantly reduce the required involvement of a specialist and thus reduce travel and labor costs. Last but not least, service calls can be planned in advance by estimating the times at which a critical condition of the heater will occur as part of an evaluation.

[0039] The invention and the technical environment are explained in more detail below with reference to the accompanying figures. It should be noted that the invention is not intended to be limited by the exemplary embodiments cited. In particular, unless explicitly stated otherwise, it is also possible to extract partial aspects of the facts explained in the figures and combine them with other components and findings from the present description, whereby the invention is defined by the claims. In particular, it should be noted that the figures and, in particular, the illustrated proportions are only schematic. They show: Fig. 1: a sequence of a method proposed here, and Fig. 2: a heating device proposed here.

[0040] Fig. 1 shows, by way of example and schematically, the sequence of a method proposed here. The method serves for an automatic inspection of a heating device 1. The sequence of steps a) and b) represented by blocks 110 and 120 can be established in a regular method sequence. In particular, step a) in block 110 can be performed multiple times, and an evaluation according to step b) can be performed for multiple captured images.

[0041] Block 110 illustrates step a), after which at least one image of at least one component within a housing of the heater is captured using at least one optical device. The image to be captured can be, for example, a light image (image in the visible wavelength range of light), a thermal image, and / or a radar or lidar image.

[0042] Block 120 illustrates step b), after which an automated evaluation of the image captured in step a) takes place. The evaluation can be performed, for example, by comparing it with an older image, particularly one taken from the same perspective.

[0043] Block 130 illustrates step c), according to which a captured image and / or a result of an evaluation of an interface to a network can be made available for retrieval, sent via a network, in particular the Internet, and / or displayed via an optical and / or acoustic display device of the heater.

[0044] Fig. 2shows, by way of example and schematically, a side view of a heater 1 with a housing 2. The heater 1 can have an optical device 3, which can comprise a device for beam focusing 14 arranged in a wall of the housing 2, an imaging sensor 4 arranged outside the housing 2 and / or an imaging sensor 8 arranged inside the housing 2. The device for beam focusing 14 can be integrated into the housing 2, so that an imaging sensor 4 arranged outside the housing 2 can capture an image of relevant components 5 within the housing 2 of the heater 1. The device for beam focusing 14 can be designed similarly to a wide-angle (attachment) lens, which can enable the capture of an image in a large first image angle 6.

[0045] The optical device 3 may also comprise an imaging sensor 8 with a second image angle 9 arranged within the housing 2 of the heating device 1.

[0046] In a further development, a reference code 7 can be arranged, in particular, at a relevant point or on a relevant component 5 of the heater 1, which can be contained in an image acquired according to step a) (block 110). The reference code can be, for example, a DataMatrix code. The reference code 7 contained in an image acquired in step a) advantageously makes it possible to identify contamination of the optical device 3. If relevant contamination of an optical device 3, i.e., in particular, the beam bundling device 14 and / or the imaging sensor 8 in the housing 2 of the heater 1, is detected by the reference code 7 during an evaluation of the image according to step b) (block 120), a relevant person, for example, a service technician or a service company, could be informed by providing information about this via a network or by sending a corresponding message.

[0047] A first detector 11 and a second detector 12 can also be arranged in or on the housing 2 of the heater 1, and when performing step a), a signal from a first detector 11 and a second detector 12 can also be detected. A detector 11, 12 can, for example, be a (structure-borne) sound, gyro, humidity, temperature, dust, and / or vibration sensor.

[0048] A method proposed here can be carried out with a heating device according to claim 10. The heating device has a control and regulating device 10. List of reference symbols

[0049] 1Heater 2Housing 3Optical device 4Imaging sensor 5Components 6First image angle 7Reference code 8Imaging sensor 9Second image angle 10Control unit 11First detector 12Second detector 13Network 14Beam focusing device

Claims

1. Method for automatically inspecting and monitoring a heating appliance (1), having at least one optical device (3), comprising at least the following steps: a) Capturing at least one image of at least one component (5) within a housing (2) of the heater (1) by means of the at least one optical device (3), b) automated evaluation of the image captured in step a).

2. Method according to claim 1, wherein in step a) the at least one optical device (3) comprises a device for focussing beams (14) and an imaging sensor (4) arranged outside the housing (2) of the heating appliance (1), and wherein the optical device (3) captures an image via the device for focussing beams (14) of at least one component (5) inside the housing (2) of the heating appliance (1)3. Method according to one of the preceding claims, wherein in step a) an image by means of the at least one optical device (3) comprising at least one imaging sensor (8) within the housing (2) of the heating appliance is captured.

4. Method according to claim 3, wherein in step a) an image by means of an imaging sensor (8) is captured, wherein the imaging sensor (8) is a light sensor, an IR sensor, a lidar sensor and / or a radar sensor.

5. Method according to one of the preceding claims, wherein an evaluation of the captured image in step b) comprises a comparison with a reference image.

6. Method according to one of the preceding claims, wherein a time series of a plurality of images captured in step a) is included in an evaluation according to step b).

7. Method according to one of the preceding claims, wherein a reference code is captured in an image captured in step a) (7) and included in an evaluation in step b).

8. Method according to one of the preceding claims, wherein in step a) data is additionally recorded by at least one detector (11, 12) and analysed in step b).

9. Method according to claim 6, wherein in step a) data of at least one detector (11, 12) is recorded, wherein the detector (11, 12) is a sound, gyro, humidity, temperature, dust and / or vibration sensor.

10. Method according to one of the preceding claims, wherein an image captured in step a) and / or a result of an evaluation according to step b) according to a step c) is provided for retrieval via an interface to a network (13) and / or is sent via a network (13).

11. A heating appliance (1) comprising a housing and at least one imaging sensor (8) within the housing (2) and arranged such that an image of components (5) of the heater relevant for inspection (1) can be captured, wherein the heating appliance (1) comprises a regulation and control unit (10) for data processing, comprising a processor and means configured such that the regulation and control unit (10) performs the steps of a method according to any one of claims 1 to 9.

12. A computer program comprising instructions that cause a heater (1) according to claim 10 to perform the steps of the method according to any one of claims 1 to 9.