Inspection device for silo

Abstract

To accurately detect the internal state of a silo, and acquire basic data for an appropriate cleaning plan for the silo, quality control of a stored object, repair of the silo, etc.SOLUTION: An inspection device (200) for a silo comprises a detecting part (18), and a hanging tool (20) connected to the detecting part (18), and inspects the inside of the silo. The detecting part (18) is hung inside the silo, and detects the internal state of the silo.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a silo inspection device. [Background technology]

[0002] Silos are widely used to store grain, coal, gravel, cement, ore, fertilizer, etc. Silos have the advantage of being able to store a large amount of material per unit area, and some are cylindrical and over 30 meters tall.

[0003] Silos are typically inspected by workers through visual inspection, and silo cleaning is typically done by workers entering the silo and manually cleaning it.

[0004] Conventionally, various automation and mechanization measures have been implemented from the viewpoint of labor saving and safety in the inspection and cleaning of silos.

[0005] Patent Document 1 discloses a silo inventory management device equipped with a silo inventory management computer that calculates an estimated grain inventory level from the difference between the input and output amounts, determines a predetermined correlation through learning (neuro, etc.) using the history of occurrence of hollows in the grain obtained from the difference between the estimated grain inventory level and the actual measured grain inventory level, and predicts the inventory amount in the silo.

[0006] Patent Document 2 discloses an internal container cleaning tool that does not require disassembly when being carried into or out of the container and can thoroughly clean the conical part of the container. The tool comprises a flexible pressure-resistant rubber hose that serves as a passage for pressurized fluid, a rigid horizontal pipe that communicates with the pressure-resistant rubber hose, two flexible hoses connected to both ends of the horizontal pipe, and a rope for carrying the container out. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 6-259139 [Patent Document 2] Japanese Patent Application Laid-Open No. 2016-52625 Summary of the Invention [Problem to be solved by the invention]

[0008] Silos are tall and dark inside, so even if workers visually inspect them through inspection hatches, they may not be able to fully grasp the condition of the interior.

[0009] Specifically, after all stored grains and other materials inside a silo are shipped, workers visually check the remaining amount of stored material from the top of the silo and clean the inside as necessary. However, because this method relies on the worker's visual perception, there is a large margin of error, which leads to inconsistent judgments about subsequent measures. Therefore, there is a need to accurately grasp the condition inside the silo and develop an appropriate cleaning plan.

[0010] Furthermore, if the remaining amount, temperature, storage condition, etc. of the stored items can be grasped even before all of the stored items are shipped, quality control of the stored items will be easier.

[0011] Furthermore, workers must also be able to properly judge whether there are any cracks or other damage on the inner walls of the silo.

[0012] Patent Documents 1 and 2 do not propose any means for automating such various inspections.

[0013] The objective of the present disclosure is to accurately detect the internal condition of a silo and obtain basic data for appropriate silo cleaning planning, quality control of stored materials, silo repair, etc. [Means for solving the problem]

[0014] The silo inspection device disclosed herein is a device for inspecting the inside of a silo, comprising a detection unit and a hanging tool connected to the detection unit, wherein the detection unit is suspended inside the silo and detects the condition inside the silo. [Effects of the Invention]

[0015] According to the present disclosure, the internal condition of a silo can be accurately detected, and basic data can be obtained for appropriate silo cleaning planning, quality control of stored materials, silo repair, etc. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a schematic cross-sectional view showing an inspection device of the present disclosure suspended inside a silo. FIG. [Figure 2] 1 is a configuration diagram showing an inspection device according to a first embodiment. [Figure 3] FIG. 3 is a perspective view showing a main part of the inspection device of FIG. 2. [Figure 4] FIG. 10 is a configuration diagram showing an inspection device according to a second embodiment. [Figure 5] FIG. 10 is a flow chart showing a silo inspection method according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, a silo inspection method and inspection device according to the present disclosure will be described with reference to the drawings.

[0018] FIG. 1 is a schematic cross-sectional view showing a state in which an inspection device according to the present disclosure is suspended within a silo.

[0019] The silo 100 shown in this figure includes a body 10 and a conical portion 11. An inspection hatch 12 is provided on the top surface of the silo 100, and an inspection hatch 14 is provided in the conical portion 11. A fumigation gas supply unit 16 is installed inside the conical portion 11. A gas supply port (not shown) is provided in the center of the underside of the fumigation gas supply unit 16. The body 10 typically has an outer shape of a circular cylinder or a square prism. The conical portion 11 has a shape corresponding to the shape of the body 10, and has an outer shape of a cone or truncated cone, or a square pyramid or truncated pyramid.

[0020] This figure shows a state in which a device main body 18 (detection unit), which is the main body of the inspection device, is suspended inside the silo 100. The device main body 18 is fixed to the lower end of a rope 20. The device main body 18 is inserted into the silo 100 through the inspection hatch 12. The device main body 18 is configured so that it can be moved vertically inside the silo 100 by adjusting the length of the rope 20. [Example]

[0021] FIG. 2 is a configuration diagram showing the inspection device of the first embodiment.

[0022] The inspection device 200 shown in FIG. 2 includes a device main body 18, a rope 20, a rope support unit 22, and a reel unit 28 (detection unit position adjustment unit). The device main body 18 and the rope 20 are connected by a connection unit 24. Therefore, the device main body 18 and the reel unit 28 are connected by the connection unit 24 and the rope 20. The rope 20 is wound by the reel unit 28 installed on the rope support unit 22. This allows the length of the rope 20 to be adjusted. The connection unit 24 can also be considered part of the device main body 18. Furthermore, it is desirable that the major axis of the rope support unit 22 is disposed in a substantially horizontal direction. The rope 20 is supported by one end of the rope support unit 22 and is suspended vertically downward from that end into the silo.

[0023] The connection part 24 may be rotatable around the axis of the rope 20. In this case, it is desirable that the angle of rotation of the connection part 24 be adjusted by a wire or the like (not shown) other than the rope 20. The wire or the like is configured to connect the rope support part 22 or the like to the connection part 24, and by transmitting a predetermined tension to the connection part 24, the angle of rotation of the connection part 24 can be adjusted.

[0024] From the viewpoint of strength, durability, etc., it is desirable that the rope 20 and the wires, etc. be made of metal, carbon fiber, etc. A roller chain (sprocket), link chain, ball chain, etc. (hereinafter referred to as "chain, etc.") may be used instead of the rope 20. Also, a chain, etc. may be used instead of the wire, etc. The rope 20 is a type of "hanging equipment." The rope support portion 22 is a type of "hanging equipment support portion." The wire is a type of "rotation angle adjustment equipment." In this way, the rope 20 and the wires, etc. may have other configurations.

[0025] An imaging unit 30 (camera, etc.) is installed in the device body 18. The imaging unit 30 may be a 360-degree camera (omnidirectional camera).

[0026] A laser distance meter (not shown) may also be installed in the device main body 18. If the laser distance meter is capable of emitting a laser downward, it can measure the distance to the bottom of the silo, the distance to the top surface of the stored material remaining in the silo, etc. Note that the distance meter may be one that does not use a laser, and may be one that uses, for example, sound waves, ultrasonic waves, radio waves, etc.

[0027] Furthermore, it is desirable to install in the device main body 18 a temperature sensor that measures the environmental temperature inside the silo, a humidity sensor that measures the humidity inside the silo, a temperature sensor that measures the surface temperature of the stored items, a gas sensor that measures the concentration of a specific gas inside the silo, a lighting unit (light) that facilitates observation of the inside of the silo using visible light, etc. Here, the temperature sensor that measures the surface temperature of the stored items may be configured to measure the temperature by directly contacting a temperature-sensing part (probe) with the surface of the stored items, or it may be an infrared sensor that detects infrared rays emitted from the surface of the stored items. The moisture (humidity) contained in the stored items may be estimated from data from the humidity sensor.

[0028] Gas sensors include CO2 sensors, O2 sensors, CO sensors, and odor sensors that detect alcohols such as acetic acid, methanol, and ethanol. If the stored goods are grains, these gas sensors can be used to detect gases generated as the grains ferment or decay, or O2 that decreases as the grains ferment or decay.

[0029] The data acquired by the device main body 18 may be stored in a recording device built into the device main body 18. It is desirable to wirelessly transmit the data to a mobile device such as a smartphone or tablet (hereinafter simply referred to as a "mobile device") of an operator, a personal computer (PC), or the like. The data may also be transmitted via the Internet to a server, recording device, or the like installed in a location remote from the silo. In this case, it is desirable to store the data in a database installed in the mobile device, PC, server, recording device, or the like, and perform a predetermined calculation using the data using a calculation unit installed in the mobile device, PC, server, recording device, or the like, and store the calculation results in the mobile device, PC, server, recording device, or the like. It is also desirable to perform a predetermined calculation using the data using a calculation unit built into the device main body 18, and transmit the calculation results to the mobile device, PC, server, recording device, or the like. Therefore, the calculation unit may be located outside the inspection device 200 or in the device main body 18 or another predetermined location of the inspection device 200. Here, the device main body 18 and other predetermined portions can be rephrased as "the inside of the inspection device 200."

[0030] Note that, although the inspection device 200 shown in the drawing is configured to include the rope support unit 22 and the reel unit 28, the inspection device according to the present disclosure is not limited to this, and the device main body 18 connected to the rope 20 may be manually suspended into the inside of the silo by a worker without using the rope support unit 22 and the reel unit 28. In this case, the worker can determine the position of the device main body 18 inside the silo by adjusting the length of the suspended rope 20.

[0031] FIG. 3 is a perspective view showing a main part of the inspection device of FIG.

[0032] As shown in Figure 3, a reel unit 28 is installed on the rope support unit 22 of the inspection device. The rope support unit 22 is fixed to a movable unit 32. The movable unit 32 is supported by a fixed rail unit 34. A stopper 36 is installed at the rear end of the fixed rail unit 34. The direction in which the movable unit 32 moves is limited by the fixed rail unit 34. The movable unit 32 stops at a position where it comes into contact with the stopper 36. This allows the movable unit 32 to move only horizontally within a limited range. [Example]

[0033] FIG. 4 is a configuration diagram showing an inspection device according to the second embodiment.

[0034] Regarding this figure, only the differences from FIG. 2 of the first embodiment will be explained.

[0035] In the inspection device 400 shown in Fig. 4, a lighting unit 42 (light) is installed at a predetermined position (rope 20 or rope support part 22) above the device main body 18. The lighting unit 42 is preferably provided with an umbrella part so as to focus on illuminating the area below it. By providing the lighting unit 42, it becomes easier to obtain an image using visible light above the device main body 18 as well.

[0036] In this figure, the light is installed above the device main body 18, but the installation location of the light is not limited to the example shown in this figure, and the light may be installed at the inspection hatch on the top surface of the silo (Configuration T1). Also, the light may be installed on the side of the device main body 18, or may be installed near the imaging unit 30 (camera, etc.) and above the camera, etc. (Configuration T2).

[0037] In the case of configuration T1, the light of configuration T2 may be turned on or off. Even in the case of configuration T1, the light of configuration T1 may be turned on or off.

[0038] The light of configuration T1 can also be used when taking photos with a camera.

[0039] Furthermore, the light of configuration T1 is not only used for illumination, but can also be used to align the coordinates of the photographed image inside the silo as a light point (Big Dipper) of the photographing origin coordinate when photographing a 360-degree spherical model. This makes it possible to prevent any blurring of the position of the actual structure and state inside the silo.

[0040] The light source being photographed (circle: size width W, height H) can be used to measure the distance between the camera and the inspection hatch (light source). When photographing with a camera (simplified pinhole model), the height h of an object on the image photographed at distance L becomes 2 / h on the photographed image when photographed at distance 2L. This makes it possible to measure the relative distance between them. Note that the viewpoint conversion from the 360-degree photographed image to the camera photographed image (W x H) facing the light source, the camera focal length, and the size of the light receiving part such as a CCD are used.

[0041] The light of configuration T2, installed at a certain distance from the camera, can also be used as a light source to photograph the state of the surface of the grain vertically below the camera and the surface of the grain piled up at the bottom.

[0042] The light in configuration T1 is a light source for full-frame photography, and the light in configuration T2 is a light source for close-up photography.

[0043] When taking photographs to calculate the hanging distance, the light of the configuration T2 is turned off during the photographing and the light of the configuration T1 is turned on. When taking photographs of the silo wall surface, the light of the configuration T1 is turned off and the light of the configuration T2 is turned on.

[0044] When photographing the surface of the grain, the distance between the light of configuration T2 and the camera is adjusted to match the distance L1 to the surface of the grain, and the light intensity is adjusted.When photographing the silo wall, the distance between the light of configuration T2 and the camera is adjusted to match the distance L2 to the silo wall.

[0045] Next, a silo inspection method performed using the inspection device of the first or second embodiment will be described. [Example]

[0046] FIG. 5 is a flow chart showing a silo inspection method according to the third embodiment.

[0047] As shown in the figure, in inspecting a silo, the detector position adjustment unit suspends the detector of the inspection device inside the silo (step S11). Then, the detector inspects the inside of the silo (step S12). In other words, in step S12, the detector acquires a predetermined state (including images, numerical values, etc.) inside the silo. Then, the detector is pulled up and collected (step S13).

[0048] Next, the calculation unit determines whether or not to clean the inside of the silo (step S14). In step S14, it may also be determined whether or not the silo needs repair. In this case, the determination is made based on image data, etc. In step S14, it may also be determined about the quality of the stored material, etc. In addition, step S13 may be performed after step S14.

[0049] When cleaning is to be performed, the inside of the silo is cleaned according to a predetermined procedure (step S15). Cleaning, repairs, etc. may be performed by a worker entering the silo, or by a cleaning device or cleaning robot. When cleaning, repairs, etc. by a worker are required, a notification to that effect is sent to the worker's mobile device, etc.

[0050] After the cleaning is completed, the process returns to step S11 and an inspection is performed (step S12).

[0051] If it is determined in step S14 that cleaning is not to be performed, the inspection of the silo is terminated.

[0052] On the other hand, if it is determined in step S14 that cleaning is to be performed, cleaning and inspection are repeated (steps S11 to S15).

[0053] In this way, by inspecting the silo with an inspection device suspended inside, the condition of the silo can be accurately detected and the need for cleaning of the silo can be accurately determined. This allows unnecessary cleaning to be omitted and the number of cleanings to be reduced. In addition, the remaining amount and location of stored materials can be determined, ensuring the safety of subsequent work by workers.

[0054] This inspection also makes it possible to determine whether or not there are any cracks or other damage on the inner wall surface of the silo.

[0055] The data acquired in step S12 and the data on the judgment results of step S14 regarding the necessity of cleaning, repairs, etc., and the quality of the stored items are preferably stored in a database provided in a mobile terminal, PC, server, recording device, etc. This data, etc. can be used to create a silo cleaning plan, manage the quality of the stored items, and set the timing for silo repairs, part replacement, etc. Technologies such as artificial intelligence (AI), machine learning, and deep learning may be used in these processes.

[0056] In step S11 shown in the figure, the detector position adjustment unit suspends the detector of the inspection device inside the silo, but the silo inspection method of the present disclosure is not limited to this, and the detector may be manually suspended inside the silo by an operator without using the detector position adjustment unit. In this case, the operator can determine the position of the detector inside the silo by adjusting the length of the suspended suspension tool.

[0057] Other effects of the present disclosure than those described above will be summarized below.

[0058] According to the present disclosure, when there are multiple silos, it is possible to determine which silo newly arrived stored materials should be dumped into, and the order of dumping can be planned in advance. The order of cleaning the silos can also be planned in advance. Furthermore, it is possible to automatically notify workers of the schedule of necessary work, etc.

[0059] In other words, information about silos can be accumulated and visualized, and inspections of the internal conditions of silos can be automated. [Explanation of symbols]

[0060] 10: body part, 11: cone part, 12, 14: inspection hatch, 16: fumigation gas supply part, 18: device main body, 20: rope, 22: rope support part, 28: reel part, 30: imaging part, 32: movable part, 34: fixed rail part, 36: stopper, 42: lighting unit, 100: silo, 200, 400: inspection device.

Claims

1. An inspection device for inspecting the inside of a silo, comprising: a detection unit; and a hanging tool connected to the detection unit, The detection unit is suspended inside the silo and detects the condition of the inside of the silo.

2. Further provided with a detection unit position adjustment unit, the hanging tool is connected to the detection unit position adjustment unit, The silo inspection device according to claim 1 , wherein the detector position adjustment unit suspends the detector inside the silo.

3. 2. The silo inspection device according to claim 1, wherein a calculation unit disposed outside or inside the inspection device determines whether or not to perform cleaning or repair of the silo based on the condition inside the silo.

4. After the cleaning or repair is performed, The detection unit is suspended within the silo, the detection unit detects the state inside the silo, The silo inspection device according to claim 3 , wherein the calculation unit determines whether to perform the cleaning or the repair based on the state of the interior of the silo.

5. 2. The silo inspection device according to claim 1, wherein the detection unit has a sensor that measures at least one of the temperature or humidity inside the silo, the surface temperature of the stored material, and the concentration of a predetermined gas.

6. The silo inspection device according to claim 1 , wherein the detection unit includes an imaging unit.

7. The silo inspection device according to claim 6 , wherein the imaging unit is an omnidirectional camera.

8. Further provided is a hanging equipment support portion that supports the hanging equipment, a major axis of the hanging equipment support portion is disposed in a substantially horizontal direction; 2. The silo inspection device according to claim 1, wherein the hanging tool is supported at one end of the hanging tool support portion and is configured to be suspended vertically downward from the end into the interior of the silo.

9. The silo inspection device according to claim 8 , wherein an illumination unit is installed on the detection unit, the hanging tool, or the hanging tool support unit.

Images