Inspection system

Abstract

To provide an inspection system capable of detecting a remaining amount of contents in a container without requiring large-scale construction on an existing container.SOLUTION: An inspection system includes an inspection device attached to an outer peripheral surface of a wall that stands in a vertical direction of a container. The inspection device includes a transmission unit that generates and outputs an acoustic signal, and a reception unit that receives a reception signal that is a reflected signal of the acoustic signal reflected by the wall. The inspection system detects a remaining amount of contents in the container on the basis of signal information of the reception signal.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to an inspection system for detecting the amount of content remaining in a container. [Background technology]

[0002] Patent Document 1 describes a device for measuring the remaining amount of content in a container. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Publication No. 3037528 Summary of the Invention [Problem to be solved by the invention]

[0004] According to the device in Patent Document 1, the remaining amount can be measured using a sensor that detects the weight of the container and the weight of the contents. However, in order to measure the contents of an existing container that does not have a sensor, it is necessary to install a sensor under the container, which requires extensive construction work if the container is large.

[0005] Therefore, the present disclosure provides an inspection system that can detect the amount of content remaining in a container without requiring major construction work on an existing container. [Means for solving the problem]

[0006] [First technical feature] A first technical feature of the inspection system disclosed herein is that it includes an inspection device attached to the outer peripheral surface of a wall that is vertically adjacent to the container, and the inspection device includes a transmitting unit that generates and outputs an acoustic signal and a receiving unit that receives a received signal that is a reflected signal from the acoustic signal reflected by the wall, and detects the remaining amount of contents in the container based on signal information of the received signal.

[0007] [Second technical feature] As a second technical feature of the inspection system of the present disclosure, it is preferable that the inspection device includes a sheet member that is capable of partially deforming in thickness and that comes into contact with the wall when attached to the wall.

[0008] [Third technical feature] As a third technical feature of the inspection system of the present disclosure, it is preferable that the inspection system includes a plurality of inspection devices, and the inspection devices are arranged to be spaced apart from each other in the vertical direction.

[0009] [Fourth technical feature] As a fourth technical feature of the inspection system of the present disclosure, it is preferable that the inspection device includes a power supply unit and a control unit that is driven by the power supply unit, commands the transmitting unit to output an acoustic signal, and commands the receiving unit to output signal information.

[0010] [Fifth Technical Feature] As a fifth technical feature of the inspection system of the present disclosure, it is preferable that the transmitting unit and the receiving unit are configured as a single transmitting / receiving unit, and the control unit instructs the transmitting / receiving unit to switch between functioning as a transmitting unit and functioning as a receiving unit.

[0011] [Sixth Technical Feature] As a sixth technical feature of the inspection system of the present disclosure, it is preferable that the transmitting unit and the receiving unit include a piezoelectric element.

[0012] [7th Technical Feature] As a seventh technical feature of the inspection system of the present disclosure, the inspection device preferably includes a power supply unit and a wireless unit that is driven by the power supply unit and is capable of wireless communication with an external device that is remote from the inspection device, and at least one of the inspection device or the external device preferably includes an analysis unit that analyzes the remaining amount of the contained items based on the signal information.

[0013] [8th Technical Feature] An eighth technical feature of the inspection system of the present disclosure is that it includes a first inspection device group consisting of one or more inspection devices each having approximately the same vertical coordinate, and a second inspection device group consisting of one or more inspection devices located vertically above the first inspection device group and having approximately the same vertical coordinate, and it is preferable that the remaining amount of contents in the container is detected by comparing first signal information acquired by the first inspection device group with second signal information acquired by the second inspection device group.

[0014] [9th Technical Feature] A ninth technical feature of the inspection system of the present disclosure is that it includes a first inspection device group consisting of one or more inspection devices each with approximately the same vertical coordinate, a second inspection device group consisting of one or more inspection devices located vertically above the first inspection device group and with approximately the same vertical coordinate, and a third inspection device group consisting of one or more inspection devices located vertically above the second inspection device group and with approximately the same vertical coordinate, and it is preferable that the remaining amount of contents in the container is detected by comparing first signal information acquired by the first inspection device group, second signal information acquired by the second inspection device group, and third signal information acquired by the third inspection device group.

[0015] [10th Technical Feature] As a tenth technical feature of the inspection system of the present disclosure, the signal information includes a first received signal, which is a reflected signal reflected from the outer peripheral surface of the wall, and a second received signal, which is a reflected signal reflected from the inner peripheral surface of the wall, and it is preferable to detect the remaining amount of contents in the container by comparing the first received signal and the second received signal.

[0016] [11th Technical Feature] As an eleventh technical feature of the inspection system of the present disclosure, it is preferable that the inspection device includes a sensor unit that detects the height above ground. [Effects of the Invention]

[0017] According to a first technical feature of the inspection system of the present disclosure, the remaining amount of contents in a container can be detected without requiring major construction work on an existing container.

[0018] According to a second technical feature of the inspection system of the present disclosure, acoustic signals can be output efficiently and reception signals can be received efficiently.

[0019] According to a third technical feature of the inspection system of the present disclosure, it is possible to estimate the height of the surface position of the contained item by each inspection device.

[0020] According to a fourth technical feature of the inspection system of the present disclosure, the inspection device can be installed and inspected in a location where it is difficult to supply power from an external power source.

[0021] According to a fifth technical feature of the inspection system of the present disclosure, the transmitting unit and the receiving unit are integrated into one component, so there is no need to adjust the receiving position relative to the transmitting unit.

[0022] According to a sixth technical feature of the inspection system of the present disclosure, general-purpose piezoelectric elements can be used as the transmitter and receiver.

[0023] According to a seventh technical feature of the inspection system of the present disclosure, the remaining amount of the contained contents can be monitored remotely from the container.

[0024] According to the eighth technical feature of the inspection system of the present disclosure, highly accurate detection is possible.

[0025] According to the ninth technical feature of the inspection system of the present disclosure, highly accurate detection is possible.

[0026] According to the tenth technical feature of the inspection system of the present disclosure, the influence of variations in the output strength of the acoustic signal on detection can be suppressed.

[0027] According to the eleventh technical feature of the inspection system of the present disclosure, it is possible to detect the remaining amount based on the height information of the contained items. [Brief explanation of the drawings]

[0028] [Figure 1] FIG. 1 is a block diagram showing the device configuration of an inspection system S according to a first embodiment. [Figure 2] FIG. 2 is a block diagram showing the functional configuration of an inspection device M and an external device E according to the first embodiment. [Figure 3] FIG. 2 is a diagram showing an example in which the inspection device M of the first embodiment is arranged on a container C. [Figure 4] 1 is a cross-sectional view showing a state in which the inspection device M of the first embodiment is attached to the wall C1 of the container C. FIG. [Figure 5] Enlarged view of a portion of Figure 4. [Figure 6] FIG. 10 is a block diagram showing the functional configuration of an inspection device M and an external device E according to a modified example of the first embodiment. [Figure 7] 10 is a flowchart showing a remaining amount detection method when only the external device has an analysis unit. [Figure 8] 10 is a flowchart showing a remaining amount detection method when the inspection device has an analysis unit. [Figure 9] FIG. 4 is a diagram showing a detailed example of first and second signal information. [Figure 10] FIG. 10 is a diagram showing a detailed example of first to third signal information. [Figure 11] FIG. 2 is a diagram showing an example of the functional configuration of a computer. DETAILED DESCRIPTION OF THE INVENTION

[0029] Hereinafter, embodiments of the present disclosure will be described in detail. Components having the same function will be assigned the same numbers, and duplicate explanations will be omitted. It should be noted that the components of the examples and embodiments described below can be combined with each other as long as they are not inconsistent. It should also be noted that the materials, shapes, dimensions, numbers, and arrangements of the components in each aspect of the examples and embodiments described below are merely examples, and that any design modifications are possible as long as the same functions can be achieved. [Example]

[0030] An inspection system according to the first embodiment will be described below with reference to FIGS.

[0031] In the following figures, the letters X1, X2, Y1, Y2, Z1, and Z2 are used to indicate directions. The Z axis is also referred to as the first axis, the Y axis as the second axis, and the X axis as the third axis. The Z1 side is also referred to as one side of the first axis, the Z2 side as the other side of the first axis, the Y1 side as one side of the second axis, the Y2 side as the other side of the second axis, the X1 side as one side of the third axis, and the X2 side as the other side of the third axis. The first axis (Z) is a vertical direction corresponding to the direction in which the wall of the container described below is in contact with the wall. The Z1 side corresponds to the vertical downward side, and the Z2 side corresponds to the vertical upward side. The second axis (Y) is a horizontal direction approximately perpendicular to the first axis (Z), and the third axis (X) is a horizontal direction approximately perpendicular to the first axis (Z) and the second axis (Y).

[0032] As shown in FIG. 1, the inspection system S includes one or more inspection devices M and an external device E. As shown in FIG. 2, the inspection device M includes a transmitting unit 1 and a receiving unit 2, and is attached to the outer peripheral surface C11 of a wall C1 that is adjacent to the container C in the vertical direction (Z) as shown in FIG. 3. The transmitting unit 1 generates an acoustic signal and outputs it as an acoustic signal T. The receiving unit 2 receives a received signal R, which is a reflected signal of the acoustic signal T reflected by the wall C1. The inspection system S detects the remaining amount of the contents C2 in the container C based on signal information D obtained from the received signal R. The signal information D may include information regarding the strength and reception time of the received signal R received by the receiving unit 2.

[0033] <Sheet member 3> The inspection device M may include a sheet member 3 that contacts the wall C1 when attached to the wall C1 as shown in FIG. 4. The thickness of the sheet member 3 may be at least partially deformed depending on the shape of the wall C1 of the container C. For example, if the container C has a cylindrical shape with an axis parallel to the first axis (Z), the central portion of the sheet surface along the third axis (X) will be thinnest in thickness depending on the curvature of the wall C1, and the X1 and X2 sides will be thickest, and the sheet will be disposed in the gap between the wall C1 facing the transmitter 1 and receiver 2 of the inspection device M. Note that the sheet member 3 can be omitted if the transmitter 1 vibrates an object to generate an acoustic signal. The sheet member 3 is preferably formed of a plastic or elastic material.

[0034] <Number and placement of inspection equipment> The inspection system S may include a plurality of inspection devices M. As shown in Fig. 3, the inspection devices M may be arranged to be spaced apart from each other in the first axis (Z) direction.

[0035] The inspection devices M may be arranged in multiple rows in the first axis (Z) direction on the outer peripheral surface C11, and when the inspection devices M are arranged in multiple rows, they may be arranged at the same position in the first axis (Z) direction, or the position in the first axis (Z) direction may be shifted for each row. When the inspection devices M are arranged in two rows, they may be arranged in a staggered pattern.

[0036] When the inspection devices M are arranged in multiple rows, they may be arranged evenly on the outer peripheral surface C11 of the wall C1 of the container C. For example, when the container C has a cylindrical shape with an axis parallel to the first axis (Z) and the inspection devices M are arranged in two rows, one row may be arranged on the Y1 side and the other row may be arranged on the Y2 side.

[0037] Similarly, if the container C has a cylindrical shape with an axis parallel to the first axis (Z) and the inspection devices M are arranged in four rows, one row of the inspection devices M may be arranged on each of the Y1 side, Y2 side, X1 side, and X2 side, as illustrated in Figure 3.

[0038] <Power supply unit 4, control unit 5> As shown in FIG. 2, the inspection device M may include a power supply unit 4 and a control unit 5. The power supply unit 4 may include a battery 41. The battery 41 may be a primary battery or a secondary battery, and may be configured to supply power based on power obtained by at least one of self-power generation and contactless power supply. Self-power generation refers to ambient power generation using, for example, photovoltaic power generation, thermal power generation, or kinetic energy such as vibration. In this case, it is preferable that the battery 41 be configured using a self-power generation element. Contactless power supply refers to power supply via, for example, a wireless power supply receiving coil or a rod-shaped, horn-shaped, or a receiving antenna formed as a pattern on a substrate, without contacting the terminals of the receiving coil and the antenna. Of course, other elements having a power supply function may also be used.

[0039] The control unit 5 may be driven by the power supply unit 4. The control unit 5 may also instruct the transmitting unit 1 to output an acoustic signal T, and may also instruct the receiving unit 2 to output signal information D.

[0040] <Modification: Transmitter / Receiver 8> 6, the transmitting unit 1 and the receiving unit 2 may be configured as a single transmitting / receiving unit 8. In this case, it is preferable that the control unit 5 instructs the transmitting / receiving unit 8 to switch between the function as the transmitting unit 1 and the function as the receiving unit 2.

[0041] <Details of Transmitter 1 and Receiver 2> As shown in Fig. 2, the transmitting unit 1 may include a piezoelectric element 1a or the like and generate an acoustic signal by itself, or may generate an acoustic signal by vibrating an object with an impulse hammer or the like. In other words, outputting an acoustic signal T may mean that the transmitting unit 1 is the source of the acoustic signal T, or the transmitting unit 1 may generate the source of the acoustic signal T. The acoustic signal may also be ultrasonic. By using sound waves or ultrasonic waves, they are not absorbed by metal like millimeter waves or microwaves, and signal loss can be reduced.

[0042] As shown in FIG. 2, the receiving unit 2 may include a piezoelectric element 2a, a microphone, an acceleration sensor, or the like that can receive an acoustic signal, and the form thereof is not limited.

[0043] <Radio section 6, analysis section 7> 2, the inspection device M may include a wireless unit 6 powered by a power supply unit 4. It is preferable that at least one of the inspection device M or the external device E includes an analysis unit 7 that analyzes the remaining amount of the contained item C2 based on the signal information D. The analysis unit 7 may be included in both the inspection device M and the external device E.

[0044] The wireless unit 6 may be capable of wireless communication with an external device E remote from the inspection device M, and may wirelessly transmit signal information D to the external device E. If the inspection device M includes an analysis unit 7, the analysis result A by the analysis unit 7 may be wirelessly communicated to the external device E, or may support bidirectional wireless communication with the external device E. The wireless unit 6 may also be compatible with a long-distance wireless standard, specifically, a communication distance of 1 km or more, or a short-distance wireless standard, specifically, a communication distance of up to 100 m. For example, to support a long-distance wireless standard, a device compliant with LPWA (Low Power Wide Area), 5G, LTE, or the like may be used. To support a short-distance wireless standard, a device compliant with Wi-Fi, Bluetooth (registered trademark), Private LoRa, Z-Wave, ZigBee (registered trademark), Thread (registered trademark), Matter (registered trademark), or the like may be used.

[0045] Furthermore, the radio unit 6 may include an antenna 61 for wireless communication. The antenna 61 may be an antenna member mounted on the substrate, a pattern antenna formed on the surface of the substrate, or may be built into a wireless IC (an example of a radio unit) mounted on the substrate.

[0046] As described above, the analysis unit 7 may be included in the inspection device M or in the external device E. Furthermore, the analysis unit 7 may analyze the remaining amount of the contained item C2 based on the signal information D, or may analyze the remaining amount of the contained item C2 based on the analysis result A received from the inspection device M.

[0047] <Inspection equipment group> As shown in Figure 3, the inspection device M may include a first inspection device group M1 consisting of one or more inspection devices M each having approximately the same coordinate on the first axis (Z), and a second inspection device group M2 located on the Z2 side of the first inspection device group M1 and consisting of one or more inspection devices M each having approximately the same coordinate on the first axis (Z), or may include a third inspection device group M3, ... located further on the Z2 side of the second inspection device group M2 and consisting of one or more inspection devices M each having approximately the same coordinate on the first axis (Z).

[0048] The first to third inspection device groups are referred to as inspection device "groups" regardless of the number of inspection devices, but as mentioned above, an inspection device group may be composed of only one inspection device M, and in this case, for convenience, they are also referred to as inspection device "groups."

[0049] Details will be described later, but for example, if the inspection device M includes a first inspection device group M1 and a second inspection device group M2, it is preferable to detect the remaining amount of contents C2 in the container C by comparing the first signal information D1 acquired by the first inspection device group M1 with the second signal information D2 acquired by the second inspection device group M2.

[0050] Details will be described later, but for example, if the inspection device M includes a first inspection device group M1, a second inspection device group M2, and a third inspection device group M3, it is preferable to detect the remaining amount of contents C2 in the container C by comparing the first signal information D1 acquired by the first inspection device group M1, the second signal information D2 acquired by the second inspection device group M2, and the third signal information D3 acquired by the third inspection device group M3.

[0051] <Detection using the outer surface C11 and inner surface C12 of wall C1> As will be described in more detail later, the signal information D includes a first received signal R1, which is a reflected signal reflected by the outer peripheral surface C11 of the wall, and a second received signal R2, which is a reflected signal reflected by the inner peripheral surface C12 of the wall, and it is preferable to detect the remaining amount of contents C2 in the container C by comparing the first received signal R1 and the second received signal R2.

[0052] <Sensor part 9> 2, the inspection device M may include a sensor unit 9. The sensor unit 9 may be a sensor that detects the height above ground of the location where the inspection device M is installed. The sensor unit 9 may also include a function to detect the location where it is installed using a GPS or the like and communicate the location information to an external device E via a wireless unit 6.

[0053] <Case 10> As shown in FIG. 2 , the inspection device M may include a housing 10. The housing 10 may include a housing section 101 that houses at least one of the transmitter 1, receiver 2 (or transceiver 8), power supply 4, controller 5, wireless unit 6, analyzer 7, and sensor 9. The transmitter 1, receiver 2 (or transceiver 8), power supply 4, controller 5, wireless unit 6, analyzer, and sensor 9 housed in the housing section 101 may be supported by the housing 10 or may be mounted on a board or the like and housed together with the board or the like. When housed in the housing 10, at least a portion of the transmitter 1, receiver 2, or transceiver 8 may be exposed, or the exposed portion may face the sheet member 3. Furthermore, the housing 10 may be configured so that it can be attached to the outer peripheral surface C11 of the wall C1 by a mounting member 11. The housing section 101 may have a waterproof or explosion-proof structure. Furthermore, the housing 10 may include multiple members, such as a main body 102 and a lid 103.

[0054] The mounting member 11 may be a screw, a magnet, adhesive, double-sided tape, or the sheet member 3 itself, and the method of mounting the inspection device M to the wall C1 using the mounting member 11 is not limited.

[0055] [How to install inspection device M] Next, a method for attaching the inspection device M to the container C will be described. First, the transmitter 1, receiver 2 (or transmitter / receiver 8), power supply 4, controller 5, wireless unit 6, analyzer 7, and sensor 9 are housed in the housing 10's housing section 101 to assemble the inspection device M. The surface of the housing 10 on which at least a portion of the transmitter 1 and receiver 2, or the transmitter / receiver 8, is exposed is attached to the outer peripheral surface C11 of the wall C1 of the container C with the sheet member 3 sandwiched between them by the attachment member 11. If the sheet member 3 is adhesive, the sheet member 3 may be attached first to the surface of the housing 10 on which at least a portion of the transmitter 1 and receiver 2, or the transmitter / receiver 8, is exposed.

[0056] Similarly, multiple inspection devices M are installed at predetermined intervals in the first axis (Z) direction. At this time, one inspection device M may be placed closest to the Z1 side of the container C, another inspection device M may be placed closest to the Z2 side of the container C, and the other inspection devices M may be placed so that there are approximately equal intervals between them. The container C to which the inspection device M is installed may be one that is already installed at the installation site, or the inspection device M may be installed before installation and then moved to the installation site and installed.

[0057] [Method 1 for detecting remaining amount of contained items in embodiment 1] With reference to FIG. 7, a method for detecting the remaining amount (storage capacity) of the stored items C2 by the inspection system S in the case where only the external device E has the analysis unit 7 will be described.

[0058] Here, each of the one or more inspection devices M having approximately the same coordinate on the first axis (Z) is referred to as a first inspection device group M1, and each of the one or more inspection devices M located on the Z2 side of the first inspection device group M1 and having approximately the same coordinate on the first axis (Z) is referred to as a second inspection device group M2. Furthermore, signal information D that can be acquired from the received signal R received by the first inspection device group M1 is referred to as first signal information D1, and signal information D that can be acquired from the received signal R received by the second inspection device group M2 is referred to as second signal information D2.

[0059] First, the external device E is powered on (S201), and the external device E wirelessly commands all of the inspection devices M to perform an inspection (S202). This command includes commands to (1) output an acoustic signal T to the transmitter 1, (2) output signal information D to the receiver 2, and (3) transmit the signal information D to the wireless unit 6. Upon receiving this command, each inspection device M wirelessly transmits the signal information D to the external device E (S203-S205). The external device E receives the signal information D from all of the inspection devices M. The analysis unit 7 of the external device E performs an analysis based on the signal information D and obtains the analysis result A. The analysis unit 7 detects the remaining amount of the contained item C2 based on the analysis result A (S206).

[0060] [Method 2 for detecting remaining amount of contained items in embodiment 2] With reference to FIG. 8, a method for detecting the remaining amount (storage capacity) of the stored items C2 by the inspection system S in the case where at least each inspection device M has an analysis unit 7 will be described.

[0061] As described above, one or more inspection devices M having approximately the same coordinate on the first axis (Z) are referred to as the first inspection device group M1, and one or more inspection devices M located on the Z2 side of the first inspection device group M1 and having approximately the same coordinate on the first axis (Z) are referred to as the second inspection device group M2. Furthermore, signal information D that can be acquired from the received signal R received by the first inspection device group M1 is referred to as the first signal information D1, and signal information D that can be acquired from the received signal R received by the second inspection device group M2 is referred to as the second signal information D2. Furthermore, the analysis result A obtained by analyzing the first signal information D1 is referred to as the first analysis result A1, and the analysis result A obtained by analyzing the second signal information D2 is referred to as the second analysis result A2.

[0062] First, the power of external device E is turned ON (S301), and external device E wirelessly commands all inspection devices M to perform an inspection (S302). This command includes commands to (1) output an acoustic signal T to the transmitter 1, (2) output signal information D to the receiver 2, (3) analyze the signal information D and output the analysis result A to the analyzer 7, and (4) transmit the analysis result A to the wireless unit 6. Upon receiving this command, each inspection device M wirelessly transmits the analysis result A to external device E (S303-S306). External device E receives the analysis results A from all inspection devices M. The analysis unit 7 of external device E detects the remaining amount of contained item C2 based on the first analysis result A1 and the second analysis result A2 (S307).

[0063] [Method 1 for estimating the surface position of contained items to detect remaining amount] We will now explain the method for estimating the surface position C21 of the contained items for remaining amount detection performed by the analysis unit 7. The analysis unit 7 that performs the estimation may be included in either the inspection device M or the external device E, and estimation may be performed by a series of analyses in both.

[0064] Because the acoustic signal T output from the transmitter 1 is a sound wave, the receiver 2 receives a first received signal R1 (see FIG. 5), which is a reflected signal reflected from the outer peripheral surface C11 of the wall C1 of the container C, and a second received signal R2 (see FIG. 5), which is a reflected signal that penetrates into the wall C1 and is reflected from the inner peripheral surface C12. The receiver 2 acquires signal information D from each received signal R. This signal information D includes information regarding the strength and reception time of the received signal R. Therefore, a chart with the strength of the received signal R on the vertical axis and time on the horizontal axis will show a first peak P1 indicating the reception of the first received signal R1 and a second peak P2 indicating the reception of the second received signal R2, which arrives after a delay from the first peak P1 equivalent to twice the thickness of the wall C1. The acoustic signal, which is a sound wave, is reflected at the boundary surface of the acoustic impedance Zo shown in equation (1), and the position of the surface C21 of the contained item C2 is estimated by utilizing the principle that the reflectivity RE (%) increases as the difference in acoustic impedance Zo increases, as shown in equation (2).

[0065] For example, if wall C1 is made of iron and the contents are water, the acoustic impedance Zo of iron is 46,456,600 N·s / m 3 and the characteristic value of the acoustic impedance Zo of water is 1,680,000 N·s / m 3 and the characteristic value of the acoustic impedance Zo of air is approximately 429 N·s / m 3 A difference occurs between the second received signal R2 when the item surface C21 is located closer to the Z1 side than the inspection device M and the second received signal R2 when the item surface C21 is located closer to the Z2 side than the inspection device M. This difference is due to the difference in reflectivity RE, so the position of the item surface C21 can be estimated by comparing the intensities of the second received signal R2. Note that the received signal R is affected by the acoustic impedance Zo of the inspection device M and the sheet member 3 when it passes through the wall C1 to the receiver 2. However, the boundary conditions between the inspection device M, including the sheet member 3, and the wall C1 are common to each inspection device M and do not affect the estimation of the remaining amount of the item C2. Therefore, by comparing the second peak P2 representing the intensity of the second received signal R2 included in the analysis result A of the signal information D based on the received signal R, the approximate position of the item surface C21 on the first axis (Z) relative to the inspection device M can be estimated.

[0066] Zo=ρxc···(1) where ρ is the density of the material and c is the speed of sound in the material.

[0067] RE=(Zb-Za) / (Zb+Za)×100...(2) Here, Zb is the acoustic impedance of the wall C1, and Za is the acoustic impedance of the contained item C2 or the acoustic impedance of air when the contained item C2 is not present.

[0068] For example, when the surface C21 of the water-containing item C2 is located on the Z1 side of the inspection device M, the reflectance REa is approximately 99.9% (calculation result: formula (3)) when the characteristic value of the acoustic impedance Zo of air is substituted for Zb in formula (2), and when the surface C21 of the water-containing item C2 is located on the Z2 side of the inspection device M, the reflectance REb is approximately 93.0% (calculation result: formula (4)) when the characteristic value of the acoustic impedance of water is substituted for Zb in formula (2).

[0069] Therefore, as shown in Figure 9, if the second reflectance RE2 obtained by analyzing the first signal information D1 that can be obtained from the received signal R received by the first inspection device group M1 is approximately 93.0%, it can be estimated that the contained item surface C21 is located on the Z2 side of the first inspection device group M1, and if the second reflectance RE2 obtained by analyzing the second signal information D2 that can be obtained from the received signal R received by the second inspection device group M2 is approximately 99.9%, it can be estimated that the contained item surface C21 is located on the Z1 side of the second inspection device group M2, and therefore it can be estimated that the contained item surface C21 is located between the first inspection device group M1 and the second inspection device group M2.

[0070] REa=(46,456,600−429) / (46,456,600+429)≒99.9(%)···(3) REb=(46,456,600−1,680,000) / (46,456,600+1,680,000) ≒93.0(%) (4) [Method 2 for estimating the surface position of contained items to detect remaining amount] One or more inspection devices M located further on the Z2 side relative to the second inspection device group M2 and having approximately the same coordinate on the first axis (Z) are referred to as a third inspection device group M3. Furthermore, signal information D that can be acquired from the received signal R received by the third inspection device group M3 is referred to as third signal information D3, and an analysis result A obtained by analyzing the third signal information D3 is referred to as a third analysis result A3, and the third analysis information A3 includes a third reflectance RE3 obtained by analyzing the third signal information D3 acquired by the third inspection device group M3.

[0071] As illustrated in Figure 10, when the first reflectance RE1 (93.3%), the second reflectance RE2 (94.0%), and the third reflectance RE3 (99.9%) are three different values, it can be estimated that the surface C21 of the contents is at the same position on the first axis (Z) as the second inspection device group M2 or is closer than any other inspection device.

[0072] [Method 3 for estimating the surface position of contained items to detect remaining amount] The analysis unit 7 compares peak 1 with peak 2 and obtains an analysis result A.

[0073] [Method 4 for estimating the surface position of contained items to detect remaining amount] In estimation methods 1 to 3, the position of the contained item surface C21 is estimated by comparing the reflectance RE based on the acoustic impedance Zo, but since the signal information D contains information other than the reflectance RE, this information can be used to estimate the position of the contained item surface C21. For example, it is possible to obtain a transfer function (frequency response function) from the frequency characteristics of the received signal R for each inspection device M and compare them to estimate the position of the contained item surface C21. Machine learning may be used to compare the transfer functions.

[0074] [Technical features and effects] The inspection system S configured as above has the following technical features and effects.

[0075] <Effect of the first technical feature> According to the inspection system S of the present disclosure, the inspection device M can be attached to the container C, which is the object to be inspected, either after the container C has been installed at the installation location or before it has been moved to the installation location. Furthermore, since the installation of the inspection device M does not require lifting or moving the container C, no major construction work is required. Therefore, even for an existing container C, it is possible to easily construct an inspection system S that installs the inspection device M and inspects the remaining amount of the contained item C2.

[0076] A TOF (Time of Flight) method is known that estimates the position of the surface C21 of the contained item by utilizing the time it takes to transmit an electromagnetic wave or an acoustic signal in the vertical direction and receive the signal reflected by the surface C21 of the contained item.

[0077] If the container C is very large (for example, a cylindrical container with a diameter of about 3 m and a length of about 10 m), when measuring distance from the vertically upward direction toward the surface C21 of the contents, if the remaining amount of the contents C2 is small, the measurement distance becomes long and the attenuation of the received signal R becomes large, making it impossible to perform accurate distance measurement.

[0078] Similarly, when measuring distance from the vertically downward direction toward the surface C21 of the contents, if there is a large amount of remaining contents C, the measurement distance becomes long and the attenuation of the received signal R becomes large, making it impossible to measure distance accurately.

[0079] On the other hand, the inspection system S disclosed herein outputs an acoustic signal T and utilizes received information D obtained from a received signal R, which is a reflected signal reflected by a wall C1, thereby enabling accurate inspection regardless of the size of the container.

[0080] Furthermore, since the transmitting unit 1 outputs the acoustic signal T, it is possible to omit adjustments for the receiving unit 2 to efficiently receive the reception signal R after the inspection device M is attached.

[0081] Furthermore, in a workplace where the remaining amount of the contained items C2 is detected by manual hammering inspection, the inspection system S of the present disclosure can be used instead of the manual hammering inspection.

[0082] The inspection system S of the present disclosure can be used as a system that predicts when to replenish the contents C2 or issues a replenishment instruction by detecting the remaining amount of the contents C2. It can also be used as a management system for managing the amount of the contents C2 that is carried out.

[0083] <Second technical feature and effect> Since the thickness of the sheet member 3 can be changed, it can fill the gap between the inspection device M and the wall C1 of the container C, preventing the air layer from interfering with the transmission of acoustic signals, and enabling acoustic signals to be output efficiently and received signals to be received efficiently.

[0084] <Third technical feature and effect> By mounting multiple inspection devices M at a predetermined interval along the first axis (Z), the height of the contained item C2 along the first axis (Z) can be determined from the mounting position of the inspection device M on the container C, which estimates the position of the contained item surface C21, and the remaining amount of contained item C2 contained in the container C can be detected based on the internal shape of the container C.

[0085] Furthermore, by arranging one inspection device M closest to the Z1 side of the container C, and another inspection device M closest to the Z2 side of the container C with approximately equal intervals between them, the remaining amount of the contents C2 can be precisely detected.

[0086] Furthermore, the inspection device M is positioned so that it can detect the remaining amount of the contained item C2 and detect the remaining amount necessary to predict when to replenish the contained item C2 or to give an instruction to replenish, and installation at a location where it detects the remaining amount not necessary to predict when to replenish the contained item C2 or to give an instruction to replenish can be omitted, thereby making it possible to reduce the number of inspection devices M. For example, the inspection device M can be installed in a location where it can detect that the remaining amount of the contained item C2 is 90 to 100%, and in a location where it can detect that the remaining amount of the contained item C2 is 0 to 10%, 10 to 20%, 20 to 30%, 30 to 40%, or 40 to 50%, and the inspection device M can be avoided from being installed in a location where it can detect that the remaining amount is 50 to 90%.

[0087] By arranging the inspection devices M in multiple rows on the first axis (Z), it is possible to estimate the position of the contained item surface 21 even if the contained item C2 is a powder or the like and the contained item surface C21 is not horizontal. For example, if there is a difference between the position of the contained item surface 21 estimated by the inspection device M arranged on the Y2 side and the position of the contained item surface 21 estimated by the inspection device M arranged on the Y1 side, it can be inferred that the contained item surface 21 is inclined relative to the horizontal direction, and it is possible to estimate the remaining amount of the contained item C2 by analyzing the inclination rate.

[0088] Furthermore, even if the contained item C2 is a powder or the like and the surface C21 of the contained item has a conical depression shape, the reflected signal that penetrates from the wall C1 into the contained item C2 and is reflected on the surface of the depression can be read from the peak that occurs some time after the second peak of the signal information D of the received signal R, and the slope of the depression can be inferred, so it is possible to analyze the depression ratio and estimate the remaining amount of the contained item C2.

[0089] <Fourth Technical Feature and Effect> Since the inspection device M has the battery 41 of the power supply unit 4, an inspection system can be constructed by attaching the inspection device to a container that is installed in a location where it is difficult to supply power from outside, such as outdoors.

[0090] Furthermore, since the control unit 5 is provided, it is possible to control the transmitting unit 1, receiving unit 2, wireless unit 6, analyzing unit 7, and sensor unit 9 to complete the test simply by starting the test.

[0091] <Fifth Technical Feature and Effect> The transmitter 1 and receiver 2 are configured as a single transmitter / receiver 8, and when the control unit 5 commands switching between the function as transmitter 1 and the function as receiver 2, the receiver 2 is positioned at a position where the acoustic signal T output by the transmitter 1 is reflected by the wall C1, so there is no need to adjust the output direction of the acoustic signal T or the position or orientation of the receiver 2.Therefore, by attaching the inspection device M to the container C, the received signal R can be received efficiently, and the position of the surface C21 of the contained item can be estimated based on the accurate signal information D.

[0092] <Sixth Technical Feature and Effect> Using general-purpose piezoelectric elements as the transmitter and receiver can reduce the cost of the inspection device M and the risk of production adjustments due to supply shortages.

[0093] <Seventh Technical Feature and Effect> The inspection device M includes a wireless unit 6 and is capable of wireless communication with an external device E that is remote from the inspection device M, so that the remaining amount of the contents C2 in the container C can be monitored remotely.

[0094] The inspection device M analyzes the received information D using each inspection device M including the analysis unit 7, and can wirelessly communicate the analysis results A to the external device E, thereby simplifying the analysis process in the external device E and shortening the analysis time, making it possible to monitor in real time the progress of loading the contents C2 onto a transport vehicle or the like for transport, and to monitor the amount of material being transported.

[0095] It is also possible to build a system in which inspection devices M are attached to multiple containers C and an external device E performs centralized monitoring.

[0096] <8th Technical Feature and Effect> It can be estimated that the surface C21 of the contained items exists between the first inspection device group M1 and the second inspection device group M2, which are adjacent to each other on the first axis (Z), and the remaining amount can be detected with high accuracy.

[0097] <Ninth Technical Feature and Effect> Of the first inspection device group M1, the second inspection device group M2, and the third inspection device group M3, which are adjacent on the first axis (Z), it can be estimated that the surface 21 of the contents is at the same height as or near the second inspection device group M2, making it possible to detect the remaining amount with higher accuracy. In other words, detection with half the resolution of the eighth technical feature is possible.

[0098] <10th Technical Feature and Effect> Even if the acoustic impedance Zo is the same, if there is variation in the output strength of the acoustic signal T due to individual differences in the transmitting unit 1, differences will occur in the strength of the received signal R, which will affect the estimation of the position of the surface C21 of the contained item.However, by comparing the first received signal R1 with the second received signal R2, the effect of variation in the output strength of the acoustic signal T on the analysis result A can be reduced, and the effect on the detection of the remaining amount of the contained item C2 can be suppressed.

[0099] <Eleventh Technical Feature and Effect> The inspection device M includes a sensor unit 9 that detects the height above the ground, and by outputting information on the height above the ground where the inspection device M is installed along with the received data D and the analysis result A, the height of the surface C21 of the contents can be estimated and the remaining amount can be detected.

[0100] Furthermore, if the sensor unit 9 includes a GPS, the external device E can recognize the installation position of the container C, making it possible to use the sensor unit 9 in a system in which multiple containers C are centrally monitored by the external device E. Even if the sensor unit 9 does not include a GPS, it is possible to recognize the installation position of the container C by using wireless communication with a base station via 5G or LPWA. [Industrial Applicability]

[0101] The inspection system of the present disclosure can be used as a system for inspecting the remaining amount of contents in a large container that is installed outdoors, such as a cement silo.

[0102] <Additional Notes> The functions performed by the components described herein may be implemented in circuitry or processing circuitry, including general-purpose processors, application-specific processors, integrated circuits, ASICs (Application Specific Integrated Circuits), a CPU (a Central Processing Unit), conventional circuits, and / or combinations thereof, programmed to perform the described functions. A processor includes transistors and other circuits and is considered to be circuitry or processing circuitry. A processor may also be a programmed processor that executes programs stored in memory.

[0103] In this specification, a circuitry, unit, or means is hardware that is programmed to realize or performs the described functions, which may be any hardware disclosed herein or any hardware known to be programmed to realize or perform the described functions.

[0104] If the hardware is a processor considered to be a type of circuitry, the circuitry, means, or unit is a combination of the hardware and software used to configure the hardware and / or processor.

[0105] The various processes described above can be implemented by loading a program that executes each step of the above method into the recording unit 10020 of the computer shown in Figure 11 and operating the control unit 10010, input unit 10030, output unit 10040, etc.

[0106] The program describing the processing contents can be recorded on a computer-readable recording medium, which may be, for example, a magnetic recording device, an optical disk, a magneto-optical recording medium, a semiconductor memory, or any other suitable recording medium.

[0107] The program may be distributed, for example, by selling, transferring, lending, etc. a portable recording medium such as a DVD or CD-ROM on which the program is recorded. Furthermore, the program may be stored in a storage device of a server computer, and then transferred from the server computer to another computer via a network, thereby distributing the program.

[0108] A computer that executes such a program may first temporarily store the program recorded on a portable recording medium or transferred from a server computer in its own storage device. Then, when executing a process, the computer reads the program stored on its own recording medium and executes the process in accordance with the read program. Alternatively, the computer may read the program directly from a portable recording medium and execute the process in accordance with the program. Furthermore, the computer may execute the process in accordance with the program each time a program is transferred from a server computer to the computer. The server computer may not transfer the program to the computer, but may instead execute the process through a so-called ASP (Application Service Provider) service, which realizes the processing function by issuing an execution instruction and obtaining the results. Furthermore, the server computer may execute the process on a terminal using a so-called SaaS (Software as a Service) service, which allows users to use part of the server computer along with the program. In this embodiment, the program includes information used for computer processing that is equivalent to a program (such as data that is not a direct instruction to the computer but has properties that define computer processing).

[0109] Furthermore, in this embodiment, the device is configured by executing a predetermined program on a computer, but at least a part of the processing contents may be realized by hardware.

Claims

1. The inspection device is attached to the outer peripheral surface of a wall that is in vertical contact with the container, The inspection device includes: a transmitter that generates and outputs an acoustic signal; a receiving unit that receives a received signal in which the acoustic signal is a reflected signal reflected by the wall, An inspection system that detects the remaining amount of the contents in the container based on signal information of the received signal.

2. 10. The inspection system of claim 1, The inspection device includes: a sheet member that is capable of partially deforming in thickness and that comes into contact with the wall when attached to the wall; Inspection system.

3. 10. The inspection system of claim 1, The inspection device includes a plurality of the inspection devices, The inspection device includes: They are spaced apart vertically. Inspection system.

4. 10. The inspection system of claim 1, The inspection device includes: A power supply unit; a control unit that is driven by the power supply unit, commands the transmitting unit to output the acoustic signal, and commands the receiving unit to output the signal information; Inspection system.

5. 5. The inspection system of claim 4, the transmitting unit and the receiving unit are configured as a single transmitting / receiving unit, The control unit Instructing the transmitting / receiving unit to switch between the function as the transmitting unit and the function as the receiving unit Inspection system.

6. 10. The inspection system of claim 1, The transmitter and receiver include piezoelectric elements. Inspection system.

7. 10. The inspection system of claim 1, The inspection device includes: A power supply unit; a wireless unit that is driven by the power supply unit and is capable of wireless communication with an external device that is remote from the inspection device; At least one of the inspection device and the external device, and an analysis unit that analyzes the remaining amount of the contained item based on the signal information. Inspection system.

8. 10. The inspection system of claim 1, a first inspection device group consisting of one or more of the inspection devices each having approximately the same vertical coordinate; and a second inspection device group consisting of one or more of the inspection devices each having approximately the same vertical coordinate and located vertically above the first inspection device group, The first signal information acquired by the first inspection device group is compared with the second signal information acquired by the second inspection device group to detect the remaining amount of the contents in the container. Inspection system.

9. 10. The inspection system of claim 1, a first inspection device group consisting of one or more of the inspection devices each having approximately the same vertical coordinate; a second inspection device group consisting of one or more of the inspection devices each located vertically above the first inspection device group and having approximately the same vertical coordinate; and a third inspection device group consisting of one or more of the inspection devices each located vertically above the second inspection device group and having approximately the same vertical coordinate, The remaining amount of the contents in the container is detected by comparing first signal information acquired by the first inspection device group, second signal information acquired by the second inspection device group, and third signal information acquired by the third inspection device group. Inspection system.

10. 10. The inspection system of claim 1, The signal information is a first received signal that is a reflected signal reflected by the outer peripheral surface of the wall, and a second received signal that is a reflected signal reflected by the inner peripheral surface of the wall, The first received signal is compared with the second received signal to detect the remaining amount of the content in the container. Inspection system.

11. 10. The inspection system of claim 1, The inspection device includes: Includes a sensor unit that detects the height above ground Inspection system.

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