Inspection System for Large Machinery and Inspection Method for Large Machinery

Abstract

To provide a large-sized machine inspecting system and a large-sized machine inspecting method which can relatively easily or relatively safely inspect a large-sized machine.SOLUTION: An inspecting system for a large-sized machine 11 which transmits, to control devices 26, 42, 71 and 91, an inspection result obtained by inspecting a large-sized machine using inspecting equipment 48 attached to an unmanned aircraft 40 includes the control devices 26, 42, 71 and 91 which cause the unmanned aircraft 40 to fly along a predefined flight route R, and which determine or correct a partial flight route or a flight timing, or determine or correct an inspecting method in accordance with the state of the large-sized machine 11 or a positional relation with the large-sized machine 11.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an inspection system for large machinery and an inspection method for large machinery, which transmit inspection results obtained by inspecting large machinery using inspection equipment mounted on an unmanned aerial vehicle to a control device.

Background Art

[0002] As an example, for large machinery with a height exceeding 2.5 m from the floor surface, conventionally, an operator has climbed to the upper part of the machinery using a ladder or the like installed on the large machinery to perform an inspection operation. However, the above inspection operation is a high-altitude operation and may be dangerous for the operator. In addition, there are cases where an operator cannot perform an inspection operation while the large machinery is in operation. Furthermore, depending on the type of large machinery, there are also cases where the operator cannot approach the inspection area due to the influence of high temperature, gas, etc. As a countermeasure for these, it is also conceivable to use a special gondola carrying an operator, but there are many cases where there is no space to introduce the gondola in the factory, and the cost of the gondola itself is also high. Furthermore, it is also assumed that inspection equipment is attached to a crane installed in the factory and an operator operates the crane to perform an inspection operation on the large machinery. However, not all factories where large machinery is housed have a crane optimal for inspection work, and even when a crane is available, it has been difficult to perform an optimal inspection from an optimal position in a short time.

[0003] On the other hand, as described in Patent Document 1, it is also known to inspect equipment in a factory using an unmanned aerial vehicle (UAV) commonly called a drone. Patent Document 1 describes monitoring the operating status of equipment installed in a factory building from the air by an operating status imaging means.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, Patent Document 1 has the following problems because it involves a person operating a flying object indoors for inspection. That is, since it requires skill for a person to operate the flying object, those who are not skilled in operating the flying object cannot perform the inspection. Also, since the flying object is operated by a person, the inspection position with respect to the equipment varies each time, and an accurate comparison with the previous inspection results cannot be made. Furthermore, since the flying object is operated by a person, there is a possibility of colliding with the equipment due to an incorrect operation and damaging the equipment, or damaging the flying object itself including the inspection equipment. Moreover, since the flying object is flown regardless of the operating status of the equipment, if there are parts where the situation changes such as moving parts or temperature in the equipment, it may cause inconvenience to the flight and inspection of the flying object.

[0006] Therefore, an object of the present invention is to provide an inspection system for large machinery and an inspection method for large machinery that can inspect large machinery relatively easily or relatively safely.

[0007] Other problems and novel features will become apparent from the description of this specification and the accompanying drawings.

Means for Solving the Problems

[0008] The inspection system for large machinery according to claim 1 of the present invention is an inspection system for large machinery that transmits the inspection results obtained by inspecting large machinery using inspection equipment attached to an unmanned aerial vehicle to a control device, and flies the unmanned aerial vehicle along a predetermined flight route, and is provided with a control device that determines or corrects part of the flight route or the timing of flight, or determines or corrects the inspection method according to the state of the large machinery or the positional relationship with the large machinery.

Effects of the Invention

[0009] The inspection system for large machinery of the present invention is an inspection system for large machinery that transmits the inspection results obtained by inspecting large machinery using inspection equipment attached to an unmanned aircraft to a control device. The control device is provided to fly the unmanned aircraft along a predetermined flight route and to determine or modify part of the flight route or the timing of flight, or to determine or modify the inspection method based on the state of the large machinery or the positional relationship with the large machinery. Therefore, the large machinery can be inspected relatively easily or relatively safely.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0011] <Configuration of Large Machinery> Referring to Fig. 1, a vertical rotary injection molding machine 11, which is a type of large machine, will be described. The vertical rotary injection molding machine 11 and its mold clamping device 12 are installed on the floor surface 10 inside the factory building, with a height of at least 2.5 m or more from the floor surface 10 of the building, and usually having a height of 5 m to 10 m. In the mold clamping device 12, each tie bar 14 is fixed vertically to the fixed platen 13, which is the lower platen, and the upper part of each tie bar 14 is fixed to the pressure platen 15, which is the upper platen. Also, a movable platen 16 is provided so as to be vertically movable guided by the tie bars 14. The vertical movement of the movable platen 16 is performed by the mold opening and closing cylinders 17 of two mold opening and closing mechanisms provided to connect between the pressure platen 15 and the movable platen 16. Note that the mold opening and closing mechanism may use a servo motor or a ball screw mechanism. Further, the pressure platen 15 is provided with a mold clamping mechanism such as a mold clamping cylinder 18, and the ram 19 of the mold clamping cylinder 18 is fixed to the back surface of the movable platen 16. Also, a tank, a pump, a valve, etc. (not shown) for supplying hydraulic oil to the mold clamping cylinder 18 are attached to the upper part and side part of the pressure platen 15. Note that the mold clamping mechanism may use an electric motor and a toggle mechanism.

[0012] The injection molding machine 11 of the present embodiment is for multi-color molded products, and a rotary table 20 is provided on the lower surface of the movable platen 16 so as to be rotatable with respect to the movable platen 16. The rotary table 20 is fixed to the side surface of the movable platen 16 and rotated via a belt by a servo motor for table rotation (not shown). And two movable molds 21, 21 are attached to the lower surface of the rotary table 20. Also, two fixed molds 22, 22 that are mold opened and closed with the movable molds 21, 21 are attached to the upper surface of the fixed platen 13. Also, on the side of the region where the movable molds 21, 21 move between the fixed platen 13 and the movable platen 16, on the operation side on the right side in Fig. 1, a safety door 23 is attached so as to be horizontally openable and closable. Also, a safety door 24 is provided on the anti-operation side on the left side in Fig. 1 so as to be horizontally openable and closable. Further, an ejector (not shown) is provided on the side of the mold clamping device 12.

[0013] In addition, a plurality of injection devices (not shown) are arranged on the side of the mold clamping device 12 of the injection molding machine 11. Further, the injection molding machine 11 includes a setting and display device 25 that also serves as a display device, and a control device 26 (which can be one of the control devices of the present invention). The control device 26 includes an operation control unit 27 and a storage unit 28 (storage device) that communicate with each sensor of the injection molding machine 11 to control the operation of the injection molding machine 11 and grasp its state, and a transmission and reception unit 29 that communicates with the control device 71 (which can be one of the control devices of the present invention) of the controller 70 described later. In addition, although the control device 26 has various other functions, descriptions of parts that have no or little relevance to the present invention are omitted.

[0014] In this embodiment, a landing platform 30 for the unmanned aircraft 40 is provided on the setting and display device 25 of the injection molding machine 11. When the landing platform 30 is provided on the setting and display device 25, the landing platform 30 is held horizontally fixably by a rotating shaft provided on the side surface of the setting and display device 25. When the landing platform 30 is not in use, the landing platform 30 is rotated together with the hinge-type rotating shaft and stored in a direction along the side surface of the setting and display device 25. Note that the landing platform 30 may be attached to another part such as the fixed platen 13 of the injection molding machine 11 or an injection device (not shown). Further, the landing platform 30 may be provided at a position separated within a certain distance from the injection molding machine 11.

[0015] Furthermore, each part of the mold clamping device 12 of the injection molding machine 11, which is a large machine, is provided with a marker 31 for checking whether the unmanned aircraft 40 is flying along the flight route R and correcting it when a deviation occurs from the flight route R. In this embodiment, the marker 31 is provided at the upper center of the cylinder of the mold clamping cylinder 18, the upper end of each tie bar 14, the upper part of the mold opening and closing cylinder 17 of the mold opening and closing mechanism, the side of the movable platen 16 where the rod of the mold opening and closing cylinder 17 is attached to the bracket 32, the side part of the fixed platen 13, and the central part of the upper surface of the landing platform 30. It is desirable that the shape of each marker 31 is different and can be identified by a camera 48, which also serves as a detection device for detecting the marker 31 mounted on the unmanned aircraft 40, and its inspection control unit 44.

[0016] In the case where the large machine is an injection molding machine 11, if it is at a height of 2.5 m or more that is out of reach of the operator, a horizontal injection molding machine in which the movable platen moves horizontally may be used. The type of large machine is not limited, and it may be a press device including a forging device. In the case of a press device, those equipped with a number of hot plates in the chamber are also included. Furthermore, the large machine may be a crusher that crushes ores, earth and stones, artificial objects, etc., a mixing device that mixes various materials, a storage device equipped with a crane and a conveyor. Furthermore, the large device may be a melting device including a melting furnace that melts ores and artificial objects. These large machines are mainly targeted at those with a height of 2.5 m or more from the floor surface 10 or the ground. Exceptionally, even if the height is less than 2.5 m, as long as the length of the short side in the horizontal direction of the device is 3.0 m or more, and the length from the standing position of the inspector on the side of the machine to the inspection area where the inspector cannot enter is 1.0 m or more, it may also be acceptable.

[0017] Next, with reference to FIGS. 2 and 3, the unmanned aerial vehicle 40, the detection device, and the inspection device of the inspection system for large machines will be described. As described above, the unmanned aerial vehicle 40 (UAV) is a flying object commonly called a drone, and motors 49 such as brushless motors are attached near the four corners of the main body 41. A plurality of rotors 50 (propellers) are attached to the rotation shafts of the motors 49. In FIG. 2, only two flight units 51 composed of the motor 49 and the rotor 50 are drawn, but the number of flight units 51 in the present embodiment is the most common four. The number of flight units 51 provided in the unmanned aerial vehicle 40 of the present invention is a plurality of three or more and, as an example, ten or less. A rechargeable battery 52 (battery) is mounted on the main body 41, and the battery 52 is connected to the motor 49 via a voltage controller 53 such as an ESC including a switch (not shown). Further, a flight control unit 43 for autonomously controlling the attitude of the unmanned aerial vehicle 40 is mounted on the main body 41. The flight control unit 43 includes an acceleration sensor 45 that controls the attitude according to changes in speed, an angular velocity sensor 46 (gyro sensor) that controls the attitude according to changes in inclination and direction, and an autonomous flight determination unit 47.

[0018] The unmanned aircraft 40 is also equipped with a detection device for detecting its proximity to the injection molding machine 11, which is a large machine. In this embodiment, the detection device consists of an ultrasonic sensor 54. During flight, the ultrasonic sensor 54 constantly transmits ultrasonic waves to the injection molding machine 11 being measured to measure the distance from the injection molding machine 11. Then, it controls the unmanned aircraft 40 so as not to approach the injection molding machine 11 beyond a predetermined distance. The detection device for safe flight, such as the ultrasonic sensor 54, is connected to the autonomous flight determination unit 47 of the flight control unit 43 of the control device 42 (which can be one of the control devices of the present invention) mounted on the main body 41. The flight control unit 43 is also connected to the voltage controller 53. Furthermore, the control device 42 includes a transmission / reception unit 55 including an antenna and is capable of communicating with a controller 70 that is held and operated by an inspector, which will be described later.

[0019] In addition, in order to grasp the operating status of the injection molding machine 11, which is a large machine, and the distance from the injection molding machine 11, as the detection device, a camera 48, which is an inspection device, may be used, or the camera 48 may be used in combination with other detection devices. In that case, the flight control unit 43 or the inspection control unit 44 determines the operating status and distance of the injection molding machine 11 from the image captured by the camera 48. Alternatively, the flight control unit 43 of the control device 71 of the controller 70, which will be described later, or the determination unit 93 of the host computer 90 (which can be one of the control devices of the present invention) may determine the above state. Also, as the detection device, other sensors such as an infrared sensor or a photoelectric sensor may be used, or a combination of multiple sensors may be used.

[0020] In addition, the unmanned aircraft 40 is provided with a chuck device 56 for detachably mounting various inspection devices on the lower surface side, and the unmanned aircraft 40 can be mounted by exchanging various inspection devices. In the present embodiment, the chuck device 56 holds a camera angle changing mechanism 57 for controlling the angle of the camera 48. The camera angle changing mechanism 57 includes a motor (not shown), a speed reduction mechanism, a rotary drive shaft for holding the camera 48 on its axis, a holding portion that directly contacts the camera 48, and the like. And the camera 48 can change the angle during camera shooting not only in the horizontal direction but also upward or downward. It is desirable that the camera angle changing mechanism 57 can rotate the camera 48 in the vertical direction to capture an image directly below the unmanned aircraft 40.

[0021] Note that the unmanned aircraft 40 may always carry at least one or at least two inspection devices including the camera 48, and the other inspection devices may be selectively and detachably mounted. As the inspection devices mounted on the unmanned aircraft 40, in addition to the camera 48 such as a CCD camera, various sensors such as a noise sensor 62, a temperature sensor 63, a vibration sensor, an ultrasonic flaw detection sensor, a sensor for component analysis of gas or liquid, and a load cell including a strain sensor are assumed. These sensors are connected to the inspection control unit 44. Then, the inspection is executed according to a command from the inspection control unit 44, and the detected data is signal-converted in the inspection control unit 44 and the inspection data can be transmitted from the transmission / reception unit 55 connected to the inspection control unit 44 to the controller 70. In FIG. 3, the inspection control unit 44 is described as one block, but it is common for the inspection control unit 44 to be provided corresponding to each sensor.

[0022] The unmanned aircraft 40 is provided with a guard portion 58 that prevents the flight portion 51, inspection devices such as the camera 48, and detection devices such as the ultrasonic sensor 54 from directly contacting the injection molding machine 11, which is a large machine. The guard portion 58 is composed of resin or rubber, and the frame portion 59 is connected by the connecting portion 60 to form a three-dimensional structure. Also, it is desirable in terms of shock absorption to attach a sponge for buffering (porous elastomer) or a resin airbag, etc. to at least a part of the outside of the frame portion 59 and the connecting portion 60. And a part of the frame portion 59 of the guard portion 58 is connected to the main body portion 41. And the flight portion 51, the main body portion 41, the control device 42, the inspection devices, etc. are protected and held inside the guard portion 58. Therefore, even if the unmanned aircraft 40 deviates from the pre-assumed flight route R, the guard portion 58 only contacts the large machine, and the large machine will not be damaged, nor will the unmanned aircraft 40 be damaged.

[0023] At least three legs 61 are provided downward from the lower surface of the main body portion 41 of the unmanned aircraft 40. The legs 61 are for placing the unmanned aircraft 40 on the landing pad 30 or landing it. When the unmanned aircraft 40 is placed or landed on the landing pad 30, the tip of the legs 61 contacts the landing pad 30 to place the unmanned aircraft 40. Due to the presence of the legs 61, the inspection devices, etc. do not directly contact the landing pad 30, the weight of the unmanned aircraft 40 does not act on the detection devices, and the unmanned aircraft 40 is stably placed. Note that the lower part of the guard portion 58 of the unmanned aircraft 40 may serve as a substitute for the legs 61.

[0024] The main body 41 of the unmanned aircraft 40 is equipped with a control device 42. The control device 42 of the unmanned aircraft 40 in the present invention grasps the operating status of large machinery or the distance or positional relationship with large machinery by detection devices mounted on the unmanned aircraft 40, and performs at least one of the means of grasping the operating status of large machinery through communication with at least one of the control device 71 of another control device, i.e., the controller 70, the control device 26 of large machinery, and the control device 91 of the host computer 90, to determine or correct a partial flight route or flight timing, or to determine or correct an inspection method using inspection equipment. In the above, the control device 71 of the controller 70 only performs simple relay and transfer. The basic flight route R and inspection position information may be obtained from the control device 26 of large machinery or the control device 91 of the host computer 90, or the functions of the present invention may be distributed among two or more control devices.

[0025] Next, with reference to FIG. 3, the system configuration of the inspection system for large machinery will be further described. The control device of the inspection system flies the unmanned aircraft 40 along a predetermined flight route R, and determines or corrects a partial flight route or flight timing, or determines or corrects an inspection method according to the state of the large machinery or the positional relationship with the large machinery. Here, the control device may be at least one of the control device 42 of the unmanned aircraft 40, the control device 26 of the injection molding machine 11, the control device 71 of the controller 70, and the control device 91 of the host computer 90. That is, as long as there is a control device anywhere, flight control of the unmanned aircraft 40 and inspection implementation can be performed through the communication function. According to the above, in the inspection system of the present invention, the unmanned aircraft 40 flies along a predetermined flight route R, communicates with the large machinery, or grasps the operating status of the large machinery by the detection mechanism of the unmanned aircraft 40 itself, and can perform the inspection of the large machinery by the inspection equipment while determining or correcting at least one of a partial flight route, flight timing, and inspection method.

[0026] The control device 42 of the unmanned aircraft 40 includes a flight control unit 43, an inspection control unit 44, and a transceiver unit 55. The transceiver unit 55 is connected to the transceiver unit 72 of the handy-type controller 70 held by the inspector. The controller 70 includes a control device 71. The control device 71 roughly includes a flight control unit 73 and an inspection control unit 74 of the unmanned aircraft 40, and also includes a storage unit 80 and an audio processing unit 81. The flight control unit 73 of the control device 71 includes an automatic flight control unit 75 and a manual flight control unit 76. The inspection control unit 74 includes an inspection command unit 77 and an inspection result determination unit 78. The flight control unit 73, the inspection control unit 74, and the audio processing unit 81 are connected to the transceiver unit 72 that communicates with the unmanned aircraft 40. The flight control unit 73 and the inspection control unit 74 are also connected to the transceiver unit 72 that performs transmission and reception with respect to the unmanned aircraft 40, the host computer 90, and the control device 26 of the injection molding machine 11 which is a large machine.

[0027] The storage unit 80 is also connected to the flight control unit 73 and the inspection control unit 74. Furthermore, the audio processing unit 81 is provided with a microphone and a speaker, and the inspector can communicate with the technician on the host computer 90 side. Furthermore, the controller 70 includes a setting display device 79 that also serves as a display device and a flight operation device 82. The setting display device 79 is connected to the flight control unit 73, the inspection control unit 74, etc. The flight operation device 82 is the part where the inspector operates when the unmanned aircraft 40 automatically flies along a predetermined flight route R, including the start operation and the end operation, and also when the unmanned aircraft 40 manually flies.

[0028] Note that at least one of the connections between the controller 70, the unmanned aircraft 40, the control device 26 of the injection molding machine 11, and the host computer 90 may be made not wirelessly but via a signal line (wired). When the large machine is a machine that generates strong electromagnetic waves or the like that have a great impact on wireless communication, it is also desirable to connect the controller 70 and other devices via a signal line. Further, the control device 26 of the injection molding machine 11 and the controller 70 may be integrated. That is, the setting display device 25 and the control device 26 provided in the injection molding machine 11 may be provided with the functions of the controller 70, or in addition to the main setting display device 25 of the injection molding machine 11, a handy-type controller capable of checking at least a part of the control and operating status of the injection molding machine 11 is provided. In this case, the handy-type controller may be provided with the control function of the unmanned aircraft 40. In any case, by the control device 26 including the operation control unit 27 of the injection molding machine 11 and the unmanned aircraft 40 communicating via the controller 70, the unmanned aircraft 40 side can grasp the operation status of the injection molding machine 11, which is a large machine, and while determining or correcting at least one of a partial flight route, flight timing, and inspection method, the large machine can be inspected by the inspection device.

[0029] Also, in the present embodiment, the controller 70 and the control device 26 of the injection molding machine 11 are connected to the transmission / reception unit 92 of the control device 91 of the host computer 90, which is a control device that oversees the entire system. The transmission / reception unit 92 of the host computer 90 is connected to a determination unit 93, a storage unit 94, a setting display device 96 that also serves as a display device, and an audio processing unit 95. The storage unit 94 may be a server connected to the host computer 90. Therefore, the image of the camera 48 attached to the unmanned aircraft 40 can also be viewed on the host computer 90 side. Further, the audio processing unit 95 of the host computer 90 includes a microphone and a speaker, and an inspector on the controller 70 side and an operator on the host computer 90 side can communicate with each other. Note that in the inspection system of the present invention, if the functions on the controller 70 side are enhanced, the host computer 90 can be eliminated or made into a mere storage device with only a server function.

[0030] The host computer 90 is also connected to the control device 26 of the injection molding machine 11. The location where the host computer 90 is provided may be within the same factory building, or it may be in another building of the same company. Furthermore, the host computer 90 may be placed at least at one of the injection molding machine manufacturer, the unmanned aircraft manufacturer, the unmanned aircraft operation management company, and the cloud management company. Also, all the control functions for flight control and inspection control may be provided on the host computer 90 side, and only the minimum functions may be provided for the controller 70. Conversely, all the functions may be provided for the controller 70, or the controller 70 and the control device 26 of the large machine, and the host computer 90 may not be provided. Also, at least one of the control device 42 of the unmanned aircraft 40, the controller 70 of the unmanned aircraft 40, the control device 26 of the injection molding machine 11, and the control device 91 of the host computer 90 may be equipped with an AI (artificial intelligence) capable of machine learning.

[0031] Next, a method for inspecting a large machine using the inspection system for a large machine will be described with reference to FIGS. 1 to 3. One of the features of the present invention is that inspection is possible even while the large machine is operating. Generally, when an inspector himself / herself performs an inspection, there are often problems with approaching an operating machine, and inspections cannot be performed at most locations. Moreover, especially inspections of the high parts of a large machine during operation cannot be performed. Therefore, it is necessary to perform inspection work on days or times when the large machine is not operating, and overtime work may occur. Also, as an example, there are some things that cannot be measured unless the large machine is operating, such as noise measurement, vibration measurement, and temperature measurement. The ability to perform inspections during operation has great advantages.

[0032] Furthermore, one of the features of the present invention is that the operator does not manually fly the unmanned aircraft 40 throughout the entire process for inspection. Instead, the unmanned aircraft 40 flies along a predetermined flight route R in at least the part including the first flight part, and inspects the large machinery with inspection equipment at preset inspection positions. As a result, even if the inspector is not familiar with the flight of the unmanned aircraft 40, it is possible to fly and inspect without colliding the unmanned aircraft 40 with large machinery such as the injection molding machine 11. Also, by saving the previous inspection position, the unmanned aircraft 40 can perform inspections at almost the same position as the previous time, enabling accurate inspections including comparison with past data.

[0033] However, the controller 70 is provided with a manual flight control unit 76, and it is also possible to concurrently execute the manual operation of the unmanned aircraft 40 by the inspector. As an example, when an abnormality such as an oil leak is visually confirmed in the injection molding machine 11 during inspection, the unmanned aircraft 40 may be brought closer to the part where the abnormality is visually confirmed by manual operation to further confirm the state. However, when the manual flight control is released, it is desirable for the unmanned aircraft 40 to automatically return to the predetermined flight route R.

[0034] When creating the flight route R of the unmanned aircraft 40, data such as the height of the ceiling of the building, the shape and arrangement position of equipment including cranes and peripheral equipment, and the shape of large machinery are taken into a determination unit 93 such as a host computer 90 in advance as three-dimensional coordinate data and used for creating the flight route R. Note that the large machinery is not limited to those inside the building, and even if it is inside the building, if there is a large space clearly around the large machinery, only the three-dimensional coordinate data of the large machinery may be used for creating the flight route R. Since the present invention mainly aims at inspecting large machinery in the factory, the control of the unmanned aircraft 40 using GPS is not usually assumed. However, it does not exclude those that use the position control of the unmanned aircraft 40 using GPS in combination.

[0035] A large machinery inspection system usually has an inspection flight route R corresponding to the manufacturing number etc. unique to each large machinery. However, for the same type of large machinery, the same flight route R can also be used or utilized with some modifications. The starting and ending points of the flight route are the large machinery itself or the takeoff and landing platform 30 of the unmanned aircraft 40 provided near the large machinery. Usually, the inspector brings the unmanned aircraft 40 and first places the unmanned aircraft 40 on the takeoff and landing platform 30. The flight route R based on the three-dimensional coordinate data (space coordinates) of this embodiment starts from the takeoff and landing platform 30 (the origin) and is determined by the positional relationship (distance) of the coordinates from the takeoff and landing platform 30. However, the origin position for flight control may be another part other than the takeoff and landing platform 30.

[0036] Next, the inspector operates the flight operation device 82 of the controller 70 to activate the motor 49 etc. of the unmanned aircraft 40, causing the unmanned aircraft 40 to take off from the takeoff and landing platform 30 and fly along the predetermined flight route R. When the unmanned aircraft 40 arrives at the inspection point P1 preset on the flight route R, it stops at the same position by hovering. When the inspection device is a CCD camera, for example, at the inspection point P1, the state of the upper surface of the movable disk 16, the damage and oil leakage situation of the ram 19, the damage and oil leakage situation of the mold opening and closing cylinder 17, etc. are confirmed by the camera 48 directed horizontally or slightly downward from the horizontal direction. At this time, the camera image taken by the CCD camera may be checked by the inspector for the presence or absence of abnormalities, or may be mechanically checked for abnormalities. The image may be a video or a still image. Mechanical checking may be performed by quantifying the contrast and color of the image of the CCD camera and determining whether it exceeds a threshold value, or by having the mechanical learning device perform mechanical learning (supervised learning) on the color etc. of the image of the CCD camera for normal states, abnormal states, etc. to determine abnormalities.

[0037] Also, the time (flight timing) to stop the unmanned aircraft 40 at the inspection point P1 and the timing when inspecting using the camera 48 may be performed at a predetermined timing. However, in this embodiment, it is determined or corrected according to the operating state of the mold clamping device 12 of the injection molding machine 11. Specifically, the flight control unit 43 and the inspection control unit 44 of the unmanned aircraft 40 are communicatively connected to the control device 26 of the injection molding machine 11 via the controller 70. Then, the situation of the mold closing operation from the mold open state to the mold closed state of the movable platen 16 of the mold clamping device 12, or the situation of the mold opening operation from the mold closed state to the mold open state, is sent from the control device 26 to the flight control unit 43 and the inspection control unit 44 of the unmanned aircraft 40. And only during the mold closing process or during the mold opening process, the unmanned aircraft 40 stops at the inspection point P1, and the camera 48 inspects the ram 19 of the mold clamping cylinder 18 and the situation of the mold opening and closing cylinder 17. Therefore, the inspection system for large machinery of the present invention has at least a part of the flight route R determined in advance, and includes those in which the inspection position and inspection method are determined after detecting the state of the large machinery. Or although the inspection method (inspection position, inspection time, control method of inspection equipment, etc.) is determined in advance, it may be one that corrects the inspection method according to the situation of the large machinery.

[0038] Then, the images captured by the camera 48 continue to be transmitted as a video to the controller 70 and the host computer 90. As a result, it is possible to check whether the mold closing process or the mold opening process is being properly performed using the setting display device 79 that also serves as the display device of the controller 70 and the setting display device 96 that also serves as the display device of the host computer 90. And as an example, even if the inspector operating the controller 70 is not familiar with the analysis of abnormal conditions of large machinery, such as a salesperson, by connecting to the host computer 90 of the injection molding machine manufacturer, it is also possible to conduct the inspection while seeking the guidance of a technician who is familiar with the analysis of abnormal conditions of large machinery. Also, since these inspection points P1 are set in three-dimensional coordinates with respect to the mold clamping device 12 of the injection molding machine 11 including the loading and unloading platform 30, it is always possible to perform the inspection at the same position with respect to the mold clamping device 12. In principle, the inspection at the inspection point P1 stops the unmanned aircraft 40 as described above. However, in the case where only one still image is taken at the inspection point P1, the inspection (imaging) may be performed while moving the unmanned aircraft 40 without stopping it at the inspection point P1.

[0039] However, when the unmanned aircraft 40 is flown according to predetermined three-dimensional coordinates, it is conceivable that the unmanned aircraft 40 may deviate from the flight route R due to disturbances. As types of disturbances, electromagnetic waves generated from motors of large machinery, the influence of airflows due to heat, etc. are considered. When the large machinery is installed outdoors, the influence of wind is considered as the most significant factor. Also, even if the flight route R is stored in advance in the storage unit of the control device 42 of the unmanned aircraft 40, it may deviate from the flight route R due to operating errors of the unmanned aircraft 40.

[0040] Regarding the problem that the unmanned aircraft 40 deviates from the predetermined flight route R, the present invention has taken two countermeasures. First, the position and type of the marker 31 attached to the mold clamping device 12, which is a large machine, are detected by a camera 48 such as a CCD camera mounted on the unmanned aircraft 40, and the flight route R is corrected. As an example, even though the flight route R is set so that the unmanned aircraft 40 passes directly above or directly beside a certain marker 31, if the unmanned aircraft 40 does not pass, correction is made according to the error. At this time, the current position of the unmanned aircraft 40 may be calculated based on the position of the marker 31 (the angular relationship between the unmanned aircraft 40 and the marker 31) in the entire image taken by the camera 48 and the size of the marker 31 (the distance between the unmanned aircraft 40 and the marker 31), or the current position of the unmanned aircraft 40 may be calculated from the positional relationship and type of a plurality of markers 31. Also, a plurality of cameras 48 may be mounted on the unmanned aircraft 40 to detect the distance and angle from the marker.

[0041] Second, the unmanned aircraft 40 can measure the distance to large machinery using detection equipment. Specifically, ultrasonic sensors 54 emit ultrasonic waves, and the distance between the large machinery and the unmanned aircraft 40 and the height from the floor surface 10 are measured based on the reflection from the large machinery or the floor surface 10. This distance measurement can be used to correct the flight route R, but it is mainly used for collision avoidance when the unmanned aircraft 40 unexpectedly approaches the large machinery too closely in the traveling direction of the unmanned aircraft 40. Therefore, it is assumed that the ultrasonic sensors 54 are attached so that the direction of emitting ultrasonic waves can be changed, or a plurality of ultrasonic sensors 54 are attached facing the traveling direction and the vertical direction. That is, when the distance between the large machinery and the unmanned aircraft 40 becomes equal to or less than a certain threshold value, the unmanned aircraft 40 is programmed to stop continuous movement in the same traveling direction. Also, as a similar protection function for the unmanned aircraft 40, at least one of a temperature sensor, a gas concentration sensor, an accelerometer for measuring air flow, an electromagnetic wave measurement sensor, and a camera for grasping the state change of the large machinery is mounted on the detection equipment, and if conditions more severe than predetermined conditions are detected, control is performed so as not to approach the large machinery any further. By mounting at least one of these detection devices, the unmanned aircraft 40 can fly more safely autonomously.

[0042] As shown in FIG. 1, the unmanned aircraft 40 inspects in the order of inspection points P2, P3, P4, P5, and P6 set on a predetermined flight route R, and finally lands on the landing pad 30 to end the inspection. As described above, since the flight route R of the unmanned aircraft 40 uses three-dimensional coordinates, generally, the movement of the unmanned aircraft 40 is controlled by a combination of vertical movement (ascending and descending) and horizontal movement. However, when inspecting a particularly special part of the large machinery, those using diagonal movement are not excluded. Also, since the unmanned aircraft 40 flies by a plurality of flight units 51, vertical movement can be performed with higher accuracy than horizontal movement. Therefore, when the distances from the inspection point P2 to the horizontal plane (plane) and the vertical plane (side surface) of the large machinery are not very different, as in the case of moving to the inspection point P2 in FIG. 1, it is more desirable to reach the inspection point P2 by vertical movement.

[0043] At inspection point P3, inspect for oil leakage from the connection part of the pipe that sends hydraulic oil to the mold clamping cylinder 18, the state of the valve, the fastening state of the tie bar 14, etc. At inspection point P4, inspect the state of the ram 19 of the mold clamping cylinder 18 and the state of the mold opening / closing cylinder 17 as viewed from the side opposite to inspection point P1. Also, at inspection points P5 and P6, inspect the state of the cavity surface of the mold. When performing inspections on both the upper movable molds 21, 21 and the lower fixed molds 22, 22 by the camera 48 at inspection points P5 and P6, the camera 48 attached to the tip of the horizontal holder 102 via the camera angle changing mechanism 57 is rotated 180° by the method described later. Also, when inspecting the lower surface side of other large machines, it is performed in the same manner as the inspection of the upper movable molds 21, 21.

[0044] Also, when the unmanned aircraft 40 enters inspection points P5 and P6, the control device 42 of the unmanned aircraft 40 and the control device 26 of the injection molding machine 11 communicate with each other, and it is necessary to confirm that the safety doors 23, 24 are in an open state and that the movable platen 16 is raised and the movable molds 21, 21 are in an open state with respect to the fixed mold 22. Therefore, when performing inspections with the unmanned aircraft 40, even if the flight route R is predetermined, the unmanned aircraft 40 is temporarily hovered and the flight timing is corrected until the state of the large machine (such as the opening / closing movement of the safety doors 23, 24 and the opening / closing movement of the movable molds 21, 21) becomes a state where inspections are possible. Or, even if the unmanned aircraft 40 has reached the inspection point, inspections such as camera shooting are performed after waiting for the operating state of the large machine to become optimal for inspection (correcting the inspection timing).

[0045] Also, in order to prevent damage to the cavity surfaces of the movable molds 21, 21 and the fixed molds 22, 22, etc., they are parts where contact with the metal parts of the unmanned aircraft 40 must be absolutely avoided. In the unmanned aircraft 40 of the present embodiment, the rotors 50 of the metal flight part 51 and the periphery of the inspection equipment are covered by a guard part 58 to which resin, rubber, or in part, sponge or airbag as a buffer material is attached. Therefore, even if the unmanned aircraft 40 deviates from the predetermined flight route R and comes into contact with the movable molds 21, 21 or the fixed molds 22, 22, etc., it will not have a great impact. Also, when the unmanned aircraft 40 cannot take off again due to contact with large machinery or other reasons and falls outside the landing position of the regular landing pad 30, it is desirable to issue an alarm such as a warning sound and temporarily stop the operation of large machinery such as the injection molding machine 11 in order to recover the fallen unmanned aircraft 40.

[0046] Then, after the unmanned aircraft 40 performs inspections such as temporarily stopping at the inspection points P1, P2, P3, P4, P5, P6 along the predetermined flight route R, it lands on the landing pad 30 and ends the inspection. As described, the inspection data of inspection equipment such as cameras is sent to the controller 70 and the host computer 90 in real time during the flight of the unmanned aircraft 40. However, only some of the inspection data may be sent in real time, or all of the inspection data may be collected after the unmanned aircraft 40 lands. In any case, the inspection data is stored in a storage device such as a server, which is the storage unit 94 of the host computer 90, and is used for comparison with the inspection data when the same inspection is performed next time and for grasping changes in the state.

[0047] Also, since inspection equipment other than the camera can be mounted on the chuck device 56 of the unmanned aircraft 40, it is possible to first perform an inspection with the camera 48 and then replace it with inspection equipment other than the camera 48 (for example, any one of a noise sensor 62, a temperature sensor 63, a vibration sensor, and an ultrasonic sensor) to perform an inspection. It is also possible to mount a plurality of inspection equipment on the unmanned aircraft 40 and perform a plurality of inspections during one flight. In that case, generally, a combination of the camera 48 and other inspection equipment is often used.

[0048] Next, a case (application form) in which a noise sensor 62, which is an inspection device other than the camera 48, is attached to the unmanned aircraft 40 for inspection will be described with reference to FIG. 4. In large machines such as injection molding machines 11, the magnitude of the noise during device operation is measured to inspect the state of the belt such as deflection and deterioration, the state of the pump, the state of the valves of the hydraulic equipment, etc., and to consider the timing of failure prediction and component replacement. The magnitude of the noise of a large machine is compared with the previous measured value of the same large machine or with the state of another large machine of the same type. Therefore, even if the noise caused by the rotation of the rotor 50 during the flight of the unmanned aircraft 40 is picked up by the microphone of the noise sensor 62, it is not impossible to measure the noise. However, in many cases, more precise measurement can be achieved by providing the noise meter at a position as far as possible from the rotor 50 of the unmanned aircraft 40.

[0049] Therefore, in the present embodiment, the noise sensor is attached to the tip or near the tip of the downward holding tool 101 provided downward from the main body of the unmanned aircraft 40 for noise measurement. Alternatively, the noise sensor is attached to the tip or near the tip of the horizontal holding tool 102 provided at the tip or near the tip of the downward holding tool 101 for noise measurement. Furthermore, the noise sensor 62 may be attached to the tip of the horizontal holding tool directly provided on the main body 41.

[0050] More specifically, a through hole 103 is provided at the center of the main body 41, and a downward holding tool 101 for suspending and holding inspection devices such as the noise sensor 62 is provided so as to be slidable up and down with respect to the through hole 103. In the present embodiment, the downward holding tool 101 is made of a metal or resin pipe with a length of 0.5 m to 3.0 m, and a stopper 104 is provided at the upper part of the pipe so that the downward holding tool 101 does not fall off from the main body 41. Note that, for the downward holding tool 101, in addition to using the pipe, a wire may be used. When using a wire, it is desirable to use a wire with a length of 1 m to 5 m. When the inspected part of the large machine is under severe conditions such as a high temperature state, it is necessary to increase the length of the downward holding tool 101, and it is desirable to set the length of the pipe or wire to 2 m or more.

[0051] Also, in the present embodiment, a horizontal direction holder 102 fixed in a direction perpendicular to the vertical direction holder 101 is provided at the tip of the vertical direction holder 101. And a noise sensor 62 is detachably attached to one end of the horizontal direction holder 102. Further, a weight portion 105 is attached to the tip or near the tip on the other side of the horizontal direction holder 102 across the vertical center of gravity line of the unmanned aircraft 40. Note that inspection equipment such as a camera may also be detachably provided on the other side of the horizontal direction holder 102. Or the horizontal direction holder 102 is not limited to one, and two horizontal direction holders 102 may be provided in the cross direction centering on the vertical direction holder 101 in a plan view, and inspection equipment such as a camera 48 or a weight portion 105 may be provided at the tip or near the tip of these horizontal direction holders 102. In the above, since the unmanned aircraft 40 uses a plurality of flight units 51 to fly with the main body 41 in a horizontal state almost all the time, the member names of the vertical direction holder 101 and the horizontal direction holder 102 are used. However, the main body 41 of the unmanned aircraft 40 during flight may not be able to maintain a horizontal state. Therefore, the vertical direction holder 101 only needs to be generally in a hanging state, and the horizontal direction holder 102 only needs to be generally in a horizontal state.

[0052] In addition, it is also desirable that inspection equipment such as the noise sensor 62 directly attached to the tip of the vertical direction holder 101, or inspection equipment attached to the tip of the vertical direction holder 101 via the horizontal direction holder 102, be surrounded by the guard part 106 in the same way as the main body part 41 and the like. Further, a shielding member 107 is attached as needed to the upper part of the guard part 106 or the middle position of the vertical direction holder 101 between the unmanned aircraft 40 and the inspection equipment. The shielding member 107 is composed of a frame part with a shielding sheet attached thereto or a flat shielding plate. The shielding member 107 is for making it difficult for the influence of the flight part 51 of the unmanned aircraft 40 to affect the inspection equipment, and for making it difficult for the influence of the part to be inspected of the large machine to affect the control device 42 and the like of the unmanned aircraft 40. When the inspection equipment is the noise sensor 62, a sound insulation board with excellent sound insulation effect is attached to the shielding member 107. Then, the unmanned aircraft 40 is flight-controlled to approach the vicinity of the mechanism part where the noise sensor 62 is desired to measure the noise of the large machine, and the noise measurement is performed. The measured data is sent to the controller 70 and the host computer 90 in the same way as the data of the camera image.

[0053] Next, a case where a temperature sensor 63 is attached to the unmanned aircraft 40 to measure the temperature of a large machine will be described. In this case as well, since the motor 49 of the unmanned aircraft 40 has a heat generation effect during rotational drive, it is desirable to separate the motor 49 and the like from the temperature sensor 63, and the temperature sensor is attached to the tip or the vicinity of the tip of the above-described vertical direction holder 101 or horizontal direction holder 102 to measure the temperature of the part where the temperature of the large machine is desired to be measured. When performing temperature measurement with the temperature sensor 63, if a shielding member 107 is provided at the upper position or the middle position of the vertical direction holder 101, it is desirable to use one with a high heat shielding effect. Regarding the type of the temperature sensor 63, a non-contact type is desirable. In that case, temperature measurement can be performed without bringing the temperature sensor 63 into contact with the measurement part. However, temperature measurement may also be performed by controlling the unmanned aircraft 40 so that the contact type temperature sensor 63 comes into contact with the measurement part. In the case of an injection molding machine, the temperature of the part where the temperature sensor 63 is not fixedly attached to the equipment such as hydraulic piping, valves, servo motors, and speed reducers can be measured.

[0054] In the case of a die-casting machine (metal injection molding machine) that melts metal by a large machine or a melting device such as a blast furnace, if the unmanned aircraft 40 approaches too close to a molten metal storage tank, a heating cylinder, etc., it may adversely affect the control device 42 of the unmanned aircraft 40 due to the influence of the released heat. In such a case as well, by attaching the temperature sensor 63 to the tip or the vicinity of the tip of the vertical direction holder 101 or the horizontal direction holder 102 as described above, the life of the unmanned aircraft 40 can be extended. Also, in the case of a melting device such as a melting furnace, the temperature of the peripheral part varies depending on the opening and closing state of the furnace, and the range where the unmanned aircraft 40 can approach may also vary. Therefore, the "predetermined flight route R" in the present invention only needs to have at least a part of the entire flight route predetermined, and from the middle, the unmanned aircraft 40 can be autonomously controlled according to the situation of the large machine, or manually controlled by the inspector, and those that correct a part of the flight route or the timing of flight (including time elements such as stop and speed) are also included. Or, a part of the remaining flight route or the timing of flight other than the predetermined flight route R may not be set from the beginning and may be determined according to the situation of the large machine.

[0055] Also, when the inspection point is in a severe situation other than temperature, it is desirable to separate the main body 41 and the control device 42 of the unmanned aircraft 40 from the inspection equipment, and pipes, wires of the above-mentioned vertical direction holder 101, pipes of the horizontal direction holder 102, etc. are used. With the above configuration, even when the part to be inspected is in a dangerous state while the large machine is operating, or when the periphery of the part to be inspected of the large machine is in a severe situation and the inspection by the operator is impossible, it becomes possible to perform the inspection using the unmanned aircraft 40.

[0056] In the case of a multi-stage hot press machine in which a large machine is equipped with a vacuum chamber, the unmanned aircraft 40 grasps through communication from the multi-stage hot press machine that the door of the vacuum chamber is open and that there is a space between the multi-stage hot plates due to mold opening, and then starts the inspection. Alternatively, the image captured by the camera 48 of the detection device of the unmanned aircraft 40 is analyzed using artificial intelligence or the like, and it is determined that the door is open and that there is a space between the hot plates, and the flight timing of the unmanned aircraft 40 is determined and it is moved. When it reaches the inspection point, the inspection is started. During the inspection, the state of the hot plate in the opened vacuum chamber is inspected using the camera 48 or the temperature sensor 63 attached to the tip or near the tip of the horizontal holder 102.

[0057] Regarding the present invention, although not listed one by one, it is not limited to the above-described embodiments, and it goes without saying that it is also applicable to those modified by those skilled in the art based on the gist of the present invention and those obtained by individually combining some parts of the above embodiments. The number of large machines inspected by the unmanned aircraft 40 at one time is not limited to one, and it may be possible to inspect a plurality of large machines in one inspection. Alternatively, for the purpose of inspecting the synchronization of each operating part of one large machine, the inspection may be performed using two or more unmanned aircraft 40 at the same time.

[0058] Furthermore, when an abnormality is found at a high place of a large machine through the above inspection and an operator performs part replacement or the like, the inspection device of the chuck device 56 of the unmanned aircraft 40 is removed, and replacement parts, work tools, etc. are loaded, and the unmanned aircraft 40 may be transported to the working position at a high place of the large machine. In that case, it is desirable to use three-dimensional coordinates for the flight route of the unmanned aircraft 40, but the operation of some or all of the unmanned aircraft 40 may be manually performed by the operator.

Explanation of Signs

[0059] 11 Injection molding machine 12 Mold clamping device 26, 42, 71, 91 Control device 40 Unmanned aircraft 48 Camera (inspection device) 51 Flight section 54 Ultrasonic sensor (detection device) P1, P2, P3, P4, P5, P6 Inspection points R Flight route

Claims

1. A large machine inspection system that transmits inspection results obtained by inspecting a large machine using inspection equipment consisting of at least one of a camera, temperature sensor, noise sensor, vibration sensor, ultrasonic sensor, sensor for analyzing components of gas or liquid, strain sensor, infrared sensor, and photoelectric sensor attached to an unmanned aircraft to a control device, wherein the unmanned aircraft is flown along a predetermined flight route, communicates with the large machine in an operating state during flight to grasp the state of the large machine, and a control device is provided that communicates to the flight control unit or inspection equipment of the unmanned aircraft the determination or modification of the flight route or flight timing during inspection, or the determination or modification of the inspection method.

2. The large machine inspection system according to claim 1, wherein during flight, the operating status of the large machine is grasped by a detection device consisting of at least one of a camera, ultrasonic sensor, infrared sensor, photoelectric sensor, temperature sensor, gas concentration sensor, accelerometer for measuring air flow, and electromagnetic wave measurement sensor mounted on the unmanned aircraft, or the distance between the large machine and the unmanned aircraft or the positional relationship between the large machine and the unmanned aircraft is grasped, and a control device is provided that communicates to the flight control unit or inspection equipment of the unmanned aircraft the determination or modification of the flight route or flight timing during inspection, or the determination or modification of the inspection method using the inspection equipment.

3. The inspection equipment is attached to the tip or near the tip of a vertically downward holding tool provided in the downward direction from the main body of the unmanned aircraft, or to the tip or near the tip of one of the horizontally provided holding tools provided horizontally on both sides across the vertical center of gravity line of the unmanned aircraft, and an inspection device or a weight part is also attached to the tip or near the tip of the horizontally provided holding tool on the other side across the vertical center of gravity line. The large machine inspection system according to claim 1 or claim 2.

4. A method for inspecting a large machine, which transmits inspection results obtained by inspecting the large machine using inspection equipment consisting of at least one of a camera, temperature sensor, noise sensor, vibration sensor, ultrasonic sensor, sensor for analyzing components of gas or liquid, strain sensor, infrared sensor, and photoelectric sensor attached to an unmanned aircraft to a control device, wherein the unmanned aircraft flies along a predetermined flight route, By communicating with a large machine in an operating state during flight, the operating status of the large machine is grasped, and while determining or modifying at least one of the flight route, flight timing, and inspection method during inspection, An inspection method for a large machine that inspects the large machine in the operating state with the inspection device.

5. An inspection method for a large machine that transmits inspection results obtained by inspection using an inspection device comprising at least one of a camera, temperature sensor, noise sensor, vibration sensor, ultrasonic sensor, sensor for analyzing components of gas or liquid, strain sensor, infrared sensor, and photoelectric sensor attached to an unmanned aircraft to a control device, The large machine is an injection molding machine with a height of 2.5 m or more that performs a mold closing process and a mold opening process in which a movable platen is moved by a mold opening and closing mechanism, The unmanned aircraft flies along a predetermined flight route, By communicating with the injection molding machine in an operating state during flight, the state of the mold closing process or the state of the mold opening process of the injection molding machine is grasped, and while determining or modifying at least one of the flight route, flight timing, and inspection method during inspection, An inspection method for a large machine that inspects the mold closing process or the mold opening process of the injection molding machine with the inspection device.

6. An inspection method for a large machine that transmits inspection results obtained by inspection using an inspection device comprising at least one of a camera, temperature sensor, noise sensor, vibration sensor, ultrasonic sensor, sensor for analyzing components of gas or liquid, strain sensor, infrared sensor, and photoelectric sensor attached to an unmanned aircraft to a control device, The large machine is a press device with a height of 2.5 m or more having a number of hot plates in a vacuum chamber, The unmanned aircraft flies along a predetermined flight route, By communicating with the press device in an operating state during flight, the state where the door of the vacuum chamber of the press device is opened or the state where there is a space between the hot plates is grasped, and while determining or modifying at least one of the flight route, flight timing, and inspection method during inspection, An inspection method for a large machine that inspects the state of the hot plates of the press device with the inspection device.

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