Materials management system, materials management method, and materials management program

Abstract

To provide a material management system, a material management method, and a material management program that allow appropriate management of material stored in a container.SOLUTION: A management server 20 comprises: a control unit 21 that is connected with cameras 20a, 20b that can photograph an upper part of a silo 10 storing cement M1; and a stock information storage unit 23 that records the amount of material in stock. The control unit 21 acquires, from the cameras 20a, 20b, photographed images of an upper clearance of the cement M1 flattened and stored in the silo 10, calculates the space volume of the upper clearance by using the photographed images, subtracts the space volume from the entire volume of the silo 10 to calculate the amount of the cement M1 in stock, and records it in the stock information storage unit 23.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a materials management system, a materials management method, and a materials management program for managing materials such as cement stored in a container. [Background technology]

[0002] In shield construction and other projects, cement-based and bentonite-based powder materials stored in horizontal silos are used when manufacturing backfill cement as a mud additive or backfill injection material. Normally, inventory is managed by subtracting the amount received according to the delivery slip from the amount used, measured by load cell weighing for each patch. However, accurate inventory management is difficult when a measurement error occurs. Therefore, it is necessary to check the inventory amount through an inspection hatch installed in the ceiling of the horizontal silo, which is time-consuming.

[0003] Therefore, techniques for managing powder and granular materials using images are also being considered (see, for example, Patent Documents 1 and 2). The technique described in Patent Document 1 measures the powder surface of the powder and granular material using the autofocus function of a camera. In addition, the technique described in Patent Document 2 estimates the amount of powder from a captured image using a powder amount estimation model generated by machine learning using the captured image and the amount of powder in the container at the time of capture as training data. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 59-042416 [Patent Document 2] Japanese Patent Publication No. 2020-193923 Summary of the Invention [Problem to be solved by the invention]

[0005] However, cementitious powder materials can be affected by moisture in the air and exhibit partial hardening behavior, which can cause the edges to become self-supporting or localized holes to appear in the material.

[0006] As shown in Figure 8, in a silo 10 equipped with ribs 11, cement M1 is charged through an inlet 12, transported by a screw 13, and discharged through a discharge port 14. In such a silo 10, a large depression D1 may occur in the central region.

[0007] Furthermore, as shown in FIG. 9, a valley-like depression D2 may be generated. 10 is an image P01 captured inside the silo 10. In this image P01, a large depression has occurred in the center, and the state of the depression (shape, size, etc.) cannot be grasped.

[0008] In the image P02 shown in FIG. 11, it can be seen that multiple peaks and valleys have occurred within the silo 10. As shown in Figures 10 and 11, if there are areas within the silo that are out of the camera's sight, it is difficult to accurately estimate the inventory of powdered and granular materials within the silo. [Means for solving the problem]

[0009] A materials management system that solves the above problem includes a control unit connected to a camera that can capture images of the upper part of a container that stores materials, and an inventory information storage unit that records the inventory amount of the materials. The control unit acquires an image of the space above the materials stored flat in the container from the camera, calculates the volume of the space above the material using the image, and calculates the inventory amount of the material by subtracting the volume of the space from the total volume of the container and recording the calculated inventory amount in the inventory information storage unit. [Effects of the Invention]

[0010] According to the present invention, materials stored in a container can be managed accurately. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is an explanatory diagram of a material management system according to an embodiment. [Figure 2] FIG. 2 is an explanatory diagram of a hardware configuration according to an embodiment. [Figure 3] FIG. 4 is an explanatory diagram of a processing procedure according to an embodiment. [Figure 4] FIG. 4 is an explanatory diagram of an upper space in a silo according to an embodiment. [Figure 5] FIG. 10 is an explanatory diagram of an image captured on the upstream side during filling in the embodiment. [Figure 6] FIG. 10 is an explanatory diagram of a captured image of the downstream side during filling in the embodiment. [Figure 7] FIG. 4 is an explanatory diagram of a processing procedure according to an embodiment. [Figure 8] FIG. 1 is an explanatory diagram of a cement storage state according to the prior art. [Figure 9] FIG. 1 is an explanatory diagram of a cement storage state according to the prior art. [Figure 10] FIG. 10 is an explanatory diagram of a photographed image of the storage state of cement according to the prior art. [Figure 11] FIG. 10 is an explanatory diagram of a photographed image of the storage state of cement according to the prior art. DETAILED DESCRIPTION OF THE INVENTION

[0012] An embodiment of a material management system, a material management method, and a material management program will be described below with reference to Figures 1 to 7. In this embodiment, cement (powdered material) stored in a container and used at a construction site is managed. Here, the inventory of cement is managed using an image measurement process (first measurement process) and a weight measurement process (second measurement process).

[0013] As shown in Figure 1, a management server 20 serving as a material management system is used to manage cement M1 stored in a silo 10 (container). The silo 10 is equipped with a plurality of vertical ribs 11a, 11b (structural members) that reinforce the structure. The silo 10 also has an inlet 12, a screw 13, and a discharge port 14. The cement M1 introduced into the silo 10 through the inlet 12 is transported by the screw 13 and discharged to the outside of the silo 10 through the discharge port 14.

[0014] (Example of hardware configuration) FIG. 2 shows an example of the hardware configuration of an information processing device H10 that functions as the management server 20.

[0015] The information processing device H10 includes a communication device H11, an input device H12, a display device H13, a storage device H14, and a processor H15. Note that this hardware configuration is an example, and the information processing device H10 may include other hardware.

[0016] The communication device H11 is an interface that establishes a communication path with another device and executes data transmission and reception, and is, for example, a network interface or a wireless interface.

[0017] The input device H12 is a device that receives input from an administrator, etc., and is, for example, a mouse, a keyboard, etc. The display device H13 is a display, a touch panel, etc. that displays various information.

[0018] The storage device H14 is a storage device that stores data and various programs for executing various functions of the management server 20. Examples of the storage device H14 include a ROM, a RAM, and a hard disk.

[0019] The processor H15 controls each process in the management server 20 (for example, the process in the control unit 21, which will be described later) using programs and data stored in the storage device H14. Examples of the processor H15 include a CPU and an MPU. The processor H15 loads a program stored in a ROM or the like into a RAM and executes various processes corresponding to the various processes. For example, when an application program of the management server 20 is started, the processor H15 runs a process that executes each process.

[0020] The processor H15 is not limited to a processor that performs all of its processing using software. For example, the processor H15 may include a dedicated hardware circuit (e.g., an application-specific integrated circuit (ASIC)) that performs hardware processing for at least part of the processing it performs. The processor H15 may be configured with the following:

[0021] (1) One or more processors operating according to a computer program (software) (2) One or more dedicated hardware circuits that perform at least some of the processes; or (3) Circuits, including combinations thereof The processor includes a CPU and memory, such as RAM and ROM, that stores program code or instructions configured to cause the CPU to perform processes. Memory, or computer-readable media, includes any available media that can be accessed by a general-purpose or special-purpose computer.

[0022] (Functions of material management system) The silo 10 is equipped with cameras 20a and 20b. The camera 20a is an imaging means capable of capturing images of the interior space of the silo 10 from the upstream side where the inlet 12 is located. The camera 20a is positioned so that the upstream vertical rib 11a appears in the captured image. The camera 20b is an imaging means capable of capturing images of the interior space of the silo 10 from the downstream side where the discharge outlet 14 is located. The camera 20b is positioned so that the downstream vertical rib 11b appears in the captured image. The cameras 20a and 20b are positioned so that they capture images of at least the upper space within the silo 10.

[0023] The silo 10 also includes a load cell 20c (measuring unit) that measures the weight of the cement discharged from the discharge port 14. Furthermore, the cameras 20a and 20b and the load cell 20c are connected to a management server 20 via a network.

[0024] The management server 20 includes a control unit 21, a schedule information storage unit 22, and an inventory information storage unit . The control unit 21 functions as a filling management unit 210, an image processing unit 211, and an inventory management unit 212 by executing the material management program.

[0025] The filling management unit 210 executes a process for managing the inventory amount when the cement M1 is filled in. The filling management unit 210 holds information on the total volume V0 in the silo 10 and the specific gravity γ of the cement. The image processing unit 211 executes a process for calculating the inventory amount using an image of the internal space of the silo 10. The inventory management unit 212 executes a process for managing inventory using the weight of the discharged cement M1. The inventory management unit 212 also stores a reference value for replenishing cement. Based on information about the weight (current inventory) of the cement M1 in the silo 10 and information about the planned amount of use obtained from the process chart, the inventory management unit 212 calculates the date and time when the future inventory amount will fall below the reference value, determines the next delivery date and time, and creates an order form.

[0026] The schedule information storage unit 22 stores a schedule management record related to the weight of cement M1 planned to be used at the construction site. This schedule management record is recorded when a usage plan for cement M1 is registered. This schedule management record stores data related to the planned amount in association with the planned date.

[0027] The planned date data area records data relating to the planned date of use of the cement M1. In the planned amount data area, data on the weight of cement M1 to be used on this planned date is recorded.

[0028] The inventory information storage unit 23 stores an inventory management record that measures the weight (inventory amount) of cement M1 in the silo 10. This inventory management record is recorded when information on the inventory amount is acquired. Data on the measurement date and time and the inventory amount are recorded in this measurement management record.

[0029] The measurement date and time data area records data relating to the date and time when the inventory amount was calculated. In the inventory data area, data on the weight of cement stocked in the silo 10 is recorded.

[0030] (Processing during image measurement) Next, the image measurement process (first measurement process) will be described with reference to Fig. 3. This process is performed when the silo 10 is filled with cement M1.

[0031] First, the control unit 21 of the management server 20 executes a filling completion detection process (step S101). Specifically, the filling management unit 210 of the control unit 21 detects the completion of filling of the cement M1 into the silo 10. For example, the completion of filling is detected by detecting the flow of the cement M1 at the inlet 12 and detecting the cessation of this flow. By filling the cement M1, the surface of the cement M1 in the silo 10 is flattened.

[0032] Next, the control unit 21 of the management server 20 executes a standby process (step S102). Specifically, the filling management unit 210 of the control unit 21 waits for a predetermined time after detecting the completion of filling. This predetermined time is the time required for the cement that was blown up inside the silo 10 during filling to settle. This standby state allows the cameras 20a and 20b to visually observe the inside of the silo 10.

[0033] Next, the control unit 21 of the management server 20 executes an image acquisition process (step S103). Specifically, the image processing unit 211 of the control unit 21 acquires images of the inside of the silo 10 from the cameras 20a and 20b, respectively.

[0034] Next, the control unit 21 of the management server 20 executes a process of calculating the spatial volume (step S104). Here, the spatial volume of the upper space SP1 shown in FIG. 4 is calculated. Specifically, first, the image processing unit 211 of the control unit 21 calculates the height of the upper space in the silo 10 filled with the cement M1, using the captured images acquired from the cameras 20a and 20b.

[0035] 5 is a first captured image of the upstream side of the silo 10 captured by the camera 20a. The image processing unit 211 calculates heights Ha1 and Ha2 of the vertical ribs 11a exposed from the cement M1 on both sides of the silo 10 in the image P10. For example, the vertical ribs 11a are identified by edge detection processing, and their heights are calculated.

[0036] 6 is a second captured image of the downstream side of the silo 10 captured by the camera 20b. The image processing unit 211 calculates heights Hb1 and Hb2 of the vertical ribs 11b exposed from the cement M1 on both sides of the silo 10 in the image P20. For example, the vertical ribs 11b are identified by edge detection processing, and their heights are calculated.

[0037] Then, the image processing unit 211 estimates the height Ha0 of the space up to the surface position on the upstream side and the height Hb0 of the space up to the surface position on the downstream side using the following equations. Ha0=(Ha1+Ha2) / 2 Hb0=(Hb1+Hb2) / 2 In this case, as shown in FIG. 4, the volume V1 of the upper space SP1 in the upper part of the silo 10 that is not filled with the cement M1 is roughly calculated by the following formula, assuming it to be a truncated square pyramid. V1=B1×L1×(Ha0+Hb0) / 2 Here, B1 is the empty width inside the silo 10, and L1 is the empty length inside the silo 10. It is assumed that the vertical ribs 11a and 11b are sufficiently close to the ends of the silo 10 with respect to the empty length L1.

[0038] Using the total volume V0 in the silo 10, the filling volume V2 of the cement M1 is calculated by the following formula. V2=V0-V1

[0039] Next, the control unit 21 of the management server 20 executes a process of recording the inventory amount (step S105). Specifically, the filling management unit 210 of the control unit 21 calculates the inventory amount W (weight) using the specific gravity γ of the cement M1. W=V2·γ

[0040] Then, the filling management unit 210 generates an inventory management record in which the measurement date and time (current date and time) and the calculated inventory amount W are recorded, and records the record in the inventory information storage unit 23.

[0041] (Processing during weight measurement) Next, the weight measurement process (second measurement process) will be described with reference to Fig. 7. This process is carried out when cement is discharged for use.

[0042] First, the control unit 21 of the management server 20 executes a process for acquiring the amount of cement used (step S201). Specifically, the inventory management unit 212 of the control unit 21 acquires the weight (amount of cement used) of the cement discharged from the discharge port 14 from the load cell 20c.

[0043] Next, the control unit 21 of the management server 20 executes a process for calculating the inventory amount (step S202). Specifically, the inventory management unit 212 of the control unit 21 calculates the weight by subtracting the usage amount from the inventory amount recorded in the most recent inventory management record. The inventory management unit 212 then generates an inventory management record that records the measurement date and time (current date and time) and the calculated weight, and records the record in the inventory information storage unit 23.

[0044] Next, the control unit 21 of the management server 20 executes an order slip creation process (step S203). Specifically, the inventory management unit 212 of the control unit 21 identifies, in the schedule information storage unit 22, the date and time when the future inventory amount will fall below a reference value, based on the current inventory amount and the scheduled amount in the schedule management record, which records scheduled dates within a predetermined period. The inventory management unit 212 then identifies the next delivery date and time, and generates and outputs an order slip. Note that if it is determined that the amount of cement used is less than the scheduled amount in the schedule management record due to progress on site, and that the inventory amount will not fall below the reference value by the identified order date and time, the order date and time are recalculated and the order is changed.

[0045] According to this embodiment, the following effects can be obtained. (1) In this embodiment, the control unit 21 of the management server 20 executes a filling completion detection process (step S101) and a standby process (step S102). This allows the cement M1 that has been blown up by filling to settle down, and an image can be acquired at a stage where the void above the cement M1 can be clearly photographed.

[0046] (2) In this embodiment, the control unit 21 of the management server 20 executes an image acquisition process (step S103). This allows the state of the upper void SP1 (spatial region) that is not filled with cement M1 to be grasped. Although the rate at which the cement M1 is consumed varies each time, immediately after delivery of the cement M1, the cement M1 fills up localized holes and steep sections, and is filled evenly at a substantially constant gradient from the inlet 12 toward the back (the opposite discharge port side). This makes it easy to identify the spatial volume of the upper void SP1.

[0047] Here, the height of the vertical ribs 11a, 11b exposed from the cement M1 is calculated. This makes it possible to identify the height of the upper space SP1 using a characteristic member extending in the height direction within the silo 10 covered with cement M1.

[0048] (3) In this embodiment, the control unit 21 of the management server 20 executes a process of calculating the spatial volume (step S104) and a process of recording the inventory amount (step S105). Since the upper space SP1 is free of obstacles and can be seen by the cameras 20a and 20b, the volume of the space filled with the cement M1 can be estimated by identifying the spatial volume of the upper space SP1.

[0049] (4) In this embodiment, the control unit 21 of the management server 20 executes a process for acquiring the usage amount (step S201) and a process for calculating the inventory amount (step S202), thereby making it possible to grasp the inventory amount based on the usage amount. (5) In this embodiment, the control unit 21 of the management server 20 executes the process of creating an order slip (step S203), thereby enabling efficient ordering.

[0050] This embodiment can be modified as follows: This embodiment and the following modifications can be combined and implemented within the scope of technical compatibility.

[0051] In the above embodiment, the management server 20 is used to manage the cement M1 stored in the silo 10 as a material management program. The present invention is not limited to managing the inventory of cement M1 in the silo 10. For example, the present invention can be applied to inventory management of materials in which the shape of the remaining amount of powder that flows in a closed space changes depending on the usage situation.

[0052] In the above embodiment, cameras 20a and 20b are provided inside the silo 10. The arrangement of the cameras is not limited to this. For example, one camera 20b may be arranged downstream and capable of capturing images from the downstream side to the upstream side, to identify the vertical ribs 11a and 11b on the upstream and downstream sides. More cameras may be arranged to identify the distribution of the cement surface position.

[0053] In the above embodiment, the control unit 21 of the management server 20 executes a filling completion detection process (step S101). The method for detecting filling completion is not limited to this. For example, the control unit 21 of the management server 20 may acquire completion information input by an operator.

[0054] In the above embodiment, the control unit 21 of the management server 20 executes a standby process (step S102). Here, the control unit 21 waits for a predetermined time. The standby method is not limited to using time. For example, an image of the inside of the silo 10 may be acquired from a camera, and image processing may be performed to determine whether or not vertical ribs can be detected. If vertical ribs are detected, the standby process ends.

[0055] In the above embodiment, the control unit 21 of the management server 20 executes a process for calculating the spatial volume (step S104). Here, images of the vertical ribs 11a, 11b are used to calculate the exposed height. The method for calculating the spatial volume is not limited to this. For example, the structural members used to calculate the spatial volume are not limited to the vertical ribs 11a, 11b, and structural members that are partially buried by filling can be used. In addition, the method for calculating the exposed height may also be, for example, to generate a prediction model that estimates the section volume from the surface image by machine learning using training data consisting of cement surface images and actual measured values ​​of the spatial volume.

[0056] In the above embodiment, the control unit 21 of the management server 20 executes a filling completion detection process (step S101). Here, the silo 10 may be vibrated to flatten the surface. In this case, a vibrator provided in the silo 10 is operated. This allows the cement M1 in the silo 10 to be further flattened.

[0057] In the above embodiment, the image measurement process (first measurement process) is executed when the cement M1 is being filled. The timing of executing the image measurement process is not limited to when the cement in the silo 10 is filled, as long as the cement is flat. For example, the image measurement process may be executed after the cement is flattened by operating a vibrator during the filling process.

[0058] In the above embodiment, the control unit 21 of the management server 20 executes a process for acquiring the usage amount (step S201). In this case, the load cell 20c is used. The method for acquiring the usage amount is not limited to the method using the load cell. In the above embodiment, the weight measurement process (second measurement process) is performed after the image measurement process (first measurement process). Here, powder or granular material may be used while waiting for the image measurement process (step S102). In this case, the weight measured in the weight measurement process is subtracted from the inventory amount calculated using the acquired image to determine the inventory amount at the time of filling.

[0059] In the above embodiment, the control unit 21 of the management server 20 executes a process for calculating the spatial volume (step S104). In this case, the average values ​​(Ha0, Hb0) of the vertical ribs 11a, 11b on both sides are used. The method for determining the height of the upper void SP1 is not limited to the method using the average value. For example, the image processing unit 211 may use the ribs as markers to calculate the distance from the camera to the ribs, and determine the surface shape of the cement at a focal depth according to this distance. The image processing unit 211 may then perform statistical processing of this surface shape to determine the height of the upper void.

[0060] In the above embodiment, the control unit 21 of the management server 20 executes the process of creating an order form (step S203). Here, the inventory management unit 212 may send the created order form to the supplier. In this case, the inventory management unit 212 stores the supplier's destination information. [Explanation of symbols]

[0061] 10...Silo, 11, 11a, 11b...Vertical ribs, 12...Inlet, 13...Screw, 14...Outlet, 20...Management server, 20a, 20b...Camera, 20c...Load cell, 21...Control unit, 210...Filling management unit, 211...Image processing unit, 212...Inventory management unit, 22...Schedule information storage unit, 23...Inventory information storage unit.

Claims

1. a control unit connected to cameras disposed above the upstream side and the downstream side of a horizontal container for storing materials, the camera having spaces above the upstream side and the downstream side and capable of photographing an upper portion of the container; an inventory information storage unit that records the inventory amount of the material; a weight measuring unit for measuring the amount of the material used on the downstream side, The control unit Acquire, from the camera, photographed images of the upper space of the material stored in a flattened state in the container, the upper space on the upstream side and the upper space on the downstream side; Calculating the spatial volume of the upper void using the captured image; calculating an inventory amount of the material using the specific gravity of the material by subtracting the void volume from the total volume of the container, and recording the calculated amount in the inventory information storage unit; A materials management system characterized in that, when the usage amount is obtained from the weight measurement unit, the current inventory amount is calculated by subtracting the usage amount from the inventory amount recorded in the inventory information storage unit.

2. The material management system according to claim 1 , wherein the control unit acquires the photographed image when the material is being filled into the container.

3. The control unit acquiring a first captured image of the upstream side of the container and a second captured image of the downstream side of the container; 3. The material management system according to claim 1, wherein the volume of the upper space is calculated using the first photographed image and the second photographed image, and the calculated volume is recorded in the inventory information storage unit.

4. a structural member of the container is disposed within the container; The control unit calculates a height of the structural member exposed from the material in the upper space within the container, 4. The material management system according to claim 1, wherein the spatial volume of the upper space is calculated using the height of the structural member.

5. A materials management system as described in any one of claims 1 to 4, characterized in that the control unit uses a schedule management record in which the scheduled date and scheduled quantity of the material are recorded to subtract the scheduled quantity from the current inventory quantity recorded in the inventory information storage unit, identify the scheduled date on which the future inventory quantity will be below a reference value as the next delivery date and time, and generate and output an order form for the delivery date and time.

6. a control unit connected to cameras disposed above the upstream side and the downstream side of a horizontal container for storing materials, the camera having spaces above the upstream side and the downstream side and capable of photographing an upper portion of the container; an inventory information storage unit that records the inventory amount of the material; a weight measuring unit for measuring a usage amount of the material on the downstream side, The control unit Acquire, from the camera, photographed images of the upper space of the material stored in a flattened state in the container, the upper space on the upstream side and the upper space on the downstream side; Calculating the spatial volume of the upper void using the captured image; calculating an inventory amount of the material using the specific gravity of the material by subtracting the void volume from the total volume of the container, and recording the calculated amount in the inventory information storage unit; A materials management method characterized in that, when the usage amount is obtained from the weight measurement unit, the current inventory amount is calculated by subtracting the usage amount from the inventory amount recorded in the inventory information storage unit.

7. a control unit connected to cameras disposed above the upstream side and the downstream side of a horizontal container for storing materials, the camera having spaces above the upstream side and the downstream side and capable of photographing an upper portion of the container; an inventory information storage unit that records the inventory amount of the material; a weight measuring unit for measuring the amount of the material used on the downstream side, The control unit Acquire, from the camera, photographed images of the upper space of the material stored in a flattened state in the container, the upper space on the upstream side and the upper space on the downstream side; Calculating the spatial volume of the upper void using the captured image; calculating an inventory amount of the material using the specific gravity of the material by subtracting the void volume from the total volume of the container, and recording the calculated amount in the inventory information storage unit; A materials management program characterized in that, when the usage amount is obtained from the weight measurement unit, it functions as a means for calculating the current inventory amount by subtracting the usage amount from the inventory amount recorded in the inventory information storage unit.

Images