Camera unit and monitoring system

Abstract

To provide a camera unit and a monitoring system capable of monitoring in an adverse environment.SOLUTION: A camera unit comprises: a camera module having a lens; an exterior part; a space part partitioned into the exterior part to store the camera module; a case having a lens hole provided at the exterior part, connected to the space part and exposing the lens so as to face the surface of the lens and a discharge flow passage located between the lens hole and the surface of the lens to be connected to the space part and the lens hole; and a gas introduction flow passage provided at the exterior part, connected to the space part, and in which a gas is introduced into the space part to make the space part into a positive pressure, so that the gas is passed through the surface of the lens via the discharge flow passage and is purged from the lens hole.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to a camera unit including a camera module having a lens, and a monitoring system including the camera unit.

Background Art

[0002] In die casting of zinc, aluminum, etc., casting defects caused by abnormal rise in the mold surface temperature are a major problem. Due to the rise in the surface temperature, solidification is insufficient within the set cycle time, gas accumulates inside the casting, and deformation and dimensional defects occur. The factors causing the rise in the mold surface temperature are deterioration of the cooling efficiency inside the mold, for example, deterioration of the cooling water, clogging due to rust or foreign matter混入 in the cooling pipes, etc. Also, there is a rise in the mold surface temperature due to mold deterioration, temperature changes in the casting environment, and fluctuations in casting conditions. There are also changes during mass production in a day, resulting in casting defects and becoming a major problem. As a countermeasure, it is necessary to monitor the mold temperature, cooling water temperature, temperature control machine, and directly monitor the mold surface temperature.

[0003] The need to monitor the mold surface temperature is not limited to die casting molds. In injection molding as well, monitoring the abnormal rise in the mold surface temperature during mass production, which directly leads to defective molded products, is essential for preventing molding defects such as deformation and dimensional defects. In addition, it has been found that changes in the mold surface temperature are related to defective parts in rubber molds, vacuum molding, and recently in press molds, and the need for measuring the mold surface temperature is increasing.

Prior Art Documents

Non-Patent Documents

[0004]

Non-Patent Document 1

Non-Patent Document 2

[0005] One method for measuring mold surface temperature involves directly measuring the mold surface using a thermocouple sensor (Non-Patent Documents 1 and 3). However, this direct measurement method requires installation inside the mold, which complicates and necessitates modifications to the mold structure, and is costly as it requires installation for each mold.

[0006] Another method for measuring mold surface temperature is a non-contact remote measurement method using thermosensors such as cameras or infrared sensors (Non-Patent Literature 2). However, with the remote measurement method, the sensor is installed externally, and especially in the case of die-casting molds, measurement is required in a harsh environment with mold temperatures approaching 400 degrees Celsius, and with gases, sprays, air blows, dust, and molten material splatter generated during solidification. As a result, an effective sensor system has not been put into practical use. On the other hand, injection molding molds are relatively less affected by ambient temperature, dust, and gases, but many injection-molded products are small, and macroscopic temperature distribution measurement is not suitable for measuring temperature changes in detail. As a result, an effective mold surface camera module system has not been put into practical use.

[0007] In view of the above circumstances, the object of the present invention is to provide a camera unit and a monitoring system that enable monitoring in adverse environments. [Means for solving the problem]

[0008] A camera unit relating to one form of this disclosure is A camera module having a lens, A case comprising: an exterior section; a space section partitioned within the exterior section for housing the camera module; a lens hole provided in the exterior section, communicating with the space section and facing the surface of the lens, exposing the lens; a discharge channel located between the lens hole and the surface of the lens, communicating with the space section and the lens hole; and a gas introduction channel for introducing gas into the space section to create positive pressure in the space section, thereby purging the gas through the discharge channel, passing through the surface of the lens, and out of the lens hole. It is equipped with.

[0009] According to this embodiment, by keeping the surface of the camera module's lens clean through the flow of gas, high-precision monitoring becomes possible even in harsh environments with gases and dust.

[0010] The lens hole and the gas introduction channel may be provided in the outer casing portion facing the optical axis direction of the lens, and may be spaced apart in at least one direction perpendicular to the optical axis direction.

[0011] This arrangement allows the gas to circulate more evenly.

[0012] The diameter of the lens hole is greater than or equal to the diameter of the lens. The center of the lens hole may coincide with the center of the lens.

[0013] This arrangement ensures the lens's field of view despite the fact that the lens surface and the lens hole are spaced apart via an ejection channel.

[0014] The gas introduction channel may be composed of a plug unit provided in the exterior portion and communicating with the space portion.

[0015] By configuring the gas introduction flow path with the plug unit, the space part can be efficiently made into a positive pressure.

[0016] It further includes a heat generating component accommodated in the space part and generating heat. The heat generating component may be arranged in an internal flow path which is a flow path of the gas from the gas introduction flow path to the discharge flow path.

[0017] When the camera module itself generates heat and also the surrounding heat generating components generate heat and the temperature of the camera module rises, there is a possibility that the detection performance of the camera module may deteriorate. In contrast, according to the present embodiment, since the gas flows through the internal flow path in which the heat generating component is arranged and the gas is discharged from the lens hole, the rise in the temperature of the heat generating component can be suppressed. Thereby, the rise in the temperature of the camera module can be suppressed and the deterioration of the detection performance of the camera module can be prevented.

[0018] The width in the direction orthogonal to the flow direction of the gas in the discharge flow path may be smaller than the width in the direction orthogonal to the flow direction of the gas in the internal flow path.

[0019] For this reason, the gas flowing through the internal flow path will flow relatively fast in the narrow discharge flow path, pass through the surface of the lens at a relatively high speed, and eject from the lens hole toward the environment. Thereby, the gas can clean the surface of the lens and prevent foreign matter from entering from the environment into the inside of the lens hole.

[0020] The heat generating component may include a controller module that controls the camera module.

[0021] The camera module may be a thermal camera module having a temperature sensor, detecting the temperature of a subject, and generating thermographic data.

[0022] [[ID=The controller module may generate and transmit temperature data in CSV format, which arranges the temperature detected by the camera module in a two-dimensional matrix representing the positions of the detection points.

[0023] As a result, the position of the detection point is represented by the cell position of a two-dimensional matrix in CSV format, and the temperature is associated with that position. Thereby, temperature data indicating the temperature of the detection point of the subject can be generated in a small data volume format.

[0024] The camera unit further includes an antenna module provided in the exterior portion. further includes an antenna module provided in the exterior portion. The controller module may wirelessly transmit the thermography data or the temperature data via the antenna module.

[0025] When the camera unit and an external device are connected by wire, the wiring may be disconnected due to the movement of the movable part of a movable machine such as a machine tool, or the wiring being caught by a part when a part inside the machine is removed or replaced. As a result, the communication connection between the camera unit and the external device is interrupted. In contrast, according to the present embodiment, by making the communication connection of the camera unit wireless, it is possible to prevent the interruption of the communication connection.

[0026] The camera unit may further include an internal temperature sensor that detects the temperature of the space portion. may further include.

[0027] Thereby, when the temperature of the space portion inside the camera unit rises above a threshold value, it is possible to notify of a temperature abnormality.

[0028] The camera unit further includes an imaging module housed in the space portion and having a lens and an image sensor that captures an object to generate image data. The exterior portion further has another lens hole that exposes the lens of the imaging module. The discharge channel is located between the other lens hole and the surface of the lens of the imaging module, and may communicate with the space and the other lens hole.

[0029] According to this embodiment, the surface of the lens of the imaging module can also be kept clean by the flow of gas.

[0030] The controller module may wirelessly transmit the image data generated by the imaging module together with the temperature data via the antenna module.

[0031] A monitoring system relating to one form of this disclosure is: A camera module which is a thermal camera module having a lens and a temperature sensor, and which detects the temperature of a subject and generates thermographic data, Control the camera module, The thermal imaging data generated by the aforementioned camera module is transmitted without going through a network. The camera module generates temperature data in CSV format, in which the temperature values ​​it detects are arranged in a two-dimensional matrix representing the location of the detection point, and transmits this data via or without the network. Controller module and A camera unit having, Upon receiving the aforementioned thermographic data, the system displays a thermographic image based on the aforementioned thermographic data, or Upon receiving the temperature data in CSV format, the system generates and displays a thermographic image in which color elements representing temperature are arranged in a two-dimensional matrix representing the positions of the detection points, based on the temperature data in CSV format. A terminal device having a display control unit, A terminal device having, It is equipped with.

[0032] According to this embodiment, the controller module converts the thermographic image into CSV format temperature data and transmits it to a first terminal device connected via the network N. The first terminal device converts the CSV format temperature data back into a thermographic image and displays it. On the other hand, the controller module transmits the thermographic image as is to a second terminal device connected via an access point without using the network. This prevents increased traffic by transmitting small amounts of CSV format temperature data when communicating via the network, and enables real-time display by transmitting the thermographic image as is when communicating without using the network.

[0033] The terminal device may further include a monitoring unit that monitors the temperature of a specific detection point included in the CSV-formatted temperature data.

[0034] For example, the monitoring unit monitors the temperature of a specific number of detection points, rather than the temperature of all detection points. These specific detection points can be defined as the points to be monitored, i.e., locations where changes in mold surface temperature may be related to part defects.

[0035] The monitoring unit may determine whether the temperature at the specific detection point has reached a threshold.

[0036] This allows us to determine whether the molded product has reached the upper and / or lower limits that guarantee its quality.

[0037] The monitoring unit may set the emissivity of the subject.

[0038] The system may have an emissivity setting function that allows the emissivity to be set according to the material, etc. Emissivity represents how easily an object emits heat, and even for the same material, a rougher surface will have a higher emissivity. By setting the emissivity according to the material, appropriate monitoring can be performed according to the material. In addition, changes in surface roughness due to aging can be detected, and by changing the emissivity setting according to the change in surface roughness, appropriate monitoring can be performed even when there is aging deterioration.

[0039] The aforementioned camera unit is A case comprising: an exterior section; a space section partitioned within the exterior section for housing the camera module; a lens hole provided in the exterior section that communicates with the space section and exposes the lens facing the surface of the lens; a discharge channel located between the lens hole and the surface of the lens and communicating with the space section and the lens hole; and a gas introduction channel provided in the exterior section that communicates with the space section and introduces gas into the space section to create positive pressure in the space section, thereby purging the gas through the discharge channel to the surface of the lens and out of the lens hole. It may further have and be housed in the space.

[0040] According to this embodiment, by keeping the surface of the camera module's lens clean through the flow of gas, high-precision monitoring becomes possible even in harsh environments with gases and dust.

[0041] The camera unit further comprises an imaging module having a lens and an image sensor that captures a subject and generates image data. The controller module transmits the image data generated by the imaging module together with the CSV-formatted temperature data or thermographic data. The display control unit of the terminal device may superimpose the received image data onto the thermographic image and display it such that the received image data coincides in position with the two-dimensional matrix.

[0042] By superimposing image data onto a thermographic image so that the image data is positionally aligned with a two-dimensional matrix, it becomes easier to visually understand the temperature of different parts of the subject.

[0043] The exterior portion further has another lens hole that exposes the lens of the imaging module, The discharge channel is located between the other lens hole and the surface of the lens of the imaging module, and may communicate with the space and the other lens hole.

[0044] According to this embodiment, the surface of the lens of the imaging module can also be kept clean by the flow of gas.

[0045] The camera unit further includes an antenna module provided on the exterior, The camera unit and the terminal device may be connected to each other via an access point so that they can communicate with each other.

[0046] The monitoring system is A setup terminal that obtains the SSID, password, and IP address of the access point, and sets the SSID, password, and IP address of the access point on the camera unit located within a predetermined distance range via the network, thereby establishing a network communication connection between the camera unit and the access point. It may also be provided with the following features.

[0047] According to this embodiment, by making the communication connection of the camera unit wireless, it is possible to prevent the interruption of the communication connection between the camera unit and external devices. [Effects of the Invention]

[0048] According to the present invention, a camera unit and monitoring system that enable monitoring in adverse environments can be provided.

[0049] The effects described herein are not necessarily limited to those described herein and may include any of the effects described herein. [Brief explanation of the drawing]

[0050] [Figure 1] This document outlines the monitoring system for one embodiment of the present invention. [Figure 2] This shows the hardware and functional configuration of the camera unit and terminal device. [Figure 3] An example of a screen displayed on a terminal device is shown. [Figure 4] This is a front view showing the camera unit. [Figure 5] Figure 4 shows a schematic cross-sectional view along line AA of the camera unit. [Figure 6] This diagram schematically illustrates the gas flow within the camera unit. [Modes for carrying out the invention]

[0051] Embodiments of this disclosure will be described below with reference to the drawings.

[0052] 1. Overview of the Monitoring System

[0053] Figure 1 shows an overview of a monitoring system according to one embodiment of the present invention.

[0054] The monitoring system 1 includes at least one camera unit 10 (in this embodiment, a first camera unit 10A and a second camera unit 10B) and at least one terminal device 40 (in this embodiment, a first terminal device 40A and a second terminal device 40B). The monitoring system 1 may further include a setup terminal 50.

[0055] The hardware and functional configurations of the first camera unit 10A and the second camera unit 10B are the same. Hereafter, when describing a single camera unit 10 without distinguishing between the first camera unit 10A and the second camera unit 10B, it will simply be referred to as camera unit 10.

[0056] The first camera unit 10A is attached to the movable mold C1 (core). The second camera unit 10B is attached to the fixed mold C2 (cavity). The pair of movable mold C1 and fixed mold C2 is typically a pair of die-casting molds, injection molding molds, rubber molding molds, vacuum forming molds, or press molds. Multiple pairs of the first camera unit 10A and the second camera unit 10B are typically installed on the fixed mold C2 and movable mold C1 of multiple (e.g., dozens) target machines installed at the same site (manufacturing plant, etc.).

[0057] The first camera unit 10A is capable of detecting the surface temperature of the fixed mold C2 (fixed mold surface temperature T2). Specifically, the first camera unit 10A is capable of detecting multiple temperatures (fixed mold surface area temperatures) for each of multiple areas obtained by dividing the surface of the fixed mold C2 (the surface on which the molded product is manufactured) into two dimensions (matrix). As shown in the figure, the first camera unit 10A is mounted at an arbitrary position on the movable mold C1 so that it can capture substantially the entire surface of the fixed mold C2 (dashed line in the figure). The first camera unit 10A may be small and lightweight so that it can be mounted on the movable mold C1 (for example, fitted into a mounting jig bonded to the movable mold C1). The first camera unit 10A has a built-in battery (not shown).

[0058] The second camera unit 10B is capable of detecting the surface temperature of the movable mold C1 (movable mold surface temperature T1). Specifically, the second camera unit 10B is capable of detecting multiple temperatures (movable mold surface area temperatures) for each of multiple areas obtained by dividing the surface of the movable mold C1 (the surface on which the molded product is manufactured) into two dimensions (matrix-like). As shown in the figure, the second camera unit 10B is attached to an arbitrary position on the fixed mold C2 so that it can capture almost the entire surface of the movable mold C1 (dashed line in the figure). The second camera unit 10B may be small and light enough to be attached to the movable mold C1 (for example, fitted into a mounting jig bonded to the fixed mold C2). The second camera unit 10B has a built-in battery (not shown).

[0059] Access point 30 is installed within communication range of camera unit 10. Camera unit 10 is wirelessly connected to access point 30. Access point 30 is connected to network N. Typically, network N is a wireless LAN installed in a manufacturing plant, etc. First terminal device 40A is connected to network N. Camera unit 10 and first terminal device 40A are wirelessly connected via network N. On the other hand, second terminal device 40B is a mobile terminal and is connected to access point 30 when it is located within a predetermined distance range from access point 30. Camera unit 10 and second terminal device 40B are wirelessly connected via access point 30 and without going through network N. For example, second terminal device 40B is a mobile terminal (tablet computer, laptop computer, etc.) carried by a user such as a worker who is in close proximity to the target machine on which camera unit 10 is installed, while first terminal device 40A is a computer (stationary, mobile, etc.) for managing the target machine.

[0060] The hardware and functional configurations of the first terminal device 40A and the second terminal device 40B are the same. Hereinafter, when describing a single terminal device 40 without distinguishing between the first terminal device 40A and the second terminal device 40B, it will simply be referred to as terminal device 40.

[0061] The terminal device 40 receives and processes temperature data from the camera unit 10. The terminal device 40 is either a general-purpose personal computer or a dedicated computer. If the terminal device 40 is a general-purpose personal computer, the information processing program that implements the monitoring system of this embodiment can be recorded on a portable, non-transient, computer-readable recording medium, or downloaded via the Internet, and then installed on the general-purpose personal computer. If the terminal device 40 is a dedicated computer, a dedicated computer with the information processing program that implements the monitoring system of this embodiment installed can be shipped.

[0062] The setup terminal 50 communicates wirelessly with the camera unit 10 via the access point 30 and without using the network N. The setup terminal 50 establishes a wireless network communication connection (initial setup) between the camera unit 10 and the access point 30 via the network N. First, the user operates the setup terminal 50 to manually enter the setup IP address into a general-purpose web browser and access the setup website. The user manually enters the SSID, password, and IP address of the access point 30 into the setup website. As a result, the setup terminal 50 obtains the SSID, password, and IP address of the access point 30. The setup terminal 50 establishes a network communication connection between the camera unit 10 and the access point 30 by setting the SSID, password, and IP address of the access point 30 on the camera unit 10 located within a predetermined distance range via the network. The setup terminal 50 is a general-purpose personal computer, tablet computer, smartphone, etc. Note that a second terminal device 40B may have the functions of the setup terminal 50.

[0063] 2. Hardware and Functional Configuration of Camera Unit and Terminal Device

[0064] Figure 2 shows the hardware and functional configuration of the camera unit and terminal device.

[0065] The camera unit 10 includes a camera module 100, a controller module 110, and an antenna module 120.

[0066] The camera module 100 is, for example, a long-wavelength infrared (LWIR) camera module having a lens 101 and a shutter. The camera module 100 is a thermal camera module that has a temperature sensor 102 (for example, an uncooled VOx microbolometer) to detect the temperature of a subject. The camera module 100 detects the surface temperature of a subject and generates thermographic data with a resolution of approximately 80x60 pixels (pixel size 17 μm) or 160x120 pixels (pixel size 12 μm).

[0067] The antenna module 120 is, for example, a dipole antenna.

[0068] The controller module 110 is, for example, a microcontroller having a CPU, RAM, and Wi-Fi® module. The camera module 100 and the controller module 110 are connected via serial buses such as SPI (Serial Peripheral Interface) and I2C (Inter-Integrated Circuit). For example, the controller module 110 controls the camera module 100 via I2C, and the camera module 100 transmits data to the controller module 110 via SPI.

[0069] The camera unit 10 further includes an internal temperature sensor. The internal temperature sensor is typically implemented in the controller module 110. The internal temperature sensor detects the temperature of the space 132 (described later) inside the camera unit 10. The controller module 110 has a function to notify of a temperature anomaly if the temperature of the space 132 inside the camera unit 10 detected by the internal temperature sensor rises above a threshold.

[0070] The controller module 110 wirelessly transmits the thermographic data generated by the camera module 100 directly to the second terminal device 40B. Furthermore, if the temperature detected by the internal temperature sensor rises above a threshold, the controller module 110 wirelessly notifies the second terminal device 40B of the temperature anomaly.

[0071] Furthermore, the controller module 110 generates temperature data in CSV format based on the thermographic data from the camera module 100 and transmits it to the first terminal device 40A. Specifically, the controller module 110 generates temperature data in CSV format in which the temperatures detected by the camera module 100 are arranged in a two-dimensional matrix representing the positions of the detection points. For example, consider the case where the camera module 100 has a resolution of 80x60 pixels and can detect the surface temperature of an object. In this case, the controller module 110 inputs the temperature of the object corresponding to its position as a numerical value (e.g., 5 digits) into 80x60 cells in a two-dimensional matrix in CSV format. As a result, the positions of the 80x60 detection points are represented by the cell positions in the two-dimensional matrix in CSV format, and the temperature is associated with those positions. This makes it possible to generate temperature data showing the temperatures of the 80x60 detection points of the object in a small data size format. The controller module 110 wirelessly transmits the generated temperature data in CSV format to the first terminal device 40A via the antenna module 120. Furthermore, if the temperature detected by the internal temperature sensor rises above a threshold, the controller module 110 wirelessly notifies the first terminal device 40A of the temperature anomaly.

[0072] The terminal device 40 includes a control circuit 410 having a CPU, ROM, and RAM, a communication interface 420, and a display device 430 (display). The CPU of the control circuit 410 operates as a receiving unit 411, a display control unit 412, and a monitoring unit 413 by loading an information processing program recorded in ROM into RAM and executing it.

[0073] When the receiving unit 411 receives thermographic data, the display control unit 412 of the terminal device 40 displays a thermographic image based on the thermographic data. On the other hand, when the receiving unit 411 receives temperature data in CSV format, the display control unit 412 generates and displays a thermographic image based on the temperature data in CSV format. Specifically, this is as follows.

[0074] The receiving unit 411 of the second terminal device 40B receives thermographic data transmitted from the camera module 100 via the communication interface 420.

[0075] The display control unit 412 of the second terminal device 40B displays the thermographic image on the display device 430 based on the thermographic data received from the camera module 100. For example, the display control unit 412 can display the thermographic image using a web browser.

[0076] The receiving unit 411 of the first terminal device 40A receives temperature data in CSV format transmitted from the camera module 100 via the communication interface 420.

[0077] The display control unit 412 of the first terminal device 40A generates display information based on the CSV-formatted temperature data received from the camera module 100 and displays it on the display device 430. Specifically, the display control unit 412 generates a thermographic image as display information based on the CSV-formatted temperature data received from the camera module 100, in which color elements representing temperature are arranged in a two-dimensional matrix (80x60 in this example) representing the positions of the detection points, and displays it on the display device 430. In this embodiment, "color elements" means color gradient or grayscale. This makes it possible to display temperature information in a highly visible, detailed thermographic image, even though the temperature data indicating the temperature of the detection points of the subject is in a small-data-volume CSV format. Furthermore, the display control unit 412 may also display the CSV-formatted temperature data received from the camera module 100 in CSV format, that is, display numerical values ​​in a matrix-like cell format. This allows the user to know the temperature of each detection point numerically.

[0078] The monitoring unit 413 of the first terminal device 40A monitors the temperature of specific detection points included in the temperature data received from the camera module 100. For example, the monitoring unit 413 monitors the temperature of a specific number of detection points, rather than the temperature of all 80x60 detection points. The specific number of detection points can be set to be the detection points to be monitored, i.e., locations where changes in mold surface temperature may be related to part defects. For example, the monitoring unit 413 can determine whether the temperature of a specific number of detection points has reached a predetermined threshold (upper and / or lower limit that can guarantee the quality of the molded product), whether the gradient (temperature difference) of the mold surface area temperature has reached a predetermined threshold (upper and / or lower limit that can guarantee the quality of the molded product), etc., and display the determination result, or it can calculate the average, maximum, and minimum temperatures and display the calculation results.

[0079] The monitoring unit 413 of the first terminal device 40A may have an emissivity setting function that sets the emissivity according to the material of the movable mold C1 and the fixed mold C2, which are the subjects of observation. Emissivity represents the ease with which an object radiates heat, and even for the same material, a rougher surface will result in higher emissivity. By setting the emissivity according to the material of the movable mold C1 and the fixed mold C2, appropriate monitoring can be performed according to the material. In addition, changes in surface roughness due to aging can be noticed, and by changing the emissivity setting according to the change in surface roughness, appropriate monitoring can be performed even in the case of aging deterioration. The monitoring unit 413 of the first terminal device 40A may have an actual measurement value correction setting that corrects the mold surface temperatures T1 and T2 of the movable mold C1 and the fixed mold C2, which are the subjects of observation, to values ​​actually measured with a thermocouple or the like. The monitoring unit 413 may set different thresholds for each of the multiple detection points. The monitoring unit 413 may set different emissivity values ​​for each of the multiple detection points and perform actual measurement value correction for each of the multiple detection points. Furthermore, multiple detection points may be independent points, or a collection of adjacent detection points may constitute the area to be detected.

[0080] The display control unit 412 of the first terminal device 40A further displays the judgment results and calculation results of the monitoring unit 413 on the display device 430.

[0081] According to this embodiment, the controller module 110 converts the thermographic image into CSV format temperature data and transmits it to the first terminal device 40A connected via the network N. The first terminal device 40A converts the CSV format temperature data back into a thermographic image and displays it. On the other hand, the controller module 110 transmits the thermographic image as is to the second terminal device 40B connected via the access point 30 without going through the network N. As a result, when communicating via the network N, it is possible to prevent an increase in traffic by transmitting small amounts of CSV format temperature data, and when communicating without going through the network N, it is possible to achieve real-time display by transmitting the thermographic image as is.

[0082] Furthermore, the controller module 110 of the camera unit 10 may also send temperature data in CSV format to the second terminal device 40B. This allows the monitoring unit 413 of the second terminal device 40B to monitor the temperature of a specific detection point included in the temperature data received from the camera module 100. The monitoring unit 413 of the second terminal device 40B may also have an emissivity setting function and an actual measurement value correction setting. Furthermore, the display control unit 412 may display the temperature data received from the camera module 100 in CSV format, that is, display the numerical values ​​in a matrix cell format. This allows users, such as workers, to know the temperature of each detection point numerically.

[0083] Typically, a sensor device and an external device (corresponding to the camera unit 10 and terminal device 40 in this embodiment) are connected by a wire. However, the wiring may be interrupted due to the movement of movable parts of a movable machine such as a machine tool, or when the wiring gets caught on parts during removal or replacement of parts inside the machine. As a result, the communication connection between the sensor device and the external device is interrupted. In contrast, according to this embodiment, by making the communication connection between the camera unit 10 installed on a movable machine and the terminal device 40 wireless, it is possible to prevent the interruption of the communication connection.

[0084] 3. Example of a display screen

[0085] Figure 3 shows an example of a screen displayed on a terminal device.

[0086] The display control unit 412 of the terminal device 40 displays a matrix-shaped thermograph 521 on the screen 520 showing multiple temperatures (movable mold surface area temperatures) for multiple areas obtained by dividing the surface of the movable mold C1 in two dimensions. The display control unit 412 also displays a matrix-shaped thermograph 522 on the screen 520 showing multiple temperatures (fixed mold surface area temperatures) for multiple areas obtained by dividing the surface of the fixed mold C2 in two dimensions. In short, the display control unit 412 displays the movable mold surface temperature T1 and the fixed mold surface temperature T2, which are detected and synchronized in the same cycle, on a single screen 520.

[0087] The display control unit 412 of the terminal device 40 displays the judgment results and calculation results of the monitoring unit 413 on the display device 430. For example, if any value exceeds a threshold, the display control unit 412 displays the comparison results so that the location of the mold surface with the value (temperature) that exceeded the threshold can be visually identified (alarm through highlighting such as changing the color).

[0088] The display control unit 412 displays the average, maximum, and minimum values ​​523 of the movable mold surface area temperature and the average, maximum, and minimum values ​​524 of the fixed mold surface area temperature on the screen 520. For example, for each cycle of operation of the movable mold C1, the first camera unit 10A detects and outputs the fixed mold surface temperature T2, and the second camera unit 10B detects and outputs the movable mold surface temperature T1. The display control unit 412 may also display the time-series changes of the average values ​​of the movable mold surface area temperature and the fixed mold surface area temperature received for each cycle as graphs 525 and 526.

[0089] 4. Camera Unit Structure

[0090] Figure 4 is a front view showing the camera unit. Figure 5 is a schematic cross-sectional view of the camera unit along line AA in Figure 4.

[0091] As described above, the camera unit 10 includes a camera module 100 having a lens 101, a controller module 110, and an antenna module 120. The camera unit 10 further includes a case 130.

[0092] The case 130 has an outer casing 131, an inner housing space 132 partitioned within the outer casing 131, and a plug unit 140. An antenna module 120 is provided in the outer casing 131. The antenna module 120 is connected to an antenna chip 121, which is a high-power type chip, via an SMA conversion cable (not shown). The housing space 132 accommodates a controller module 110, an antenna chip 121, a camera module 100, etc. A lens hole 134 is provided in the front part 133 of the outer casing 131. A plug unit 140 is provided in the rear part 136 of the outer casing 131, that is, the part facing the front part 133 in the optical axis direction (Y direction) of the lens 101. The lens hole 134 and the plug unit 140 are spaced apart in at least one direction (Z direction) perpendicular to the optical axis direction (Y direction) of the lens 101. In other words, the lens hole 134 and the plug unit 140 are spaced apart in the optical axis direction (Y direction) of the lens 101, but they are not facing each other in the optical axis direction (Y direction) of the lens 101, but are spaced apart (shifted) in the Z direction.

[0093] The lens hole 134 is simply a through-hole, and there is no shutter or transparent cover that can cover the lens hole 134. The lens hole 134 faces the surface of the lens 101, exposing the lens 101 to the external environment. The surface of the lens 101 and the surface of the camera module 100 are not in contact with the exterior part 131 that partitions the lens hole 134, but are positioned with a space in the optical axis direction (Y direction) of the lens 101 relative to the exterior part 131. As a result, the lens hole 134 communicates with the space 132 and the external environment. The space between the lens hole 134 and the space 132 is the discharge channel 137. That is, the discharge channel 137 is located between the lens hole 134 and the surface of the lens 101, and is a spatial region that communicates with the space 132 and the lens hole 134. The diameter of the lens hole 134 is greater than or equal to the diameter of the lens 101, and typically, the center of the lens hole 134 coincides with or approximately coincides with the center of the lens 101. This arrangement ensures the field of view of the lens 101, even though the surface of the lens 101 and the lens hole 134 are spaced apart via the discharge channel 137 (i.e., the lens 101 is positioned recessed).

[0094] As described above, the plug unit 140 is provided on the rear surface 136 of the outer casing 131 of the case 130. The plug unit 140 includes a blind plug 141 and a speed controller 142 installed on the outer casing 131. The plug unit 140 communicates with the space 132. The space 132 communicates with the lens hole 134 via the discharge passage 137. The plug unit 140 constitutes a gas introduction passage and efficiently creates a positive pressure in the space 132.

[0095] As described above, the controller module 110, antenna chip 121, and camera module 100 are housed in the space 132. The controller module 110, antenna chip 121, and camera module 100 are heat-generating components. All of these heat-generating components are located in the internal flow path 138, which is the gas flow path from the plug unit 140 to the discharge flow path 137 (i.e., most of the space area of ​​the space 132 excluding the discharge flow path 137).

[0096] Figure 6 schematically shows the gas flow in the camera unit.

[0097] The gas flow in the camera unit 10 is described below. The gas is typically air. The plug unit 140, which constitutes the gas introduction channel, introduces gas from the blind plug 141 through the speed controller 142 into the space 132 (arrow A), thereby creating positive pressure in the space 132. By creating positive pressure in the space 132, the plug unit 140 prevents the gas from stagnating in the space 132, allowing it to pass through the internal channel 138 (arrow B), through the discharge channel 137, and across the surface of the lens 101 (arrow C), and be purged from the lens hole 134 (arrow D). As described above, the plug unit 140 and the lens hole 134 are spaced apart in the Z direction. This arrangement makes it easier for the gas to flow evenly through the internal channel 138 in the Z direction. Therefore, as the gas passes through the internal channel 138 in the Z direction from the plug unit 140 toward the lens hole 134, the heat-generating components (controller module 110, antenna chip 121, and camera module 100) located in the internal channel 138 are cooled.

[0098] If the camera module 100 itself generates heat, and the surrounding heat-generating components (controller module 110 and antenna chip 121) also generate heat, causing the temperature of the camera module 100 to rise, the detection performance of the camera module 100 may decrease. In contrast, according to this embodiment, gas flows through the internal channel 138 where the heat-generating components (controller module 110, antenna chip 121, and camera module 100) are located, and the gas is discharged from the lens hole 134, thereby suppressing the rise in temperature of the heat-generating components. As a result, the rise in temperature of the camera module 100 can be suppressed, and the decrease in the detection performance of the camera module 100 can be prevented.

[0099] The width of the discharge channel 137 in the direction perpendicular to the gas flow direction (X or Z direction) (Y direction) is smaller than the width of the internal channel 138 in the direction perpendicular to the gas flow direction (Z direction) (Y direction). In other words, the channel width of the discharge channel 137 is narrower than the channel width of the internal channel 138. Therefore, the gas that has flowed through the internal channel 138 flows relatively faster in the narrow discharge channel 137, passes through the surface of the lens 101 at a relatively high speed, and is ejected from the lens hole 134 toward the environment. This allows the gas to clean the surface of the lens 101 and prevents foreign matter (such as gas, spray, air blow, dust, or molten material splatter) from entering the inside of the lens hole 134 from the environment.

[0100] As described above, according to this embodiment, the flow of gas suppresses the temperature rise of the camera module 100, preventing a decrease in the detection performance of the camera module 100. At the same time, by keeping the surface of the lens 101 of the camera module 100 clean, monitoring becomes possible even in harsh environments with gas and dust.

[0101] 5. Variations

[0102] The camera unit 10 may further include an imaging module (not shown) in addition to the camera module 100, which is a thermal camera module. The imaging module is housed in a space 132 and has a lens and an image sensor that photographs a subject and generates image data. The front surface 133 of the exterior 131 of the case 130 is provided with a lens hole 134 that exposes the lens 101 of the camera module 100, as well as another lens hole that exposes the lens of the imaging module. The discharge channel 137 is located between the lens hole 134 and the surface of the lens 101 and communicates with the space 132 and the lens hole 134, and is also located between the other lens hole and the surface of the lens of the imaging module and communicates with the space 132 and the other lens hole. In other words, the gas flowing through the internal channel 138 passes through the surfaces of the lens of the camera module 100 and the lens of the imaging module and is ejected from the lens hole 134 and the other lens hole. This keeps both the lens 101 of the camera module 100 and the lens of the imaging module clean.

[0103] The controller module 110 of the camera unit 10 wirelessly transmits the image data generated by the imaging module, along with temperature data or thermographic data in CSV format, to the terminal device 40 via the antenna module 120.

[0104] The receiving unit 411 of the terminal device 40 receives image data transmitted from the camera module 100 along with temperature data via the communication interface 420. The display control unit 412 of the terminal device 40 overlays the image data onto the thermographic image and displays it on the display device 430 so that the image data is positionally aligned with a two-dimensional matrix. This makes it easy to visually understand the temperature of each part of the mold being photographed.

[0105] Although various embodiments and modifications of this technology have been described above, this technology is not limited to the embodiments described above, and various modifications can be made without departing from the gist of this technology. [Explanation of Symbols]

[0106] 1. Monitoring System 10 Camera Units 100 Camera Modules 101 Lens 102 Temperature Sensor 10A First camera unit 10B Second camera unit 110 Controller Module 120 Antenna Modules 121 Antenna chip 130 cases 131 Exterior part 132 Space section 133 Front part 134 lens holes 136 Rear part 137 Discharge channel 138 Internal flow path 140 Plug Unit 141 Blind Plug 142 Speed ​​Controller 30 access points 40A First terminal device 40B Second terminal device 410 Control Circuit 411 Receiving Unit 412 Display Control Unit 413 Monitoring Department 420 Communication Interfaces 430 Display device 50 Setup terminals

Claims

1. A camera module having a lens, A case comprising: an exterior section; a space section partitioned within the exterior section for housing the camera module; a lens hole provided in the exterior section, communicating with the space section and facing the surface of the lens, exposing the lens; a discharge channel located between the lens hole and the surface of the lens, communicating with the space section and the lens hole; and a gas introduction channel for introducing gas into the space section to create positive pressure in the space section, thereby purging the gas through the discharge channel, passing through the surface of the lens, and out of the lens hole. An imaging module housed in the aforementioned space includes an imaging module lens and an image sensor that captures a subject and generates image data, It is equipped with, The exterior portion further has another lens hole that exposes the imaging module lens, The discharge channel is further located between the other lens hole and the surface of the imaging module lens, and communicates with the space and the other lens hole. The gas that has flowed through the internal channel, which is the gas path from the gas introduction channel to the discharge channel, passes through the surface of the lens of the camera module and the imaging module lens, and is ejected from the lens hole and the other lens hole. Camera unit.

2. A camera unit according to claim 1, The lens hole and the gas introduction channel are provided in the outer casing portion facing the optical axis direction of the lens, and are spaced apart in at least one direction perpendicular to the optical axis direction. Camera unit.

3. A camera unit according to claim 1 or 2, The diameter of the lens hole is greater than or equal to the diameter of the lens. The center of the lens hole coincides with the center of the lens. Camera unit.

4. A camera unit according to any one of claims 1 to 3, The gas introduction passage is composed of a plug unit provided in the exterior portion and communicating with the space portion. Camera unit.

5. A camera unit according to any one of claims 1 to 4, The aforementioned space is further equipped with a heat-generating component that is housed within the space and generates heat, The heat-generating component is arranged in the internal flow path. Camera unit.

6. The camera unit according to claim 5, The width of the discharge channel in the direction perpendicular to the gas flow direction is smaller than the width of the internal channel in the direction perpendicular to the gas flow direction. Camera unit.

7. A camera unit according to claim 5 or 6, The heat-generating component includes a controller module that controls the camera module. Camera unit.

8. The camera unit according to claim 7, The camera module is a thermal camera module that has a temperature sensor and detects the temperature of a subject to generate thermographic data. Camera unit.

9. A camera unit according to claim 8, The controller module generates and transmits temperature data in CSV format, in which the temperatures detected by the camera module are arranged in a two-dimensional matrix representing the location of the detection point. Camera unit.

10. The camera unit according to claim 9, The exterior part further comprises an antenna module, The controller module wirelessly transmits the thermographic data or temperature data via the antenna module. Camera unit.

11. The camera unit according to claim 10, The controller module wirelessly transmits the image data generated by the imaging module, along with the temperature data, via the antenna module. Camera unit.

12. A camera unit according to any one of claims 1 to 11, An internal temperature sensor that detects the temperature of the space. A camera unit further equipped with these features.

13. A camera module which is a thermal camera module having a lens and a temperature sensor, and which detects the temperature of a subject and generates thermographic data, Control the camera module, The camera module transmits the thermographic data it generates. The camera module generates and transmits temperature data in CSV format, in which the temperature values ​​detected by the camera module are arranged in a two-dimensional matrix representing the location of the detection point. Controller module and A camera unit having, Upon receiving the aforementioned thermographic data, the system displays a thermographic image based on the aforementioned thermographic data, or Upon receiving the temperature data in CSV format, a thermographic image is generated and displayed, in which color elements representing temperature are arranged in a two-dimensional matrix representing the position of the detection point, based on the temperature data in CSV format. A terminal device having a display control unit, A monitoring system equipped with the following features.

14. The monitoring system according to claim 13, The terminal device further includes a monitoring unit that monitors the temperature of a specific detection point included in the CSV-formatted temperature data. Monitoring system.

15. A monitoring system according to claim 14, The monitoring unit determines whether the temperature at the specific detection point has reached a threshold. Monitoring system.

16. A monitoring system according to claim 14 or 15, The monitoring unit sets the emissivity of the subject. Monitoring system.

17. A monitoring system according to any one of claims 13 to 16, The aforementioned camera unit is A case comprising: an exterior section; a space section partitioned within the exterior section for housing the camera module; a lens hole provided in the exterior section that communicates with the space section and exposes the lens facing the surface of the lens; a discharge channel located between the lens hole and the surface of the lens and communicating with the space section and the lens hole; and a gas introduction channel for introducing gas into the space section to create positive pressure in the space section, thereby purging the gas through the discharge channel, passing through the surface of the lens, and out of the lens hole. It further comprises and is housed in the space. Monitoring system.

18. A monitoring system according to claim 17, The camera unit further comprises an imaging module having an imaging module lens and an image sensor that captures a subject and generates image data. The controller module transmits the image data generated by the imaging module together with the CSV-formatted temperature data or thermographic data. The display control unit of the terminal device superimposes the received image data onto the thermographic image and displays it so that the image data coincides positionally with the two-dimensional matrix. Monitoring system.

19. A monitoring system according to claim 18, The imaging module is housed in the space, The exterior portion further has another lens hole that exposes the imaging module lens, The discharge channel is further located between the other lens hole and the surface of the imaging module lens, and communicates with the space and the other lens hole. The gas that has flowed through the internal channel, which is the gas path from the gas introduction channel to the discharge channel, passes through the surface of the lens of the camera module and the imaging module lens, and is ejected from the lens hole and the other lens hole. Monitoring system.

20. A monitoring system according to any one of claims 17 to 19, The camera unit further includes an antenna module provided on the exterior, The camera unit and the terminal device are connected to communicate via an access point. Monitoring system.

21. A monitoring system according to claim 20, A setup terminal that obtains the SSID, password, and IP address of the access point, and sets the SSID, password, and IP address of the access point on the camera unit located within a predetermined distance range via the network, thereby establishing a network communication connection between the camera unit and the access point. A monitoring system further equipped with these features.

Images