Anomaly monitoring device and method

Abstract

To grasp a cause of an abnormality with a simple configuration without making any change to an existing facility.SOLUTION: An abnormality monitoring device is additionally installed using a signal lamp provided in a facility of an existing manufacturing line, and comprises: a color sensor 63 that receives light from a signal lamp 70 and outputs a signal representing an intensity of each color component of the received light; a camera 60 that images a manufacturing facility, forms an image file at a predetermined time interval from dynamic image data which includes the manufacturing facility obtained by imaging in a subject, and temporarily records the formed image file in a memory; a recording device 62 that stores the image file; and a controller 61 that controls the camera 60 and the recording device 62 so as to record an image file containing dynamic image data on the recording device 62 when a lighting color representing an abnormality is detected among the image files temporarily recorded in the memory of the camera 60 in response to the detection of the lighting color indicating the abnormality in the manufacturing facility according to the signal output by the color sensor 63.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] This invention relates to an abnormality monitoring device and method.

Background Art

[0002] A food or beverage production line includes a plurality of processes such as formulation, extraction, liquid treatment, material supply, container molding, filling, labeling, inspection, casing, palletizer, etc. Dedicated equipment (production equipment) is provided for each process, and a conveying device or the like connecting between the processes is also provided. Generally, a plurality of workers are arranged on the production line, but in recent years, with the decrease in the labor population, it has become necessary to reduce the number of workers arranged on the production line.

[0003] Generally, a signal lamp indicating the operating status of the equipment is installed on each of the plurality of pieces of equipment installed on the production line, and the operating status of each piece of equipment is shown to the worker by the signal lamp. When an abnormality occurs in the equipment, the lighting color of the signal lamp changes based on an alarm signal from the control device that controls the equipment. In addition to or instead of this, a warning buzzer sounds, and thus the worker can know the equipment abnormality. However, if the number of workers arranged on the production line is small, the worker will reach the equipment after the equipment abnormality occurs, and the cause of the abnormality occurrence will be difficult to understand.

[0004] Patent Document 1 discloses a monitoring system that transmits signal data such as a failure of a production device to a management server by a wireless communication unit and transmits an email including information on the abnormality content and treatment method to a worker terminal carried by a worker. Although the time until the recovery of the production device in which an abnormality such as a failure occurs can be shortened, the cause of the abnormality occurrence is still difficult to understand. Also, for example, in order to cause a wireless communication unit to acquire signal data such as a failure, it is necessary to connect the existing equipment and the wireless communication unit by wire, and wiring and connection for that are required, so the system introduction is troublesome.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Japanese Patent Publication No. 2014-164598 [Overview of the project] [Problems that the invention aims to solve]

[0006] The purpose of this invention is to enable the identification of the cause of abnormalities simply by adding a simple configuration without modifying the existing equipment itself.

[0007] The abnormality monitoring device according to this invention includes a color sensor that receives light from a signal light that selectively illuminates multiple different colored lights and outputs a signal representing the intensity of each color component of the received light; an imaging device that images manufacturing equipment installed on a production line, creates an image file at predetermined intervals from moving image data including the manufacturing equipment acquired by imaging, and temporarily records the created image file in memory; an image file storage device that stores the image file; and a control device that controls the imaging device and the image file storage device in response to the detection of an illuminated color indicating an abnormality of the manufacturing equipment according to the signal output by the color sensor, so as to record an image file containing the moving image data at the time of detection of the illuminated color indicating the abnormality from the image file temporarily recorded in the memory of the imaging device to the image file storage device.

[0008] This invention also provides an anomaly monitoring method. The anomaly monitoring method according to this invention is characterized by receiving light from a signal lamp that selectively illuminates multiple different colored lights using a color sensor, outputting a signal representing the intensity of each color component of the received light, imaging the manufacturing equipment installed on the production line using an imaging device, creating an image file at predetermined intervals from the motion image data acquired by imaging that includes the manufacturing equipment as the subject, temporarily recording the created image file in memory, and, in response to the detection of an illumination color indicating an anomaly in the manufacturing equipment according to the signal output by the color sensor, recording an image file containing the motion image data at the time of detection of the illumination color indicating the anomaly from the image file temporarily recorded in the memory of the imaging device to an image file storage device.

[0009] The signal lights illuminate in several different colors, such as green, yellow, and red. For example, a green light illuminates when the manufacturing equipment is operating normally, and a red light illuminates when a malfunction occurs in the manufacturing equipment. A yellow light illuminates in other situations (for example, when the equipment is in standby mode due to another piece of equipment located upstream or downstream of the manufacturing process). The selective illumination of one of several different colors visually indicates the operating status of the manufacturing equipment to the workers.

[0010] Light from a signal light is received by a color sensor. The color sensor can identify the color of the received light and output a signal corresponding to the color component. For example, a photodiode equipped with a color filter can be used as a color sensor.

[0011] According to this invention, when a color sensor detects a color indicating an abnormality in manufacturing equipment, such as red light, an image file containing the video data at the time of detection of the abnormal color is recorded (saved) in the image file storage device from among the image files temporarily recorded in the memory of the imaging device. The manufacturing equipment at the time the abnormality occurred can be confirmed by playing back the image file recorded in the image file storage device.

[0012] The anomaly monitoring device according to this invention consists of a color sensor, an imaging device, an image file storage device, and a control device, and can be realized by installing a color sensor that can receive light from signal lights on existing manufacturing equipment. No modifications are required to the existing equipment itself, and an anomaly monitoring function can be added flexibly and easily.

[0013] In one embodiment, the imaging device temporarily records the latest image file in the memory by overwriting the image file temporarily stored in the memory. This is because there is little or no need to save image files if the manufacturing equipment is operating normally. By allowing so-called overwriting, but saving an image file containing dynamic image data before and after an abnormality occurs, the imaging device can be adequately monitored even if its memory has limited storage capacity.

[0014] In other embodiments, the control device controls the imaging device to stop driving in response to the recording of an image file containing dynamic image data at the time of detection of the illumination color indicating the abnormality to the image file storage device. This prevents image files from being saved one after another while an abnormality is occurring in the manufacturing equipment.

[0015] Preferably, the control device controls the imaging device to restart its operation in response to the detection of a light color indicating normal operation of the manufacturing equipment, according to the signal output by the color sensor. Monitoring of the manufacturing equipment can be resumed in accordance with the restart of the manufacturing equipment (for example, the red light being turned off and the green light being turned on). [Brief explanation of the drawing]

[0016] [Figure 1] This is a schematic plan view of a bottled beverage manufacturing line. [Figure 2] This block diagram shows a perspective view of a signal light and the electrical configuration of an abnormality monitoring device. [Figure 3] This is a flowchart showing the operation of the anomaly monitoring device. [Examples]

[0017] Figure 1 shows a schematic diagram of a bottled beverage manufacturing line.

[0018] The bottle beverage production line automatically executes a series of processes including forming a bottle from a preform, filling the formed bottle with a beverage, and closing the cap.

[0019] A large number of preforms P are prepared at the preform supply station 1. The preforms P are supplied from the preform supply station 1 to the heating station 2 along the conveyance path. The heating station 2 includes a plurality of heaters 25, and the preforms P are heated to a blow-molding temperature by the heaters 25.

[0020] The heated preform P proceeds to the forming station 3. The forming station 3 includes a rotating wheel 10 and a plurality of forming molds 8 arranged around the wheel 10. The forming molds 8 revolve around the wheel 10 at a constant speed as the wheel 10 rotates.

[0021] A stretching rod is inserted into the mouth of the preform P set in the forming mold 8, and the preform P is stretched axially. Further, air is blown in, and the preform P is stretched radially. The bottle B is formed from the preform P.

[0022] The formed bottle B is transferred from the forming station 3 to the sterilization station 4.

[0023] The sterilization station 4 includes a sterilizing agent spray nozzle 27 and an air rinse nozzle 28. A sterilizing agent, for example, hydrogen peroxide solution, is sprayed from the sterilizing agent spray nozzle 27 and sprayed onto the mouth of the bottle B. Sterile air is ejected from the air rinse nozzle 28, and the hydrogen peroxide solution remaining on the inner and outer surfaces of the bottle B is decomposed and removed thereby.

[0024] The bottle B that has been sterilized proceeds to the content filling station 5.

[0025] The content filling station 5 includes a number of filling nozzles 32 that rotate together with the wheel 9, and beverages are filled into the bottle B from each of the filling nozzles 32.

[0026] Bottle B, filled with beverage, proceeds to container sealing station 6.

[0027] The container sealing station 6 is supplied with bottles B filled with beverages and caps C that have been sterilized at the cap sterilization station 7. At the container sealing station 6, the sterilized caps C are attached to the mouths of bottles B, thus completing the bottling of the beverages.

[0028] Multiple cameras 60 are installed in the bottled beverage manufacturing line. These multiple cameras 60 monitor the operating status of the bottled beverage manufacturing line, and each of the various manufacturing equipment included in the line (conveying equipment, drive equipment, sterilization equipment, filling equipment, etc.) is imaged by each of the multiple cameras 60.

[0029] Figure 2 shows a block diagram of the abnormality monitoring device (image recording system) including the signal light 70 installed in the control panel and the camera 60 mentioned above.

[0030] Each piece of manufacturing equipment included in the production line is equipped with a control panel 75, and a signal light 70 is installed on the top surface of the control panel 75. The signal light 70 includes three different colored indicators 70A, 70B, and 70C, which light up in red, yellow, and green, respectively. For example, red indicates equipment malfunction, yellow indicates standby, and green indicates normal operation (automatic operation). When the control panel 75 detects an abnormality in the manufacturing equipment (for example, an abnormal stop of a conveying device), the green indicator 70C of the signal light 70 turns off and the red indicator 70A lights up.

[0031] The abnormality monitoring device includes the aforementioned camera 60, a controller 61 that controls the operation of the camera 60 and the creation and recording of video files containing moving image data acquired by the camera 60, a recording device 62 that stores the video files, and a color sensor 63.

[0032] The color sensor 63 is equipped with a photodiode and detects the intensity of the color components of the received light. Typically, a photodiode equipped with a color filter is used, and the color sensor 63 outputs a signal representing the intensity (amount of light received) of each of the R (red), G (green), and B (blue) color components of the received light. The output signal from the color sensor 63 is provided to the controller 61, which then detects the color of the signal light 70.

[0033] A camera 60 and a color sensor 63 are provided for each signal light 70, and typically for each piece of manufacturing equipment on a production line. A controller 61 and a recording device 62 may be provided for each camera 60, or a single unit may be provided for use with multiple cameras 60.

[0034] Figure 3 is a flowchart showing the operation flow of the abnormality monitoring device.

[0035] The camera 60 installed in the abnormality monitoring device captures images of the manufacturing equipment installed on the production line. A video file is created at predetermined intervals, for example every 3 minutes, and is temporarily recorded in the memory (not shown) of the camera 60 (step 81).

[0036] If video files created at predetermined intervals are continuously recorded in the camera 60's memory, the memory capacity will be exceeded. Therefore, if no abnormality in the manufacturing equipment is detected by the control panel, newly created video files are temporarily recorded in the memory by overwriting the video files already recorded in the memory (NO in step 82, step 83, step 81). The memory only needs to have enough capacity to record at least one most recent video file. Of course, if there is enough capacity to record two or more video files, two or more video files may be recorded in the memory and overwritten sequentially starting with the oldest video file. In this case, in addition to the most recent video file, the video file created immediately before it is also temporarily recorded in the memory.

[0037] When the control panel detects an abnormality in the equipment, the color of the signal lights 70 described above changes. For example, the green light of the lighter 70C turns off, and the red light of the lighter 70A turns on. The abnormality in the manufacturing equipment, indicated by the change in the color of the signal lights 70, is detected by the color sensor 63 attached to the signal lights 70 (YES in step 82).

[0038] The time at which the anomaly is detected (for example, date and time data based on the machine time of camera 60 or controller 61) is recorded in a video file created (step 84), and the video file containing the image data at the time of anomaly detection is transferred from the memory of camera 60 to the recording device 62 and saved (step 85). The video file saved in the recording device 62 includes video images not only at the time the anomaly was detected but also at the time before and after that.

[0039] If an abnormality is detected, the camera 60 may stop capturing images and creating video files immediately after the abnormality is detected, once it has finished creating and saving the video file that would normally be created at that moment. Only video files representing the moment when the state changed from normal to abnormal can be transferred to the recording device 62 and saved, preventing video files from being transferred to the recording device 62 while the abnormal state persists. In this case, the camera 60 can resume capturing images and creating video files when normal operation resumes, i.e., when the color sensor 63 detects that the red light on the light switch 70A has turned off and the green light switch 70C has turned on.

[0040] It goes without saying that the video files recorded in the recording device 62 can be played back and displayed on a monitor or the like. The manufacturing equipment at the time the abnormality occurred can be confirmed by the video displayed on the monitor or the like. [Explanation of symbols]

[0041] 1. Preform supply station 2 Heating Station 3. Molding Station 4 Sterilization Station 5. Contents filling station 6. Container sealing station 7 Cap sterilization station 60 Camera (imaging device) 61 Controllers 62 Recording device (image file storage device) 63 Color Sensor 70 Signal lights 70A,70B,70C Lighter 75 Control Panel

Claims

1. A color sensor that receives light from a signal light that selectively illuminates multiple different colored lights, and outputs a signal representing the intensity of each color component of the received light. An imaging device that images manufacturing equipment installed on a production line, creates an image file at predetermined intervals from the video data acquired by imaging that includes the manufacturing equipment as the subject, and temporarily records the created image file in memory. Image file storage device for storing image files, and The system includes a control device that controls the imaging device and the image file storage device so that, in response to the detection of a color indicating an abnormality in the manufacturing equipment according to the signal output by the color sensor, it records an image file containing the video data at the time of detection of the abnormality in the color from among the image files temporarily recorded in the memory of the imaging device to the image file storage device. The above control device is In response to the recording of an image file containing motion data at the time of detection of the above-mentioned abnormality in the illuminated color to the image file storage device, the imaging device is further controlled to stop its operation. Abnormality monitoring device.

2. The above-mentioned imaging device temporarily records the latest image file in the memory by overwriting the image file that is temporarily recorded in the memory. An abnormality monitoring device according to claim 1.

3. The above control device is In response to the detection of a lit color indicating the normal operation of the manufacturing equipment, according to the signal output by the above-mentioned color sensor, the imaging device is controlled to restart its operation. An abnormality monitoring device according to claim 1.

4. A color sensor receives light from a signal light that selectively illuminates multiple different colored lights, and outputs a signal representing the intensity of each color component of the received light. The imaging device captures images of the manufacturing equipment installed on the production line, creates image files at predetermined intervals from the video data acquired by the imaging that includes the manufacturing equipment as the subject, and temporarily records the created image files in memory. In response to the detection of a color indicating an abnormality in the manufacturing equipment according to the signal output by the above color sensor, an image file containing the video data at the time of detection of the abnormality-indicating color is recorded in the image file storage device from among the image files temporarily recorded in the memory of the above imaging device. In response to the recording of an image file containing motion data at the time of detection of the above abnormality in the illuminated color to the image file storage device, the operation of the imaging device is stopped. Anomaly monitoring method.

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