Ultrasonic sensor device

Abstract

This ultrasonic sensor device detects a position change of a sensor holder according to a sensing signal of a gyro sensor in the sensor holder to which the gyro sensor is coupled, and thus can sound a position change alarm if the position change exceeds a normal range. According to the present invention, a sensor coupled to the sensor holder is used to detect a movement change of the sensor holder, and thus the position of a sensor holder can be corrected, and various sensing signals of the sensor can be used as a failure prediction signal of equipment.

Description

ultrasonic sensor device

[0001] The present invention relates to an ultrasonic sensor device, and more particularly, to an ultrasonic sensor device that detects a change in the position of a sensor holder combined with a gyro sensor based on a sensing signal of a gyro sensor and generates a position change alarm when the change exceeds a normal range.

[0002] In general, in industrial settings, equipment that must operate stably and continuously is being researched and developed to predict equipment failures in advance to prevent sudden failures that can cause fatal damage to the equipment line itself and to prevent production losses caused by unexpected equipment line shutdowns.

[0003] The currently used failure prediction method senses abnormal condition information of equipment using various sensors installed on a sensor stand and analyzes the sensing signals to predict equipment failure.

[0004] A sensor holder that combines sensors is fixed to a specific location and points toward a target point of a specific facility. However, if the sensor holder is misplaced or moves due to various reasons over time, the target point may change, which may act as a factor that interferes with the sensor's detection, causing problems in accurately predicting failures.

[0005] The purpose of the present invention is to provide an ultrasonic sensor device that detects a change in the position of a sensor holder combined with a gyro sensor according to a sensing signal of a gyro sensor and generates a position change alarm when the change exceeds a normal range.

[0006] The purpose of the present invention is to provide an ultrasonic sensor device that predicts equipment failure by analyzing sound wave signals generated from equipment and distance information between the sensor holder and the equipment using a sensor provided on a sensor holder.

[0007] An ultrasonic sensor device according to a feature of the present invention for achieving the above object includes a mounting portion, a sensor mounting portion coupled to one surface of the mounting portion and positioned adjacent to and facing the equipment, a sensor portion coupled to the sensor mounting portion and generating a signal for detecting a change in the position of the sensor mounting portion or sensing an acoustic signal generated from the equipment, and a control portion for transmitting one or more sensing signals received from the sensor portion or analyzing the sensing signals to determine a prediction of a failure of the equipment.

[0008] An ultrasonic sensor device according to a feature of the present invention comprises a distance sensor unit having a mounting unit, a sensor mounting unit coupled to one surface of the mounting unit and positioned adjacent to and facing an equipment, a gyro sensor coupled to the sensor mounting unit and outputting rotational angular velocity data in response to movement of the sensor mounting unit, a microphone coupled to the sensor mounting unit and collecting sound wave signals generated when the equipment operates, a transmitter unit transmitting a transmission signal to a target point of the equipment, and a receiver unit receiving a reflection signal in which the transmission signal is reflected from the target point.

[0009] By the above-described configuration, the present invention has the effect of detecting a change in the movement of the sensor holder using a sensor coupled to the sensor holder and correcting the position of the sensor holder, and using various sensing signals of the sensor as a signal for predicting equipment failure.

[0010] Figure 1 is a perspective view showing the configuration of a facility failure prediction system according to an embodiment of the present invention.

[0011] Figure 2 is a drawing showing the configuration of a sensor unit according to an embodiment of the present invention.

[0012] FIG. 3 is a drawing showing the configuration of an ultrasonic sensor device according to an embodiment of the present invention.

[0013] FIG. 4 is a drawing showing the position of a moving target point of a sensor holder according to an embodiment of the present invention.

[0014] FIG. 5 is a drawing showing the movement of a target point of a facility according to an embodiment of the present invention.

[0015] FIG. 6 is a drawing showing a process step of a facility recognized based on distance information according to an embodiment of the present invention.

[0016] Hereinafter, embodiments disclosed in this specification will be described in detail with reference to the attached drawings. Regardless of the drawing reference numerals, identical or similar components will be assigned the same reference numerals, and redundant descriptions thereof will be omitted. Furthermore, when describing embodiments disclosed in this specification, if a detailed description of a related known technology is judged to obscure the gist of the embodiments disclosed in this specification, the detailed description thereof will be omitted.

[0017] Terms that include ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by these terms. These terms are used solely to distinguish one component from another.

[0018] Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0019] In this application, each step described may be performed regardless of the listed order, except in cases where a special causal relationship requires that the steps be performed in the listed order.

[0020] In this application, terms such as “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but should be understood not to exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0021] If a defect or damage occurs in equipment at a manufacturing site, it can cause equipment downtime, and the resulting economic damage is enormous. Therefore, taking action before a breakdown occurs is recognized as very important for cost reduction.

[0022] Equipment failure prediction is a technology that can improve equipment stability by diagnosing the equipment's status in real time, detecting abnormalities early, and predicting future failures in advance so that appropriate measures can be taken.

[0023] Hereinafter, the present invention will be described with reference to the attached drawings.

[0024] FIG. 1 is a drawing showing the configuration of an equipment failure prediction system according to an embodiment of the present invention, FIG. 2 is a drawing showing the configuration of a sensor unit according to an embodiment of the present invention, and FIG. 3 is a drawing showing the configuration of an ultrasonic sensor device according to an embodiment of the present invention.

[0025] An equipment failure prediction system according to an embodiment of the present invention may include a sensor holder (10), an ultrasonic sensor device (100), and a server (150).

[0026] The sensor holder (10) is attached to one side of a mounting portion (11), such as a wall, and can be positioned adjacent to and facing the equipment (30). Here, the equipment (30) refers to process equipment that is operated in a manufacturing or production process, and examples thereof include press equipment, transport equipment, extrusion equipment, etc. that are applied to a compression process, a transport process, a discharge process, etc.

[0027] The sensor holder (10) can be configured by attaching a holder body of a certain shape in a horizontal direction to one side of a holder portion (11), attaching a strong magnetic member (20) to one side of the holder body using an adhesive, and attaching a sensor portion (110) to one side of the magnet member (20).

[0028] The sensor stand (10) may further include a sensor unit (110) having a plurality of sensors that are physically located apart from each equipment (30) and collect sensing data necessary for predicting failure of the equipment (30).

[0029] The sensor holder (10) and sensor unit (110) are aimed at the target point of the equipment (30) at a certain angle.

[0030] The ultrasonic sensor device (100) may include a sensor unit (110) coupled to one side of the stand body, and a laser generation unit (113), an amplifier unit (117), a distance calculation unit (118), an image processing unit (141), a control unit (120), and a communication unit (130) formed inside the sensor stand (10).

[0031] The sensor unit (110) includes a microphone (111), a laser pointer (112), a gyro sensor (119), and a distance sensor unit (130).

[0032] The sensor unit (110) can detect a change in the position of the sensor holder (10) using a gyro sensor (119) or generate a signal for sensing a sound wave signal generated from the equipment (30) using a microphone (111).

[0033] The control unit (120) can transmit one or more sensing signals received from the sensor unit (110) to the server (150) via the communication unit (130), or analyze the sensing signals to determine a failure prediction of the equipment (30).

[0034] The microphone (111) collects sound wave signals generated when the equipment (30) operates.

[0035] The signal processing unit (121) converts the sound wave signal, which is an analog signal received from the microphone (111), into a digital signal and transmits it to the control unit (120).

[0036] The control unit (120) samples the sound wave signal collected from the microphone (111), removes noise using various noise removal algorithms, and determines whether the noise-removed sampling data is a normal signal or an abnormal signal, so that it can be used as a signal for predictive maintenance of failure.

[0037] The laser pointer (112) illuminates the target point of the equipment (30) to be measured with a visible laser.

[0038] The laser pointer (112) has a laser generating unit (113) that generates a laser and irradiates it to a target point of the equipment (30), and the laser can visually display the target of the transmission signal irradiation of the distance sensor unit (114).

[0039] The distance sensor unit (114) includes a transmitter unit (115) and a receiver unit (116).

[0040] The distance sensor unit (114) aims at the target point of the equipment (30) using a laser pointer (112).

[0041] The transmitter (115) generates a transmission signal for distance measurement and transmits it to the target point of the equipment (30). Here, the transmission signal for distance measurement may be a laser or ultrasonic signal.

[0042] The receiver (116) receives a reflected signal from the target point of the equipment (30).

[0043] The amplifier (117) can amplify the reflected signal received from the receiver (116) to a certain size.

[0044] The distance calculation unit (118) calculates the time difference between the transmission time of the transmission signal transmitted from the transmission unit (115) and the reception time of the reflection signal received from the reception unit (116), and calculates distance information between the sensor unit (110) and the target point based on the calculated time difference.

[0045] If the distance information calculated by the distance calculation unit (118) is outside the error range of the preset reference distance information, the control unit (120) calculates a distance correction value indicating the difference between the calculated distance information and the reference distance information.

[0046] The control unit (120) can transmit the calculated distance correction value to the server (150) via the communication unit (130).

[0047] When the control unit (120) receives distance information calculated by the distance calculation unit (118), it automatically transmits the received distance information to the server (150) via the communication unit (130), and when the calculated distance information is outside the error range of the preset reference distance information, it calculates a distance correction value indicating the difference between the calculated distance information and the reference distance information and transmits the calculated distance information to the server (150) via the communication unit (130).

[0048] In other words, when the ultrasonic sensor device (100) is installed on the sensor holder (10), it can automatically calculate the distance between the sensor holder (10) and the target point of the equipment (30) and transmit it to the server (150).

[0049] When the transmission signal is an ultrasonic signal, the present invention sets the signal detection band in which the microphone (111) collects the acoustic signal and the signal detection band in which the distance sensor unit (114) transmits and receives the transmission signal differently.

[0050] The movement of the target point position of this sensor holder (10) is described in detail in FIGS. 4 and 5.

[0051] FIG. 4 is a drawing showing the movement of the target point of a sensor holder according to an embodiment of the present invention, and FIG. 5 is a drawing showing the movement of the target point of a device according to an embodiment of the present invention.

[0052] As illustrated in FIGS. 4 and 5, the sensor holder (10) may warp or move over time due to various environmental factors. If the sensor holder (10) moves, the initial laser irradiation target of the laser pointer (112) may move, and problems may also occur in the sensing of the distance sensor unit (114).

[0053] To solve this problem, the gyro sensor (119) detects the angular velocity of the movement of the sensor holder (10) about the yaw axis and the pitch axis, i.e., the rotational angular velocity, and outputs the corresponding rotational angular velocity data.

[0054] The gyro sensor (119) outputs rotational angular velocity data in response to the movement of the sensor holder (10).

[0055] If the rotational velocity data received from the gyro sensor (119) is outside the error range of the preset reference angular velocity data, the control unit (120) can generate position change alarm information including position correction information of the sensor holder (10) and transmit the information to the server (150).

[0056] The camera unit (140) is tilted at a certain angle as a CCTV camera to aim the camera focus direction toward the target point of the equipment (30) to capture the target point of the equipment (30), and can capture the target point of the equipment (30).

[0057] The image processing unit (141) has an input terminal connected to the camera unit (140) and an output terminal connected to the control unit (120).

[0058] The image processing unit (141) receives image information including the target point of the equipment (30) photographed from the camera unit (140) and processes the image data generated by converting an analog signal into a digital signal.

[0059] The control unit (120) may also transmit image information including the target point of the equipment (30) received from the image processing unit (141) to the server (150) via the communication unit (130).

[0060] The control unit (120) periodically stores image frames of an object area including a target point of the equipment (30), extracts a feature map of the image frame using YOLOv8 (an object recognition algorithm) from the stored image frames, and extracts at least one area in which the presence of a target point object is estimated from the image based on the extracted feature map.

[0061] The control unit (120) extracts a feature map from the input image information using one of the following neural networks: deep neural networks (DNN), convolutional deep neural networks (CNN), recurrent neural networks (RNN), and deep belief networks (DBN).

[0062] The control unit (120) can generate a feature map using a model that has already been trained by the learning unit based on deep learning. Deep learning is defined as a set of machine learning algorithms that attempt a high level of abstraction (summarizing key content or functions in a large amount of data or complex data) through a combination of various nonlinear transformation methods.

[0063] The control unit (120) extracts an area where a target point is estimated to exist in the image frame, and extracts a feature map representing features from the extracted area.

[0064] The control unit (120) extracts at least one region in which the presence of a target point object is estimated from the image based on the extracted feature map. Methods for extracting the region may include, for example, faster RCNN, SSD (Single Shot Multibox Detector), YOLO (You Only Look Once), etc., and the present invention uses the YOLO object recognition module (YOLOv8) as an example.

[0065] The control unit (120) can select a feature map that includes coordinates of each class of an image region from among the feature maps, identify coordinates that distinguish the region from the selected feature map, and then extract the identified coordinates as a region where the existence of an object is estimated.

[0066] The control unit (120) can display each of at least one extracted area as a bounding box surrounding the outermost portion of the corresponding target point object.

[0067] Each bounding box indicates the possibility of a target point object existing at the location of that bounding box in the image.

[0068] The YOLOv8 model uses a single-network architecture to predict class probabilities and corresponding bounding boxes for the entire input image. The bounding boxes can include coordinate information for target point objects.

[0069] The control unit (120) performs an object tracking algorithm that extracts and compares coordinates of each target point object for each piece of received image information, and when the distance between the coordinates of the target point objects exceeds a preset threshold, it can generate position change alarm information including position correction information of the sensor holder (10) and transmit it to the server (150).

[0070]

[0071] Hereinafter, one embodiment of the present invention will be described with reference to FIG. 6.

[0072] FIG. 6 is a drawing showing a process step of a facility recognized based on distance information according to an embodiment of the present invention.

[0073] The control unit (120) can set the distance information between the sensor unit (110) and the target point differently depending on the process step (e.g., compression process, discharge process, etc.) that the equipment (30) operates.

[0074] The distance information between the sensor unit (110) and the target point may vary at each process step.

[0075] For example, when the equipment (30) is in a compression process, it is assumed that the distance between the sensor unit (110) and the target point is 2.81 m, or when the equipment (30) is in a compression process, it is assumed that the distance between the sensor unit (110) and the target point is 2.84 m, and so on. The minute distance of the equipment (30) may vary depending on the process.

[0076] Accordingly, the control unit (120) can set and store distance information between the sensor unit (110) and the target point corresponding to the process step (step A, step B, step C, step D) driven by the equipment (30).

[0077] When the control unit (120) receives distance information from the distance calculation unit (118), it can determine the process step corresponding to the input distance information.

[0078] In the present invention, the distance calculation unit (118), the image processing unit (141), and the control unit (120) can be configured in the server (150) rather than in the sensor holder (10).

[0079] In other words, the control unit (120) can transmit the sensing signal received from the sensor unit (110) as raw data to the server (150) or client terminal (not shown) through the communication unit (130).

[0080] Here, the sensing signal may include rotational angular velocity data output from the gyro sensor (119), sound wave signals collected from the microphone (111), and distance information between the sensor unit (110) and the target point calculated from the distance sensor unit (114).

[0081] A server (150) or a client terminal (not shown) can calculate a change in the position of the sensor holder (10) based on rotational angular velocity data, determine whether a signal is normal or abnormal in each process based on a sound wave signal, determine a change in the position of the sensor holder (10) based on distance information between the sensor unit (110) and the target point, or determine a process step based on distance information between the sensor unit (110) and the target point.

[0082] In addition, in the case where the position of the sensor holder (10), the position of the target point, or the distance information between the sensor unit (110) and the target point exceeds a preset normal range, the server (150) or the client terminal (not shown) can generate an alarm signal and transmit it to the user terminal.

[0083] The control unit (120) can determine whether the equipment (30) is in a failure state by performing a failure prediction maintenance when the sound signal collected from the microphone (111) that differs for each process step and the distance information between the sensor unit (110) and the target point set for each process step exceeds a preset normal range.

[0084] Hereinafter, embodiments of the ultrasonic sensor device of the present invention have been described. The technical features disclosed in each embodiment of the present invention are not limited to that embodiment, and, unless mutually incompatible, the technical features disclosed in each embodiment may be combined and applied to other embodiments.

[0085] Therefore, although each embodiment focuses on its own technical features, each technical feature can be applied in combination with each other as long as they are not mutually incompatible.

[0086] The present invention is not limited to the above-described embodiments and the attached drawings, and various modifications and variations are possible within the scope of those skilled in the art. Therefore, the scope of the present invention should be defined not only by the claims of this specification but also by equivalents thereof.

Claims

1. In an ultrasonic sensor device, Supporting part; A sensor holder coupled to one side of the above-mentioned holder and positioned opposite to the equipment; A sensor unit that is coupled to the sensor holder and generates a signal that detects a change in the position of the sensor holder or senses a sound wave signal generated from the equipment; and A control unit that transmits one or more sensing signals received from the sensor unit or analyzes the sensing signals to determine a failure prediction of the equipment. An ultrasonic sensor device comprising:

2. In paragraph 1, The above sensor part, It further includes a gyro sensor that outputs rotational velocity data in response to the movement of the above sensor holder, The control unit generates and transmits position change alarm information including position correction information of the sensor holder when the rotational velocity data received from the gyro sensor is outside the error range of the preset reference angular velocity data. Ultrasonic sensor device.

3. In paragraph 1, The above sensor part, The above equipment further includes a microphone for collecting sound signals generated when the equipment operates, and the control unit samples the sound signals collected from the microphone to remove noise, and determines whether the noise-removed sampling data is a normal signal or an abnormal signal and uses it as a signal for predictive maintenance of failure. Ultrasonic sensor device.

4. In paragraph 1, The above sensor part, It further includes a distance sensor unit having a transmitter that generates a transmission signal for distance measurement and transmits it to a target point of the equipment, and a receiver that receives a reflection signal from the transmission signal reflected from the target point. It further includes a distance calculation unit that calculates the time difference between the transmission time of the transmission signal transmitted from the above-mentioned transmission unit and the reception time of the reflection signal received from the above-mentioned reception unit, and calculates distance information between the sensor unit and the target point based on the calculated time difference. Ultrasonic sensor device.

5. In paragraph 4, The control unit calculates a distance correction value indicating the difference between the calculated distance information and the reference distance information when the distance information calculated by the distance calculation unit is outside the error range of the preset reference distance information. Ultrasonic sensor device.

6. In paragraph 4, The above sensor part, It further includes a laser pointer having a laser generating unit that generates a laser and irradiates it to a target point of the equipment, and the laser visually displays the target of the irradiation signal transmitted from the distance sensor unit. Ultrasonic sensor device.

7. In paragraph 1, The above sensor holder is configured by attaching a holder body having a predetermined shape in a horizontal direction to one side of the holder, attaching a magnetic member to one side of the holder body using an adhesive, and attaching the sensor unit to one side of the magnetic member. The above sensor unit is aimed toward the target point of the equipment. Ultrasonic sensor device.

8. In paragraph 6, It further includes a camera unit that sets the target point of the equipment in the direction of the camera focus by tilting it at a certain angle and takes a picture of the target point of the equipment. The control unit extracts the area and coordinates in which each target point object exists for each image information received from the camera unit using an object recognition algorithm, calculates the distance value between the coordinates of each target point object, and, when the calculated distance value exceeds a preset threshold distance value, generates position change alarm information including position correction information of the sensor holder. Ultrasonic sensor device.

9. In paragraph 4, When the control unit receives the distance information calculated by the distance calculation unit, it transmits it to an external server, and when the calculated distance information is outside the error range of the preset reference distance information, it calculates a distance correction value representing the difference between the calculated distance information and the reference distance information and transmits it to the server. Ultrasonic sensor device.

10. In paragraph 4, The control unit sets the distance information between the sensor unit and the target point differently according to the process step driven by the equipment, and when the distance information is input from the distance calculation unit, determines the process step corresponding to the input distance information. Ultrasonic sensor device.

11. In the ultrasonic sensor device, Supporting part; A sensor holder coupled to one side of the above-mentioned holder and positioned opposite to the equipment; A gyro sensor coupled to the sensor holder and outputting rotational velocity data in response to movement of the sensor holder; A microphone coupled to the sensor holder and collecting sound wave signals generated when the equipment operates; and A distance sensor unit having a transmitter that transmits a distance measurement signal to a target point of the equipment, and a receiver that receives a reflection signal from the target point of the transmission signal. An ultrasonic sensor device comprising:

12. In paragraph 11, It further includes a laser pointer having a laser generating unit that generates a laser and irradiates it to a target point of the above equipment, The above laser visually displays the target of the signal transmitted by the distance sensor unit. Ultrasonic sensor device.

13. In paragraph 11, A distance calculation unit that calculates the time difference between the transmission time of the transmission signal transmitted from the above-mentioned transmitter and the reception time of the reflection signal received from the above-mentioned receiver, and calculates distance information between the sensor holder and the target point based on the calculated time difference; and When receiving distance information calculated by the distance calculation unit, it transmits it to an external server, and when the calculated distance information is outside the error range of the preset reference distance information, it further includes a control unit that calculates a distance correction value representing the difference between the calculated distance information and the reference distance information and transmits it to the server. Ultrasonic sensor device.

14. In paragraph 13, The above control unit samples the sound wave signal collected from the microphone to remove noise, and determines whether the noise-removed sampling data is a normal signal or an abnormal signal and uses it as a signal for failure prediction and maintenance. When receiving distance information calculated by the above distance calculation unit, it is transmitted to an external server, and when the calculated distance information is outside the error range of the preset reference distance information, a distance correction value representing the difference between the calculated distance information and the reference distance information is calculated and transmitted to the server. Ultrasonic sensor device.

15. In paragraph 11, It further includes a control unit that transmits distance information between the sensor holder and the target point calculated by the distance sensor unit, sound wave signals collected by the microphone, and rotational velocity data indicating the movement of the sensor holder output from the gyro sensor as raw data to an external server. Ultrasonic sensor device.

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