Real-time interactive monitoring process

Abstract

The invention relates to a method for a real-time monitoring and fault diagnostic process in a sorting and processing installation environment, having the method steps, which are carried out in particular in the following order: a) initializing a decentralized control and monitoring system; b) integrating a 3D graphics rendering engine using the three.js library in the decentralized control and monitoring system; c) rendering a dynamic and interactive 3D model of the industrial machine on a display of the decentralized control and monitoring system, said 3D model being updated on the basis of industrial machine operating data obtained by the industrial machine; d) detecting operating anomalies of the industrial machine on the basis of the obtained operating data; e) displaying and / or visualizing the detected operating anomalies directly on the corresponding component of the 3D model by means of visual indicators, and f) enabling a user interaction with the 3D model.

Description

[0001] INTERACTIVE REAL-TIME MONITORING

[0002] The present invention relates to the technical field of monitoring and fault analysis in sorting and processing plants, in particular in the area of ​​monitoring, control and data acquisition systems, by means of decentralized control and monitoring systems, such as Supervisory Control and Data Acquisition Systems (SCADA systems), preferably in real time.

[0003] The present invention preferably relates to sorting and processing plants, including industrial plants and / or machine plants. The invention is also applicable to individual machines involved in the sorting, processing, preparation, and fractionation of recyclable materials, recycling, and waste processing. Furthermore, the invention is also applicable in the field of conveyors and conveying systems, preferably in the area of ​​waste separation and / or baling systems for waste bales.

[0004] The term Supervisory Control and Data Acquisition (SCADA) describes the computer system or software used to monitor and control technical processes in industrial control systems. To enable the rapid and timely assessment of complex situations in industrial environments and the corresponding responses, SCADA systems offer 2D interfaces. However, depending on the complexity of the system, 2D representation requires a high degree of abstraction or division into individual sections, which can limit the operator's or user's capabilities and overview. There is a growing need for intuitive and interactive options for visualizing operating states and monitoring the condition of complex systems.

[0005] The technical objective of the invention is therefore to improve the state of the art and to propose alternatives.

[0006] The solution offers the possibility of generating three-dimensional and dynamic representations of machines and systems in real time, enabling fault visualization and detection, thereby optimizing operational efficiency and user-friendliness. A real-time visualization update refers to the immediate adaptation of graphical representations to newly arriving data. This allows for a continuous, up-to-date display without any noticeable delay for the user.

[0007] The technical problem is solved by an object with the technical features according to the independent claims. Advantageous embodiments are the subject of the dependent claims, the description, and the figures.

[0008] Automation architecture is divided into several levels, which can be illustrated by an automation pyramid. Level 1 is the process-oriented layer with sensors and actuators. Level 2 is responsible for control. Real-time monitoring and fault diagnostic systems are located on Level 3, the process control level, for monitoring and controlling the systems and processes.

[0009] The condition of the machine or system is determined using interfaces and the evaluation of operational data acquisition or machine data acquisition. This condition assessment can include the proper functioning of the machine, its current operating state (preferably in real time), or the occurrence of an anomaly, such as when values ​​exceed a certain threshold. In the latter case, an error may be generated and an alarm triggered, allowing users to react and, for example, resolve the problem through inspection, maintenance, repairs, and / or rescheduling.

[0010] The term real-time monitoring and fault diagnosis systems refers to decentralized systems that monitor, visualize, control and regulate the entire plant or plant sections.

[0011] Data acquisition begins at Level 1 and includes the connection to measuring devices and status information such as switch positions, which are recorded by the system. The data is then presented in a user-friendly interface, enabling intervention in the process.

[0012] In real-time monitoring and fault diagnosis systems, a distributed database containing data points is used. A data point contains an input or output value that is monitored and controlled by the system. A physical data point represents an input or output of, for example, a sensor or other physical measurement device on the system, while a calculated point is derived from the system's state through mathematical operations. Data points are treated as a combination of values ​​with a timestamp. A series of data points enables chronological analysis and historical data storage of the system's operational history.

[0013] For the purposes of the invention, the term three.js describes a cross-browser JavaScript library and application programming interface for creating and displaying animated 3D computer graphics in a web browser using the JavaScript programming interface Web Graphics Library (WebGL).

[0014] For the purposes of this invention, the term "graphics engine" refers to a part of a computer program or computer hardware, a so-called engine, responsible for displaying computer graphics. This involves 3D computer graphics that are as realistic as possible, such as objects, environments, and / or people, for example, also in connection with virtual reality. In the context of 3D computer graphics, the graphics engine is therefore also to be understood as a 3D engine. It is an integrated or externally located program code that is responsible for calculating the graphics interface in parallel with the actual program. In contrast, the term "rendering engine" is to be understood as one that only outputs the data present in the 3D environment to the display.

[0015] According to one aspect of the invention, the technical problem of the invention is solved by means of a method for real-time monitoring and fault diagnosis in a sorting and processing plant for waste and recyclable material mixtures. The method comprises the following process steps: a) Initialization of a decentralized control and monitoring system; a1) Connection of the decentralized control and monitoring system to an interface for providing operational data of the sorting and processing plant; b) Integration of a 3D graphics rendering engine using the three.js library in the decentralized control and monitoring system; c) rendering a dynamic and interactive 3D model of the sorting and processing plant on a display of the decentralized control and monitoring system, c1) wherein the 3D model is updated based on operational data received from the sorting and processing plant; d) recording operational anomalies of the sorting and processing plant based on the received operational data; e) displaying and / or visualizing the recorded operational anomalies directly on a corresponding component of the 3D model using visual indicators; f) enabling user interaction with the 3D model.

[0016] This can advantageously improve the operational capabilities of industrial plants and optimize fault detection and the responsiveness of industrial machinery. Representing the sorting and processing plant as a 3D model allows for the spatial allocation of operational data or visual indicators for the user, without the need to display different levels or integration stages of the sorting and processing plant staggered or side-by-side, as is the case in 2D models.

[0017] Furthermore, when using rendered 3D representations, which can depict components contained in the volume in their complexity completely or at least with sufficient complexity for the purpose, it is possible to cut through components or hide parts in order to make indicators visible and to relate them to the corresponding components of the sorting and processing system.

[0018] In other words, the system architecture is based on a hierarchical structure, with the sorting and processing system operated by a programmable logic controller (PLC). The PLC is coupled to a human-machine interface.

[0019] The flexibility of corresponding interfaces is advantageously used to integrate custom web controls, enabling the addition of a tailored control element. This custom control integrates the three.js library to render a detailed 3D model of the industrial machine, thereby enhancing the user's or operator's interactive experience with real-time visual feedback and control functions. This technically improves the control and / or regulation of the industrial machine. Furthermore, it enables more efficient operation and improved oversight when monitoring operating parameters and troubleshooting in the operation of the sorting and processing plant.

[0020] The creation of the 3D models can be defined as a highly detailed process in which each component of the machine can be digitally reconstructed and coded with the desired level of detail, also taking into account the available resources of the 3D graphics rendering engine.

[0021] It is possible for components such as individual conveyor belts, grippers, separators, or diverters, as well as assemblies or components like sorting units, presses, separators, or cutting devices, to be equipped with dynamic parameters and move in the 3D model in sync with their respective real-world physical counterparts. By taking into account the operational data received from the sorting and processing plant, changes in state and anomalies in the behavior of the 3D model components can also be visualized, thus providing the user with an immediate indication of how the sorting and processing plant is currently behaving in operation.

[0022] When the machine is in operation, the 3D model can, for example, be animated to reflect every action and provide a virtual live representation of the machine's condition.

[0023] In a non-essential embodiment of the method, it is provided that the process steps a) to f) are carried out in the following sequence. In particular, the steps can be repeated consecutively.

[0024] However, the plan is also to update the 3D model only to the extent required by changes in the operational data of the sorting and processing plant. This saves computing capacity and resources by not having to adjust unchanged components.

[0025] In a technically advantageous embodiment, the 3D model is updated in real time, i.e., without any offset perceptible to the user compared to the actual operation of the sorting and processing system. This advantageously enables more precise monitoring, control, and regulation of the sorting and processing system, resulting in overall improved operation and a fault-free condition. Anomalies can also be displayed at different levels of relevance, allowing the user to intervene even before a defect occurs, for example, by reducing the speed of infeed or outfeed devices or adjusting operating parameters such as the separation or sorting performance of components like wire removers or ballistic separators.

[0026] In a further advantageous embodiment, the visual indicators include color changes and / or flashing and / or text annotations. Different relevance levels of the indicators can also be signaled to the user, so that, similar to a traffic light system (green, yellow, red), different states and their relevance are immediately recognizable.

[0027] In addition to displaying separate visual indicators, the entire rendered section of the 3D model can also be colored or otherwise marked, e.g., by blinking or similar means, to signal operating states or anomalies. A corresponding representation of components or sections, down to individual parts, is also conceivable.

[0028] This allows for the most intuitive operation possible, which has the technical advantage that the sorting and processing plant can be controlled and operated much faster and more precisely.

[0029] Furthermore, a technically advantageous embodiment provides that user interaction with the 3D model enables changes to the view and / or focus on specific components of the 3D model. This includes the ability to perform cross-sections in the 3D model and / or to hide components or parts of the 3D model, thereby revealing underlying components. Other advantageous adjustments to the 3D model's display are also conceivable.

[0030] This allows for a much faster and more detailed analysis, which can further improve and optimize the operation of the sorting and processing plant. Furthermore, in a technically advantageous embodiment, the 3D graphics rendering engine is configured to provide a user interface that allows the input of commands, and / or the selection of components of the sorting and processing plant within the 3D model, and / or the display of detailed operating data and / or diagnostic information for the selected components of the sorting and processing plant.

[0031] This allows for direct influence on, for example, the ongoing operation of the sorting and processing plant, and enables its optimization and improvement.

[0032] Furthermore, in a technically advantageous embodiment, the method further comprises the following process step, in particular following the preceding process steps: g) Implementation of a feedback loop from the decentralized control and monitoring system to the sorting and processing plant, enabling automatic or manual adjustments to the operation of the sorting and processing plant based on diagnosed errors.

[0033] This can also be advantageous in improving the operation of the sorting and processing plant. The interaction of the components in the 3D model can be used to make operational adjustments that might not be easily, or at all, detectable or identifiable based on the operating parameters of a single component. For example, the feed or discharge speed of conveyor systems can be adjusted to the utilization of connected sorting or separation components, such as air classifiers, ballistic separators, or wire removers, if a material jam is indicated in the 3D model.

[0034] Furthermore, in a technically advantageous embodiment, the rendering engine based on the three.js library is designed to allow access via standardized web browsers within a web-based interface, particularly enabling remote monitoring capabilities. This advantageously allows for a spatially separated and / or remotely located sorting and

[0035] Control and / or regulation of the sorting and processing plant located at the processing plant

[0036] Processing plant, for example, can be enabled by users or operators.

[0037] According to a further aspect, the technical problem of the invention is solved by means of a system for monitoring, controlling and diagnosing sorting and processing plants, comprising: a) a computer device, wherein the computer device is equipped with the decentralized control and monitoring system; b) a user-defined web control module, wherein the web control module is configured such that an interface to the decentralized control and monitoring system is formed and such that data transmission to and / or from a system on the three.a rendering engine based on a js library; c) a display connected to a computer device, wherein the display is configured to show a 3D model of the sorting and processing plant, the 3D model representing the operating state and real-time movements of the components of the sorting and processing plant, in particular dynamically; d) a diagnostic module, wherein the diagnostic module is configured to analyze operating data from the sorting and processing plant and identify faults, the diagnostic module transmitting fault specifics to the rendering engine, thereby updating the 3D model with visual fault indications on relevant components of the machine.

[0038] The aforementioned advantages of this method can be advantageously leveraged within a single system. The system can be designed for the timely, and especially real-time, acquisition and display of data. Information from the machine can be processed and transmitted to the display with minimal latency, ensuring that the visualization reflects the machine's current operating status. Upon detecting a malfunction, the system can issue a warning through various visual cues applied directly to the affected areas of the 3D model, such as components, assemblies, parts, or entire machine sections like conveyor belts, sorting devices, cutting and separating systems, or other components. These cues, which can vary in color, intensity, or pattern, indicate, for example, the nature and urgency of a problem, enabling rapid identification and resolution.In a technically advantageous embodiment, it is provided that the fault indicators comprise multicolored displays, in particular in the form of a light-emitting diode display, on the 3D model, wherein the displays change color depending on the severity and / or type of the detected fault.

[0039] This can be advantageously used as an intuitive, fast and easy-to-understand way to communicate and / or display information in order to optimize and improve the operation of the industrial machine.

[0040] Furthermore, in a technically advantageous embodiment, the web control module is designed in such a way that the view of the 3D model can be adjusted by means of rotation and / or zoom and / or section view.

[0041] This can advantageously create improved interactive possibilities for the user or operator of the sorting and processing plant, which can further benefit its operation. Intuitive navigation and interaction with the 3D model can thus be enabled. The operator or user can, for example, easily change the viewing angle and / or zoom in on areas of interest and / or access operating data and / or fault diagnostics using simple controls, thus enabling an effective monitoring and control environment.

[0042] Exemplary embodiments of the invention are shown in the figures and are described in more detail below.

[0043] They show:

[0044] Fig. 1 shows a schematic representation of the process;

[0045] Fig. 2 shows a schematic representation of a 3D model with exemplary visual indicators.

[0046] Figure 1 shows a schematic representation of the method, illustrating the following process steps: a) Initialization of a decentralized control and monitoring system (1); b) Integration of a 3D graphics rendering engine using the three.js library in the decentralized control and monitoring system (2); c) rendering a dynamic and interactive 3D model of the sorting and processing plant on a display of the decentralized control and monitoring system (3), wherein the 3D model is updated based on operational data of the industrial machine obtained from the sorting and processing plant; d) recording operational anomalies of the sorting and processing plant based on the obtained operational data (4); e) displaying and / or visualizing the recorded operational anomalies directly on the corresponding component of the 3D model using visual indicators (5); f) enabling user interaction with the 3D model (6).(g) Implementation of a feedback loop from the decentralized control and monitoring system to the sorting and processing plant (6), enabling automatic or manual adjustments to the machine operation based on diagnosed faults.

[0047] Figure 2 shows in detail a sorting and processing plant (1) with a feed unit (2), for example, a bag opener or a feed dispenser. The feed unit provides a mixture of recyclable materials or a waste fraction to be processed for the plant. An example of a first visual indicator (3) is provided on the feed unit (2), which, based on received operating data, can signal the status of the feed unit, for example, the current motor output relative to the maximum output, the fill level, the output volume flow rate, or the like. A simple traffic light system with "green" for proper operation, "yellow" for reaching a load limit, and "red" for a malfunction is also conceivable.

[0048] In addition to displaying separate visual indicators, the entire rendered section of the 3D model can also be colored or otherwise marked, e.g., by blinking, to signal operating states or anomalies. A corresponding representation of components or sections is also conceivable.

[0049] Following the feed unit (2) in the material flow (4) is a first conveyor belt (5) for feeding to a sorting unit (6), for example, a ballistic separator or an air classifier. The sorting unit also includes at least one visual indicator (7), which can be designed in a variety of ways or even implemented in the 3D model rendering itself. Individual components, such as a sorting level (8), can also be designed and displayed as visual indicators, for example, by being colored, flashing, or otherwise drawing attention to themselves in the event of an anomaly during operation.

[0050] Following the material flow (9), a second conveyor belt (10) is provided as an example, which is also equipped with an indicated visual indicator (11) with a comparable function to provide information about the operating status.

[0051] The conveyor belt (10) transfers the material, for example, to a baling press (12), which is also rendered as a 3D model in a sufficiently realistic representation.

[0052] In this case, bales (13) are dispensed from the baler (12) onto an output conveyor (14). The number of bales (13) is simulated in real time such that the quantity of bales dispensed, and possibly other data such as composition and material purity, correspond to the actual, physically present bales at the system.

[0053] A visual indicator (15) can also be provided for the dispensed bales (13), which identifies the quality and grade of the bales and, for example, identifies poorly pressed bales or bales with an unfavorable composition. The selection of different bale qualities can also be made clear to the user by the indicator (15) or by other means of marking the bales, e.g., by coloring.

[0054] Reference symbol list: a Initialization of a decentralized control and monitoring system b Integration of a 3D graphics rendering engine c Rendering of a 3D model d Detection of operational anomalies of the industrial machine e Display and / or visualization of the detected operational anomalies f Enabling user interaction g Implementation of a feedback loop from the decentralized control and monitoring system to the industrial machine (6) h Enabling automatic or manual adjustments of the

[0055] Machine operation

[0056] 1 Sorting and processing plant

[0057] 2 Task Aggregate

[0058] 3 visual indicators

[0059] 4 Material flow

[0060] 5 Conveyor belt

[0061] 6 sorting units

[0062] 7 visual indicators

[0063] 8 sorting levels

[0064] 9 Material flow

[0065] 10 Conveyor belt

[0066] 11 visual indicators

[0067] 12 balers

[0068] 13 bales

[0069] 14 Output section

[0070] 15 visual indicators

Claims

Claims:

1. Method for real-time monitoring and fault diagnosis in a sorting and processing plant for waste and recyclable mixtures, comprising the process steps: a) Initialization of a decentralized control and monitoring system; a1) Connection of the decentralized control and monitoring system to an interface for providing operational data of the sorting and processing plant; b) Integration of a 3D graphics rendering engine using the three.js library in the decentralized control and monitoring system; c) rendering a dynamic and interactive 3D model of the sorting and processing plant on a display of the decentralized control and monitoring system, c1) wherein the 3D model is updated based on operational data of the sorting and processing plant received via the interface; d) recording operational anomalies of the sorting and processing plant based on the received operational data; e) displaying and / or visualizing the recorded operational anomalies directly on a corresponding component of the 3D model using visual indicators; f) enabling user interaction with the 3D model.

2. The method according to claim 1, characterized in that the method steps a) to f) are carried out in the following successive order.

3. Method according to claim 1 or 2, wherein the 3D model is fully or partially updated in real time in method step c1, and / or the 3D model is updated in real time only in those components of the sorting and processing plant in which operational anomalies are detected based on the operational data obtained.

4. Method according to any of the preceding claims, wherein the visual indicators comprise color changes and / or flashing and / or text annotations.

5. Method according to one of the preceding claims, wherein user interaction with the 3D model enables a change in the view and / or focus on specific components of the 3D model, and / or wherein sections can be made in the 3D model by means of user interaction, and / or wherein components or parts of the 3D model can be hidden by means of user interaction, and thus underlying components of the 3D model can be made visible.

6. Method according to any of the preceding claims, wherein the 3D graphics rendering engine is configured to provide a user interface, wherein the user interface is configured to allow the input of commands, and / or the selection of components of the sorting and processing plant within the 3D model, and / or the display of detailed operating data and / or diagnostic information on the selected components of the sorting and processing plant.

7. Method according to one of the preceding claims, further comprising the following process step, in particular the step following the preceding process steps: g) Implementation of a feedback loop from the decentralized control and monitoring system to the sorting and processing plant, wherein automatic or manual adjustments to the operation of the sorting and processing plant are enabled on the basis of diagnosed errors.

8. Method according to one of the preceding claims, wherein the rendering engine based on the three.js library is designed such that it operates within a web-based interface accessible via standardized web browsers, in particular enabling remote monitoring capabilities.

9. A system for monitoring, controlling and diagnosing a sorting and processing plant, comprising: a) a computer device, wherein the computer device is equipped with the decentralized control and monitoring system; b) a user-defined web control module, wherein the web control module is configured to form an interface to the decentralized control and monitoring system and to enable data transmission to and / or from a system on the three.a rendering engine based on a js library; c) a display connected to a computer device, wherein the display is configured to show a 3D model of the sorting and processing plant, the 3D model representing the operating state and real-time movements of the components of the sorting and processing plant, in particular dynamically; d) a diagnostic module, wherein the diagnostic module is configured to analyze operating data from the sorting and processing plant and identify faults, the diagnostic module transmitting fault specifics to the rendering engine, thereby updating the 3D model with visual fault indications on relevant components of the machine.

10. System according to claim 9, wherein the fault indicators comprise multicolored displays, in particular in the form of a light-emitting diode display, on the 3D model, wherein the displays change color depending on the severity and / or type of the detected fault.

11. System according to claim 9 or 10, wherein the web control module is designed such that the view of the 3D model can be adjusted by means of rotation and / or zoom and / or section view.

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