3D Malfunction Analysis with Time-Synced Virtual Facility Replay

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Solution Overview

Problem

Conventional malfunction analysis systems require multiple cameras to observe a manufacturing facility from different directions, limiting the understanding of the overall situation and complicating the installation process.

Innovation Solution

A malfunction analysis support program that performs log data acquisition, action reproduction, three-dimensional data display, program operation display, waveform display, and video display, allowing inspection from any direction without multiple cameras, using a computer to simulate and synchronize data for comprehensive analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If multiple cameras are installed to observe the manufacturing facility from different directions, then the understanding of the overall situation is improved, but the device complexity and installation cost increase

Engineering Contradiction:
Improveunderstanding of overall situationVSAvoidnumber of cameras
Core Design Contradiction:
Loss of informationVSDevice complexity

Solution Approach 1:

The patent creates a virtual copy (three-dimensional virtual image) of the manufacturing facility that can be viewed from multiple directions. Instead of installing multiple physical cameras, a single camera captures images that are processed to generate a virtual model, allowing observers to inspect the facility from any angle without adding physical observation devices.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent transitions from two-dimensional camera images to a three-dimensional virtual representation. By converting planar images into a three-dimensional virtual model, the system enables multi-directional observation without requiring multiple cameras, as the virtual model can be rotated and viewed from any perspective.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Device complexity

If a single camera is used to image the manufacturing facility, then the device complexity is reduced, but the ability to inspect conditions from different directions is limited

Engineering Contradiction:
Improvenumber of camerasVSAvoidinspection from any direction
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent transforms two-dimensional image data into a three-dimensional virtual model, adding a dimensional aspect that enables multi-directional viewing. This allows a single camera to provide the versatility of multiple cameras by representing the facility in three dimensions that can be virtually rotated and inspected from any angle.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The three-dimensional virtual image serves multiple functions: it can be viewed from any direction, allows time-series comparison of facility states, and provides comprehensive inspection capabilities that would otherwise require multiple physical cameras positioned at different locations.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Area of stationary object

If multiple cameras are installed to capture different views, then the coverage area is improved, but the installation cost and system complexity increase

Engineering Contradiction:
Improvecoverage areaVSAvoidnumber of cameras
Core Design Contradiction:
Area of stationary objectVSDevice complexity

Solution Approach 1:

The system creates a virtual copy of the entire manufacturing facility that encompasses all areas visible to the camera. This virtual representation provides comprehensive coverage of the facility without requiring multiple physical cameras, as the three-dimensional model can be virtually navigated to view any captured area.

Inventive Principle:
Principle #26Copying

Data Source

PatentUS12422812B2Malfunction analysis support program storage medium and malfunction analysis support apparatus
Publication Date: 2025.09.23 MITSUBISHI ELECTRIC CORP
  • US12422812B2 patent drawing
  • US12422812B2 patent drawing
  • US12422812B2 patent drawing

AI summary

A malfunction analysis support program causes a computer to perform a log data acquisition step, an action reproduction step, a three-dimensional data display step, a processing step being at least one of a program operation display step, a waveform display step, or a video display step, and a time synchronization step. The log data acquisition step obtains log data temporally sequentially recording a state of an operational part and input-output data of a control signal. The action reproduction step generates action reproduction simulation data obtained by causing a virtual object-to-be-controlled to reproduce an action based on the log data. The three-dimensional data display step displays the action reproduction simulation data as three-dimensional data. The time synchronization step synchronizes time between three-dimensional data displayed by the three-dimensional data display step and data displayed by the processing step. The three-dimensional data display step displays the three-dimensional data according to display setting information.