Camera-Control Data Synchronization for Predictive Maintenance
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Solution Overview
Problem
There is a time lag between when an imaging start command is transmitted to a camera and when it starts imaging, causing delays in displaying moving images relative to waveform data, which makes it unsuitable for predictive maintenance in factory automation systems.
Innovation Solution
A control system that includes a control unit to transmit an imaging start command to an imaging unit, a data collection unit to collect control data, and a time management unit to manage the time lag between the control data and the captured image, allowing for accurate synchronization and display of both data types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an imaging start command is transmitted to the camera to capture moving images, then the moving image can be displayed, but there is a time lag between the command transmission and actual imaging start, causing the moving image display to be delayed relative to waveform data
Solution Approach 1:
The patent applies preliminary action by measuring the time lag between imaging start command transmission and actual imaging start in advance, before the display process begins. The time management unit continuously monitors and records this time lag, allowing the system to pre-calculate compensation values that are then applied during display to synchronize the moving image with the waveform data, eliminating the synchronization delay.
Solution Approach 2:
The patent implements feedback by having the time management unit continuously monitor the actual time lag between command transmission and imaging start, and use this measured information to adjust the display timing. The system feeds back the time lag measurement to the display control mechanism, dynamically adjusting the moving image display timing to maintain synchronization with the waveform data despite variations in processing delays.
2Ease of operation
If the moving image is displayed with the time lag, then the imaging function is achieved, but the display information becomes inappropriate for predictive maintenance support
Solution Approach 1:
The time management unit acts as an intermediary between the imaging unit and the display unit. It measures the time lag introduced by the imaging system and introduces a compensating time adjustment in the display pipeline. This intermediary component decouples the imaging function from the display timing, allowing the imaging to proceed at its natural pace while the display is adjusted to maintain synchronization with the waveform data, thereby preserving both imaging availability and predictive maintenance accuracy.
3Device complexity
If the time lag is not managed, then the system structure remains simple, but the control data and image data cannot be accurately synchronized
Solution Approach 1:
The time management unit implements self-service by autonomously measuring the time lag between imaging command transmission and actual imaging start, and automatically applying compensation adjustments without requiring external intervention. The system monitors its own timing characteristics and self-corrects the synchronization issue, maintaining measurement precision while adding only the minimum necessary complexity through a dedicated timing management component.
Data Source
AI summary
A control system includes a controller that controls a control target, and an imager that has an imaging range in which the control target that can be imaged as a subject can be captured. The controller transmits, upon detection of an event, an imaging start command to the imager, and causes a data collector to collect control data with the control data associated with a collection time, and the imager starts imaging in accordance with the imaging start command transferred from the controller and causes an image collector to collect a captured image with the captured image associated with an imaging time. The control system manages a time lag between the control data collected by the data collector and the image collected by the imager.