Controller Operation Guidance via Camera-Based Data Capture
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Solution Overview
Problem
Existing production plant controllers that are not network-connected face challenges in connecting information without physical modification, requiring manual SOP checks and lacking data digitalization, leading to inefficiencies and high modification costs.
Innovation Solution
A work management system that includes a server device, worker terminal, and controller, utilizing cameras and eye-tracking sensors to acquire and analyze operation data, providing real-time work instructions and notifications to workers, without physically modifying the controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If controllers are not connected to a network, then device complexity and modification costs are reduced, but information connectivity and data digitalization are lost
Solution Approach 1:
The patent introduces an intermediary system consisting of image capturing devices (cameras) and processing servers that act as mediators between non-networked controllers and the central management system. The cameras capture operation data from controllers, and the server processes this data to enable information connectivity without requiring physical network connections to the controllers themselves.
Solution Approach 2:
The patent creates digital copies of controller operation data by capturing images of the controller displays and operation panels. These image copies are then processed through OCR and image recognition technologies to extract and digitize the information, enabling data utilization without direct network access to the original controllers.
2Productivity
If manual SOP checks are required, then data digitalization is avoided, but worker productivity and efficiency deteriorate
Solution Approach 1:
The system enables self-service operation guidance by automatically capturing controller display images, recognizing the displayed information through OCR and image recognition, and presenting relevant operation instructions to workers. This eliminates the need for workers to manually consult SOP documents, as the system automatically provides context-appropriate guidance based on the controller's current state.
Solution Approach 2:
The patent implements a feedback mechanism where the system continuously monitors controller operation data through image capture, processes this information to understand the current operational context, and provides real-time feedback in the form of targeted work instructions to the worker. This closed-loop feedback system replaces manual SOP checking with automated contextual guidance.
3Ease of manufacture
If physical modification of controllers is avoided, then ease of manufacture and deployment are improved, but adaptability to digital systems is reduced
Solution Approach 1:
The patent replaces the mechanical/physical connection approach (network cables and direct controller integration) with an optical/digital approach using image capture and recognition technologies. Instead of modifying controllers to connect physically to networks, the system uses cameras to optically capture controller information and processes it digitally through image recognition and OCR systems.
Data Source
AI summary
A server device acquires operation data for identifying operation that is performed on a controller by a worker in accordance with a work instruction on a predetermined work process related to the controller that is operated by the worker, analyzes the operation data, determines a notification content for the worker, and notifies the worker of the determined notification content.