Motion Analysis for Industrial Event Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional process monitoring systems require specialized programming and direct connection to Programmable Logic Controllers (PLCs) to detect industrial process stoppages, leading to unmonitored equipment and inability to log stoppages effectively due to varying PLC types and lack of machine interfaces.
Innovation Solution
A system and method that analyze motion data from industrial processes using imaging devices to determine deviations from reference motion, allowing for event logging without specialized programming or direct PLC connection, utilizing processors and program code to compare motion data and log events when deviations exceed predetermined thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional process monitoring systems connect to PLCs to detect stoppages, then event detection capability is improved, but device complexity and programming requirements increase
Solution Approach 1:
The patent introduces an imaging device as an intermediary component that captures visual data of the industrial process. This mediator translates physical process states into image data that can be analyzed without direct PLC connection, eliminating the need for specialized programming while maintaining event detection capability
Solution Approach 2:
The patent replaces the electrical/connection-based monitoring system (PLC interfaces) with an optical/imaging-based system. By substituting the mechanical/electrical connection requirement with visual field analysis, the system eliminates programming complexity while preserving reliability
2Adaptability or versatility
If process monitoring systems are individually configured for specific PLC types, then compatibility with controlled equipment is improved, but ease of operation deteriorates
Solution Approach 1:
The imaging device serves multiple functions: it captures visual data, detects motion, identifies events, and generates logs without requiring configuration for different PLC types. This universal approach allows the same device to monitor any industrial process regardless of the underlying control system
Solution Approach 2:
The imaging device acts as a universal intermediary that interfaces with the physical process directly through visual observation, bypassing the need to adapt to different PLC communication protocols and addressing schemes
3Ease of operation
If motion analysis is used to detect industrial process events, then ease of operation is improved, but measurement precision may worsen
Solution Approach 1:
The system continuously compares current image data against reference data and adjusts event detection based on motion thresholds and patterns. This feedback mechanism refines measurement precision by learning from accumulated data while maintaining ease of operation
Solution Approach 2:
The system performs preliminary analysis by establishing reference motion patterns and thresholds before actual event detection begins. This preliminary action calibrates the measurement precision without requiring complex configuration during operation
Data Source
AI summary
Systems, methods, and computer program products for monitoring an industrial process. Motion related to the industrial process is monitored to identify the occurrence of events such as equipment stoppages and/or to characterize the process. Motion data may be extracted from a video of the industrial process. Based on an analysis of the motion data, a determination is made whether an event has occurred, such as an equipment malfunction, work stoppage, or another process anomaly. In response to determining an event has occurred, an error log may be generated and stored in a database. Analysis of the timing and amount of motion may be used to determine a root cause of the event and/or to count the number of products produced by the process being monitored.