Production Plant Error Handling With Zone Image Buffers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current production plants require significant time and effort for error analysis due to the manual detection and reconstruction of errors, which hampers efficiency and productivity.
Innovation Solution
Implementing a method with image acquisition units and error detection units connected to a control unit that automatically forwards image data to a user upon error detection, allowing for rapid analysis and reducing the need for extensive retrospective analysis by providing timestamped image data from a predetermined time period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual error detection and retrospective analysis are used in production plants, then error detection capability is maintained, but time investment and effort for error analysis increase significantly
Solution Approach 1:
The system performs preliminary actions by continuously recording image data in circular buffers before errors occur. When an error is detected, the relevant image data is already available for immediate analysis, eliminating the need for retrospective data collection and significantly reducing error analysis time.
Solution Approach 2:
The system creates copies of image data from multiple cameras and stores them in circular buffers. These copied data representations can be retrieved and analyzed without affecting the ongoing production process, enabling rapid error analysis while maintaining continuous operation.
2Reliability
If multiple image acquisition units are deployed to cover all work zones, then comprehensive error monitoring is achieved, but device complexity and cost increase
Solution Approach 1:
The circular buffer system serves multiple functions: it continuously stores image data for all work zones, automatically manages data retention based on error detection events, and provides historical data for analysis. This multi-functional approach eliminates the need for separate systems for continuous monitoring and error investigation.
Solution Approach 2:
The system automatically discards old image data when the circular buffer is full, retaining only the most recent data within the predetermined time period. When errors occur, the system recovers and provides the relevant image data from the buffer for analysis, optimizing storage utilization while maintaining reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly simplifies error analysis by providing timely and relevant image data, reducing the time required to identify and address errors, thereby optimizing production plant operations.
Implementation Method 1
The camera can in particular be configured to detect light in the spectrum visible to humans and/or outside this spectrum, e.g., in the range of X-ray radiation, and to generate image data based thereon
Implementation Method 2
providing a plurality of image acquisition units and a plurality of error detection units at a production plant
Data Source
AI summary
A method comprising a plurality of image acquisition units and a plurality of error detection units at a production plant. The production plant comprises a plurality of work zones, each of which are assigned at least one of the image acquisition units and at least one of the error detection units. A control unit is configured to detect a signal of at least one of the error detection units and based on this detection detect whether an error in the production plant has occurred in the work zone to which the error detection unit is assigned. When the control unit detects an error in a work zone, it provides image data from at least one image acquisition unit of that work zone to a user via an output unit. The invention also relates to a production plant using this method.