Industrial Plant Video Overlay for Precise Object Position Confirmation
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Solution Overview
Problem
Current industrial plant data reproduction systems lack precision and efficiency in confirming the motion position of objects captured in video data, requiring costly and inflexible solutions such as visual inspection, markers, or expensive laser sensors.
Innovation Solution
An industrial plant data reproduction device that collects process and video data, stores graphic data for specific material specifications, and overlays selected graphic data onto video data in real-time, allowing for precise confirmation of object positions without additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection is used to confirm object positions in video data, then operational simplicity is maintained, but measurement precision remains low
Solution Approach 1:
The patent creates a virtual copy of the physical object's motion trajectory and overlays it onto the video data. This graphic representation accurately replicates the expected motion path based on process data, allowing operators to verify actual object positions against the virtual model without adding physical markers or sensors to the production line.
2Measurement precision
If physical markers or tapes are attached to objects for position indication, then measurement precision is improved, but device complexity and operational costs increase
Solution Approach 1:
Instead of attaching physical markers to objects, the system creates a virtual graphic representation of the expected motion trajectory and overlays it on video data. This eliminates the need for physical markers, tapes, or additional sensors on the production line, maintaining system simplicity while achieving precise position verification.
Solution Approach 2:
The patent replaces physical marking systems with a digital/graphic overlay system. Rather than using mechanical or physical indicators attached to objects, the system uses software-generated graphics that are superimposed on video footage, eliminating the need for physical intervention in the production process.
3Measurement precision
If laser sensors are deployed for precise detection of device and material positions, then measurement precision is improved, but device complexity and operational costs increase
Solution Approach 1:
The system creates a virtual copy of the expected motion trajectory using process data and overlays it on video footage. This graphic representation serves as a digital twin of the actual object motion, enabling precise position verification without deploying physical sensors like laser detectors into the production environment.
Solution Approach 2:
The patent substitutes expensive laser sensors and physical detection systems with a software-based graphic overlay system. By processing existing video data and superimposing virtual trajectory information, the system achieves precise position detection without adding complex sensing hardware to the production line.
4Measurement precision
If signs are customized for each material size to improve confirmation accuracy, then measurement precision is improved, but ease of operation deteriorates due to recognition complexity
Solution Approach 1:
The system uses a single universal graphic overlay mechanism that automatically adapts to different material sizes and types. The graphic representation of motion trajectory is generated dynamically based on process data corresponding to each material, eliminating the need for multiple pre-configured signs or manual adjustments for different material specifications.
Solution Approach 2:
The graphic overlay is dynamically generated and updated based on real-time process data for each material being processed. Rather than using static signs that need to be manually changed, the system automatically adjusts the virtual motion trajectory graphic to match the current material specifications, maintaining both precision and ease of operation.
Data Source
AI summary
An industrial plant data reproduction device includes the following. A process data collection unit collects process data regarding a group of devices and materials to be processed by the group of devices. A video data collection unit collects video data in which an object whose image is to be obtained is captured, the object pertaining to the group of devices. A graphic data storage unit stores in advance graphic data indicative of a motion target position of the object whose image is to be obtained for each material specification. A graphic data selection unit selects the graphic data corresponding to the material specifications included in the process data every time each of the materials reaches the object whose image is to be obtained. A display processing unit outputs synthetic data in which the selected graphic data is overlaid on the video data.