Industrial Process Video Monitoring for Real-Time Parameter Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial processes face challenges in monitoring and controlling equipment and item movements due to limitations in real-time surveillance and measurement rates, leading to delayed detection of deviations and manufacturing defects.
Innovation Solution
A method and system that analyze media elements from industrial processes to extract attribute values, construct arrays, and combine them into data structures for real-time monitoring and control, facilitating timely identification of deviations and adjustments in processing parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If still image surveillance equipment is used to monitor industrial processes, then large problems in individual items can be detected, but variations over time in items and gradual variations in manufacturing processes cannot be revealed
Solution Approach 1:
The patent divides the monitoring task into two distinct systems: still image surveillance for detecting large problems in individual items, and video surveillance for capturing variations over time. This segmentation allows each system to specialize in specific detection needs without compromise.
Solution Approach 2:
The patent transitions from static 2D image analysis to dynamic temporal analysis by introducing video surveillance. This adds the time dimension to monitoring, enabling detection of gradual variations and process changes that static images cannot capture.
2Speed
If closed-circuit television systems are used for real-time surveillance, then equipment malfunctioning can be monitored, but gradual variations over time and minor variations in rapid processes are missed due to slow frame rates
Solution Approach 1:
The patent changes the temporal sampling parameter by using high frame rate video surveillance (e.g., 60 fps or higher) instead of standard television frame rates. This parameter change enables accurate capture of rapid industrial processes while maintaining real-time monitoring capability.
3Measurement precision
If control systems operate at slow rates to measure properties of equipment components, then measurements can be taken, but processing parameters cannot be corrected timely, leading to defective items
Solution Approach 1:
The patent implements preliminary action by continuously monitoring process parameters in real-time and automatically adjusting equipment settings before defects occur. The system proactively corrects deviations from desired parameters, preventing defective item production rather than detecting defects after they occur.
Solution Approach 2:
The patent establishes a closed-loop feedback system where real-time video surveillance data is continuously fed back to control systems, which automatically adjust processing parameters. This rapid feedback loop enables timely corrections that prevent defective item production.
Data Source
AI summary
Various embodiments include methods, apparatuses, systems, and computing devices that are configured to: (1) receive media of a processing region of an industrial process, where the processing region comprises at least one object, the media comprises a plurality of media elements, and each of the media elements comprises a field of view of the at least one object; (2) identify based on an area of interest, a set of pixels, wherein the field of view comprises the area of interest; (3) for each media element of the plurality of media elements: (a) extract an attribute value from each pixel of the set of pixels found in the media element, and (b) construct a respective array comprising each attribute value; (4) combine each of the respective arrays in a data structure; and (5) analyze the data structure to provide data on a processing parameter associated with the industrial process.