Single-Camera Work Process Mapping Using PLC and Image Analysis
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Solution Overview
Problem
Existing methods for improving work processes using imaging data require multiple cameras, leading to high introduction costs for existing production sites.
Innovation Solution
An information processing device that uses a single wide-area imaging camera to acquire imaging data, determines worker presence through image analysis, and correlates this with process information from apparatus operations to generate data on the correspondence between apparatus operation times and worker presence times for each work process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple cameras are used to monitor work status, then measurement precision of worker presence is improved, but device complexity and introduction cost increase
Solution Approach 1:
The patent divides the work site into multiple monitoring regions, each associated with specific work processes. A single camera captures the entire area, and the system segments the image data by analyzing different regions to determine worker presence in each monitoring zone, achieving multi-point monitoring without multiple cameras
Solution Approach 2:
The patent transitions from multiple discrete camera viewpoints to a single overhead/wide-area camera perspective, utilizing the vertical dimension and broader field of view to capture the entire work site in one shot, enabling comprehensive monitoring from a different spatial dimension
2Area of stationary object
If multiple cameras are deployed, then coverage area is improved, but introduction cost increases
Solution Approach 1:
The single wide-area camera performs multiple functions: it monitors the entire work site, identifies worker presence across multiple monitoring regions, and tracks apparatus operations. This multi-functional approach replaces what would traditionally require multiple specialized cameras, reducing both cost and complexity while maintaining comprehensive coverage
3Device complexity
If a single wide-area camera is used, then introduction cost is reduced, but measurement precision of worker presence may deteriorate
Solution Approach 1:
The patent introduces an image processing system that acts as an intermediary between the single camera and the monitoring requirements. The system processes the captured images by analyzing specific monitoring regions, identifying worker presence through pattern recognition, and correlating with apparatus operation data, thereby achieving precise measurements despite using a single camera
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 approach allows for the ascertainment of correspondence between apparatus operations and worker activities while significantly reducing realization costs, using a single camera to monitor an entire work site.
Implementation Method 1
a single wide-area imaging camera imaging an entire work site including a plurality of monitoring regions
Implementation Method 2
a worker determination part that determines whether a worker is present in each of the plurality of monitoring regions through image analysis for the imaging data
Data Source
AI summary
The present invention ascertains the correspondence between the actual operation of an apparatus used to execute a work process and work performed by a worker while suppressing costs. This information processing device associates basic imaging data obtained by capturing the entire work site (WS) by one ceiling camera with process information acquired from a programmable logic controller (PLC).