Synchronizing Control Network Data With Video Screens
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Solution Overview
Problem
Conventional data collectors cannot synchronously collect and analyze control network data and screen information from monitors, leading to incomplete information during abnormality analysis and prolonged analysis times, and they also fail to capture mechanical operations outside camera view.
Innovation Solution
A plant operating state analysis system that includes a controller, control network, monitor, video capturer, and data collector, where the data collector synchronizes and displays control network data and monitoring screen video data, enabling simultaneous analysis of plant operating states and reducing recovery time during abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If control network data is collected by a conventional data collector, then control network data can be obtained, but screen information on the monitor cannot be collected
Solution Approach 1:
The data collector is enhanced to perform multiple functions: it collects both control network data and screen information from the monitoring network. This multi-functionality allows a single device to gather comprehensive data from different networks, eliminating the need for separate collection mechanisms and reducing overall system complexity.
Solution Approach 2:
A synchronization processing unit acts as an intermediary between control network data and monitoring screen video data. It adds delay time to the control network data timestamp to match the screen information timing, enabling accurate correlation of data from both networks without requiring complex real-time coordination.
2Measurement precision
If control network data is analyzed without screen information, then analysis can be performed with available data, but correct information cannot be obtained and analysis time increases
Solution Approach 1:
The data collector merges control network data and monitoring screen video data into a single synchronized dataset. By combining these data sources and aligning their timestamps through the synchronization processing unit, the system enables comprehensive abnormality analysis that leverages both control data and visual screen information simultaneously, improving accuracy without extending analysis time.
3Loss of information
If video data captured by camera is collected, then photographed operating conditions can be checked, but mechanical operation outside camera range cannot be checked
Solution Approach 1:
The system transitions from purely visual camera monitoring to a multi-dimensional approach by incorporating monitoring screen video data that displays mechanical information such as speed and position. This complementary data dimension provides coverage of mechanical operations beyond what camera vision can capture, creating a more complete monitoring picture without adding physical cameras to every location.
Data Source
AI summary
A plant operating state analysis system includes a data collector which is connected to both a control network and a monitoring network and which collects both control network data and monitoring screen video data. The data collector includes a synchronization processing unit and a data display processing unit. The synchronization processing unit synchronizes the control network data and the monitoring screen video data by adding a delay time due to transmission through the monitoring network, which includes an encoding time spent by a video capturer, to the time at which the control network data has been collected. The data display processing unit reproduces and displays, on a screen, the control network data and monitoring screen video data that are synchronized by the synchronization processing unit.