Image Recording Control for Trigger-Based Fault Inspection
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Solution Overview
Problem
The existing process monitoring devices in factory automation sites face delays in image data storage due to communication lag and complex control programs, making it difficult to inspect images promptly when trouble occurs.
Innovation Solution
A control device that connects to imaging devices and environment detectors, allowing for immediate image information saving through separate trigger signals, bypassing the need for complex control program execution and reducing communication lag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the control device uses a complex control program to process trigger signals from sensor devices and imaging devices, then the control functionality is comprehensive, but the time lag increases and image inspection becomes difficult
Solution Approach 1:
The patent divides the trigger signal processing into two independent paths: (1) trigger signals from sensor devices are processed by a dedicated trigger signal input unit that directly outputs to the image recording unit, and (2) trigger signals from imaging devices are processed by a dedicated image information acquisition unit that directly outputs to the image recording unit. This segmentation eliminates the need for complex control program execution, reducing time lag while maintaining comprehensive control functionality.
Solution Approach 2:
The patent introduces a dedicated image recording unit as an intermediary component that receives trigger signals and image information directly from various sources (sensor devices, imaging devices) without requiring control program execution. This intermediary structure enables direct processing paths that reduce time lag while maintaining system versatility.
2Device complexity
If the control device processes all trigger signals through the control program execution unit, then the control logic is centralized, but communication time lag increases
Solution Approach 1:
The patent segments the trigger signal processing architecture into multiple independent processing paths: a trigger signal input unit for sensor device triggers, an image information acquisition unit for imaging device triggers, and a dedicated image recording unit. This segmentation eliminates the bottleneck of centralized control program execution, reducing communication time lag while maintaining structured control logic.
3Reliability
If the device stores video data based on trigger signals from the PLC, then the storage is synchronized with control events, but the image record has time lag from PLC logs
Solution Approach 1:
The patent introduces a dedicated image recording unit as an intermediary that receives trigger signals directly from sensor devices and imaging devices, bypassing the PLC control program execution path. This intermediary structure enables direct synchronization between trigger events and image recording, eliminating the time lag that occurs when images are recorded based on PLC-processed trigger signals.
Data Source
AI summary
A control device (10) connectable to an imaging device (42) for controlling a control-target device includes an execution unit (11) that executes a control program to control the control-target device and outputs a first trigger signal when data (112) variable with execution of the control program satisfies a first condition, a receiver (63) that repeatedly receives image information indicating an image captured by the imaging device (42) and receives, from an environment detector including the imaging device (42) or a device (41) different from the imaging device, a second trigger signal indicating detection of environmental information including a result of detection performed by the environment detector satisfying a second condition, and a saver (66) that saves the image information received by the receiver (63) into a second storage (67) when receiving the first trigger signal from the execution unit (11) or receiving the second trigger signal with the receiver (63).