JP-7856985-B2 - Manufacturing line monitoring system

JP7856985B2JP 7856985 B2JP7856985 B2JP 7856985B2JP-7856985-B2

Inventors

武市博樹
今川英則
河相大介
中川純希

Assignees

三ツ星ベルト株式会社
株式会社ジザイエ

Dates

Publication Date: 20260512
Application Date: 20240830

Claims (4)

A manufacturing line monitoring system that monitors the manufacturing line for producing products, The aforementioned manufacturing line is the subject of the filming, and multiple manufacturing line surveillance cameras are installed along the aforementioned manufacturing line, A notification device monitoring camera that photographs a notification device that visually notifies changes in the aforementioned manufacturing line, A storage device that stores multiple images taken by the aforementioned multiple manufacturing line monitoring cameras , A control device is provided, The control device is Continuous storage processing involves continuously acquiring multiple images captured by each of the multiple manufacturing line monitoring cameras and storing them in the storage device as multiple time-series data associated with each of the multiple manufacturing line monitoring cameras . The system continuously acquires images of the notification device captured by the notification device monitoring camera , and uses image analysis to determine whether the notification device visually notified of a change in the manufacturing line from the acquired images of the notification device. If it is determined that the notification device visually notified of a change in the manufacturing line, the system detects the change in the manufacturing line through a change detection process. A manufacturing line monitoring system characterized by the following: when the change detection process detects a change in the manufacturing line, the system performs an event storage process, for all of the multiple manufacturing line monitoring cameras , extracting from the multiple time-series data associated with each of the multiple manufacturing line monitoring cameras stored in the storage device in the continuous storage process, a set of images that includes the time of change that is determined to have visually notified the change in the manufacturing line, and for the change period that includes at least the time before the time of change among the time periods before and after the time of change, and storing the extracted set of images as clip images corresponding to each of the multiple manufacturing line monitoring cameras in the storage device.
The manufacturing line monitoring system according to claim 1, characterized in that the visual notification of changes in the manufacturing line by the notification device is at least one of the following: notification by lighting or flashing a lamp, notification by the color of the lamp's illumination, or notification by a numerical value displayed on an instrument or monitor.
The aforementioned storage device stores images captured by the notification device monitoring camera . The control device is In the continuous storage process described above, multiple images captured by each of the multiple manufacturing line monitoring cameras and the notification device monitoring cameras are continuously acquired and stored in the storage device as time-series data associated with each of the multiple manufacturing line monitoring cameras and the notification device monitoring cameras . The manufacturing line monitoring system according to claim 1, characterized in that, in the event storage processing, when a change in the manufacturing line is detected by the change detection processing, a plurality of image groups for the change period are extracted from the time-series data associated with each of the plurality of manufacturing line monitoring cameras and the notification device monitoring cameras stored in the storage device in the continuous storage processing, and the extracted plurality of image groups are stored in the storage device as clip images corresponding to each of the plurality of manufacturing line monitoring cameras and the notification device monitoring cameras .
The control device is A manufacturing line monitoring system according to any one of claims 1 to 3, further characterized in that, for at least two of the multiple clip videos stored in the event storage processing, the video for at least a portion of the change period is output as data that can be displayed in a list on the screen of a display device owned by the manufacturing line monitoring system or owned by a system outside the manufacturing line monitoring system and played back.

Description

This invention relates to a manufacturing line monitoring system for monitoring a manufacturing line. Conventionally, in factory manufacturing line systems, if any change occurs in the manufactured product or process (including not only abnormalities but also cases where the state deviates from the normal range), a state detection means (motion detection sensor (e.g., light sensor or ultrasonic sensor), abnormal sound detection sensor, camera, temperature sensor, etc.) is used to detect the change in the manufacturing line, and the detection of such a change is visually notified to managers, etc., by the illumination of a notification device such as a three-color light or a warning light (see Patent Documents 1-2). Furthermore, while such manufacturing line monitoring systems can detect changes in the manufacturing line, they may not be able to determine the nature or cause of the change. This can lead to delays in restoring and improving the manufacturing line, resulting in decreased productivity due to reduced operating rates. To address this problem of decreased productivity, conventional monitoring systems have been disclosed that use surveillance cameras to film the manufacturing line, and when changes in the manufacturing line are detected using state detection means, the system analyzes the state of the changes in the manufacturing line by reviewing the surveillance camera footage to determine the cause of the changes (see Patent Documents 3-5). Japanese Patent Publication No. 2019-46293Japanese Patent Publication No. 2020-198047International Publication No. 2022/239123Japanese Patent Publication No. 2023-24346Japanese Patent Publication No. 2023-075578 This diagram illustrates the manufacturing line monitoring system according to this embodiment and the manufacturing line system including the manufacturing line on which the manufacturing line monitoring system is installed.This is a block diagram of the manufacturing line monitoring system and the manufacturing line system according to this embodiment.This is a flowchart of the manufacturing line control process.This is a flowchart of the manufacturing line monitoring process by the manufacturing line monitoring system according to this embodiment.This is an explanatory diagram showing an example of how clipped video is played back in the manufacturing line monitoring system according to this embodiment.This is an explanatory diagram showing an example of a clip image displayed on the display device of the manufacturing line monitoring system according to this embodiment.This is an explanatory diagram illustrating a specific example of a notification device that visually notifies users of changes in a manufacturing line. (Embodiment) As shown in Figure 1, the manufacturing line monitoring system 1 according to this embodiment is installed on a manufacturing line M that transports a large number of products (industrial products Y1, etc.) by belt conveyors M1 to M4 according to a processing or assembly procedure. (Manufacturing line M) First, let's explain the manufacturing line M that will be monitored by the manufacturing line monitoring system 1. As shown in Figure 2, the manufacturing line M is included in the manufacturing line system 2. As shown in Figures 1 and 2, the manufacturing line system 2 includes belt conveyors M1 to M4, a state detection sensor (state detection means) A, an alarm device D including a three-color lamp D1, a manufacturing line management device 21 that controls the manufacturing line M, a manufacturing line input device 24, and a manufacturing line display device 25. As shown in Figure 2, the manufacturing line management device 21 includes a manufacturing line control device 22 and a manufacturing line storage device 23. (Belt conveyors M1 to M4) The belt conveyor M1 has a structure in which a conveyor belt is wrapped between a drive pulley connected to a drive motor and a driven pulley, but it may also be a roller conveyor or the like. Belt conveyors M2 to M4 have the same structure as belt conveyor M1. In this embodiment, for the sake of explanation, the layout is as shown in Figure 1, in which the four belt conveyors M1 to M4 are arranged in a straight line in order from the upstream side to the downstream side. However, the layout is not limited to a straight line and can be of various shapes. In this embodiment, for the sake of explanation, the manufacturing line M includes only belt conveyors M1 to M4, but other belt conveyors or work equipment may be present before and after belt conveyors M1 to M4. The industrial products Y1 and the like placed on belt conveyor M1 are transported by the belt conveyors M1 to M4 from belt conveyor M1 to belt conveyor M4 (i.e., from upstream to downstream). (State detection sensor A) The state detection sensor A is a sensor that detects the state of multiple industrial products being transported in a manufacturing line M, which includes belt conveyors M1 to M4. The signal from the