BG3822U1 - Smart ethernet ip camera for monitoring and analysis of production processes - Google Patents

Abstract

This utility model relates to a smart Ethernet IP camera for monitoring and analysis of production processes, which provides continuous high-speed recording and analysis of production processes, while performing automatic optical quality control of the manufactured products using specially designed firmware. The recording is synchronized with the IEEE 1588 precision time production server, thus, the time and spatial coordinates of each manufactured product are uniquely determined. When a problem is detected, the smart Ethernet IP camera can alert by notifying of the "noticed" irregularity, and determine the exact location of the fault and send a short video containing the information to the smartphone, tablet or computer of the person in charge. A specially designed graphical user interface allows the line operator to monitor multiple smart Ethernet IP cameras simultaneously, and to receive information about the parameters of the production process, regardless of the geographical location of the individual production lines.

Description

Field of technology

This utility model relates to an intelligent Ethernet IP camera for monitoring and analysis of production processes, which will find application in the field of industrial automation and in particular for continuous high-speed recording and analysis of production processes by reproducing video information.

BACKGROUND OF THE INVENTION

Almost every modern production process uses machine vision systems. These systems provide fast, accurate and repeatable measurements, thus ensuring consistent product quality. The main component of any machine vision system is the imaging camera. In most conventional systems, the camera provides an image that is analyzed by a user computer connected to the camera. Machine vision systems are also known - intelligent cameras that integrate imaging and image analysis functions. Typically, these cameras are equipped with special image processing algorithms developed by the manufacturer and selected in such a way as to meet the most popular and sought-after customer needs.

In high-speed production lines, in addition to a system for monitoring and analysis of manufactured products, it is necessary to monitor the proper course of the production process. Monitoring the process itself is very important because in many cases the process is interrupted for unknown reasons and the production line stops, which leads to the shutdown of the entire production process. Because standard machine vision systems do not monitor the movement of the tape itself, finding and removing the cause of the interruption is time consuming. Modern production lines move very fast and sudden shutdowns can lead to congestion of the product line, damage and damage to the production line itself, as well as loss of revenue, as products damaged as a result of the interruption must be destroyed.

Technical essence of the utility model

The task of the utility model is to create an intelligent Ethernet IP camera for monitoring and analysis of production processes, which will provide continuous high-speed monitoring and analysis of the movement of the production line, as well as the ability for automatic optical quality control of manufactured products.

The task was solved by creating an intelligent Ethernet IP camera for monitoring and analysis of production processes, which consists of at least one image capture module equipped with a housing to which are mechanically connected an image focusing lens, a light-sensitive sensor, an interface connector and lighting unit. The housing houses a sensor processing unit, a process analysis unit consisting of a circular buffer, an internal precision time server and an image analysis module, an output unit and a power supply unit. The light-sensitive sensor, on the one hand, is optically connected to the image focusing lens, and on the other hand, is connected in both directions by means of a first system bus to the sensor processing unit. The sensor processing unit, on the one hand, is connected in one direction to the lighting unit and, on the other hand, is connected in two directions by means of a second system bus to the circuit buffer and to the image analysis module in the process analysis unit. The circular buffer is connected in both directions to the output unit and to the internal precision time server, which in turn is connected to the output unit via a third system bus. The image analysis module via a fourth system bus is connected to the output unit, which is bidirectionally connected to the interface connector. The interface connector is bidirectionally connected to an external control center, including a file server, bidirectionally connected to a production IEEE 1588 precision time server, which is bidirectionally connected to a production process control and monitoring unit. The power supply unit is connected in one direction by power busbars with light

3822 UI sensory sensor, with lighting unit, with sensor processing unit, with process analysis unit and with output unit.

The advantage of the created intelligent Ethernet IP camera is that it allows continuous high-speed recording and analysis of the movement of the production line, as well as image analysis and automatic optical quality control of the manufactured products. The operation of the intelligent Ethernet IP camera is synchronized in time with a production server for precise time, operating according to the IEEE 1588 protocol, which controls the entire production process, as well as the movement of the production line. In this way, the temporal and spatial coordinates of each manufactured product are uniquely defined. This allows potential problems in the operation of the production line to be registered and localized from the very beginning, before they have led to a significant deviation or interruption of the production cycle. In addition, the intelligent Ethernet IP camera can alert and notify about the "noticed" irregularity, determine the exact location of the fault and send a short video containing information about the irregularity to the smartphone, tablet or computer of the responsible person.

Another advantage is that many intelligent Ethernet IP cameras, synchronized with the production server for precise time, can be connected to a common computer network, thus the entire production process is controlled from one place, regardless of the geographical location of individual production lines. .

Explanation of the attached figure

The present utility model is illustrated in the attached figure 1, which is a schematic diagram of an intelligent Ethernet 1P camera for monitoring and analysis of production processes, according to the utility model.

Example of implementation of the utility model

The created intelligent Ethernet 1P camera for monitoring and analysis of production processes, shown in figure 1, consists of at least one imaging module equipped with a housing 100, to which are mechanically connected an image focusing lens 101, a light-sensitive sensor 102, interface connector 109 and lighting unit 110. A sensor processing unit 103, a process analysis unit 104 consisting of a circular buffer 104.1, an internal precision time server 104.2 and an image analysis module 104.3, an output unit 105 and power supply unit 106.

The photosensitive sensor 102, on the one hand, is optically connected to the image focusing lens 101, and on the other hand, is bidirectionally connected via a first system bus to the sensor processing unit 103. The sensor processing unit 103 is, on the one hand, connected to the the lighting unit 110, on the other hand, is connected in both directions by means of a second system bus to the circuit buffer 104.1 and to the image analysis module 104.3 in the process analysis unit 10. The circular buffer 104.1 is bidirectionally connected to the output unit 105 and to the internal precision time server 104.2, which in turn is connected to the output unit 105 via a third system bus. The image analysis unit 104.3 is connected to the output unit 105 via a fourth system bus. which is bidirectionally connected to the interface connector 109. The interface connector 109 is bidirectionally connected to an external control center 200 including a file server 201 bidirectionally connected to a production IEEE 1588 precision time server 202 that is bidirectionally connected to a production management and control module process 203. The power supply unit 106 is connected in one direction by power busbars to the light-sensitive sensor 102, to the lighting unit 110, to the sensor processing unit 103, to the process analysis unit 104, and to the output unit 105.

A production line 300 on which the products move is, on the one hand, connected in two directions to the control center 200 and, on the other hand, optically connected to the image focusing lens 101 and to the lighting unit 110.

The power busbars used are power busbars designed to provide the necessary voltages and current to the individual units. The system buses used are signal buses designed to provide high-speed bidirectional data flow, control signals and communication signals.

3822 UI

The image focusing lens 101 includes at least one optical element, such as a lens, a blister, or a plate, through which it creates a clear image of a certain portion of a moving production line 300 and the products located thereon on the surface of the light-sensitive sensor 102.

The light-sensitive sensor 102 includes at least one linear or matrix CCD or CMOS type light receiver. Its functions are to create a digital equivalent of the image focused on its surface and to transmit it to the sensor processing unit 103, as well as to receive control signals from the sensor processing unit 103.

The sensor processing unit 103 includes dynamic memory type RAM, non-volatile memory type FLASH and a processor, which may consist of one or more identical or different microcontrollers, processors type ARM, DSP, CPU or programmable hardware such as CPLD or FPGA. The functions of the sensor processing unit 103 are to generate and transmit to the light-sensitive sensor 102 the signals necessary for its proper operation; to receive the signals generated by the sensor 102, decode them and format them as a data stream and control signals; to submit to the process analysis unit 104 the formatted data and signal flow; to receive feedback and control signals from the process analysis unit 104; to generate control signals of the lighting unit 110, as well as to monitor the proper functioning of all units.

The process analysis unit 104 receives the data stream and control signals generated by the sensor processing unit 103 by dividing the incoming data stream into two identical internal streams. The first internal stream creates and saves a dynamic sequence of images in the circular buffer 104.1, each time the buffer 104.1 contains a predetermined number of images. Each image is encoded with the exact production time received by the IEEE 1588 internal precision time server 104.2. The process analysis unit 104 sends the current contents of the circular buffer 104.1 to the output unit 105 upon request and receives a time code for the exact production time. from the external production server 202, operating according to the IEEE 1588 protocol. Through the second internal flow and by means of the set algorithms in the image analysis module 104.3 a new data stream is created, carrying information about the parameters of the product located on the production line. to the output unit 105. The process analysis unit 104 transmits to the output unit 105 control signals that are internally generated as well as control signals generated by the sensor processing unit 103.

The output unit 105 includes a circuit for reformatting the data flow and control signals, and a circuit for interface to an external device. The functions of the output unit 105 are to receive the data stream generated by the process analysis unit 104, carrying information about the product parameters from the internal server for precise time 104.2; to receive the generated data stream representing the contents of the circular buffer 104.1; to integrate and format both streams as a new stream of data and control signals, according to standard or non-standard communication protocol type GigE, GigE Vision, TCP / IP, Wi-Fi and / or Bluetooth; transmitting the newly formatted data stream and control signals to the interface connector 109; to receive and transmit control signals to and from the control center 200; to receive and retrieve information about the exact production time encoded in the communication protocol and to submit it to the internal server for precise time 104.2 in the process analysis unit 104; to receive an external power supply supplied by the interface connector 109 and / or to extract a power supply provided by the communication protocol, if the protocol allows it, as well as to supply the received and / or created power supply to the power supply unit 106.

The power supply unit 106 includes a plurality of pulse and linear voltage converters, as well as a circuit for sequentially turning the individual voltages on and off. The functions of the power supply unit 106 are to generate different operating voltages necessary for the proper operation of the individual modules; to provide protection against overload of the individual voltage converters; to switch the individual converters on and off in a predetermined sequence, as well as to receive the supplied voltage from the output unit 105.

The interface connector 109 includes a connector, the type of which is determined by the output selected

3822 UI drink block 105 standard or non-standard communication protocol. The functions of the interface connector 109 are to receive from the output unit 105 the formatted new data stream and to transmit it to the external control center 200; to receive and transmit control signals to and from the module for management and control of the production process 203; to receive supply voltage from an external source and transmit it to the power supply unit 106.

The lighting unit 110 includes at least one light emitter and a circuit for controlling the brightness of the emitted light. Its functions are to receive control signals from the sensor processing unit 103; to receive a supply voltage from the power supply unit 106 and convert it into light with a desired spectral range; to control the brightness of the emitted light depending on the given control signals and to illuminate a certain part of the production line 300 and the products on it, located in front of the lens 101.

The housing 100 of the chamber is a mechanical structure that envelops and protects the individual blocks of the chamber, taking away the heat generated by the inner blocks. The housing 100 can be attached to external surfaces and allows external elements to be attached to it.

The external control center 200 may be a computer or server comprising a file server 201 for storing information received from individual intelligent Ethernet IP cameras, a production time server 202 operating according to the IEEE 1588 protocol for submitting a time code to the connected cameras and the module. for controlling and controlling the production process 203. The external control center 200 may be local or remote, and the connection between the center 200 and the camera may be wired or wireless.

The created intelligent Ethernet 1P camera for monitoring and analysis of production processes is used as follows.

The lighting unit 110 receives voltage from the power supply unit 106 and control signals from the sensor processing unit 103, generating a stream of light that illuminates a certain part of the production line 300 and the products located on that part. The light reflected from the products and the production line 300 passes through the lens 101 and focuses on the light-sensitive surface of the sensor 102. The sensor 102 converts the created projection into a digital data stream representing a digital model of the defined part of the production line and products. The sensor processing unit 103 generates all the necessary signals to ensure proper operation of the sensor 102, while also receiving the data stream generated by the sensor 102. The sensor processing unit 103 processes the data stream and converts it into a data stream and control signals using the available sensor processing algorithms. The thus obtained new data stream and control signals are fed for further processing of the process analysis unit 104. The process analysis unit 104 receives the data stream and control signals generated by the sensor processing unit 103 and divides it into a data stream. and a flow of control signals. The process analysis unit 104 further divides the newly created data stream into two identical internal streams and uses the first internal stream to create and maintain the dynamic sequence of images in the circular buffer 104.1, at any time the buffer 104.1 contains a predetermined number of images. on a new image, the oldest is deleted. Circular buffer 104.1 retrieves from the internal IEEE 1588 precision time server 104.2 the exact production time and encodes it in each image before it is saved. Upon receiving a signal to stop and / or malfunction the production line 300, the contents of the circular buffer 104.1 are fed to the output unit 105 and sent to the control center 200. Because the circular buffer 104.1 stores a number of images taken before the line stops , and each image carries information about the exact time and place where it was obtained, the analysis of these images will show unambiguously where, when and what led to the malfunction of the production line. The process analysis unit 104 uses the second internal data stream and feeds it to the image analysis module 104.3, where by means of the algorithms set in the module, an assessment is made as to whether the product meets the set quality parameters. The image analysis module 104.3 creates a new data stream carrying

3822 UI information about the parameters and quality of the product located on the production line 300 and feeds it to the output unit 105. If the analysis of the parameters of the product proves that the product is unfit or does not meet the standard, the control center 200 is fed control signal and the product is removed from the production line 300. In parallel, the process analysis unit 104 converts the flow of control signals received from the sensor processing unit 103, mixes it with an internally generated flow of control signals and transmits it to the output unit 105. The output unit 105 receives the newly created from the process analysis unit 104 data streams and control signals and reformats them into the appropriate output format, which can be digital, working with some of the standards TCP / IP, GigE, GigE Vision, USB, wireless Wi-Fi, Bluetooth or any other standard or non-standard output format. The output signal thus formed is fed to the interface connector 109, which is connected to the external control center 200. Additionally, an external voltage is applied through the interface connector 109, which is necessary for the operation of the camera. The camera can also receive voltage by extracting the voltage that is integrated with the data in the output protocol. Some digital standards, such as GigE, GigE Vision and USB, allow such integration. The power supply module 106 receives the supplied external and / or extracted internal power supply and converts it into voltages that are applied to the individual units of the chamber. Additionally, during the start and stop of the camera, the power supply 106 sets the sequence in which these voltages are activated and deactivated. The control center 200 supplies to the smart camera and the production line 300 information about the exact production time obtained from the production time server 202 operating according to the IEEE 1588 protocol. Thus, the time and spatial coordinates of each section of the production line 300 and the products moving on it are unambiguously defined.

Examples of application of the utility model

The use of the created intelligent Ethernet IP camera will significantly improve productivity and production costs, eliminating the need to use separate machine vision systems to monitor the production line and to check the quality of manufactured products. The created intelligent Ethernet 1P camera will instantly recognize the defective products and will take them out of the production process in the early stages of production, so that further processing will not be performed on defective products. This will further lead to a significant reduction in costs, energy and the use of natural resources. In addition, the intelligent Ethernet IP camera will improve line performance, reduce downtime, help determine the cause of production line malfunctions, allow you to "track" when a problem has occurred and alert the line operator in a timely manner. . This will allow the identified problem areas to be "marked" and the information about them to be used to prevent similar problems from occurring in other similar production processes. Due to its small size, this camera can be used in difficult working conditions or where there are dangerous or toxic working conditions.

Claims (1)

3822 UI Claims Intelligent Ethernet IP camera for monitoring and analysis of production processes, characterized in that it consists of at least one image capture module equipped with a housing (100) to which a lens for image focusing is mechanically connected (101) ), a light-sensitive sensor (102), an interface connector (109) and a lighting unit (110), wherein a sensor processing unit (103), a process analysis unit (104) consisting of a circular buffer are arranged in the housing (100). (104.1), an internal precision time server (104.2) and an image analysis module (104.3), an output unit (105) and a power supply unit (106), the light-sensitive sensor (102) being optically connected to the lens on the one hand. for focusing an image (101), and on the other hand, is connected in two directions by means of a first system bus to the sensor processing unit (103), wherein the sensor processing unit is, on the one hand, unidirectionally connected to the lighting unit (110) and the other side is bidirectionally connected by means of a second system bus with the circuit buffer (104.1) and the image analysis module (104.3) in the process analysis unit (104), the circuit buffer (104.1) being connected in both directions to the output unit (105) and to the internal server for precision time (104.2), which in turn is connected to the output unit (105) via a third system bus, and the image analysis module (104.3) is connected to the output unit (105) via a fourth system bus, which is connected in both directions to the interface connector (109), wherein the interface connector (109) is bidirectionally connected to an external control center (200) including a file server (201) bidirectionally connected to a production IEEE 1588 precision time server (202) that is bidirectionally connected to a module for controlling and controlling the production process (203), the power supply unit (106) being connected in one direction by power busbars to the light-sensitive sensor (102), to the lighting unit (110), to the sensor processing unit (103), to the analysis unit on processes (104) and with the output unit (105).