JPH09200734A - Monitoring device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device for monitoring abnormality which gradually proceeds, at low cost. SOLUTION: A device to be a monitor object performs a cyclic operation. The image of this operation is picked up by three television camera 11 at prescribed positions. The image picked up by the television cameras 11 is sent to a switcher 15. A video switching signal is sent from a controller 31 at the device to be the monitor object to a control part 20 at rescribed timing and each time this signal is received, an image to be fetched is switched by controlling the switcher 15. The fetched image is compared with a reference image previously stored in a reference pattern memory 12 by a comparator 19, the operation shift of device or the position shift to work is detected and in the case of position shift exceeding a specified value, this image is stored in an abnormal pattern memory 21.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a monitoring device for monitoring a specific event during operation of a device to be monitored such as a production line or a processing machine.

[0002]

In Japanese Patent Laid-Open No. 63-24779, the operation of a device to be monitored is imaged by a television camera, and an image obtained from this television camera is recorded by a VTR to be obtained from the device. When a specific signal, for example, an abnormal signal is output, a recorded image within a predetermined time including the generation time point of this specific signal is left, and by observing it, the cause of the abnormality can be analyzed. Is proposed.

[0003]

In the monitoring device described in the above-mentioned publication, the video to be left out of the recorded video is determined by receiving an abnormal signal from the device to be monitored. Generally, a processing machine or a production line is provided with an abnormality detection function as a safety measure for temporarily stopping the operation when a person or machine itself is damaged or damaged. Therefore, in the monitoring device described in the above publication, it is possible to easily monitor for an abnormality as described above by receiving an abnormality signal,
Although it does not lead to abnormalities, it may become abnormal if left unattended.For example, an abnormality that gradually shifts the position at a specific location during cyclic operation, or the work conveyed by the conveyor varies at a specific location. There was a drawback that it was not possible to monitor for abnormalities that would cause a large positional shift.

The present invention has been made in consideration of the above problems, and provides a monitoring device for monitoring a displacement of a processing machine or a production line, a displacement of a processing target or a manufacturing target at a low cost. The purpose is to do.

[0005]

In order to achieve the above object, in the invention according to claim 1, a television camera for picking up an operation of a device to be monitored and the television camera at a specific timing during normal operation of the device are provided. An image obtained from the television camera is stored in advance as a reference image, and an image obtained from the television camera is captured at a specific timing during operation of the device, and the captured image is compared with the reference image read from the memory. It is provided with an abnormality detecting means for judging whether the operation of the device is good or not, and sending an abnormal signal when the judgment is negative, and an abnormality processing means for storing the captured image by receiving the abnormal signal. According to this, since the abnormality detecting means is provided, it is not necessary to separately provide the abnormality detecting mechanism in the device to be monitored. Also,
The image for which an abnormality has been determined is stored by the abnormality processing means, so there is no need to take data for the abnormality.

According to the second aspect of the present invention, the abnormality processing means records the image obtained from the television camera, and when the abnormality signal is received, the image is recorded within a predetermined time including the time when the abnormality signal is generated. It is provided with a recording means for leaving an image. According to this, it is possible to record the images before and after the image in which the abnormality is determined, which is useful for analyzing a sudden abnormality, for example.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION A monitoring device 10 shown in FIG. 1 comprises a television camera 11, a reference pattern memory 12, an abnormality detecting means, an abnormality processing means and the like. One or a plurality of TV cameras 11 are arranged in order to pick up an image of a positional deviation of a work machine or a production line or a positional deviation of a work at a specific location. The reference pattern memory 12 stores in advance, as a reference pattern image, an image obtained from the television camera at a specific timing during normal operation of each processing machine by input from the keyboard 13. This reference pattern image is required only for monitoring by the TV camera 11. This preparatory operation is performed by inputting from the keyboard 13, and C is used to confirm the captured image at this time.
RT14 is provided.

The abnormality detecting means is composed of the switch 15, the A / D 1
6, an image processing unit 17, an anomaly display unit 18, a comparator unit 19, and a control unit 20 for controlling these units. The control unit 20 switches and controls the switch 15 so as to capture a predetermined image among the images obtained from the television camera 11 according to a specific timing during operation of the device to be monitored. After switching the switching device 15, A / D1
6 is controlled to capture an image, where the image processing of a cutout image or the like is performed, and then the image is sent to the comparator 19. The comparator 19 compares the captured image with the reference image read out from the reference pattern memory 12 on the memory to determine whether the operation machine or the production line or the like is out of position or the work is out of position. If judged, an abnormal signal is sent out. Control unit 2
0 receives the abnormality signal and controls the abnormality indicator 18 to notify the outside of the abnormality.

The abnormality detecting means is the abnormality pattern memory 21.
And a control unit 20 for controlling this. Upon receiving the abnormal signal, the control unit 20 controls to store this image in the abnormal pattern memory 21. As a method of storing the abnormal image, if an image judged to be abnormal by the comparator 19 is recorded for each type of abnormality, later analysis is easy. In this case, a means for comparing the positional deviation between the image in which the abnormality is detected and the image previously stored in the abnormality pattern memory 21 on the data is required. Then, in the case of the same position shift, if this image is not recorded and only the previously recorded image is left, the memory can be saved.

The abnormality detecting means is provided with a recording means. The recording means records the video that has passed through the switching device 15 and, upon receiving the abnormal signal, leaves the recorded video within a predetermined time including the time when the abnormal signal occurs. This recording means comprises two VTRs (video tape recorders) 2
2, 23, a CRT 24, and a control unit 20 that controls these in a centralized manner. The video that has passed through the switch 15 is always recorded on the VTR 22. Control unit 20
By receiving the abnormal signal, the video recorded by the VTR 22 within another predetermined time including the time when the abnormal signal is generated is displayed on another VT.
Record on R23 and leave. The video recorded on VTR23 is
It can be displayed on the CRT 24 by operating the keyboard 13.

[0011]

EXAMPLE A processing line 25 shown in FIG. 2 conveys works 26 one by one by a conveyor 27, and first, second, and third
Processing is sequentially performed by the processing machines 28 to 30. These first, second,
The third processing machines 28 to 30 are collectively controlled by the controller 31. This processing line 25
Three TV cameras 11a to 11c are arranged to monitor the operation deviations of the first, second, and third processing machines 28 to 30 and the work position deviations on the respective processing machines 28 to 30, respectively. There is.

A specific timing signal of each of the processing machines 28 to 30 is sent from the processing line controller 31 to the control section 20. This signal is composed of a monitoring timing signal and a video switching signal. The monitoring timing signal is A /
This is a timing signal for driving D to capture an image in the comparator 19. As this signal, an output signal of a sensor or the like for detecting the operation of each of the processing machines 28 to 30 may be used as it is, or may be separately output in synchronization with the output signal of the sensor or the like.

The video switching signal is a timing signal for controlling the switch 15. This signal is sent to the first processing machine 2
8 before and after the operation of 8, the video captured by the TV camera 11a, before and after the operation of the second processing machine 29, the video captured by the TV camera 11b, before and after the operation of the third processing machine 30 TV camera 1
Each processing machine 2 so that the image picked up by 1c is captured.
The signal obtained from a sensor or the like for detecting the operations of 8 to 30 is used for output.

First, when the work 26 is set on the first processing machine 28, a video switching signal is sent from the controller 31 to the controller 20. The control unit 20 receives the video switching signal and controls the switching unit 15 to capture the video imaged by the television camera 11a. The video that has passed through the switch 15 is recorded by the VTR 22.

The operation of the above structure will be described with reference to FIG. The monitoring timing signal is output, for example, when the first processing machine 28 starts processing or at a specific timing during processing. Upon receiving this signal, the control unit 20 causes the A / D 16
Control to start capturing an image for one frame.
The A / D 16 digitizes this image and performs image processing 17
Send to The image processing 17 processes an image for one frame into a predetermined cutout range, and sends this to the comparator 19. The comparator 19 reads a predetermined reference image from the reference pattern memory 12, superimposes it on the captured image, and determines the degree of coincidence between the two by using the pattern matching method to determine the operation of the processing machine and the positional deviation from the work. To detect. When the comparator 19 determines that this positional deviation exceeds the specified value, an abnormal signal is sent to the control unit 20. Control unit 20
Receives an abnormality signal and displays an abnormality on the abnormality indicator 18.

As a pattern matching method, a binarized luminance signal is compared pixel by pixel to determine the number of pixels having different luminances, or a luminance signal having a gradation without binarization is used as a pixel. For example, there is a method of comparing each pixel and making a determination based on the number of pixels having different brightness. In the latter, for example, the luminance signal of the reference image is subtracted from the luminance signal of the captured image, and the number of pixel points of the luminance signal difference that exceeds a predetermined reference value is counted,
When the number exceeds a predetermined value, it is regarded as abnormal.

The captured image judged to be abnormal is stored in the abnormal pattern memory 21. In the captured image recorded here, the control unit 20 determines whether the positional deviation detected by the comparator 19 is the same as the positional deviation of the previously recorded captured image. The captured image of is not recorded and the captured image previously recorded is stored in the memory 2
Leave to 1. Further, in the case of different position shifts, they are recorded in the memory 21, respectively. As a result, since the abnormality is stored for each type, it is not necessary to perform data acquisition and analysis of the positional deviation one after another.

When the control unit 20 receives an abnormality from the comparator 19, the control unit 20 controls the dubbing of the image recorded by the VTR 22 to the VTR 23. This control
The recording operation of the VTR 22 is temporarily stopped, the video tape is rewound for a predetermined time from the time when the abnormality occurs, and the rewound portion of the video tape is played back when the rewind is completed. This reproduction is performed for a predetermined time from the time when the abnormality is received to the elapse of a predetermined time.
At the same time, the control unit 20 causes the VTR 23 to start the recording operation.

As a result, the images before and after the abnormality reproduced by the VRT 22 are recorded on the video tape of the VTR 23. When the reproduction of the VTR 22 is completed, the control unit 20
Stops the recording operation of the VTR 23 and
The video tape 22 is rewound to the beginning and the recording operation is continued again from the initial state. When analyzing the abnormal operation of the processing line 25, only the image recorded by the VTR 23 should be displayed on the CRT 24 and observed. It should be noted that a VTR may be newly provided so that the VTR 22 records the video while the VTR 22 is reproducing and rewinding.

Next, the work 26 is set on the second processing machine 29, and the video switching signal is sent from the controller 31 to the control section 20. The control unit 20 receives the video switching signal and controls the switching unit 15 to capture the video imaged by the television camera 11b. Then, the monitoring timing signal is output, for example, at a specific timing when the second processing machine 29 starts processing or during processing. As a result, the abnormality detection in the second processing machine 29 is performed as described above.

When the work 26 is set in the third processing machine 30, a video switching signal is sent from the controller 31 to the control section 20, and the switching device 15 is controlled so as to capture the video imaged by the television camera 11c. It Then, the monitoring timing signal is output, for example, at a specific timing when the third processing machine 30 starts processing or during processing.
Thereby, the abnormality detection in the third processing machine 30 is performed as described above.

As described above, in the present embodiment, the processing machines 28 to 30 that perform a cyclic operation are sequentially imaged by the television camera 11, and the abnormality is detected based on each of the captured images. It is possible to detect even an abnormality such as a deviation or a positional deviation of the work that gradually progresses.

The keyboard 13 is used to set or replace the reference image. As for the operation, first, the image based on the monitoring timing signal is captured, and the captured image is CR.
Check by displaying on T14. The keyboard 13 is provided with a position designation circuit. By using this position designating circuit, the range of the cut-out image in the image range is designated. The position designation data at this time is also used when creating a cutout image by image processing. During this operation, a specified value, a reference value, or the like, which is a judgment factor in pattern matching, is set.

In the above embodiment, the processing line is used as the device to be monitored, but the present invention is not limited to this, and
It goes without saying that any device that performs a periodic operation can be used.

[0025]

As described above in detail, in the invention according to the first aspect, since the memory and the abnormality detecting means are provided, the abnormality can be detected by the monitoring device itself. For this reason, it is possible to reliably detect gradually advancing abnormalities, which were conventionally judged by a person visually, and it is not necessary to separately provide an abnormality detecting mechanism or the like in the device to be monitored. Can be made at low cost. Further, since the abnormal image is stored in the abnormal processing means, the operation of analyzing the abnormality can be easily performed, and an early countermeasure can be taken.

According to the second aspect of the present invention, since the abnormality processing means is provided with the recording means, it is possible to observe the images before and after the image judged to be abnormal, and to analyze the sudden abnormality. You can

[Brief description of drawings]

FIG. 1 is a block diagram of a monitoring device of the present invention.

FIG. 2 is an explanatory diagram showing an outline of an embodiment of an apparatus to be monitored.

FIG. 3 is a flowchart showing the operation of the monitoring device.

[Explanation of symbols]

 11 TV camera 12 Reference pattern memory 15 Switching device 17 Image processor 19 Comparator 20 Control unit

Claims (2)

[Claims] 1. A television camera that captures an operation of a device to be monitored, a memory that stores in advance an image obtained from the television camera as a reference image at a specific timing during normal operation of the device, and an operation of the device. Capture the image obtained from the TV camera at a specific timing inside,
The captured image is compared with a reference image read from the memory to judge whether the operation of the apparatus is good or not, and an abnormal signal is transmitted when it is judged to be unsatisfactory, and the captured image by receiving the abnormal signal. A monitoring apparatus comprising: an abnormality processing unit that stores an image. 2. The abnormality processing means records a video image obtained from the television camera, and, upon receiving the abnormal signal, a recording means for leaving a video image recorded within a predetermined time including a time point of occurrence of the abnormal signal. The monitoring device according to claim 1, wherein the monitoring device is provided.