TWI700567B - Image analysis apparatus for industrial plants and industrial plant monitoring control system - Google Patents
Image analysis apparatus for industrial plants and industrial plant monitoring control system Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
- B21B37/28—Control of flatness or profile during rolling of strip, sheets or plates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
- B21B37/46—Roll speed or drive motor control
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- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
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Abstract
Description
本發明係有關一種產業工廠用畫像解析裝置及產業工廠監視控制系統。 The present invention relates to an image analysis device for an industrial factory and an industrial factory monitoring and control system.
已知有生產工業活動所需之材料、資源的產業工廠(鋼鐵工廠、發電工廠、石油工廠、化學工廠等)。產業工廠的工廠監視控制系統係經由控制用網路具備連接有構成工廠之大量的現場設備(包含致動器、感測器)的輸出入裝置(I/O)、控制大量的現場設備之可編程邏輯控制器(以下稱為PLC)彼此連接的構成。 Known to have industrial plants (steel plants, power plants, petroleum plants, chemical plants, etc.) that produce materials and resources required for industrial activities. The factory monitoring and control system of an industrial factory is equipped with input and output devices (I/O) connected to a large number of field devices (including actuators and sensors) that constitute the factory through a control network, and can control a large number of field devices. A configuration in which programming logic controllers (hereinafter referred to as PLCs) are connected to each other.
此外,做為PLC、輸出入裝置之輸出入信號的製程資料係被收集在具有資料收集功能和資料播放功能的資料收集裝置。資料收集裝置係顯示所收集的製程資料,操作者為掌握產業工廠的狀態而使用。 In addition, the process data as the input and output signals of the PLC and I/O devices are collected in a data collection device with data collection and data playback functions. The data collection device displays the collected process data and is used by the operator to grasp the status of the industrial plant.
就輸出製程資料之感測器的一例而言,專利文獻1已揭示配置在鋼鐵工廠的HMD(Hot Metal Detector,熱金屬探測器)。該HMD係設置在軋輥下游之 輥道正上方的預定高度的位置,檢測的方向設定在與軋輥大致垂直之方向且朝向水平方向的方向。HMD為具有狹窄視野的雷射感測器,在視野中若檢測到熱質量就輸出ON信號,若沒有檢測到熱質量則輸出OFF信號。 As for an example of a sensor that outputs process data,
專利文獻1:日本特開2016-87652號公報 Patent Document 1: Japanese Patent Application Publication No. 2016-87652
專利文獻2:國際公開第2014/002176號 Patent Document 2: International Publication No. 2014/002176
如專利文獻1所述,藉由配置感測器可檢測熱質量(軋材)的向上翹曲。但是感測器價格昂貴,其設置地點亦有所限定。另外,感測器僅輸出ON信號或OFF信號,無法詳細掌握軋材的狀態(形狀、位置等)。 As described in
為解決上述缺點,本案發明人進行深入研究的結果,開發出將以一般的照相機拍攝之拍攝對象的動態畫像資料當作感測器而使用。藉由使用照相機可得到成本降低、相較於上述感測器拍攝範圍廣且設置地點的自由度高、資訊量比感測器輸出多等優點。 In order to solve the above-mentioned shortcomings, the inventor of the present case has conducted in-depth research and developed the dynamic image data of the subject taken with a general camera to be used as a sensor. By using a camera, the advantages of cost reduction, wider shooting range compared with the above-mentioned sensor, higher freedom of installation location, and more information output than the sensor can be obtained.
另一方面,在對以照相機拍攝之拍攝對象的狀態進行確認時,單純以肉眼觀察動態畫像資料也僅是以目測進行的判斷,確認的準確度低。因此期望提高確認的準確度的處理。 On the other hand, when confirming the state of the subject photographed by the camera, the visual observation of the dynamic image data is only a visual judgment, and the accuracy of the confirmation is low. Therefore, processing to improve the accuracy of confirmation is desired.
本發明係為解決上述課題而成者,目的在於提供一種產業工廠用畫像解析裝置,該裝置係使用動態畫像資料將拍攝對象的狀態即時量化解析,並可支援確認產業工廠之營運狀況的操作者。 The present invention was made in order to solve the above problems, and its purpose is to provide an image analysis device for industrial factories, which uses dynamic image data to quantitatively analyze the state of the subject in real time, and can support operators who confirm the operating conditions of industrial factories .
又,本發明的另一目的在於提供一種產業工廠監視控制系統,該系統係使用藉由產業工廠用畫像解析裝置量化的資料,可實現依照拍攝對象的狀態進行之適當的控制。 In addition, another object of the present invention is to provide an industrial factory monitoring and control system that uses data quantified by the industrial factory's image analysis device to achieve appropriate control according to the state of the subject.
為達成上述目的,本實施形態之產業工廠用畫像解析裝置係構成如下。產業工廠用畫像解析裝置係具備動態畫像資料收集部、畫像加工處理部、畫像量化部及數值輸出部。 In order to achieve the above-mentioned object, the image analysis device for industrial factories of this embodiment is configured as follows. The image analysis device for industrial plants is equipped with a dynamic image data collection unit, an image processing unit, an image quantization unit, and a numerical output unit.
動態畫像資料收集部係即時收集拍攝構成產業工廠的機器及在該機器加工的材料而得之動態畫像資料。即時不一定指拍攝的瞬間,包含因通訊路徑、資料處理而導致之會伴隨延遲的資料收集,或間隔一定周期的資料收集。 The dynamic image data collection department collects real-time dynamic image data obtained by photographing the machinery that constitutes an industrial factory and the materials processed in the machinery. Real-time does not necessarily refer to the moment of shooting. It includes data collection with delays due to communication paths and data processing, or data collection at a certain interval.
畫像加工處理部係在每個一定周期從前述動態畫像資料抽出畫像,將指定顏色轉換為第一顏色,該指定顏色以外的顏色轉換為第二顏色,而對該畫像進行二值化。一定周期較佳為儘可能為短周期,較理想為即時。畫像係指從動態畫像資料抽出的1幀畫像。指定顏色不僅為單一顏色,亦包含所指定之顏色的範圍。 The image processing unit extracts an image from the aforementioned dynamic image data every certain period, converts the specified color into a first color, and converts colors other than the specified color into a second color, and binarizes the image. The certain period is preferably as short as possible, and more preferably instant. Portrait refers to a frame of portrait extracted from dynamic portrait data. The specified color is not only a single color, but also includes the specified color range.
畫像量化部係依據轉換為前述第一顏色之 畫素數來量化前述二值化的畫像。在一形態中,畫像量化部係計算將前述二值化的畫像以與前述材料的搬運方向平行地分割而成之各帶狀區域中前述第一顏色所佔的比例。在其他形態中,畫像量化部係計算將前述二值化的畫像分割成格子狀的各格子狀區域中前述第一顏色所佔的比例。 The image quantization unit quantifies the binarized image based on the number of pixels converted into the first color. In one aspect, the image quantization unit calculates the proportion of the first color in each band-shaped region formed by dividing the binarized image parallel to the conveying direction of the material. In another aspect, the image quantization unit calculates the proportion of the first color in each grid-like region that divides the binarized image into a grid.
數值輸出部係輸出前述量化的資料。 The numerical output unit outputs the aforementioned quantized data.
為達成上述目的,本實施形態之產業工廠監視控制系統係構成如下。產業工廠監視控制系統係具備上述之產業工廠用畫像解析裝置及控制前述機器的可編程邏輯控制器。 To achieve the above-mentioned object, the industrial plant monitoring and control system of this embodiment is configured as follows. The industrial factory monitoring and control system is equipped with the aforementioned industrial factory image analysis device and a programmable logic controller that controls the aforementioned equipment.
前述機器係包含軋製做為前述材料之軋材的一對軋輥。畫像加工處理部係將從寬度方向觀看前述軋材之前述畫像進行二值化。 The aforementioned machine system includes a pair of rolls for rolling a rolled material as the aforementioned material. The image processing unit binarizes the image of the rolling material viewed from the width direction.
在一形態中,畫像量化部和可編程邏輯控制器係構成如下。 In one aspect, the image quantization unit and the programmable logic controller are configured as follows.
畫像量化部係使前述二值化的畫像與前述軋材的搬運方向平行,至少分割成第1區域及相鄰於第1區域上方的第2區域,計算各區域中前述第一顏色所佔的比例。 The image quantization unit makes the binarized image parallel to the conveying direction of the rolling material, and divides it into at least the first area and the second area adjacent to the first area, and calculates the amount of the first color in each area proportion.
可編程邏輯控制器係在第2區域中之前述第一顏色所佔的比例的增加量與第1區域中之前述第一顏色所佔的比例的減少量的差比臨界值大時,輸出警告信號及控制信號中的至少一個,該控制信號係改變前述一對軋輥之旋轉速度以抑制前述軋材向上翹曲。例如控制信號為 使前述一對軋輥停止的信號,或者為使下軋輥之旋轉速度比上軋輥之旋轉速度慢的信號。 The programmable logic controller outputs a warning when the difference between the increase in the proportion of the first color in the second area and the decrease in the proportion of the first color in the first area is greater than the threshold At least one of a signal and a control signal. The control signal changes the rotation speed of the pair of rolls to suppress the upward warping of the rolled material. For example, the control signal is a signal for stopping the aforementioned pair of rolls, or a signal for making the rotation speed of the lower roll slower than the rotation speed of the upper roll.
在另一形態中,畫像量化部和可編程邏輯控制器係構成如下。 In another aspect, the image quantization unit and the programmable logic controller are configured as follows.
畫像量化部係將前述二值化的畫像至少分割成格子狀的第1區域、相鄰於第1區域橫向的第2區域、相鄰於第1區域上方的第3區域、相鄰於第2區域上方且相鄰於第3區域橫向的第4區域,並計算各區域中前述第一顏色所佔的比例。 The image quantization unit divides the binarized image into at least a grid-like first area, a second area adjacent to the first area laterally, a third area adjacent to the upper side of the first area, and a second area adjacent to the second area. The fourth area above the area and adjacent to the third area laterally, and the proportion of the aforementioned first color in each area is calculated.
可編程邏輯控制器係在前述第一顏色所佔的比例依第1區域、第2區域之順序增加,且第4區域中之前述第一顏色所佔的比例依據第3區域中之前述第一顏色所佔的比例的減少而增加時,輸出警告信號及控制信號中的至少一個,該控制信號係改變前述一對軋輥之旋轉速度以抑制前述軋材向上翹曲。例如控制信號為使前述一對軋輥停止的信號或者為使下軋輥之旋轉速度比上軋輥之旋轉速度慢的信號。 In the programmable logic controller, the proportion of the aforementioned first color increases in the order of the first area and the second area, and the proportion of the aforementioned first color in the fourth area is based on the aforementioned first color in the third area. When the proportion of the color decreases and increases, at least one of a warning signal and a control signal is output. The control signal changes the rotation speed of the pair of rollers to suppress the upward warpage of the rolled material. For example, the control signal is a signal to stop the aforementioned pair of rolls or a signal to make the rotation speed of the lower roll slower than the rotation speed of the upper roll.
根據本發明之產業工廠用畫像解析裝置,可使用動態畫像資料將拍攝對象的狀態即時量化解析,並可支援確認產業工廠之營運狀況的操作者。又,根據本發明之產業工廠監視控制系統,使用藉由產業工廠用畫像解析裝置量化的資料,可實現適當的控制。 According to the image analysis device for industrial factories of the present invention, dynamic image data can be used to quantitatively analyze the state of the subject in real time, and can support operators who confirm the operating conditions of industrial factories. Furthermore, according to the industrial factory monitoring and control system of the present invention, appropriate control can be achieved by using data quantified by the image analysis device for the industrial factory.
1‧‧‧畫像解析裝置 1‧‧‧Image analysis device
2‧‧‧第1監視照相機 2‧‧‧The first surveillance camera
3‧‧‧第2監視照相機 3‧‧‧Second surveillance camera
4‧‧‧畫像資料轉換器 4‧‧‧Image data converter
5‧‧‧畫像用信號線 5‧‧‧Signal line for portrait
6‧‧‧動態畫像用網路 6‧‧‧Network for dynamic portrait
7‧‧‧資料收集裝置 7‧‧‧Data collection device
8‧‧‧人機界面 8‧‧‧Human Machine Interface
9‧‧‧可編程邏輯控制器 9‧‧‧Programmable Logic Controller
10‧‧‧控制用網路 10‧‧‧Control network
21‧‧‧動態畫像資料收集部 21‧‧‧Dynamic Portrait Data Collection Department
22‧‧‧畫像加工處理部 22‧‧‧Image Processing Department
23‧‧‧畫像量化部 23‧‧‧Image Quantization Department
24‧‧‧數值輸出部 24‧‧‧Numerical output
31‧‧‧左視窗 31‧‧‧Left Window
32‧‧‧中央視窗 32‧‧‧Central Window
33‧‧‧右視窗 33‧‧‧Right window
41‧‧‧濾色器部 41‧‧‧Color filter
42‧‧‧二值化部 42‧‧‧Binaryization Department
43‧‧‧映像加工部 43‧‧‧Image Processing Department
50‧‧‧帶狀量化處理部 50‧‧‧Strip quantization processing section
51‧‧‧帶狀區域A 51‧‧‧Band A
52‧‧‧帶狀區域B 52‧‧‧Band B
53‧‧‧帶狀區域C 53‧‧‧belt area C
54‧‧‧帶狀區域D 54‧‧‧Banded area D
60‧‧‧格子狀量化處理部 60‧‧‧Grid-shaped quantization processing unit
61‧‧‧格子狀區域A 61‧‧‧Grid-shaped area A
62‧‧‧格子狀區域B 62‧‧‧Grid-shaped area B
63‧‧‧格子狀區域C 63‧‧‧Grid-like area C
64‧‧‧格子狀區域D 64‧‧‧Grid-like area D
65‧‧‧格子狀區域E 65‧‧‧Grid-like area E
66‧‧‧格子狀區域F 66‧‧‧Grid-like area F
67‧‧‧格子狀區域G 67‧‧‧Grid-shaped area G
68‧‧‧格子狀區域H 68‧‧‧Grid-like area H
69‧‧‧格子狀區域I 69‧‧‧Grid-like area I
70‧‧‧格子狀區域J 70‧‧‧Grid-like area J
71‧‧‧格子狀區域K 71‧‧‧Grid-like area K
72‧‧‧格子狀區域L 72‧‧‧Lattice area L
111‧‧‧CPU 111‧‧‧CPU
112‧‧‧記憶體 112‧‧‧Memory
113‧‧‧儲存器 113‧‧‧Storage
113a‧‧‧程式記憶部 113a‧‧‧Program Memory
113b‧‧‧資料記憶部 113b‧‧‧Data Memory Department
114‧‧‧外部機器界面部 114‧‧‧External machine interface
115a‧‧‧控制用網路界面部 115a‧‧‧Network interface for control
115b‧‧‧動態畫像用網路界面部 115b‧‧‧Network interface for dynamic image
116‧‧‧內部匯流排 116‧‧‧Internal bus
117‧‧‧顯示器 117‧‧‧Display
118‧‧‧鍵盤 118‧‧‧Keyboard
119‧‧‧滑鼠 119‧‧‧Mouse
311‧‧‧軋材 311‧‧‧Rolled products
312‧‧‧軋輥 312‧‧‧roll
313‧‧‧搬運輥 313‧‧‧Transport roller
321‧‧‧表示軋材的部分 321‧‧‧ indicates the part of rolled material
322‧‧‧其他的部分 322‧‧‧Other parts
第1圖係顯示實施形態1之產業工廠的工廠監視控制系統的構成的示意圖。 Fig. 1 is a schematic diagram showing the configuration of the factory monitoring and control system of the industrial factory in the first embodiment.
第2圖係實施形態1之畫像解析裝置的方塊圖。 Fig. 2 is a block diagram of the image analysis device in the first embodiment.
第3圖係實施形態1之畫像解析裝置的畫面顯示例。 Fig. 3 is an example of screen display of the image analysis device of the first embodiment.
第4圖係顯示畫像解析裝置所具有之處理電路的硬體構成例的方塊圖。 Figure 4 is a block diagram showing an example of the hardware configuration of the processing circuit included in the image analysis device.
第5圖係實施形態2之畫像解析裝置的方塊圖。 Fig. 5 is a block diagram of the image analysis device of the second embodiment.
第6圖係實施形態2之畫像解析裝置的解析例。 Fig. 6 is an analysis example of the image analysis device of the second embodiment.
第7圖係實施形態3之畫像解析裝置的方塊圖。 Fig. 7 is a block diagram of the image analysis device of the third embodiment.
第8圖係實施形態3之畫像解析裝置的解析例。 Fig. 8 is an analysis example of the image analysis device in the third embodiment.
以下,參照圖面詳細說明本發明之實施形態。另外,對於各圖中的共同元件係賦予同樣的符號並省略重複說明。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, the same reference numerals are given to common elements in the respective drawings, and repeated descriptions are omitted.
實施形態1
(系統構成) (System Components)
第1圖係顯示實施形態1之產業工廠的工廠監視控制系統的構成的示意圖。 Fig. 1 is a schematic diagram showing the configuration of the factory monitoring and control system of the industrial factory in the first embodiment.
鋼鐵工廠為生產工業活動所需之材料、資源的一種產業工廠。在熱軋中,以加熱爐加熱之高溫的板坯(軋材)係藉由搬運輥搬運,用粗軋機和精軋機薄薄地延伸至所需的厚度,同時加工成所需的寬度,最後用捲取機捲繞。 A steel factory is an industrial factory that produces materials and resources required for industrial activities. In hot rolling, the high-temperature slab (rolled material) heated by the heating furnace is transported by conveying rollers, stretched thinly to the required thickness by the roughing mill and finishing mill, and processed to the required width at the same time, and finally used Coiler winding.
工廠監視控制系統係連接畫像解析裝置1、第1監視照相機2、第2監視照相機3、資料收集裝置7、HMI(HUMAN MACHINE INTERFACE,人機界面)8、PLC 9及構成產業工廠之機器(省略圖示)等而構成。 The factory monitoring and control system is connected to the
第1監視照相機2及第2監視照相機3係配置成將構成產業工廠之機器及在機器加工之材料包含於拍攝範圍。第1監視照相機2係經由畫像用信號線5連接在畫像資料轉換器4。第1監視照相機2的影像輸出係藉由畫像資料轉換器4轉換為能夠進行網路通訊的信號,並經由動態畫像用網路6傳送至畫像解析裝置1。第2監視照相機3為網路照相機,所拍攝的動態畫像資料經由動態畫像用網路6傳送至畫像解析裝置1。 The
畫像解析裝置1係經由控制用網路10連接控制構成產業工廠之機器(包含致動器、感測器)的可編程邏輯控制器(PLC)9、做為操作者在產業工廠的一般操作或監視中使用之監視控制裝置的人機界面(HMI)8及資料收集裝置7。此外,也有畫像解析裝置1組裝到資料收集裝置7的情況。 The
控制用網路10具備複數個具有公用記憶體的節點,藉由在複數個節點間周期性廣播傳輸使公用記憶體上的資料同步。藉此,在畫像解析裝置1、PLC 9、HMI 8之間共有虛擬的同一個記憶體空間。在公用記憶體分配有各資料的記憶區域(位址)。連接在各節點的裝置可藉由對公用記憶體的寫入、讀取來傳送及接收資料。 The
(畫像解析裝置) (Image analysis device)
畫像解析裝置1係具備動態畫像資料收集部21、畫像加工處理部22、畫像量化部23及數值輸出部24。 The
動態畫像資料收集部21係即時收集拍攝構成產業工廠的機器及在該機器加工的材料之動態畫像資料。即時不一定指拍攝的瞬間,亦包含因通訊路徑、資料處理而導致伴隨著延遲的資料收集或間隔一定周期的資料收集。具體而言,動態畫像資料收集部21係經由動態畫像用網路6從第1監視照相機2、第2監視照相機3間隔一定周期收集動態畫像資料。動態畫像資料收集部21係將動態畫像資料輸出至畫像加工處理部22。動態畫像資料收集部21係將所收集的動態畫像儲存在儲存器113的資料記憶部113b。 The dynamic image
畫像加工處理部22係在每個一定周期從動態畫像資料抽出畫像,將指定顏色轉換為第一顏色,該指定顏色以外的顏色轉換為第二顏色,而對該畫像進行二值化。一定周期較佳為儘可能為短周期,較理想為即時。畫像係指從動態畫像資料抽出的1幀畫像。指定顏色不僅為單一顏色,亦包含所指定之顏色的範圍。 The
具體而言,畫像加工處理部22係使用第2圖所示的濾色器部41、二值化部42、映像加工部43將畫像加工,再將已加工的畫像輸出至畫像量化部23。 Specifically, the
濾色器部41係抽出與畫像中的機器、材料相關的指定顏色。就指定顏色而言,例如預先設定熾熱之 材料的顏色、顯示機器或材料的溫度異常的顏色等。 The
二值化部42係將指定顏色轉換為第一顏色(例如:白色),該指定顏色以外的顏色轉換為第二顏色(例如:黑色),而對該畫像進行二值化。藉此可以縮小資料量,減少畫像加工處理、量化處理的計算負荷,並可確保即時性。 The
映像加工部43係在第1監視照相機2或第2監視照相機3從對角線拍攝拍攝對象時,藉由進行映像轉換,轉換成從旁邊或上方觀看的畫像。藉此,照相機設置的靈活度高,不僅在拍攝對象的上方或旁邊無法設置照相機的情況,在拍攝對象的附近難以設置感測器的環境亦可應對。另外。能夠在拍攝對象的上方或旁邊設置照相機時,不一定要執行映像加工部43的處理。 When the
畫像量化部23係依據轉換為第一顏色之畫素數來量化前述二值化的畫像。例如依據藉由畫像加工處理部22轉換為第一顏色(例如:白色)之畫素數來算出第一顏色在畫像中所佔的比例。畫像量化部23係將已量化的資料輸出至數值輸出部24。 The
數值輸出部24係將已量化的資料經由控制用網路10輸出至資料收集裝置7、HMI 8、PLC 9。 The
第3圖係顯示畫像解析裝置1顯示在顯示器117(參照第4圖)的顯示例的圖。畫像解析裝置1係在左視窗31即時顯示所收集的動態畫像資料。在第3圖的例子中係顯示拍攝範圍包含軋製做為材料的軋材311的一對軋 輥312(粗軋機或精軋機)及搬運輥313,軋材311從左向右搬運並被一對軋輥312軋製的狀態。此外,畫像解析裝置1係在中央視窗32顯示將左視窗31顯示中的畫像二值化的畫像。表示軋材的部分321以白色顯示,其他的部分322以黑色顯示。又,畫像解析裝置1係在右視窗33顯示在二值化的畫像中表示白色所佔的比例之時間變化的圖表。在第6圖的例子中係顯示表示沿水平方向分割之各區域中白色所佔的比例之時間變化的圖表。 FIG. 3 is a diagram showing a display example displayed by the
資料收集裝置7係從PLC 9、HMI 8收集製程資料。製程資料係包含與構成產業工廠的機器以及在機器加工之材料相關的各種資料。例如包含致動器的控制值、感測器的檢測值、材料規格等。在鋼鐵工廠等的大規模工廠有多達數千、數萬的輸出入點,並存在有各式各樣的製程資料。該等製程資料係被收集在具有資料收集功能、資料播放功能的資料收集裝置7,並使用於測試時、調整時、操作時、故障時的資料分析。 The
另外,資料收集裝置7係從畫像解析裝置1接收量化的資料,且與製程資料同步並同時收集而予以儲存。又,資料收集裝置7係從畫像解析裝置1接收必要的資料,可實現與第3圖同樣的顯示。 In addition, the
HMI 8係將從PLC 9接收之製程資料以數值、文字以及燈號顯示。此外,HMI 8係具備發送按鈕輸入信號、數值輸入信號的操作按鈕,依據押下操作按鈕輸出用來控制PLC 9的信號。又,HMI 8係從畫像解析裝置 1接收量化的資料,並可顯示其數值,或可在其數值超過預定的臨界值時發出警報。
PLC 9係依據來自產業工廠的感測器的輸入進行計算,並輸出信號至閥門、馬達等致動器藉以控制產業工廠。此外,以與來自感測器的輸入相同的方式接收從畫像解析裝置1輸出的資料進行計算,並輸出信號至閥門、馬達等致動器藉以控制產業工廠。又,在計算結果超過臨界值時發出警報。 The PLC 9 performs calculations based on the input of sensors from industrial factories and outputs signals to actuators such as valves and motors to control industrial factories. In addition, the data output from the
如上述說明,根據實施形態1的畫像解析裝置1,藉由將從監視照相機即時收集的動態畫像予以量化,可以掌握拍攝對象進入拍攝範圍內的程度。因此,畫像解析裝置1可即時以量化方式解析機器及材料的位置和形狀,並可支援操作者對於營運狀態的確認作業。又,由於未使用特別的感測器故成本較低。例如可降低進行檢測熱軋帶鋼和厚板的翹曲時的感測器的設置費用。又,相較於感測器,拍攝範圍廣且設置場所的自由度高,故可在各種環境下掌握拍攝對象的狀態。 As described above, according to the
在上述的實施形態1中,係針對整體畫像計算轉換為第一顏色的畫素數,但並不限於此。亦可指定畫像的部分區域,計算該區域中轉換為第一顏色的畫素數。藉由規定在畫像內應注意的區域,可減少雜訊並提高檢測準確度。 In the first embodiment described above, the number of pixels converted into the first color is calculated for the entire image, but it is not limited to this. You can also specify a partial area of the portrait, and calculate the number of pixels in the area converted to the first color. By specifying the area that should be paid attention to in the image, noise can be reduced and detection accuracy can be improved.
此外,藉由使用上述實施形態1的畫像解析裝置1和資料收集裝置7,可以在資料收集裝置7上即 時顯示動態畫像資料,亦可從任意的指定時刻在資料收集裝置7上播放存儲在資料收集裝置7的動態畫像資料。使掌握過去現象的位置和尺寸變得容易,而可提高位置和尺寸的確認準確度。另外,亦可進行動態畫像的停止、快進、快退。又,上述內容在以下的實施形態亦相同。 In addition, by using the
此外,在上述實施形態1的畫像解析裝置1雖未包含後述之第4圖所示的顯示器117、鍵盤118、滑鼠119,在畫像解析裝置1亦可包含該等配備。又,上述內容在以下的實施形態亦相同。 In addition, although the
另外,在上述實施形態1中雖以鋼鐵工廠為例說明產業系統,但並不限於此。產業系統亦包含發電工廠、石油工廠、化學工廠等。 In addition, although the industrial system was explained by taking a steel factory as an example in the above-mentioned
(硬體構成例) (Example of hardware configuration)
參照第4圖說明畫像解析裝置1的硬體構成。第4圖係顯示畫像解析裝置1所具有之處理電路的硬體構成例的方塊圖。第2圖所示之畫像解析裝置1的各部位係表示畫像解析裝置1所具有之功能的一部分,各功能藉由處理電路實現。例如:處理電路係經由內部匯流排116連接CPU111、記憶體112、HDD或大容量記憶體等的儲存器113、外部機器界面(I/F)部114、控制用網路界面部115a、動態畫像用網路界面部115b而構成。又,資料收集裝置7亦為同樣構成。 The hardware configuration of the
CPU111係藉由執行儲存在儲存器113之程式記憶部113a的各種程式來實現畫像解析裝置1之各部位 的功能。 The
記憶體112係在CPU111執行各種程式時做為暫時儲存或展開資料的運算區域部來使用。 The
儲存器113係具有程式記憶部113a及資料記憶部113b。程式記憶部113a係儲存OS(OPERATING SYSTEM,操作系統)、各種程式。又,資料記憶部113b係記憶所收集之各時刻的製程資料、動態畫像資料。 The
又,在第4圖所示的例子中,雖在一個儲存器113中設置程式記憶部113a與資料記憶部113b,惟亦可在複數個儲存器分開設置程式記憶部113a與資料記憶部113b。 Furthermore, in the example shown in FIG. 4, although the
外部機器界面部114係用來連接顯示器117、鍵盤118、滑鼠119等的外部機器與畫像解析裝置1的界面。 The external
控制用網路界面部115a係用來連接控制用網路10與畫像解析裝置1的界面。又,動態畫像用網路界面部115b係用來連接動態畫像用網路6與畫像解析裝置1的界面。 The control
實施形態2
接著,參照第5圖和第6圖說明實施形態2。在上述的實施形態1中,係算出第一顏色佔整體畫像的比例。相對於此,在實施形態2中,係算出將畫像分割成帶狀之各帶狀區域中第一顏色所佔的比例,比較第一顏色在各帶狀區域所佔的比例的變化,更詳細地解析拍攝對象的狀態。 Next, the second embodiment will be described with reference to Figs. 5 and 6. In the first embodiment described above, the ratio of the first color to the overall image is calculated. On the other hand, in the second embodiment, the proportion of the first color in each band-shaped region that divides the image into bands is calculated, and the change in the proportion of the first color in each band-shaped region is compared in more detail. Analyze the state of the subject.
第5圖係實施形態2之畫像解析裝置1的方塊圖。第5圖所示的構成除了畫像量化部23具備帶狀量化處理部50之外,其餘與第2圖相同,故省略或簡略共通之構成的說明。 Fig. 5 is a block diagram of the
畫像加工處理部22係將從寬度方向觀看材料的畫像進行二值化。 The
帶狀量化處理部50係對於將藉由畫像加工處理部22進行二值化的畫像以與材料的搬運方向平行地分割而得各帶狀區域,算出第一顏色(例如:白色)所佔的比例。在第5圖的例子中,二值化的畫像係沿水平方向分割為4個區域。該分割的4個區域係由下而上稱為帶狀區域A51、帶狀區域B52、帶狀區域C53、帶狀區域D54。帶狀量化處理部50係算出在各帶狀區域中白色之畫素數的比例。 The band-shaped
即時算出將畫像分割為層狀而成的各帶狀區域中第一顏色所佔的比例(以下稱為第一顏色比例),藉由確認第一顏色比例的變化可定量地掌握拍攝對象的位置、形狀的變化。 Calculate the ratio of the first color in each band-shaped area (hereinafter referred to as the first color ratio) by dividing the image into layers in real time, and by confirming the change in the first color ratio, you can quantitatively grasp the position of the subject , Changes in shape.
例如會有做為材料的軋材311(參照第3圖)在鋼鐵工廠的搬運輥313(參照第3圖)上跳動的情況。此時,拍攝對象(軋材)係從帶狀區域A51平行移動至帶狀區域B52。因此,藉由確認帶狀區域B52之第一顏色比例的增加量等於帶狀區域A51之第一顏色比例的減少量,可確認拍攝對象為進行了平行移動。 For example, the rolled material 311 (refer to FIG. 3) used as a material may jump on the conveying roller 313 (refer to FIG. 3) of a steel factory. At this time, the photographic subject (rolled material) moves in parallel from the band-shaped area A51 to the band-shaped area B52. Therefore, by confirming that the increase in the first color ratio of the belt-shaped area B52 is equal to the decrease of the first color ratio in the belt-shaped area A51, it can be confirmed that the photographic subject has moved in parallel.
另一方面,會有拍攝對象的形狀變形的情況。例如在鋼鐵工廠的熱軋線、厚板線會有因軋製而在軋材311(參照第3圖)發生向上翹曲的情況。參照第6圖來說明畫像解析的例子。t1係前一周期之軋材的形狀,t2係現在周期之軋材的形狀。帶狀量化處理部50係使二值化的畫像以與軋材的搬運方向平行地,至少分割為帶狀區域A51和與帶狀區域A51上方相鄰的帶狀區域B52,算出各區域之第一顏色比例。帶狀區域A51和帶狀區域B52的邊界設定在軋材的上面和下面之間。 On the other hand, the shape of the subject may be deformed. For example, in a hot rolling line and a thick plate line of a steel plant, the rolled material 311 (refer to Fig. 3) may be warped upward due to rolling. Refer to Figure 6 to explain an example of image analysis. t1 is the shape of the rolled material in the previous cycle, and t2 is the shape of the rolled material in the current cycle. The band-shaped
操作者確認伴隨t1至t2的變化之各帶狀區域中的第一顏色比例的變化。藉由確認帶狀區域B52中的第一顏色比例的增加量與帶狀區域A51中的第一顏色比例的減少量的差的大小可定量地掌握軋材的向上翹曲。 The operator confirms the change in the first color ratio in each band-shaped area accompanying the change from t1 to t2. By confirming the magnitude of the difference between the increase in the first color ratio in the band-shaped area B52 and the decrease in the first color ratio in the band-shaped area A51, the upward warpage of the rolled material can be quantitatively grasped.
畫像解析裝置1係藉由顯示如第3圖的右視窗33所例示之表示各帶狀區域中的第一顏色比例的時間變化的圖表而可支援操作者的確認作業。 The
PLC9係接收由數值輸出部24所輸出的資料(各帶狀區域中的第一顏色比例)。PLC9可從各帶狀區域中的第一顏色比例來進行依據拍攝對象的位置之控制、依據拍攝對象的變化移動量之控制、依據拍攝對象的形狀之控制(例如依據向上翹曲量的控制)。 The PLC9 receives the data (the first color ratio in each band-shaped area) output by the
參照上述的第6圖說明依據向上翹曲量的控制。PLC9在帶狀區域B52中的第一顏色比例的增加量與帶狀區域A51中的第一顏色比例的減少量的差比臨界值 大時,輸出警告信號及控制信號中的至少一個,該控制信號係改變一對軋輥312之旋轉速度以抑制軋材向上翹曲。例如控制信號為使一對軋輥312停止的信號,或者為使下軋輥之旋轉速度比上軋輥之旋轉速度慢的信號。 The control based on the amount of upward warpage will be described with reference to the above-mentioned Fig. 6. The PLC9 outputs at least one of a warning signal and a control signal when the difference between the increase in the first color ratio in the belt-shaped area B52 and the decrease in the first color ratio in the belt-shaped area A51 is greater than the critical value, and the control The signal is to change the rotation speed of the pair of
另外,PLC9在帶狀區域B52中的第一顏色比例的增加量與帶狀區域A51中的第一顏色比例的減少量的差比第一臨界值大時,輸出使下軋輥之旋轉速度比上軋輥之旋轉速度慢的信號,當該差比第二臨界值(比第一臨界值大)大時,亦可輸出使一對軋輥312停止的信號。 In addition, when the difference between the increase in the first color ratio in the band-shaped area B52 and the decrease in the first color ratio in the band-shaped area A51 in the PLC9 is greater than the first critical value, the output is to make the rotation speed of the lower roll be higher than the upper The signal that the rotation speed of the rollers is slow, and when the difference is greater than the second critical value (larger than the first critical value), a signal to stop the pair of
又,PLC9在該差愈大時,亦可輸出緊急性高的警告信號。 In addition, the PLC9 may output a warning signal with high urgency when the difference becomes larger.
如上述說明,根據具備帶狀量化處理部50之本實施形態的系統,相較於實施形態1可更準確支援操作者對於機械、材料的位置或尺寸的確認作業。此外,PLC9使用藉由帶狀量化處理部50量化的資料可實現依據拍攝對象的狀態之適當的控制。例如改變控制值使做為拍攝對象的機器能夠移動到適當的位置,或是改變控制值以防止拍攝對象的軋材與感測器、機械碰撞。 As described above, according to the system of the present embodiment equipped with the band-shaped
又,上述之實施形態2的系統可與實施形態1的系統組合。這一點在以下的實施形態亦相同。 In addition, the system of
此外,上述之實施形態2的帶狀量化處理部50雖沿水平方向設定帶狀區域,惟亦可在垂直方向或傾斜方向設定帶狀區域。 In addition, although the band-shaped
另外,上述之實施形態2的帶狀量化處理 部50係將畫面分割為4個,惟亦可分割為2個、3個或5個以上。 In addition, the stripe
實施形態3
接著,參照第7圖和第8圖說明實施形態3。在上述的實施形態1中,係算出第一顏色佔整體畫像的比例。相對於此,在實施形態3中,係算出將畫像分割成格子狀之各格子狀區域中第一顏色所佔的比例,比較第一顏色在各格子狀區域所佔的比例的變化,更詳細地解析拍攝對象的狀態。 Next, the third embodiment will be described with reference to Figs. 7 and 8. In the first embodiment described above, the ratio of the first color to the overall image is calculated. On the other hand, in
第7圖係實施形態3之畫像解析裝置1的方塊圖。第7圖所示的構成除了畫像量化部23具備格子狀量化處理部60之外,其餘與第2圖或第5圖相同,故省略或簡略共通之構成的說明。 Fig. 7 is a block diagram of the
畫像加工處理部22係將從材料的寬度方向觀看的畫像進行二值化。 The
格子狀量化處理部60係算出將藉由畫像加工處理部22進行二值化而得的畫像分割為格子狀而成的各格子狀區域中,第一顏色(例如:白色)所佔的比例。在第7圖的例子中,二值化的畫像係在水平方向分割為4個區域、在垂直方向分割為3個區域,合計分割為12個區域。分割的區域稱為格子狀區域A61、格子狀區域B62、格子狀區域C63、格子狀區域D64、格子狀區域E65、格子狀區域F66、格子狀區域G67、格子狀區域H68、格子狀區域I69、格子狀區域J70、格子狀區域K71、格子狀區域 L72。格子狀量化處理部60係算出在各格子狀區域中白色之畫素數的比例。 The grid-like
即時算出將畫像分割為格子狀而成的各格子狀區域中第一顏色所佔的比例(以下稱為第一顏色比例),藉由確認第一顏色比例的變化可以量化方式掌握拍攝對象的位置、形狀的變化。 Calculate the proportion of the first color in each grid area (hereinafter referred to as the first color ratio) by dividing the image into grids in real time. By confirming the change in the first color ratio, the position of the subject can be grasped in a quantitative way , Changes in shape.
例如:會有做為材料的軋材311(參照第3圖)在鋼鐵工廠的搬運輥313(參照第3圖)上跳動的情況。此時,拍攝對象(軋材)係從格子狀區域A61平行移動至格子狀區域B62。因此,藉由確認格子狀區域A61之第一顏色比例的增加量等於格子狀區域B62之第一顏色比例的減少量,可確認拍攝對象平行移動。 For example, the rolled material 311 (refer to Fig. 3) used as a material may jump on the conveying roller 313 (refer to Fig. 3) of a steel plant. At this time, the imaging object (rolled material) moves in parallel from the grid-shaped area A61 to the grid-shaped area B62. Therefore, by confirming that the increase of the first color ratio of the grid-shaped area A61 is equal to the decrease of the first color ratio of the grid-shaped area B62, it can be confirmed that the photographic subject moves in parallel.
又,拍攝對象傾斜延伸而從格子狀區域A61延伸至格子狀區域F66時,格子狀區域A61的第一顏色比例飽和,格子狀區域F66的第一顏色比例會增加。由相鄰之格子狀區域B62之第一顏色比例的增減量與格子狀區域E65之第一顏色比例的增減量可確認拍攝對象是否未水平搖動而延伸。 Moreover, when the photographic subject extends obliquely and extends from the grid-shaped area A61 to the grid-shaped area F66, the first color ratio of the grid-shaped area A61 is saturated, and the first color ratio of the grid-shaped area F66 increases. From the increase or decrease of the first color ratio of the adjacent grid-shaped area B62 and the increase or decrease of the first color ratio of the grid-shaped area E65, it can be confirmed whether the photographic subject extends without shaking horizontally.
此外,會有拍攝對象的形狀變形的情況。例如在鋼鐵工廠的熱軋線、厚板線會有因軋製而在軋材311(參照第3圖)發生向上翹曲的情況。參照第8圖來說明畫像解析的例子。t3係前一周期之軋材的形狀,t4係現在周期之軋材的形狀。格子狀量化處理部60係將二值化的畫像至少分割為格子狀的格子狀區域F66、相鄰於格子狀區 域F66橫向的格子狀區域J70、相鄰於格子狀區域F66上方的格子狀區域G67、相鄰於格子狀區域J70上方且相鄰於格子狀區域G67橫向的格子狀區域K71,並算出各區域之第一顏色比例。格子狀區域F66和格子狀區域G67的邊界設定在軋材的上方。 In addition, the shape of the subject may be deformed. For example, in a hot rolling line and a thick plate line of a steel plant, the rolled material 311 (refer to Fig. 3) may be warped upward due to rolling. Refer to Figure 8 to explain an example of image analysis. t3 is the shape of the rolled material in the previous cycle, and t4 is the shape of the rolled material in the current cycle. The grid-like
操作者確認伴隨t3至t4的變化之各格子狀區域中的第一顏色比例的變化。藉由確認到第一顏色比例依格子狀區域F66、格子狀區域J70之順序增加,且格子狀區域K71中第一顏色比例依據格子狀區域G67中第一顏色比例的減少而增加,能夠以量化方式掌握軋材的向上翹曲。 The operator confirms the change of the first color ratio in each grid-shaped area accompanying the change from t3 to t4. By confirming that the first color ratio increases in the order of the grid-shaped area F66 and the grid-shaped area J70, and the first color ratio in the grid-shaped area K71 increases according to the decrease in the first color ratio in the grid-shaped area G67, it can be quantified Ways to control the upward warpage of the rolled material.
PLC9係接收由數值輸出部24所輸出的資料(各格子狀區域中的第一顏色比例)。PLC9可從各格子狀區域中的第一顏色比例來進行依據拍攝對象的位置之控制、依據拍攝對象的變化移動量之控制、依據拍攝對象的形狀之控制(例如依據向上翹曲量的控制)。 The PLC9 receives the data (the first color ratio in each grid-shaped area) output by the
參照上述的第8圖說明依據向上翹曲量的控制。PLC9係在第一顏色比例依格子狀區域F66、格子狀區域J70之順序而增加,且格子狀區域K71中第一顏色比例依據格子狀區域G67中第一顏色比例的減少來增加時,輸出警告信號及控制信號中的至少一個,該控制信號係改變一對軋輥312之旋轉速度以抑制軋材向上翹曲。例如控制信號為使一對軋輥312停止的信號,或者為使下軋輥之旋轉速度比上軋輥之旋轉速度慢的信號。 The control based on the amount of upward warpage will be described with reference to the above-mentioned Figure 8. PLC9 outputs a warning when the first color ratio increases in the order of grid area F66 and grid area J70, and the first color ratio in grid area K71 increases according to the decrease in the first color ratio in grid area G67 At least one of a signal and a control signal. The control signal changes the rotation speed of the pair of
如上述說明,根據具備格子狀量化處理部60之本實施形態的系統,相較於實施形態1可更準確支援操作者對於機械、材料的位置或尺寸的確認作業。此外,PLC9使用藉由格子狀量化處理部60量化的資料而可實現依據拍攝對象的狀態進行之適當的控制。 As described above, according to the system of the present embodiment provided with the grid-like
又,上述之實施形態3的系統可與實施形態1的系統及實施形態2的系統組合。 In addition, the system of
此外,上述之實施形態3的格子狀量化處理部60係依水平方向及垂直方向將區域定義成格子狀,惟亦可在傾斜方向設定格子狀區域。 In addition, the grid-like
另外,上述之實施形態3的格子狀量化處理部60係將畫面分割為12個,若為等分割則不限制分割數量。尤其是從傾斜的角度拍攝拍攝對象時,藉由映像轉換加工成從旁邊或上方拍攝的畫像。此時,會有拍攝對象的移動量、變形量變小的情況。在這種情況時,藉由增加格子狀的分割數量可檢測變小的移動量、變形量。 In addition, the grid-like
以上說明本發明的實施形態,惟本發明並不限於上述的實施形態,在不脫離本發明之目的的範圍內可進行各種變更。 The embodiments of the present invention have been described above, but the present invention is not limited to the above-mentioned embodiments, and various modifications can be made without departing from the purpose of the present invention.
1‧‧‧畫像解析裝置 1‧‧‧Image analysis device
2‧‧‧第1監視照相機 2‧‧‧The first surveillance camera
3‧‧‧第2監視照相機 3‧‧‧Second surveillance camera
4‧‧‧畫像資料轉換器 4‧‧‧Image data converter
5‧‧‧畫像用信號線 5‧‧‧Signal line for portrait
6‧‧‧動態畫像用網路 6‧‧‧Network for dynamic portrait
7‧‧‧資料收集裝置 7‧‧‧Data collection device
8‧‧‧人機界面(HMI) 8‧‧‧Human Machine Interface (HMI)
9‧‧‧可編程邏輯控制器(PLC) 9‧‧‧Programmable Logic Controller (PLC)
10‧‧‧控制用網路 10‧‧‧Control network
21‧‧‧動態畫像資料收集部 21‧‧‧Dynamic Portrait Data Collection Department
22‧‧‧畫像加工處理部 22‧‧‧Image Processing Department
23‧‧‧畫像量化部 23‧‧‧Image Quantization Department
24‧‧‧數值輸出部 24‧‧‧Numerical output
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