FIELD OF APPLICATION

The present invention relates to a video monitoring system for operating equipment, in particular production equipment.

The present invention further relates to a video monitoring method for operating equipment, in particular production equipment.

In particular, the present invention relates to a system and a video monitoring method for operating equipment, in particular production equipment, for an analysis of conditions of conditioned operation, in particular an equipment shutdown.

PRIOR ART

Existing video monitoring systems enable a generic video recording of an industrial line, or an individual machine or unit of equipment.

The recording generates videos of large dimensions which are difficult to analyse, particularly due to the duration of the video generated.

In addition, most equipment operates at speeds far exceeding the normal ability of visual perception of a human being.

It is undoubtedly not efficient to dedicate operating resources (personnel/operators) to real-time visual analysis of the machine/equipment, as the error can be random over a period of time and the operator's assessment can be subjective.

It is well known that, in the event of line shutdowns arising from failures/faults, the causes can be better identified starting from time instants (seconds, minutes, hours) after the occurrence of the failure/fault.

The failures/faults can be internal or external, the latter being caused for example by nonconforming material fed to the machine/equipment in question.

The prior art, in dealing with generic videos of large dimensions and/or which refer to equipment operating at very high speeds, is not capable of providing an efficient association between the instant of occurrence of the failure/fault - as described previously - and a possible analysis thereof to determine an efficient solution.

US 2001 /047504 discloses a maintenance system and method for industrial machinery.

US 2001 /047504 envisages that, upon the detection of an operating error, a request is sent to an operator in order to receive instructions regarding a recovery procedure; in response to the request, the operator constructs a recording of the error, which will then have to be analysed in order to investigate the causes of the error itself. The object of the present invention is to provide a video monitoring method/system for operating equipment that overcomes the drawbacks of the prior art.

A particular object of the present invention is to provide a video monitoring method/system for operating equipment that requires no human intervention for activation of the monitoring.

A particular object of the present invention is to provide a video monitoring method/system for operating equipment that is efficient in terms of detecting and resolving internal or external failures/faults that have occurred and/or intervals of operation that are of interest to the user of the system/method.

Another object of the present invention is to provide a video monitoring method/system for operating equipment that is not complex to construct.

A further object of the present invention is to provide a video monitoring method/system for operating equipment that is simple to operate and use.

SUMMARY OF THE INVENTION

In a first aspect, the invention describes a video monitoring system for operating equipment, according to what is described in claim 1 .

Advantageous aspects are described in dependent claims 2 to 16.

In a second aspect, the invention describes a video monitoring method for operating equipment, according to what is described in claim 17.

Advantageous aspects are described in dependent claims 17 to 19.

In a third aspect, the invention of the second aspect is implemented by means of a computer, according to what is described in claim 20.

In a fourth aspect, the invention describes a computer program configured to perform the steps of the method of the third aspect, according to what is described in claim 21 .

In a fifth aspect, the invention describes a specific viewing system in a video monitoring system for operating equipment.

The invention makes it possible to produce a timed recording of the equipment's operation and to isolate only specific intervals of a corresponding video suitable for analysing the causes of a conditioned operation.

In particular, the invention makes it possible to produce a timed recording of the operation of the equipment and to isolate only the intervals of the video recording that are of interest for analysing the causes of a conditioned operation.

The invention achieves the following technical effects: - activation of monitoring independent of human intervention;

- generation of data usable for an objective examination of the events that can provoke the shutdown and/or conditioned operation of the equipment;

- detection efficiency and generation of objective data for resolving the failures/faults that have occurred;

- non-complex construction of the system;

- simplicity of operation and use.

- possibility of performing an examination / analysis of the causes that have generated incoming products fed to the machine/ equipment that are incompatible with use, for example equipment and/or production processes or processing of the products upstream of the machine/equipment.

The technical effects/advantages mentioned and other technical effects/advantages of the invention will emerge in greater detail from the description, given here below, of an embodiment given by way of non-limiting example with reference to the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic view of a video monitoring system for production equipment, according to the invention.

DETAILED DESCRIPTION

The present invention relates to a video monitoring system for production equipment. The invention envisages obtaining a video of the operation of operating equipment or a part thereof in the instants corresponding to a conditioned operation which may occur due to internal or external causes and an identification of the instants corresponding to the conditioned operation, and enables the causes of the shutdown to be analysed in a short time, providing the users of the equipment with instantaneous information which is useful for solving the problem.

In the course of the description, conditioned operation will mean one among the following: machine shutdown - due to internal or external causes - start-up outside quality standards, format change, tooling change, switching on, switching off, production start-ups, setting-up, equipment adjustment.

In particular, the conditioned operating phase F2 comprises instants/intervals of operating time necessary for management of the operating equipment 1 which the user wants to store.

In other words, it is possible to record instants/intervals of operation that the operator deems necessary for management of the operating equipment 1 and which the user wants to store, for example on/off switching, format changes, tooling changes and start-ups.

Figure 1 schematically shows a video monitoring system for production equipment. With reference to figure 1 , the system of the invention comprises operating equipment 1 .

In one embodiment of the invention, the operating equipment is production equipment.

In both embodiments described, the operating equipment 1 preferably comprises specific equipment 10 adapted to manage elements 3 from an equipment infeed position IN to an equipment outfeed position OUT.

In particular, the specific equipment 10 can be a machine or existing equipment.

In particular, the specific equipment 10 is configured to convey and/or process and/or handle elements 3.

The operating equipment 1 is adapted to operate between an operating phase F1 and a conditioned operating phase F2.

In particular, the conditioned operating phase F2, more in particular an equipment shutdown, can be caused by a micro failure or micro stoppage indicative of the presence of a defect in a machine or an incoming material used / fed to the machines which continuously repeats itself; in this specific case, the shutdown of the production of a machine or equipment during operation can be resolved by an operator directly with a stoppage of limited duration.

In particular, the conditioned operating phase F2 can be caused by a macro failure or macro stoppage; in this case there is a shutdown of the production of a machine or equipment during operation whose resolution requires an intervention lasting minutes or hours; an intervention of personnel at various levels of competence/experience may become necessary, for example production staff, maintenance staff and possibly also an outside technician.

The system of the invention comprises a viewing system 2 configured to make a timed recording Rec_temp at least in a video format F_Vid of the operating equipment 1 in the operating phase F1 and the conditioned operating phase F2, in particular an equipment shutdown.

In one embodiment of the invention, the viewing system 2 comprises a camera.

Alternatively, or in addition, the viewing system 2 comprises sensors, in particular shape sensors, size sensors, temperature sensors, etc.

It is understood that the timed recording Rec_temp at least in a video format produced by the viewing system 2 is the output generated by the aforesaid viewing system 2 from a generic input signal of analysis of a confined or unconfined environment.

In other words, the signal input to the viewing system 2 is not necessarily a visual signal.

In particular, according to the invention, the viewing system 2 is configured to make the timed recording Rec_temp also in an audio format F_Aud.

The recordings Rec_temp are temporarily or permanently stored in a memory unit 200 associated with the viewing system 2.

The viewing system 2 can preferably be trained on the operating equipment 1 according to a visual field FV, so that the timed recording Rec_temp takes place according to the aforesaid visual field.

Advantageously, the visual field FV is defined a priori based on the area(s) of the equipment that are most subject to causes of conditioned operation F2 and/or the areas in which the manager/operator of the equipment presumes or has already found that the conditioned operation of the machine/equipment might occur.

The viewing system 2 preferably comprises at least one camera.

In the event of multiple interoperating cameras, the visual field FV can be divided into subareas covered by different cameras.

Alternatively, or in addition, the viewing system 2 comprises sensors, in particular shape sensors, size sensors, temperature sensors, etc.

In one embodiment, the viewing system 2 is configured to make the timed recording Rec_temp of the specific equipment 10 in the operating phase F1 and conditioned operating phase F2.

The system according to the invention comprises a control unit 100 in data communication with the operating equipment 1 and the viewing system 2.

In general it should be noted that, in the present context and in the following claims, the control unit 100 is presented as divided into distinct functional modules (memory modules or operating modules) for the sole purpose of describing the functions thereof clearly and thoroughly.

In reality the control unit may in one case consist of a single electronic device, suitably programmed for performing the functions described, and the various modules can correspond to a hardware entity and/or routine software that are part of the programmed device.

Alternatively, or in addition, these functions can be performed by a plurality of electronic devices over which the aforesaid functional modules can be distributed. The control unit 100 can moreover rely on one or more processors to execute the instructions contained in the memory modules.

Moreover, the aforesaid functional modules can be distributed over several local or remote computers based on the architecture of the network they reside in.

In the specific context of the invention, the control unit 100 is configured to monitor the operation of the operating equipment 1 .

According to the invention, the activation of monitoring is independent of human intervention.

In other words, the timed recording Rec_temp is automatically generated by the invention, without the continuous presence of an operator alongside the equipment and/or a remote supervisor that monitors several units of equipment.

According to the invention, the control unit 100 comprises a first detecting module 101 .

The first detecting module 101 is configured to detect a current operating phase F_corr of the operating equipment 1 .

In other words, the control unit continuously monitors the operating equipment 1 in order to promptly detect every situation of faulty operation.

The control unit 100 comprises a control module 102.

The control module 102 is configured to check whether the current operating phase F_corr corresponds (C_cond) to the conditioned operating phase F2.

The control unit 100 comprises a second detecting module 103.

The second detecting module 103 is configured, in a case of correspondence C_cond, to detect a reference time instant (T_corr) that is representative of said conditioned operating phase (F2) as a function of said detected correspondence (C_cond).

The time instant T_corr is preferably the initial time instant tO of the conditioned operating phase F2, in particular an equipment shutdown.

The technical effect achieved by the detection of the time instant T_corr is an efficiency of detection and generation of objective information for the operator/technician, available in real time for the resolution of failures/faults, and resulting from the identification of the critical point of occurrence of the event that has generated the conditioned operation, be it internal to the machine/equipment and/or generated by nonconforming incoming material.

In particular, the time instant T_corr is defined by one from among:

- a signal of conditioned operation received by the operating equipment 1 ;

- a signal received from machines located upstream or downstream of the operating equipment 1 ;

- a manual control/pushbutton managed by the operator (by way of non-limiting example, a machine not attended by an operator);

- a signal representative of a count of incoming elements.

According to the invention, the control unit 100 further comprises a calculating module 104.

The calculating module 104 is configured to calculate a reference time interval Acheck for analysing the conditioned operation F2 as a function of the reference time instant T_corr.

According to the invention, the reference time interval Δ check for analysing the conditioned operation F2 corresponds to a first predefined time interval ΔΤ- preceding the reference time instant T_corr.

The technical effect achieved by the analysis of the equipment in a period immediately preceding the occurrence of a failure is the efficiency of determination of the causes of the failure.

Alternatively, according to the invention the reference time interval Acheck for analysing the conditioned operation F2 corresponds to a second predefined time interval ΔΤ+ following said reference time instant T_corr.

The technical effect achieved by the analysis of the equipment in a period immediately following the occurrence of a failure is the efficiency of determination of the initial effects of the failure, which are important for defining a rapid solution.

As a further alternative, or in addition to the previous cases, according to the invention the reference time interval Acheck for analysing the conditioned operation F2 corresponds to a sum ΔΤ-+ of a first predefined time interval ΔΤ- preceding the reference time instant T_corr and a second predefined time interval ΔΤ+ following the reference time instant T_corr.

The technical effect achieved by the analysis of the equipment in a period preceding and following the failure is the provision of complete visual and/or instrumental and/or operational and/or sound data relating to the occurrence of the failure and the immediate consequences.

In one embodiment, the reference time interval Acheck is defined as a function of management parameters for the specific equipment 10 representative of the elements 3, input to the machine/equipment in question, managed, i.e. processed and/or used by the system in correct operation.

In other words, the reference time interval Acheck is definable based on a number ΔΝ of elements 3 that must be analysable, i.e. included in the recording Rec_temp, in the case of conditioned operation F2.

In particular, ΔΝ is the number of elements 3 preceding the element n which generated the conditioned operation at the time T_corr.

The interval η-ΔΝ defines the interval of the recording Rec_temp, in particular of the video, which must be viewed in order to analyse the conditioned operation F2 that has occurred.

By way of example, the elements 3 can comprise one or more containers, packages, bottles, pallets, and/or generic elements, objects, products used in the correct operation of the equipment etc.

The control unit 1 00 comprises a first configuration module 1 04A connected to a user interface 300 whereby the reference time interval Acheck is configurable as a function of one from among an interval of time ΔΤ-, ΔΤ+, ΔΤ-+ or a number ΔΝ of elements 3. In other words, the configuration module 1 04A enables a configuration of the reference time interval Acheck.

In a preferred embodiment of the invention, the first configuration module 1 04A is configured to configure the reference time interval Acheck before the beginning of the recording Rec_temp, in particular of the video.

This makes the intervention of an operator unnecessary once the recording is made. According to the invention, the control unit 1 00 further comprises a search module 105.

The search module 1 05 is configured to search, in the timed recording Rec_temp, for a recorded portion ARec corresponding to the reference time interval Acheck.

In other words, once the value of the reference time interval Acheck has been configured, the invention envisages that said interval is searched for in the timed recording Rec_temp contained in the memory unit 200.

The memory unit 200 is thus configured to memorise the recorded portion ARec for an analysis of causes of the conditioned operation F2.

In other words, the recorded portion ARec is a timed recording of the operation of the operating equipment 1 in which only the reference time intervals Acheck of a corresponding video of interest are isolated in order to analyse the causes of the conditioned operation F2.

The invention thus makes it possible to produce a timed recording of the operation of the operating equipment 1 and to isolate only the reference time intervals Acheck of the corresponding video that are of interest for analysing the causes of the conditioned operation.

In particular, the invention makes it possible to produce a timed video recording of the operation of the operating equipment 1 and to isolate only the reference time intervals Acheck of the video recording that are of interest for analysing the causes of the conditioned operation.

In still other words, the recorded portion ARec is a recording, in particular a timed video recording, of the operation of the operating equipment 1 in which only the specific reference time intervals Acheck suitable for analysing the causes of the operation F2 are isolated.

The invention thus makes it possible to produce a recording, in particular a timed video recording, of the operation of the operating equipment 1 and to isolate only the specific reference time intervals Acheck for an analysis of the causes of the conditioned operation.

According to the invention, the storage of the recorded portion ARec is independent of human intervention.

In other words, the recorded portion ARec is automatically stored by the invention without the continuous presence of an operator alongside the equipment and/or a remote supervisor that monitors several units of equipment.

The technical effect achieved is that the videos obtained are available to the operator who manages the equipment substantially in real time, without the need to send the videos to a third party for hierarchical or centralised inspection, thereby maximising the dynamism and efficiency of the system.

In one embodiment of the invention, the control unit 100 and/or the memory unit 200 is locally coupled to the operating equipment 1 .

In this particular configuration, the operator is present locally at the time of analysis and analyses the causes of the conditioned operation F2 on the basis of the recording ARec produced; the operator is normally also employed in other functions that require his presence elsewhere.

In another embodiment of the invention, the control unit 100 and/or the memory unit 200 is remotely coupled to the operating equipment 1 .

In this alternative configuration, the operator can be remotely available and analyse the causes of the conditioned operation F2 on the basis of the recording ARec produced despite not being physically present in the place in which the conditioned operation F2 occurred.

The technical effect achieved by this specific solution is the efficiency and promptness of the analysis of the failure by the expert, whereby it is not necessary to wait for the expert to move locally to the site of the equipment shutdown and/or necessarily require the constant presence of the operator in order to perform a direct visual examination of the area of the machine/equipment in which it is presumed that the determination/cause of the conditioned operation, in particular an equipment shutdown, will occur.

In this particular case, the invention envisages a particular embodiment of the viewing system 2 in a video monitoring system for operating equipment.

The viewing system 2 in a video monitoring system for operating equipment, wherein the video monitoring system comprises operating equipment 1 adapted to operate between an operating phase F1 and a conditioned operating phase F2, is configured to:

- make a timed recording Rec_temp at least in a video format F_Vid of the operating equipment 1 in the operating phase F1 and in the conditioned operating phase F2;

- transmit the timed recording Rec_temp for processing.

In this embodiment, the video monitoring system is in data communication with a control unit 100 comprising:

- a first detecting module 101 configured to detect a current operating phase F_corr of the operating equipment (1 );

- a control module 102 configured to check whether the current operating phase F_corr corresponds C_cond to the conditioned operating phase F2;

- a second detecting module 103 configured, in a case of correspondence C_cond, to detect a reference time instant T_corr that is representative of the conditioned operating phase F2 as a function of the detected correspondence (C_cond);

- a calculating module 104 configured to calculate a reference time interval Acheck for analysing the conditioned operation F2 as a function of the reference time instant T_corr;

- a search module 105 configured to search, in the timed recording Rec_temp, for a recorded portion ARec corresponding to the reference time interval Acheck for storage in a memory unit 200.

In all embodiments the control unit 100 further comprises a playback module 201 configured to play the recorded portion ARec on a playback medium 50.

In one embodiment of the invention, the viewing system 2 comprises a camera.

Alternatively, or in addition, the viewing system 2 comprises sensors, in particular shape sensors, size sensors, temperature sensors, etc.

It is understood that the timed recording Rec_temp at least in a video format produced by the viewing system 2 is the output generated by the aforesaid viewing system 2 from a generic input signal of analysis of a confined or unconfined environment.

In other words, the signal input to the viewing system 2 is not necessarily a visual signal.

The playback medium 50 preferably comprises a computer provided with a display, in particular a PC, tablet, smartphone, smart TV and the like.

According to the invention, the playback module 201 is configured to play back the recorded portion ARec on the playback medium 50.

In particular, playback takes place as a function of playback parameters P1 i(i=1 ..3) that are representative of criteria of analysis of the conditioned operation F2.

According to the invention, the playback parameters P1 i and, consequently, the reference time interval Acheck, are configurable, in particular by an operator of the equipment, prior to start-up of the operating equipment 1 or at the time of the conditioned operation F2.

In other words, the reference time interval Acheck is defined as a function of the playback parameters P1 i that are representative of criteria of analysis of the conditioned operation F2.

For this configuration the control unit 100 comprises a second configuration module 104B connected to the user interface 300, by means of which the user configures the playback parameters P1 i.

In other words, the configuration module 104B enables a configuration of the playback parameters P1 i. The technical effect achieved is a configuration flexibility that enables the most appropriate interval of selection of the video to be chosen also on the basis of environmental considerations, almost in real time.

The playback parameters P1 i comprise one or more among at least:

- a first playback parameter (P1 1 ), representative of a posteriori analysis of the recorded portion (ARec) for identifying only the crucial reference time instants (T_corr) which determine the conditioned operation F2 .

In other words, it is envisaged to use the video only a posteriori in order to identify only the crucial instants leading to the conditioned operation of the machine.

- a second playback parameter P12, representative of a dynamic analysis of the recorded portion ARec for analysing instants preceding and following said conditioned operation F2.

In other words, it is envisaged to use the video as a dynamic instrument: that is, the stop and replay function enables the operator to see what has happened in his absence on the machine by playing back the video of the seconds preceding the machine shutdown and carrying out a real-time diagnosis without the need to have a full-time operator who performs only a visual analysis.

This is fundamental for analysis on high-speed equipment in which it is possible, through the system of the invention, to analyse the video at increased or decreased speeds.

- a third playback parameter P13, representative of an analysis of the recorded portion ARec from a remote position according to one or more of the two preceding parameters P1 1 , P12.

In other words, it is envisaged to use the video sent in real time to the supplier of the equipment and/or an identified smartphone, possibly inside the factory (company user) or outside the factory (user / supplier of the equipment).

The invention also comprises a method implemented by means of a video monitoring computer for production equipment which comprises performing the functions described in the operating modules and memory modules described.

The method according to the invention comprises the steps of:

- providing an operating equipment 1 adapted to operate between an operating phase F1 and a conditioned operating phase F2;

- making a timed recording Rec_temp, at least in a video format F_Vid, of the operating equipment 1 in the operating phase F1 and in the conditioned operating phase F2;

In one embodiment of the invention, the recording is made by means of a camera. Alternatively, or in addition, the recording is made by sensors, in particular shape sensors, size sensors, temperature sensors, etc.

It is understood that the timed recording Rec_temp, produced at least in a video format, is an output signal generated from a generic input signal of analysis of a confined or unconfined environment.

In other words, the input signal is not necessarily a visual signal.

- monitoring, by means of a control unit (100), the operation of the operating equipment 1 according to the sub-steps of:

detecting a current operating phase F_corr of the operating equipment 1 ;

checking whether the current operating phase F_corr corresponds C_cond to the conditioned operating phase F2;

in a case of correspondence C_cond,

detecting a reference time instant T_corr that is representative of the conditioned operating phase F2 as a function of the detected correspondence (C_cond);

calculating a reference time interval Acheck for analysing the conditioned operation F2 as a function of the reference time instant T_corr;

searching in the timed recording Rec_temp for a recorded portion ARec corresponding to said reference time interval Acheck;

- storing the recorded portion ARec for an analysis of causes of the conditioned operation F2.

The recorded portion ARec is a timed recording, in particular a video, of the operation of the operating equipment 1 in which only the reference time intervals Acheck of a corresponding video that is of interest for analysing causes of the conditioned operation F2 are isolated.

In other words, the recorded portion ARec is a timed recording, in particular a video, of the operation of the operating equipment 1 in which only the specific reference time intervals Acheck suitable for analysing the causes of the operation F2 are isolated.

The method according to the invention further comprises a step of configuring the reference time interval Acheck as a function of one from among:

- a first predefined time interval AT-; - a second predefined time interval ΔΤ+,

- a sum ΔΤ-+;

wherein the configuration step is performed by the control unit 100.

The invention further comprises playing back the recorded portion ARec on a playback medium 50, in particular as a function of playback parameters P1 i that are representative of criteria of analysis of the conditioned operation F2.

The method further comprises the operating steps described in reference to the operating and memory modules described in reference to the system of the invention.

According to the method, one from among the following conditions is included:

- the steps of monitoring the operation of the operating equipment 1 and storing the recorded portion ARec for an analysis of causes of the conditioned operation F2 are performed locally at the operating equipment 1 ;

- the steps of monitoring the operation of the operating equipment 1 and storing the recorded portion ARec for an analysis of causes of the conditioned operation F2 are performed remotely with respect to the operating equipment 1 .

The invention also relates to a computer program configured to carry out one or more of the steps of the method described when run on a computer.

A system, a method and a computer program for video monitoring of production equipment have been described.

The invention achieves the following technical effects:

- activation of monitoring independent of human intervention;

- generation of data usable for an objective examination of the events that can provoke a shutdown and/or conditioned operation of equipment;

- efficiency of detection and generation of objective data for resolving failures/faults that have occurred;

- non-complex construction of the system;

- simplicity of operation and use.