U.S. patent application number 14/113003 was filed with the patent office on 2014-02-20 for shovel, monitoring device of the same and output device of shovel.
This patent application is currently assigned to SUMITOMO HEAVY INDUSTRIES, LTD.. The applicant listed for this patent is Kaoru Tsukane. Invention is credited to Kaoru Tsukane.
Application Number | 20140052349 14/113003 |
Document ID | / |
Family ID | 47176920 |
Filed Date | 2014-02-20 |
United States Patent
Application |
20140052349 |
Kind Code |
A1 |
Tsukane; Kaoru |
February 20, 2014 |
SHOVEL, MONITORING DEVICE OF THE SAME AND OUTPUT DEVICE OF
SHOVEL
Abstract
A temporary storage device temporarily stores image data
acquired by an imaging device. Each of a plurality of sensors
detects a plurality of physical quantities relating to an operation
state of a shovel. A control device performs an operation
abnormality determination based on detection values detected by the
sensors. When an operation is determined to be abnormal, the
control device transmits the image data, which corresponds to a
period from a first time prior to a time at which the operation is
determined to be abnormal to at least the time at which the
operation is determined to be abnormal, from the temporary storage
device to the abnormality information storage device. Therefore, it
is easy to specify a cause of abnormality of the operation state of
the shovel.
Inventors: |
Tsukane; Kaoru;
(Yokosuka-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tsukane; Kaoru |
Yokosuka-shi |
|
JP |
|
|
Assignee: |
SUMITOMO HEAVY INDUSTRIES,
LTD.
Tokyo
JP
|
Family ID: |
47176920 |
Appl. No.: |
14/113003 |
Filed: |
May 14, 2012 |
PCT Filed: |
May 14, 2012 |
PCT NO: |
PCT/JP2012/062288 |
371 Date: |
October 21, 2013 |
Current U.S.
Class: |
701/50 ;
701/29.1; 701/33.4 |
Current CPC
Class: |
E02F 9/267 20130101;
H04Q 2209/823 20130101; G05B 23/0264 20130101; H04Q 9/00 20130101;
G07C 5/0816 20130101 |
Class at
Publication: |
701/50 ;
701/33.4; 701/29.1 |
International
Class: |
E02F 9/26 20060101
E02F009/26 |
Foreign Application Data
Date |
Code |
Application Number |
May 16, 2011 |
JP |
2011-109437 |
Claims
1. A shovel comprising: an imaging device; a temporary storage
device that temporarily stores image data acquired by the imaging
device; a plurality of sensors that each detect a plurality of
physical quantities relating to an operation state of the shovel;
an abnormality information storage device; and a control device
that determines whether or not an operation is abnormal based on
detection values detected by the sensors, and transmits the image
data, which corresponds to a period from a first time prior to a
time at which the operation is determined to be abnormal to at
least the time at which the operation is determined to be abnormal,
from the temporary storage device to the abnormality information
storage device when the operation is determined to be abnormal.
2. The shovel according to claim 1, wherein the control device
stores the detection values detected by the sensors as well as the
image data at the time at which the operation is determined to be
abnormal in the abnormality information storage device.
3. The shovel according to claim 1, wherein the control device
additionally transmits the image data, which corresponds to a
period until a second time following the time at which the
operation is determined to be abnormal, from the temporary storage
device to the abnormality information storage device when the
operation is determined to be abnormal.
4. The shovel according to claim 1, wherein the control device
acquires the detection values detected by the plurality of sensors,
during a normal operation, and decides an unit space, which is used
in Mahalanobis-Taguchi method, based on the acquired detection
values, calculates Mahalanobis distance from the center of the unit
space to detection values of an evaluation-target detected by the
plurality of sensors, and performs the operation abnormality
determination based on the calculated Mahalanobis distance.
5. The shovel according to claim 1, wherein the temporary storage
device has a ring buffer structure where the oldest image data are
overwritten with new image data when no free storage area remains,
wherein the control device has an image capture mode storage
portion for storing an image capture mode which specifies the
resolution of image data to be stored in the temporary storage
device, and wherein the image data which is acquired by the imaging
device is stored in the temporary storage device at the resolution
specified in the image capture mode stored in the image capture
mode storage portion.
6. The shovel according to claim 1, further comprising: an output
device for displaying an image, wherein the control device displays
a time indicator for an operator to specify a time on the output
device, and displays the image data at the time specified by the
time indicator, out of the image data stored in the abnormality
information storage device, on the output device as an image.
7. The shovel according to claim 6, wherein the control device
displays information about the time range within which a time can
be specified to be displayed on the time indicator and displays a
temporal variation of alarm levels on the output device,
corresponding to the time range displayed on the time
indicator.
8. A shovel comprising: an imaging device; a temporary storage
device that temporarily stores image data acquired by the imaging
device; a plurality of sensors that each detect a plurality of
physical quantities relating to an operation state of the shovel; a
transmitter for transmitting the data, and a control device that
performs an operation abnormality determination based on detection
values detected by the sensors, and transmits the image data stored
in the temporary storage device, which corresponds to a period from
a first time prior to a time at which an operation is determined to
be abnormal to at least the time at which the operation is
determined to be abnormal, from the transmitter when the operation
is determined to be abnormal.
9. The shovel according to claim 8, wherein the control device
transmits the detection values detected by the sensors at the time
at which the operation is determined to be abnormal as well as the
image data from the transmitter.
10. The shovel according to claim 8, wherein the control device
additionally transmits the image data, which corresponds to a
period until a second time following the time at which the
operation is determined to be abnormal, from the transmitter when
the operation is determined to be abnormal.
11. The shovel according to claim 8, wherein the control device
acquires the detection values detected by the plurality of sensors,
during a normal operation, and decides an unit space which is used
in Mahalanobis-Taguchi method, based on the acquired detection
values, calculates a Mahalanobis distance from the center of the
unit space to detection values of an evaluation-target acquired by
the plurality of sensors, and performs the operation abnormality
determination of an operation based on the calculated Mahalanobis
distance.
12. A monitoring device of a shovel, comprising: a transceiver that
receives a plurality of detection values detected by sensors for
detecting a plurality of physical quantities relating to an
operation state of the shovel and image data acquired by an imaging
device installed on the shovel and transmits a command to the
shovel; an abnormality information storage device; and a control
device, wherein the control device determines whether or not an
operation is abnormal based on the detection values which are
detected by the sensors and input from the transceiver, and the
control device transmits a command instructing transmission of
image data, which corresponds to a period from a first time prior
to a time at which the operation is determined to be abnormal to at
least the time at which the operation is determined to be abnormal,
to the shovel via the transceiver when the operation is determined
to be abnormal, and wherein the control device stores the image
data which is transmitted from the shovel to the transceiver in the
abnormality information storage device in response to the
command.
13. The monitoring device of a shovel according to claim 12,
further comprising: an output device for displaying an image,
wherein the control device displays a time indicator for an
operator to specify a time on the output device, and displays the
image data at the time specified by the time indicator, out of the
image data stored in the abnormality information storage device, on
the output device as an image.
14. The monitoring device of a shovel according to claim 13,
wherein the control device displays information about the time
range within which a time can be specified on the time indicator
and displays a temporal variation of alarm levels on the output
device, corresponding to the time range displayed on the time
indicator.
15. A monitoring device of a shovel comprising: a receiver that
receives image data from a shovel that has an imaging device, a
temporary storage device temporarily storing image data acquired by
the imaging device, a plurality of sensors that each detect a
plurality of physical quantities relating to an operation state of
the shovel, and a local control device that performs an operation
abnormality determination based on detection values detected by the
sensors, reads out the image data from the temporary storage device
when the operation is determined to be abnormal, and transmits the
image data to the monitoring device of the shovel; an abnormality
information storage device for storing image data; an output device
for displaying an image; and a control device, wherein the control
device stores the image data received by the receiver in the
abnormality information storage device and displays the image data
stored in the abnormality information storage device on the output
device as an image.
16. The monitoring device of a shovel according to claim 15,
wherein the control device displays a time indicator for an
operator to specify a time on the output device, and displays the
image data at the time specified by the time indicator, out of the
image data stored in the abnormality information storage device, on
the output device as an image.
17. An output device of a shovel that displays image data acquired
by an imaging device mounted on a shovel, wherein the image data,
which corresponds to a period from a first time prior to a time at
which the shovel is determined to be abnormal to at least the time
at which the shovel is determined to be abnormal, is displayed.
18. A method of monitoring a shovel, comprising: storing image data
acquired by an imaging device mounted on a shovel in a temporary
storage device temporarily; detecting a plurality of physical
quantities relating to an operation state of the shovel by a
plurality of sensors mounted on the shovel, respectively, and
performing an operation abnormality determination based on
detection values detected by the sensors; reading out the image
data from the temporary storage device and transmitting the image
data to the monitoring device of the shovel when an operation is
determined to be abnormal in performing an operation abnormality
determination; storing the image data received by the monitoring
device in an abnormality information storage device of the
monitoring device; and displaying the image data stored in the
abnormality information storage device as an image on an output
device of the monitoring device.
19. The method of monitoring the shovel according to claim 18,
further comprising: displaying a time indicator for an operator to
specify a time on the output device; and specifying a time on the
time indicator by an operator, wherein the image data at the time
specified by an operator, out of the image data stored in the
abnormality information storage device, is displayed as an image on
the output device in displaying the image data as an image on the
output device.
20. A method of monitoring a shovel, comprising: acquiring image
data acquired by an imaging device mounted on a shovel; and
displaying the image data, which corresponds to a period from a
first time prior to a time at which the shovel is determined to be
abnormal to at least the time at which the shovel is determined to
be abnormal, out of the image data acquired in the step of
acquiring the image data, on an output device.
Description
TECHNICAL FIELD
[0001] The present invention relates to a shovel capable of
determining an operational abnormality, a monitoring device of the
shovel, and an output device mounted on a shovel capable of
determining an operational abnormality.
BACKGROUND ART
[0002] A failure determination method for construction equipment,
based on a detection value detected by a sensor mounted on the
construction equipment, has been known (see PTL 1). Failure
information is sent to a center, and therefore a failure diagnosis
procedure is extracted in the center, based on the sensor detecting
an abnormal value. An operator of the construction equipment
conducts a failure diagnosis in accordance with the failure
diagnosis procedure.
PRIOR ART DOCUMENT
Patent Literature
[0003] [PTL 1] Japanese Unexamined Patent Application Publication
No. 2002-332664
SUMMARY OF INVENTION
Problems to be Solved by Invention
[0004] In some cases, it is difficult to specify the cause of
failure only by performing a diagnosis based on the detection value
of the sensor and following the failure diagnosis procedure even
when the failure diagnosis procedure is provided. Particularly, an
attachment, such as a boom, and a cabin are mounted on a revolving
superstructure of a shovel. Thus, motion not only in a front-rear
direction but also in a right-left direction is carried out in the
shovel. Since a working range of the shovel is extensive as
described above, a situation in which the shovel encounters failure
is likely to occur. An object of the invention is to provide a
shovel which enables an operator to easily specify the cause of
failure by making the operator confirm the circumstances at the
time of failure and a monitoring device of the shovel.
Means of Solving Problems
[0005] According to an aspect of the invention, there is provided a
shovel including:
[0006] an imaging device;
[0007] a temporary storage device that temporarily stores image
data acquired by the imaging device;
[0008] a plurality of sensors that each detect a plurality of
physical quantities relating to an operation state of the
shovel;
[0009] an abnormality information storage device; and
[0010] a control device that performs an operation abnormality
determination based on a detection value detected by the sensors
and causes the image data, which corresponds to a period from a
first time prior to a time at which an operation is determined to
be abnormal to at least the time at which the operation is
determined to be abnormal, to be transmitted from the temporary
storage device to the abnormality information storage device when
the operation is determined to be abnormal.
[0011] According to another aspect of the invention, there is
provided a shovel including:
[0012] an imaging device;
[0013] a temporary storage device that temporarily stores image
data acquired by the imaging device;
[0014] a plurality of sensors that each detect a plurality of
physical quantities relating to an operation state of the
shovel;
[0015] a transmitter for transmitting the data, and
[0016] a control device that performs an operation abnormality
determination based on a detection value detected by the sensors
and causes the image data stored in the temporary storage device,
which corresponds to a period from a first time prior to a time at
which an operation is determined to be abnormal to at least the
time at which the operation is determined to be abnormal, to be
transmitted from the transmitter when the operation is determined
to be abnormal.
[0017] According to still another aspect of the invention, there is
provided a monitoring device of a shovel including:
[0018] a transceiver that receives a plurality of detection values
detected by a sensor for detecting a plurality physical quantities
relating to an operation state of the shovel and image data
acquired by an imaging device installed on the shovel and transmits
a command to the shovel;
[0019] an abnormality information storage device; and
[0020] a control device,
[0021] wherein the control device performs an operation abnormality
determination based on the detection values which are detected by
the sensor and input from the transceiver and causes a command
instructing transmission of image data, which corresponds to a
period from a first time prior to a time at which an operation is
determined to be abnormal to at least the time at which the
operation is determined to be abnormal, to be transmitted to the
shovel via the transceiver when the operation is determined to be
abnormal, and
[0022] wherein the image data which is transmitted from the shovel
to the transceiver is stored in the abnormality information storage
device in response to the command.
Advantageous Effects of Invention
[0023] It is possible to investigate the cause of abnormality using
image data at the time where an operation state is determined to be
abnormal.
BRIEF DESCRIPTION OF DRAWINGS
[0024] FIG. 1A and FIG. 1B are a side view and a plan view,
respectively, of a shovel according to an embodiment 1.
[0025] FIG. 2 is a block diagram of the shovel according to the
embodiment 1.
[0026] FIG. 3 is a flowchart showing a process of an image capture
control device of the shovel according to the embodiment 1.
[0027] FIG. 4 is a flowchart showing a process of a control device
of the shovel according to the embodiment 1.
[0028] FIG. 5 is a view showing an example of an image displayed on
an output device of the shovel according to the embodiment 1.
[0029] FIG. 6 is a flowchart showing a process of a control device
of a shovel according to an embodiment 2.
[0030] FIG. 7 is a chart showing an example of a detection value
detected by a sensor.
[0031] FIG. 8 is a view showing an example of an image displayed on
an output device of the shovel according to the embodiment 2.
[0032] FIG. 9 is a block diagram of a shovel and a monitoring
device according to an embodiment 3.
[0033] FIG. 10 is a flowchart showing a process of a control device
of the shovel according to the embodiment 3.
[0034] FIG. 11 is a block diagram of a shovel and a monitoring
device according to an embodiment 4.
[0035] FIG. 12 is a flowchart showing a process of a control device
of the monitoring device according to the embodiment 4.
DESCRIPTION OF EMBODIMENTS
Embodiment 1
[0036] FIG. 1A and FIG. 1B are a side view and a plan view,
respectively, of a shovel according to an embodiment 1. A hydraulic
shovel exemplifies a shovel, in the embodiment 1. However, the
embodiment 1 can be adopted to other shovels, such as a hybrid
shovel or an electric shovel.
[0037] An upper revolving superstructure 12 is mounted to an
undercarriage 10 via a revolving bearing 11. The upper revolving
superstructure 12 revolves clockwise or counter-clockwise with
respect to the undercarriage 10. A boom 13 is installed on the
upper revolving superstructure 12. An arm 15 is connected to a tip
of the boom 13. A bucket 17 is connected to a tip of the arm 15.
The boom 13 is driven by a hydraulic cylinder 14. The arm is driven
by a hydraulic cylinder 16. The bucket 17 is driven by a hydraulic
cylinder 18. Furthermore, a cabin 19 is mounted to the upper
revolving superstructure 12, and a driver gets into the cabin 19
and operates a hydraulic shovel.
[0038] An imaging device 20 is mounted to the upper revolving
superstructure 12. A frontward imaging device 20F, a right imaging
device 20R, a left imaging device 20L and a backward imaging device
20B constitute the imaging device 20. The frontward imaging device
20F, the right imaging device 20R, the left imaging device 20L and
the backward imaging device 20B respectively image front, right,
left and back sides of the upper revolving superstructure 12. The
frontward imaging device 20F is mounted between the cabin 19 and
the boom 13, for example. An omnidirectional image can be obtained
by combining images obtained by these imaging devices.
[0039] FIG. 2 shows a block diagram of an abnormality determination
function of the shovel. An image capture control device 24 stores
image data acquired by the imaging device 20 in a temporary storage
device 25 at a predetermined cycle. The temporary storage device 25
has a ring buffer structure, for example. In other words, the
oldest image data are overwritten (replaced) with new image data
when no free storage area remains.
[0040] Information that specifies a capturing method of the image
data, such as resolution and a capturing cycle, is stored in an
image capture mode storage portion 26. A parameter for specifying
the resolution is set to any one of a "high resolution", a "normal
resolution" and a "low resolution", for example. A parameter for
specifying the capturing cycle is set to any one of a "long cycle",
a "normal cycle" and a "short cycle". An image capture mode is
determined by the resolution and the capturing cycle. An operator
operates an input device 33 to input the image capture mode to a
control device 30. Then, the image capture mode is set to the image
capture mode storage portion 26. An image capture cycle is about
several hundred ms to 1 sec, for example.
[0041] The image capture control device 24 stores image data
acquired by the imaging device 20, based on the image capture mode
set to the image capture mode storage portion 26, in the temporary
storage device 25. By decreasing image resolution or lengthening
the capturing cycle, it is possible to store a long term image data
in the temporary storage device 25. On the contrary, by increasing
the image resolution and shortening the capturing cycle, it is
possible to increase an information amount of image data in a
predetermined time.
[0042] A plurality of sensors 34 are installed on the shovel. The
sensors 34 detect physical quantities relating to an operation
state of the shovel. An engine speed, a radiator coolant
temperature, a fuel temperature, an atmospheric pressure, an engine
oil pressure, a boost temperature, an intake temperature, a
hydraulic operating fluid temperature, a boost pressure, a battery
voltage, a hydraulic pressure of each part, a machine operation
time, a traveling operation time, a revolving operation time, an
idle time and the like are exemplified as the physical quantities
relating to the operation state.
[0043] The control device 30 controls the temporary storage device
25, the image capture mode storage portion 26, an output device 31,
and an abnormality information storage device 32.
[0044] Instructions of an operator are input to the control device
30 via the input device 33. The detection values detected by the
sensors 34 are input to the control device 30. A liquid crystal
display device is adopted as the output device 31, for example. A
touch-panel type liquid crystal display device maybe adopted as a
device functioning as the output device 31 and the input device
33.
[0045] FIG. 3 shows a flowchart of an operation of the image
capture control device 24. When an engine start key of the shovel
is turned on, the image data is acquired from the imaging device 20
in step SA1. The resolution of the image data is converted so as to
be the resolution specified in the image capture mode, and then the
converted image data is stored in the temporary storage device 25.
When a free area for storing the image data does not remain, the
oldest image data are overwritten with new image data.
[0046] In step SA2, a period of a capturing cycle specified in the
image capture mode elapses. Then, whether or not the start key of
the shovel is in a stopped state is determined in step SA3. When
the start key of the shovel is in a stopped state, the process is
finished. When the start key of the shovel is not in a stopped
state, the process returns to step SA1.
[0047] FIG. 4 shows a flowchart of an operation of the control
device 30. When the engine start key of the shovel is turned on,
the detection values detected by the sensors 34 are acquired in
step SB1. Whether or not the acquired detection values are within
an allowable range is determined in step SB2. The allowable range
is preset for each physical quantity relating to the operation
state.
[0048] Whether or not the operation state is abnormal is determined
in step SB3. When at least one of the detection values is out of
the allowable range, the operation state of the shovel is
determined to be abnormal. When all the detection values are within
the allowable range, the operation state is determined to be
normal. When the operation state is determined to be normal,
whether or not the shovel is in a stopped state is determined in
step SB5. When the operation state is determined to be abnormal,
step SB4 is executed. Then, whether or not the shovel is in a
stopped state is determined in step SB5.
[0049] Hereinafter, a process of step SB4 will be described. Among
the image data stored in the temporary storage device 25, the image
data which corresponds to a period from a first time prior to a
time at which the operation is determined to be abnormal to the
present is read out and stored in the abnormality information
storage device 32. Furthermore, the detection value of each sensor
34 at the time when the operation is determined to be abnormal is
stored in the abnormality information storage device 32. The stored
image data and the detection value of the sensor 34 are associated
with each other. The image data and the detection value of the
sensor 34 may be associated with each other, based on indices given
thereto, for example. In addition, the image data and the detection
value of the sensor 34 may be associated with each other, based on
the time at which the data is acquired.
[0050] Furthermore, in addition to the image data corresponding to
a period prior to the time at which the operation is determined to
be abnormal, image data corresponding to a period after that time
may be stored in the abnormality information storage device 32. At
a second time following the time at which the operation is
determined to be abnormal, the image data corresponding to a period
from the first time to the second time may be transmitted from the
temporary storage device 25 to the abnormality information storage
device 32 after waiting for the image data transmission until the
second time, for example. A period from the first time to the time
at which the operation is determined to be abnormal is set to about
30 sec to 5 min, and a period from the time at which the operation
is determined to be abnormal to the second time is set to about 10
sec to 1 min.
[0051] Furthermore, an alarm may be raised from the output device
31 to inform an operator that the operation state is abnormal.
[0052] When, in step SB5, it is determined that the shovel is in a
stopped state, the process is finished. When it is determined that
the shovel is not in a stopped state, the process returns to step
SB1 after a predetermined time elapses in step SB6. The waiting
time of step SB6 is set to several hundred ms to 1 sec, for
example.
[0053] In the embodiment 1, the image data corresponding to a
period before the time at which the operation is determined to be
abnormal or a period before and after the time is stored in the
abnormality information storage device 32. The image data is useful
in specifying the cause of abnormality. When any abnormality occurs
in the shovel, it is possible for a maintenance person to search
for the cause of the abnormality by operating the input device 33
(see FIG. 2).
[0054] FIG. 5 is a view showing an example of an image displayed on
the output device 31 at the time of searching for the cause of
abnormality. An image display window 35, a progress status bar 36,
operating icons 37 and a character information display window 38
are shown in a display screen. A display screen when it is
determined that an abnormality has occurred at the time of 10:35:20
on Apr. 26, 2012 is exemplarily shown in FIG. 5.
[0055] The progress status bar 36 shows a period from a data
collection start time of the image data stored in the abnormality
information storage device 32 (see FIG. 2) to a finish time. When a
slider 36A displayed in the progress status bar 36 is slid, an
image at the time corresponding to the position of the slider 36A
is displayed on the image display window 35. A mark 36B for
indicating abnormality occurrence time is displayed on the progress
status bar 36 at the position corresponding to a time of
abnormality occurrence. The progress status bar 36 and the slider
36A function as a time indicator by which the time of the image to
be displayed on the image display window 35 is indicated. The
length of the progress status bar 36 corresponds to a time range
within which the time can be specified by the slider 36A. A numeric
input window used for inputting a time as a numeric value maybe
displayed as a time indicator, instead of the slider 36A.
[0056] A playback, a frame-by-frame playback, a pause or the like
of moving image can be carried out by operating the operating icon
37. In addition, the operating icon 37 includes an instruction
button used for jumping to the time of abnormality occurrence. When
the instruction button is operated, the image at the time when the
operation is determined to be abnormal in step SB2 shown in FIG. 4
is displayed on the image display window 35. It is possible to
quickly display the image at the time immediately before the time
of abnormality occurrence, by providing the instruction button used
for jumping to the time of abnormality occurrence.
[0057] FIG. 5 shows an example of an image at the time when the
hydraulic abnormality is detected. It is possible to know that a
truck intrudes between the upper revolving superstructure 12 and
the bucket 17 (see FIGS. 1A and 1B), from the image shown in FIG.
5. Here, the following estimation can be carried out. The truck is
in contact with hydraulic piping, and thus the hydraulic piping is
broken. Therefore, a hydraulic abnormality is detected. In this
way, it is possible to specify the cause of the abnormality by
inspecting the image data corresponding to a period before and
after the time at which the abnormality occurs.
Embodiment 2
[0058] A functional block diagram of a shovel according to an
embodiment 2 is the same as the functional block diagram of the
shovel according to the embodiment 1 shown in FIG. 2.
[0059] FIG. 6 is a flowchart showing an operation of the control
device 30 (see FIG. 2) of the shovel according to the embodiment 2.
The control device 30 of the shovel according to the embodiment 2
includes a unit space defining flag and an area for storing the
inverse matrix of a correlation matrix.
[0060] The detection value is acquired from the sensor 34 (see FIG.
2), in step SC1. Whether or not the unit space is defined is
determined in step SC2. Specifically, it is determined whether the
unit space defining flag is set to "defined" or "undefined", in
step SC2. The unit space is used as a reference for determination
when the abnormality determination using Mahalanobis-Taguchi method
is carried out in the following step. When the unit space is
undefined, the detection value of the sensor 34 is accumulated as a
sample, in step SC3. Whether or not the number of accumulated
samples is enough is determined in step SC4. When the number of
samples is enough, the unit space is defined in step SC5.
Specifically, the correlation matrix of physical quantities of
samples which constitute the unit space and the inverse matrix of
the correlation matrix are calculated.
[0061] Hereinafter, a method of defining the unit space will be
described.
[0062] FIG. 7 shows an example of the detection values detected by
the sensor 34. The number of physical quantities of a detection
target is represented by K, and the number of accumulated samples
is represented by N. The detection values of N samples constitute
the unit space. In a sample to which the sample number n is
assigned, the detection value of a physical quantity k is indicated
as x (n, k). The mean value and the standard deviation are
calculated with respect to the detection values of each physical
quantity. The mean value and the standard deviation of the physical
quantity k are indicated as m(k) and a(k), respectively.
[0063] The detection values of each sample are standardized,
whereby standardized detection values are calculated. The
standardized detection value X(n,k) of the detection value x(n,k)
of the physical quantity k in the sample to which the sample number
n is assigned is shown as the following Equation.
X ( n , k ) = x ( n , k ) - m ( k ) .sigma. ( k ) [ Equation 1 ]
##EQU00001##
[0064] Correlation coefficients between the physical quantities are
calculated based on the standardized detection values X (n,k).
[0065] A correlation coefficient r(i,j) of a physical quantity i
and a physical quantity j is calculated by the following
Equation.
r ( i , j ) = 1 N l = 1 N X ( l , i ) X ( l , j ) [ Equation 2 ]
##EQU00002##
[0066] A correlation matrix R of the physical quantities 1 to K is
shown as the following Equation.
R = ( 1 r ( 1 , 2 ) r ( 1 , K ) r ( 2 , 1 ) 1 r ( 2 , K ) r ( K , 1
) r ( K , 2 ) r ( K , K ) ) [ Equation 3 ] ##EQU00003##
[0067] An inverse matrix A of the correlation matrix R is
calculated. The inverse matrix A is stored in the control device 30
so as to be available in the following step.
[0068] In step SC6, the unit space defining flag is set to
"defined". In the case where the number of samples is determined to
be not enough in step SC4, or after the unit space defining flag is
set to "defined" in step SC6, the process waits for a predetermined
time in step SC11. The waiting time is set to about several hundred
ms to 1 sec, for example. After waiting for the predetermined time,
the process returns to step SC1.
[0069] Furthermore, the unit space defining flag can be reset by
the operation of an operator. In other words, it is possible to set
the unit space defining flag to "undefined".
[0070] When, in step SC2, the unit space is determined to be
defined, a Mahalanobis distance (MD) of the detection values
(verification data) detected by each sensor 34 is calculated in
step SC7. Hereinafter, a calculation method of the Mahalanobis
distance will be described.
[0071] The value of a physical quantity k, out of K detection
values (verification data) detected by the sensors 34, is indicated
as y(k). The detection value y(k) is standardized, whereby a
standardized detection value Y (k) is calculated. The standardized
detection value Y(k) can be calculated by the following
Equation.
Y ( k ) = y ( k ) - m ( k ) .sigma. ( k ) [ Equation 4 ]
##EQU00004##
[0072] The square (D.sup.2) of the Mahalanobis distance of the
verification data can be calculated by the following Equation using
the inverse matrix A of the correlation matrix R.
D 2 = 1 K ( Y ( 1 ) Y ( 2 ) Y ( K ) ) A ( Y ( 1 ) Y ( 2 ) Y ( K ) )
[ Equation 5 ] ##EQU00005##
[0073] When the Mahalanobis distance MD (or the square D.sup.2 of
the Mahalanobis distance) is calculated, the Mahalanobis distance
MD and a threshold are compared in step SC8. The threshold is set
in advance. The threshold is set to 2, for example. When the
threshold is compared to the square D.sup.2 itself of the
Mahalanobis distance defined in Equation described above, the
threshold is set to 2.sup.2=4. When the Mahalanobis distance MD is
greater than the threshold, the process of step SC9 is to start.
The process of step SC9 is the same as the process of step SB4 (see
FIG. 4) in the embodiment 1.
[0074] When the process of step SC9 is finished or when the
Mahalanobis distance MD is determined, in step SC8, to be equal to
or less than the threshold, whether or not the shovel is in the
stopped state is determined in step SC10. When the shovel is in the
stopped state, the process is finished. When the shovel is not in
the stopped state, the process waits for a predetermined time in
step SC11. Then, the process returns to step SC1.
[0075] In the embodiment 2, the Mahalanobis-Taguchi method is
adopted as a method of determining whether or not an operation
state is abnormal. Thus, it is unnecessary to set the allowable
range to each detection value of the sensors 34.
[0076] In the embodiment 1 described above, the allowable range of
the detection value is set based on cases where the abnormality
occurred in the past or the like, for example. Thus, there is a
possibility that a new abnormality which has not occurred in the
past may not be detected in some cases. However, by adopting the
Mahalanobis-Taguchi method, it is unnecessary to set the allowable
range of the detection value based on cases in the past. Therefore,
it is possible to detect a new abnormality which has not occurred
in the past.
[0077] Furthermore, deviation amounts of the plurality of detection
values with respect to allowed values are integrated into the
Mahalanobis distance (MD) in the embodiment 2, and thus it is
possible to easily determine whether or not the operation is
abnormal.
[0078] FIG. 8 shows an example of an image displayed on the output
device 31 (see FIG. 2) when the cause of abnormality is searched
for in the shovel according to the embodiment 2. Hereinafter,
differences between the embodiment 2 and the embodiment 1 shown in
FIG. 5 will be described. Besides the image display window 35, the
progress status bar 36, the operating icon 37 and the character
information display window 38, a window 39 for displaying an alarm
level variation is shown in the embodiment 2. A variation graph of
alarm levels with the elapsed time corresponding to a time range
specified by the slider 36A is displayed in the window 39 for
displaying the alarm level variation. A display image time line 39A
is displayed in the window 39 for displaying alarm level variation
at a position corresponding to the time (the time corresponding to
the displayed image) specified by the slider 36A. Furthermore, an
abnormality occurrence time line 39B is displayed in the window 39
for displaying the alarm level variation at a position
corresponding to the mark 36B for indicating abnormality occurrence
time. The alarm level shows the level of possibility that an
abnormality is occurring in the shovel. The Mahalanobis distance
calculated in step SC7 (see FIG. 6) is adopted as the alarm level.
It is conceived that any cause of abnormality is generated
immediately before the alarm level is increased rapidly.
Embodiment 3
[0079] FIG. 9 shows a functional block diagram of a shovel and a
monitoring device according to an embodiment 3. Hereinafter, a
description focuses on differences between the shovel of the
embodiment 3 and the shovel of the embodiment 1. A description of
the same configuration will not be repeated.
[0080] In the embodiment 1, an abnormality determination process
and the accumulation process of data when the abnormality occurs
are completed only in the shovel. In the embodiment 2, the
abnormality determination process is carried out by the local
control device 30 mounted on a shovel 50. The image data and the
like when the operation is determined to be abnormal are
accumulated in a monitoring device 60. A transceiver 40 which
transmits various data, such as image data, to the monitoring
device 60 via a communication line 45 is mounted on the shovel
50.
[0081] A transceiver 41, a control device 61, an output device 62,
an input device 63 and the abnormality information storage device
32 are provided in the monitoring device 60. The transceiver 41
receives data sent from the shovel 50 via the communication line
45. The control device 61 controls the output device 62, the input
device 63 and the abnormality information storage device 32.
[0082] FIG. 10 shows a flowchart of a process performed by the
local control device 30 mounted on the shovel 50. Steps SB1, SB2,
SB3, SB5, and SB6 are, respectively, the same as steps SB1, SB2,
SB3, SB5, and SB6 of the embodiment 1 shown in FIG. 4. The process
of step SD4 is executed instead of step SB4 in the embodiment 1.
Hereinafter, step SD4 will be described.
[0083] When the operation state is determined, in step SB3, to be
abnormal, the local control device 30 waits until the second time
following the determination time such that image data is
accumulated in the temporary storage device 25. The image data
corresponding to a period from the first time prior to a time at
which the operation is determined to be abnormal to the second
time, out of the image data stored in the temporary storage device
25, and the detection values of the sensors 34 when the operation
is determined to be abnormal are transmitted from the transceiver
40 to the monitoring device 60. Instead, the image data
corresponding to a period from the first time prior to the time at
which the operation is determined to be abnormal to the time at
which the operation is determined to be abnormal, out of the image
data stored in the temporary storage device 25, may be transmitted.
Furthermore, an alarm is raised from the output device 31, whereby
the abnormality is notified to an operator.
[0084] Subsequently, a process of the control device 61 of the
monitoring device 60 will be described. When the image data
corresponding to a period before and after the time at which the
operation state is determined to be abnormal and the detection
values of the sensors are received from the shovel 50, the control
device 61 stores the received image data in the abnormality
information storage device 32. At the same time, an alarm is raised
from the output device 62.
[0085] When an observer of the monitoring device 60 commands a data
display via the input device 63, the control device 61 outputs the
detection values of the sensor and the image data, which are
accumulated in the abnormality information storage device 32, to
the output device 62. The image data corresponding to a period
before and after the time at which the operation is determined to
be abnormal becomes useful information when an observer specifies
the cause of abnormality. The image displayed on the output device
62 is the same as the image output on the output device 31
according to the embodiment 1 shown in
[0086] FIG. 5 or the image output on the output device 31 according
to the embodiment 2 shown in FIG. 8.
Embodiment 4
[0087] FIG. 11 is a functional block diagram of a shovel and a
monitoring device according to an embodiment 4. Hereinafter, a
description focuses on differences of the shovel and the monitoring
device between the embodiment 4 and the embodiment 3. A description
of the same configuration will not be repeated.
[0088] The local control device 30 mounted on the shovel 50 carries
out the abnormality determination process in the embodiment 3.
However, the control device 61 mounted on the monitoring device 60
carries out the abnormality determination process in the embodiment
4. The shovel 50 transmits an abnormality determination request as
well as the detection values of the sensor 34 to the monitoring
device 60 at predetermined cycles.
[0089] FIG. 12 shows a flowchart of a process performed by the
control device 61 of the monitoring device 60. Whether or not the
abnormality determination request is received from the shovel 50 is
determined in step SE1. When the abnormality determination request
is not received, step SE1 is repeated until the abnormality
determination request is received.
[0090] When the abnormality determination request is received, the
abnormality determination is performed in step SE2, based on the
detection value of the sensor which is received from the shovel 50.
The abnormality determination process is the same as the
abnormality determination process of steps SB2 and SB3 (see FIG. 4)
according to the embodiment 1 or steps SC7 and SC8 (see FIG. 6)
according to the embodiment 2.
[0091] When the operation state is determined to be abnormal in
step SE3, it is commanded, in step SE4, that shovel 50 transmits
the image data. This command includes a start time (the first time)
and a finish time (the second time) of the image data to be
transmitted. When receiving the transmission command of the image
data, the shovel 50 transmits the image data corresponding to a
period from the first time to the second time, out of the image
data accumulated in the temporary storage device 25, to the
monitoring device 60 as a response to the command. In addition, it
is preferable to perform a data compression of the image data
before transmission.
[0092] In step SE5, the image data received from the shovel 50 and
the detection values of the sensor at the time when the operation
is determined to be abnormal are stored in the abnormality
information storage device 32 in a state of being associated with
each other. When a process of step SE5 is finished, whether or not
the operation of the monitoring device 60 is in a stopped state is
determined in step SE6. Whether or not the operation of the
monitoring device 60 is in a stopped state is determined in step
SE6, even when the operation is determined, in step SE3, not to be
abnormal.
[0093] When the monitoring device 60 is determined, in step SE6,
not to be in a stopped state, the process returns to step SE1. When
the monitoring device 60 is determined to be in a stopped state,
the process is finished.
[0094] To specify the cause of the abnormality, an observer of the
monitoring device 60 can use the image corresponding to a period
before and after the time of the detected abnormality which is
displayed on the output device 62, even in the case of the
embodiment 4. The image displayed on the output device 62 is the
same as the image output on the output device 31, according to the
embodiment 1 shown in FIG. 5, or the image output on the output
device 31, according to the embodiment 2 shown in FIG. 8.
[0095] Although the invention is described with reference to the
embodiments described above, it is not limited thereto. For
example, it is apparent to those skilled in the art that the
invention can be modified, improved, combined, or the like in
various ways.
REFERENCE SIGNS LIST
[0096] 10: undercarriage [0097] 11: revolving mechanism [0098] 12:
upper revolving superstructure [0099] 13: boom [0100] 14: hydraulic
cylinder [0101] 15: arm [0102] 16: hydraulic cylinder [0103] 17:
bucket [0104] 18: hydraulic cylinder [0105] 19: cabin [0106] 20F:
frontward imaging device [0107] 20R: right imaging device [0108]
20L: left imaging device [0109] 20B: backward imaging device [0110]
24: image control device [0111] 25: temporary storage device [0112]
26: operation mode storage portion [0113] 27: sensor [0114] 30:
control device [0115] 31: output device [0116] 32: abnormality
information storage device [0117] 33: input device [0118] 34:
sensor [0119] 35: image display window [0120] 36: progress status
bar [0121] 36A: slider [0122] 36B: mark for indicating abnormality
occurrence time [0123] 37: operating icon [0124] 38: character
information display window [0125] 39: window for displaying alarm
level variation [0126] 39A: display image time line [0127] 39B:
abnormality occurrence time line [0128] 40, 41: transceiver [0129]
45: communication line [0130] 50: shovel [0131] 60: monitoring
device [0132] 61: control device [0133] 62: output device [0134]
63: input device
* * * * *