ABSTRACT Production-line sensors are essential for synchronisation and execution of the correct workflow in a manufacturing process. Usually, sensor faults lead to serious delays, or even the complete termination of the manufacturing process, to carry out maintenance. Thus, sensor faults compromise the reliability of the manufacturing system and disturb the production schedule. This study proposes a multiple-sensor fault detection and isolation scheme for manufacturing series production lines. The proposed scheme adopts a global-redundancy method, using a digital camera and an ad-hoc video processing algorithm to detect and isolate faulty sensors. The main objective of this research is to preserve continuity of the production workflow and solve the problem of production delays and interruptions. Moreover, the scheme provides the possibility of online and post-process system maintenance. Further, the collected information on sensor false alarm rates can be used for a reliability analysis of the production line. The proposed scheme was tested using a laboratory production line model. The results show that the proposed scheme achieves the established objectives and improves the reliability of the manufacturing process.

中文翻译：

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使用视频处理的生产线多传感器故障检测和隔离

摘要 生产线传感器对于制造过程中正确工作流程的同步和执行至关重要。通常，传感器故障会导致严重延误，甚至导致制造过程完全终止，无法进行维护。因此，传感器故障会损害制造系统的可靠性并干扰生产计划。本研究提出了一种用于制造系列生产线的多传感器故障检测和隔离方案。所提出的方案采用全局冗余方法，使用数码相机和ad-hoc视频处理算法来检测和隔离故障传感器。这项研究的主要目标是保持生产工作流程的连续性并解决生产延迟和中断的问题。而且，该方案提供了在线和后处理系统维护的可能性。此外，收集到的有关传感器误报率的信息可用于生产线的可靠性分析。使用实验室生产线模型对所提出的方案进行了测试。结果表明，所提出的方案达到了既定的目标，提高了制造过程的可靠性。