AUTOMATION OPERATING AND MANAGEMENT SYSTEM

• US 20150323926A1
• Filed: 05/06/2015
• Published: 11/12/2015
• Est. Priority Date: 05/08/2014
• Status: Active Grant

• Current Assignee: Beet, LLC
• Original Assignee: Beet, LLC
• Inventors: Wang, David Jingqiu
• Granted Patent: US 10,048,670 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G05B 11/01 electric
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 19/048 Monitoring; Safety
• CPC Class Codes: G05B 19/409 characterised by using manual data input [MDI] or by using control panel, e.g. controlling functions with the panel; characterised by control panel details or by setting parameters G05B19/408, G05B19/4093 take precedence
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 19/4183 characterised by data acquisition, e.g. workpiece identification
• CPC Class Codes: G05B 2219/15126 Calculate duration of cycle
• CPC Class Codes: G05B 2219/25387 Control sequences so as to optimize energy use by controlled machine
• CPC Class Codes: G05B 2219/25407 Delay between operations
• CPC Class Codes: G05B 2219/31368 MAP manufacturing automation protocol
• CPC Class Codes: G05B 2219/31472 Graphical display of process
• CPC Class Codes: G05B 2219/35472 Mode selection
• CPC Class Codes: G05B 2219/39447 Dead man switch
• CPC Class Codes: G05B 23/0216 Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
• CPC Class Codes: G05B 23/0272 Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An automation operating and management system consolidates and analyzes inputs from multiple machines within an automated enterprise to predict failures and provide instructions for counteractions to prevent failures during machine operation, and to identify opportunities for efficiency improvement, including actions for reduction in peak power consumption demand within a facility including multiple machines. A machine can include a machine controller and at least one base layer controller, where the base layer controller acts as a low level controller to directly control the motion of elements in communication with the base layer control, according to parameters set by the machine controller. The base layer controller collects timing data for the elements under its control, compares the timing data with the parameters and sets an alarm when the timing data is outside of tolerance limits defined by the parameters.

Claims

1. A system for controlling automation, the system comprising:

a plurality of machines;

wherein each machine of the plurality of machines includes a machine controller and a plurality of elements;

wherein the machine controller is configured to control the plurality of elements to perform an operational sequence and to collect data generated during performance of the operational sequence by the plurality of elements; and

a server in communication with each of the plurality of machine controllers to collect the data.

2. The system of claim 1, wherein the server includes programming for predicting a failure of at least one element of the plurality of elements using the data collected from the plurality of machine controllers.

3. The system of claim 2, wherein in response to predicting the failure, the server generates an instruction to the machine controller of the respective machine including the at least one element;

wherein the instruction is a countermeasure to prevent failure of the at least one element during operation of the respective machine.

4. The system of claim 3, wherein the countermeasure is a command to substitute a back-up element for the at least one element.

5. The system of claim 3, further comprising:

a facility comprising;

the server;

a first facility system including the plurality of machines;

a second facility system;

wherein the server is in communication with the second facility system to collect facility system data from the second facility system;

wherein the server includes programming for predicting the failure of the at least one element of the plurality of elements using the data collected from the plurality of machine controllers in combination with the facility system data collected from the second facility system.

6. The system of claim 5, wherein the second facility system is an infrastructure system for controlling a power supply of the facility.

7. The system of claim 5, where the second facility system is one of a product assurance system and a production control system.

8. The system of claim 1, wherein at least one machine of the plurality of machines further comprises:

a first station including a first element of the plurality of elements;

a second station including a second element of the plurality of elements;

a first base layer controller in communication with the machine controller and the first station to directly control the first element according to parameters received from the machine controller by the first base layer controller; and

a second base layer controller in communication with the machine controller and the second station to directly control the second element according to parameters received from the machine controller by the second base layer controller.

9. The system of claim 8, further comprising:

the first station including a first sensor for sensing a first condition state of the first element;

the second station including a second sensor for sensing a second condition state of the second element;

wherein the first base layer controller and the second base layer controller are in communication with each other such that the first base layer controller communicates the first condition state to the second base layer controller and the second base layer controller communicates the second condition state to the first base layer controller.

10. The system of claim 9, wherein:

the first base layer controller selectively actuates the first element in response to the first condition state and the second condition state; and

the second base layer controller selectively actuates the second element in response to the first condition state and the second condition state.

11. The system of claim 10, wherein:

the first base layer controller includes a first data matrix for storing data collected from the first station;

the second base layer controller includes a second data matrix for storing data collected from the second station;

the machine controller collects the data from the first data matrix and the second data matrix and coordinates control functions of the first and second base layer controllers using the collected data.

12. The system of claim 11, wherein:

the first base layer controller compares the data collected from the first station to the parameters received from the machine controller;

the first base layer controller sets an alarm when the data is outside of the parameters.

13. A system for controlling automation, the system comprising:

a machine comprising;

a first controller;

a first element actuable by the first controller at machine start-up to perform a first cycle characterized by a first cycle time;

a second element actuable by the first controller at machine start-up to perform a second cycle characterized by a second cycle time;

wherein the first cycle time is longer in duration than the second cycle time;

wherein the first controller;

actuates the first element to perform the first cycle at machine start-up; and

delays actuation of the second element to perform the second cycle by a first delay time, such that the second element performs the second cycle at a delayed start time relative to the machine start-up;

wherein the sum of the duration of the first delay time and the second cycle time is less than the first cycle time.

14. The system of claim 13, wherein the first controller delays actuation of the second element by the delay time when the sum of the duration of the delay time and the second cycle time is less than a predetermined limit;

and

wherein the predetermined limit is less than the first cycle time.

15. The system of claim 13, further comprising:

a power source for energizing the first element and the second element;

the power source in communication with the first controller;

wherein the first controller commands the power source to energize the first element at machine start-up and commands the power source to energize the second element at the delayed start time.

16. The system of claim 13, wherein the machine further comprises:

a second controller;

a third element actuable by the second controller at machine start-up to perform a third cycle characterized by a third cycle time;

wherein the third cycle time is shorter in duration than the first cycle time;

wherein the second controller delays actuation of the third element to perform the third cycle by a second delay time, such that the third element performs the third cycle at a delayed start time relative to the machine start-up; and

wherein the sum of the duration of the second delay time and the third cycle time is less than the first cycle time.

17. The system of claim 16, wherein the duration of the first delay time is different from the duration of the second delay time.

18. The system of claim 16, wherein the machine further comprises:

a third controller in communication with the first controller and the second controller;

wherein the third controller includes programming defining a sequence of operations including the first, second and third cycles; and

wherein the first delay time and the second delay time are defined by the sequence of operations.

19. The system of claim 18, wherein:

the first controller receives the first delay time from the third controller; and

the second controller receives the second delay time from the third controller.

20. The system of claim 18, wherein:

the third controller collects actual timing data for the first cycle and actual timing data for the second cycle from the first controller;

the third controller collects actual timing data for the third cycle from the second controller; and

at least one of the first delay time and the second delay time are determined using the actual timing data collected by the third controller.