Processor-based process control system with intuitive programming capabilities

• US 6,272,398 B1
• Filed: 09/21/1998
• Issued: 08/07/2001
• Est. Priority Date: 09/21/1998
• Status: Expired due to Fees

• Current Assignee: Siebolt Hettinga
• Original Assignee: Siebolt Hettinga
• Inventors: Spicer, Mark W., Whited, Berton G., Osborne, Richard D.
• Primary Examiner(s): Cuchlinski, Jr., William A.
• Assistant Examiner(s): Marc, McDieunel, Marc, McDieunel
• Application Number:
  US09/157,731
• Time in Patent Office: 1,051 Days
• Field of Search: 700/18, 700/7, 700/200, 700/9, 700/130, 700/140, 700/84, 700/197, 700/203, 700/121, 700/118, 700/213, 264/40.6, 264/40.1, 709/218
• US Class Current: 700/245
• CPC Class Codes: B29C 2037/903 by means of a computer
• CPC Class Codes: B29C 2037/906 using visualisation means or linked accessories, e.g. screens, printers
• CPC Class Codes: B29C 2945/76043 derivative, change thereof
• CPC Class Codes: B29C 45/76 Measuring, controlling or regulating measuring in general G01; controlling or regulating in general G05
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 2219/31138 Profibus process fieldbus
• CPC Class Codes: G05B 2219/34267 Windows nt and cooperating real time extension
• CPC Class Codes: G05B 2219/45244 Injection molding
• 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

A system having a processor-based process control system for a plastic injection molding machine performing a plastic injection molding process having an I/O bus network containing a plurality of I/O modules operably connected to a corresponding I/O device associated with the plastic injection molding machine and a first computer having and I/O bus controller directly connected to the I/O bus network, a real-time operating system, and a first processor executing a plastic injection molding control program for controlling the plastic injection molding process.

Claims

1. A processor-based process control system for a plastic injection molding machine performing a plastic injection molding process, comprising:

(a) an I/O bus network having a plurality of I/O modules operably connected to a corresponding I/O device associated with the plastic injection molding machine;

(b) a first computer comprising;

(1) an I/O bus controller directly connected to the I/O bus network;

(2) a real-time operating system; and

(3) a first processor executing a plastic injection molding control program for controlling the plastic injection molding process; and

(c) a second computer comprising;

(1) an application-specific program configured to operate with the plastic injection molding control program for allowing an operator to view parameters related to the plastic injection molding process and input information related to the plastic injection molding process; and

(2) a second processor for executing the application-specific program.

2. The processor-based process control system of claim 1 wherein the second computer further comprises storage for storing information relating to the plastic injection molding process.

3. The processor-based process control system of claim 1 wherein the first computer further comprises a first interface and the second computer further comprises a second interface, and wherein the first and second interface are communicatingly linked.

4. The processor-based process control system of claim 1 wherein the second computer is operably connected via a network to a third computer such that the third computer is capable of viewing parameters related to the plastic injection molding process and capable of inputting information related to the plastic injection molding process.

5. The processor-based control system of claim 4 wherein the third computer comprises the application-specific program.

6. A processor-based process control system for a plastic injection molding machine performing a plastic injection molding process comprising:

(a) an I/O bus network having a plurality of I/O modules operably connected to a corresponding I/O device associated with the plastic injection molding machine;

(b) a first computer comprising;

(1) an I/O bus controller directly connected to the I/O bus network;

(2) a real-time operating system; and

(3) a first processor executing a plastic injection molding control program for controlling the plastic injection molding process; and

(c) a second computer comprising;

(1) an application-specific program configured to operate with the plastic injection molding control program for allowing an operator to view parameters related to the plastic injection molding process and input information related to the plastic injection molding process;

(2) a second processor for executing the application-specific program;

(3) a hierarchy of programming levels, including an N programming level and an N+1 programming level, wherein N is a positive integer;

(4) a defined set of N programming level commands; and

(5) a GUI window for defining N+1 programming level commands by enabling a user to select and arrange a plurality of defined N programming level commands.

7. The processor-based control system of claim 6, wherein the GUI window enables a user to define an N+1 programming level command such that the N+1 programming level command has two functions.

8. The processor-based control system of claim 7,wherein the two functions correspond to the normal operation of the plastic injection molding machine and an aborted operation of the plastic injection molding machine.

9. The processor-based process control system of claim 6 wherein the second computer further comprises a GUI window for each programming level other than the first programming level, and wherein the program for creating the plastic injection molding control program is configurable such that the user cannot gain access to a subset of the GUI windows.

10. The processor-based control system of claim 9, wherein a command defined in the GUI window for the highest programming level comprises all of the first programming level commands in the plastic injection molding control program.

11. A processor-based process control system for a plastic injection molding machine performing a plastic injection molding process comprising:

(a) an I/O bus network having a plurality of I/O modules operably connected to a corresponding I/O device associated with the plastic injection molding machine;

(b) a first computer comprising;

(1) an I/O bus controller directly connected to the I/O bus network;

(2) a real-time operating system; and

(3) a first processor executing a plastic injection molding control program for controlling the plastic injection molding process;

(c) a second computer comprising;

(1) an application-specific program configured to operate with the plastic injection molding control program for allowing an operator to view parameters related to the plastic injection molding process and input information related to the plastic injection molding process; and

(2) a second processor for executing the application-specific program; and

(d) a third computer, operably connected via a network to the second computer, capable of viewing and inputting parameters related to the plastic injection molding process and further comprising an application specific program for creating the plastic injection molding control program, comprising;

(a) a hierarchy of programming levels, including an N programming level and an N+1 programming level, wherein N is a positive integer;

(b) a defined set of N programming level commands; and

(c) a GUI window for defining N+1 programming level commands by enabling a user to select and arrange a plurality of defined N programming level commands.

12. A processor-based process control system for a plastic injection molding machine, comprising:

(a) an I/O bus network having a plurality of I/O modules operably connected to a corresponding I/O device associated with the plastic injection molding machine;

(b) a first computer comprising;

(1) an I/O bus controller directly connected to the I/O bus network;

(2) a real-time operating system; and

(3) a first processor executing a plastic injection molding control program for controlling the plastic injection molding process;

(c) a second computer comprising;

(1) an application-specific program configured to operate with the plastic injection molding control program for allowing an operator to view parameters related to the plastic injection molding process and input information related to the plastic injection molding process;

(2) a second processor for executing the application-specific program; and

(d) a stand-alone computer comprising a program for creating the plastic injection molding control program, comprising;

(1) a hierarchy of programming levels, including an N programming level and an N+1 programming level, wherein N is a positive integer;

(2) a defined set of N programming level commands; and

(3) a GUI window for defining N+1 programming level commands by enabling a user to select and arrange a plurality of defined N programming level commands.