Computer integrated manufacturing control and information system

• US 6,507,765 B1
• Filed: 02/10/1999
• Issued: 01/14/2003
• Est. Priority Date: 02/10/1998
• Status: Expired due to Fees

• Current Assignee: HM Electronic Systems Limited
• Original Assignee: HM Electronic Systems Limited
• Inventors: Hopkins, Scott, McGregor, William, Moffat, Alec
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Bahta, Kidest
• Application Number:
  US09/247,376
• Time in Patent Office: 1,434 Days
• Field of Search: 700/95, 700/96, 700/108, 700/109, 700/110, 700/112, 700/111, 700/215, 700/204, 700/116, 700/117, 297/05, 297/40, 298/32, 340/674
• US Class Current: 700/95
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/31152 Separate lan for sensors, detectors
• CPC Class Codes: G05B 2219/31434 Zone supervisor, collects error signals from, and diagnoses different zone
• CPC Class Codes: G05B 2219/32181 Monitor production, assembly apparatus with multiple sensors
• CPC Class Codes: G05B 2219/45029 Mount and solder parts on board
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/53022 with means to test work or product

Abstract

The present invention is directed to a distributed computerized control and information system for a manufacturing system which generates a product from distinct components, where the manufacturing system includes a plurality of processing machines which generate signals indicative of parameters of the processing machines'"'"' operation. The system includes a plurality of sensors in communication with an associated processing machine for non-intrusively obtaining parameter signals in real-time from the processing machine so as to not interfere with the parameter signal generation and transmission. Also included is a plurality of command apparatus in communication with an associated sensor for providing real-time analysis of the received parameter signal of the associated processing machine, and a summary station in communication with the plurality of command apparatus for providing real-time summary and detailed analysis of received parameter signals from associated processing machines. The operation of the processing equipment is independent of the operation of the summary station and the plurality of associated command apparatus.

Claims

1. A monitoring and control system for use with a manufacturing system that generates a product from distinct components and includes at least one processing machine in communication with at least one host computer, wherein the processing machine generates parameter signals indicative of the processing machine'"'"'s operation and the host computer provides closed loop control of the processing machine in response to the parameter signals, said monitoring and control system comprising:

one or more units each associated with a separate processing machine, wherein each said unit includes;

a non-intrusive data sensor;

a command apparatus;

a means for tracking components processed by the processing machine;

a means for tracking product entering or leaving the processing machine;

a means for identifying an operator of the processing machine;

wherein said sensor is in open loop communication with the processing machine to non-intrusively obtain the parameter signals in real-time so as to minimally interfere with parameter signal generation and transmission; and

wherein said command apparatus is in communication with said sensor and is operable to generate analysis signals indicative of a real-time analysis of processing machine performance from the parameter signals,

wherein said command apparatus permits only work related functions and is disposed local to the processing machine; and

wherein the operation of the processing machine is independent of the analysis signals generated by said command apparatus.

2. The system of claim 1, further comprising:

a summary station in communication with a plurality of said units, said summary station operable to generate and display summary signals indicative of a real-time summary of the analysis signals; and

wherein the operation of each processing machine is independent of the functioning of said summary station.

3. The system of claim 2, further comprising:

a line controller in communication with said command apparatus, said line controller operable to store the parameter signals and said analysis signals, said line controller also in communication with said summary station for transmitting the parameter signals and said analysis signals to said summary station.

4. The system of claim 2, further comprising a computer server in communication with said summary station for presentation of said summary signals to a computer network.

5. The system of claim 1, wherein each said unit further comprises a mini patch positioned between said sensor and said command apparatus, wherein said mini patch is operable to cease the operation of said processing machine.

6. The system of claim 1, wherein said sensor is coupled between said processing machine and a host computer.

7. The system of claim 1, wherein said means for tracking components includes:

a handheld scanner operable to create component signals by scanning components loaded on the processing machine; and

a docking station for receiving the handheld scanner;

wherein said docking station communicates said component signals to said command apparatus, thereby enabling the recordation of components processed by the processing machine.

8. The system of claim 1, wherein the means for tracking product includes:

a stationary scanner operable to create product signals by scanning product entering or leaving the processing machine, and to communicate said product signals to said command apparatus.

9. The system of claim 1, wherein the means for identifying includes:

a dogtag operable to produce a dogtag signal, wherein said dogtag signal is indicative of said operator; and

a dogtag reader for reading said dogtag signal, said dogtag reader in communication with said command apparatus.