System and a method for remote assistance in a foundry

• US 8,798,783 B2
• Filed: 02/08/2010
• Issued: 08/05/2014
• Est. Priority Date: 03/02/2009
• Status: Active Grant

• Current Assignee: Sintokogio Limited
• Original Assignee: Sintokogio Limited
• Inventors: Niinomi, Akiyoshi, Kawamoto, Yoshitake, Miwa, Yasuhiro, Natsume, Nobuaki, Ishiguro, Kenji
• Primary Examiner(s): Padmanabhan, Kavita
• Assistant Examiner(s): STEVENS, THOMAS H
• Application Number:
  US13/201,247
• Publication Number:
  US 20120041588A1
• Time in Patent Office: 1,639 Days
• US Class Current: 700/197
• CPC Class Codes: B22C 19/04 Controlling devices specially designed for moulding machines
• CPC Class Codes: B22C 25/00 Foundry moulding plants for preparing mould materials B22C5/18; in combination with casting plants B22D47/02
• CPC Class Codes: B22D 46/00 Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons controlling or regulating in general G05
• CPC Class Codes: G05B 2219/31457 Factory remote control, monitoring through internet
• CPC Class Codes: G05B 2219/35458 Control command embedded in video, audio stream, signal
• CPC Class Codes: G05B 2219/36168 Touchscreen
• CPC Class Codes: G05B 2219/45244 Injection molding
• 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

Abstract

The object of the present invention is to provide a remote assistant system for a foundry, i.e., a plant that comprises a plurality of machines. The remote assistant system in a foundry includes a first sequencer for controlling a molding line and a second sequencer for controlling a molding machine. It further includes a sequencer-communicating mechanism for connecting the first sequencer to the second sequencer, a first mobile computer for transmitting information by video images, etc. to a remote location, a mechanism for providing communication between mobile computers to selectively connect one of the sequencers to the first mobile computer, a second mobile computer for receiving the information from the first mobile computer, for displaying the information, and for correcting the ladder logic program and giving instructions to the operator by an assistant at a remote location.

Claims

1. A remote assistant system in a foundry comprising at least a touchscreen panel for operating a molding line having a molding machine, a first sequencer for controlling the molding line, a touchscreen panel for operating the molding machine, and a second sequencer for controlling the molding machine, the system further comprising:

a sequencer-communicating means for connecting the first sequencer to the second sequencer;

a first mobile computer connected to a means for providing communication between mobile computers, the first mobile computer taking information by video images and information by voice on an appearance of the molding machine or the molding line that has trouble and the information on a ladder program of the first sequencer or the second sequencer of the molding line or the molding machine that has trouble, and transmitting the information by video images, the information by voice, or the information on the ladder logic program of the first or second sequencer;

a means for providing wireless communication between mobile computers, the means selectively connecting one of the sequencers to the first mobile computer;

a second mobile computer receiving the information by video images, the information by voice, or the information on the ladder logic program of the first or second sequencer, and displaying the information, the second mobile computer transmitting online data for correcting the ladder logic program and instructions for repairing the molding machine or the molding line; and

a means for providing communication between the first mobile computer and the second mobile computer.

2. The remote assistant system in the foundry of claim 1, wherein the second sequencer comprises, for each expendable part of the molding machine, a means for memorizing a criterion on how many times the part can be used, a means for counting a number of times the part is actually used, and a means for comparing the number that is counted with a number used as a criterion.

3. The remote assistant system in the foundry of claim 1 or 2, further comprising:

a personal computer for analyzing waveforms generated by the molding machine to recognize a location of the trouble in the molding machine.

4. The remote assistant system in the foundry of claim 1, wherein the first mobile computer is located in a control room of the foundry or in the foundry during a normal operation, and the first mobile computer has software for communicating while it moves when the molding machine or the molding line has trouble.

5. A method for remote assistance using the remote assistant system in the foundry of claim 1 comprising the steps of:

searching for a first possible location that has trouble by moving locations to obtain the information by video images or by voice regarding the molding line or the molding machine, or the information on the ladder logic program;

identifying a second possible location in the molding machine or the molding line that has trouble by using the ladder logic program;

checking to see if the first possible location is the same as the second possible location; and

assisting to give instructions for repair work on the molding machine or the molding line based on a location that has been checked.