HUMAN-MACHINE EXECUTION SYSTEM APPLIED TO MANUFACTURING

Abstract

An integrated human-machine execution system and related method for manufacturing automation, includes a computer, a graphical user interface, one or more programmable input/outputs, one or more human-machine interface components, and a network adapter. The computer is enabled to execute all necessary software to operate the functions of the integrated system and orchestrate the execution of one or more automated manufacturing operations. In some examples, data updates are event-based instead of time-based such that data updates transmitted by the system when data value changes initiate an event, independently of time elapsed since occurrence of a prior event. The system can be configured to connect to an external and discrete programmable logic controller attached an automation component and instructions to the automation component are instantiated at the human-machine execution system, obviating the need for programming at the programmable logic controllers.

Claims

1. An integrated human-machine execution system for manufacturing automation, comprising: a computer, a graphical user interface, one or more programmable input/outputs, one or more human-machine interface components, and a network adapter; wherein the computer is enabled to execute all necessary software to operate the functions of the integrated system and orchestrate the execution of one or more automated manufacturing operations; and wherein data updates are transmitted by the system when data value changes initiate an event, independently of time elapsed since occurrence of a prior event.

2. The human-machine execution system of claim 1, wherein the computer comprises: a. a processor; b. a microcontroller; c. local storage; d. one or more external interfaces and a component interconnect bus attached to the one or more programmable input/outputs; e. firmware and a peripheral interface enabling communication between the processor and the microcontroller; and f. an integrated circuit interface.

3. The human-machine execution system of claim 1, wherein the graphical user interface is enabled through a display connected to the computer.

4. The human-machine execution system of claim 1, wherein the graphical user interface is enabled through a touch screen connected to the computer through (a) a high-definition multimedia interface configured to send a video signal and (b) a universal serial bus interface configured to receive data related to a touch signal transmitted through the touch screen.

5. The human-machine execution system of claim 1, wherein a network interface is exposed through the network adapter to connect the computer to an enterprise network.

6. The human-machine execution system of claim 1, including an automation network or fieldbus configured to interface with one or more automation control devices.

7. The human-machine execution system of claim 1, wherein the system is configured to be connected to at least one external and discrete programmable logic controller attached to at least one automation component.

8. The human-machine execution system of claim 7, wherein instructions to the automation component are instantiated at the human-machine execution system, obviating programming at the programmable logic controllers.

9. A method of executing an automated manufacturing operation a. providing an integrated human-machine execution system for manufacturing automation, comprising: a computer, a graphical user interface, one or more programmable input/outputs, one or more human-machine interface components, and a network adapter; wherein the computer is enabled to execute all necessary software to operate the functions of the integrated system and orchestrate the execution of the automated manufacturing operation; b. connecting the human-machine execution system to an external and discrete programmable logic controller, wherein the programmable logic controller is attached to at least one automation component; c. instantiating one or more instructions for the automation component at the human-machine execution system; d. transmitting the instructions from the human-machine execution system to the automation component through the programmable logic controller without instructing or programming the programmable logic controller;

10. The method of claim 9, wherein instructions are transmitted by the human-machine execution system when data value changes initiate an event, independently of time elapsed since occurrence of a prior event.

11. The method of claim 9, wherein the computer comprises: a. a processor; b. a microcontroller; c. local storage; d. one or more external interfaces and a component interconnect bus attached to the one or more programmable input/outputs; e. firmware and a peripheral interface enabling communication between the processor and the microcontroller; and f. an integrated circuit interface.

12. The method of claim 9, wherein the graphical user interface is enabled through a display connected to the computer.

13. The method of claim 9, wherein the graphical user interface is enabled through a touch screen connected to the computer through (a) a high-definition multimedia interface configured to send a video signal and (b) a universal serial bus interface configured to receive data related to a touch signal transmitted through the touch screen.

14. The method of claim 9, wherein a network interface is exposed through the network adapter to connect the computer to an enterprise network.

15. The method of claim 9, including an automation network or fieldbus configured to interface with one or more automation control devices.

16. An integrated human-machine execution system for manufacturing automation, comprising: a computer, a graphical user interface, one or more programmable input/outputs, one or more human-machine interface components, and a network adapter; wherein the computer is enabled to execute all necessary software to operate the functions of the integrated system and orchestrate the execution of one or more automated manufacturing operations; wherein data updates are transmitted by the system when data value changes initiate an event, independently of time elapsed since occurrence of a prior event; wherein the system is configured to be connected to at least one external and discrete programmable logic controller attached to at least one automation component, and wherein instructions to the automation component are instantiated at the human-machine execution system, obviating programming at the programmable logic controllers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this disclosure invention and is not meant to limit the inventive concepts disclosed herein.

[0020] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings, given below, explain the principles of the disclosure.

[0021] FIG. 1 is a schematic representation of the architecture of an embodiment of the HME system.

[0022] FIG. 2 is a schematic representation of the architecture of traditional programmable logic controller systems that rely on discrete components.

[0023] FIG. 3 is a schematic representation of the internal architecture of the computer of the HME system.

[0024] FIG. 4A is a diagram of a set of exemplary automation controllers.

[0025] FIG. 4B is a snippet of a graphical user interface pertaining to the controller.

[0026] FIG. 4C is another snippet of a graphical user interface pertaining to the controller.

[0027] FIG. 4D is yet another snippet of a graphical user interface pertaining to the controller.

[0028] The drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the embodiments illustrated herein.

BEST MODE FOR CARRYING OUT THE INVENTION

[0029] The present invention provides its benefits across a broad spectrum of endeavors. It is applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. Thus, to acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment of the system is disclosed for the purpose of illustrating the nature of the invention. The exemplary method of operating the system is described in detail according to the preferred embodiment, without attempting to describe all the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the art, can be modified in numerous ways within the scope and spirit of the invention, the invention being measured by the appended claims and not by the details of the specification.

[0030] Although the following text sets forth a detailed description of numerous different embodiments, the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.

[0031] It should also be understood that, unless a term is expressly defined herein, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. § 112, subparagraph (f).

[0032] With reference to FIG. 1, shown is a schematic representation of the architecture of a human-machine execution system of the present invention. In some embodiments, the human-machine execution system is an integrated system comprising at least one computer (101) which can use an Intel processor and a microcontroller such as the STM32 to expose programmable digital and analog inputs and outputs (103) to which the human-machine interface components (104) are directly connected. In some embodiments, the graphical user interface (102) is connected to the computer through a display. In some embodiments, a touch screen is connected to the computer (101) through a high-definition multimedia interface to send the video signal and a universal serial bus interface to receive data related to the touch signal. A network interface is exposed through a network adapter (105) that is part of the computer (101) and connects the computer (101) to the enterprise network (106) via a TCP connection as well as to the automation network or fieldbus (107) to interface with automation control devices (108) such as robots, drives, sensors, etc. Notably the connection to automation control devices (108) is optional. The HME system uses computer (101) to execute the software and programs necessary to orchestrate an automated manufacturing operation as well as operate the functions of the human-machine interface. In some embodiments, more than one computer 101 may be employed, which can enable virtualization or distributed computing techniques, such as edge computing or the use of a distributed cluster, such as Kubernetes.

[0033] With reference to FIG. 2, shown is a schematic representation of the architecture of a traditional manufacturing system using a programmable logic controller. The programmable logic controller (201) runs the orchestration of the manufacturing process. It can exchange data with a manufacturing execution system (204) through the Ethernet adapter (202) which is necessary to change the orders of what needs to be manufactured, and to inform the manufacturing execution system of what is built. Automation devices (205 and 206) are connected to the programmable logic controller via respectively an automation fieldbus (203) and a set of optional analog and digital inputs and outputs (207). In some implementations, the user interface (209) is connected to a human-machine interface server (208) while in some other cases it is connected to the programmable logic controller via the network adapter (203). It is also possible to connect the user interface through the automation controls fieldbus (203). Complex logic sometimes referred to as business logic, e.g. logic that enables the traceability of material flows, tasks, and process steps, and variations thereof, can be executed on the programmable logic controller (201) to fulfill the manufacturing process, particularly when data from the manufacturing execution system requests a change in the manufacturing process. Here is seen how the need for multiple, discrete components and specifically separating the programmable logic controller from the user interference results in increased and undesirable complexity.

[0034] With reference to FIG. 3, shown is a schematic of the internal architecture of the computer (101) of the HME system. It is built around an Intel x86 compatible processor (301). The current embodiment uses an 8th generation Intel i7 processor and could use any Intel or AMD processor compatible with the modern Intel x86 architecture and instruction set. Peripherals that are found in common Intel-based computers such as the local storage (308) which uses a solid-state drive in the current implementation and all external interfaces (310) such as universal serial buses, serial AT attachments (SATA), etc. are connected to the system via a peripheral component interconnect bus (309). The augmentation of the Intel-based architecture lies in the addition of a microcontroller (302) such as the STM32 developed by ST Microelectronics that exposes multiple analog and digital inputs and outputs. The behavior of these inputs and outputs as well as the logic for scanning, communicating with, and controlling these inputs and outputs are implemented in the firmware (306) of the microcontroller which can be uploaded from a software executed in the Intel processor space through the serial peripheral interface (303). The communication between the Intel program space and the microcontroller (302) is ensured by an integrated circuit interface (304).

[0035] With reference to FIGS. 4A-4D, the HME system can connect with industrial or other types of automation controllers, and abstraction of the components connected to, or running on these controllers is automatically managed by the HME system so these components can be managed, for example, as if they were connected directly on HME system. In the GUI shown in FIG. 4A, shown for exemplary purposes as an instance of the Vitesse HME software running on the HME system for a production line, 2 sensors and 1 motor driving a conveyor are physically connected to a line PLC.

[0036] With reference to FIG. 4B, the HME system manages a software instance of the controller, detecting its content and allowing for the reading and writing of properties and commands hosted on that controller, remotely. Once connected to the controller, the HME system allows for an ongoing bi-directional connection with the remote PLC that enables the control of components connected to it, through accessing the IO port data, or logical routines that manage the IO port data. Such routines are commonly referred to as Function Blocks or Add-on Instruction (AOIs).

[0037] For instance, with reference to FIG. 4C, in one current implementation for a production line, the motor of the conveyor MAIN.CONV1 is managed by a simple Function Block named “MAIN.CONV1” on the controller named “Line_PLC.” In this implementation the “MAIN.CONV1” function block sets a variable in memory that passes the value to the physical output after checking that safety requirements are met.

[0038] With the HME system, the need to use logic in the PLC is obviated and, in some embodiments, the inputs and outputs on the PLC are directly exposed to the HME system where the logic lies, except when certain requirements such as specific needs for some low latency and/or safety critical processing require some logic to run on the PLC on which these inputs and outputs are physically connected.

[0039] For instance, as shown in FIG. 4D, in one current implementation an inductive part present sensor that is connected to the 3rd input of a Beckhoff EL1809 input block on the PLC is instantiated in the HME system and directly mapped to the 3rd index of the digital instance of the EL1809 input block. As a result, no programming is required at the PLC level. This allows for the programming of a more complex process at the HME system level, obviating the need for programming at the PLC level.

[0040] In some embodiments, the software components of the HME system can be installed on a PLC directly, as long as the controller utilizes an Intel or ARM based CPU. In such a mode of operation, the software doesn't have to rely on network connectivity and latency to communicate with the HME system and can manage the inputs and outputs of the HME system with performances close to those offered by the native development tools specific to the PLC. For example, on popular Beckhoff controllers, performance measurements have revealed that for a similar process execution, the scan time of the HME system on the PLC is about 10% faster than the native execution (ex: 2.6 ms vs. 2.4 ms).

[0041] One aspect of the communication between the PLC and the HME system is that it is event driven, as opposed to the most used communication model in the field of industrial automation that uses constant time-based scanning. With a traditional PLC, inputs and outputs are scanned at a given, constant frequency (called scan time, typically in the range of 2 to 100 Hz) and data is exchanged between PLCs and other industrial components over a fieldbus at another constant frequency (typically 0.5 to 10 Hz). This results in constant data exchange even if the values don't change. For instance, if a PLC monitors the rotational velocity of a motor, it will receive a numerical representation of the velocity on a given frequency, independently of the variation of the value. On the other hand, the HME system of the present invention is event-driven such that data updates are transmitted when data value changes initiate an event, independently of the elapsed time since the last event occurred. A threshold for the change can be set to control the granularity of the data acquisition and when an event should be sent, this allows for controlling the bandwidth required to keep signals up to date, based on a desired accuracy. The monitoring of the speed of different joints of an industrial robot, or the angular speed of a motor, using both fixed scan rate and event driven data recording has revealed that an event-based monitoring system reduces the network bandwidth by up to 120 times (12000%) for an equivalent set of data.

[0042] The included descriptions and figures depict specific implementations to teach those skilled in the art how to make and use the best mode. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these implementations that fall within the scope of the invention. Those skilled in the art will also appreciate that the features described above can be combined in various ways to form multiple implementations. As a result, the invention is not limited to the specific implementations described above, but only the claims and equivalents.

[0043] The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

[0044] Moreover, though the present disclosure has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the disclosure, e.g., the use of a certain component described above alone or in conjunction with other components may comprise a system, while in other aspects the system may be the combination of all of the components described herein, and in different order than that employed for the purpose of communicating the novel aspects of the present disclosure. Other variations and modifications may be within the skill and knowledge of those in the art, after understanding the present disclosure. This method of disclosure is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.