Method and apparatus for the automated management of a coating plant

Abstract

A plant for manufacturing products, in particular for applying a coating on parts, includes apparatuses having radiofrequency transmitters, with a pre-set periodicity, of a radio signal containing a unique identifier of each apparatus; a portable device carried by an operator and receiving the radio signal; a program loaded on and performed by the portable device to extract a unique identifier of the apparatus and detect the operator-apparatus distance through an analysis of the trend of the radio signal, the radio-transmitters transmitting periodically their unique identifier and having a remote configuring/setting channel through radio-frequency communication with an external control device to exchange data packets; and a connecting procedure between the portable device and the radio-frequency transmitter to receive information on the operating status of the apparatuses, the signals being transmitted to a remote server or a cloud to monitor the operating conditions of the apparatuses.

Claims

1.-27. (canceled)

28. A plant for manufacturing, including a plant for applying a coating on parts, comprising a plurality of apparatuses, the plant further comprising: a radio-transmitter embedded in each apparatus and transmitting with a pre-set periodicity a radio signal containing at least a unique identifier configured to identify the apparatus; a portable device adapted to be carried by an operator and receiving the radio signal transmitted by the radio-transmitter; a program loaded on and performed by the portable device, the program being configured to extract a univocal unique identifier of the apparatus and detect a distance between the operator and the apparatus through an analysis of features characterizing the radio signal, the features including an intensity of the radio signal, wherein the radio-transmitter comprises an electronic module operating according to a Bluetooth® standard, performing an active function of transmission operating as an advertising function of beacon, whereby the radio-transmitter transmits periodically the unique identifier and, optionally, a part of measurement data recorded by sensors configured to measure functional conditions, the beacon including the sensors and having a remote configuring/setting channel through radio-frequency communication with an external control device, whereby the beacon and the external control device can exchange data packets; a connecting procedure between the portable device and the radio-frequency transmitting device, the connecting procedure enabling a reception of information on a working status of the apparatuses; and at least one apparatus comprising a control processing unit and a display interface with the operator, wherein the at least one apparatus includes representative data of the apparatuses and sensors configured to measure values of parameters relating to a working status of the apparatuses, the sensors being connected to the control processing unit, which collects and stores the values that were measured, wherein there is loaded in the processing unit a second program coding an instruction for carrying out a calculation algorithm of QR codes or barcodes and the processing unit executes the calculation algorithms of the QR codes and/or the barcodes starting from representative data of the apparatuses or from the information related to the working status of the apparatuses, and then visualizes a graphical result after processing on the operator's display interface, wherein each portable device comprises a camera or sensor configured to scan the QR codes and/or the barcodes, and acquire the visualized graphical result representing information on the representative data of the apparatuses or the information related to the working status of the apparatuses through a click of the camera or sensor, and wherein the information on the representative data of the apparatuses or the information relating to the working status of the apparatuses, and optionally measurement data of the sensors connected to the radio-transmitter is transmitted by the portable device to a remote server or a cloud, for monitoring working conditions of the apparatuses in the plant through a wireless network connection of the portable device with the remote server or the cloud.

29. The plant according to claim 28, wherein the portable device provided with the program determines a position of the operator associated with or wearing the portable device through data obtained from an analysis of an intensity of the radio signal received from the radio-transmitter.

30. The plant according to claim 28, wherein the portable device comprises the camera for scanning the QR codes or the barcodes placed on the apparatuses, on parts, on production orders of a material to be coated, or on consumables with which the apparatuses are supplied.

31. A method of correlating information about operation a plant according to claim 1 and comprising at least a radio-transmitter which is optionally connected to a sensor for measuring at least one control parameter of an apparatus in the plant, the at least one control parameter being a non-natively monitored control parameter by a control unit of the apparatus, a radio-transmitter and the at least one sensor applied to the apparatus in the plant, the method comprising the steps of: providing the apparatus with a communication unit of natively monitored parameters representing an operating condition, which codifies information in a QR code or in a barcode, and with a visualization device of the QR code or the barcode; collecting information from different sources, even not electrically connected to each other, to monitor the operating condition of the plant; detecting a presence of an operator with a portable device associated to the operator through an interaction between the radio-transmitter and the portable device, a control program being loaded on the portable device, the portable device being configured to perform a program that extracts an unique identifier of the apparatus and the a control parameter of the apparatus; reading and interpreting the QR code by the portable device performing the control program, the control program configuring the mobile device so that a detected QR code is acquired and interpreted; causing the portable device or a cloud server connected thereto, to use information acquired through the QR-code or the barcode and the unique identifier of the apparatus to generate command and configuration signals for each apparatus of the plant; and transmitting the command and configuration signals selectively to the apparatus through a wireless receiving unit.

32. The method according to claim 31, wherein the radio-transmitter is a beacon, wherein the unique identifier of the apparatus is coded in an advertising message transmitted continuously or iteratively by the beacon, wherein the command and configuration signals are transmitted to the apparatus through the beacon by exploiting, as a receiving channel of the command and configuring signals, a channel of configuration of the radio-transmitter, working through a radio connection and an output port of the radio-transmitter to interface a configuration channel with the radio-transmitter of the apparatus.

33. The method according to claim 32, wherein the apparatus processes calculation algorithms of the QR codes or the barcodes starting from representative data of the apparatus or from information related to an operating status measured by a native sensor of the apparatus, and then visualizes a graphical result of a processing on the operator's interface, so that each portable device comprising a camera or sensor configured to scan the QR codes or the barcodes is able to acquire information through a click of the camera or sensor.

34. The method according to claim 32, wherein the portable device is configured to adjust a set-up of the apparatuses through operator input.

35. An apparatus for carrying out a manufacturing operation, the apparatus comprising: a control unit comprising a processor configured to execute a control program loaded therein, a user-input interface, and a display; and one or more sensors configured to measure parameters representative of an operating status of the apparatus, wherein the control unit further comprises a generator of a graphic code representing parameters measured by native sensors of the apparatus, the graphic code being displayed on the display, wherein the apparatus is configured to connect to a portable device comprising a camera or a sensor for scanning the graphic code that is displayed, wherein the portable device comprises a graphic code encoder to interpret the graphic code and extract a measured parameter, wherein the portable device, a remote server, or a cloud server comprises a processor configured to analyze the measured parameter after extraction and to generate commands or configuration controls of the apparatus as a function of the measured parameter, and wherein the portable device is wirelessly connected to the remote server or the cloud by a wireless communication network.

36. The apparatus according to claim 35, further comprising a radio-transmitter transmitting continuously or cyclically a message comprising identification data of the apparatus to which the radio-transmitter is associated, the portable device being provided with a program configured to determine a position of the portable device and of an operator associated with or wearing the portable device through data obtained from an analysis of an intensity of a signal carrying a message received from the radio-transmitter.

37. The apparatus according to claim 36, wherein the radio-transmitter comprises one or more sensors configured to measure parameters representative of the operating status of the apparatus additional to parameters measured by the native sensors of the apparatus, values of measured parameters being sent to the portable device and being included in the message transmitted by the radio-transmitter, the portable device analyzing the additional parameters received from the radio-transmitter and generating commands or configuration controls of the apparatus as a function of the additional parameters, and the portable device transmitting the additional parameters received from the radio-transmitter and an apparatus identification code to a cloud server, or the commands or the configuration controls being generated at least in part by the cloud server as a function of the additional parameters and then being transmitted to the portable device for input in the control unit of the apparatus.

38. The apparatus according to claim 37, wherein the one or more sensors connected to the radio-transmitter are selected from the group consisting of sensors detecting environment conditions, vibration sensors, inclination sensors, and magnetometers.

39. The apparatus according to claim 36, wherein the radio-transmitter not in communication with the apparatus and commands or configuration controls are inputted by the operator manually with a user-input interface of the control unit of the apparatus.

40. The apparatus according to claim 36, wherein the radio-transmitter is connected by a communication link with the apparatus and commands or configuration controls are inputted by the operator through the portable unit.

41. The apparatus according to claim 40, wherein the radio-transmitter is a beacon and command or configuration signals are transmitted to the apparatus through the beacon by exploiting, as receiving channel of the command or configuring signals, a channel of configuration of the radio-transmitter operating through a radio connection and an output port of the radio-transmitter to interface a configuration channel with the radio-transmitter of the apparatus.

42. The apparatus according to claim 35, wherein the graphic code is selected from the group consisting of a QR-code, a barcode, an alphanumeric representation of names of the parameters and of corresponding measured parameter data, and wherein the portable device is provided with a decoder selected respectively from the group consisting of a QR-code decoder, a barcode decoder, and a character recognition decoder.

43. The apparatus according to claim 35, wherein the portable device is selected from the group consisting of a cell phone, a tablet, a wearable computer device, a notebook, and a handheld computer.

44. A method of collecting data about parameters representative of an operating status of an apparatus provided stand alone or as one of a plurality of apparatuses in a plant, wherein the apparatus or plurality of apparatuses comprises a dedicated control unit with a sensor connected to the control unit and configured to measure a parameter representative of the operating status or a memory of identification and configuration data of the apparatus and a display, the method comprising the following steps: coding a measured parameter and optionally identification or configuration data using a graphic code or strings of alphanumeric characters to obtain codes, and displaying the codes on the display; providing a portable unit comprising a reader configured to read the graphic code or the strings of alphanumeric characters; interpreting the graphic code or the strings of alphanumeric characters to extract data coded therein; using the extracted data to identify the apparatus and determine an operating status thereof; using the extracted data to generate generating commands or configuration controls of the identified apparatus; and inputting the commands or configuration controls to the control unit of the identified apparatus.

45. The method according to claim 44, further comprising additional steps for collecting additional parameters representative of the operating status for a measurement, of which the apparatus is not natively configured for, the additional steps comprising: associating to the apparatus a radio-transmitter and an additional sensor connected to the radio-transmitter that measures at least one additional parameter representative of the operating status of the apparatus; monitoring the at least one additional parameter by the additional sensor; providing the portable device with a communication unit for at least receiving data from the radio-transmitter; transmitting the data of the at least one additional parameter by the additional sensor to the portable device; and using the measured data of the at least one additional parameter either alone or in combination with the data extracted from the graphic code or from the alphanumeric strings for generating the commands or configuration controls of the identified apparatus.

Description

[0040] Further advantages and properties of the present invention are disclosed in the following description, in which exemplary embodiments of the present invention are explained in detail based on the drawings:

[0041] FIG. 1 Schematic representation of the state of the art;

[0042] FIG. 2 Represents the scheme of FIG. 1 modified according to the present invention;

[0043] FIG. 3 Scheme representing the system principle according to the present invention, wherein the difference with respect to a traditional client-server system is highlighted; in the traditional architecture the operating machines of the line work with their PLC like the clients of a network;

[0044] FIG. 4 Schematic representation of a plant for applying a coating;

[0045] FIG. 5 Schematic representation of the gathering of data by operators through beacon sensors;

[0046] FIG. 6 Schematic representation of data exchange between the app loaded on the portable device of an operator and Bluetooth® sensors;

[0047] FIG. 7 Schematic representation of data gathering by operators through scanning of barcodes/QR codes of apparatuses, or barcodes/QR codes present on other object used in the plant;

[0048] FIG. 8 Schematic representation of data gathering by operators through scanning of barcodes on apparatuses/objects.

[0049] FIG. 1 shows an outline of the present state of the art, wherein each room (A, B, C) has an architecture of data gathering totally separated from the other rooms. Connecting the apparatuses to obtain information requires heavy investments in hardware and software.

[0050] FIG. 2 shows the same scheme modified according to the principles of the present invention. In this scheme, the operating units of the different lines L1, L2, L3, L4 are not provided each with a computerized control system connected in a network, which overall is under the control of a program performed by a server. The computerized control system of the operating units communicates with one or more mobile control units P1, P2, P3, P4. At least one of these units is associated to its corresponding line. Said units can be a unique identical unit, or a plurality of mobile units. Each unit receives from the operating groups of the different lines L1, L2, L3, L4 information about the operating conditions, the set configuration parameters or diagnostic conditions through a transmission unit in the form of a so-called beacon. The control program of the operating units is performed by a dedicated processor for each operating unit, which is not intended to communicate through a network directly to a control server, but transmits data to said mobile devices P1, P2, P3, P4, to all of them or only some of the, and receives setting data of the operating parameters.

[0051] Many variations are possible, and many management modes of the communication and of the qualification of said mobile devices P1, P2, P3, P4 to perform given command and/or control activities, thanks to the reading of the data provided by the different beacons B1,1, B2,1, B3,1, B4,1, . . . , B1,n, B2,n, B3,n, B4,n, and to the sending of setting data. As will appear in the following, advantageously the channels of beacon configuration can be used to transmit to the control processors of the different operating system, without the need of adding weight from the hardware and software point of view.

[0052] From the above, it is apparent that the single operating unit can have control unit that are less onerous in their hardware. Moreover, the possible continual upgrading or servicing of the control program performing the dialogue of the operating unit in the single lines and within the lines according to the workflow pre-set for the production activity under course is greatly simplified.

[0053] The sundry mobile devices P1, P2, P3, P4 are wirelessly connected to at least one server cooperating with them, both for the access to operating functions residing at least partially in the server itself, and for a centralized control of the different management activities delegated to mobile devices.

[0054] FIG. 3 is a generalization of the example of FIG. 2, and shows that an interaction of a plurality of lines with the same mobile unit can work. From this scheme it is clear that the system according to the present invention breaks the traditional client/server architecture. Here intelligence is distributed according to a different scheme, wherein local networks among operating units of a line do not control the line anymore, making reference to a server through a wired network, but the operating unit control functions only, transferring the setting of the synchronized parameters activities in a workflow to local mobile units, which in their turn cooperate with a server.

[0055] FIG. 4 shows a typical line 1 for applying a coating to a part according to the present invention. Said line 1 comprises a plurality of apparatuses, generally arranged in series; e.g. in FIG. 4, an apparatus 11 for pre-treating parts, an apparatus 12 for spraying a coating through a robot, an oven 13 for drying the applied coating.

[0056] In said coating line 1, there is provided a plurality of beacon sensors: e.g. a first beacon 111 is placed on apparatus 11, a second beacon 112 is placed on a pump of a liquid to apply, a third beacon 113 is connected to the piping for channelling said liquid to sprayer 12. Each beacon 111, 112, 113, . . . is characterized by its unique identifier, and transmits information visible by all the personal devices 31, 32, 33 . . . of operators 21, 22, . . . which enter into the area of transmission of a given beacon. Beacon sensors 111, 112, 113 . . . allow to correctly localize the personal portable devices (smartphone, tablet, or other kinds of devices) of operators 21, 22 on which an app with location-based functions is loaded.

[0057] On each portable personal device 31, 32 an app 41, 42 is loaded.

[0058] In the present invention, the personal devices 31, 32, . . . of operators 21, 22, . . . , on which devices an app 41, 42, . . . is loaded, work as concentrators.

[0059] Said app 41, 42 can exchange data through a private Wi-Fi network or through a wireless public 2g, 3g, 4g, etc. network, connecting to a remote databank (cloud), having the suitable reading and writing right of access.

[0060] In this context, cloud indicates a type of Internet-based computing that provides shared computer processing resources and data to computers and other devices on demand. It is a model for enabling ubiquitous, on-demand access to a shared pool of configurable computing resources (e.g., computer networks, servers, storage, applications and services), which can be rapidly provisioned and released with minimal management effort.

[0061] In detail, said app 41, 42 can transmit to remote cloud database 200 the information gathered from personal devices 31, 32, . . . coming from beacon sensors 111, 112, 113, . . . or from apparatuses through scanning of the barcodes/QR codes 51, 52, 53 present on them, or directly acquired from the camera of the personal devices 31, 32 or from scanning barcode 121 (FIG. 8) through the same camera. The successful delivery of signals coming from beacons 111, 112, 113 proves that the transferred data relate to the plant 1 and not to another plant.

[0062] If portable personal devices 31, 32 have an active geolocation system, said app 41, 42 can transfer to the remote cloud database 200 the geographical position of the plant, too, and the information relating to its productive status.

[0063] FIG. 5 shows an operator 21 connecting to remote cloud 200; said operator can visualize the geographical position of all the plants that adopted this technology and their productive status.

[0064] In parallel, an operator 21, provided with a personal device 31 on which an app 41 is loaded, can perform a query in the remote server 200 in order to receive information, as will be better explained in the following.

[0065] A beacon sensor 111 placed on apparatus 12 can make public to all the operators provided with said app the working status of the apparatus itself (pausing machine, working machine, machine undergoing an emergency, etc.).

[0066] As shown in FIG. 5, the operator 31, localized according to context by beacon sensor 111 as placed in front of apparatus 12, can easily download context-aware contents, i.e. the contents related to apparatus 12: e.g. user's manual, spare parts manual, service instructions for, etc.

[0067] In the same way, the operators 21, 22 in proximity to one of the apparatuses 11, 12, 13 can consult with great ease the documentation relating to the apparatuses to which they are near.

[0068] In the line 1 there are provided beacon sensors 111, 112, 113, . . . in particular relevant points, transmitting information according to an advertising modality.

[0069] It is worth mentioning that the normal working of a beacon consists in transmitting with a pre-determined periodicity data relating to its unique identifier (this modality is called advertising). Furthermore, the beacon can transmit also information relating to the data recorded by sensors.

[0070] In fact, beacons 111, 112, 113, . . . can be provided with a wide range of sensors, like temperature, vibration, inclination sensors, magnetometers, etc.; it is known that measuring vibrations can help to diagnostic failures in apparatuses, even in an early phase.

[0071] As shown in FIG. 6, approaching to Bluetooth® sensors, the app 41, 42 loaded on personal devices 31, 32, in addition to gathering the information transmitted according to advertising mode, can open a data connection with the beacon sensor, for a wider data exchange, as above explained.

[0072] As shown in FIG. 7, each apparatus 11, 12, 13 provided with a graphical interface shows on its first page a bar code/QR code 51, 52, 53, . . . which periodically updates the visualization of statistics and data relating to production status.

[0073] A QR code (abbreviation of Quick Response Code) is a two-dimensional bar code (or 2D code), or a matrix code, consisting of black squares arranged in a square grid on a white background. It is used to memorize information generally intended to be read by an imaging device such as a camera present in a cell phone or a smartphone. In a single cryptogram there are provided up to 7.089 numeric characters or 4.296 alphanumeric characters. Generally, the matrix format is of 29×29 little squares.

[0074] E.g. the scanning of a bar code/QR code 51, 52, 53, . . . placed e.g. on apparatus 12 or on the parts which underwent coating inside plant 1 allows to gather information on the statistics of number of parts and square meters produced by the apparatus in a unit of time.

[0075] It is worthwhile mentioning that on the operator interface display of the single apparatus 11, 12, 13 a dynamic QR code is visualized, automatically updating over time, containing the data relating to the statistics of the apparatus. The operator 21, 22 can read said QR code with the camera present in her/his personal device 31, 32. This configuration allows to prevent the need of hardware wiring in plant 1, and from plant 1 towards portable device 31, 32.

[0076] The data visualized in QR Code 51, 52, 53 can be available in an encrypted form, so that they can be interpreted and saved only by someone having explicit rights to perform this operation. The decryption operation can take place directly in the app 41, 42, or even only inside remote cloud 200, accessing through a password or a reserved token.

[0077] Said app 41, 42 loaded on the personal device 31, 32 of operator 21, 22 also has the function of camera for scanning barcodes and/or QR code 51, 52, 53.

[0078] As shown in FIG. 8, the operator can scan barcodes 121, e.g. of coating liquid cans or diluent cans which arrive into the plant.

[0079] Moreover, the operator can scan barcodes/QR codes of the production orders of the parts that undergo the coating treatment.

[0080] When the operator 21 does an inspection in the line with her/his personal device 31, immediately the app 41 loaded on her/his personal device 31 receives all the information from beacon sensor 111, 112, 113, . . . which were enabled by her/his app 41 and can perform a data exchange with remote server 200.

[0081] Every time the operator scans a bar code and/or a QR code, said app updates the databank on cloud 200.

[0082] In this way, a remote user, e.g. the administrative department, can know the progress of the working, simply consulting remote cloud 200.

[0083] In relation to the disclosed QR-code or barcode, according to the present invention other kinds of codes can be used. One special code consists in the alphanumeric strings coding the information and the data values in a human intelligible language, so that the operator may directly read the data on the display of an apparatus. The decoder executed by the portable device can in this case be a character recognition software, a so-called OCR which transforms the alphanumerical characters in digital signals which can be interpreted and processed by the software executed by the printable devices and/or by the remote server.

[0084] Considering the example of the figures it appears that one embodiment of the present invention may be limited to an apparatus having a display on which a graphic or alphanumeric code is displayed. This code is generated by the processor of the control unit of the apparatus which executes a coding algorithm. Although in the case that the apparatus 13 and 11 cannot be connected to a common network each other and/or to a server, reading the graphic codes representing the measured parameters describing the working status of the apparatus by means of the portable device allow easily to integrate the apparatus 11 and 13 in a central monitoring and management process executed by the portable device and/o by a remote server. The network to be configured is in this case only the one connecting the portable devices with the server and in the present examples with a cloud.

[0085] As it appears by saving the monitored data in the cloud advantages are also provided consisting in a remote monitoring by way of the producer or maintenance services of the apparatus in the plant. Furthermore the same ones can also be able to monitor the development level of the apparatus and suggest new upgrades when these are available. Furthermore the monitoring data in the cloud allow the organisations producing and or carrying out maintenance of the apparatus to analyse the use which the clients makes of the apparatus in the plant and to help in modifying or integrating the plant with devices or add-ons in order to optimize the functionality and efficiency of the plant in relation to the mode of use followed by the client. [0086] 1 Coating plant [0087] 11 First apparatus [0088] 12 Second apparatus [0089] 13 Third apparatus [0090] 21 First operator [0091] 22 Second operator [0092] 31 Portable device of first operator [0093] 32 Portable device of second operator [0094] 41 App on the portable device of first operator [0095] 42 App on the portable device of second operator [0096] 51 QR code on first apparatus [0097] 52 QR code on second apparatus [0098] 53 QR code on third apparatus [0099] 111 First beacon sensor [0100] 112 Second beacon sensor [0101] 113 Third beacon sensor [0102] 121 Barcode [0103] 200 Cloud [0104] P1, . . . , Pk−1, Pk Mobile units [0105] B1,1 B1,m−1, B1,m Beacons [0106] L1, . . . Lm Production lines