EP4066074A1 - Automated troubleshooting assistance system and method in a plant for processing containers for pourable products - Google Patents

Automated troubleshooting assistance system and method in a plant for processing containers for pourable products

Info

Publication number
EP4066074A1
EP4066074A1 EP19839095.7A EP19839095A EP4066074A1 EP 4066074 A1 EP4066074 A1 EP 4066074A1 EP 19839095 A EP19839095 A EP 19839095A EP 4066074 A1 EP4066074 A1 EP 4066074A1
Authority
EP
European Patent Office
Prior art keywords
machine
data
processing
troubleshooting assistance
troubleshooting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP19839095.7A
Other languages
German (de)
French (fr)
Inventor
Paolo Cavazzini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sidel Participations SAS
Original Assignee
Sidel Participations SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sidel Participations SAS filed Critical Sidel Participations SAS
Publication of EP4066074A1 publication Critical patent/EP4066074A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
    • G05B23/0216—Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
    • G05B23/0267—Fault communication, e.g. human machine interface [HMI]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B67—OPENING, CLOSING OR CLEANING BOTTLES, JARS OR SIMILAR CONTAINERS; LIQUID HANDLING
    • B67C—CLEANING, FILLING WITH LIQUIDS OR SEMILIQUIDS, OR EMPTYING, OF BOTTLES, JARS, CANS, CASKS, BARRELS, OR SIMILAR CONTAINERS, NOT OTHERWISE PROVIDED FOR; FUNNELS
    • B67C3/00—Bottling liquids or semiliquids; Filling jars or cans with liquids or semiliquids using bottling or like apparatus; Filling casks or barrels with liquids or semiliquids
    • B67C3/007—Applications of control, warning or safety devices in filling machinery
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/24—Pc safety
    • G05B2219/24086—Expert system, guidance operator, locate fault and indicate how to repair
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/32—Operator till task planning
    • G05B2219/32408—Case based diagnosis to assist decision maker, operator
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/33—Director till display
    • G05B2219/33209—Protocol, mailbox, email, mail system
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/33—Director till display
    • G05B2219/33284—Remote diagnostic

Definitions

  • the present invention relates to an automated troubleshooting assistance system, and to a corresponding method, in a plant for processing containers for pourable products.
  • the present solution may be implemented in plants for processing any type of containers, such as bottles (or other kinds of receptacles) made of glass, plastic (PET), aluminium, steel and composite materials, that are to be filled with a pourable product, in particular a food product, including sparkling liquids, such as sparkling water, non-alcoholic beverages and beer; non-effervescent liquids, such as natural water, milk, juices, tea, integrators for sport activities or wine.
  • containers such as bottles (or other kinds of receptacles) made of glass, plastic (PET), aluminium, steel and composite materials, that are to be filled with a pourable product, in particular a food product, including sparkling liquids, such as sparkling water, non-alcoholic beverages and beer; non-effervescent liquids, such as natural water, milk, juices, tea, integrators for sport activities or wine.
  • a plant for processing containers comprises a number of processing machines arranged so as to form a container processing line, amongst which: a forming machine, for example a blower, configured to form, for example by blowing, containers to be filled starting from so-called preforms; a filling machine, configured to fill the containers with a pourable product, for example a sparkling beverage; a capping machine, configured to cap the filled containers; a labelling machine, configured to label the filled containers; and a packaging machine, configured to perform suitable packaging of the containers, at the end of the container processing line for their subsequent transport.
  • a forming machine for example a blower
  • a filling machine configured to fill the containers with a pourable product, for example a sparkling beverage
  • a capping machine configured to cap the filled containers
  • a labelling machine configured to label the filled containers
  • a packaging machine configured to perform suitable packaging of the containers, at the end of the container processing line for their subsequent transport.
  • the container processing plant may also include further processing machines, such as product preparation machines, a sterilising machine, a pasteurizer, a palletizer, a bottle washer, a crate washer, etc.
  • the plant may also include package transportation equipment such as LGV's, product preparation machinery and equipment, and even storage equipment such as automated warehouses.
  • each processing machine comprises: an input path configured to receive a succession of containers to be processed; a container processing path, typically comprising a rotary conveyor (the so-called carousel), which carries a number of container processing units, each configured for carrying out processing operations on a respective container; and an output path, designed to transfer the processed containers towards a subsequent processing machine in the line of the container processing plant.
  • the containers are transferred between the various processing machines by means of transfer wheels or conveyor belts.
  • Technicians or other operators at the site of the container processing plant therefore send service requests to the centralized service team requiring assistance for the troubleshooting operations.
  • the present Applicant has realized that there are a number of issues affecting known solutions for remote troubleshooting assistance.
  • these solutions are dependent on the ability by the technicians (who may have a highly variable skill and experience) at the site of the container processing plant to understand the problems and faults and to correctly report the same problems and faults, by conveying all relevant technical information.
  • Verbal dialogue and/or e-mail exchanges between technicians and centralized service team may be affected by misunderstandings, misinterpretations, also due to possible differences in languages and expressions used.
  • the aim of the present invention is to provide a solution that will enable the problems highlighted previously to be solved.
  • FIG. 1 is a general block diagram of a system for automated troubleshooting assistance according to an embodiment of the present solution
  • - Figure 2 is a schematic depiction of a HMI (Human Machine Interface) unit implemented in the system of Figure i;
  • HMI Human Machine Interface
  • Figures 3A and 3B are schematic depictions of interactions between the HMI unit and a user mobile electronic device in the system of Figure 1;
  • FIG. 4 shows a schematic flowchart of operations performed in the system of Figure 1.
  • a container processing plant 1 in particular for pourable products, comprises a number of processing machines 2, cooperating in the processing of containers (for example including a filling machine, a capping machine, a labelling machine, a packaging machine and/or other processing machines for processing of containers for pourable products).
  • processing machines 2 cooperating in the processing of containers (for example including a filling machine, a capping machine, a labelling machine, a packaging machine and/or other processing machines for processing of containers for pourable products).
  • each processing machine 2 is provided with a respective data collector, which may be implemented in a control unit 4, for example a PLC (Programmable Logic Controller) unit, configured to manage and control operation of the same processing machine 2 (also based on information received from a supervising unit of the container processing plant 1, here not shown).
  • a control unit 4 for example a PLC (Programmable Logic Controller) unit, configured to manage and control operation of the same processing machine 2 (also based on information received from a supervising unit of the container processing plant 1, here not shown).
  • an automated troubleshooting assistance system 10 comprises a HMI (Human Machine Interface) unit 12, preferably located at the site of the container-processing plant 1 and operable by an operator 14 of the same container-processing plant 1 to initiate an automated troubleshooting assistance procedure (as will be detailed in the following).
  • HMI Human Machine Interface
  • a central monitoring station 15 of the automated troubleshooting assistance system 10 is located remotely (at a remote site or at a plurality of interconnected sites) with respect to the container processing plant 1 and is configured to cooperate with the HMI unit 12 in the automated troubleshooting assistance procedure.
  • the central monitoring station 15 is operable by a service team of experts and may be coupled to a number of container processing plants 1 placed in a number of different locations worldwide (in a manner not shown in Figure 1).
  • a troubleshooting database 16 is operatively coupled to the central monitoring station 15.
  • a dashboard unit 18 at the same central monitoring station 15, receiving data from the troubleshooting database 16, provides a general depiction of all open issues at all monitored container processing plants (allowing e.g. to perform statistical and any other suitable data analysis).
  • the dashboard unit 18 at the same central monitoring station 15, receiving data from the troubleshooting database 16, provides a general depiction of all open issues at all monitored container processing plants (allowing e.g. to perform statistical and any other suitable data analysis).
  • the dashboard unit 18 at the same central monitoring station 15, receiving data from the troubleshooting database 16, provides a general depiction of all open issues at all monitored container processing plants (allowing e.g. to perform statistical and any other suitable data analysis).
  • the dashboard unit 18 at the same central monitoring station 15, receiving data from the troubleshooting database 16, provides a general depiction of all open issues at all monitored container processing plants (allowing e.g. to perform statistical and any other suitable data analysis).
  • the dashboard unit 18 at the same central monitoring station 15, receiving data from the troubleshooting database 16, provides a general
  • 18 may provide an overview including: processing machines 2 with issues or not running (the issues being mapped worldwide); resolved issues; open tickets (associated with service requests) per customer; personnel occupation (number of service tickets per expert or team of experts).
  • the HMI unit 12 may be implemented by any suitable computing unit and comprises a display or monitor, to provide visual information to the operator 14, and input means (such as a keyboard and a mouse); in a possible embodiment the HMI unit 12 is implemented as a touch-screen unit.
  • the HMI unit 12 of the troubleshooting assistance system 10 is communicatively coupled (via any suitable wired or wireless communication protocol) to the data collectors, in particular to the control units 4, of the processing machines 2 of the container-processing plant 1, and is configured to collect from the same control units 4 data relating to the respective processing machines 2.
  • the HMI unit 12 is configured to collect static and dynamic data.
  • Static data are related to fixed characteristics of the processing machines 2 (such as name of the machine, name of the customer, identification code, position in the container processing plant 1, contact person on site and so on); dynamic data are instead related to the dynamic operation of the processing machines 2 during processing of the containers, in particular relating to faults and malfunctions, and may include a functional history of issues and machine-generated alarms for the same processing machines 2 (detailing the type of issues or alarm and also the duration thereof).
  • the HMI unit 2 in the event of a malfunction (or any kind of issue) and in response to a user command, is configured to combine the static and dynamic data related to the relevant processing machine 2 (the dynamic data including possible further dynamic data related to activities performed on-site to recover and restore the correct operation of the processing machines 2 and the container processing plant 1) and arrange the data into a structured data set, formatted according to standard, uniform and pre-set criteria, intended for a data communication towards the central monitoring station 15 in association with a troubleshooting assistance request.
  • the central monitoring station 15 is configured to: receive the structured data set associated with the troubleshooting assistance request; retrieve in an automated manner from the structured data set the static and dynamic data related to the processing machine 2 (or processing machines 2) involved in the malfunction; store the retrieved data into the troubleshooting database 16; and process the retrieved data in order to provide troubleshooting assistance data in response to the troubleshooting assistance request.
  • the HMI unit 12 is configured to generate a machine-readable code 20, in a preferred embodiment a QR (Quick Response) code, based on the structured data set of the relevant processing machine 2; the machine-readable code 20 is presented to the operator 14, e.g. being displayed on the display of the same HMI unit 12.
  • the HMI unit 12 may generate the machine-readable code 20, such as the QR code, using a proprietary software solution.
  • the operator 14 is able to scan the machine-readable code 20 by means of a mobile electronic device 22 (e.g. a personal smartphone, tablet, phablet or the like), to enable automatic generation of the troubleshooting assistance request, based on the structured data set, for the associated data communication towards the central monitoring station 15.
  • a mobile electronic device 22 e.g. a personal smartphone, tablet, phablet or the like
  • data communication may be implemented via an e-mail message, a SMS (Short Message Service) or any other kind of instant messaging communication (even via a proprietary software mobile application installed in the mobile electronic device 22), and the content of the data communication is automatically generated by reading of the machine-readable code 20; the same content corresponds to the structured data set and is therefore formatted according to standard, uniform and pre-set criteria, thus being suitable for automatic reading and interpretation at the central monitoring station 15.
  • SMS Short Message Service
  • any other kind of instant messaging communication even via a proprietary software mobile application installed in the mobile electronic device 22
  • Data communication towards the central monitoring station 15 may be implemented e.g. via the cellular mobile network or landline internet.
  • one and the same data communication infrastructure may be used both for sending of the troubleshooting assistance request and for the central monitoring station 15 to return back the response with the troubleshooting assistance data towards the operator 14 (e.g., again, via an e-mail message, a SMS or any other kind of instant messaging communication that has been previously used for transmission of the troubleshooting assistance request).
  • FIG. 2 shows diagrammatically the display, here denoted with 28, of the HMI unit 12 showing a user interface 30, that is presented to the operator 14 (in a dedicated "support or service page") for generation of troubleshooting assistance requests in response to a command by the same operator 14.
  • the user interface 30 comprises a first portion 30a listing all the processing machines 2 of the container-processing plant 1 and allowing the operator 14 to select any one of the same processing machines 2 for display of the relevant data (i.e. the static and dynamic data).
  • the user interface 30 may further comprise: a second portion 30b showing the static data for the selected processing machine 2 (e.g. including the name of the machine, name of the customer, identification code, contact person on site); a third portion 30c showing the dynamic data for the same selected processing machine 2 received from the respective control unit 4 (e.g. including the current or actual operating status, running time and functional history of issues and machine-generated alarms and event codes); and a fourth portion 30d, which may be edited by the operator via the input means, to detail the activities performed on-site to recover and restore the correct operation of the processing machine 2 and the container processing plant 1 (these representing the further dynamic data to be included in the above-discussed structured data set).
  • a second portion 30b showing the static data for the selected processing machine 2 (e.g. including the name of the machine, name of the customer, identification code, contact person on site); a third portion 30c showing the dynamic data for the same selected processing machine 2 received from the respective control unit 4 (e.g. including the current or actual operating status, running time and functional
  • the user interface 30 further comprises a main portion 32, configured to display the machine-readable code 20, in particular the QR code, that is generated for the selected processing machine 2, as a function of the structure data set defined by the combination of the static and dynamic data.
  • the static data are received from the control unit 4 of the processing machine (or may be pre-stored in the HMI unit 12); and the dynamic data include data received from the control unit 4 of the processing machine 2 and, moreover, data that may be inserted by the operator 14 via the user interface 30 (in particular, the fourth portion 30d thereof).
  • selection by the operator 14 of a different processing machine 2 causes generation and visualization of a different machine-readable code 20 in the main portion 32 of the user interface 30, associated with that processing machine 2 (and its current operating status).
  • the generated machine-readable code 20 for a same processing machine 2 is time-dependent, since the dynamic data change over time and based on the operation of the same processing machine 2.
  • the user interface 30 further comprises a direct- communication element 34, which may be selected by the operator 14 to generate a direct communication towards the central monitoring station 15 (i.e. without the use of the mobile electronic device 22 of the operator 14), e.g. an e mail communication via the internet network, whose content corresponds to the structured data set and is formatted according to the standard, uniform and pre-set criteria, thus being suitable for automatic reading at the central monitoring station 15.
  • a direct- communication element 34 which may be selected by the operator 14 to generate a direct communication towards the central monitoring station 15 (i.e. without the use of the mobile electronic device 22 of the operator 14), e.g. an e mail communication via the internet network, whose content corresponds to the structured data set and is formatted according to the standard, uniform and pre-set criteria, thus being suitable for automatic reading at the central monitoring station 15.
  • the operator 14 uses the mobile electronic device 22 to scan the machine-readable code 20 displayed on the display 28 of the user interface 30 of the HMI unit 12, to automatically generate the troubleshooting assistance request and send the associated data communication towards the central monitoring station 15.
  • the data communication may be implemented via an e-mail message, whose content is automatically generated by reading of the machine-readable code 20, and which may be sent to a suitable e-mail address associated with the central monitoring station 15.
  • a problem occurs in the container-processing plant 1, e.g. a malfunction or a fault of one or more of the processing machines 2.
  • the operator In response to the problem, at step 41, the operator
  • the 14 accesses the HMI unit 12, and in particular the "support or service page" (as shown in Figure 2) dedicated to the troubleshooting assistance procedure, and selects the processing machine 2 associated with the malfunction (if more than one processing machines 2 are involved, these machines may be consecutively selected by the operator 14, in a manner not shown here, for clarity of depiction).
  • the HMI unit 12 collects the data related to the selected processing machine 2, and in particular the static data (the static data may be received from the control unit 4 of the processing machine 2 or may be already available to the same HMI unit 12, e.g. being stored therein) and the dynamic data (which may be received both from the control unit 4 of the processing machine 2 and from the same HMI unit 12, as discussed previously) for generation of the structured data set.
  • the same static and dynamic data may be shown to the operator 14 in the corresponding portions of the user interface 30.
  • the HMI unit 12 generates the machine-readable code 20, e.g. the QR code, based on (and including) the structured data set, and displays the same machine-readable code 20 in the main portion 32 of the user interface 30.
  • the machine-readable code 20 e.g. the QR code
  • an e-mail or other data communication may be sent directly to the central monitoring station 15, with a content corresponding to the structured data set and formatted according to the standard pre-set criteria.
  • the operator 14 is then able to scan the displayed machine-readable code 20 with the mobile electronic device 22, to automatically generate the SMS, e- mail or other suitable data communication to be sent to the central monitoring station 15.
  • the same e-mail (or other suitable data communication) and the associated troubleshooting assistance request is then sent to the central monitoring station 15 via the same mobile electronic device 22 (using the cellular mobile network or the landline internet network).
  • the troubleshooting assistance request is received at the central monitoring station 15, and the associated structured data set is automatically retrieved.
  • the same data, in particular the dynamic data, are then stored in the troubleshooting database 16, with the static data, in connection with the processing machine(s) 2 associated with the issue.
  • the same data are also used to update the dashboard unit 18 at the same central monitoring station 15.
  • retrieved data are then processed in order to identify a solution to the malfunction of the processing machine 2 (automatic machine troubleshooting procedure). It is noted that, advantageously, retrieved data associated with a number of processing machines 2 of the same container processing plant 1 may be jointly processed in order to identify the solution to the issue.
  • troubleshooting assistance data may be automatically sent in response to the troubleshooting assistance request, e.g. including a detailed guide of operations to be performed at the processing machine 2 fore resolution of the issue.
  • the same data communication infrastructure 24, used for sending of the troubleshooting assistance request may be used by the central monitoring station 15 to send back the response with the troubleshooting assistance data towards the operator 14.
  • the service team is able to contact the operator 14, again using the same data communication infrastructure 24 that was used for sending of the troubleshooting assistance request.
  • the disclosed troubleshooting assistance system allows not only to collect (static and dynamic) data directly from the processing machines, but it also generates troubleshooting assistance request messages to the central monitoring station service team with factual and technically relevant information, automatically and with minimum effort (or competence required) by the operators of the container processing plant; possibility of errors in the fault reporting procedure is substantially eliminated.
  • the troubleshooting assistance system also allows a real-time or near real-time exchange of information between the service team and the operator at the site of the container-processing plant.
  • the troubleshooting assistance system allows to generate messages (with the associated data structure sets) not only for the processing machine where the fault or malfunction has occurred, but also, in a simple and quick manner, for other processing machines in the same container-processing plant; this increases the possibility for the service team to actually solve the issue, since it is a known possibility for a malfunction in a given processing machine to be caused (at least in part) by concurrent issues occurring in other, cooperating, processing machines of the same plant.
  • the troubleshooting assistance system may be retro-fitted with existing processing machines and container-processing plants.
  • the troubleshooting assistance system disclosed can advantageously be applied irrespective of the type of processing plant or the type of containers being processed.
  • any kind of data communication may be implemented for sending the troubleshooting assistance requests from the HMI interface to the central monitoring station; for example an encrypted data communication may be implemented.
  • the HMI interface may have any other function in addition to management of the troubleshooting assistance requests by the operator, for example also managing and controlling general operation of the associated processing machine (or machines).

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  • Engineering & Computer Science (AREA)
  • Human Computer Interaction (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Testing And Monitoring For Control Systems (AREA)

Abstract

A troubleshooting assistance system (10), for a container processing plant (1) with a number of processing machines (2) cooperating in processing of containers for pourable products, each processing machine (2) having a control unit (4), the system having: a HMI – Human Machine Interface - unit (12) coupled to the control units (4) of the processing machines (2) and operable by an operator (14) to initiate a troubleshooting assistance request; and a central monitoring station (15) located remotely with respect to the container processing plant (1), to receive the troubleshooting assistance request and provide troubleshooting assistance data in response to the troubleshooting assistance request. The HMI unit (12), in the event of an issue and in response to a command from the operator (14), retrieves data relating to at least a selected processing machine (2) and relevant to the issue, and arranges the data into a structured data set, formatted according to pre-set criteria, for a data communication towards the central monitoring station (15) in association with the troubleshooting assistance request. In particular, the HMI unit generates a machine-readable code (20) based on the structured data set of the selected processing machine and displays the generated machine-readable code to the operator.

Description

AUTOMATED TROUBLESHOOTING ASSISTANCE SYSTEM AND METHOD IN A
PLANT FOR PROCESSING CONTAINERS FOR POURABLE PRODUCTS
TECHNICAL FIELD
The present invention relates to an automated troubleshooting assistance system, and to a corresponding method, in a plant for processing containers for pourable products.
BACKGROUND ART
In general, the present solution may be implemented in plants for processing any type of containers, such as bottles (or other kinds of receptacles) made of glass, plastic (PET), aluminium, steel and composite materials, that are to be filled with a pourable product, in particular a food product, including sparkling liquids, such as sparkling water, non-alcoholic beverages and beer; non-effervescent liquids, such as natural water, milk, juices, tea, integrators for sport activities or wine.
As is known, a plant for processing containers comprises a number of processing machines arranged so as to form a container processing line, amongst which: a forming machine, for example a blower, configured to form, for example by blowing, containers to be filled starting from so-called preforms; a filling machine, configured to fill the containers with a pourable product, for example a sparkling beverage; a capping machine, configured to cap the filled containers; a labelling machine, configured to label the filled containers; and a packaging machine, configured to perform suitable packaging of the containers, at the end of the container processing line for their subsequent transport.
The container processing plant may also include further processing machines, such as product preparation machines, a sterilising machine, a pasteurizer, a palletizer, a bottle washer, a crate washer, etc. The plant may also include package transportation equipment such as LGV's, product preparation machinery and equipment, and even storage equipment such as automated warehouses.
In general, each processing machine comprises: an input path configured to receive a succession of containers to be processed; a container processing path, typically comprising a rotary conveyor (the so-called carousel), which carries a number of container processing units, each configured for carrying out processing operations on a respective container; and an output path, designed to transfer the processed containers towards a subsequent processing machine in the line of the container processing plant. Generally, the containers are transferred between the various processing machines by means of transfer wheels or conveyor belts.
In a known manner, faults, malfunctions or desired performance not reached in any of the processing machines of the container processing plant may impair the container processing operations; when any of such issues occurs, it is important to take suitable and timely actions (so called troubleshooting operations) in order to restore the correct operation of the container processing plant.
In order to assist troubleshooting operations at the site of the container processing plant, it is common practice for the manufacturer of the processing machines to provide a centralized assistance service (which in practice may be located at one site or at a number of interconnected sites), with a service team of highly skilled personnel providing remote assistance in order to assist identification of the faults and restoring of correct operation of the processing machines.
Technicians or other operators at the site of the container processing plant therefore send service requests to the centralized service team requiring assistance for the troubleshooting operations.
The present Applicant has realized that there are a number of issues affecting known solutions for remote troubleshooting assistance. In particular, these solutions are dependent on the ability by the technicians (who may have a highly variable skill and experience) at the site of the container processing plant to understand the problems and faults and to correctly report the same problems and faults, by conveying all relevant technical information.
Verbal dialogue and/or e-mail exchanges between technicians and centralized service team may be affected by misunderstandings, misinterpretations, also due to possible differences in languages and expressions used.
DISCLOSURE OF INVENTION
The aim of the present invention is to provide a solution that will enable the problems highlighted previously to be solved.
According to the present invention a system and a method for automated troubleshooting assistance are provided, as defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, preferred embodiments thereof are now described, purely by way of non-limiting example, with reference to the attached drawings, wherein:
- Figure 1 is a general block diagram of a system for automated troubleshooting assistance according to an embodiment of the present solution; - Figure 2 is a schematic depiction of a HMI (Human Machine Interface) unit implemented in the system of Figure i;
Figures 3A and 3B are schematic depictions of interactions between the HMI unit and a user mobile electronic device in the system of Figure 1; and
- Figure 4 shows a schematic flowchart of operations performed in the system of Figure 1.
BEST MODE FOR CARRYING OUT THE INVENTION
As schematically shown in Figure 1, a container processing plant 1, in particular for pourable products, comprises a number of processing machines 2, cooperating in the processing of containers (for example including a filling machine, a capping machine, a labelling machine, a packaging machine and/or other processing machines for processing of containers for pourable products).
In a known manner, each processing machine 2 is provided with a respective data collector, which may be implemented in a control unit 4, for example a PLC (Programmable Logic Controller) unit, configured to manage and control operation of the same processing machine 2 (also based on information received from a supervising unit of the container processing plant 1, here not shown).
According to an aspect of the present solution, an automated troubleshooting assistance system 10 comprises a HMI (Human Machine Interface) unit 12, preferably located at the site of the container-processing plant 1 and operable by an operator 14 of the same container-processing plant 1 to initiate an automated troubleshooting assistance procedure (as will be detailed in the following).
A central monitoring station 15 of the automated troubleshooting assistance system 10 is located remotely (at a remote site or at a plurality of interconnected sites) with respect to the container processing plant 1 and is configured to cooperate with the HMI unit 12 in the automated troubleshooting assistance procedure.
The central monitoring station 15 is operable by a service team of experts and may be coupled to a number of container processing plants 1 placed in a number of different locations worldwide (in a manner not shown in Figure 1).
A troubleshooting database 16 is operatively coupled to the central monitoring station 15.
Moreover, a dashboard unit 18 at the same central monitoring station 15, receiving data from the troubleshooting database 16, provides a general depiction of all open issues at all monitored container processing plants (allowing e.g. to perform statistical and any other suitable data analysis). In particular, the dashboard unit
18 may provide an overview including: processing machines 2 with issues or not running (the issues being mapped worldwide); resolved issues; open tickets (associated with service requests) per customer; personnel occupation (number of service tickets per expert or team of experts).
The HMI unit 12 may be implemented by any suitable computing unit and comprises a display or monitor, to provide visual information to the operator 14, and input means (such as a keyboard and a mouse); in a possible embodiment the HMI unit 12 is implemented as a touch-screen unit.
In more details, the HMI unit 12 of the troubleshooting assistance system 10 is communicatively coupled (via any suitable wired or wireless communication protocol) to the data collectors, in particular to the control units 4, of the processing machines 2 of the container-processing plant 1, and is configured to collect from the same control units 4 data relating to the respective processing machines 2.
In particular, the HMI unit 12 is configured to collect static and dynamic data. Static data are related to fixed characteristics of the processing machines 2 (such as name of the machine, name of the customer, identification code, position in the container processing plant 1, contact person on site and so on); dynamic data are instead related to the dynamic operation of the processing machines 2 during processing of the containers, in particular relating to faults and malfunctions, and may include a functional history of issues and machine-generated alarms for the same processing machines 2 (detailing the type of issues or alarm and also the duration thereof).
The HMI unit 2, in the event of a malfunction (or any kind of issue) and in response to a user command, is configured to combine the static and dynamic data related to the relevant processing machine 2 (the dynamic data including possible further dynamic data related to activities performed on-site to recover and restore the correct operation of the processing machines 2 and the container processing plant 1) and arrange the data into a structured data set, formatted according to standard, uniform and pre-set criteria, intended for a data communication towards the central monitoring station 15 in association with a troubleshooting assistance request.
As will be detailed in the following, the central monitoring station 15 is configured to: receive the structured data set associated with the troubleshooting assistance request; retrieve in an automated manner from the structured data set the static and dynamic data related to the processing machine 2 (or processing machines 2) involved in the malfunction; store the retrieved data into the troubleshooting database 16; and process the retrieved data in order to provide troubleshooting assistance data in response to the troubleshooting assistance request.
According to a particular aspect of the present solution, as shown schematically in the same Figure 1, the HMI unit 12 is configured to generate a machine-readable code 20, in a preferred embodiment a QR (Quick Response) code, based on the structured data set of the relevant processing machine 2; the machine-readable code 20 is presented to the operator 14, e.g. being displayed on the display of the same HMI unit 12. In particular, the HMI unit 12 may generate the machine-readable code 20, such as the QR code, using a proprietary software solution.
The operator 14 is able to scan the machine-readable code 20 by means of a mobile electronic device 22 (e.g. a personal smartphone, tablet, phablet or the like), to enable automatic generation of the troubleshooting assistance request, based on the structured data set, for the associated data communication towards the central monitoring station 15.
For example, data communication may be implemented via an e-mail message, a SMS (Short Message Service) or any other kind of instant messaging communication (even via a proprietary software mobile application installed in the mobile electronic device 22), and the content of the data communication is automatically generated by reading of the machine-readable code 20; the same content corresponds to the structured data set and is therefore formatted according to standard, uniform and pre-set criteria, thus being suitable for automatic reading and interpretation at the central monitoring station 15.
Data communication towards the central monitoring station 15 may be implemented e.g. via the cellular mobile network or landline internet.
Advantageously, one and the same data communication infrastructure, denoted in general with 24 in Figure 1, may be used both for sending of the troubleshooting assistance request and for the central monitoring station 15 to return back the response with the troubleshooting assistance data towards the operator 14 (e.g., again, via an e-mail message, a SMS or any other kind of instant messaging communication that has been previously used for transmission of the troubleshooting assistance request).
Figure 2 shows diagrammatically the display, here denoted with 28, of the HMI unit 12 showing a user interface 30, that is presented to the operator 14 (in a dedicated "support or service page") for generation of troubleshooting assistance requests in response to a command by the same operator 14.
In detail, in a possible embodiment, the user interface 30 comprises a first portion 30a listing all the processing machines 2 of the container-processing plant 1 and allowing the operator 14 to select any one of the same processing machines 2 for display of the relevant data (i.e. the static and dynamic data).
The user interface 30 may further comprise: a second portion 30b showing the static data for the selected processing machine 2 (e.g. including the name of the machine, name of the customer, identification code, contact person on site); a third portion 30c showing the dynamic data for the same selected processing machine 2 received from the respective control unit 4 (e.g. including the current or actual operating status, running time and functional history of issues and machine-generated alarms and event codes); and a fourth portion 30d, which may be edited by the operator via the input means, to detail the activities performed on-site to recover and restore the correct operation of the processing machine 2 and the container processing plant 1 (these representing the further dynamic data to be included in the above-discussed structured data set).
According to a particular aspect of the present solution, the user interface 30 further comprises a main portion 32, configured to display the machine-readable code 20, in particular the QR code, that is generated for the selected processing machine 2, as a function of the structure data set defined by the combination of the static and dynamic data.
In particular, and as discussed above, the static data are received from the control unit 4 of the processing machine (or may be pre-stored in the HMI unit 12); and the dynamic data include data received from the control unit 4 of the processing machine 2 and, moreover, data that may be inserted by the operator 14 via the user interface 30 (in particular, the fourth portion 30d thereof).
It is noted that, selection by the operator 14 of a different processing machine 2 causes generation and visualization of a different machine-readable code 20 in the main portion 32 of the user interface 30, associated with that processing machine 2 (and its current operating status). Moreover, the generated machine-readable code 20 for a same processing machine 2 is time-dependent, since the dynamic data change over time and based on the operation of the same processing machine 2.
In a possible embodiment, as shown in the same Figure 2, the user interface 30 further comprises a direct- communication element 34, which may be selected by the operator 14 to generate a direct communication towards the central monitoring station 15 (i.e. without the use of the mobile electronic device 22 of the operator 14), e.g. an e mail communication via the internet network, whose content corresponds to the structured data set and is formatted according to the standard, uniform and pre-set criteria, thus being suitable for automatic reading at the central monitoring station 15.
As schematically shown in Figure 3A, in a preferred embodiment, the operator 14 uses the mobile electronic device 22 to scan the machine-readable code 20 displayed on the display 28 of the user interface 30 of the HMI unit 12, to automatically generate the troubleshooting assistance request and send the associated data communication towards the central monitoring station 15.
In particular, as schematically shown in Figure 3B, the data communication may be implemented via an e-mail message, whose content is automatically generated by reading of the machine-readable code 20, and which may be sent to a suitable e-mail address associated with the central monitoring station 15.
With reference to Figure 4, operations performed by the automated troubleshooting assistance system 10 are now discussed, with reference to a timeline (time is denoted by the vertical arrow in the same Figure 4).
As shown at step 40, at an initial time (start of the timeline), a problem occurs in the container-processing plant 1, e.g. a malfunction or a fault of one or more of the processing machines 2. In response to the problem, at step 41, the operator
14 accesses the HMI unit 12, and in particular the "support or service page" (as shown in Figure 2) dedicated to the troubleshooting assistance procedure, and selects the processing machine 2 associated with the malfunction (if more than one processing machines 2 are involved, these machines may be consecutively selected by the operator 14, in a manner not shown here, for clarity of depiction).
As shown at step 42, the HMI unit 12 collects the data related to the selected processing machine 2, and in particular the static data (the static data may be received from the control unit 4 of the processing machine 2 or may be already available to the same HMI unit 12, e.g. being stored therein) and the dynamic data (which may be received both from the control unit 4 of the processing machine 2 and from the same HMI unit 12, as discussed previously) for generation of the structured data set. The same static and dynamic data may be shown to the operator 14 in the corresponding portions of the user interface 30.
As shown at step 43, the HMI unit 12 generates the machine-readable code 20, e.g. the QR code, based on (and including) the structured data set, and displays the same machine-readable code 20 in the main portion 32 of the user interface 30.
As shown at step 44, in addition to the code generation, in response to a command of the operator 14, an e-mail or other data communication may be sent directly to the central monitoring station 15, with a content corresponding to the structured data set and formatted according to the standard pre-set criteria.
As shown at step 45, the operator 14 is then able to scan the displayed machine-readable code 20 with the mobile electronic device 22, to automatically generate the SMS, e- mail or other suitable data communication to be sent to the central monitoring station 15.
As shown in the same step 45, the same e-mail (or other suitable data communication) and the associated troubleshooting assistance request is then sent to the central monitoring station 15 via the same mobile electronic device 22 (using the cellular mobile network or the landline internet network).
As shown at step 46, the troubleshooting assistance request is received at the central monitoring station 15, and the associated structured data set is automatically retrieved.
The same data, in particular the dynamic data, are then stored in the troubleshooting database 16, with the static data, in connection with the processing machine(s) 2 associated with the issue. The same data are also used to update the dashboard unit 18 at the same central monitoring station 15.
The retrieved data are then processed in order to identify a solution to the malfunction of the processing machine 2 (automatic machine troubleshooting procedure). It is noted that, advantageously, retrieved data associated with a number of processing machines 2 of the same container processing plant 1 may be jointly processed in order to identify the solution to the issue.
If the malfunction is a known issue, troubleshooting assistance data may be automatically sent in response to the troubleshooting assistance request, e.g. including a detailed guide of operations to be performed at the processing machine 2 fore resolution of the issue.
As previously discussed, the same data communication infrastructure 24, used for sending of the troubleshooting assistance request, may be used by the central monitoring station 15 to send back the response with the troubleshooting assistance data towards the operator 14.
If the malfunction is not a known issue, so that troubleshooting assistance data may not be automatically sent, intervention of the service team of highly skilled personnel is determined to be required, in order to provide remote assistance for the solution of the issue; accordingly, a so-called service ticket is opened at the central monitoring station 15 to properly deal with the troubleshooting assistance request.
In particular, the service team is able to contact the operator 14, again using the same data communication infrastructure 24 that was used for sending of the troubleshooting assistance request.
The advantages of the present solution emerge clearly from the foregoing description.
It is in any case underlined that the disclosed troubleshooting assistance system allows not only to collect (static and dynamic) data directly from the processing machines, but it also generates troubleshooting assistance request messages to the central monitoring station service team with factual and technically relevant information, automatically and with minimum effort (or competence required) by the operators of the container processing plant; possibility of errors in the fault reporting procedure is substantially eliminated.
The troubleshooting assistance system also allows a real-time or near real-time exchange of information between the service team and the operator at the site of the container-processing plant.
Moreover, it is again underlined that the troubleshooting assistance system allows to generate messages (with the associated data structure sets) not only for the processing machine where the fault or malfunction has occurred, but also, in a simple and quick manner, for other processing machines in the same container-processing plant; this increases the possibility for the service team to actually solve the issue, since it is a known possibility for a malfunction in a given processing machine to be caused (at least in part) by concurrent issues occurring in other, cooperating, processing machines of the same plant.
Moreover, the troubleshooting assistance system may be retro-fitted with existing processing machines and container-processing plants.
Finally, it is clear that modifications and variations may be made to what has been described and illustrated herein, without thereby departing from the scope of the present invention, as defined in the appended claims.
In particular, it is underlined that the troubleshooting assistance system disclosed can advantageously be applied irrespective of the type of processing plant or the type of containers being processed.
Moreover, any kind of data communication may be implemented for sending the troubleshooting assistance requests from the HMI interface to the central monitoring station; for example an encrypted data communication may be implemented.
It is also underlined that the HMI interface may have any other function in addition to management of the troubleshooting assistance requests by the operator, for example also managing and controlling general operation of the associated processing machine (or machines).

Claims

1. A troubleshooting assistance system (10), for a container processing plant (1) including a number of processing machines (2) cooperating in processing of containers for pourable products, each processing machine (2) having a control unit (4), the system comprising: a HMI - Human Machine Interface - unit (12) coupled to the control units (4) of the processing machines (2) and operable by an operator (14) to initiate a troubleshooting assistance request; and a central monitoring station (15) located remotely with respect to the container processing plant (1) and configured to receive the troubleshooting assistance request and provide troubleshooting assistance data in response to the troubleshooting assistance request, wherein the HMI unit (12), in the event of an issue and in response to a command from the operator (14), is configured to retrieve data relating to at least a selected processing machine (2) and relevant to the issue, and to arrange the data into a structured data set, formatted according to pre-set criteria, for a data communication towards the central monitoring station (15) in association with the troubleshooting assistance request.
2. The system according to claim 1, wherein the HMI unit (12) is configured to retrieve from the control unit (4) of the selected processing machine (2) dynamic data related to the operation of the selected processing machine (2) during processing of the containers, including a history of issues and machine-generated alarms, and to combine the dynamic data with static data related to fixed characteristics of the selected processing machine (2) into the structured data set, formatted according to standard, uniform and pre-set criteria.
3. The system according to claim 2, wherein the HMI unit (12) is configured to combine into the structured data set further data related to activities performed in the container processing plant (1) to recover and restore the correct operation of the selected processing machine (2) and the container processing plant (1).
4. The system according to any of the preceding claims, wherein the HMI unit (12) is configured to generate a machine-readable code (20) based on the structured data set of the selected processing machine (2) and to present the generated machine-readable code (20) to the operator (14), by displaying the generated machine-readable code (20) on a display (28) of the HMI unit (12).
5. The system according to claim 4, wherein the machine-readable code (20) is a QR - Quick Response - code.
6. The system according to claim 4 or 5, wherein the data communication towards the central monitoring station (15) is automatically generated by a mobile electronic device (22) of the operator (14) upon scanning of the generated machine-readable code (20).
7. The system according to any of the claims 4-6, wherein the HMI unit (2) is configured to display a user interface (30) having a main portion (32) displaying the machine-readable code (20); the user interface (30) comprising a selection portion (30a) listing all processing machines (2) of the container-processing plant (1) and allowing the operator (14) to select any one of the processing machines (2) for display of the relevant machine-readable code (20).
8. The system according to any of the preceding claims, wherein the central monitoring station (15) is configured to receive the structured data set associated with the troubleshooting assistance request; retrieve in an automated manner the data relating to the selected processing machine (2); and process the retrieved data in order to provide the troubleshooting assistance data in response to the troubleshooting assistance request.
9. The system according to claim 8, wherein the central monitoring station (15) is configured to store the retrieved data into a troubleshooting database (16); further comprising a dashboard unit (18), at the central monitoring station (15), configured to receive data from the troubleshooting database (16) and provide an overview of troubleshooting assistance requests.
10. The system according to any of the preceding claims, wherein the data communication may be implemented via an e-mail, a SMS - Short Message Service - or an instant messaging communication, whose content is based on the structured data set and is formatted according to standard, uniform and pre-set criteria, thus being suitable for automatic reading at the central monitoring station (15); and wherein a same data communication infrastructure (24) is used both for sending of the troubleshooting assistance request and for the central monitoring station (15) to return back the response with the troubleshooting assistance data.
11. A container processing plant (1), comprising the troubleshooting assistance system (10) according to any one of the preceding claims.
12. A troubleshooting assistance method, for a container processing plant (1) including a number of processing machines (2) cooperating in processing of containers for pourable products, each processing machine (2) having a control unit (4), the method comprising: initiating a troubleshooting assistance request, by an operator (14) through a HMI - Human Machine Interface - unit
(12) coupled to the control units (4) of the processing machines (2); and receiving the troubleshooting assistance request and providing troubleshooting assistance data in response to the troubleshooting assistance request, by a central monitoring station (15) located remotely with respect to the container processing plant (1), further comprising, in the event of an issue and in response to a command from the operator (14), retrieving by the HMI unit (12) data relating to at least a selected processing machine (2) and relevant to the issue, and arranging the data into a structured data set, formatted according to pre-set criteria, for a data communication towards the central monitoring station (15) in association with the troubleshooting assistance request.
13. The method according to claim 12, further comprising, by the HMI unit (12): retrieving from the control unit (4) of the selected processing machine (2) dynamic data related to the operation of the selected processing machine (2) during processing of the containers, including a history of issues and machine-generated alarms; and combining the dynamic data with static data related to fixed characteristics of the selected processing machine (2) into the structured data set, formatted according to standard, uniform and pre-set criteria.
14. The method according to claim 12 or 13, further comprising, by the HMI unit (12): generating a machine-readable code (20) based on the structured data set of the selected processing machine (2); displaying the generated machine-readable code (20) to the operator (14) on a display (28) of the HMI unit (12).
15. The method according to claim 14, further comprising, by a mobile electronic device (22) of the operator (14), automatically generating the data communication towards the central monitoring station (15) upon scanning of the generated machine-readable code (20).
16. The method according to any of claims 12-15, further comprising, by the central monitoring station (15): receiving the structured data set associated with the troubleshooting assistance request; retrieving in an automated manner the data relating to the selected processing machine (2); and processing the retrieved data in order to provide the troubleshooting assistance data in response to the troubleshooting assistance request.
EP19839095.7A 2019-11-28 2019-11-28 Automated troubleshooting assistance system and method in a plant for processing containers for pourable products Withdrawn EP4066074A1 (en)

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