EP4698960A1

EP4698960A1 - Composite system communications

Info

Publication number: EP4698960A1
Application number: EP24724409.8A
Authority: EP
Inventors: James R. Beal; Dieter Hildebrandt; Donovan G. KUHSTOSS; Brian K. RAMEY; Mike Palmer; David M. Pendley; Uma GOKAK; Alexander R. DOWNS
Original assignee: Nordson Corp
Current assignee: Nordson Corp
Priority date: 2023-04-15
Filing date: 2024-04-15
Publication date: 2026-02-25
Also published as: CN120958401A; WO2024220349A1

Abstract

Systems and methods for improved production line control system communications are disclosed. The production line control system includes a plurality of components, such as a master component and a client component. At least one of the master component and the client component is configured to implement or execute a composite controller, which is configured to be in operative communication with each of the plurality of components, to receive information from each of the plurality of components, to determine composite information of the production line control system based upon the received information from each of the plurality of components, to generate a user interface displaying information relating to each of the plurality of components and the composite production line control system, and to transmit commands to controllers of each of the plurality of components.

Description

COMPOSITE SYSTEM COMMUNICATIONS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent App. No. 63/496,391, filed April 15, 2023, the entire disclosure of which is hereby incorporated by reference as if set forth in its entirety herein.

TECHNICAL FIELD

[0002] This disclosure relates generally to production line control and, more particularly, to systems and methods for improved production line control and communications, such as for a liquid dispensing system.

BACKGROUND

[0003] Liquid dispensing systems find use in a variety of applications. For example, such a system may apply hot melt adhesives during the manufacture of disposable hygiene products. As another example, a hot melt liquid dispensing system may apply hot melt adhesive to assemble various types of packaging, such as paper-based packaging for food and beverages. Hot melt adhesives used in such applications may include moisture curing hot-melt polyurethane adhesives ("hot-melt PURs"), which are often used where a stable surface-to-surface bond must be formed. Other conventional hot melt adhesives may be used in securing a variety of both similar and dissimilar materials together in a mating relationship, such as wood, plastics, corrugated films, paper, carton stocks, metals, rigid polyvinylchlorides (PVCs), fabrics, leathers, and others. Hot melt adhesives may be especially useful in applications where it is desirable to have the adhesive solidify rapidly after being melted and dispensed.

[0004] In an example configuration of a hot melt liquid dispensing system, hot melt adhesive in a solid or semi-solid form is provided to one or more melters or melter units. A melter heats the solid or semi-solid hot melt adhesive until it reaches a molten state. The molten hot melt adhesive may be then pumped to one or more applicators (also referred to as applicator modules, dispensers, or the like). The applicators thereby dispense the melted hot melt adhesive to the desired surface or substrate, often as a series of dots or lines. It is most always crucial, however, that the adhesive be applied within narrow positioning, timing, and volume tolerances. For example, an insufficient volume of dispensed adhesive may result in ineffective bonds while an excessive volume of adhesive may result in not only wasted material but also undesirable flow once the adhesive is applied to a surface.

[0005] Proper operation of the melter(s) within the hot melt liquid dispensing system is one important factor in achieving the necessary dispensing results. For example, hot melt adhesive temperature affects hot melt adhesive viscosity. The viscosity of the hot melt adhesive, in turn, affects the volume of hot melt adhesive that is dispensed during each adhesive application, particularly when the hot melt adhesive is pressure driven. Yet a host of operating parameters, settings, data measurements, hardware configuration, etc. must be carefully managed to ensure optimal melter performance. Clearly then, effectively managing these many parameters presents challenges.

[0006] Further complicating these challenges, a hot melt liquid dispensing system often includes multiple melters supporting a production line containing multiple applicators or a production line may be supported by multiple hot melt liquid dispensing systems that each include one or more melters. In addition, a plant or production facility may have multiple production lines operating simultaneously, each associated with a separate hot melt liquid dispensing system which, in turn, comprises one or more melters.

[0007] Known production line systems also typically require an additional controller (hardware and software) within the system for composite control, including often requiring a controller or a human-machine interaction (HMI) device on each component of the system, with each component of the system being individually controlled. This often leads to a repetitive and otherwise time-consuming process of requiring an operator to individually access each component to effectuate operations, such as loading a recipe or turning ON/OFF a control. It would thus be desirable for the operator to be capable of performing this action once and have the same effectuated to multiple connected machines designated for production.

[0008] These and other shortcomings are addressed in the present disclosure.

SUMMARY

[0009] Disclosed herein are systems and methods for improved production line control system communications.

[0010] In one example, a production line control system is provided. The production line control system is configured to monitor and/or control at least one dispensing device. The production line control system includes a plurality of components. The plurality of components includes a master component. The plurality of components further includes at least one client component. At least one of the master component and the at least one client component is configured to implement or execute a composite controller. The composite controller is configured to be in operative communication with each of the plurality of components. The composite controller is further configured to receive an operational status of the master component. The composite controller is configured to receive the operational status of the master component from a controller of the master component. The composite controller is further configured to receive an operational status of the at least one client component. The composite controller is configured to receive the operational status of the at least one client component from a controller of the at least one client component. The composite controller is further configured to determine a composite operational status of the production line control system. The composite controller is configured to determine the composite operational status of the production line control system based at least in part upon the operational status of the master component and the operational status of the at least one client component. The composite controller is further configured to generate a user interface. The user interface displays a plurality of control tiles. Each of the plurality of control tiles represents at least one of (a) a component of the plurality of components and (b) user-selectable component data of the plurality of components. The user interface further displays an indicator of the operational status of the master component. The user interface further displays an indicator of the operational status of the at least one client component. The user interface further displays an indicator of the composite operational status of the production line control system. The composite controller is further configured to transmit a command to the controller of the master component. The composite controller is further configured to transmit the command to the controller of the at least one client component.

[0011] In a further example, another production line control system is provided. The production line control system is configured to monitor and/or control at least one dispensing device. The production line control system includes a plurality of components. The plurality of components includes a master component. The master component includes a controller. The plurality of components further includes at least one client component. The at least one client component includes a controller. The plurality of components further includes a backup master component. The backup master component includes a controller. The controller of the master component is configured to be in operative communication with each of the plurality of components. The controller of the backup master component is also configured to be in operative communication with each of the plurality of components. The controller of the master component is configured to implement or execute a composite controller. The controller of the backup master component is configured to determine if the controller of the master component has lost operative communication with the at least one client component and the backup master component. If the controller of the backup master component determines that the controller of the master component has lost operative communication with the at least one client component and the backup master component for a predetermined minimum amount of time, the controller of the backup master component is further configured to implement or execute the composite controller. The composite controller is configured to receive an operational status of the master component. The composite controller is configured to receive the operational status of the master component from the controller of the master component. The composite controller is further configured to receive an operational status of the at least one client component. The composite controller is further configured to receive an operational status of the backup master component. The composite controller is configured to receive the operational status of the backup master component from the controller of the backup master component. The composite controller is configured to receive the operational status of the at least one client component from a controller of the at least one client component. The composite controller is further configured to determine a composite operational status of the production line control system. The composite controller is configured to determine the composite operational status of the production line control system based at least in part upon the operational status of the master component, the operational status of the at least one client component, and the operational status of the backup master component. The composite controller is further configured to generate a user interface. The user interface displays a plurality of control tiles. Each of the plurality of control tiles represents at least one of (a) a component of the plurality of components and (b) user-selectable component data of the plurality of components. The user interface further displays an indicator of the operational status of the master component. The user interface further displays an indicator of the operational status of the at least one client component. The user interface further displays an indicator of the operational status of the backup master component. The user interface further displays an indicator of the composite operational status of the production line control system. The composite controller is further configured to transmit a command to the controller of the master component. The composite controller is further configured to transmit the command to the controller of the at least one client component. The composite controller is further configured to transmit the command to the controller of the backup master component.

[0012] In yet another example, a method of transmitting a command to a plurality of components of a production line control system is provided. The production line control system includes a master component. The production line control system further includes at least one client component. The method includes receiving an operational status of the master component. The operational status of the master component is received at a composite controller. The composite controller is implemented or executed by at least one of the master component and the at least one client component. The operational status of the master component is received at the composite controller from a controller of the master component. The method further includes receiving an operational status of the at least one client component. The operational status of the at least one client component is received at the composite controller from a controller of the at least one client component. The method further includes determining a composite operational status of the production line control system. The composite operational status of the production line control system is determined based at least in part upon the operational status of the master component and the operational status of the at least one client component. The method further includes generating a user interface. The user interface displays a plurality of control tiles. Each of the plurality of control tiles represents at least one of (a) a component of the plurality of components and (b) user-selectable component data of the master component or the at least one client component. The user interface further displays an indicator of the operational status of the master component. The user interface further displays an indicator of the operational status of the at least one client component. The user interface further displays an indicator of the composite operational status of the production line control system. The method further includes transmitting a command to the controller of the master component. The method further includes transmitting the command to the controller of the at least one client component.

BRIEF DESCRIPTION OF DRAWINGS

[0013] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments and together with the description, serve to explain the principles of the methods and systems:

[0014] FIG. 1 illustrates an example production line control system;

[0015] FIG. 2 illustrates an example schematic diagram of a composite system;

[0016] FIG. 3 illustrates an example schematic diagram of another composite system; [0017] FIG. 4 illustrates an example diagram of a composite system;

[0018] FIG. 5 illustrates an example diagram of another composite system;

[0019] FIG. 6 illustrates an example method flow chart;

[0020] FIG. 7 illustrates another example method flow chart;

[0021] FIG. 8 illustrates an example diagram of a user interface;

[0022] FIG. 9 illustrates an example diagram of a user interface element;

[0023] FIG. 10 illustrates an example diagram of another user interface element;

[0024] FIG. 11 illustrates an example diagram of another user interface element; and

[0025] FIG. 12 illustrates an example schematic diagram of an automatic network switch.

[0026] Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise.

DETAILED DESCRIPTION

[0027] The systems and methods of the present disclosure relate to improved production line system communications. Although reference shall be made primarily to hot melt adhesive, the techniques described herein may be applicable to any sort of liquid, including nonadhesives.

[0028] FIG. 1 illustrates an example production line control system 10 (e.g., a hot melt adhesive dispensing system or other type of production line control system) with which the techniques described herein may be implemented. The production line control system 10 may include a melter unit 20, which may include an adhesive supply 22 for receiving and melting solid or semi-solid adhesive 24a, such as pellets, a manifold 26 connected to the adhesive supply 22, a controller 28, and a user interface 29. The adhesive supply 22 may be a tank-style melter, or a grid and reservoir melter, among others. Upon melting, the solid or semi-solid adhesive 24a stored in the adhesive supply 22 may transform into a liquid adhesive 24. The adhesive supply 22 may include side walls 30, a removable cover 31, and a base 32, which may include one or more adhesive supply heaters 34 for melting and heating the adhesive 24a and the liquid adhesive 24 in the adhesive supply 22. An adhesive supply outlet 36 proximate the base 32 may be coupled to a passage 38, which may connect to an inlet 40 of the manifold 26.

[0029] A positive-displacement pump 58, such as a vertically-oriented piston pump (as shown) or a gear pump, may be coupled to the manifold 26 for pumping liquid adhesive 24 from the adhesive supply 22 into the manifold 26, where it may be split into separate flows. A pump motor 59 may drive the pump 58. By operation of the pump 58 (and thus also as a function of the pump motor 59), the adhesive may be supplied to the manifold 26 and applicators 48, 50 under pressure. Such pressure may affect the volume of adhesive that is dispensed in one applicator cycle (also referred to as a gun cycle) of an adhesive dispensing module 54, as well as generally the flow volume and flow rate of adhesive into, through, and/or out of the manifold 26.

[0030] The manifold 26 may be mounted to a side wall 30 of the adhesive supply 22 with a spacer 41 and may be spaced from the adhesive supply 22 a distance 42 sufficient to provide thermal isolation of the adhesive supply 22 from the manifold 26. The manifold 26 may include a plurality of outlet ports 44, which may be fitted with heated hoses 46 attached to one or more adhesive applicators 48, 50, such as to supply the liquid adhesive 24 to the applicators 48, 50. The manifold 26 may include a manifold heater 56, which may separate from the adhesive supply heater 34 and which may be independently controlled by the controller 28. In examples, a single heater may be used for heating the adhesive supply 22 and the manifold 26. While FIG. 1 illustrates the adhesive supply 22 in close physical proximity to the manifold 26, other arrangements are also possible, such as where the source of adhesive is physically distant from the manifold. In such arrangements, more than one pump may be used to move adhesive from the adhesive supply 22 toward the ultimate point of application.

[0031] The manifold 26 may create a plurality of flow streams, which may be carried by corresponding heated hoses 46 to the applicators 48, 50. The hoses 46 may be electrically coupled to the controller 28 by cord sets 62 associated with each hose 46. The applicators 48, 50 may include one or more adhesive dispensing modules 54 configured to dispense and/or apply the liquid adhesive 24 to a product, such as a carton, package, or other object. The adhesive dispensing modules 54 may be mounted to applicator bodies 51, which may have applicator heaters 53 and be supported on a frame 52. The production line control system 10 may include two applicators 48, 50, with one applicator located on each side of the melter unit 20 as shown in FIG. 1, although other implementations of the production line control system 10 may use a different number of applicators, dispensing modules, and other configurations as desired to suit a particular application. For example, the applicators 48, 50 may each be configured with a single adhesive dispensing module 54 or may each be configured with a pair of adhesive dispensing modules 54. The adhesive dispensing modules 54 of an applicator 48, 50 may be commonly monitored, controlled, and/or actuated by a common air supply. Alternatively, the adhesive dispensing modules 54 of an applicator 48, 50 may be independently monitored, controlled, and/or actuated by separate air supplies. An applicator 48, 50 and/or an adhesive dispensing module 54 may be variously referred to as an applicator or dispenser. [0032] The pump 58 may be located external to the adhesive supply 22 and may be connected to an air pressure regulator 70 that receives air from an air supply 61. More particularly, the air pressure regulator 70 may be mounted to the melter unit 20 and may connect to the air supply 61. In some implementations, the pump 58 may be attached to the manifold 26 and heated by the manifold heater 56. This arrangement permits a larger tank opening 60, increases the tank capacity, and reduces the time required to heat the pump 58. Further, a flow meter 80 may be attached to the manifold 26 to measure adhesive flow therethrough. The flow meter 80 may include a pair of sensors that are electrically coupled to the controller 28 by respective cords 63a, 63b associated with each sensor. At least one product detector 90, such as a photo-sensor, may also be electrically coupled to the controller 28.

[0033] The melter unit 20 may include the controller 28. The controller 28 may house the power supply and electronic controls for the production line control system 10. The controller 28 may be configured with one or more processors and memory configured to store instructions that, when executed by the one or more processors, cause the controller 28 to effectuate various operations described herein. The controller 28 may be configured to manage various types of data associated with the production line control system 10 and components thereof, including the melter unit 20, the applicators 48, 50, and/or the controller 28 itself. Managing such data may include storing the data, capturing the data (e.g., measured by various sensors), modifying or setting the data, receiving like data from other controllers 28 of other melter units 20 or production line control systems 10 and/or providing the data to other controllers 28 of other melter units 20 or production line control systems 10 (e.g., via a composite controller or cloud system as described herein). [0034] Data managed by the controller 28 (collectively referred to as control data) may include operating parameters, measured data, and/or hardware configuration data. Example operating parameters may relate to temperature setpoint, control loop settings (e.g., temperature control loop), control loop type, pump speed, melter duty cycle (or individual heaters thereof), applicator cycle rate, and pump and/or pump motor speed. Example measured data may relate to liquid temperatures (including at various points within melter unit 20, the tank 22, the manifold 26, the applicators 48, 50, and the heated hoses), liquid flow rate (e.g., from the manifold 26), liquid flow volume (e.g., from the manifold 26), and/or liquid pressure. Example hardware configuration data may include the number of pumps, the types of pump(s), the holding capacity of the tank 22, the number of hose outlets of the manifold 26, the power capacity, the control interfaces to and from the controller 28, the weight (e.g., of the melter unit 20), the external dimensions (e.g., of the melter unit 20), the liquid throughput from the melter unit 20, and/or the melt rate of the melter unit 20.

[0035] With respect to the heating features of the production line control system 10, the controller 28 may be electrically coupled to the heaters, including the adhesive supply heater 34, the manifold heater 56, the applicator heaters 53, and/or any hose heaters. The controller 28 may also be coupled with various temperature sensors in the production line control system 10, which may be associated with or included in the adhesive supply heater 34, the manifold heater 56, the applicator heaters 53, and/or any hose heaters. The controller 28 may independently monitor and adjust the adhesive supply heater 34, the manifold heater 56, the applicator heaters 53, and/or any hose heaters, to melt solid or semi-solid adhesive 24a received in the adhesive supply 22 and to maintain the temperature of (melted) adhesive 24 to ensure proper viscosity of the adhesive 24 supplied to the applicators 48, 50 and dispensed by the adhesive dispensing modules 54. [0036] FIG. 2 illustrates a schematic diagram of a composite system 200 comprising a plurality of melter units 202a-e at a production facility. In aspects, the composite system 200 may be a compilation of all systems installed on a single production line to produce a product, may be a compilation of all systems installed on multiple production lines to produce a product, may be a compilation of all systems installed on multiple production lines to produce multiple products, and/or the like. In aspects, the composite system 200 may take a number of different forms including: a Homogeneous composite network that includes multiple systems in the same product line, for example a production line that has multiple melters; a Heterogeneous composite system that may include multiple systems at least one of which is from a different product line, for example a melter, a drum unloader, and a pattern controller. Although melter units 202a-e are shown in FIG. 2, any other component of the production line control system 10 or a plurality of the production line control systems 10 may be used to control data flow as described below. Data flow within the composite system 200 may be performed according to a publish/subscribe communication model or architecture, such as the Open Platform Communications (OPC) Unified Architecture (OPC/UA). In particular, control data may be published by a melter unit 202 to a composite controller 210. As used herein, the term “composite controller” may refer to hardware, software, or combinations thereof. By way of non-limiting example, the composite controller described herein is a software implementation that may, in certain non-limiting examples, be implemented or executed by a controller of one of the components of the composite system or a cloud system as described herein. The control data published to the composite controller 210 may be propagated by the composite controller 210 to select melter units 202 via subscription. As described herein, in examples, client components (e.g., melter units 202a-d) may publish information (e.g., an operational status of the respective component) to the master component (e.g., melter unit 202e). In further examples, the master component may (e.g., simultaneously) publish commands or control messages to the client components as described herein. As described herein, the composite system may, in some examples, be a homogenous system (e.g., including melter units of the same type) or, in other examples, may be a heterogenous system (e.g., including melter units of different types or other components, such as a drum unloader or pattern controller). In any of the foregoing examples, the composite controller may be configured to decode information received from such components and to publish commands or control messages to any component, regardless of type. This advantageously allows for a single composite controller that is configured to operatively connect to any type of controller of the composite system for improved production line control and communications.

[0037] As shown in FIG. 2, the composite controller 210 may be implemented as part of the melter unit 202e, including, in certain examples, as software implemented or executable by the controller 204 of melter unit 202e. Alternatively, the composite controller 210 may be implemented or executed by a stand-alone unit co-located with the melter units 202a-e. As a further alternative, the composite controller 210 may be implemented as or executed by a cloud system, as will be discussed with respect to FIG. 3. As described herein, in examples, each component of the composite system 200 may be configured with software implemented or executable as the composite controller, such that the composite controller 210 may be implemented or executed by any component of the composite system 200 (i .e., each and any component may be configured to assume the role of the master component as desired to suit a particular application). Determining which of the component(s) of the composite system 200 to implement or execute as the composite controller 210 may be based upon a predetermined hierarchical identifier, such as the first component of the composite system 200 to be operatively connected to the composite system 200, the component of the composite system 200 having the lowest serial number, or the like, including combinations thereof.

[0038] The melter units may be referred to generically as melter units 202 or melter unit 202 or the melter units may be referred to specifically as one of the particular melter units 202a-e, as appropriate. The system 200 may be referred to as a composite system. The system 200 may represent a single liquid (e.g., adhesive) dispensing system (e.g., the production line control system 10 of FIG. 1) configured with multiple melter units 202 or other components. The system 200 alternatively may represent multiple production line control systems each having a single melter unit 202. For example, the melter unit 202a may belong to a first production line control system, the melter unit 202b may belong to a second production line control system, and so forth. Yet further, the system 200 may comprise a combination thereof in which some melter units 202 all belong to a common production line control system while other melter units 202 each belong to separate single-melter-unit production line control systems. Although the system 200 is generally discussed with respect to melter units 202, the techniques described herein may be applied to other components of a production line control system, such as an applicator or subcomponents of a melter unit 202 (e.g., a manifold, adhesive tank, hose, etc.).

[0039] Each melter unit 202 may include and/or be associated with a controller 204. The controller 204 of and/or associated with a melter unit 202 may generally control operations of the melter unit 202 and communications to and from the melter unit 202. In some instances, the controller 204 may additionally control operations of at least some aspects of the production line control system associated with the melter unit 202. The controller 204 may further manage control data stored at the controller 204, including receiving control data, modifying control data, and transmitting control data to other systems or components. For example, the controller 204 may receive control data from the composite controller 210 as a subscriber. Conversely, the controller 204 may transmit control data to the composite controller 210 as a publisher. Control data may include operating parameters, measured data, and hardware configuration. The controller 204 may be the same as or similar to the controller 28 of FIG. 1. The controller 204 may comprise an OPC Unified Architecture (OPC/UA) controller.

[0040] Each controller 204 may be configured with a server 214 and a client 216. The server 214 and the client 216 may be implemented as part of the controller 204. Additionally or alternatively, the server 214 and the client 216 may be implemented, at least in part, as separate physical components. The server 214 and the client 216 may be considered as an embedded server and embedded client, respectively, of the melter unit 202 and/or its controller 204. The server 214 may comprise an embedded OPC/UA server and the client 216 may comprise an embedded OPC/US client. The server 214 may generally be configured to publish control data (i.e., control data messages) to the composite controller 210. The client 216 may generally be configured to subscribe to and receive published control data (i.e., control data messages) from the composite controller 210. The server 214 may be regarded as the publisher and the client 216 may be regarded as the subscriber in the publish-subscribe architecture of the system 200.

[0041] As indicated, the melter unit 202e may include and/or be associated with the composite controller 210. The composite controller 210 may be configured to coordinate and direct various control data messages to and from the melter units 202, in particular the controllers 204 of the melter units 202 (including the controller 204 of the melter unit 202e itself). For example, the composite controller 210 may receive a published control data message from a server 214 of a melter unit 202 and send the control data message to the client 216 of one or more other melter units 202 according to subscription criteria. The composite controller 210 may act as a message broker for the control data messages in certain examples.

[0042] The composite controller 210 may filter the published control data messages to determine which, if any, of the melter units 202 should receive the published control data messages. The composite controller 210 may filter the published control data messages according to one or more classifications of the control data messages. In some examples, the classification (or class) of a published control data message may be defined, at least in part, by the publishing server 214. The composite controller 210 may filter the published control data messages further based on subscription profiles (e.g., subscription criteria) associated with other melter units 202. A melter unit 202 may define, at least in part, the subscription profile associated with the melter unit 202. Filtering by the composite controller 210 may be done according to a topic-based model, a content-based model, or a combination thereof.

[0043] In the topic-based model, classifications may be with respect to a type of component (e g., pump, heater, adhesive tank, applicator, manifold, heated hoses, controller, etc.) associated with the control data. Classifications further may be with respect to a type of operating parameter (e.g., temperature setpoint, applicator cycle rate, melter/heater duty cycle, control loop settings, control loop type, pump speed, etc.) associated with the control data. Classifications further may be with respect to a type of measured data (e.g., adhesive temperature, adhesive flow rate, adhesive flow volume, and adhesive pressure) indicated in the control data. Classifications further may be with respect to a type of hardware configuration data (e.g., a number of pumps, types of pump(s), a holding capacity of an adhesive tank, a number of hose outlets of a manifold, a power capacity, control interfaces to and from a controller, a melter unit weight, external dimensions of a melter unit, an adhesive throughput from a melter unit, and a melt rate of a melter unit) indicated in the control data. A classification may be further based on the type of data in general: e.g., operating parameter data, measured data, or hardware configuration data.

[0044] In a content-based classification model, classifications may be with respect to the particular melter unit 202 that published the control data. Classification may be further with respect to a value of an operating parameter or measured data. For example, classification may be based on an operating parameter or measured data value exceeding a threshold, being below a threshold, being outside of a threshold range, or being within a threshold range. For instance, control data from one melter unit 202 indicating an adhesive temperature may be sent by the composite controller 210 to other melter units 202 based on the composite controller 210 determining that the adhesive temperature value is outside of a threshold range.

[0045] The melter unit 202e comprising the composite controller 210 may be configured with a panel 206, which is also referred to as a control panel. One or more of the other melter units 202 may be also configured with a panel 206. The panel(s) 206 may optionally be excluded in certain examples. A panel 206 may comprise a display (e.g., an LCD or LED display) and one or more user inputs (e.g., a pointing device, a keyboard, or various control buttons). The display may be configured as a touchscreen display for user input. The panel 206 may output a graphical user interface, which may be configured to display a visual layout of the melter units 202 and other components/units of the system 200. The graphical user interface may be also configured with one or more interface elements (e.g., “tiles”) to display various data associated with a system. An interface element may be additionally or alternatively associated with a melter unit 202 or other component/unit of the system 200. Upon activation of an interface element for a particular production line control system, data relating to that system may be displayed, such as the system’s operating parameters, various measured data, and/or aspects of the system’s hardware configuration. The graphical user interface may be also used to input various changes to the production line control system and other components of the system 200. For example, an operator may use the graphical user interface and the panel 206 generally to modify an operating parameter of a production line control system, which modified operating parameter may be communicated or transmitted to the components of the system as described herein.

[0046] The melter unit 202e (the composite controller 210 in particular) may be configured for mutual communication with a computing device 222. The computing device 222 may be in communication with the melter unit 202e via a wired connection, a fiber-optic connection, a wireless connection, and/or the like. For example, the computing device 222 may be in communication with the computing device 222 via a WAN (wide area network), a LAN (local area network), a WLAN (wireless LAN), an intranet, the Internet, a communication channel as defined herein, and/or the. The computing device 222 may be located at the same production facility as the melter units 202. For example, an operator may move through the floor of a production facility with a portable computing device 222 to monitor and manage the production operations. Additionally or alternatively, the computing device 222 may be located remote from a production facility. As some examples, the computing device 222 may be a personal computer (PC), a laptop computer, a mobile device, a tablet computer, or a smartphone. The computing device 222 may be configured to perform similar functions as the panel 206 of the melter unit 202e. In some examples, the melter unit 202e may be configured without the panel 206 and the panel 206 functionality may be instead transferred to the computing device

222. [0047] First and second control data messages 208a, 208b illustrate example publish/subscribe data flows within the system 200. The first (“publish”) control message 208a may generally be used to send information (e.g., operational status) from one or more client components (e.g., melter units 202a-d) of the composite system 200 to the master component (e g., melter unit 202e). In examples, the first control data message 208a may additionally or alternatively include other information, such as user-selectable information of the corresponding component to be displayed on the user interface (e.g., as a control tile) as described herein. The second (“subscribe”) control message 208b may generally be used to send information (e.g., commands or control messages) from the master component (e.g., melter unit 202e) to one or more client components of the composite system 200 (e.g., melter units 202a-d). In examples, the second control data message 208b may be used to control one or more of the client components, such as by controlling sub-components (e.g., pumps, heaters) thereof, loading recipes, and/or the like as described herein.

[0048] With regard to the first control data message 208a, the server 214 of the melter unit 202a may generate the first control data message 208a and publish the first control data message 208a to the composite controller 210. The composite controller 210 may filter the first control data message 208a according to subscription profiles associated with the other melter units 202 and aspects of the first control data message 208a. Aspects of the first control data message 208a may comprise one or more classifications of the first control data message 208a. Such classification(s) may have been defined by the server 214 of the melter unit 202a. In this example, the first control data message 208a may indicate a heater duty cycle of the melter unit 202a. The subscription profiles associated with the melter units 202b, 202c, 202d may indicate that these melter units 202b, 202c, 202d should receive control data from other melter units 202 relating to heater duty cycle (e.g., a classification of the first control data message 208a). Additionally or alternatively, the subscription profiles associated with the melter units 202b, 202c, 202d may indicate that these melter units 202b, 202c, 202d should receive control data published by the melter unit 202a (e.g., an additional or alternative classification of the first control data message 208a). In either or both cases, the first control data message 208a may be sent via subscription to the respective clients 216 of the melter units 202b, 202c, 202d.

[0049] With regard to the second control data message 208b, the server 214 of the melter unit 202b may generate the second control data message 208b and publish the second control data message 208b to the composite controller 210. The composite controller 210 may filter the second control data message 208b according to subscription profiles associated with the other melter units 202 and aspects of the second control data message 208b (e.g., one or more classifications of the second control data message 208b). In this example, the second control data message 208b may indicate a temperature setpoint operating parameter of the melter unit 202b. The subscription profiles associated with the melter units 202a, 202d may indicate that these melter units 202a, 202d should receive control data from other melter units 202 relating to temperature setpoint operating parameters (e.g., a classification of the second control data message 208b). Accordingly, the composite controller 210 may send the second control data message 208b via subscription to the respective clients 216 of the melter units 202a, 202d. Further to this example, the subscription profiles associated with the melter units 202c, 202e may indicate that these melter units 202c, 202e should only receive control data associated with temperature setpoint operating parameters if the temperature setpoint operating parameter is outside of a threshold range (e.g., another classification of the second control data message 208b). In this example, the temperature setpoint operating parameter indicated in the second control data message 208b is not outside of the threshold range. Therefore, the melter units 202c, 202e are not sent the second control data message 208b in this example.

[0050] The composite controller 210 may also be configured to coordinate as least some operations of the melter units 202. For example, the composite controller 210 may receive control data from one melter unit 202 and direct a second melter unit 202 to operate accordingly. For instance, the composite controller 210 may receive control data indicating that the first melter unit 202 is inoperable or suffers from reduced melted adhesive output. The composite controller 210 may therefore direct the second melter unit 202 to increase its melted adhesive output to compensate for the inoperability or reduced melted adhesive output of the first melter unit 202.

[0051] FIG. 3 illustrates a schematic diagram of a system 300 configured according to a cloud/edge architecture. The system 300 may be similar in at least some aspects to the system 200 of FIG. 2. Accordingly, like reference characters indicate like components or parts. Yet instead of a composite controller being implemented as part of a melter unit 202, as is the case with the system 200 in FIG. 2, a composite controller 232 is implemented by a server 230. The server 230 may be part of a cloud/edge system and the melter units 202 may communicate with the server 230 via a network 250. As such, the server 230 may be located remote from the production facility housing the melter units 202, although the disclosure is not so limited. For example, the server 230 may be located at the same production facility as the melter units 202 and connect to the melter units 202 via a LAN (e.g., WLAN) and/or a communication channel as defined at the production facility. The server 230 is not limited to a single computing device, but may comprise multiple networked computing devices, storage units (e.g., databases), and/or networking devices. [0052] The composite controller 232 implemented at the server 230 may be similar in at least some aspects to the composite controller 210 of FIG. 2. Indeed, the composite controller

232 may be considered analogous to the composite controller 210 in many aspects of functionality. For example, like the composite controller 210, the composite controller 232 may receive published control data messages from the servers 214 of the melter units 202. The composite controller 232 may fdter the control data messages according to subscription profiles associated with the melter units 202 and aspects of the control data itself. The composite controller 232 may thereby transmit the control data message to the clients 216 of the determined melter units 202 (or none at all).

[0053] A computing device 222 may communicate with the server 230 and in particular the composite controller 232. The computing device 222 may implement at least some of the functionality provided by the panel 206 of the melter unit 202e in FIG. 2. For example, the computing device 222 may display a graphical user interface providing a visual layout of the production line control systems and other components within the production facility. The graphical user interface may display various data relating to the production line control systems, such as operating parameters, measured data, and hardware configuration data. The data displayed by the graphical user interface may be derived from control data messages published by or otherwise received from the melter units 202. The graphical user interface may provide various interactive interface elements (“tiles”) that may be activated to display further data of a production line control system associated with the interface element. The graphical user interface, and the computing device 222 generally, may be used to control various aspects of a production line control system and other components of the system. For example, the computing device 222 may be used to adjust various operating parameters of a production line control system. Such control may be effectuated via the server 230 and/or the composite controller 232.

[0054] FIG. 4 illustrates at least a portion of an example composite system 400 including four operatively connected melter units 402, labeled as melter units 402a-d. The system 400 of FIG. 4 may be the same as or similar to the production line control system 10 of FIG. 1, the system 200 of FIG. 2, and/or the system 300 of FIG. 3 in at least some aspects. Likewise, a melter unit 402 of FIG. 4 may be the same as or similar to the melter unit 20 of FIG. 1 and/or a melter unit 202 of FIG. and FIG. 3 in at least some aspects. As such, a melter unit 402 may comprise a reservoir configured with one or more heaters to melt solid or semi-solid adhesive supplied to the melter unit 402. A melter unit 402 may further comprise a manifold to distribute the melted adhesive, via connected hoses (e.g., heated hoses), to one or more applicators (e.g., the applicators configured to dispense the melted adhesive). Additional heaters may be found throughout the system 400, including at or within the manifold, hoses, or applicators associated with respective melter units 402. The system 400 may likewise comprise one or more sensors to measure the temperature of the melted adhesive at various points within the system 400, such as within the reservoir, manifold, hoses, or applicators of respective melter units 402. Although they are not shown in FIG. 4, the one or more applicators, hoses, and any adhesive supply device(s) (e.g., a hopper) may be considered part of the system 400. It is contemplated that each melter unit 402 of the system 400 provides melted adhesive to one or more applicators particularly associated with that melter unit 402.

[0055] While the system 400 is depicted in FIG. 4 as having four melter units 402, it will be understood that the system 400 may have any suitable number of melter units 402 depending on the type of melter units 402, the type of material to be dispensed, the quantity of material that will need to be melted and dispensed, and/or other manufacturing factors. Further, the melter units 402 of the system 400 may include melter units 402 of different types (such as melter unit 406 illustrated in FIG. 5) and/or melter units operating according to different operating parameters or configurations. Additionally or alternatively thereto, it will be understood that the system 400 may include any other components (referred to as client components, which may be operable as a master component or backup master component as described herein), such as a pattern control device 408 as illustrated in FIG. 5.

[0056] A melter unit 402 (e.g., in particular the associated control device 410) may further comprise a communication interface, such as a wireless interface, to effectuate network communication with other devices, including another control device 410 or a cloud system. The wireless interface may communicate via Wi-Fi, for example and/or other communication channel as defined herein. The wireless interface may additionally or alternatively comprise a cellular communication device.

[0057] The system 400 may comprise one or more control devices 410 configured to display information relating to the system 400, such as information relating to one or more of the melter units 402 or other components of the system 400. A control device 410 of FIG. 4 and FIG. 5 may be the same as or similar to the controller 28 of FIG. 1 and/or the composite controllers 204 of FIGS. 2 and 3 in at least some aspects. A control device 410 may be disposed on one or more of the melter units 402 or other component. For example, such a control device 410 may be embedded in a melter unit 402. In an aspect, only a single melter unit 402 of the system 400 is configured with a control device 410. For example, such single melter unit 402a configured with the control device 410 may be the same as or similar to the melter unit 202e of FIG. 2 that is configured with the composite controller 210. Indeed, the composite controller 210 and the control device 410 may be implemented in the same computing module or device.

[0058] Additionally or alternatively, a control device 420 may be a stand-alone device that is in communication with (e.g., wireless or wired) one or more of the individual melter units 402 or other components of the system 400. A stand-alone control device 420 may comprise a desktop computer, a portable computer, a tablet, and/or a mobile phone. In an aspect, the system 400 may include multiple control devices 410, 420. For example, the system 400 may have one or more control devices 410 in direct wired communication with one or more other melter units 402 and/or one or more stand-alone control devices 420 in wireless communication with one or more melter units 402. A stand-alone control device 420 may be the same as or similar to the computing device 222 of FIGS. 2 and 3 in some examples. Control functions of a stand-alone control device 420 may be facilitated by a cloud system, which may comprise a server the same as or similar to the server 230 of FIG. 3 in some examples.

[0059] As described herein, the composite controller may generally be implemented or executed by the controller of any one of the components of the production line control system, which thereby causes such component to assume the role of master component insofar as such component is operating as the master component and its controller is implementing or executing the composite controller. For example, the composite control capability described herein may generally be included in the software that is implemented or executed on or by each controller of each component of the production line control system, thereby allowing each component to assume any role within the composite system as described herein without the need for additional control hardware. As may be appreciated and as described herein, a control device and/or the composite controller is not required for each component of the production line control system; instead, the control device and/or the composite controller may generally be located anywhere within the composite system as described herein, although it is to be understood that the term

“within” does not necessarily require the control device and/or the composite controller to be physically located at the same premises as the other components of the production line control system. In examples, the master component may include the composite controller. In other examples, a cloud server located remote from a premises housing the production line control system may include the composite controller. In examples, an operator may navigate from any connected device (e.g., an HMI device) into the control screens associated with the production line control system or any component thereof as described herein. In examples, the controller of any one of the components of the production line control system may implement or execute the composite controller and may be determined based upon a predetermined hierarchical identifier, such as the first component of the production line control system to be operatively connected to the production line control system, the component of the production line control system having the lowest serial number, or the like, including combinations thereof.

[0060] The controllers of the components of the production line system, including the composite controller, may be configured with one or more processors and memory configured to store instructions that, when executed by the one or more processors, cause the controllers to effectuate various operations described herein. The controllers may be configured to manage various types of data associated with the production line control system and components thereof. Managing such data may include storing the data, capturing the data (e.g., measured by various sensors), modifying or setting the data, receiving like data from other controllers of other components or production line control systems and/or providing the data to other controllers of other components or production line control systems (e.g., via a composite controller or cloud system as described herein). In examples, any of the controllers, including the composite controller, may be a human-machine interaction (HMI) device.

[0061] In examples, the production line control system may include a backup master component. The backup master component is generally configured to operate in a similar fashion to the other client components as long as the master component remains in operative communication with the client components. For example, the composite controller may receive an operational status of the backup master component, and the composite controller may transmit commands and/or control messages to the backup master component, similarly to as is performed for the other client components as described herein. In such examples, the determination of the composite operation status of the production line control system may include consideration of the operational status of the backup master component similarly to as is performed for the other client components as described herein. However, in addition, the backup master component may receive and/or monitor commands and control messages communicated to, from, or between the master component and the other components. For example, the backup master component may monitor receipt of commands and/or control messages published by the master component (e.g., at regular or predetermined intervals). As with the master component, any of the components of the system may generally operate as the backup master component. In examples, the system may include a singular master component, a singular backup master component, and one or more client components, although the backup master component may also generally be referred to as one of the client components when the backup master component has not transitioned to assume the role of master component.

[0062] The backup master component may be configured (e.g., via a controller thereof) to determine if the master component (e.g., in particular the controller thereof) has lost operative communication with the client component(s) and/or the backup master component. Such determination may, in examples, be performed by the backup master component (e.g., in particular the controller thereof) by recognizing that the backup master component has not received any commands and/or control messages published by the master component for a predetermined minimum amount of time (e.g., about five seconds) or over a predetermined minimum number of missed frames. If such a determination is made indicating that the master component has lost operative communication with the client component(s) and/or the backup master component, the backup master component may be operable as the master controller, with the controller of the backup master controller implementing or executing the composite controller (e.g., by the backup master component transitioning to the role of the master component, with the controller of the backup master component implementing or executing the composite controller). During the period in which the backup master component operates as the master component and the controller of the backup master component operates as the composite controller, the backup master component and its controller may operate as described herein with respect to the master component and the composite controller. In addition, the controller of the backup master component (which is then operating as the composite controller) may monitor if the master component’s controller regains operative communication with the client component(s) and/or the backup master component. Until such operative communication is regained, the controller of the backup master component may continue operating as the composite controller, as described herein. If, however, such operative communication is regained (i.e., the master component’s controller regains operative communication with the client component(s) and/or the backup master component), the controller of the backup master component may transition back by causing the controller of the master component to resume operating as the composite controller, as described herein. After such transition, the controller of the backup master component may resume operation as a backup “bookkeeper,” including receiving and/or monitoring commands and control messages communicated to, from, or between the master component and the other components (e.g., including receiving and/or recording the composite operational status of the production line control system from the composite controller).

[0063] As may be appreciated and as described herein, the master component, the backup master component, and the other client components may be any component of the production line control system. As illustrated in FIG. 4, the master component may be a melter unit 402a, and the other client components (any of which may be operable as a backup master component) may likewise be melter units 402b-d, although other examples of the disclosure are not so limited. For example, as illustrated in FIG. 5, the master component may be a melter unit 402a, and the other client components (any of which may be operable as a backup master component) may include melter units 402b-d of one type, a melter unit 406 of another type, and a pattern control device 408, although other combinations may be employed as desired to suit a particular application.

[0064] FIG. 6 illustrates a data flow diagram of a method 600 for transmitting a command to a plurality of components of a production line control system or components, such as melter units. Specifically, the method 600 may transmit a command (e.g., including control data) between a master component (e.g., a first melter unit of a plurality of melter units) and one or more client components (e.g., a second melter unit of the plurality of melter units). The production line control system may be, for example, the production line control system 10 of FIG. 1. The method 600 may, for example, be executed within the system 200 of FIG. 2 and/or the system 300 of FIG. 3. As such, the plurality of production line control system melter units may be the same as or similar to the melter units 202 of FIGS. 2 and 3. The melter units may comprise melter units for a single production line control system, the melter units may comprise melter units for multiple different production line control systems, or a combination thereof. For example, the first melter unit and the second melter unit may both belong to the same production line control system, or the first melter unit and the second melter unit may belong to different production line control systems.

[0065] At step 602, an operational status of the master component (e.g., a first melter unit, such as the melter unit 202a of FIG. 2 and FIG. 3 and/or one of the melter units 402a of FIG. 4 or FIG. 5) is received. As described herein, the operational status of the master component may be received at the composite controller. In examples in which the composite controller is the controller of the master component, the operational status of the master component may be received by the controller of the master component operating as the composite controller.

[0066] At step 604, an operational status of a client component (e.g., another melter unit, such as one of the melter units 202b-d of FIG. 2 and FIG. 3 and/or one of the melter units 402b-d or 406 or pattern control device 408 of FIG. 4 or FIG. 5) is received. As described herein, the operational status of the client component(s) may be received at the composite controller. In examples in which the composite controller is the controller of the master component, the operational status of the master component may be received by the controller of the master component operating as the composite controller.

[0067] The operational status of the master component and/or the operational status of the client component(s) may, in examples, include a status of an operating parameter associated with such component and/or an operation mode of such component, such as a production mode, a setup mode, or a service mode. In examples, the operational status of the master component and/or the operational status of the client component s) may be in the form of a signal generated by the respective component. The signal may generally be generated by the controller of the respective component (e.g., a controller 204 of FIGS. 2 and 3). In examples, the controller may be a melter unit. The signal may comprise a beacon signal, for example. The signal may be detected by the composite controller on a network to which the composite controller is connected. As an example, the network may comprise a LAN (e.g., a WLAN) at the production facility housing the composite system. The respective component may generate the signal responsive to the component being connected to the network. Each component may be configured to generate a signal (e.g., of the operational status thereof) at predetermined intervals.

[0068] In examples, the operational status of the master component and/or the operational status of the client component(s) may include, or be in the form of, a control data message, which may include control data relating to an operating parameter of the respective component. For example, the operating parameter may comprise a temperature setpoint, a temperature control loop settings, a control loop type, a pump speed, a pump motor speed, a heater duty cycle, or applicator cycle rate. The control data message may comprise data measured about and/or by the component, such as a liquid temperature, a liquid flow rate, a liquid flow volume, or liquid pressure. The control data message may comprise a hardware configuration of the first melter unit, such as a number of pumps, a pump type, a liquid holding capacity, a number of hose outlets, a power capacity, a number of control interfaces, a melter unit weight, melter unit external dimensions, flow throughput, or melt rate. In examples, the operational status of one component (e.g., a status of an operating parameter associated with such component and/or an operation mode of such component) may affect the operational status of one or more other components. For example, one or more components may change operation mode based on the operational status of one or more other components. By way of one nonlimiting example, a pattern controller may not be configured to dispense patterns until a melter has achieved a temperature setpoint and/or a pump associated with the melter is set to on. By way of another non-limiting example, after a prolonged prior of trigger inactivity for the pattern controller, the melter may be placed into a temperature setback (standby) state.

[0069] At step 606, a composite operational status of the production line control system is determined. As described herein, the composite operational status of the production line control system may be determined by the composite controller. The composite operational status of the production line control system may be determined (e.g., by the composite controller) based, at least in part, upon the operational status of the master component and the operational status of the client component(s). As a general example, if the operational status of the master component and the operational status of the client component(s) are all determined to be of a specific value or character (e.g., in production mode), the composite controller may determine the composite operational status of the production line control system to be of the same value or character (e.g., in production mode).

[0070] In examples, the composite operational status of the production line control system may be determined (e.g., by the composite controller) based, at least in part, upon a hierarchy of the operational status of the master component and the operational status of the client component(s). For example, the hierarchy may be determined based on pre-defined user hierarchy settings or predetermined hierarchy settings. In some examples, it may be determined (e.g., by the composite controller) if any of the components of the production line control system is or is not required for production. Continuing with such examples, if a particular component is determined to be required for production but has an operational status indicating that such component is not in production (such as that the component is inoperable or, in the case of a melter unit, is suffering from reduced melted adhesive output), the composite operational status may reflect that the composite system is not in production or otherwise indicate an error or alert within the composite system. Conversely, if a particular component is determined not to be required for production, the operational status of such component may be ignored when determining the composite operational status of the production line control system (e.g., via the composite controller).

[0071] At step 608, a user interface is generated (e.g., by the composite controller). In examples, the user interface may be displayed, such as via the screen 412 of the control device 410 of the master component (e.g., the first melter unit 402a of FIG. 4 or FIG. 5). The user interface may display (e.g., simultaneously) a plurality of control tiles (e.g., user-selectable control tiles), as described herein. Each of the plurality of control tiles may represent a component of the plurality of components of the production line control system. By way of nonlimiting example, the user interface may display a control tile representing the master component and additional control tiles representing the client component(s). The user interface may also additionally display (e.g., simultaneously) an indicator of the operational status of the master component, an indicator of the operation status of the client component(s), and an indicator of the composite operational status of the production line control system. Such indicator may generally take any form as desired to suit a particular application, such as a textual indicator (e.g., “Production,” “Setup,” “Service”). In examples, the user interface may display the control tiles and any other displayed information based on pre-defined user display settings or predetermined display settings, such as a location and/or a size of one or more of the control tiles.

[0072] In examples, the user interface may display an indicator of the operational status of each component of the plurality of components that is determined to be required for production, as described herein. Additionally, the user interface may display an indicator of the operational status of each component of the plurality of components that is determined to not be required for production, as described herein, regardless of whether such operational status is ignored when determining the composite operational status of the production line control system.

[0073] Control data relating to the production line control system (e.g., a component thereof) may be displayed, including any control data included in or indicated by the command transmitted by the composite controller. Such control data may be displayed via a user interface (e.g., the user interface 800 of FIG. 8 and/or the user interface 1004 of FIG. 10) associated with the production line control system, such as an operating parameter of the production line control system or a dispensing system(s) comprising one or more melter units. The control tiles may, in examples, include one or more control tiles configured to display an operating parameter status associated with the operating parameter as described herein. As also described herein, via the user interface, an operator may control at least some aspects of the production line control system or a dispensing system(s) comprising one or more melter units. For example, the user interface may be configured to enable adjustment of the operating parameter of the production line control system or any component thereof (e.g., a melter unit) based on user input to the user interface.

[0074] The user interface may be output (e.g., displayed) by one or more of the components of the production line control system (e.g., the melter unit 202e of FIG. 2). Any of the melter units or other components may comprise a control panel (e.g., the panel 206 of FIGS. 2 and 3) and the control panel may display the user interface. In examples, the composite system 200 may include a single user interface, although other examples are not so limited. For instance, in some examples, the composite system 200 may include a plurality of user interfaces. Each user interface provided in the composite system 200 may generally be configured to navigate to (e.g., for the display of information pertaining to) any component of the composite system, and each user interface provided in the composite system 200 may generally be configured to monitor and/or control (e.g., for the transmission of commands or control messages) any component of the composite system. Generally, the user interface(s) may provide access to each component of the control system. The component that displays the user interface may or may not include the composite controller. The user interface may be additionally or alternatively output by a computing device (e.g., the computing device 222 of FIGS. 2 and 3) associated with the production line control system. The computing device may be in communication with one or more of the components. For example, in instances in which one of the components includes the composite controller, the computing device may be in communication with the composite controller of such component. The computing device may receive control data, including control data indicated in the command or control data message, via such component. This control data may be represented in the user interface that is output by the computing device.

[0075] Additionally or alternatively, the computing device may be in communication with a cloud/edge server (e.g., the server 230 in FIG. 3) located remote from the premises housing the production line control system. In instances in which the cloud/edge server comprises the composite controller, the computing device may be in communication with the composite controller of the cloud/edge server. The computing device may receive control data, including control data indicated in the command or control data message, via the cloud/edge server. This control data may be represented in the user interface that is output by the computing device. The computing device may be located remote from the premises housing the production line control system, such as a production facility, or the computing device may be at the same premises as that housing the production line control system.

[0076] The user interface may comprise a production line element (e.g., the production line element 802 of FIG. 8) representing a production line associated with the components of the production line control system. The user interface may further comprise a plurality of system elements (e.g., the system elements 804 of FIG. 8). A system element of the plurality of system elements may represent a production line control system liquid dispensing system. For example, a first system element may represent a first production line control system or liquid dispensing system comprising a first melter and a second system element may represent a second production line control system or liquid dispensing system comprising a second melter. The production line element and the plurality of system elements may be arranged on the user interface to reflect the relative positions at an associated premises (e.g., production facility) of the production line and/or the liquid dispensing systems represented by the plurality of system elements. The user interface may comprise a composite state element (e.g., the composite status element 812 of FIG. 8) representing the composite operational status of the production line control system as described herein. The composite state element may, in examples, have a corresponding unique symbol or image according to the indicated the composite operational status of the system, such as is illustrated with a check mark (composite status element 812 of FIG. 8) indicating a positive composite operational status. In other examples, the composite state element could include a “X” or other symbol or image indicating a negative composite operational status. Additionally or alternatively, the composite state element may, in examples, be color-coded to represent the composite operational status of the production line control system, such as a colored border or colored text “Composite.”

[0077] At least one system element of the plurality of system elements may comprise an operation mode element (e.g., an operation mode element 1019 of FIG. 10) indicating an operation mode of the represented production line control system or liquid dispensing system. For example, an operation mode element may indicate that the represented component or liquid dispensing system is in a production mode, a setup mode, or a service mode. At least one system element of the plurality of system elements may comprise a fdl level element (e.g., a fdl level element 1034 of FIG. 10) indicating a fdl level associated with the represented production line control system or liquid dispensing system. The fdl level may be with respect to a fdl level of liquid in a melter unit of the liquid dispensing system, for example. A system element may be configured such that, upon activation, an interface element (e.g., a popup) is displayed. The interface element may indicate control data associated with the production line control system or liquid dispensing system represented by the system element. For example such control data may comprise a plurality of measured temperatures at various points within the production line control system or liquid dispensing system.

[0078] At step 610, a command (e.g., including, or in the form of, a control message) is transmitted (e.g., by the composite controller) to the master component. At step 612, the command (e.g., including, or in the form of, a control message) is transmitted (e.g., by the composite controller) that was transmitted to the master component may be likewise transmitted to the client component(s). The command transmitted to the master controller and the client component(s) may, in examples, include instructions for operating the master component and/or the client component(s), as described herein. In examples, the command may include an operating parameter of the production line control system or one or more components thereof. As described herein, the operating parameter may be set and modified by user input (e.g., via the user interface). Upon receipt of such user input, the command (in some cases, a modified command) may be transmitted (e g., by the composite controller) to the master component and/or client component(s), such as to operate the component(s) at operating parameter (in some cases, a modified operating parameter. After transmission of the command or modified command, the method flow of FIG. 6 may be repeated beginning with receipt of the operational status (e.g., an updated status) of the master component and/or the client component(s).

[0079] One of the components of the production line control line system may include the composite controller, and, in examples, may include a control panel (e.g., the panel 206) configured to display at least a portion of any control data indicated in the command.

Additionally or alternatively, a remote cloud/edge server (e.g., the server 230 of FIG. 3) associated with the production line control line system may implement the composite controller.

[0080] A computing device (e.g., the computing device 222 of FIGS. 2 and 3) may access, via the composite controller, any control data indicated in the command. The computing device may be located external to the premises housing the plurality of liquid dispensing system melter units or the computing device may be located at the same premises housing the production line control system. The computing device may comprise at least one of a personal computer (PC), a laptop computer, a mobile device, a tablet computer, or a smartphone. In examples, the computing device or HMI device may utilize a web browser of custom application for implementing or executing any of the features or processes described herein. [0081] In examples, the client component(s) may be configured to be transitioned between multiple modes, such as a production mode, a setup mode, and a service mode. In the production mode, a controller of the client component in the production mode may be configured to receive commands and/or control messages from the composite controller and operate the component in response to such commands and/or control messages as described herein. In the service mode, the controller of the client component in the service mode may be configured as “read-only,” such as by being configured to only receive commands and/or control messages from the composite controller without operating the component in response to the commands and/or control messages.

[0082] In some examples, it may become desirable to a user to quickly identify one of the components of the production line control system via the user interface. In some examples, the user interface may identify each of the components of the production line control system by name, photograph, or another unique identifier. For example, the control tiles displayed at the user interface may display such unique identifiers, with unique identifiers corresponding to respective ones of the components of the production line control system. It may also be desirable to identify a particular one of the components of the production line control system, such as by transmitting a command (e.g., via the composite controller) to a selected one of the components of the production line control system to emit an identifier, such as an audible identifier (e.g., emitted by a horn of the user-selected one of the components of the production line control system) and/or a visible identifier (e.g., emitted by a flashing indicator of the user-selected one of the components of the production line control system and/or emitted by a light tower of the user- selected one of the components of the production line control system, such as is illustrated for melter unit 402c having light tower 402d in FIG 4). [0083] FIG. 7 illustrates a data flow diagram of a decisional method 700 employed by the production line control system, in particular the backup master component.

[0084] Specifically, the method 700 may determine which controller of the several components of the production line control system should implement or execute the composite controller. The method 700 may, for example, be executed as a sub-routine of the method 600 of FIG. 6, as described herein.

[0085] At step 702, it may be determined (e.g., by the controller of the backup master component) if the master component’s controller has lost operative communication with the client component(s) and/or the backup master component, as described herein. If it is determined at step 702 that the master component’s controller has lost operative communication with the client component(s) and/or the backup master component (as represented by the “Yes” arrow extending away from step 702), in step 704a, the backup master component’s controller may be configured to implement or execute the composite controller, as described herein. Thereafter, in step 706, it may be determined (e.g., by the controller of the backup master component) if the master component’s controller has regained operative communication with the client component(s) and/or the backup master component, as described herein.

[0086] If it is determined at step 706 that the master component’s controller has regained operative communication with the client component(s) and/or the backup master component (as represented by the “Yes” arrow extending away from step 706), in step 708a, the master component’s controller may be configured to implement or execute the composite controller, as described herein. Thereafter, the master component’s controller may operate as the composite controller and proceed to effectuate the steps of method 600 in FIG. 6. If, however, it is determined at step 706 that the master component’s controller has not regained operative communication with the client component(s) and/or the backup master component (as represented by the “No” arrow extending away from step 706), in step 708b, the backup master component’s controller may be configured to implement or execute the composite controller, as described herein. Thereafter, the backup master component’s controller may operate as the composite controller and proceed to effectuate the steps of method 600 in FIG. 6. Additionally, the backup master component’s controller may continue to monitor the connection status of the master controller’s controller, such as by repeating step 706 (e.g., continuously or at predetermined intervals) until the master component’s controller regains operative connection with the client component(s) and/or the backup master component.

[0087] If, however, it is determined at step 702 that the master component’s controller has not lost operative communication with the client component(s) and/or the backup master component (as represented by the “No” arrow extending away from step 702), in step 704b, the master component’s controller may be configured to implement or execute (or continue to implement or execute) the composite controller as described herein. Thereafter, the master component’s controller may implement or execute the composite controller and proceed to effectuate the steps of method 600 in FIG. 6.

[0088] The backup master’s controller may be configured to repeat method 700 of FIG. 7 (e.g., continuously or at predetermined intervals) to generally ensure that the production line control system remains operative without unnecessary interruption.

[0089] FIG. 8 illustrates a user interface 800 that may be used in conjunction with the systems described herein. The user interface 800 may display a visual representation of a production line and associated systems that reflects the actual layout at the production facility (i.e., a premises). The user interface 800 may indicate various data relating to such systems. The user interface 800 may be implemented by a controller (e.g., controller 204 of FIGS. 2 and 3) and a panel (e.g., panel 206 of FIGS. 2 and 3) of one or more components (e.g., the melter units 202 of FIGS. 2 and 3) of the production line control system. The user interface 800 may be additionally or alternatively be implemented by a composite controller (e g., the composite controller 210 of FIG. 2) and a panel of the component comprising the composite controller (e.g., the melter unit 202e of FIG. 2). The user interface 800 may additionally or alternatively be implemented by a composite controller (e.g., the composite controller 232 of FIG. 3) at a server (e.g., the server 230 of FIG. 3). The user interface 800 may be additionally or alternatively be implemented by a computing device (e.g., the computing device 222 of FIGS. 2 and 3) in communication with the composite controller.

[0090] The user interface 800 may be associated with a production line (e.g., a production machine). A production line may comprise a production line to manufacture disposable hygiene products or assemble cardboard packaging, for example. The production line may be represented in the user interface 800 by a production line element 802. The user interface 800 may include a plurality of system elements 804a-f (referred to generically as a system element 804 or system elements 804). A system element 804 may be considered a “tile” of the user interface 804. Each tile or system element 804 may be associated with and represent a component of a production line control system (e.g., the production line control system 10 of FIG. 1) or other type of system. A component corresponding to a system element 804 may, in examples, be a melter unit, pattern control device, or similar component as described herein. The components corresponding to the system elements 804 may be associated with one another via a common composite controller as described herein. For example, the composite controller may be configured to be in operative communication with each component of the production line control system, and, in examples, the composite controller may operatively interconnect the components to one another such that information (e.g., control data) can be communicated therebetween.

[0091] A system element 804 may be labeled according to its function in the production line or by another type of designator. Each system element 804 may include an operation mode element 806 configured to indicate an operational mode or status of the corresponding component. For example, the operation mode element 806f for the system element 804f shown in FIG. 9 indicates that the corresponding system is in production mode. As another example, the operation mode element could indicate that the corresponding component is in setup mode or service mode. An operation mode element 806 may have a corresponding unique image according to the indicated operation mode, such as is illustrated for operation mode element 806f for System Name 06 814f (system element 804f shown in FIG. 9).

[0092] The system elements 804 and the production line element 802 are visually arranged on the user interface 800 according to (e.g. to reflect or to correspond with) the relative positions of the corresponding components and production line at the production facility. For example, a component represented by a system element 804 may be positioned at a particular point on the production line and this position at the production line is reflected in the placement of the system element 804 in the user interface 800 relative to the production line element 802. The relative positioning (and sizing) of the production line element 802 and the system elements 804 are not necessarily to scale.

[0093] The position of a system element 804 on the user interface may be adjusted. For example, a user may provide an input to the user interface 800 to adjust the position of a system element 804. Additionally or alternatively, the system implementing the user interface 800 may automatically adjust the positioning of a system element 804. As an example, when a new component or liquid dispensing system is installed at the production line, this component or liquid dispensing system may be automatically detected and inserted into the production architecture represented by the user interface 800. A system element 804 may be created in the user interface 800 that corresponds to the newly installed component or liquid dispensing system. The user (or a controller) then may position the system element 804 according to the actual position of the new component or liquid dispensing system relative to the production line and the other components. A user (or a controller) may similarly adjust the position of a system element 804 if the corresponding component is moved from one position on the production line to another position on the production line.

[0094] Each system element 804 may further include a system status element 808 to indicate the status of the associated system, such as a running status, an off status, or a fault status. In particular, a system status element 808 may be color-coded to represent the system status of the associated system. For example, the green-colored border for system status element 808f for System Name 06 (system element 804f shown in FIG. 9) may indicate that System Name 06 is running.

[0095] The system elements 804 may further comprise other elements, such as subsystem statuses and/or user-selectable data, such is illustrated in sub-system status elements 816f and data elements 818f (e.g., user-selectable data elements) of system element 804f shown in FIG. 9. In examples, the data elements 818f may show unique data for the component represented by system element 804f and may intuitively display up to ten or more different data points (e.g., temperatures or pressures of different zones or features, pump speeds, output). The particular data displayed by the data elements 818f may be selected by the user or auto-populated based upon user-defined display settings. [0096] The user interface 800 of FIG. 8 and other user interfaces contemplated herein may advantageously provide increased ease-of-use, accessibility, and/or control. For example, the user interface 800 of FIG. 8 shows a “status-at-a-glance” view of the composite operational status of the production line control system (e.g., via a composite status element 812), which provides an operator with a quick and comprehensive way to recognize the composite operational status of the production line control system (e.g., the status of all relevant components of the system that are used in determining the composite operation status as described herein). Additionally, by viewing the user interface 800 or by individually clicking or activating any of the components via the user interface 800 as described herein, the operator may view the operational status of each individual component or sub-component. Accessibility is increased by providing an intuitive means for the operator to view and quickly navigate to the user-interface screen of any component as described herein. Control is increased by providing a comprehensive means for the operator to control all of the components and sub-components (e g., heater and pump control) from a single set of controls (e g., via the control device). Further yet, in examples, the user interface 800 may permit recipes to be loaded to each of the components from a single, thereby providing a comprehensive and efficient means by which the operator can effectively control the production line control system. In examples, a recipe may be a collection of product-specific settings used to make periodic production runs of the same product with consistent output. A recipe may include selection of enabled external zones and their set point temperatures, pressure settings, pump selections, adhesive add-on, and/or the like. A composite recipe may be a master or central control used to (e.g., globally and/or simultaneously) to all connected components designated for production within the composite system. In examples, the composite recipe may contain product-specific settings for all such connected components or may load a common recipe name or number on each component where the product specific settings are stored locally within the component. The use of such composite recipes may eliminate the repetitive and otherwise time-consuming process of requiring an operator to individually access each component to load a recipe. Additionally or alternatively to the foregoing, the user interface 800 may provide a means for an operator to effectuate composite master controls, such as a set of one or more commands or control messages used to issue such commands or control messages (e.g., globally and/or simultaneously) to all connected components designated for production within the composite system. By way of non-limiting examples, such composite master controls include master heaters ON/OFF, temperature setback ON/OFF, pump release ON/OFF, and/or the like. The use of such composite master controls may eliminate the repetitive and otherwise time-consuming process of requiring an operator to individually access each component to turn ON/OFF a master control.

[0097] The system elements 804 may be interacted with or activated (e.g., clicked on) to access further information and functionality relating to the corresponding system. For example, activation of a system element 804 may cause a popup interface element to appear over the user interface 800, or a new, different user interface may be presented to access the further information and functionality. For example, FIG. 10 shows a user interface 1004 that is displayed after an operator has selected system element 804a of FIG. 8. The further information displayed upon activation of a system element 804 may include operating parameters for the corresponding component, current and/or past measured data for the corresponding component, and/or hardware configuration data for the corresponding component. The popup or new user interface may comprise additional user interface elements or “tiles” that correspond to various data categories or components of the component, such as a fill level monitoring tile 1034, a pump monitoring tile 1035, a pattern control or recipe tile 1036, and/or a temperature monitoring tile 1040 as illustrated in FIG. 10. For example, activation of the temperature monitoring tile 1040 may cause yet another popup or user interface to be shown that displays the temperature setpoint(s) and measured temperatures values for the system, such as is illustrated in FIG. 11. As another example, activation of an interface element for a particular melter unit of the system may cause another popup or user interface to be shown that displays various aspects of the hardware configuration of the melter unit, such as a number of hose outlets, flow throughput capacity, pump type, physical dimensions, and available control interfaces. A popup or new user interface may be closed to return back to the previous popup or user interface within the hierarchy, including the user interface 800 as it is currently shown in FIG. 8. The user interface 1004 and elements thereof shown in FIG. 10 are examples of such user interfaces, popups, tiles, or windows that may be integrated with the user interface 800.

[0098] FIG. 10 and FIG. 11 illustrate various aspects of a user-customizable graphical user interface 1004 output by the control device 410, such as via the screen 412 of the control device 410. While the user interface 1004 and associated features are generally discussed in relation to melter units, such disclosure is equally applicable to other components of the system 400, including patten control devices, applicators, dispensing modules, hoses, solid or semi-solid adhesive supply devices, or heaters disposed within such other components. Generally, the user interface 1004 is configured to display control data (e.g., operating parameters or status information) of the multiple melter units 402 and other components of the system 400. The user interface 1004 is further configured to enable a user to set or adjust various operating parameters of the melter units 402 and other components of the system 400. It will be understood that the specific parameters that may be displayed and/or controlled via the user interface 1004 will depend on the particular type of melter unit 402, the material to be dispensed, and/or the specific manufacturing protocols implemented in the given system 400. As examples, such parameters may include, but are not limited to, temperature of various components, pump rotation speed, volume of material, pressure, dispensing pattern, quantity of material dispensed, type of material dispensed, presence of a gas, operational status of a melter, geographical and distance information, specific permission information, and relative positionings of the melter units 402 and other components of the system 400 at a production facility. In an aspect, the user interface 1004 is configured to display, set, modify, communicate, and otherwise manipulate control data, such as the control data discussed herein.

[0099] The control device 410 may allow access to multiple modes of operation. For example, in a “Production” mode, certain parameters may be changed. Setpoints and modes of operation may be altered, while other system configurations may be prevented from being changed. In a “Setup” mode, the control device 410 may allow for simulation of the system, initial set up of parameters, verifying component functionality, and purging of the system. In a “Service” mode, the control device 410 may allow for maintenance of a melter unit 402 or other component (e.g., replacing pumps, filters, or other components).

[0100] The control device 410 may allow one or more users to monitor and/or change parameters of multiple melter units 402 or other components simultaneously. This may reduce the time necessary to monitor each individual melter unit 402 or other component separately. Additionally, the user may send commands to all melter units 402 or other components in the system 400 at the same time rather than have to individually modify parameters for each separate melter unit 402 or other component. [0101] The control device 410 may allow a user to compare individual melter units 402 to determine damage, defects, or other inconsistencies within the system 400. By allowing control of all melter units 402 in the system 400, a user may stop or pause one or more melter units 402 for any number of reasons (e.g., maintenance, overheating, reloading of material, etc.) and ensure that the remaining melter units 402 within the system 400 compensate for the stopped or paused melter. This may help maintain consistent production and reduce downtime.

[0102] As noted, the user interface 1004 is configured for user customization. For example, much of the status/parameter information and control functions are presented via a series of interactive interface elements referred to as “tiles.” The particular configuration as to which tiles are displayed on the user interface 1004, where they are displayed on the user interface 1004, and when they are displayed on the user interface 1004 may be determined, at least in part, by a user’s preference settings.

[0103] As shown in FIG. 10, the user interface 1004 may be divided into a status area 1030 and a dashboard area 1031. The dashboard area 1031 may generally be the area within which the aforementioned tiles are displayed and interacted.

[0104] With regard to the status area 1030, an element 1018 indicates a selected melter unit 402 or other component (in this case, “System Name 01”) for which various information and control functions are presented, at least in part, within the dashboard area 1031. The selected components indicated in the element may be selected from the various components represented in the user interface 800 shown in FIG. 8. Additionally or alternatively, the component indicated by the element 1018 may be selected via a drop down menu associated with the element 1018. An operation mode element 1019 indicates the operation mode of the selected component, such as Production, Setup, or Service. The operation mode of the selected component may be controlled via the operation mode element 1019. A composite state element 1012 may indicate a state of the composite system 400, which may also be controlled via the composite state element 1012. The status area 1030 may also include an interface element 1038 that may be activated to initiate various user functions. For example, a user may enter the user’s id and password to log into the system and load the user’s preference settings relating to user interface configuration.

[0105] The dashboard area 1031 is configured to display one or more tiles. A tile may display various information relating to the system 400, a selected component, and/or statuses/operating parameters of various sub-systems or functions of the selected component. A tile may additionally or alternatively enable various operating parameters or settings to be set or adjusted. Some tiles may be configured with multiple sub-tiles. Some tiles (including sub-tiles) may be configured to open other tiles or windows, which typically provide further information or access to additional settings or controls related to the initial tile. Via user preference settings, a user may customize various attributes of the dashboard area 1031 that are applied when the user is logged into the user interface 1004 and/or control device 410. For example, user preference settings may define which tiles are initially displayed in the dashboard area 1031. User preference settings may further define the initial placement of the tiles within the dashboard area 1031 and/or the relative sizes of the tiles. User preference settings may yet further define what actions or functions are performed when particular tiles or tile elements are activated or interacted with (e.g., clicked or pressed). A user may additionally or alternatively alter the arrangement or appearance of the tiles while the user interface 1004 is displayed, such as closing a tile, moving a tile (e.g., drag and drop), or minimizing a tile. A tile may also be positioned on top of another tile, in whole or in part. [0106] With continued reference to FIG. 10, the “System Name 01” component is selected. This may cause a fill level monitoring tile 1034, a pump monitoring tile 1035, a pattern control or recipe tile 1036, and a temperature monitoring tile 1040 to be displayed in the dashboard area. The fill level monitoring tile 1034 visually, as well as numerically, indicates the current fill level percentage (72%) of the adhesive reservoir associated with the “System Name 01” melter unit. A user may directly set or adjust the parameters indicated in the fill level monitoring tile 1034. The pump monitoring tile 1035 includes one or more pump sub-tiles 1039 each corresponding to a pump of the selected “System Name 01” melter unit. Each pump sub-tile

1039 indicates one or more of a name (e.g., “Pump 1,” “Pump 2”) of the corresponding pump and the current speed (rpm) of the pump. The pattern control or recipe tile 1036 may, upon activation, initiate loaded recipe or a dispensing pattern selection function. The loaded recipe or the dispensing pattern may be used by one or more components of the selected “System Name 01” melter unit to prepare or dispense adhesive or other liquid. The temperature monitoring tile

1040 generally indicates the temperatures of various portions of selected “System Name 01,” including an associated grid, reservoir, hose, and applicator. Such temperature points (e.g., temperature channels) each correspond to one of the temperature sub-tiles 1041 within the temperature monitoring tile 1040. Depending on the particular component or location at which the temperature is measured, the component’s status, and/or various display settings, a temperature sub-tile 1041 may indicate a current measured temperature and a name of the heater or other component. As a non-limiting example, FIG. 11 illustrates the temperature monitoring tile 1040 after being activated so as to now show additional information in the temperature subtiles 1041 for each portion of the component, such as a temperature setpoint, a current measured temperature, and a name of the portion (e.g., “Grid (Tl)”). [0107] Typically, the controller of each component of the production line control system may have a fixed Ethernet address determined by such controller. However, in other examples, the controller of each component of the production line control system may be assigned an Ethernet address (e.g., by the composite controller using Dynamic Host Configuration Protocol (DHCP)). Turning now to FIG. 12, the production line control system may include an automatic network switch 1220. The automatic network switch 1220 may be configured to operatively connect each component of the production line control system to one another over a composite network), such as by being connected to a network adapter 1210 (e.g., Wi-Fi). The automatic network switch 1220 may be further configured to mechanically (e.g., by a relay or switch) or electronically (e.g., by one or more integrated circuits) isolate a selected component from the composite network. This can be useful when an operator desires to operate one of the components in a non-composite mode, such as by reverting the Ethernet address of such component to its fixed address to avoid conflicts that could arise if the component remained connected to the composite network (e.g., resulting in unexpected and unpredictable operation).

[0108] As illustrated in FIG. 12, the automatic network switch 1220 may include a plurality of ports. By way of non-limiting example, the automatic network switch 1220 may include one or more of a first port configured to operatively connect the automatic network switch 1220 to other components (no connections to the first port shown in FIG. 12), a second port configured to operatively connect 1215 the automatic network switch 1220 to a network adapter 1210, a third port configured to operatively connect 1225 the automatic network switch 1220 to the composite network, a fourth port configured to operatively connect 1235 the automatic network switch 1220 to a controller and/or an operator interface of the client component 1230, and a fifth port configured to operatively connect 1245 the automatic network switch to other components. In examples, the automatic network switch 1220 may be configured to isolate a component of the production line control system from the composite network by disabling the third port, thereby allowing the operator interface of such component to operatively communicate with the controller of such component. Additionally or alternatively, the controller of such component may be configured to disable the third port via software control. In examples, the client component 1230 may be operatively connected 1255 to a USB Ethernet adapter 1250 or other components.

[0109] The following are a number of non-limiting EXAMPLES of aspects of the disclosure. One EXAMPLE includes: EXAMPLE 1A. A production line control system configured to monitor and/or control at least one dispensing device, the production line control system comprising: a plurality of components including a master component and at least one client component, wherein at least one of the master component and the at least one client component is configured to implement or execute a composite controller, the composite controller configured to be in operative communication with each of the plurality of components and configured to: receive, from a controller of the master component, an operational status of the master component; receive, from a controller of the at least one client component, an operational status of the at least one client component; determine a composite operational status of the production line control system based at least in part upon the operational status of the master component and the operational status of the at least one client component; generate a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) a component of the plurality of components and (b) user-selectable component data of the plurality of components; an indicator of the operational status of the master component; an indicator of the operational status of the at least one client component; and an indicator of the composite operational status of the production line control system; transmit a command to the controller of the master component; and transmit the command to the controller of the at least one client component. EXAMPLE IB. A production line control system configured to monitor and/or control at least one dispensing device, the production line control system comprising: a plurality of components including a master component including a controller, at least one client component including a controller, and a backup master component including a controller, wherein the controller of the master component and the controller of the backup master component are both configured to be in operative communication with each of the plurality of components, wherein the controller of the master component is configured to implement or execute a composite controller, wherein the controller of the backup master component is configured to: determine if the controller of the master component has lost operative communication with the at least one client component and the backup master component; and if the controller of the backup master component determines that the controller of the master component has lost operative communication with the at least one client component and the backup master component for a predetermined minimum amount of time, implement or execute the composite controller, and wherein the composite controller is configured to: receive, from the controller of the master component, an operational status of the master component; receive, from the controller of the at least one client component, an operational status of the at least one client component; receive, from the controller of the backup master component, an operational status of the backup master component; determine a composite operational status of the production line control system based at least in part upon the operational status of the master component, the operational status of the at least one client component, and the operational status of the backup master component; generate a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) a component of the plurality of components and (b) user-selectable component data of the plurality of components; an indicator of the operational status of the master component; an indicator of the operational status of the at least one client component; an indicator of the operational status of the backup master component; and an indicator of the composite operational status of the production line control system; transmit a command to the controller of the master component; transmit the command to the controller of the at least one client component; and transmit the command to the controller of the backup master component. EXAMPLE 1C. A method of transmitting a command to a plurality of components of a production line control system including a master component and at least one client component, the method comprising: receiving, at a composite controller implemented or executed by at least one of the master component and the at least one client component, an operational status of the master component from a controller of the master component; receiving, at the composite controller, an operational status of the at least one client component from a controller of the client component; determining a composite operational status of the production line control system based at least in part upon the operational status of the master component and the operational status of the at least one client component; generating a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) a component of the production line control system including the master component and the at least one client component and (b) user-selectable component data of the master component or the at least one client component; an indicator of the operational status of the master component; an indicator of the operational status of the at least one client component; and an indicator of the composite operational status of the production line control system; transmitting a command to the controller of the master component; and transmitting the command to the controller of the at least one client component.

[0110] All combinations in this paragraph and the previous paragraph (including the removal or addition of features or steps) are contemplated in a manner that is consistent with the other portions of the present disclosure. For avoidance of doubt, the above-noted EXAMPLES 1A, IB, and 1C may further include any one or a combination of more than one of the following EXAMPLES: 2. The production line control system of any EXAMPLE herein, wherein the composite controller is implemented or executed by a human-machine interaction (HMI) device. EXAMPLE 3. The production line control system of any EXAMPLE herein, wherein the controller of the master component is configured to implement or execute the composite controller. EXAMPLE 4. The production line control system of any EXAMPLE herein, wherein a cloud server located remote from a premises housing the production line control system is configured to implement or execute the composite controller. EXAMPLE 5. The production line control system of any EXAMPLE herein, wherein the master component is a melter unit or a pattern controller. EXAMPLE 6. The production line control system of any EXAMPLE herein, wherein the at least one client component is a melter unit or a pattern controller. EXAMPLE 7. The production line control system of any EXAMPLE herein, wherein the master component is a melter unit and the at least one client component is a pattern controller. EXAMPLE 8. The production line control system of any EXAMPLE herein, wherein the at least one client component includes a plurality of client components. EXAMPLE 9. The production line control system of EXAMPLE 8, wherein one of the plurality of components is a melter unit and another of the plurality of components is of a type other than a melter unit (e.g., a pattern controller). EXAMPLE 10. The production line control system of EXAMPLE 8, wherein the composite controller is configured to determine the composite operational status of the production line control system based at least in part upon a hierarchy of the operational status of the master component and the operational status of the at least one client component. EXAMPLE 11. The production line control system of EXAMPLE 10, wherein the hierarchy is determined based on pre-defined user hierarchy settings. EXAMPLE 12. The production line control system of EXAMPLE 10, wherein the composite controller is further configured to determine if any component of the plurality of components is not required for production. EXAMPLE 13. The production line control system of EXAMPLE 12, wherein the composite controller is further configured to ignore the operational status of any component of the plurality of components that is not required for production when determining the composite operational status of the production line control system. EXAMPLE 14. The production line control system of EXAMPLE 12, wherein the composite controller is further configured to output the user interface displaying an indicator of an operational status of each component of the plurality of components that is required for production. EXAMPLE 15. The production line control system of EXAMPLE 12, wherein the composite controller is further configured to output the user interface displaying an indicator of an operational status of the component of the plurality of components that is not required for production. EXAMPLE 16. The production line control system of any EXAMPLE herein, wherein the composite controller is further configured to output the user interface displaying a production line element representing a production line associated with the plurality of components. EXAMPLE 17. The production line control system of EXAMPLE 16, wherein the production line element and the plurality of control tiles are arranged on the user interface to reflect relative positions at an associated premises of the production line and the plurality of components represented by the plurality of control tiles. EXAMPLE 18. The production line control system of any EXAMPLE herein, wherein each of the plurality of control tiles includes a unique identifier corresponding to a respective one of the plurality of components. EXAMPLE 19. The production line control system of any EXAMPLE herein, wherein the composite controller is further configured to transmit a command to a user- selected one of the plurality of components to emit an identifier. EXAMPLE 20. The production line control system of EXAMPLE 19, wherein the identifier is an audible identifier. EXAMPLE 21. The production line control system of EXAMPLE 20, wherein the audible identifier is configured to be emitted by a horn of the user-selected one of the plurality of components. EXAMPLE 22. The production line control system of EXAMPLE 19, wherein the identifier is a visible identifier. EXAMPLE 23. The production line control system of EXAMPLE 22, wherein the visible identifier is configured to be emitted by a flashing indicator of the user-selected one of the plurality of components. EXAMPLE 24. The production line control system of EXAMPLE 22, wherein the visible identifier is configured to be emitted by a light tower of the user-selected one of the plurality of components. EXAMPLE 25. The production line control system of any EXAMPLE herein, wherein the operational status of the at least one client component includes at least one of an operation mode of the at least one client component or a status of an operating parameter associated with the at least one client component. EXAMPLE 26. The production line control system of EXAMPLE 25, wherein the operational status of the at least one client component includes an operation mode selected from the group consisting of a production mode, a setup mode, and a service mode. EXAMPLE 27. The production line control system of any EXAMPLE herein, wherein the composite controller is configured to output the user interface displaying the plurality of control tiles based on pre-defined user display settings. EXAMPLE 28. The production line control system of EXAMPLE 27, wherein at least one of a location of a control tile of the plurality of control tiles and a size of a control tile of the plurality of control tiles is based on the pre-defined user display settings. EXAMPLE 29. The production line control system of any EXAMPLE herein, wherein the command includes an operating parameter. EXAMPLE 30. The production line control system of EXAMPLE 29, wherein the plurality of control tiles includes a control tile configured to display an operating parameter status associated with the operating parameter. EXAMPLE 31. The production line control system of EXAMPLE 29, wherein the plurality of control tiles includes a control tile configured to receive a user input to modify the operating parameter. EXAMPLE 32. The production line control system of EXAMPLE 31, wherein the composite controller is further configured, upon receipt of the user input to modify the operating parameter, to: transmit a modified command to at least one of the master component and the controller of the at least one client component, wherein the modified command includes instructions for operating the at least one of the master component and the controller of the at least one client component to which the modified command is transmitted to operate at the modified operating parameter; and receive an updated operational status from the at least one of the master component and the controller of the at least one client component to which the modified command is transmitted. EXAMPLE 33. The production line control system of any EXAMPLE herein, wherein the command comprises control data relating to an operating parameter of the master component or the at least one client component, the operating parameter comprising at least one of a temperature setpoint, a temperature control loop setting, a control loop type, a pump speed, a pump motor speed, a heater duty cycle, or an applicator cycle rate. EXAMPLE 34. The production line control system of any EXAMPLE herein, wherein the command comprises control data relating to data measured by the master component or the at least one client component, the data comprising at least one of a liquid temperature, a liquid flow rate, a liquid flow volume, or a liquid pressure. EXAMPLE 35. The production line control system of any EXAMPLE herein, wherein the command comprises control data relating to hardware configuration data for the master component or the at least one client component, the hardware configuration data comprising at least one of a number of pumps, a pump type, a liquid holding capacity, a number of hose outlets, a power capacity, a number of control interfaces, a unit weight, unit external dimensions, a flow throughput, or a melt rate. EXAMPLE 36. The production line control system of any EXAMPLE herein, wherein the at least one client component is configured to be transitioned between (a) a production mode in which the controller of the at least one client component is configured to receive the command and operate the at least one client component in response to the command and (b) a service mode in which the controller of the at least one client component is configured to only receive the command without operating the at least one client component in response to the command. EXAMPLE 37. The production line control system of any EXAMPLE herein, wherein the plurality of components includes a backup master component. EXAMPLE 38. The production line control system of EXAMPLE 37, wherein the backup master component includes a controller configured to be in operative communication with each of the plurality of components. EXAMPLE 39. The production line control system of EXAMPLE 38, wherein the controller of the backup master component is configured to: determine if a controller of the master component has lost operative communication with the at least one client component and the backup master component; and if the controller of the backup master component determines that the controller of the master component has lost operative communication with the at least one client component and the backup master component for a predetermined minimum amount of time, implement or execute the composite controller. EXAMPLE 40. The production line control system of EXAMPLE 39, wherein the predetermined minimum amount of time is about five seconds. EXAMPLE 41. The production line control system of EXAMPLE 39, wherein if the controller of the backup master component determines that the controller of the master component has lost operative communication with the at least one client component and the backup master component for the predetermined minimum amount of time, the controller of the backup master component is further configured to: monitor if the controller of the master component regains operative communication with the at least one client component and the backup master component; and if the controller of the backup master component determines that the controller of the master component regains operative communication with the at least one client component and the backup master component, the controller of the master component is configured to implement or execute the composite controller. EXAMPLE 42. The production line control system of EXAMPLE 39, wherein, if the controller of the backup master component determines that the controller of the master component has not lost operative communication with the at least one client component and the backup master component for the predetermined minimum amount of time: the controller of the master component is configured to implement or execute the composite controller; and the controller of the backup master component is configured to receive the composite operational status of the production line control system from the composite controller. EXAMPLE 43. The production line control system of any EXAMPLE herein, wherein the controller of the at least one client component has a fixed Ethernet address determined by the controller of the at least one client component. EXAMPLE 44. The production line control system of any EXAMPLE herein, wherein the composite controller is further configured to assign an Ethernet address for the controller of the at least one client component EXAMPLE 45. The production line control system of EXAMPLE 44, further comprising an automatic network switch configured to operatively connect each of the plurality of components to one another over a composite network. EXAMPLE 46. The production line control system of EXAMPLE 45, wherein the automatic network switch is configured to operatively connect each of the plurality of components to one another over the composite network using Dynamic Host Configuration Protocol (DHCP). EXAMPLE 47. The production line control system of EXAMPLE 45, wherein the automatic network switch is configured to mechanically isolate the at least one client component from the composite network. EXAMPLE 48. The production line control system of EXAMPLE 45, wherein the automatic network switch includes: a first port configured to operatively connect the automatic network switch to a network adapter; a second port configured to operatively connect the automatic network switch to the composite network; and a third port configured to operatively connect the automatic network switch to at least one of the controller and an operator interface of the at least one client component. EXAMPLE 49. The production line control system of EXAMPLE 48, wherein the automatic network switch is configured to electronically isolate the at least one client component from the composite network by disabling the third port, thereby allowing the operator interface of the at least one client component to operatively communicate with the controller of the at least one client component. EXAMPLE 50. The production line control system of EXAMPLE 48, wherein the controller of the at least one client component is configured to disable the third port via software control.

[0111] One skilled in the art will appreciate that the systems and methods disclosed herein may be implemented via a computing device that may comprise, but are not limited to, one or more processors, a system memory, and a system bus that couples various system components including the processor to the system memory. In the case of multiple processors, the system may utilize parallel computing. [0112] For purposes of illustration, application programs and other executable program components such as the operating system are illustrated herein as discrete blocks, although it is recognized that such programs and components reside at various times in different storage components of the computing device, and are executed by the data processor(s) of the computer. An implementation of service software may be stored on or transmitted across some form of computer readable media. Any of the disclosed methods may be performed by computer readable instructions embodied on computer readable media. Computer readable media may be any available media that may be accessed by a computer. By way of example and not meant to be limiting, computer readable media may comprise “computer storage media” and “communications media.” “Computer storage media” comprise volatile and non-volatile, removable and non-removable media implemented in any methods or technology for storage of information such as computer readable instructions, data structures, program modules, or other data. Exemplary computer storage media comprises, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which may be used to store the desired information and which may be accessed by a computer. Application programs and the like and/or storage media may be implemented, at least in part, at a remote system.

[0113] Aspects of the disclosure may be implemented in any type of computing devices, such as, e g., a desktop computer, personal computer, a laptop/mobile computer, a personal data assistant (PDA), a mobile phone, a tablet computer, cloud computing device, and the like, with wired/wireless communications capabilities via the communication channels. [0114] Aspects of the disclosure may include communication channels that may be any type of wired or wireless electronic communications network, such as, e.g., a wired/wireless local area network (LAN), a wired/wireless personal area network (PAN), a wired/wireless home area network (HAN), a wired/wireless wide area network (WAN), a campus network, a metropolitan network, an enterprise private network, a virtual private network (VPN), an internetwork, a backbone network (BBN), a global area network (GAN), the Internet, an intranet, an extranet, an overlay network, Near field communication (NFC), a cellular telephone network, a Personal Communications Service (PCS), using known protocols such as the Global System for Mobile Communications (GSM), CDMA (Code-Division Multiple Access), GSM/EDGE and UMTS/HSPA network technologies, Long Term Evolution (LTE), 5G (5th generation mobile networks or 5th generation wireless systems), WiMAX, HSPA+, W-CDMA (Wideband Code- Division Multiple Access), CDMA2000 (also known as C2K or IMT Multi-Carrier (IMT-MC)), Wireless Fidelity (Wi-Fi), Bluetooth, and/or the like, and/or a combination of two or more thereof. The NFC standards cover communications protocols and data exchange formats, and are based on existing radio-frequency identification (RFID) standards including ISO/IEC 14443 and FeliCa. The standards include ISO/IEC 18092[3] and those defined by the NFC Forum.

[0115] It should also be noted that the software implementations of the disclosure as described herein are optionally stored on a tangible storage medium, such as: a magnetic medium such as a disk or tape; a magneto-optical or optical medium such as a disk; or a solid state medium such as a memory card or other package that houses one or more read-only (nonvolatile) memories, random access memories, or other re-writable (volatile) memories. A digital file attachment to email or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium, as listed herein and including art-recognized equivalents and successor media, in which the software implementations herein are stored.

[0116] Additionally, the various aspects of the disclosure may be implemented in a non-generic computer implementation. Moreover, the various aspects of the disclosure set forth herein improve the functioning of the system as is apparent from the disclosure hereof. Furthermore, the various aspects of the disclosure involve computer hardware that it specifically programmed to solve the complex problem addressed by the disclosure. Accordingly, the various aspects of the disclosure improve the functioning of the system overall in its specific implementation to perform the process set forth by the disclosure and as defined by the claims.

[0117] Aspects of the disclosure may include a server executing an instance of an application or software configured to accept requests from a client and giving responses accordingly. The server may run on any computer including dedicated computers. The computer may include at least one processing element, typically a central processing unit (CPU), and some form of memory. The processing element may carry out arithmetic and logic operations, and a sequencing and control unit may change the order of operations in response to stored information. The server may include peripheral devices that may allow information to be retrieved from an external source, and the result of operations saved and retrieved. The server may operate within a client-server architecture. The server may perform some tasks on behalf of clients. The clients may connect to the server through the network on a communication channel as defined herein. The server may use memory with error detection and correction, redundant disks, redundant power supplies and so on. [0118] As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0119] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.

[0120] It will be apparent to those skilled in the art that various modifications and variations may be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.

Claims

What is claimed is:

1. A production line control system configured to monitor and/or control at least one dispensing device, the production line control system comprising: a plurality of components including a master component and at least one client component, wherein at least one of the master component and the at least one client component is configured to implement or execute a composite controller, the composite controller configured to be in operative communication with each of the plurality of components and configured to: receive, from a controller of the master component, an operational status of the master component; receive, from a controller of the at least one client component, an operational status of the at least one client component; determine a composite operational status of the production line control system based at least in part upon the operational status of the master component and the operational status of the at least one client component; generate a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) a component of the plurality of components and (b) user- selectable component data of the plurality of components; an indicator of the operational status of the master component; an indicator of the operational status of the at least one client component; and an indicator of the composite operational status of the production line control system; transmit a command to the controller of the master component; and transmit the command to the controller of the at least one client component.

2. The production line control system of claim 1, wherein the controller of the master component is configured to implement or execute the composite controller.

3. The production line control system of claim 1, wherein the at least one of the master component and the at least one client component configured to implement or execute the composite controller is determined based upon a predetermined hierarchical identifier.

4. The production line control system of claim 1, wherein the master component is a melter unit or a pattern controller and the at least one client component is a melter unit or a pattern controller.

5. The production line control system of claim 1, wherein the at least one client component includes a plurality of client components.

6. The production line control system of claim 5, wherein one of the plurality of components is a melter unit and another of the plurality of components is a pattern controller.

7. The production line control system of claim 5, wherein the composite controller is configured to determine the composite operational status of the production line control system based at least in part upon a hierarchy of the operational status of the master component and the operational statuses of the plurality of client components.

8. The production line control system of claim 7, wherein the hierarchy is determined based on pre-defined user hierarchy settings.

9. The production line control system of claim 7, wherein the composite controller is further configured to determine if any component of the plurality of components is not required for production.

10. The production line control system of claim 9, wherein the composite controller is further configured to ignore the operational status of any component of the plurality of components that is not required for production when determining the composite operational status of the production line control system.

11. The production line control system of claim 1, wherein the command includes an operating parameter.

12. The production line control system of claim 11, wherein the plurality of control tiles includes a control tile configured to receive a user input to modify the operating parameter.

13. The production line control system of claim 12, wherein the composite controller is further configured, upon receipt of the user input to modify the operating parameter, to: transmit a modified command to at least one of the controller of the master component and the controller of the at least one client component, wherein the modified command includes instructions for operating the at least one of the master component and the at least one client component to which the modified command is transmitted to operate at the modified operating parameter; and receive an updated operational status from the controller of the at least one of the master component and the controller of the at least one client component to which the modified command is transmitted.

14. The production line control system of claim 1, wherein the at least one client component is configured to be transitioned between (a) a production mode in which the controller of the at least one client component is configured to receive the command and operate the at least one client component in response to the command and (b) a service mode in which the controller of the at least one client component is configured to only receive the command without operating the at least one client component in response to the command.

15. The production line control system of claim 1 , wherein the composite controller is further configured to assign an Ethernet address for the controller of the at least one client component.

16. The production line control system of claim 15, further comprising an automatic network switch configured to operatively connect each of the plurality of components to one another over a composite network.

17. The production line control system of claim 16, wherein the automatic network switch includes: a first port configured to operatively connect the automatic network switch to a network adapter; a second port configured to operatively connect the automatic network switch to the composite network; and a third port configured to operatively connect the automatic network switch to at least one of the controller of the at least one client component and an operator interface of the at least one client component.

18. The production line control system of claim 17, wherein the automatic network switch is configured to electronically isolate the at least one client component from the composite network by disabling the third port, thereby allowing the operator interface of the at least one client component to operatively communicate with the controller of the at least one client component.

19. A production line control system configured to monitor and/or control at least one dispensing device, the production line control system comprising:

'll a plurality of components including a master component including a controller, at least one client component including a controller, and a backup master component including a controller, wherein the controller of the master component and the controller of the backup master component are both configured to be in operative communication with each of the plurality of components, wherein the controller of the master component is configured to implement or execute a composite controller, wherein the controller of the backup master component is configured to: determine if the controller of the master component has lost operative communication with the at least one client component and the backup master component; and if the controller of the backup master component determines that the controller of the master component has lost operative communication with the at least one client component and the backup master component for a predetermined minimum amount of time, implement or execute the composite controller, and wherein the composite controller is configured to: receive, from the controller of the master component, an operational status of the master component; receive, from the controller of the at least one client component, an operational status of the at least one client component; receive, from the controller of the backup master component, an operational status of the backup master component; determine a composite operational status of the production line control system based at least in part upon the operational status of the master component, the operational status of the at least one client component, and the operational status of the backup master component; generate a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) a component of the plurality of components and (b) user- selectable component data of the plurality of components; an indicator of the operational status of the master component; an indicator of the operational status of the at least one client component; an indicator of the operational status of the backup master component; and an indicator of the composite operational status of the production line control system; transmit a command to the controller of the master component; transmit the command to the controller of the at least one client component; and transmit the command to the controller of the backup master component.

20. A method of transmitting a command to a plurality of components of a production line control system including a master component and at least one client component, the method comprising: receiving, at a composite controller implemented or executed by at least one of the master component and the at least one client component, an operational status of the master component from a controller of the master component; receiving, at the composite controller, an operational status of the at least one client component from a controller of the client component; determining a composite operational status of the production line control system based at least in part upon the operational status of the master component and the operational status of the at least one client component; generating a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) a component of the production line control system including the master component and the at least one client component and (b) user-selectable component data of the master component or the at least one client component; an indicator of the operational status of the master component; an indicator of the operational status of the at least one client component; and an indicator of the composite operational status of the production line control system; transmitting a command to the controller of the master component; and transmitting the command to the controller of the at least one client component.