Classifications

• • C—CHEMISTRY; METALLURGY
  • C03—GLASS; MINERAL OR SLAG WOOL
  • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
  • C03B9/00—Blowing glass; Production of hollow glass articles
  • C03B9/30—Details of blowing glass; Use of materials for the moulds
  • C03B9/40—Gearing or controlling mechanisms specially adapted for glass-blowing machines
  • C03B9/41—Electric or electronic systems

Definitions

• the invention relates generally to controllers for controlling the cyclical operation of a plurality of machine components. More specifically, the invention relates to computer based timing and control of the plurality of components in each section of a multi-section glassware forming machine. Description of the Prior Art
• Electronic timing or control systems are well known for the control of a plurality of components of a machine.
• the components are arranged in a plurality of identical sections, each operating independently of the others in predetermined phase relationship relative to the machine cycle.
• Prior art electronic control systems have controlled the operation of such sections as a unit and have consequently required use of a single central processing unit (CPU) or supervisory controller connected in hierarchical fashion to a plurality of section controllers.
• CPU central processing unit
• supervisory controller connected in hierarchical fashion to a plurality of section controllers.
• a disadvantage of such systems is that a malfunction of the central controller of the hierarchy prevents operation of any subordinate section controllers.
• An example of a multi-section machine of this type is the well-known individual section (IS) glassware forming machine.
• Electronic timing systems for glassware forming machines have been used for many years in place of mechanical, rotating timing drums.
• the old timing drums control the actuation of the various components within each section of the machine by actuating associated pneumatic valves with cams placed in circumferential grooves on the drum surface.
• Electronic timing systems replaced the rotating drum and cams with a solenoid actuated valve block (such as that disclosed in U.S. Patent No. 3,918,489 assigned to the assignee of the present invention) and control means for actuating selected valves at predetermined times in a predetermined sequence relative to a machine cycle reference point.
• Timing settings of the various components may be adjusted during machine operation.
• Some prior art IS machine electronic timing systems use timing pulse generators and counters to count pulses occurring during the machine cycle and compare the current count to preset counts to determine when each component or machine event should be actuated (for example, U.S. Patent No. 3,762,907).
• Other prior art electronic timing systems use similar count comparisons, but store the preset component timing settings (or machine events) in a core memory (for example, U.S. Patent No. 3,974,432).
• Each device disclosed in these two prior art patents serves to control actuation of all section components within the machine but does not provide for independent control of each section.
• U.S. Patent No. 4,152,134 Another type of programmable prior art controller is disclosed in U.S. Patent No. 4,152,134. This device is limited because it requires a central, machine supervisory computer to load control program and timing data into individual section computers. A malfunction in the machine supervisory computer would affect efficient operation of the sections of the machine. Yet another programmable controller is disclosed in U.S. Patent No. 4,247,317 which shows one way to store event timing data in a random access memory and means to alter same. This device uses a central console to control the relative timing of each section which effectively ties all section computer-memory controllers together into one hierarchical machine control system incapable of truly independent section operation.
• U.K. Patent Specification No. 1,594,532 assigned to the assignee of the present invention, discloses a prior art electronic control system which utilizes independent, asynchronous clock signals which are produced at a rate independent of the speed of the glassware forming machine.
• the system disclosed is also for the control of a machine rather than a section.
• U.S. Patent No. 3,877,915 and Re. No. 29,188 assigned to the assignee of the present invention.
• U.K. Patent GB 2,022,870B discloses a control system with one memory controller controlling each section of a machine. Even if this memory controller is implemented by a microcomputer (as is disclosed in the patent) the microcomputer merely emulates the memory controller's function and the necessary result is a simplistic cycling of the memory controller through a predetermined sequence of steps. There is no means disclosed for enabling modification of this predetermined sequence of steps at the section level in response to operator control.
• auxiliary function controls include, for example, controls for drive systems (controlling feeders, shears, gob distributors, conveyors, ware transfer devices, etc.), alarms (to signal warnings or malfunctions), shear spray (to lubricate and cool gob shears), cullet water and equipment, stackers (for lehr loading), surface coating equipment, etc.
• the operation of these auxiliary functions is somewhat related to the operation of the sections of the machine although each section can operate independently of the auxiliary functions.
• Aforementioned U.S. Patent No. 4,152,134 discloses the auxiliary function of selective bottle rejection.
• a control system to enable individual section independent control while also enabling isolated data communication between selected independent section controllers and selected peripheral data input/output units including auxiliary function devices.
• a computer controlled timing system for controlling the actuation of a plurality of components of each section of a machine in accordance with a predetermined control program and selected timing data, said machine including a plurality of said sections each independently operable in phased relationship within the cycle of operation of said machine, said system for enabling the simultaneous and independent operation of said plurality of sections, said system comprising: a plurality of local computer means, each respectively associated with one of said sections, each of said local computer means having non-volatile storage means containing said predetermined control program and for containing said selected timing data therein for controlling the operation of its respective section independently of any other one of said sections; a plurality of interface means each interposed respectively between one of said local computer means and its associated section
• control system further comprises: a) a plurality of local computer means, each respectively associated with one of said sections, each of said local computer means comprising: an unalterable program storage means for storing said predetermined control program; a non-volatile setting storage means for storing said selected timing, data; first and second independent communication ports for enabling interactive data communication between said local computer means and means connected to either of said ports; b) a global terminal means operatively connected to a machine supervisory computer means; c) a machine supervisory computer means operatively connected to said first communication ports and said global terminal means for selectively connecting said global terminal means to a selected one of said first communication ports, said machine supervisory computer not inhibiting the independent operation of said plurality of sections; d) a plurality of interface means each interposed respectively between each of said local computer means and its associated section for actuating the components of said section in accordance with said predetermined control program and said selected timing data.
• Figure 1 shows a schematic block diagram of one embodiment of the invention installed for control of a multi-section glassware forming machine
• Figure 2 shows a more detailed schematic block diagram of a portion of Figure 1;
• Figure 3 is a diagrammatic view of the local terminal shown in Figure 1 ;
• Figure 4 is diagrammatic view of the machine terminal shown in Figure 1;
• Figure 5 is a more detailed schematic of the multiplexer shown in Figure 1;
• Figure 6 shows a schematic block diagram of an embodiment of the invention utilizing a global control terminal;
• FIG. 7 is a diagrammatic representation of three operator control panels. DESCRIPTION OF THE PREFERRED EMBODIMENT
• a control system 10 comprising a plurality of independent, individual stand alone section controllers (SASCON) or local computers 12b-12n each one of which includes identical hardware components although being capable of containing unique software.
• SASCON stand alone section controllers
• Each local computer 12 is assigned to a different section of an n-section multi-section machine, for example, a glassware I.S. forming machine 14.
• Timing pulse generator 15 provides synchronizing pulses to each local computer 12. The phased operation of each section is determined by the program within each local computer which basically offsets its respec-tive starting point a predetermined amount from a synchronizing pulse.
• a stand alone machine controller (SAMCON) or local computer "O" may be used to control auxiliary machine processes.
• a glassware forming machine these processes could be, for example, shear spray, cullet water and equipment, stacker, surface coating, alarms, drive systems for a feeder, shears, gob distributor conveyor, ware transfer devices etc.
• Local computer "O" is identical to all other local computers 12 from a hardware point of view and is therefore designated by the numeral 12a.
• the output of each local computer 12 is connected to a valve block 16 which serves as the actuation interface for actuating the various valves associated with the plurality of mechanical components in each corresponding individual section 18.
• the output of local computer 12a for controlling all auxiliary machines processes is connected by an actuation interface 20 to various auxiliary process actuators 22.
• a single local computer 12a may be used to control a plurality of auxiliary process actuators 22.
• one actuator could be associated with a ware transfer device, another could be associated with a gob distributor, etc.
• Each local computer 12 is further provided with two data communications ports: terminal port 61 and tape port 62. Each port 61 and 62 of each local computer 12 is connected to multiplexer 63 which is in turn connected to machine terminal 64 and tape unit 65. Plug 66 on each local computer 12 is a port to which a local or hand-held terminal 60 may be selectively connected. As will be discussed below, selected control data or timing setting data from any chosen local computer may be entered or displayed either at machine terminal 64 or hand-held terminal 60. If desired, several operators could control several sections simultaneously by each operator using his own hand-held terminal 60. As shown in Fig. 2, each local computer 12 includes a fixed, unalterable read only memory 50 and a non-volatile random access memory 52.
• ROM 50 comprises preprogrammed ROM chips (PROMs) for storing a predetermined control program to control the operation of each individual local computer 12 in accordance with timing settings or data which may be entered into RAM 52.
• PROMs preprogrammed ROM chips
• Each local computer 12 may have different control programs stored in its ROM 50 depending on the function to be performed.
• the control program stored in the local computer 12a associated with the auxiliary functions may be different from that stored in the local computers 12b-12n.
• the timing data in RAM 52 may be preprogrammed or may be entered by a machine operator through hand-held local terminal 60 or machine terminal 64.
• RAM 52 is non-volatile and may be connected to a battery back-up pack (not shown) to assure that the data in RAM 52 is not lost in the event of inadvertent power failure.
• Each local computer 12 also includes a central processing unit 54 and data communications interfaces 56 and 58 interconnecting CPU 54 to local ports 61 and 62, respectively. While ports 61 and 62 are is shown in Figure 1 as being connected to multiplexer 63 thi3 is not necessary for the operation of the preferred embodiment. Since one advantage of the invention is its flexibility and interchangeability of components, all local computers 12 are identical from a hardware point of view and are, in practice, constructed with both ports 61 and 62. However, only port 61 and plug 66 need be used since data input and output can be accomplished through hand-held terminal 60. The machine terminal 64 is nevertheless used in the preferred embodiment to provide the operator with a convenient, centrally located access point for all sections.
• Each local computer 12 also includes a non-volatile random access memory 69 for storing machine data representative of the particular machine with which the respective section of the local computer 12 is associated.
• Machine data may be considered superimposed on timing setting data and depends on the particular installation and user and may be, for example, data specific to the operation of a particular machine such as the number of sections, number of gobs or other peculiarities of machine operations.
• Machine data also includes set-up data such as assigning particular actuator valves to specific computer output drivers. The invention thus permits the flexibility to assign different drivers to different valves in the event any driven output becomes defective.
• Local control panels 67 and 68 are mounted on each individual section 18, one on the blank side of the machine and one on the blow side. Each control panel provides local operator control of various functions as is explained below with reference to Figure 8.
• each local computer 12 was chosen to be a Z-80 microcomputer with a 20K ROM, a 2K non-volatile timing data and media storage and a 1K RAM.
• I computer terminal 60 is shown in Figure 3.
• the basic structure of such a local terminal is a conventional unit available from many sources although the invention includes the unique functions to which the various keys are assigned.
• the particular local terminal 60 shown in Figure 3 includes keypad 70 having three groups of keys: the timing group comprising functions keys 71 - 75; the data entry group comprising the digits and keys 76 and 77; and the menu group comprising keys 78 - 80.
• Terminal 60 also includes LED display 81 (two rows, sixteen characters each).
• a sample display on local terminal 60 is shown in Figure 3 to include character groups 82 - 86.
• Group 82 represents the number of the event chosen by the operator for display.
• Group 83 comprises either an "X" or an "O" to indicate whether the "off" timing setting or the "on” timing setting, respectively, will be changed by the entry of data. The operator may alternately select either one of these characters by using key 72.
• Group 84 represents the name of the event (either in full or abbreviated form). This name appears automatically as a function of the number of the event identified by group 82.
• Group 85 represents the "on” time in degrees at which the particular event is actuated.
• group 86 represents the "off" time at which that event is deactivated.
• the "on” and “off” times are automatically displayed to represent the then current values associated with the particular chosen event.
• keys 73 and 74 will either incrementally increase or decrease the "on” or “off” times accordingly. If a totally new timing setting is desired such that incremental changes would be too time consuming, key 75 may be depressed to enable the entry of a new timing value by depressing the selected digits and enter key 77.
• the control program for controlling is menu driven and is accessible to the operator by use of the menu group of keys 78 -80. Access to the control program is made at predetermined points in the program to enable operator entry of various instructions, machine setting data or timing setting data.
• the key arrangement on terminal 60 is advantageous because it permits the functionality of the control system to be independent of the hardware. That is, the software control program may be changed while still enabling use of the same hardware.
• the menu driven software of the control program is traversed using the menu group of keys. Once a particular request drawing instruction is presented on display 81, the "do" key 78 will enable the operator to access the corresponding submenu, if any, by executing the menu item in the display.
• the next and previous keys 79 and 80 enable quick access to menu items.
• the next key 78 causes the display to cycle through the predetermined menu list in order to prompt the operator to access menu items in a predetermined order to enhance system control.
• Terminals 60 or 64 may be used to enter or display timing setting data or machine data in memories 52 and 66, respectively. For example, the various events utilized in sequence to form an article of glassware (as described in U.S. Patent No. 3,877,915) and their corresponding timing settings may be entered, changed and displayed by activation of the various function keys in keypad 70.
• FIG. 4 A more detailed diagrammatic view of machine terminal 64 having a keyboard 105 and display 106 is shown in Figure 4.
• the keyboard and display of machine terminal 64 provide the same input/ouput capability as hand-held terminal 60 and further provide additional capabilities to enable the machine operator to input or output data for a selected section from a central location while not interferring with the totally independent operation of each machine section.
• Keyboard 105 includes a portion 107 functionally similar to keypad 70 of hand-held terminal 60 and a portion 108 unique to machine terminal 64.
• Portion 108 includes function key3 109 and 110 for selecting "section up" or "section down,” respectively in order to enable the operator to choose a section number and increment or decrement that number to get data access to another section.
• Event fill key 111 enables timing data from any selected local computer 12 to be temporarily stored in a temporary data storage (notshown) and to be loaded therefrom into another selected local computer 12, thus facilitating duplication of timing setting data in the several local computers 12 without the necessity of entering data into each one separately.
• a similar function was performed by transferring data from one portion of a single memory to another portion of the same memory.
• the fill function may also be accomplished in the embodiment shown in Figure 1 by the addition of a microcomputer (not shown) between all local " computers 12 and multiplexor 63.
• Keys 112 and 113 may be assigned other desired functions which are not enumerated herein.
• Display 106 is, in one embodiment, a one line, twenty character display.
• a representative display is shown in Figure 4 as being identical to the display shown on the hand-held terminal in Figure 3 with an additional character group 114 showing the number of the section to which the remaining characters pertain at any one time.
• Figure 5 there is shown a more detailed schematic of the multiplexer 63 in the preferred embodiment shown in Figure 1.
• Data entered from keyboard 105 provides binary parallel inputs to decoder 102 (actually part of 64).
• decoder 102 activates a selected one of its outputs S 0 to S N , each of which is connected respectively to the enabling terminal of a bidirectional communications gate 120.
• Gate 120 may be, for example, an RS422 dual input chip with tristate enable.
• each gate 120 The input terminals A and B of each gate 120 are connected respectively to the output of RS422 bidirectional gates 122 and 124.
• the enabling terminals of each of these gates 122 and 124 are connected so as to be continuously activated to enable data transfer between gates 122 and 124 and selected gates 120 whenever the associated enabling signal S 0 to S N is activated.
• gate 122 provides an interface to machine terminal 64 and gate 124 provides an interface to external archive tape storage unit 65. In operation, only one output of decoder 102 will be activated at any one time in order to enable data transfer between a particular selected section (represented by the unique input code to the decoder) and the input/output device connected to the data terminals of the gate 120 associated with that section.
• local computer 12b for section 1 will have its communication ports 61 and 62 connected to terminal 64 and tape unit 65. This will enable local computer 12b to accept data from keyboard 105 or tape (as may be required by the control program) and will enable data from the selected local computer to be displayed on display 106. If the preprogrammed control program within the selected local computer 12b requires data transfer between it and tape unit 65 then appropriate data transfer will occur.
• Computer 90 facilitates operation of the glassware forming machine while still enabling totally independent operation of all individual sections and their respective local computers.
• Computer 90 includes a bidirectional communications interface (not shown) for interconnecting selected ones of the local computers 12 to selected input/output units connected to computer 90 such as global terminal 91, tape unit 92 and printer 93. Other peripheral I/O units may obviously be used.
• Global terminal 91 includes cathode ray tube display 96 and keyboard 97. It will be noted that the global terminal keyboard is similar to the machine terminal keyboard shown in Figure 4. Indeed, global terminal 91 is similar in function to machine terminal 64, the primary difference being the inclusion of CRT display 96 in the former.
• Display 96 obviously enables the presentation of more data to the operator so that he may, for example, compare the timing settings of all sections simultaneously.
• the local and machine supervisory computers may be housed in forming control enclosure 210.
• Enclosure 210 may be, for example, an environment-proof enclosure complying with NEMA 12 requirements and may be situated at a convenient distance from the IS machine 14.
• Each local computer is identical from a hardware point of view and is a modular unit rack mounted within enclosure 210 for easy replacement if necessary.
• Each valve block 16 is provided with a control panel 224 and each individual section 18 is provided with a blank side control panel 67 and a blow side control panel 68.
• the blank and blow panels provide local plugs (not shown) by which handheld terminal 60 may be connected to any selected section, from either the blank or blow side of the machine, and its associated local computer.
• the panels also provide the machine operator with local access to control functions such as start, emergency stop, ware reject, etc.
• Machine supervisory computer 90 provides the means to interface selected ones of local computers 12 to I/O devices such as tape unit 92 or printer 93.
• Tape unit 92 may be used to store control program data to be loaded into computer 90 to control its operation. Note that the control program stored in tape unit 92 is not the same as control program data stored in the individual local computers 12. The latter control programs are always stored in ROM within each local computer. The control program stored in tape unit 92 is used only to oontrol the operation of computer 90 and does not inhibit in any way the independent operation of each local computer and its corresponding section.
• machine supervisory computer 90 may provide access to all timing setting data within system 10. Hard copy printouts of any selected data may be obtained through printer 93. Computer 90 may also be provided with an output data channel 100 for providing selected data to external data processing equipment (not shown). Global terminal 91, tape storage unit 92, printer 93 or other peripheral units (not shown) may be connected to computer 90 and situated in a convenient location either adjacent machine 14 or in a remote control room.
• machine supervisory computer 90 may be, for example, an LSI-11 minicomputer available from Digital Equipment Corporation.
• the particular LSI-11 used in this embodiment has a 256K RAM for temporary data storage to facilitate data transfer between selected local computers and peripheral units connected to computer 90.
• data communications between computer 90 and selected local computer 12 may occur through port 62 and associated communication interface 58. It is thus apparent that communications may occur directly between CPU 54 of the selected local computer and the central processing unit included in the LSI-11.
• hand-held terminal 60 may be connected to port 61 of a chosen local computer to provide parallel communications if desired.
• each local computer 12 since each local computer 12 is provided with its own unalterable program storage means 50 as well as non-volatile timing and machine data storage means 62 and 66, respectively, each local computer 12 may operate independently of any other and independently of computer 90. Contrary to prior art control systems for glassware forming machines, no loading of control program data into local computers 12 is necessary to permit their operation.
• Terminal 91 may include coded access key slots 250-253. Each key slot will accept only a predetermined key or code.
• the control program for computer 90 is written so that control and display of various data is limited to authorized personnel according to a chosen hierarchy in the glass plant.
• a four level access hierarchy arranging from lowest to highest may be, for example, operator, set-up crew, product management and equipment maintenance.
• Operation of system 10 and access to various timing and control data within the system is a function of the particular key slot which may be activated.
• a machine operator may operate the machine and all of it sections by inserting the proper key into slot 250 corresponding to the lowest access level (level 1).
• the operator may thus control display and entry of only the timing and control data necessary to perform his work and may make certain limited changes to timing setting data and the like.
• the operator would be prevented from accessing or making changes to other data.
• a set-up crew may be given a key for slot 251 and thus permitted display and entry access to all of the data available to the operator plus some additional selected data such as machine data necessary to set-up the system for operation onn a particular machine (i.e. access level 2).
• section start available only on panel 67
• normal stop to a preprogrammed position
• blow side panel 68 is provided with a "neckring change” control in order to position the section for easy alignment and changing of neckrings, "blowhead adjust” control for adjusting the blowhead.
• Blank side panel 67 is provided with a “finish measurement” control for determining the height of the bottle's finish above the mold.
• blank side panel 67 is provided with a swab control to initiate a swab cycle to automatically position the particular section's blank side for efficient swabbing.
• panels 67 and 68 are provided with "cold blank” and “cold mold” controls for altering the sections cycle for efficient heating of blank and blow molds respectively during start up or after mold change.
• Ware reject controls are provided to assist the operator in automatically rejecting selected glassware. These controls are available from either the blank side or the blow side in order for the operator to be able to reject ware produced by either side.
• Four reject buttons are provided on each panel 67 and 68, one each for each mold within each section. (Note that the panels shown here are designed for a "quad-gob" system having four molds in each section of the machine.) Blank side panel
• Blow side panel 68 is provided with ware reject buttons capable of either continuous rejection of bottles produced by selected blow molds or rejection of a predetermined number of bottles such as, for example, after swabbing.
• the control system may also be programmed to automatically select the ware reject function after activation of either "cold blanks", “cold molds", or "swab" controls.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Control By Computers (AREA)
• Programmable Controllers (AREA)
• Stored Programmes (AREA)

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• 1984
  • 1984-01-23 AU AU25736/84A patent/AU565565B2/en not_active Expired
  • 1984-01-23 JP JP59500917A patent/JPS60500443A/ja active Granted
  • 1984-01-23 WO PCT/US1984/000084 patent/WO1984002994A1/en not_active Ceased
  • 1984-01-25 CA CA000445996A patent/CA1219934A/en not_active Expired
  • 1984-01-26 DE DE8484300470T patent/DE3462875D1/de not_active Expired
  • 1984-01-26 EP EP84300470A patent/EP0117075B1/en not_active Expired

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