WO2007135446A1

WO2007135446A1 - Control device and method of use thereof

Info

Publication number: WO2007135446A1
Application number: PCT/GB2007/001944
Authority: WO
Inventors: John Clark
Original assignee: Touchbox Systems Limited
Priority date: 2006-05-23
Filing date: 2007-05-24
Publication date: 2007-11-29
Also published as: GB0610161D0

Abstract

The invention relates to a device for use in conjunction with apparatus such as, for example, the apparatus of a production line, to allow the operation of said apparatus to be monitored and data relating to said operation to be collected, stored and assessed. The device allows particular events with respect to the apparatus to be identified and, furthermore, for particular reasons for the event occurring to be required to be entered prior to the commencement of operation the apparatus being possible. The device therefore allows for example unauthorised specific stoppages to be identified and tracked and therefore allows the operation of the apparatus to be monitored and, if required, action to be taken to improve the operation of the same.

Description

Control Device and Method of Use Thereof

This invention relates to a control device for the monitoring and management of usage of apparatus and a method of use thereof.

Although the following description refers almost exclusively to a control device for use with electrically controlled and/or operated apparatus which, in combination, forms, a production line for a manufacturing process, it will be appreciated by persons skilled in the art that the present invention could be adapted to be used to control and/or monitor any apparatus in any industry.

Conventionally, if a user wishes to analyse the efficiency and/or productivity of a production line of a manufacturing process, the user is required to manually count the units produced by the production line over time. In addition, a problem found with some production lines is that the manual operators of said line may temporarily shut down the line to allow them to have one or more unauthorised breaks. It is difficult to monitor whether a production line has been shut down during a production run for a legitimate reason, such as, for example, due to engineering problems, product refill and/or the like, or for an unauthorised reason, unless a person monitors the production line. However, problems associated with employing a person to monitor a production line are that it is both time consuming and labour intensive and unpopular with the apparatus operators and the results produced from such monitoring may not always be accurate and typically the monitoring cannot practically be performed over a long time period.

It is therefore an aim of the present invention to provide a management control device which is able to monitor and/or control electrical apparatus. It is a further aim of the present invention to provide a method of using a management control device to monitor and/or control electrical apparatus.

It is a further aim of the present invention to provide a method of using electrical apparatus including a management control device.

According to a first aspect of the present invention there is provided a control device for use with production apparatus having control means for controlling one or more functions of said apparatus, and wherein said control device is fitted in communication with said control means to monitor and/or control the usage of said apparatus.

Thus, in one embodiment, the control device can be retrofitted to existing electrical apparatus or integrally formed with said apparatus to control and/or monitor, either partially or wholly, one or more functions and/or operations performed by said apparatus control means. The device can be fitted to electrically operated , powered or controlled apparatus and/or mechanical apparatus or machinery.

The electrical apparatus can comprise a single item of apparatus or a plurality of items of apparatus.

In one embodiment the plurality of items communicate with, are linked and/or are associated in some way with each other. For example, the plurality of items can form part or whole of a production line in a manufacturing process.

The management control device can monitor and/or control one or more of said plurality of items as preselected. A control device can be provided with each of the plurality of apparatus items and, if a plurality of control devices are provided, said devices can operate independently of each other to provide data relating to that specific apparatus, which data may then be combined with other data from other apparatus.

In a preferred embodiment the device is associated with the control means of at least one item of said plurality of items in a production line and typically the item which is deemed critical to the functioning and/or efficiency of the production line, such as for example an item of electrical apparatus considered to be a bottleneck in a production line.

The control means in one embodiment is in the form of a means which allows the apparatus to be switched on and off, which selection may be made via a control panel or buttons, and the control device is provided to monitor the usage of the same and, in one embodiment require additional steps to be performed to achieve the function operation. The control device can therefore be provided as an intermediate device between the apparatus and the operator and preferably provides the interface between the operator and the apparatus.

Preferably the control device includes or is associated with display means for allowing a user to visualise data relating to said apparatus and/or said control device.

Data processing and communication means are preferably provided in said control device for processing data received via said apparatus control means and/or via one or more other communication means. The control device can be in one embodiment provided with storage means for storing data thereon.

Preferably interface user input means are provided on said control device to allow a user to input data and/or make selections via said device. The user input means can be formed as part of the display means, such as for example forming a touch screen display, or separate thereto. Alternatively, or in addition, the user input means can include any or any combination of a keyboard, mouse, joystick and/or the like.

In one embodiment the one or more functions controlled by the apparatus control means includes any or any combination of on/off operations, the speed of operation of the apparatus, temperature controls and/or other parameters relevant to the operation of the apparatus.

Typically, the control device is provided to detect and monitor at least one of the functions of said apparatus. On detection of one or more pre-defined conditions, threshold values and/or ranges relating to said one or more functions, said device can store said detected data, initiate one or more actions in response to the particular data detected and/or require a user to undertake one or more actions in respect of said management control device.

In one embodiment, the device detects when apparatus with which the same is provided is switched off or at least one part of said apparatus is stopped or switched off. The control device detects said stoppage and then requires the user to make one or more selections so that the reason for the stoppage can be determined and/or criteria relating to the stoppage can be assessed, such as the length of time of stoppage, the identity of the operator initiating said stoppage and/or the reason for the stoppage. The same can also be performed if the apparatus is detected by the control device as operating outwith predesignated operating parameters which are indicative of malfunction or incorrect operator actions.

In one embodiment, once one or more actions have been initiated by said control device, further operation of said electrical apparatus, apparatus control means and/or said management control device may be prevented until a user undertakes one or more required process steps, makes one or more required selections on said device and/or the like.

In one embodiment, when the control device detects a stoppage of said apparatus, a user is required to indicate the reason for said stoppage in said device prior to the device, apparatus control means and/or apparatus being rendered operable. For example, a plurality of options relating to the reasons for the stoppage may be displayed on the display means and a user is required to select one or more options as a reason for said stoppage before the device allows the apparatus to be switched back on or to become operational again. The reasons for stoppage may relate to a break, such as a tea break or lunch break, an engineering fault, a change in operator, a product change over and/or the like.

Preferably an override facility is provided on or associated with said control device and said override facility can be used to override the control device and allow the direct operation of the apparatus.

In one embodiment the override facility may be required if one or more options are selected via the management control device on detection of a particular event relating to said electrical apparatus. The override facility may include an unlocking/ Io eking means, such as a key, password, pin number and/or the like which needs to be input or inserted in said control device, said apparatus control means and/or said electrical apparatus before one or more further operations and/or functions of said control device, said apparatus control means and/or said electrical apparatus can be undertaken. For example, in order to prevent an operator from stopping a production line or electrical apparatus for an unauthorised tea break by selecting the option indicating there is an engineering fault, an engineer may be required to operate the override facility when the engineering fault option has been selected so that the engineer has to check and confirm that there has been an engineering fault.

The override facility can include a mechanical lock, digital lock and/or the like.

The control device can be provided with communication means to allow detected and/or received data to be communicated to one or more remote locations, such as to a database server, main computer terminal and/or the like and/or to allow data to be communicated to said device from a remote location, such as updated productivity requirements, product data, operator details and/or the like. The communication means can include cable, wireless and/or other forms of communication. The device can also operate on an internal computer network via its own Ethernet connection or on its own dedicated network.

Printing means can be associated with said control device to allow the printing out of data obtained via and/or stored on said device.

The management control device can be provided with its own power supply, such as batteries and/or connection means can be provided to allow connection to a mains power supply or the power supply of the apparatus to which the device is to be fitted in use. In a preferred embodiment, the device is operated by mains power supply and is provided with a PIc battery back up to memory to allow data to be stored upon the occurrence of a power failure.

The device further includes a user interface to allow a user to navigate through one or more options, menus and/or display screens.

Suitable software is provided in the device to allow the device to perform the required functions and/or operations.

Preferably the device is provided with attachment means for attaching the device to said apparatus.

Preferably data obtained from said monitoring and/or control of said apparatus via said control device can be used to actuate alarm means in the event that one or more undesirable parameter conditions are detected.

In one embodiment the device includes a sealable or lockable housing in which the necessary hardware and software components are provided, thereby preventing unauthorised access to said device.

According to a second aspect of the present invention there is provided a method of monitoring and/or controlling the operation of electrically powered and/or controlled apparatus of a production line using a control device, said method including the steps of selecting at least one of said items of apparatus, fitting said control device to control means associated with said selected item or items, monitoring the operation of said item and wherein upon detection of a predefined event relating to a function of the item the control device activates at least one user input requirement and stores data relating to said event and the user input.

In this manner an item or items forming part of a production line or apparatus can be selected, typically an item which is particularly critical to the running, efficiency, speed and/or productivity of the apparatus and/or process undertaken by the apparatus. For example, an item which may act as a bottle neck in the production line and/ or be a limiting factor in the efficiency, operation and/or productivity of said apparatus, would be selected and said items can be monitored and controlled, thereby providing a more accurate assessment of the efficiency, operation and/or productivity of said production line and/or said apparatus.

Typically a further step is to assess the data which is received over time and then decide, on the basis of said data, whether to take further action to adjust the operation of the item and/or take steps to change the manual operators.

According to a further aspect of the present invention there is provided a method of using apparatus including a control device.

According to a yet further aspect of the invention there is provided an item of production line apparatus including a control device as herein described.

The present invention allows the user to obtain information relating to particular electrical apparatus and said invention can be tailored to the user's requirements . The device of the present invention can be used to show potential faults of a particular 9 process or apparatus, downtime, reasons for non-performance and provides information useful in assisting control of energy efficiency and productivity, thereby providing valuable data for subsequent use in saving a user or company money and increasing the efficiency of machinery and staff productivity.

Reference to a control device herein relates to means capable of performing the function of monitoring and/or controlling one or more functions associated with the control means of an item of apparatus. It can also be used to monitor and/or control additional functions not associated with the control means if required.

Embodiments of the present invention will now be described with reference to the accompanying figures, wherein:

Figure 1 is a schematic view of electrical apparatus in the form of a production line with a control device in accordance with the invention associated therewith;

Figures 2a-2m illustrate examples of different display screens of a management control device in one embodiment of the present invention;

Figures 3a-3d illustrate examples of data produced by a management control device in one embodiment of the present invention.

Referring firstly to figure 1 , there is illustrated a schematic view of a production line 2 of a manufacturing process which can be far, for example a food processing plant. The production line 2 includes a plurality of items of apparatus 4, 6, 8, 10. A conveyor belt links each item of machinery together, as shown by arrows 11 , such that starting materials 12 inserted into item of apparatus 4, as shown by arrow 14 at the start of production line 2, undergoes various manufacturing process steps at each item of apparatus 4, 6, 8, 10 to form an end product 16 leaving the production line, as shown by arrow 18.

In this example, an operator works at a work station associated with each item of apparatus 4, 6, 8, 10 to load, unload, inspect, manipulate a product or starting material 12 and/ or undertake one or more actions in respect of the operation of the apparatus in the manufacturing process step relating to the product or starting material 12 to allow the end product 16 to be produced.

Each item of machinery 4, 6, 8, 10 typically has control means including a control panel 20, 22, 24, 26 associated therewith respectively, for allowing operator input to control on and off operations of the item and for controlling one or more further functions of said item, such as for example, the speed of said item, temperature, pressure and/or the like.

In this example item of apparatus 8 is identified as being critical to the run time of the production line and as acting as a bottle neck thereto. As such, in accordance with the invention a control device 28 is linked to control means 24 of item 8 to monitor the operation of said item and if required it may also monitor the operation of the entire production line 2. The control device 28 allows data to be obtained which can then be processed to provide indicators of the productivity and efficiency of the production line. The control device 28 typically includes a housing which can be retrofitted to item 8 to allow monitoring and control of said control means 24 and thus one or more operations and/or functions performed via said control means. The housing includes data storage means in the form of a memory, processing means for processing the data, a display screen for displaying data thereon and for allowing a user to view one or more menus and/or selectable options and user input means associated with said display screen in the form of, for example, a touchscreen.

Referring to figures 2a-2m, there are illustrated examples of displays that can be provided on a display screen 102 of the control device in accordance with the invention. In this example, at the start of a shift, the new operator is required to select the "shift start" button 104 on said screen 102, as shown in figure 2a. Selection of this allows the control device 28 to log the time and date at which the shift started.

The operator is then prompted to input a product code 106 relating to the product that is to be produced on production line 2 for that shift, as shown in figure 2b. Once input, an "OK" button 108 is provided for a user to move to the next screen display. The input data is stored in memory on the control device 28.

A message 110 appears on screen 102 to inform the user that the item of apparatus 8 is ready to start, as shown in figure 2c.

When the items of apparatus of the production line 2 are running, screen 102 displays data headings 112, including, in this example product code, labour standard, labour actual, units per cycle, unit standards, unit actual and production run time and updates and the detected data 114 relating to said data headings, as shown in figure 2d. Alternative screen displays for detected data can be granted, as shown in figure 2e in which the data items are plotted on a graph to represent a particular characteristic of the operation of the item of apparatus .

In the event of stoppage of item 8 or perhaps stoppage at some other machine item in the production line 2, as a result of a user actuating a "stop" button on the apparatus control panel, control device 28 detects this stoppage and displays a plurality of operator selectable options 116 on screen 102, as shown in figure 2f. The operator is required to select one of the options 116 before the production line 2 and/or item 8 can be restarted. The options may, for example, include a roll or product change, a problem with product quality, a scheduled break, a delay in delivery of product, a changeover of product being produced, an end of shift, an engineering problem with an item of machinery, such as an endoline, slicer, rotary table, labeller, metal detector, weigher, thermoformer, conveyer belt and/or the like.

Once the operator selection has been made, a display is shown which checks the operator has made the correct choice for the stoppage. In figure 2g, the operator has selected "roll change" and the selection appears on the screen as shown by arrow 118 and confirmation options "yes" and "no" appear as shown by areas 120, 122 respectively. If an incorrect choice has been selected, the operator presses "no" and the screen returns to the screen shown in figure 2f. If "yes" is selected, the display as shown in figure 2h appears. The screen confirms the selection and awaits restarting of the item causing the stoppage.

If an engineering problem has been selected in the screen shown in figure 2f, a further screen shown in figure 2i is displayed. This screen has an "engineering" area 124 and a "production" area 126. The user is required to select whether the stoppage is due to an engineering problem or a production problem. If the production area 126 is selected, the screen shows a plurality of production problem options . If the engineering button 124 is selected, a screen display shown in figure 2j is displayed. A message 126 is shown informing the user that an engineer will need to be called out in order to restart the machine. A user is then required to confirm the problem by selecting a "yes" or "no" option 128, 130 respectively.

If "yes" 128 is selected then in order to restart the production line or item of apparatus, an engineer is required to insert an override key into the control device 28. This prevents a user from stopping the production line for an unauthorised break by selecting an engineering problem when there is no such engineering problem. On selection of an engineering problem, the engineer with an override key is required to attend in order to restart the apparatus. The screen shown in figure 2k is displayed. A message 132 is displayed informing the engineer as to the procedure required to be followed in order to restart the machine.

At the end of the shift, a user selects an "end shift" option on the display 102 and a display shown in figure 21 is shown. A user is required to input a number 134 of products produced on the production line during that shift. An "OK" selection button 136 is provided to allow a user to confirm their selection.

A further optional display, illustrated in figure 2m, can then be shown. The control device undertakes a comparison of the products produced in the production line during that shift with average production data stored on the device in memory thereof. If the production output for the shift is less than average, the operator may be required to select a reason for this by selecting one of a "material" button 138, "operational" button 140 or an "engineering" button 142.

Based on the data input into the management control device during the shift and using other data which may be detected by one or more items of machinery in the production line and/or using data already stored in the management control device, the device can produce a table of data, an example of which is shown in figure 3a, displaying information which may be useful in managing and controlling the production line and monitoring the efficiency thereof. The data can include productivity of each operator working each item of machinery, as shown in the right hand column of the table, the length of the shift, the total time of stoppage of machinery during the shift, the reasons for the stoppage and length of time of stoppage for each reason, the output and/or the like. Other visual displays can be used to show data in different forms, such as in a graph form, as shown in figures 3b-3d.

It will be appreciated that the above display screen options are only an example of a large number of possible options. The data obtained using the control device can be used for any suitable purpose and can be communicated to a remote location or stored as required. The device of the present invention can be used in conjunction with any apparatus in any industry, and therefore provides two fold advantages . A first is that the activities of the apparatus and operator can be more accurately monitored and positive input from the operator is required and they are made more accountable for their actions. Furthermore, the data which is generated can be assessed and then used to identify any apparatus and/or operator problems and steps can be taken accordingly.

Claims

1. A control device for use with production apparatus having control means for controlling one or more functions of said apparatus, and wherein said control device is fitted in communication with said control means to monitor and/or control the usage of said apparatus.

2. A device according to claim 1 wherein the apparatus is electrically controlled and/ or powered.

3. A device according to claim 1 wherein the device is integrally formed with, or retrofitted to, said apparatus.

4. A device according to claim 1 wherein said device is provided to control and/or monitor, either partially or wholly, one or more functions of operation of the control means of said apparatus.

5. A device according to claim 1 wherein the apparatus comprises a plurality of electrical items in communication with each other to form a production line.

6. A device according to claim 5 wherein a device can be controlled to selectively monitor one or a plurality of said electrical items.

7. A device according to claim 5 wherein a device is provided on one or more of said plurality of electrical items.

8. A device according to claim 7 wherein a plurality of control devices are provided, said devices controlled to operate independently of each other and/or in communication with each other.

9. A device according to claim 5 wherein said device is associated with the control means of at least one item of said plurality of items.

10. A device according to claim 1 wherein the control means includes the ability to switch the apparatus on and off and the control device acts as an operator interface therefore.

11. A device according to claim 1 wherein the control device includes or is associated with display means for allowing a user to visualise data relating to said apparatus and/or said control device.

12. A device according to claim 1 wherein processing means are provided within the control device for processing the data received via said apparatus control means and/or via one or more communication means.

13. A device according to claim 1 wherein the device includes storage means for storing data indicative of the operation of the apparatus therein.

14. A device according to claim 1 wherein user input means are provided to allow a user to input data and/or make selections via said control device.

15. A device according to claim 14 wherein the user input means are formed as part of the display means.

16. A device according to claim 1 wherein the one or more functions controlled by the apparatus control means includes any or any combination of on/off operations, speed of apparatus operation, and/or temperature control.

17. A device according to claim 1 wherein the control device detects and monitors at least one of the functions of said apparatus control means and upon detection of a predefined condition, said control device stores said detective data, relating to said condition and/or initiates one or more actions .

18 A device according to claim 17 wherein the control device requires an operator of the apparatus, to undertake one or more actions in respect of said control device.

19. A device according to claim 1 wherein the control device detects when the apparatus is stopped or switched off and requires the operator to make one or more user input selections so that the reasons for the stoppage can be determined and/or criteria relating to the stoppage can be assessed.

20. A device according to claim 19 wherein the assessment comprises an indication of the length of time of stoppage, and/or whether the stoppage has been operator initiated or not.

21. A device according to claim 17 wherein once one or more actions have been initiated by said control device, further operation of the apparatus, apparatus control means and/or control device is prevented until an operator undertakes one or more required process steps and/or makes one or more required selections on said device.

22. A device according to claim 1 wherein when the control device detects the stoppage of said apparatus, an operator is required to input the reason for said stoppage in said control device prior to the control device, allowing further operation of the apparatus.

23. A device according to claim 22 wherein an override facility is provided on or associated with said control device which can be used to override said device.

24. A device according to claim 23 wherein the override facility is required to be used if certain user input selections indicate a particular stoppage reason.

23. A device according to claim 22 wherein the override facility includes an unlocking/locking means which can only be operated with a particular tool and/or by an authorised person.

24. A device according to claim 1 wherein the control device includes communication means to allow detected and or received data to be communicated to and from one or more remote locations .

25. Apparatus for use in a production line wherein the apparatus includes or has fitted thereto a control device in accordance with any of the claims 1 -24.

26. A method of monitoring and/or controlling the operation of electrically powered and/or controlled apparatus of a production line using a control device, said method including the steps of selecting at least one of said items of apparatus, fitting said control device to control means associated with said selected item or items monitoring the operation of said item or items and wherein upon detection of a predefined event relating to a function of the item, the control device activates at least one user input requirement and stores data relating to said event and the user input.

27. A method according to claim 26 wherein the item or items which are selected and those which are identified as acting as a bottle neck in a production line.