WO2023279183A1

WO2023279183A1 - Machine production monitoring system and process

Info

Publication number: WO2023279183A1
Application number: PCT/BR2022/050250
Authority: WO
Inventors: Andre LEAO BARCELLOS
Original assignee: Leao Barcellos Andre
Priority date: 2021-07-08
Filing date: 2022-07-06
Publication date: 2023-01-12
Also published as: BR102021013510A2

Abstract

The present invention pertains to the sector of machine monitoring and information systems and relates, more specifically, to a system and process for monitoring injection moulding machine production using data provided by the operator and by counting machine pulses. The system also comprises an online database, from which operators can retrieve data for a particular machine and from which the system captures data for processing the data. In addition, the system comprises a device installed on the injection moulding machine for the calculating software to run directly linked to the machine, allowing for data to be captured directly from each machine individually. The software captures results from the machine located within the network, generating a result relating to production of the machine, allowing for real-time production monitoring.

Description

MACHINE PRODUCTION MONITORING SYSTEM AND PROCESS Technological sector of invention

[01] The present invention belongs to the sector of computer systems and machine monitoring and refers, more specifically, to a system and process for monitoring the production of machines through data provided by the operator and by counting machine pulses. The system also comprises an online database, through which operators can access data from a given machine, and through which the system captures data for the purpose of data processing. Furthermore, the system comprises a device installed on the machine for the calculation software to run directly connected to the machine, enabling the direct capture of data from each machine individually. The software captures results from the machine located on the network, generating a result referring to the machine's production, enabling real-time monitoring of production.

State of the art [02] Currently, due to the increasing evolution of the information technology area, companies from the most diverse branches invest time and resources to develop technologies aimed at monitoring the production of different machines. With the growing market demands, the industry's production is evolving daily. With the challenge of supplying the market, production management is becoming more and more essential for the industry, becoming the main focus of resources for improvements and evolution of technologies.

[03] At the same time that production has been receiving high investments for its technological evolution and agility, the monitoring of machines has become the main way to identify the needs of the factory. Because of this, monitoring the production of individual machines has been the industry's biggest investment, enabling the generation of reports and, consequently, the proper management of resources aimed at improving the factory.

[04] The main aspect of monitoring is the capture of data from different machines simultaneously, generating a general result referring to the factory, making it possible to identify the machines that need improvement. However, the generation of machine data results in raw data, requiring technical interpretation to align the needs of the factory. This is because the machines are all connected directly to the factory's internal network, sending their data in real time to a processing center, where only one result is generated for all the machines. machines.

[05] Therefore, there is a need for a process in which each machine generates its own result, sending only the result related to the machine's production to a data center. Mainly with regard to machines, where the monitoring of the production of parts usually takes place with the use of different sensors located in the molds, requiring that there is a mechanical interference in the machine due to the installation of the sensors.

[06] According to patent CN112115635 specifically describes software with automated learning where different machine parameters are calculated based on information collected directly from the machine and information entered by operators. However, the patent does not provide for production monitoring, in addition to requiring the insertion of several parameters by the operator, making the process difficult at the factory.

[07] Patent CN111339667 describes software aimed at monitoring the temperature and pressure in the cavities of a machine, calculating the received information and presenting it graphically to the operator. The patent does not present the possibility of monitoring the machine's production, and still does not present communication with the network to send the information, requiring a display located on the machine to display the information or results. [08] The patent JPH10156910 describes a method to control and monitor several machines, receiving data from different points of each machine. The method foresees the monitoring of the production of each machine based on the capture of data in relation to the current database referring to each machine. The method also makes it possible to control the machine via the network, from any device with an operating system installed. Despite monitoring the production of the machines, the patent processes the result in a center external to the machine, making the information available not from a single machine, but from a production line, making it difficult to identify the machines that need improvements . In addition, the patent requires a mechanical modification to the machine to install sensors, making it difficult and increasing the costs of the object of the patent.

[09] The patent US2012072186 presents a method of control and monitoring of machines, where measurements of different variables of the machines are performed, allowing the identification of the production speed of each machine. Measurements are performed by sensors installed on each machine, and, optionally, being calculated together with information previously provided, comprising a formula to achieve the expected result. Despite calculating the production speed of each machine, the method does not propose a calculation of the productivity of the same, since the machine speed may not represent how much it produced in the day, due to constant machine stops. In addition, the process requires sensors installed on the machine to perform the measurements, requiring mechanical interference inside the machine, increasing the cost and making it difficult to install the device in the machine.

[010] US patent 5,012,426 presents a device with software aimed at calculating variants collected from sensors installed in the machine, in addition to being based on the collected pulses referring to the cavities of the machines. The software also presents a step for calculating and processing the signals, after sending the results via the network. The method uses different sensors installed on the machine to capture data from the machine, which generates inconveniences mainly when monitoring the cavities of the machines, implying the interference of the sensors in the quality of production, since the dimensions of the cavities are accurate for the correct injection of material.

[011] With that, from all the existing drawbacks in the systems and equipment currently used, described above in the state of the art, it is visible the existence of a gap in the creation of a system and process that is capable of measuring the production of a machine from a specific factor and count of machine pulses.

Novelties and objectives of the invention

[012] The patent application in question deals with a system and a method that uses a multiplication factor informed by the operator together with the pulses generated, captured by optical, magnetic position, or voltage sensors remotely or by wires, at the time of injection, to calculate and result in machine productivity. The device may be powered by batteries or the mains. The process also provides for the sending of information to the external network, or cloud, where it can be accessed by any device with an operating system installed.

[013] The present invention does not require complicated installations and modifications to the machine to carry out the process, since the pulses are captured directly from the machine's motors, referring to the closing or opening of the operating cycles, requiring only a wired communication or wirelessly between machine and system.

[014] The operating parameters together with the multiplication factor of the machine can be entered by keyboard. Optionally, data can be entered into the machine via the system's external network. Furthermore, the remote firmware update and, optionally, data processing takes place via the external network.

[015] With this, the invention enables real-time monitoring of a production line, enabling the generation of production reports, which identifies failures and production funnels. Based on this, it is possible to improve the production line, based on different parameters presented in the generated reports Description of attached drawings

[016] In order for the present invention to be fully understood and put into practice by any technician in this technological sector, it will be described clearly and sufficiently, based on the attached drawings, which illustrate and support it listed below: Figure 1 - flowchart referring to the functioning of the system;

Figure 2 - system block diagram;

Figure 3 - flowchart referring to a variant of system operation;

Figure 4 - flowchart referring to the operation of the process;

Figure 5 - continuation of the flowchart of Figure 3. Detailed description of the invention

MACHINE PRODUCTION MONITORING SYSTEM [017] According to figures 1 and 2, the system of the present invention comprises a device (1) installed in a machine (10), and communicating through wires, preferably a pair of wires or remote for data capture. Furthermore, the system comprises a data processing module (2), which receives data from the external data module (3) and from the pulse counter (4). The data processing module (2) is responsible for processing the data, calculating and generating the result of the machine's productivity, based on data from the external data module (3) and the pulse counter (4). Optionally, the data processing module (2) sends data to a display (5) available directly on the device.

[018] For external communication, the external data module (3) also comprises a communication module (31), capable of sending and receiving data through a wireless or cable network, prioritizing the main communications, such as Wi-Fi. Fi, Lora, 433Mhz Bluetooth, GSM, GPRS and TCP/IP. [019] The external data module (3) also comprises a data storage slot (32), where data from the external network and data entered by an operator through a keyboard (33) are stored.

[020] Through the keyboard (33), the registered operator enters the machine factor (10), as well as the operating parameters, production order, type of operation, user identification and machine identification (10) in the network and connection configuration. When the operator interrupts the machine operation, he informs the stop to the system through the keyboard (33), entering the reason for the stop, type of scrap and the amount of scrap. [021] Optionally, the data can be entered remotely, through the external network. Thus, the system receives information, for example, from a smartphone connected to the external network by wireless, sends the data to the external data module (3), which saves in the storage slot (32) to later be sent to the data processing module. data (2). [022] The pulse counter (4) is directly connected to the machine (10) to capture the activation pulses of the machine (10). When the production cycle starts, the number of pulses is sent to the data processing module (1), where the calculation steps and generation of results are performed.

[023] The processing module (2) accesses the data storage slot (32), identifying the data referring to the machine factor, the amount of pulse generated by the machine and the scrap produced. From the data, the calculation and generation of results regarding the productivity of the machine is performed.

[024] As an example, the machine factor (10) may be, in the case of injection molding machines, the number of cavities in the mold, and the pulses can be captured in the injection drive. Based on this, the real-time production of the injection machine (10) is calculated (eg).

[025] The result generated in the data processing module (2) can be made available on a display (5) and sent to the external network through the communication module (31). In the external network, or cloud, the result sent can be accessed by external equipment connected to the external network, or cloud.

[026] As an example, the system can be used to monitor the production of an injection machine (10), where the operator will enter the parameters of the injector, and the factor will be related to the number of mold cavities and the pulses will be captured directly when the injection is activated. The device (1) is installed directly on the injector that will be monitored and communicating through a pair of wires to capture data. The processing module (2) will process the data inserted in the external data module (3) together with the pulses captured by a pulse counter (4), generating the total production result, if the stop is carried out, or the result In real time. The operator will be able to observe the results on the display (5), or access them on the external network, or cloud.

[027] Optionally, in a variant, the system may present the processing module (2) in the cloud, as shown in figure 3. In this case, the external network receives data from the pulse counter (4) and the external data module (3) through the communication module (31). The results generated in the processing module (2) are sent to the display (5) through the communication module (31).

MACHINE PRODUCTION MONITORING PROCESS [028] In addition to the system, the process that enables the generation of results from captured data, defined from software installed in the system, is also presented. This makes it possible to control the sending of information, data processing, calculation and generation of the expected result.

[029] According to figures 4 and 5, the process has the following steps:

• Capture necessary data (S1);

• Process captured data (S2);

• Identify the data and send it to the calculation section (S3);

• Calculate previously processed data (S4);

• Generate the result based on the data calculation (S5);

• Send the result (S6).

[030] In the data capture stage (S1 ), the process first identifies the registered operator and, if the operator is responsible for entering information, the data are entered and saved in a data storage slot (32). Simultaneously, the process captures the pulses generated by the machine (10) from the moment of activation through the pulse counter (4), which sends the amount to the data processing module (2).

[031] Still in the data capture stage (S1), the operator enters the following data, but not restricted to these:

- Name of the operator;

- Production order;

- Machine identification; - Operation type;

- Multiplication factor.

[032] It is still possible for the operator to enter the machine stop, which in this case will require the following data:

- Reason for stop;

- Type of scrap;

- Scrap quantity.

[033] In the data processing stage (S2), in figure 4, the captured data is sent to the data processing module (2) so that it is possible to compute the data according to its origin, generating the signals referring to the counting of the pulses , and signals referring to the machine factor, also, if the machine stops, the signal referring to the amount of scrap is generated. The data is identified (S3) and sent to be calculated.

[034] To calculate the data (S4), the machine factor is multiplied by the number of pulses. The number of pulses will vary in relation to the machine stop (10), if the machine stops, the number of pulses will refer to the period of machine operation, and if the stop does not occur, the number of pulses will refer to the generation time from the previously generated result. Also, if the machine stops, the multiplication will be subtracted by the amount of scrap, thus generating an accurate result regarding machine utilization (10). [035] Optionally, if a stop occurs, the number of pulses to be used to calculate (S4) will be based on the results saved in the external network or cloud database.

[036] After completing the calculation (S4) of the data, the process generates the results (S5) referring to the productivity of the machine, detailing the total number of parts produced by the machine. It is possible to generate two types of results, where one would be the result of real-time production, and the other would be referring to the total production, after the machine's production cycle. For this, the machine stoppage is taken into account, where, in the event of a stoppage, the generated result refers to the final production (S5.1) of the machine, because in the calculation (S4) the amount of machine scrap is considered in addition to considering the number of pulses within the period of starting and stopping the machine. If the machine stoppage has not been registered, the result is generated in real time (S5.2). based on multiplying the pulses by the machine factor.

[037] After the result is sent (S6) to a display or external network. On the external network, the result can be accessed by different operators, with different limitations, ranging from viewing to editing the results. With this, it is possible to use the results referring to a machine or a line in different reports and presentations.

EXAMPLE OF PROCESS EXECUTION

[038] As an example, the process can monitor the production of an injection molding machine, where, in the data capture step (S1), the operator will identify himself and, if allowed, will enter the machine parameters, together with the factor , which in this example will be the number of cavities in the injection mold. The captured pulses will originate from the triggering of the injection. You will still have the possibility of inserting the injection stop, where the amount of production waste will be informed. With this, the data (S2) referring to the number of mold cavities, the number of pulses and, if the stop is identified, the amount of scrap, where the data are identified (S3) to enable the calculation will be processed. These data will be calculated (S4), multiplying the number of mold cavities by the number of pulses captured and, if the stop is identified, the result is subtracted by the number of rejects. From the calculation, two results are generated (S5), where one is the total production result (S5.1 ), taking into account the downtime and the amount of scrap, and the second result is generated in real time (S5 .2), taking into account only the number of pulses and the number of mold cavities. Afterwards, the result is sent (S6) to a display located in the injection machine, and even sent to the external network, or cloud, allowing access by several operators, in addition to handling the information.

[039] It is important to note that the figures and description made are not intended to limit the ways of implementing the inventive concept proposed here, but rather to illustrate and make understandable the conceptual innovations revealed in this solution. In this way, the descriptions and images must be interpreted in an illustrative and non-limiting way, and there may be other equivalent or analogous ways of implementing the inventive concept now revealed and that do not deviate from the spectrum of protection outlined in the proposed solution.

[040] This descriptive report deals with a system and process for controlling and monitoring the productivity of machines, endowed with novelty, inventive activity, descriptive sufficiency, industrial application and, consequently, coated with all the essential requirements for the granting of the claimed privilege.

Claims

1. MACHINE PRODUCTION MONITORING SYSTEM comprising a pulse counter (4), a display (5) and communication with an external network with database and accessible by users, characterized by comprising a device (1) installed in a machine (10), consisting of:

- data processing module (2);

- external data module (3); in which the data processing module (2) receives data from the external data module (3) and the pulse counter (4), and sends the processing result to the display (5) and external data module ( 3); the external data module (3) sends the results to an external network.

2. MACHINE PRODUCTION MONITORING SYSTEM according to claim 1, characterized in that the external data module (3) comprises a communication module (31), data storage slot (32) and keyboard (33).

3. MACHINE PRODUCTION MONITORING SYSTEM according to claims 1 and 2, characterized by the machine multiplier factor (10), as well as the parameters referring to the type of operation, production order, operator identification and machine identification on the network, be entered via the keyboard (33) on the external data module (3) or be entered remotely via the external network.

4. MACHINE PRODUCTION MONITORING SYSTEM according to claim 1, characterized in that the pulse counter (4) is directly connected to the machine (10) in its drive motor.

5. MACHINE PRODUCTION MONITORING SYSTEM, according to claim 1, characterized in that the processing module (2) is located in the external network, or cloud

6. MACHINE PRODUCTION MONITORING SYSTEM, according to claim 5, characterized in that the external network receives data from the pulse counter (4) and the external data module (3) through the communication module (31) ; the results generated in the processing module (2) are sent to the display (5) through the communication module (31).

7. MACHINE PRODUCTION MONITORING PROCESS characterized by the following steps: • Capture data (S1);

• Process captured data (S2), captured in the capture data stage (S1) and generate signals referring to the counting of pulses and signals referring to the machine factor;

• Identify the data and send it to the calculation section (S3);

• Calculate the previously processed data (S4), multiply the machine factor with the number of pulses;

• Generate the result based on the data calculation (S5);

• Send the result (S6).

8. MACHINE PRODUCTION MONITORING PROCESS according to claim 7, characterized in that the data capture step (S1) identifies the operator, and if responsible, the data entered are saved in a data storage slot, in addition to to insert the machine stop occurrence; simultaneously, a pulse counter captures the pulses generated by the machine and sends the amount to a data processing module.

9. MACHINERY PRODUCTION MONITORING PROCESS according to claim 8, characterized by the operator entering the following data:

- Name of the operator;

- Production order;

- Machine identification;

- Operation type;

- Multiplication factor.

10. MACHINERY PRODUCTION MONITORING PROCESS according to claim 9, characterized by in the case of injection or injection machines, the multiplication factor refers to the number of mold cavities.

11. MACHINE PRODUCTION MONITORING PROCESS according to claim 8, characterized in that after the stop occurs, the operator enters the following data:

- Reason for stop;

- Type of scrap;

- Scrap quantity.

12. MACHINE PRODUCTION MONITORING PROCESS according to claim 7, characterized in that if the machine stops, the data processing step (S2) generates a signal referring to the amount of scrap.

13. MACHINE PRODUCTION MONITORING PROCESS according to claim 7, characterized in that in the calculation step (S4), if the machine stops, the number of pulses will refer to the complete period of machine operation.

14. MACHINE PRODUCTION MONITORING PROCESS according to claim 7, characterized in that if the machine stops, the number of pulses to be used to calculate (S4) will be based on the results saved in the external network database or a cloud; if the machine does not stop, the number of pulses will refer to the generation time since the previously generated result.

15. MACHINE PRODUCTION MONITORING PROCESS according to claim 7, characterized in that if the machine stops, the multiplication will be subtracted by the amount of scrap.

16. MACHINERY PRODUCTION MONITORING PROCESS according to claim 7, characterized in that the step generate results (S5) generates two types of results, in which one would be a real-time result of production, and the other would be referring to total production, after the machine's production cycle, being differentiated from the identification of the machine stoppage.

17. MACHINE PRODUCTION MONITORING PROCESS according to claim 16, characterized in that the step of generating results (S5) generates the real-time result of production (S5.2) from the non-identification of the machine stoppage; the step of generating results (S5) generating the result of the total production (S5.1 ) from the identification of the machine stoppage.