Method for operating an industrial system

Technical field

The present invention relates to a method for operating an industrial system, an industrial system for performing the method according to the invention and a computer program with program code means to perform all steps of the method according to the invention.

Description of the Prior Art

Industrial systems for the purposes of the invention generally include all the possible areas of mechanical engineering. In particular, you include manufacturing and production facilities and plant for special machine, such as packaging or bottling plants, in particular for filling beverages in bottles.

From the <patcit><text>DE 10 2004 053 775 A1</text></patcit> are known a system and a method for wireless communication between a technical device and a mobile, a user of the portable device as well as between technical devices with each other. The technical device and the mobile device in this case have transmission means for generating the respective device surrounds, spatial communication fields. In an overlapping of the areas of communication of the mobile device and the technical device a communication between a user and the technical device is made possible.

The <patcit><text>DE 101 35 837 A1</text></patcit> describes a system and method which allow for location-independent and non-contact operation of a plant.

The following example discusses only filling an industrial system, but in addition, the present invention is also applicable to all other types of industrial systems.

Industrial systems, particularly filling, are grouped into so-called lines, each line produces a specific end product, for example, a filled with a specific beverage specific bottle size.

Within an industrial system can be provided a plurality of lines which are operated in parallel.

Each line, in turn, typically includes several machines with a certain operation is performed on the way to make the finished product on each machine. These steps may be for example, arranging, washing, conveying, filling, sealing or labeling bottles.

Each machine in turn usually has several components that work together to perform a single step of the machine.

In the prior art, various ways are known to monitor the manufacture of final products and to control. For operating devices are on each machine provided monitors on the operating status of each machine and the machine can be controlled.

Typically, therefore, for each machine, an operator needed that monitors the operation of the machine and makes inputs to the machine.

A central element in the monitoring or the operation of a machine is to be able to identify and classify errors as soon as possible. Since the functioning of an entire line is only given if all the machines of the line work, means stopping only a single machine, that the entire line can no longer work.

It can also cause damage to a machine for critical errors.

It is therefore desired to realize as quickly as possible errors in a machine, classify and can fix.

The prior art is generally provided that on each machine a warning element, for example a round luminous lamp is mounted, the outputs warnings in case of error. A person on this machine or in the vicinity then has to rush to the machine to classify the errors and to take such a decision as to proceed further.

Here, however, the disadvantage arises that many operators are required to provide an efficient monitoring and control, and in particular multiple lines. Otherwise, this may cause due to the often large distances to be covered within an industrial system takes a long time before any can be started with the classification of a fault. Furthermore, the operators of different machines usually different qualifications, so that may be the case that an operator in an errorhas classified that does not meet their individual qualifications.

Furthermore, does not vote instead about which operator has to deal with a fault occurring. As a rule, all operators who perceive a warning issued to the respective machine, so that there is always an oversupply occurs.

Even if only one operator goes to a corresponding defective machine and can classify the error, you often lack the appropriate skills and the appropriate tool to fix the error. In addition, the operator often lack the skills, ever be allowed to make a decision on how to proceed so that first has to be coordinated with higher authorities before such as the production line is stopped.

It often occurs in the coordination between the operators and the parent bodies also to misunderstandings, because not all people are the same information in the same quality. There is thus a need for a method for operating an industrial system which enables more efficient operation of the system.

Summary of the Invention

In contrast, a method for operating an industrial system according to claim 1, an industrial system according to claim 10 and a computer program according to claim 12 is provided according to the invention.

The method for operating an industrial system, wherein the system comprises a plurality of lines, each line comprising a plurality of machines, and each machine comprises a plurality of components, comprises the steps of system-wide detecting status data of each component of each machine and each line of transmitting the state data to multiple users and units of presenting state data by the user units. Further, the method comprises the steps of receiving input data for a specific component, a specific machine or a specific line of each Benutzeinheit and transmitting the input data to the respective specific component, the respective particular machine or the respective particular line.

While are so far only machines far detects the status data of a machine, and displayed on a specific, of the corresponding machine associated user unit, the inventive method provides the state data line far, or system-wide to capture on several lines, and to mindestes one, preferably several, or even to provide all user units. Characterized a ubiquitous access to the status data of all the lines, machines and components is possible, which forms the basis for a rapid monitoring and deciding by operators.

The general policy is to provide comprehensive state data lines, machines and components.

In order to facilitate navigation within this abundance of status data, is provided to organize the state data in a tree structure, wherein the condition data of each component of the corresponding machine are associated comprising the respective component, and the status data of each machine of the corresponding line are assigned, comprising the respective machine, and the status data of each line arranged next to the status data of each further line is.

Alternatively, of course, be provided to associate the status data of each line the overall system comprising the lines.

Overall, the navigation takes place within the tree structure on three levels. Level 1 forms the line level, level 2, the line-level forms subordinate machine-level and Level 3, the machine-level forms subordinate component level.

First, can thus be provided a navigation following the logical structure of the tree 3 provide, ie when selecting a line to face the user is on the subordinate machine-level all machine line and stand in it, following selection of a particular machine to the user on the component level all components are the selected machine. in order to facilitate navigation on, can be provided in addition, that the user can navigate within a plane that is "horizontal" moved within the tree structure.

So it can be provided about that when a user has selected a particular state parameters of a machine, it can horizontally move to the next machine in the line and direct the relevant state parameters of the next machine is displayed, without having to navigate through the parent line level ,

Furthermore it can be provided, the state data to assign specific topics and to group like that. Depending on the topic and the level of the tree on which the user is located within the display, hence resulting in concrete condition data displayed to the user.

For example, an overview of the machines of the line with a choice of selecting a machine and thus access to the machine level is provided on the line level a topic "Overview".

Accordingly, an overview of the components of the corresponding machine with the possibility of a selection of a specific component and thus access to the component level may then be provided on the machine level.

Furthermore it can be provided "programs" a topic. Under a program is in accordance with an automated sequence of operations of a machine or a component to be understood.

Further, the method comprises the further step of receiving input data for a specific component, a specific machine or a specific line of each user unit, and the step of transmitting the input data to the respective specific component, the respective particular machine or the respective particular line.

In this way, not only a way to monitor the entire line and all lines will each user unit provided, but also provided the ability to control of each user unit of each line, machine or component.

Thus, for example, under the topic "programs" in machine-level, a program selection and a step image of the individual steps are shown. About the program selection, a user can then cause functions such as an empty run, for a test drive, the exit of bottles for lab samples, a blow, a cleaning, a movement of the servo axes, or a provision of the machine in its basic position. At the component level, the user is provided in accordance with a step image component with a program selection of component-related functions, such as a blow or clean the component.

Furthermore it can be provided that a user can be presented with a topic "parameter" in the line-level basic parameters of the line, such as the speed, about the treadmill. On the machine level can also be provided that the machine parameters such as speed about be displayed. Furthermore it can be provided on the machine level, that a user can influence the engine power directly, as by setting speed levels that can be pre-programmed. At the component level, can also be provided that variable parameters and / or target values ​​can be displayed and influenced a corresponding component.

Under a topic "floating image" may be provided on the machine level, that is a flow chart of the corresponding machine is shown and at the component level, a corresponding component are shown of respective section of the machine flowsheet.

Under a topic "analog values" may be provided on the machine level and the component level that an overview of all analog values ​​of the machine or the document is displayed.

Furthermore it can be provided "messages" that are displayed on the lines-level messages that relate to the corresponding line under a topic. Accordingly, further be provided that are displayed on the machine level and at the component level messages that relate to the corresponding machine or component.

Under a topic "variety" can be provided that a user on the line level is shown a view on the currently manufactured end product or in the line of a bottling plant currently bottled final product.

It can be further provided that the user on the line level can set the desired variety to be filled, ie it can be a variety management be provided.

At the machine level can be provided that there is an even bottled variety appears to be filled and the variety may be changed or adjusted. Furthermore it can be provided that a variety Editor can be selected, can be created in the new varieties to choose from on the machine-level and / or at the line level. It can also be provided, which is a function for downloading varieties of another processing unit possible.

It can be provided that the use of a user entity to log a user in this and has log. For each user, a certain profile is stored, which contains various information about the user. These data the user is qualified, his position within the company and its expertise may be stored that define how the user can interact with the lines, machines and components.

Accordingly it can be provided that the presentation of the state data is dependent on the user's profile, that already takes place an automated selection or limitation of the status data shown. Furthermore, the type of input data to be profile-specific regions, ie the user can make only certain inputs depending on its specific competence and position.

Accordingly it can be provided that under a topic "persons" in the line level an overview of all the relevant line associated persons will be displayed. Accordingly it can be provided that all individuals or user are displayed on the machine level, which have logged at a user unit of the machine or associated by other assignment of the machine.

In a topic "Maintenance / Service" may be added or a history of the maintenance actions have already been made are available on the line level an overview to be carried out and after any maintenance actions. Also on the equipment level, a maintenance history be available or even predetermined maintenance intervals, general specifications of the machine or the like. It can also be provided that an input option from the start of a maintenance routine of the corresponding machine is given.

It can be further provided that the user units can communicate with each other. Of course, can also be provided that by means of a user unit liaison with outside agencies or companies may be received either via the Internet or via standard telephone connections.

For then on the machine level under the topic "Maintenance / Service" directly the opportunity be provided to establish contact with a designated service team or a certain external companies and this instructing maintenance of the appropriate machine.

At the component level can under the topic "Maintenance / Service" also be provided technical specifications or data of a corresponding unit to retrieve, as well as the maintenance history and scheduled maintenance intervals. Further information and ordering options for spare parts for the corresponding component can be displayed.

In addition, under a topic "error" on the line level an overview of known error or a history of past errors be available. On the machine-level may also be available, access to a history of error messages. Furthermore it can be provided that a floor plan of the corresponding machine is available. Of course, can also be provided to indicate the cause of the error in the corresponding machine and, directly the possibility be to instruct others to carry out the correction of the error. These in turn can be provided that they can confirm the acceptance of the contract means its troubleshooting user unit on the machine level.

As already stated above, it may be provided that some of these display or input options, especially instructing others searching troubleshooting, only users associated with a corresponding profile available, for example, users with an appropriate position within the hierarchy of the entire system operated companies.

Also at the component level, in the area of ​​"error" can be provided that the cause of the error is displayed. It may optionally be provided that at the same time a photo, a picture or sketch of the faulty component is displayed. At the component level can of course be provided to reproduce a history of error messages and it can also have the option to be provided, to give or to acknowledge troubleshooting instructions.

Furthermore it can be provided that certain error messages are displayed only to users with a specific profile. Thus, already automatically a restriction to be taken to the effect that error messages reach only those users for whom the error messages of interest or relevance. In one embodiment, the display of error messages is such that error messages are always displayed regardless of the current limitation of the representations. So then also error messages of a machine can be displayed, even if currently just anotherMachine is represented by the user unit or any other line or not belonging to the faulty machine component.

As damage may be the case that more users take an input for the same machine, line or component to react, for example, an error message, it may be provided that depending on the profile, only the input data of a single user are received. So a value of the priority of his input data can for example be stored and only the user's input data are transmitted with the highest priority value in case of conflict in each user's profile.

Furthermore, in principle, be provided that the restriction of the representation of the state data and the input data automatically depending on the spatial position of the respective user unit a line, of a machine and / or carried out relative to the at least a minimum of at least one component.

In this way, the navigation can be performed automatically within the tree structure. Basically, the user units can be stationary provided, as well as mobile terminals are provided. For the mobile user terminal units or a wireless network can be provided in an industrial system according to the invention, via which the condition data or the input data are received. For the wireless network, a wireless network or a Bluetooth network or any other suitable data transmission mode can be selected.

The spatial arrangement of the at least one line, the at least one machine and the at least one component may be stored on fixed values ​​or can be determined by appropriate channels on multiple receivers within the wireless network. In principle, a position determination by GPS is conceivable.

In the same way, a position determination of the mobile user units. From the respective position data it is then possible to compare the spatial position of the lines, machines and components with the position of the mobile user unit. This adjustment can possibly take place on another external computing unit.

So can then be provided that is displayed on a user unit always the line, machine or component that is closest geographically to the user unit. For example, to avoid that a user on a maintenance tour constantly manually has to change the display.

Basically, it can be provided that the user unit comprises means for external Show. For example, it may be provided that in a mobile user unit, a video projector is integrated, through which the current view is projected onto a wall or other flat surface. In this way, more people could simply look at the display on the mobile user unit.

Furthermore it can be provided that at a mobile user unit but also to a stationary user unit navigation can be performed by using voice dialing.

In addition, it can be provided that by means of a mobile user unit pictures can be taken and sent about from a damaged machine or component.

Moreover, it can be provided that the mobile user unit comprises a bar code scanner or a scanner generally two-dimensional code. On the lines, machines and components then corresponding one- or two-dimensional code can be attached so that the navigation is performed within the display by scanning the code by means of the mobile user unit. Further, RFID-based markers by means of a corresponding / suitable read / write system may be used.

Ultimately, it may be provided that screenshots can be made from the presentation of stationary or also the mobile unit.

The invention further relates to a computer program with program code means to perform all the steps of a described method when the computer program is executed on a computer or a corresponding computing unit, in particular in an industrial system of the invention.

The computer program can be stored on a computer readable medium.

The present description also covers a computer program product with program code means which are stored on a computer readable medium, adapted to perform all the steps of a described method when the computer program is executed on a computer or a corresponding computing unit, in particular in a control unit.

Further advantages and embodiments of the invention will be apparent from the description and the accompanying drawings.

It is understood that the features mentioned above and those yet to be explained not only in the particular combination indicated but also in other combinations or alone without departing from the scope of the present invention.

The invention is diagrammatically illustrated by way of an embodiment in the drawing and will be described in detail below with reference to the drawing.

Brief Description of Drawings

<figref>1</figref> shows an abstracted view of an industrial system.

<figref>2</figref> shows a flow diagram in the navigation within the representation of the industrial system <figref>1</figref> illustrated.

<figref>3</figref> shows a flow diagram illustrating the display of an error message.

<figref>4</figref> shows a flow chart that can be executed when approaching a mobile user unit of a stationary user unit.

<figref>5</figref> shows a flowchart illustrating the take control of a line, machine or component.

Detailed description

<figref>1</figref> shows abstracts the links within a representation of an industrial system. The industrial system has in the in<figref>1</figref> Embodiment four lines shown <figref>1</figref>. <figref>2</figref>. <figref>3</figref>. <figref>4</figref> on. The line<figref>1</figref> again comprises four machines <figref>10</figref>. <figref>12</figref>. <figref>14</figref>. <figref>16</figref>, Some may be in line<figref>1</figref> be a line for bottling beverages in bottles, each machine performs a corresponding operation within the line, such as the washing and sorting of bottles, filling, sealing the bottles and the labeling of the bottles.

The machine <figref>10</figref> in turn, comprises four components <figref>110</figref>. <figref>112</figref>. <figref>114</figref>. <figref>116</figref>,

Of course, also include the lines <figref>2</figref>. <figref>3</figref>. <figref>4</figref> and the machine <figref>12</figref>. <figref>14</figref>. <figref>16</figref> each several machines or components, but these are not shown for reasons of clarity.

The display is arranged in a tree structure of the state data. According to the invention also not only the state data for a particular machine are shown, but shown the state machines of all data of all lines. Thus, it is possible, within the display between the respective lines<figref>1</figref>. <figref>2</figref>. <figref>3</figref>. <figref>4</figref> to change and within the lines <figref>1</figref>. <figref>2</figref>. <figref>3</figref>. <figref>4</figref> to navigate. In this way, all the data of the industrial system can be accessed on a user unit.

<figref>2</figref> shows a flow diagram illustrating a possible navigation within the representation.

Starting from the starting point A, first a line <figref>1</figref> selected. In principle, of course, possible one of the other lines<figref>2</figref>. <figref>3</figref>. <figref>4</figref> select and move within a line-level between the various lines.

Within the line <figref>1</figref> is possible in one step <figref>301</figref> a specific machine on the line <figref>1</figref> select. If no selection is made, the display remains unchanged, there will be a selection, eg. As the machine<figref>10</figref>, The display on the machine is <figref>10</figref> limited.

Here it is now possible, in a step <figref>302</figref> a component of the machine <figref>10</figref> select. If no such selection instead, in a step<figref>303</figref> another machine will be selected. In this way it is also possible to horizontally within the machine-level to move without executing the navigation via the detour of the parent lines level. If a different machine is selected, the query of point B starts again.

If no other machine is selected, it is possible, in a step <figref>304</figref> bouncing back to the parent lines plane, whereupon the query to point A starts again.

If no selection is made, the display remains unchanged. The query starts again at point B.

If in step <figref>302</figref> a component <figref>110</figref> selected, the machine <figref>10</figref> is subordinate, the display jumps to the component level.

Basically, here's another component in one step <figref>305</figref> are selected so that a horizontal movement at the component level is possible, without having to take a detour via the machine-level and line level.

If no selection in step <figref>305</figref> taken in a step <figref>306</figref> jump back to the machine level. If selected, the query to point B for each ismachine <figref>10</figref>Comprising the component <figref>110</figref> includes, continued.

If no selection in step <figref>306</figref> taken, in step <figref>307</figref> directly on the lines plane back into the line <figref>1</figref> jump, the machine <figref>10</figref> comprises the component <figref>110</figref> includes. The query is then continued at point A.

If these choices not made, the query to point C is continued and the display remains unchanged.

<figref>3</figref> shows a flow diagram illustrating a preferred dealing with error messages within the presentation.

If an error message entered in the user unit at point X, in step <figref>401</figref> first determined whether the error relates to the currently selected for display line. If the selected line is not affected, so nothing is done and the search starts again.

but of course can also be provided in a modified form, that instead of the error message to ignore, a highlight in the presentation is that another line is affected by an error message.

If the selected line concerned, in steps <figref>402</figref>. <figref>403</figref>. <figref>404</figref>. <figref>405</figref> and <figref>406</figref> determines whether the message relates to a currently selected object, ie the currently selected machine or component relates, or a child, parent, alongside child or a child of a sibling object.

Therefore, in the illustration, a status line is provided, which illustrates the current position in the tree structure of the display. Here in the status line by means of an icon, the currently selected line represented the currently selected component by another icon, the currently selected machine and by means of a third icons. If one is on the line level is illustrated according to a line Nicon. If you now select a determined machine, an icon for the selected machine is displayed next to the corresponding line Nicon. If you now select another component, occurs added a third icon representing the selected component.

About these icons to navigate within the display is possible. For example, are bound by selecting the corresponding line icons back in the line-level. It may for example be provided that the user unit has a touch screen that allows for easy selection of icons.

After in steps <figref>402</figref>. <figref>403</figref>. <figref>404</figref>. <figref>405</figref> and <figref>406</figref> it has been determined which object, that is, which machine or component, is affected by the error message, there is a corresponding in appropriate highlighting an icon in the status bar steps <figref>407</figref>. <figref>408</figref>. <figref>409</figref>. <figref>410</figref>. <figref>411</figref> and <figref>412</figref>, then one selects a correspondingly pre hobenes icon, also the corresponding highlighting changes. Thus, following the emphasis in his selection a user only to enter within the tree structure to the afflicted with an error message object, ie, machine or component.

The user therefore does not need to orient themselves within the tree structure, which is a safe navigation, especially in stressful situations possible.

<figref>4</figref> shows a flow chart illustrating one possible solution for a conflict situation in which a user approaching a mobile user unit of a machine which additionally comprises a stationary control unit.

For a stationary user unit while the term panel is used.

Approaching a user of a mobile user unit of a machine with a panel, in a step <figref>401</figref> be determined whether a user is currently using the panel to monitor and control the respective machine. If this is the case, it is provided that no acceptance of the panel and the machine control functions takes place.

Of course, alternatively be provided that the user profiles are compared and the user, which is a higher priority as part of his profile, the control is passed over the panel and the machine.

If no user is logged in to the Panel, may in step <figref>402</figref> be checked whether the panel is permanently assigned to a particular machine. If this is not the case, the instantaneous display of the mobile user unit on the panel is displayed. The user can then use the panel, which has larger, more comfortable display and control elements generally.

If the panel is a particular machine permanently assigned, in a step <figref>403</figref> checks whether the user on the mobile unit currently selected machine dedicated machine complies. If so, the current representation of the mobile user unit on the panel is displayed and the user can turn to use the panel with its more convenient controls for further operation. If this is not the case, an overview of the machine is displayed on the panel, which is automatically adjusted to the user's profile, so that the user can retrieve only those state data and can enter input data that are assigned to him about his profile.

In this way, an automated service acquisition will comfortably realized by stationary user units, if a user moves to a mobile user unit within the industrial system and it approaches the stationary user unit.

<figref>5</figref> shows a flow diagram illustrating one way in which can be dealt with the case of a conflict in which two users want to access the same object, ie, component or machine.

First, it is determined that multiple users want to access the same machine or component. The situation is that a first user is already accessing a first user profile on the machine or component, and then a second user with a second profile also attempts to connect to the machine or component.

In step <figref>501</figref> it is determined whether it is the input of the second user is a safety-critical function, such as stopping a machine due to an error message.

If this is not the case, a user change is carried out.

Of course, also be additionally provided that the user switch is rejected depending despite all of the profiles of the first user and the second user.

If it is a safety-critical function, so, in a step <figref>502</figref> determine which user has a higher privilege or priority. These values ​​are stored in each user profile. If the second user has a lower privilege or priority, the change is rejected and ignored the input of the second user.

Assigns the second user a higher privilege or priority, he has, as a further security level in step <figref>503</figref> to confirm that he wants to carry out a safety critical input.

Failing confirmation this, no user switching is performed, and the input of the second user is ignored. He also confirmed this safety step<figref>503</figref>, The user switch is running and running the input of the second user. The second user is now logged in the corresponding machine and has sole control of the machine.

In this way, simply ensures that want in a safety-critical event, especially when multiple users with mobile user devices receive an error message and resolve this, only the user's input with the highest priority for this case or authorization is performed.

All the above examples were carried out for an industrial system, comprising the three levels line, engine and component.

Naturally, the invention is also suitable for an industrial system with fewer or more than three levels. In particular, the present invention is also applicable to applications other than for bottling beverages.