Method and apparatus for providing audio messages from industrial equipment

A system for providing audible messages detailing machine issues in a manufacturing process when a manufacturing machine is not operating properly comprises a transmitter associated with each machine and one or more receivers. The transmitter communicates with the manufacturing machine to identify issues and transmits a corresponding message to specific receivers based on unit identifies and network addresses. The receiver includes a message storage element, an audio playback element, and selection controls to configure the radio frequency channel, the unit address, and the network address.

FIELD OF THE INVENTION

Embodiments of the inventive concepts disclosed herein are directed generally toward industrial equipment and more particularly accessories to industrial equipment to provide near real-time feedback.

BACKGROUND

Manufacturing companies utilize manufacturing equipment to produce products. Such equipment requires human operators to run and monitor the equipment. In many cases, human operators run and monitor multiple machines to minimize labor costs. In these situations, it is difficult for these human operators to quickly identify when and why a machine stopped, leading to extended downtimes. Existing machines provide information to the human operator in the form of video displays, stack lights, and audio alarms.

Video displays present readable information but human operators are not typically monitoring the displays at all times so there is a delay in reading the information. Stack lights provide an indication of machine mode; for example, Green indicating running, Yellow indicating waiting, and Red indicating down. Stack lights typically provide limited information concerning the reasons for any issues. Stack lights are not typically noticeable by the human operator unless they are looking directly at the stack lights. Audio alarms signal the human operator that the machine requires attention. Furthermore, responses to any machine issues are not immediate. While audio alarms provide a quick notice to the operator that the machine needs attention, it does not provide the reason for any issues.

Productivity of the machines is based on operational runtime: the more downtime, the less productive the machine. Most manufacturing production lines consist of multiple machines operating in series to form a production line. If one of the machines in the production line goes down, the whole production line is down. Furthermore, manufacturing is typically a noisy environment such that human operators require hearing protection, further hindering the usefulness of audio alarms.

Consequently, it would be advantageous if an apparatus existed that is suitable for identifying faults in a machine in a manufacturing process and remotely delivering details of the fault to a human operator in a timely fashion.

SUMMARY

In one aspect, embodiments of the inventive concepts disclosed herein are directed to identifying faults in a machine in a manufacturing process, filtering those faults according to a selected set of human operators, and remotely delivering audio representations of the fault to the set of human operator in a timely fashion.

In a further aspect, audio representations are stored in a plurality of languages such that the language actually received by a particular human operator or set of human operators is specific to the recipient.

DETAILED DESCRIPTION

Broadly, embodiments of the inventive concepts disclosed herein are directed to a system and method for reducing manufacturing equipment downtime by facilitating detailed communication of machine faults to human operators and thereby improve productivity.

Referring toFIG. 1, a block diagram of an exemplary computer system for implementing embodiments of the inventive concepts disclosed herein is shown. In some embodiments, the system100comprises a processor102, memory104connected to the processor102for embodying processor executable code, a data transmission element108connected to the processor102, and one or more physical connectors110connected to the processor102for integrating the system100with a machine in a manufacturing process via a machine controller as described herein. A person skilled in the art may appreciate that the processor102may comprise a general purpose processor configured by firmware; alternatively, the processor102may comprise a specialized hardware element. The data transmission element108may be a wireless data transmission element (such as an antenna) or a wired connector. Furthermore, both wired and wireless connections may be employed in the same device.

In some embodiments, the physical connector110comprises a universal serial bus (USB) port for power and data communication for uploading, downloading, or otherwise changing audio data. Said audio data may be encoded according to an appropriate audio codex, and be stored in any language to accommodate human operators for whom English is not the primary language.

Machines in a manufacturing process generally include some internal system status and fault detection logic. The system100integrates with that internal logic via the physical connector108. The processor102receives status and fault messages from such physical connector108. The processor102may filter the status and fault messages to identify messages to forward to a corresponding human operator via the data transmission element108. In some embodiments, the processor102may deliver various subsets of messages to different receivers; for example, all messages may be delivered to a centralized process monitoring system while all fault messages are delivered to the human operator. Furthermore, critical fault messages may be delivered to a supervising human operator.

In some embodiments, the system100further comprises a data storage element106connected to the processor102for storing audio data. In some embodiments, the data storage element106may store audio messages associated with each potential fault message that might be delivered to the processor102. When delivering messages to a human operator, the processor102may transmit corresponding audio data. Furthermore, the data storage element106may buffer a plurality of audio messages based on the order each audio message was received and initiate playback accordingly.

In some embodiments, the system100further comprises a user interface114. The user interface114allows the processor102to be configured to send subsets of messages to different sets of receivers as more fully defined herein. The user interface114may comprise one or more channel switches to facilitate communication through a pre-defined set of available channels.

Referring toFIG. 2, a block diagram of an exemplary computer system for implementing embodiments of the inventive concepts disclosed herein is shown. In some embodiments, the system200comprises a processor202, memory204connected to the processor202for embodying processor executable code, a data receiving element208connected to the processor202, and a speaker210connected to the processor202for delivering audio data to a human operator. In some embodiments, the speaker210may be embodied in noise cancelling headphones to enhance the audio data in a noisy manufacturing environment.

Where machines in a manufacturing process include components for sending status and fault messages, the system200receives those messages via the data receiving element208. In some embodiments, where the messages include audio data corresponding to a description of the message, the processor202plays the audio data through the speaker210for the human operator. In some embodiments, the processor202filters the received messages based on some desired audio playback setting, provided that the received message is directed to a unit address corresponding to the system200and network address and the channel frequency of a data receiving element208matches or recognizes a transmitter network address and channel frequency.

In some embodiments, the processor202may determine playback of the audio data based on a selected subset of messages; for example, all messages may be received, but only audio data associated with fault messages are actually played.

Audio data may be stored in any language to accommodate human operators for whom English is not the primary language. Furthermore, audio data corresponding to similar fault identifiers may be stored in different languages in separate receiver systems200such that different human operators may easily comprehend the audio messages they receive.

In some embodiments, the system200further comprises a data storage element206connected to the processor202for storing audio data. In some embodiments, the data storage element206may store audio messages associated with each potential fault message that might be received by the processor202; messages in such an embodiment may comprise only an identification code. Alternatively, the processor200may be configured to parse a text string corresponding to a message into individual words and play audio elements corresponding to each word without storing a complete audio version of the complete message.

In some embodiments, the system200further comprises a user interface214. The user interface214allows the processor202to be configured to filter subsets of messages for audio playback. The user interface214may comprise one or more channel switches to facilitate communication through a pre-defined set of available channels. The user interface214may comprise a unit select component to allow the operator to select a plurality of different unit addresses of the device to identify the type of audio messages to be played. For example, the unit select component may designate messages for electrical technicians, mechanical technicians, engineers, etc. Furthermore, a unit select component may be used to select from different stored languages.

In some embodiments, the system200further comprises a display element212. Text associated with messages received by the processor202may be displayed on the display element212to provide a less transitory version of the message and allow a human operator to immediately see details contained in the message. In some embodiments, the display element212may be combined with the user interface216in the form of a touch sensitive film for selecting messages in a list of received messages.

In some embodiments, the system200further comprises a haptic feedback element214for providing a tactile sensation when a message is received, in addition to the auditory playback, or instead of the auditory playback if the message is of a type selected for removal by filtering, or if no audio data is associated with the specific message.

In some embodiments, the processor200is configured to monitor available power. When a low threshold of available power is identified, the processor200initiates a stored audio message indicating a low power state.

Referring toFIG. 3, a block diagram of machines in a production process according to embodiments of the inventive concepts disclosed herein is shown. A production process may include a plurality of production machines300,308,316, each performing a particular operation in the production process. Production machines300,308,316are generally controlled by an industrial controller302,310,318commonly referred to as a programmable logic controller (PLC). PLC's utilize an industrial communication port to communicate with a plurality of other devices, including, but not limited to, other PLC's, human-machine-interfaces, bar code readers, input and output devices, data collection systems, etc.

Each industrial controller302,310,318detects status or one or more faults in the corresponding production machine300,308,316, and delivers status and fault data to a corresponding communication element304,312,320configured to send such status and fault data, via a transmission element306,314,322, to one or more receivers324. Each industrial controller302,310,318may communicate with a corresponding communication element304,312,320via any appropriate data communication technology including, but not limited to, Ethernet, Ethernet IP, Profibus, RS232, RS422, and ControlNet. In some embodiments, each industrial controller302,310,318exchanges register information with a corresponding communication element304,312,320. In some embodiments, each communication elements304,312,320provides audio messages corresponding to the status and fault data, or some subset of the status and fault data, to one or more human operators. The one or more human operators may be divided into sets based on function or proximity. Each of the one or more receivers324may be associated with one set of human operators based on selected channels of communication where each communication element304,312,320is configured to deliver different sets of status and fault data to different channels of communication.

Each receiver324includes a processing element326that receives the status and fault data via a data receiving element328and plays audio data corresponding to the status or fault data through a speaker332. In some embodiments, the receiver324may also include a display330for displaying additional data pertaining to the status or fault data.

When a production machine300,308,316has an issue, the corresponding industrial controller302,310,318sends a fault message to the corresponding communication element304,312,320which then relays the fault message, and in some embodiments corresponding audio data, to the one or more receivers324for playback to one or more human operators. This allows the human operators to address the production machine's300,308,316issues quickly and reduce downtime.

Transmission elements and corresponding receiving elements328may utilize any of a plurality of wireless transmission technologies, including, but not limited to, wireless RF in any range of frequencies (i.e. 2.4 Ghz, 900 Mhz, etc.), WIFI, Bluetooth, etc. Alternatively, spread spectrum frequency hopping methodology may be used to avoid interference.

In some embodiments, each industrial controller302,310,318may have access to certain data pertaining to the corresponding production machine300,308,316; for example, the industrial controller310a second production machine308may track the number of articles of production, produced by a first production machine300, still available to the second production machine308when the first production machine300fails. A corresponding second communication element312may use such data to determine an estimated duration until downtime begins for the second production machine308if the failure of the first production machine300is not rectified. Similar calculations could be performed for every production machine300,308,316in the production process. Alternatively, where the receiver324receives such status data but does not report it either audibly or visually on a regular basis, the processor326may perform similar downtime estimations and report them to the human operator either audibly through the speaker332or visually through the display element330.

In one exemplary implementation, a first production machine300is connected to first communication element304which has been configured for a specific network address and a specific channel. A first human operator wears a first receiver324which has been configured with a specific unit address, network address, and channel. A second human operator wears a second receiver324which has been configured with a specific, different unit address, but the same specific network address and channel. The first human operator operates the first production machine300as needed by starting and stopping the production machine300, clearing jams, etc. The second human operator supplies production parts to the first production machine300as needed. A first industrial controller302associated with the first production machine300is configured to communicate with the first communication element304associated with the first production machine300. Communication between the first industrial controller302and the first communication element304comprises a minimum of two data registers: the first data register containing the unit address of the receiver324the message is intended to be sent to, and the second data register containing a message number to be played by the receiver324. The first industrial controller302is configured to send messages to the first human operator when errors such as “Machine Jams,” “Temperature errors,” “air pressure errors,” etc. are detected by the first industrial controller302. The first industrial controller302will be programmed to send messages to the second human operator when errors such as “Out of or low on part supply” are detected by the first industrial controller302. Each human operator only hears messages concerning their respective functions.

In another exemplary implementation, a first production machine300is connected to first communication element304which has been configured for a first network address and a specific channel, and a second production machine308is connected to second communication element312which has been configured for a second network address and a specific channel.

A first, a second, and a third human operator wear a first, a second, and a third receiver324respectively, which have been configured with a different unit addresses, but the same first network address, and channel. A fourth and a fifth human operator wear a fourth and a fifth receiver324respectively, which have been configured with a different unit addresses, but the same second network address and channel. A sixth human operator wears a sixth receiver324which has been configured with a specific unit address, and a group network address, and channel to receive all messages. Furthermore, a group receiver324connected to a loudspeaker is also configured to receive all messages from each of the production machines300,308.

The first, second, and third human operators will only hear messages from the first production machine300directed to their specific unit addresses. In some embodiments, a specific unit address may indicate receipt of all messages sent to any unit address. Likewise, the fourth and fifth operators will only hear messages from the second production machine308directed to their specific unit addresses, while the sixth human operator receives all messages from both the first and second production machines300,308.

Referring toFIG. 4, a block diagram of machines in a production process according to embodiments of the inventive concepts disclosed herein is shown. A production process may include a plurality of production machines400,408,416, each performing a particular operation in the production process. Each production machine400,408,416comprises an industrial controller402,410,418for detecting the status or one or more faults in the corresponding production machine400,408,416, and delivering status and fault data to a corresponding communication element404,412,420configured to send such status and fault data, via a transmission element406,414,422, to a receiver424. The industrial controllers402,410,418further send all status and fault data to centralized monitoring facility434, which may be embodied in one or more computer servers.

The receiver424includes a processing element426that receives the status and fault data via a data receiving element428and plays audio data corresponding to the status or fault data through a speaker432. In some embodiments, the receiver424receives status and fault data from the centralized monitoring facility434rather than separately from each of the individual communication elements communication elements404,412,420; in such embodiment, the centralized monitoring facility434may perform filtering operations on the status and fault data before sending such data to the receiver424. In some embodiments, the receiver424may also include a display430for displaying additional data pertaining to the status or fault data.

Referring toFIG. 5, a flowchart of an exemplary method for providing feedback of a machine in a production process to a human operator substantially in real-time according to embodiments of the inventive concepts disclosed herein is shown. In a production process, each production machine includes a communication element that receives500one or more status or fault messages from internal logic in the production machine. In some embodiments, the communication element filters502the one or more status or fault messages based on a desired threshold of criticality, associating subsets of messages with different recipients (mechanical failures directed to maintenance channel, technical computer failures directed to a technical support channel, and non-failure status messages directed to a general channel or filtered out completely). The communication element then sends504the filtered status or fault messages to one or more receivers configured to receive such messages in one or more channels.

A corresponding receiver element receives506the filtered status or fault messages, identifies508an audio component associated with one of the one or more filtered status or fault messages, and plays510the audio component for a human operator.

Embodiments of the inventive concepts disclosed herein provide near real-time audio messages to operators, technicians, engineers, production managers, and other associates concerning the status of machines in a production process. The audio messages, at the receiver, begin to play almost instantly enabling the operator to respond such that the machine downtime is minimized. Audio messages are directed to a specific operator or a group of operators, and technicians needed to respond to specific faults. Different faults may require different individuals, potentially in different languages, to respond, eliminating messages to associates who do not need to respond

Receivers can be set to one of a plurality of different channel frequencies or network addresses such that a plurality of systems can be utilized in the same area without interfering with one another.

While specific exemplary embodiments have been described relating to manufacturing equipment, other applications are envisioned. For example, in a medical environment, similar embodiments may be employed to alert various sub-sets of staff members whenever status messages pertaining to the state of a machine or patient connected to the machine are generated by the machine.

Also, while some embodiments employing wireless connectivity require a certain degree of proximity between transmitters and receivers to be operable, other embodiments may employ network connectivity such that messages may be delivered to non-local users or monitoring systems.

It is believed that the inventive concepts disclosed herein and many of their attendant advantages will be understood by the foregoing description of embodiments of the inventive concepts disclosed, and it will be apparent that various changes may be made in the form, construction, and arrangement of the components thereof without departing from the broad scope of the inventive concepts disclosed herein or without sacrificing all of their material advantages. The form herein before described being merely an explanatory embodiment thereof, it is the intention of the following claims to encompass and include such changes.