Abstract:
A system is provided that monitors and controls a manufacturing process at a manufacturing location from a remote location. The system includes at least one sensor which measures a discrete measurable parameter of the manufacturing process such as temperature, pressure, flow rate, cycle time or cure time. A signal generator connected to the sensor produces a digital signal which is transmitted from the manufacturing location to the remote location. The transmitted signal is processed at the remote location and operational instructions are sent from the remote location to the manufacturing location as needed.

Description:
RELATED APPLICATIONS  
       [0001]    This application is based upon provisional patent applications Ser. Nos. 60/078,605 filed Mar. 19, 1998, and 60/079,441 filed Mar. 26, 1998, U.S. Ser. No. 09/277,442, and upon U.S. Ser. No. 08/715,533 filed Sep. 18, 1996, U.S. Ser. No. 09/267,189 filed Mar. 12, 1999, and U.S. Ser. No. 09/309,160 filed May 10, 1999. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to (1) a system and process for the continuous monitoring and control of a composite material manufacturing process on a real-time basis from a location remote from the manufacturing site and (2) the manufacture of composite articles, that is, articles typically comprising a fiber reinforcement lattice within a cured resin matrix.  
           [0004]    2. Description of Related Art  
           [0005]    a. Processes for Monitoring of Manufacturing Equipment  
           [0006]    Continuous monitoring of manufacturing equipment from a remote location is disclosed in “Prigent,” U.S. Pat. No. 5,668,741. Prigent teaches using defined channels to continuously inspect fundamental elements of the manufacturing process in order to detect any changes in the products or machine. The data is processed in each channel by frequency estimators and then analyzed in order to detect major variations and to trigger an alarm signal. A monitor analyzes the various alarm signals to correlate them with expected changes in order to accept these alarms and to record the state of the manufacturing process when the alarms relate to aberrant phenomena.  
           [0007]    In the monitoring system disclosed in Prigent, the operator first determines each of the fundamental elements of the manufacturing process. Each of these fundamental elements is the subject of isolated processing in a channel. The monitoring of each fundamental element is provided by a selected sensor having particular monitoring parameters.  
           [0008]    In order to limit to the greatest possible extent the effect of external perturbations on the signal coming from the sensor, the links between the sensor and the analog-to-digital converter responsible for making this signal discrete are reduced to the maximum possible extent. The limitation of the external perturbations is needed to limit the effects of external phenomena affecting the signals before analysis.  
           [0009]    The process described in Prigent permits the study of a manufacturing process in delayed time when an abnormality has been detected. This study is carried out if an historical recording of the sensors has been effected and stored in each of the channels. Each channel is equipped with a frequency estimator for processing the signals coming from the sensor and transforming the time-related values and to values which are a function of the frequency. This is done in order to limit the data passing over the network. The values which are a function of their frequency are then taken up at the channels so as to be analyzed and the result of this analysis is sent over a network to one or more monitors.  
           [0010]    Although the prior art discloses a method for monitoring a manufacturing process from a remote location, this process does not provide for direct control of the manufacturing process from the same remote location. Moreover, the prior art monitoring process monitors transient or perturbing phenomena and directs action to be taken thereupon. The ability to directly control a manufacturing process in the absence of such transient or perturbing phenomena (i.e., in normal ordinary operation) is heretofore unreported.  
           [0011]    b. Manufacture of Composite Articles  
           [0012]    Reaction injection molding and resin transfer molding are processes wherein dry fiber reinforcement plys/preforms are loaded in a mold cavity whose surfaces define the ultimate configuration of the article to be fabricated, whereupon a flowable resin is injected under pressure into the mold cavity (mold plenum) thereby to saturate/wet the fiber reinforcement plys/preforms. After the resinated preforms are cured in the mold plenum, the finished article is removed from the mold.  
           [0013]    The prior art teaches injection molding apparatus which consist of a pair of complementary or ‘matched’ tools which provide these molding surfaces, with each tool being carefully machined, for example, from a rigid metal which is otherwise relatively nonreactive with respect to the resin to be used in conjunction therewith. Such matched metal molds are expensive to fabricate and are necessarily limited to the manufacture of a single article of a given design. Stated another way, even slight changes to the desired configuration of the article to be fabricated may necessitate the machining of an entirely new replacement tool.  
           [0014]    Additionally, such known metal tools typically have substantial thermal mass which becomes increasingly problematic as the mold temperature deviates from the desired process temperatures. In response, such tools are often provided with an integral system of internal heating and/or cooling tubes or passages through which an externally supplied heating/cooling fluid may be circulated. However, in accordance with these prior art designs, the heating/cooling passages are positioned relative to the tool surfaces so as to leave a minimum spacing of perhaps 2 inches (5 cm) therebetween to ensure that the resulting article will be free of hot and cold lines or bands which might otherwise be generated in the article as a result of disparate heating/cooling rates during resin cure. This minimum spacing, in turn, inherently limits the ability of these prior art tools to accurately control temperature during the injection molding process, again, particularly where such processes are exothermic. And temperature control of the mold plenum becomes further problematic where variable-thickness articles are to be fabricated, given that the thicker portions of the article may well polymerize earlier, and will likely reach higher temperatures, than the thinner portions thereof.  
           [0015]    Still further, where matched metal tools are utilized in processes employing reduced cycle times, the sizable thermal mass of such metal tools can often generate peak temperatures in the range of about 375 degrees F. to about 400 degrees F., resulting in ‘dry spots’, which will likely render the finished article unusable. Accordingly, such matched metal tools may have to be periodically idled for sufficient time to permit the mold to cool to an acceptable operating temperature, thereby substantially increasing the cost of article fabrication using such tools. Finally, at the other end of the temperature scale, reduced mold temperatures are known to increase the rate of styrene build-up when used with resins employing styrene monomers, thereby precipitating greater frequency of styrene build-up removal and associated labor costs and equipment down-time, with an associated increase in process cost.  
           [0016]    In an attempt to provide increased temperature control while facilitating removal of the finished article from the molding apparatus, the prior art teaches a modified molding apparatus wherein one of the mold surfaces is defined by a flexible member formed, for example, of rubber. The other mold surface is still defined by a rigid, thermally-conductive metal tool which may be backed by a pressurized fluid such as steam whereby curing heat is transferred to the mold cavity for endothermic molding operations. Unfortunately, for such endothermic processes, heating but one side of the mold cavity may limit flexibility as to surface finish and other characteristics of the resulting article and, further, limit the degree to which resin cure may be accelerated. Moreover, where such molding apparatus are used in exothermic processes, the resulting heat accelerates deterioration of the flexible mold surface, thereby preventing long-term use of the tool. Moreover, such molding apparatus often requires evacuation of the mold plenum prior to injection of the resin therein, thereby rendering use and maintenance of such molding apparatus more complex, and processes employing such apparatus more time intensive and costly.  
           [0017]    What is needed, then, is a matched-tool injection molding apparatus featuring replaceable mold surfaces which are easier and less costly to fabricate than known rigid or flexible tools while further offering increased temperature control (and the capability of remote monitor and control) during both endothermic and exothermic processes thereby to provide articles of improved quality at lower cycle times.  
         SUMMARY OF THE INVENTION  
         [0018]    The process and system of the present invention provide for the real-time monitoring and control of a manufacturing process, power balancing, formulation, testing equipment and diagnostics from a remote location.  
           [0019]    The present invention also provides an injection molding apparatus featuring reusable low-cost molding surfaces.  
           [0020]    The present invention also provides an injection molding apparatus featuring enhanced temperature control of its molding surfaces, whereby improved control of the mold process and attendant article characteristics can be achieved.  
           [0021]    In many manufacturing applications, such as in the organic processes that have aerobic changes in raw materials and the molding of plastic of fiberglass products, the ability to obtain products of consistent quality can be achieved only through the use of techniques developed through extensive trial-and-error tests. Optimal conditions, such as time, temperature, pressure, and material constituents and preferred techniques are generally possessed by a select group of artisans or technicians skilled in the particular manufacturing operation or organic chemistry. Such optimal conditions and techniques are typically not known by the manufacturer or assembler of the products, but may be known by the developer of the process equipment, chemicals and other raw materials.  
           [0022]    In order for a product manufacturer to use specialized manufacturing equipment, it must either acquire all of the technology, including the techniques necessary for the operation of the particular equipment, chemicals and other raw materials or it must hire an employee or independent contractor personnel specially trained in the operation of the particular equipment. It is generally not feasible for the product manufacturer to use the employees of the equipment developer to monitor and control the equipment on the product manufacturer&#39;s site. However, it is often desirable for the product manufacturer to have employees of the equipment developer monitor and control the operation of the equipment.  
           [0023]    In the present process, the monitoring and control of the manufacturing process is performed from a remote site through a dedicated communication line or through a secured Internet communication. Key variables in the manufacturing process that affect quality and through put and other process optimization features are selected as target variables. These target variables are then monitored by instrumentation that produces digital signals that are fed back to a PLC. The PLC operates a sequence of programmed controls that keep the process running through a predetermined sequence of events. The measurable data is then transmitted over a digital telephone line, satellite or equal digital transfer infrastructure to a remote site.  
           [0024]    At the remote site, process control software evaluates the data and adjusts the operating system&#39;s parameters within certain control limits. The remote site has the ability to change the programming of the PLC remotely and, ultimately, the manufacturing process. The remote monitoring and control is performed on a real-time basis, thereby permitting thousands of intelligent adjustments to the process variables on a real-time basis. The economics of adjusting operating variables on a micro basis in real-time fashion creates major savings in energy, material, labor, costs of quality, and the ability to optimize asset management.  
           [0025]    The operating system has a closed loop of monitoring and control features that permits programming instruction to be self-adjusting. The centralized monitoring of the systems creates data archives that can be mined at a later date in order to verify process parameters and permits the documentation of human expert system adjustments, leading to cause-and-effect problem-solving trends that can be duplicated by software that monitors the key variables and then adjust process parameters to perfect the process control. The ability to self-adjust process parameters based on variable inputs produces variable outputs that could be placed under or within control limits. The key variables are then fed back to the control programs that possess the ability to adjust the process perimeters based on input variables.  
           [0026]    Under the present invention, an injection molding apparatus includes a pair of mold sections, wherein each mold section itself includes a rigid housing and a semi-rigid membrane removably mounted to the housing so as to define a fluid-tight chamber therein. The membrane of each mold section, which, in turn, defines its molding surface, is preferably formed of an inexpensive composite material such fiberglass or reinforced nylon, or other suitable material; and, in accordance with the present invention, different membrane materials and/or characteristics may be selected for the respective membranes of each mold section. When the two mold sections are assembled with their respective molding surfaces in opposition to one another, a molding plenum is defined within which to fabricate the desired article. Thus, under the present invention, design changes to the article are readily accommodated through alteration or replacement of the low-cost membrane(s). Stated another way, under the present invention, a given mold section housing may be outfitted with a wide variety of relatively inexpensive composite membranes useful in the production of composite articles of different shapes, sizes and characteristics, thereby greatly reducing tooling costs as compared to the prior art.  
           [0027]    The present invention also provides an injection molding apparatus featuring reusable low-cost molding surfaces and an injection molding apparatus featuring enhanced temperature control of its molding surfaces, whereby improved control of the mold process and attendant article characteristics can be achieved.  
           [0028]    In accordance with the present invention, a noncompressible fluid is disposed within and fills the chamber of each mold section, whereby its respective membrane is supported so as to ensure proper dimensioning of the finished article while permitting slight dimensional flexing during resin injection thereby to evenly distribute any injection-loading of the membrane across its entire surface. The latter feature may prove especially advantageous where a spike in injection pressure is encountered during the resin injection step. As a further advantage, such slight dimensional flexing of the membrane during resin injection is believed to improve or enhance the flow of resin through the mold plenum. An expansion chamber in fluid communication with the chamber of one or both mold sections serves to accommodate thermal expansion of the membrane-backing fluid prior to injection of resin into the mold plenum, and subsequent to cure of the finished article, with a valve operating to isolate the chamber from the expansion chamber during resin injection and cure.  
           [0029]    And, in accordance with another feature of the present invention, the backing fluid is itself preferably thermally conductive; and the molding apparatus further includes means in thermal communication with the backing fluid within one or both of the mold sections for regulating the temperature of the backing fluid. For example, in a preferred embodiment, the temperature regulating means includes a system of coils extending within each chamber, and an external heater/chiller unit of conventional design which is connected to the coil system and is operative to circulate a temperature control fluid at a predetermined temperature therethrough. In this manner, the temperature of the backing fluid and, correlatively, of the molding surface of each mold section may be closely regulated, thereby offering improved characteristics of the finished article and/or improved control of process parameters, such as cure time and temperature. Additional benefits of such temperature regulation of molding surfaces include, for example, reduced styrene build-up, with an attendant reduction in mold down-time and mold maintenance costs as compared to prior art molding apparatus. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0030]    Other characteristics and advantages of the invention will be clear from a reading of the following description and an examination of the accompanying drawing in which:  
         [0031]    [0031]FIG. 1 is a partially diagrammatic, partially exploded isometric view of an injection molding apparatus in accordance with the present invention; and  
         [0032]    [0032]FIG. 2 is a cross-sectional view of the apparatus shown in FIG. 1 along vertical plane passing through line  2 - 2  thereof subsequent to assembly of the upper mold section onto the lower mold section thereof.  
         [0033]    [0033]FIG. 3 shows a schematic representation of the architecture used in a first presently preferred embodiment of the present monitoring and control process.  
         [0034]    [0034]FIG. 4 shows a schematic representation of the architecture used in a second presently preferred embodiment of the present monitoring and control process.  
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0035]    Referring to FIG. 1, an exemplary apparatus  10  under the present invention for molding a composite article includes a mold assembly  12  having an upper mold section  14  and a lower mold section  16  which define, upon assembly of the upper mold section  14  onto the lower mold section  16  with the aid of locating pins  18  and complementary locating slots  20 , a mold plenum  22  with the matched molding surfaces  24 , 26  thereof. Specifically, the lower and upper mold sections  14 , 16  each include a rigid housing  28 , 30  and a relatively thin, semi-rigid membrane  32 , 34  which is removably and sealably secured to the respective housing  28 , 30  along the membrane&#39;s peripheral edge as by a clamping ring  36 . Thus assembled, the housings  28 , 30  and membranes  32 , 34  of each mold section  14 , 16  cooperate to define fluid-tight chambers  38 , 40  therein.  
         [0036]    In accordance with one feature of the present invention, each membrane  32 , 34  is itself preferably formed of a composite overlay which, in its most elegant form, may simply comprise splash off of a blank of the article to be fabricated. And, while each membrane  32 , 34  may conveniently be formed of fiberglass or reinforced nylon, the present invention contemplates use of semi-rigid membranes  32 , 34  fabricated from other suitable materials such as light sheet metal, which membranes  32 , 34  may be conveniently and cheaply fabricated, shaped and reshaped in a pressure chamber in a manner known to those skilled in the art. In this regard, it is noted that the present invention contemplates use of either the same or different materials for the respective membranes  32 , 34  of each mold section  14 , 16  depending, for example, upon the desired characteristics of the sheet (e.g., its thermal conductivity, formability, and usable life), the desired characteristics of the fabricated article (e.g., surface finish and gloss), and/or overall process parameters (e.g., resin injection pressures, resin cure time and mold assembly cycle time).  
         [0037]    The fluid-tight chambers  38 , 40  defined within each mold section  14 , 16  are completely filled with a substantially non-compressible heat-conductive fluid  42  supplied by a fluid supply network  44  prior to injection of resin into the mold plenum  22 . The fluid  42  within each chamber  38 , 40  thereby provides support for each membrane  32 , 34  in compression during resin injection in a manner to be further described below.  
         [0038]    In the preferred embodiment shown in FIG. 1, the membrane-backing fluid  42  is conveniently tap water which is supplied by the network  44  to the upper and lower mold assemblies  14 , 16  as through respective inlet control valves  46  and quick connect couplings  48 . Other suitable backing fluids useful over different operating ranges (e.g., having higher vaporization temperatures) will be known to those skilled in the art. A pressure gauge  50  may be employed downstream of each inlet valve  46  to monitor the flow rate of backing fluid  42  into the chamber  38 , 40  of each mold section  14 , 16 . To facilitate the filling and emptying of each chamber  38 , 40 , each mold section  14 , 16  has a vent  52  through which air within each chamber  38 , 40  may escape upon the filling thereof with backing fluid  42 . Once filled, each chamber&#39;s vent  52  is sealed with a vent plug  54 , thereby imparting requisite rigidity to each mold section&#39;s membrane/molding surface  24 , 26 .  
         [0039]    As seen in FIG. 2, wherein the relative dimensions of, for example, the membranes  32 , 34  and mold plenum  22  are exaggerated for ease of illustration, each mold section  14 , 16  includes a system of heating/cooling coils  56  extending within the fluid-tight chamber  38 , 40  thereof which are themselves coupled via quick connect couplings  58  to an external heater/chiller unit  60  of conventional design. As such, the coils  56  operate in conjunction with the heater/chiller unit  60  to precisely regulate the temperature of the backing fluid  42  and, hence, the molding surface  24 , 26  of each membrane  32 , 34  throughout the injection molding process. And, while the coils are illustrated in FIG. 2 as being located proximate to the back side of the composite membrane, under the present invention, the thermal conductivity of the backing fluid  42  enables substantial design variation with respect to placement of the coils  56  within the chamber  38 , 40  of each mold section  14 , 16  which, in turn, facilitates use of a given mold section housing  28 , 30  and coil system  56  with a wide variety of membranes  32 , 34 . Indeed, under the present invention, while the membranes  32 , 34  of the exemplary apparatus  10  are shown in FIG. 2 as being of relatively uniform thickness, the efficiency with which mold temperature may be controlled under the present invention permits the use of variable-thickness membranes  32 , 34 , as may be desirable, for example, when providing the finished article with reinforcement ribs.  
         [0040]    To the extent that the backing fluid  42  with which each mold section  14 , 16  is filled is supplied at a temperature different from the desired process temperature, the fluid supply network  44  further includes a low-pressure expansion chamber  62 . Thus, upon subsequent heating or cooling of each mold section  14 , 16  to the desired temperature, any resulting thermal expansion of the backing fluid  42  within each chamber  38 , 40  will be accommodated by the expansion chamber  62 , thereby preventing distortion and/or deleterious stress on the membranes  32 , 34 .  
         [0041]    Returning to the Drawings, an injection, sprue  64  may be seen in FIG. 2 as extending through the upper mold section  14  to provide a pathway through which a desired thermoset resin from a resin supply  66  may be injected under pressure by a suitable pump  68  into the mold plenum  22 . The number and placement of such sprues  64  depends upon the configuration and desired characteristics of the article to be molded, and the flow characteristics of the resin employed, in a manner known to those skilled in the art. In this regard, it will be seen that a series of small vents  70  is provided between the opposed clamping rings  36  of the upper and lower mold sections  14 , 16  through which trapped air may bleed to atmosphere during injection of the resin into the mold plenum  22 .  
         [0042]    In accordance with another feature of the present invention, the exemplary molding apparatus  10  further includes a mechanism indicated generally by reference numeral  72  on the lower mold section  16  for vibrating the mold assembly  12  or, at a minimum, the backing fluid  42  contained in the lower mold section  16 . Vibration of the mold assembly  12 /backing fluid  42  during injection of the resin is believed to facilitate resin flow through the mold plenum  22 , as well as to improve saturation and wetting of fiber reinforcement preforms (not shown) situated therein.  
         [0043]    In accordance with the present invention, the exemplary molding apparatus shown in the Drawings may be used as follows one or more fiber reinforcement preforms are laid within the mold cavity defined by the ‘female’ molding surface  26  of the lower mold section  16 . The upper mold section  14  is thereafter lowered onto the lower mold section  16  so as to engage each locating pin  18  with its respective locating slot  20  (where desired, the upper mold section  14  may then be secured to the lower mold section  16  as through the use of suitable clamps, not shown). Each mold section  14 , 16  is then connected to the backing fluid (water) supply network  44 , and its respective vent  52  is opened and inlet valve  46  is operated, thereby to completely fill the chamber  38 , 40  therein with water.  
         [0044]    Once the chambers  38 , 40  are completely filled, each mold section vent  52  is sealed with its respective vent plug  54  and the heater/chiller unit  60  operated to bring each mold section  14 , 16  to the desired process temperature. The inlet valve  46  to each mold section  14 , 16  is thereafter closed to isolate its respective chamber  38 , 40  from the fluid supply network&#39;s expansion chamber  62  (which otherwise has accommodated any thermal expansion of the backing fluid  42  during temperature normalization). By way of example only, where the resin to be injected is a thermoset polyester or vinylester resin, the desired operating temperature necessary to provide desired flow characteristics for a given thermoset polyester or vinylester resin has been shown to be 140 degree(s) F. to about 150 degree(s) F.  
         [0045]    The desired resin is thereafter injected under pressure into the mold plenum  22  through the injection sprue  64 . Where the membranes are formed, for example, of fiberglass with a nominal thickness of perhaps about 0.375 inches (0.95 cm), a typical injection pressure used in injecting a thermoset polyester or vinylester resin having a viscosity between of between about 400 and 800 centipoise into the mold plenum  22  is preferably less than about 100 psig (690 kPa) and, most preferably, less than about 60 psig (410 kPa). Of course, the optimal flow rate at which the resin is injected is based upon a number of factors well known to those skilled in the art.  
         [0046]    Once the mold plenum  22  is completely filled with resin, as visually confirmed by discharge of resin through the air bleeds formed in the clamping rings  36  of each mold section  14 , 16 , the injection of resin ceases. The temperature of each molding surface  24 , 26  is thereafter regulated via operation of the heater/chiller unit  60  to thereby provide an optimum cure rate with which to obtain the desired surface finish and/or other desired characteristics of the finished article, or to otherwise optimize the molding process. The mold sections  14 , 16  are thereafter separated, and the finished article removed from the mold cavity in a conventional manner.  
         [0047]    In accordance with another feature of the present invention, due to the semi-rigid character of the lower mold section&#39;s membrane  34 , the membrane  34  will dimensionally flex slightly during resin injection as the backing fluid  42  distributes the resulting injection pressure load across the entire surface of the membrane  34 . In this manner, the semi-rigid membrane  34  avoids deleterious stress concentration on its molding surface  26  during resin injection. Indeed, the slight flexing of the molding surfaces  24 , 26  of one or both membranes  32 , 34  during resin injection is believed to further improve or enhance the flow of resin through the mold plenum  22 , which effect may be further enhanced by deliberately pulsing the injected resin, all without deleterious impact on the molding tools (the membranes  32 , 34 ).  
         [0048]    While the preferred embodiments of the invention have been disclosed, it should be appreciated that the invention is susceptible of modification without departing from the spirit of the invention or the scope of the subjoined claims. For example, while the preferred embodiment employs membrane-backing fluid  42  which is itself fully contained within the chamber  38 , 40  of each mold section  14 , 16 , to be heated or cooled by heater/chiller unit  60  via coils  56 , the present invention contemplates the use of a closed loop temperature regulating system wherein the backing fluid  42  is itself circulated between each mold section&#39;s internal chamber  38 , 40  and the heater/chiller unit  60 .  
         [0049]    Up until now, real-time monitoring and control of the manufacturing process from a remote location has not been feasible. FIG. 3 shows such a system  110  in which the manufacturing process performed at site  112  is monitored and controlled on a real-time basis at remote location  114 . At remote location  112 , each machine is equipped with a group of sensors  116  which monitor and record discrete operating parameters and features. The digital output from sensors  116  are transmitted to Hub Network Server  118 . Server  118  is in communication with remote location  114  either through both a dedicated voice telephone line  120  and through an Internet connection  122  to an Internet service provider  124 . To provide a measure of security to the data, a fire wall  126  is installed in connection with the Internet communication to server  118 . A leased line  128  is used to connect the Internet service provider  124  to the remote location  114 . A fire wall  130  provides protection of the data stored at remote location  114 .  
         [0050]    At remote location  114 , the communication from the manufacturing location  112  is received at web server  132 . Web server  132  receives the data and transmits the date to one or more process controllers  134 . The process controllers  134  are in communication with a database server  136  which stores historical data concerning operational guidelines for the manufacturing process conducted at location  112 . Process controllers  134  process the data from the sensors  116  and send feedback control instructions as needed to the manufacturing location  112 .  
         [0051]    The present system can also be used to monitor and control multiple manufacturing locations. These manufacturing locations can be located at the same plant or can be located at a geographically remote plant. FIG. 4 is a schematic illustration of the system to be utilized for multiple manufacturing sites. FIG. 4 illustrates two manufacturing sites  112  and  112 ′, each of which are in communication with remote location  114 . The Internet connections are accomplished through lines  122  and  122 ′, respectively. Telephone lines  120  and  120 ′ provide telephone connection between remote location  114  and manufacturing sites  112  and  112 ′, respectively. The only additional component added to the system  110  from FIG. 3 is the addition of a primary branch exchange switch  138  which accepts multiple telephone lines  1210  and  120 ′ and allows system  110 ′ to handle telephone communication with multiple manufacturing sites.  
         [0052]    Preferably, the IP/TCP protocol is utilized for the data and video transmission through the Internet. If desired, the Internet service provider can be a wireless system or can be a hard-wired system operating through either telephone lines or an ISDN line.  
         [0053]    The remote monitoring location will also enable the system to couple additional remotely located experts to the network of key process data. This permits real time access to individuals or groups of experts that have knowledge about process parameters, materials, equipment and the like. This knowledge base, coupled with the data mining capabilities from the process data documentation, helps the experts trouble shoot and enhance complex operating systems regardless of physical location.  
         [0054]    In a presently preferred embodiment, the present invention can be used to control a molding operation from a remote location. The operating system for the molding operation is monitored on a real-time basis that utilizes a digital analogue that is capable of complete traceability of process, chemistry and equipment. The operating data from the molding process is collected at a remote location by a digital telephone line or other communication system. This enables technical staff at the remote location to manage optimization of the molding operation. The central collection of data permits the use of experts and digital data collection systems for molding operations anywhere in the world. Live video conferencing, e-mail, and digital screens can be used to help the remote operator manage the molding operation and assist in preparing work instructions and address repair and maintenance issues.  
         [0055]    The invention as described previously provides a system and process for the real-time monitoring and control of a manufacturing process from a remote location. In the foregoing specification, certain practices and embodiments of this invention have been set out. However, it will be understood that the invention may be otherwise embodied within the scope of the following claims.