Patent Description:
Different types of cans are manufactured for various purposes such as containers for food and beverages. The amount of cans that are produced each year by a single factory is immense. <CIT> discloses a can production line for drawing and ironing metal into a can comprising the steps of: feeding a metal roll into a stamper; cutting the metal into circles; forming the circles into cups; feeding the cups into a body maker having a die pack with at least three dies and a punch; spraying a coolant lubricant liquid into the die pack and through the punch; ironing the cup into a thin walled cylinder; trimming the thin walled cylinder; washing, rinsing, drying and decorating the trimmed thin walled cylinder; spray coating the inside of the can with a protective coating; necking the trimmed thin walled cylinder; forming a lip on the top of the tapered thin walled cylinder; testing the trimmed thin walled cylinder for defects; and palletizing the thin walled cylinder. In a can production factory, efficiency is a significant concern. Downtime in a production line or less than optimal operation reduces the amount of cans produced by a factory. Given the amount of cans produced by a can production line, even small reductions in efficiency can have a significant impact of the volume of cans produced by the can production line. However, it can be difficult to even identify that a can production line is operating at less than optimal efficiency or to predict the reason for less than optimal production. It is also difficult to predict a failure that will cause downtime of a production line. There is room for improvement in can production factories.

These needs and other are met by embodiments of the disclosed concept in which a can production factory management and monitoring system includes a processing unit structured to gather data from sensors associated with a can production line formed from multiple machines including a cupper, a necker, and a bodymaker located in one or more can production factories and generate a user interface to show the gathered data.

In accordance with the invention, a can factory management and monitoring system is defined according to claim <NUM>.

In accordance with another aspect of the invention, a can factory management and monitoring method is defined according to claim <NUM>.

In accordance with a further aspect of the invention, a non-transitory computer readable medium is defined according to claim <NUM>.

As employed herein, the term "processor" shall mean a controller with analog and/or digital devices connected to it, that can store, retrieve, and process data; a microprocessor; a microcontroller; a microcomputer; a central processing unit; or any suitable processing device or apparatus.

The disclosed concept is related to a can production factory management and monitoring system and method.

An example can production factory includes a can production line with machines named near to their function such as cuppers, bodymakers, washers, coat ovens, base coaters, decorators, internal spray machines, neckers, light testers, and palletizers. The can production line may include other machines and other intermediate machinery such as conveyance machinery. Various sensors are disposed throughout the can production line to monitor various parameters of the can production line. The sensors may monitor various characteristics of the machines on the can production line. For example, the sensors may monitor the running speeds of cuppers and bodymakers on the can production line.

<FIG> is schematic diagram of a factory management system in accordance with an exemplary embodiment of the disclosed concept and <FIG> is a schematic diagram of a factory management system including an exemplary factory 40A shown in more detail in accordance with an exemplary embodiment of the disclosed concept.

The factory management and monitoring system includes a processing unit <NUM> and a client device <NUM>. The factory management and monitoring system further includes a number of factories 40A, 40B, 40C. Each of the factories 40A, 40B, 40C includes a can production line including a number of machines such as a cupper <NUM>, a bodymaker <NUM>, and a necker <NUM> (shown in <FIG>). Each of the factories 40A, 40B, 40C also includes a number of sensors <NUM>, <NUM>, <NUM> (shown in <FIG>). The sensors <NUM>, <NUM>, <NUM> are each associated with corresponding machines such as the cupper <NUM>, the bodymaker <NUM>, and the necker <NUM>. It will be appreciated that <FIG> shows an example of some machines and associated sensors in a can production line. However, it will also be appreciated that each of the factories 40A, 40B, 40C may include additional machines such as, without limitation, washers, coat ovens, base coaters, decorators, internal spray machines, light testers, and palletizers. It will also be appreciated that the factories 40A, 40B, 40C may include multiples of the same type of machine. The sensors <NUM>, <NUM>, <NUM> are structured to monitor various characteristics of their associated machines on the can production line. For example, the sensor <NUM> may monitor the running speed of its associated cupper <NUM> and the sensor <NUM> may monitor the running speed of its associated bodymaker <NUM> on the can production line. However, it contemplated that the sensors <NUM>, <NUM>, <NUM> may monitor numerous different characteristics of their associated machine in the production line. It will also be appreciated that sensors may be provided that monitor general characteristics of the production line itself, characteristics of the product being produced on the production line, locations of the product on the production line, or other types of characteristics. It will be appreciated that the disclosed concept is not limited to the number of machines and sensors shown in <FIG>, but rather additional machines and sensors may be provided in each factory 40A, 40B, 40C. It will also be appreciated that any number of factories 40A, 40B, 40C may be provided.

The processing unit <NUM> is structured to receive the outputs of the sensors <NUM>, <NUM>, <NUM> (e.g., without limitation, monitored characteristics of their associated machines, etc.). The processing unit <NUM> may receive the outputs of the sensors <NUM>, <NUM>, <NUM> via a network <NUM> (e. without limitation, the internet) or any other suitable communication link.

The client device <NUM> includes a display <NUM> and an input device <NUM>. The display <NUM> may be any suitable type of display such as, without limitation, an LCD, LED, or other suitable type of display. The input <NUM> device may be any suitable type of device for receiving input from a user. For example and without limitation, the input device <NUM> may be a keyboard and/or mouse, a touch screen, or any other suitable type of device for receiving input from the user. The client device <NUM> may be a computer or other type of processing device. It will be appreciated by those having ordinary skill in the art that the client device <NUM> may be incorporated into the processing unit <NUM> or vice versa.

The processing unit <NUM> may be a computer, a server, or other type of processing device. In some example embodiments, the processing unit <NUM> and client device <NUM> communicate with each other via a network connection or other suitable type of connection. The processing unit <NUM> is structured to gather data from the various sensors <NUM>, <NUM>, <NUM> and to generate a user interface to view the data. The user interface may be displayed at the processing unit <NUM> itself in example embodiments where the processing unit <NUM> includes a display or communicated to the client device <NUM> and displayed on the display <NUM> of the client device <NUM>. The data may be gathered from the sensors via a network <NUM> such as the Internet or another type of network. It is contemplated that any suitable method for communicating the data from the sensors <NUM>, <NUM>, <NUM> to the processing unit <NUM>, including any methods using intermediate collection points or repositories, may be employed. It is also contemplated that the processing unit <NUM> may gather data from sensors <NUM>, <NUM>, <NUM> located at multiple factories 40A, 40B, 40C. As previously noted, <FIG> and <FIG> illustrate exemplary factories 40A, 40B, 40C, but it will be appreciated that the processing unit <NUM> may gather data from sensors associated with any number of machines and factories. The processing unit <NUM> may be located remote from the one or more factories 40A, 40B, 40C where the sensors <NUM>, <NUM>, <NUM> are located.

The processing unit <NUM> is structured generate a user interface to view the data gathered from the sensors <NUM>, <NUM>, <NUM>. The user interface may be displayed on the same device as the processing unit <NUM>, or it may be displayed on a device remote from the processing unit <NUM>, such as the display <NUM> of the client device <NUM>. For example and without limitation, the processing unit <NUM> may be located in a server or other computing device at one location and the user may access and interact with the user interface via the client device <NUM> located elsewhere, but connected via a network to the processing device <NUM>. The processing unit <NUM> is also structured to analyze the data gathered from the sensors <NUM>, <NUM>, <NUM>. For example and without limitation, the processing unit <NUM> may compare data gathered from the sensors <NUM>, <NUM>, <NUM> including one or more particular characteristics of an associated machine to threshold values and set an alarm condition if the characteristics exceed the threshold limits. The alarm condition may be displayed on the user interface to alert a user of the condition. For example and without limitation, a sensor associated with a washer in a factory may monitor a characteristic of the washer such as the burner temperature of the washer. The processing unit <NUM> may analyze the temperature and set an alarm condition when the temperature exceeds a predetermined threshold temperature. When the temperature exceeds the predetermined threshold, the processing unit <NUM> may cause an alarm to be displayed on the user interface such that a user viewing the user interface at the processing unit <NUM> or client device <NUM> can be made aware of the alarm condition. For example, the processing unit <NUM> may set alarm conditions based on the outputs of one sensor, combinations of outputs of multiple sensors, combinations of outputs of multiple sensors across multiple factories, etc..

It is contemplated that the processing unit <NUM> may analyze the data gathered from the sensors <NUM>, <NUM>, <NUM> in various types of manners to derive any information pertinent to operation of the factory or factories 40A, 40B, 40C. It is also contemplated that the displayed user interface may include any data gathered by the sensors <NUM>, <NUM>, <NUM> or any information resulting from analysis by the processing unit <NUM>. It is further contemplated that the displayed user interface may include any data in a manner suitable for a user to contemplate, such as graphs, numerical representations, or any other suitable manner of displaying data.

In some example embodiments of the disclosed concept, the processing unit <NUM> may analyze the data gathered from sensors <NUM>, <NUM>, <NUM> using artificial intelligence or machine learning techniques. For example and without limitation, the processing unit <NUM> may use artificial intelligence or machine learning techniques to predict machine failure or maintenance, material usage, to optimize a machine or factory, or any other suitable application based on the gathered data. As an example, the processing unit <NUM> may analyze data gathered from various factories using artificial intelligence techniques to recognize optimal operating patterns based on specified goals such as efficiency or output capacity. It will be appreciated by those having ordinary skill in the art that the processing unit <NUM> may analyze the data gathered from sensors <NUM>, <NUM>, <NUM> or other sensors using any number of artificial intelligence or machine techniques. It will also be appreciated that in some example embodiments, the processing unit <NUM> may control machines in one or more factories based on such analysis.

The user interface is structured to be interactive. For example and without limitation, a user may interact with different areas of the user interface to change the arrangement or format of the information that is displayed. The input device <NUM> of the client device <NUM> or, in some example embodiments, an input device of the processing unit <NUM>, may be used to input commands to interact with the user interface. For example and without limitation, the user interface may include an overall factory view that displays a representation of an entire production line and data pertinent to the overall production line. The user may interact with the user interface (e.g., via the input device <NUM>) to cause the user interface to show a particular machine (e.g., cupper, bodymaker, necker, etc.) on the production line and data pertinent to the particular machine. It is contemplated that the user interface may include displays pertinent to a set of factories, a selected factory, a selected machine, or a particular product, and that the user may interact with the user interface to switch between these types of displays. It is also contemplated that the user may interact with the user interface to customize the data that is displayed.

In some example embodiments of the disclosed concept, the user may interact with the user interface to control aspects of the factories 40A, 40B, 40C or the machines in the factories. For example, the processing unit <NUM> may communicate with controllers of various machines in the factories 40A, 40B, 40C. In some example embodiments, the user may interact with the user interface and manipulate an alarm signal to be sent from the processing unit <NUM> to one or more of the machines (e.g., without limitation, the cupper <NUM>, the bodymaker <NUM>, or the necker <NUM>) located at one or more of the factories 40A, 40B, 40C to alert an operator remotely located at one of the factories 40A, 40B, 40C, invoke a stop to the machine, or adjust a set of parameters that would tune the operation of the machine in a specified manner, provided the user has security level access authenticated followed by specific protocol which includes but is not limited to interacting with personnel near the machine or those responsible for machine operation by means of user input acknowledgement, before a change is executed.

<FIG> are examples of the displayed user interface in accordance with example embodiments of the disclosed concept. The user may switch between the various examples shown in <FIG> by interacting with the user interface via the input device <NUM> or other suitable input devices. <FIG> is a screenshot of a factory overview screen in accordance with an exemplary embodiment of the disclosed concept. As shown in <FIG>, data gathered from sensors associated with various machines in a factory are shown. The cans per minute necker speed is an example of a characteristic of a necker, gathered from a sensor or sensors associated with the necker, and shown on the user interface. From the user interface, the user can easily view the cans per minute necker speed, as well as various other characteristics of the necker, other machines, or other characteristics of the operation of the factory gathered from other sensors.

<FIG> is a screenshot of a bodymaker overview screen in accordance with an exemplary embodiment of the disclosed concept. In this example, the characteristics of multiple bodymakers are shown in the user interface. The bodymakers may be located in one factory or in multiple factories.

<FIG> is a screenshot of a cupper overview screen in accordance with an exemplary embodiment of the disclosed concept. In this example, the characteristics of a cupper are shown in the user interface. For example, the speed of the cupper, total cups made over the life of the cupper, as well as various characteristics of components of the cupper are shown in the user interface. In this example of the user interface, a user can easily contemplate many aspects of the operation and the status of the cupper remotely at the client device <NUM> or processing unit <NUM>.

<FIG> is a screenshot of a necker overview screen in accordance with an exemplary embodiment of the disclosed concept. In this example, the characteristics of a necker are shown in the user interface. Similar to the previous example, the speed of the necker, total units over the lifetime of the necker, as well as various characteristics of the components of the necker are shown. In this example of the user interface, a user can easily contemplate many aspects of the operation and the status of the necker remotely at the client device <NUM> or processing unit <NUM>.

The examples shown in <FIG> are examples of the user interface and types of data associated with the machines in one or more factories that can be shown in the user interface. It will be appreciated that the user interface may also show information associated with different types of machine or different types of information. By interacting with the user interface and viewing the information shown on the user interface, the user may contemplate the operation and status of a single machine, multiple machines, a single factory, multiple factories, or any combination thereof. In this manner, the user may interact with the user interface to customize what is shown to view pertinent data in assessing the operation and/or status of machines and/or factories. The user may use such information to optimize and/or maintain machines and/or factories, generate material orders, or perform other actions associated with the machines and/or factories. In some example embodiments of the disclosed concept, such actions may be made via commands issued through the user interface to control one or more of the machines. Additionally, as previously noted, the user interface may show alarm conditions determined by the processing unit <NUM>. Via these alarm conditions, the user may be made aware of the alarm conditions and take remedial action. In some example embodiments of the disclosed concept, such remedial action may be made via commands issued through the user interface.

It is contemplated that the processing unit <NUM> may limit the information included in the user interface based on the rights of the user. For example, one type of user may be able to access one set of data through the user interface while another type of user may be able to access a different set of data through the user interface.

The processing unit <NUM> may also be structured generate and/or display reports based on the data gathered from the sensors <NUM>, <NUM>, <NUM> or information resulting from analysis of the data gathered from the sensors <NUM>, <NUM>, <NUM>. The reports may be, for example and without limitation, selected information that summarizes operation and/or performance of production lines or particular machines on the production line. A user may cause selected reports to be generated by interacting with the user interface.

<FIG> and <FIG> are example aggregated bodymaker reports in accordance with an example embodiment of the disclosed concept. <FIG> are example single bodymaker reports in accordance with an example embodiment of the disclosed concept. <FIG> are example single cupper reports in accordance with an example embodiment of the disclosed concept. <FIG> are example single necker reports in accordance with an example embodiment of the disclosed concept. In these example reports, various information gathered from the sensors may be aggregated. The reports may be shown on the user interface or output such that they may be viewed on other devices or mediums. For example, the reports may be output as any suitable file format (e.g., without limitation, PDF) so that they may viewed on different devices. The reports may also be printed so that they may be viewed offline.

By observing and interacting with the user interface and/or by generating reports through the user interface, a user may easily obtain information of various scope about a factory or multiple factories, or about particular machines on a production line in a factory. The information may be used to observe and improve the efficiency of a factory. For example, a user may use the user interface to observe the production of production lines in different factories. If the production line in one factory is underperforming compared to a production line in another factory, the user may use the user interface to display and compare characteristics of particular machines on the production lines. The user may identify a particular machine, or other aspect, that is causing a performance issue and may appropriately address the issue. The gathered data may also be stored and analyzed through machine learning or other techniques to predict failures, predict and optimize maintenance, or to use other methods to improve the efficiency of the factory or factories.

In some example embodiments of the disclosed concept, the processing unit <NUM> may be used to increase automation of one or more factories. For example and without limitation, the processing unit <NUM> may act on data it gathers and analyzes. For example and without limitation, the processing unit <NUM> may determine that maintenance of a machine is needed or will soon be needed based on the gathered and analyzed data. The processing unit <NUM> may make or initiate a purchase order for materials or parts needed for maintenance of the machine. The processing unit <NUM> may also make or initiate material orders based on the production of a factory or factories. For example, the processing unit may determine that a factory will need to replenish its stock of aluminum or other materials involved in the production of cans based on the gathered and analyzed data and may pre-emptively and automatically make or initiate a purchase order for materials that will be needed in production. While purchase orders of additional materials are one example of an additional action that the processing unit <NUM> may take based on its gathered and analyzed data, it is contemplated that a variety of different actions may be taken by the processing unit <NUM>, such as, without limitation, control or adjustment of machines, sending alarms, warnings, or notifications, or any other suitable actions in relation to monitoring or management of factories. It is also contemplated that the user interface may be used by a user to setup or adjust additional actions that the processing unit may automatically take in response to the gathered and analyzed data.

Claim 1:
A can production factory management and monitoring system for one or more can production factories (40A, 40B, 40C), wherein each can production factory comprises a can production line formed from multiple machines including a cupper (<NUM>), a necker (<NUM>) and a bodymaker (<NUM>):
characterised in that
the can production factory management and monitoring system comprises:
a processing unit (<NUM>) structured to receive data from a plurality of sensors (<NUM>,<NUM>,<NUM>) structured to monitor one or more of said can production factories (40A,40B,40C) or said multiple machines (<NUM>,<NUM>,<NUM>) included in the factories, to analyze the received data, and to generate a user interface including the received data or information resulting from analysis of the received data;
a display (<NUM>) structured to display the user interface; and
an input device (<NUM>) structured to receive input from the user, and
wherein the user interface is interactive responsive to inputs received via the input device,
wherein the user interface includes a plurality of views,
wherein the processing unit is structured to switch between the plurality of views based on input received via the input device, and
wherein the plurality of views includes a first view including received data or information resulting from analysis of the received data associated with a cupper (<NUM>) or a necker (<NUM>) in a single one of said one or more can production factories and a second view including received data or information resulting from analysis of the received data associated with at least said cupper (<NUM>), said necker (<NUM>), and said bodymaker (<NUM>) in said single one factory.