Patent Description:
With the move to widespread availability of data connectivity, we are seeing an increase in the number of connected devices. Users want to not only communicate by voice and electronic messages and view web pages, but also remotely see the status of their devices and control them. For example, it is desirable to remotely monitor home security systems, heating system, CCTV and the like.

The desire to remotely monitor devices also applies in the commercial world where companies have an interest in the state of assets or machines that are located elsewhere. References to machines in this context will be understood to be references to any electrical equipment that performs a functional task. Examples include motorised or mechanical devices such as powered doors, roller shutters, pumping stations, dock levellers, and car park barriers. Further examples include walk-in freezers, solar panels, air conditioning units, heating/ventilation units, horticultural irrigations systems and so on. It is desirable to monitor such devices to in order to help plan maintenance, optimise energy usage, and identify unexpected stoppages. The connectivity required for these systems would typically make data available from the machine using one of the following methods:.

The data may be stored on the machine and remotely viewed or uploaded to a separate location for storage and use.

Problems arise in that the installation of wired and wireless LAN infrastructure can be prohibitively expensive. For example, it may not be possible to install wired ethernet connections to each dock leveller in a loading bay of a large warehouse without undertaking significant remedial works.

Furthermore, installing, configuring, commissioning and operating the remote connection to the machine requires a diverse variety of skills and abilities that rarely exist within the same department. For example, it may be necessary to establish the data connection, set up firewall rules, grant access permission, manage storage, and configure the interface to the machine control system. Quite often the steps also need to be performed with different stakeholders or vendors, such as the supplier of asset to be monitored, communication device supplier, ISP or GSM data supplier, data storage supplier, and machine manufacturer. In a commercial environment this is time consuming, expensive, and particularly a problem for low-cost machines where the costs of connectivity can outweigh the benefit of being able to remotely monitor the machine.

Further issues arise in that not all machines have network interfaces capable of supplying data suitable for the required remote monitoring. Particular problems exist where legacy machines need to be connected and the operating software cannot be changed to integrate with networking devices. <CIT>, <CIT>, <CIT>, <CIT> and <CIT> each relate to communication devices and/or systems.

It is an aim of the disclosure to address these difficulties, and any other difficulties that would be apparent to the skilled person from the description herein. It is a further aim of the disclosure to provide a communication module that can be readily retrofitted to a machine in order to provide remote monitoring thereof.

According to a first aspect of the disclosure there is provided a communication module for monitoring a machine, comprising: a serial interface connectable to a serial interface of the machine; a telecommunications interface connectable to a telecommunications network, wherein the telecommunications interface is a GSM module configured to communicate over a GSM network; and a control unit configured to control operation of the communication module, the control unit being further configured to transmit data received via the serial interface to a monitoring server via the telecommunications interface, the control unit being further configured to receive configuration data via the telecommunications interface, wherein the configuration data comprises: machine type data indicating data items of the machine to be monitored, retrieved from the machine via the serial interface and transmitted via the telecommunication interface; periodicity data indicating a periodicity of transmissions of the retrieved data items to be made by the communication module via the telecommunication interface; and operating configuration data, indicating the desired operating configuration of the communication module according to which the data items are to be retrieved.

The serial interface may be a Modbus interface configured to communicate with the machine using a Modbus protocol. The serial interface may be configured to communicate with a programmable logic controller (PLC) of the machine. The serial interface may comprise a serial port, connectable to a serial port of the machine via a serial cable.

The control unit may be configured to periodically transmit data over the telecommunication interface. The periodicity of transmissions may be based on configuration data.

The communication module may comprise a location unit configured to determine a geographical location of the module. The control unit may be configured to transmit the determined location using the telecommunications interface. The location unit may comprise a GNSS (Global Navigation Satellite System) unit, configured to determine the location of the module using the GNSS system. The location unit may be configured to determine the location of the module using the telecommunications interface. The location unit may be configured to estimate the location based on signal strength and triangulation between cell mast positions.

The communication module may be configured to operate in a slave configuration. The communication module may be configured to operate in an active slave configuration, in which the module is addressable by a PLC of the machine. The communication module may be configured to operate in a passive slave configuration, in which the communication module receives data transmitted by a PLC of the machine for receipt by one or more devices of the machine.

The communication module may be configured to operate in a master configuration, in which a PLC of the machine is a slave. The communication module may selectively operate in one of the passive slave configuration, active slave configuration and master configuration.

The operating configuration may be one of the passive slave configuration, active slave configuration and master configuration.

The communication module may be configured to receive module update data via the telecommunication interface, and install the received module update data.

The communication module may be configured to receive machine update data via the telecommunication interface and transmit the received machine update data to the machine via the serial interface.

The communication module may comprise an enclosure. The enclosure may have dimensions of under <NUM> x <NUM> x <NUM>, suitably under <NUM> x <NUM> x <NUM>, suitably approximately <NUM> x <NUM> x <NUM>.

According to a second aspect of the disclosure, there is provided a communication system for monitoring a machine, the system comprising:.

The monitoring server may comprise a graphical user interface configured to allow a user to view the received data.

The system may comprise a configuration portal. The configuration portal may be configured to receive configuration information related to the communication module, input by an operator. The portal may be hosted by a suitable server connected to the internet. The configuration information may include one or more of: configuration data linking the module to a mobile network operator data service for transmission over the telecommunications network; configuration data linking the module to a customer billing account for the data used by the module; and/or configuration data indicating a storage location for the data on the server. The configuration data may include machine type data indicating the type of machine to which the communication module is connected. The monitoring server may select a UI based on the machine type data. The configuration portal may transmit a configuration data to the communication module including the machine type data.

The configuration portal may be configured to receive an operating configuration selection, and transmit a configuration message to the communication module to operate in the selected configuration.

The memory may comprise a database to store the received data.

The machine may comprise a programmable logic controller (PLC) and a device controlled by the PLC. The machine may be one of a powered door, roller shutter, pumping station, dock leveller, car park barrier, walk-in freezer, solar panel, air conditioning unit, heating/ventilation unit, or horticultural irrigation system.

According to a third aspect of the disclosure there is provided a method of monitoring a machine, comprising: receiving, by a communication module, data from the machine via a serial interface; and sending, by the communication module, the received data over a telecommunications network to a monitoring server. The telecommunications interface is a GSM module configured to communicate over a GSM network. A control unit receives configuration data via the telecommunications interface, wherein the configuration data comprises: machine type data indicating data items of the machine to be monitored, retrieved from the machine via the serial interface and transmitted via the telecommunication interface; periodicity data indicating a periodicity of transmissions of the retrieved data items to be made by the communication module via the telecommunication interface; and operating configuration data, indicating the desired operating configuration of the communication module according to which the data items are to be retrieved.

In the drawings, corresponding reference characters indicate corresponding components. The skilled person will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various example embodiments. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various example embodiments.

In overview, examples of the disclosure relate to a communication module comprising a serial interface connectable to a serial interface of a machine, and a wireless telecommunications interface connectable to a wireless telecommunications network. Accordingly, the communication module can be installed in a machine and provide monitoring information to a remote server.

Examples of the disclosure also relate to a system comprising a machine, a communication module connected to the machine via the serial interface, and a server, wherein the communication module can transmit or receive data to or from the server. The server may provide a user interface, such as a web interface, for monitoring the machine.

<FIG> shows an example communication module <NUM>.

The communication module <NUM> is a hardware device, and may comprise a processor and a memory storing suitable instructions that, when executed, carry out the functions described herein. In other examples, the communication module <NUM> may comprise suitable hardware components, such as circuitry in the form of discrete or integrated components, a Field Programmable Gate Array (FPGA) or Application Specific Integrated Circuit (ASIC), which performs certain tasks or provides the associated functionality.

The communication module <NUM> may comprise an enclosure (not shown), to retain the components of the module <NUM>. The enclosure may permit the communication module <NUM> to be installed within or on the enclosure of a machine <NUM>. The enclosure may have example dimensions of <NUM> x <NUM> x <NUM>.

The communication module <NUM> comprises a serial interface <NUM>. The serial interface <NUM> is configured to communicate with a machine <NUM>, via a serial interface of the machine <NUM>. For example, the serial interface <NUM> may comprise a serial port, connectable to a serial port of the machine <NUM> via a suitable serial cable.

The communications module <NUM> is configured to receive data from the machine <NUM> via the serial interface <NUM>. In some examples, the communications module <NUM> is also configured to transmit data to machine <NUM> via the serial interface <NUM>.

The serial interface <NUM> may be a Modbus interface, configured to communicate with the machine <NUM> using a Modbus protocol. Particularly, the serial interface <NUM> may allow the communication module <NUM> to communicate with a programmable logic controller (PLC) <NUM> of the machine <NUM> via the Modbus protocol. In other examples, the serial interface <NUM> may communicate with the machine <NUM> using another serial communications protocol. For example, the protocol may be an RS-<NUM> protocol, an RS-<NUM> protocol, a CAN (Controller Area Network) bus protocol, or any other suitable serial protocol.

The communication module <NUM> further comprises a telecommunications interface <NUM>. The telecommunications interface <NUM> comprises suitable hardware, logic and instructions for communication over a wireless telecommunications network W. For example, the network W may be a GSM network. In other examples, the network may be a CDMA network. The network may comply with a <NUM>, <NUM>, <NUM>, EDGE, <NUM>, LTE or any other telecommunications network standard. For example, the telecommunications interface <NUM> may comprise a communication chip (e.g. a GSM chip). In some examples, the telecommunications interface <NUM> comprises an antenna <NUM>. The antenna <NUM> may be disposed inside or outside the enclosure.

The communication module <NUM> further comprises a power supply unit <NUM>. The power supply unit <NUM> may receive DC power, for example 24V DC power from a mains supply via a suitable transformer.

The communication module <NUM> also comprises a control unit <NUM>, configured to control the operation of the module <NUM>. The control unit <NUM> may comprise a processor. The control unit <NUM> is configured to transmit data received via the serial interface <NUM> using the telecommunications interface <NUM>. The control unit <NUM> is configured to receive data via the telecommunications interface <NUM>. The data received includes configuration data, as described herein. The control unit <NUM> may also be configured to transmit the received data to the machine <NUM> via the serial interface <NUM>.

In one example, the control unit <NUM> is configured to periodically send data over the telecommunication interface <NUM>. The periodicity of the transmissions may be varied, for example based on the received configuration data. Accordingly, the communication module <NUM> may receive a plurality of items of data from the machine <NUM>, and then transmit the plurality of items of data over the telecommunication interface <NUM>.

The communication module <NUM> may also comprise a location unit <NUM>, configured to determine the geographical location of the module <NUM>. In one example, the location unit <NUM> comprises a GNSS (Global Navigation Satellite System) unit, configured to determine the location of the module using the GNSS system, which includes GPS and GLONASS satellites S. In other examples, the location unit <NUM> comprises a GPS unit. The location unit <NUM> may comprise an antenna <NUM>.

In further examples, the location unit <NUM> is configured to determine the location of the module <NUM> using the telecommunications interface <NUM>. For example, the location unit <NUM> may estimate the location based on signal strength, and triangulation between cell mast positions.

In examples comprising the location unit <NUM>, the control unit <NUM> is configured to transmit the determined location of the module <NUM> using the telecommunications interface <NUM>.

In one example, the application software of the module <NUM> (e.g. the instructions forming part of the control unit <NUM>) is embedded in vacant program space inside the telecommunication interface <NUM>. For example, the application software is embedded in a GSM module.

<FIG> shows the communication module <NUM> connected to a machine <NUM> in a slave configuration. The machine <NUM> comprises a PLC <NUM>, and devices <NUM> and <NUM> controlled by the PLC <NUM>. In the example of <FIG>, the machine is an air conditioning control unit, and the devices <NUM> are a human machine interface (HMI) and an inverter <NUM>. However, it will be understood that different machines serving different purposes may comprise different devices.

The PLC <NUM>, and devices <NUM> and <NUM> are connected via a bus <NUM>, which may be a serial Modbus connection. Furthermore, the communication module <NUM> is also connected to the bus <NUM> via the serial interface <NUM>. In this configuration, the PLC <NUM> is the master device of the Modbus, with the devices <NUM>, <NUM> and the communication module <NUM> acting as slave devices.

In one example, the communication module <NUM> is configured to operate as an active slave. In such an example, the communication module <NUM> may be directly addressed by the PLC <NUM>. Accordingly, the PLC <NUM> is configured to send data over the bus <NUM> specifically intended for the communication module <NUM>. For example, the PLC <NUM> may write relevant data items (e.g. particular variables or field such as uptime data, status data, etc) to the communication module <NUM>. This mode may be suitable for new applications or machines, where the PLC <NUM> can be readily configured to write to the communication module <NUM>, for example by suitably editing configuration settings or updating the firmware or other software of the PLC <NUM>.

In another example, the communication module <NUM> is configured to operate as a passive slave. In such an example, in contrast to the active slave mode, the communication module <NUM> is not directly addressed by the PLC <NUM>. Instead, the communication module <NUM> receives data transmitted over the bus <NUM> by the PLC <NUM> intended for receipt by the devices <NUM>, <NUM>. Accordingly, the communication module <NUM> effectively "eavesdrops" on the bus <NUM>. This allows the communication module <NUM> to monitor the operation of the machine <NUM>, by receiving control instructions and other instructions sent by the PLC <NUM> to the devices <NUM>, <NUM>. The control unit <NUM> may process the received data to extract relevant data items, for example based on suitable configuration data indicating particular fields or variable names to be retrieved.

The passive slave mode may be particularly suitable in circumstances when the module <NUM> is used with legacy applications or machines. In such circumstances, it may not be possible or desirable to update the PLC <NUM> such that it can directly address the communication module <NUM>, but the mode still allows the communication module <NUM> to monitor the machine <NUM>.

<FIG> illustrates a further configuration of the communication module <NUM>. In the illustrated configuration, the machine <NUM> is structured as discussed above, with a PLC <NUM> and devices <NUM>, <NUM> connected by a first bus <NUM>. In contrast to the configurations discussed above, in the configuration of <FIG>, the communication module <NUM> and PLC <NUM> are connected by a second bus <NUM>. For example, the PLC <NUM> or the machine <NUM> may comprise a Modbus slave port, to which the communication module <NUM> may be connected.

In this arrangement, the communication module <NUM> is configured to operate as the master device of the second bus <NUM>, with the PLC <NUM> acting as a slave. Accordingly, the communication module <NUM> may directly address the PLC <NUM> via the bus <NUM> to retrieve the required data. Particularly, the module <NUM> may retrieve particular data items (e.g. particular fields or variables) from the memory of the PLC <NUM>. This may for example be according to suitable configuration data of the communication module <NUM> indicating which data items should be retrieved.

In one example, the operating configuration of the module <NUM> may be selected according to received configuration data. Accordingly, the module <NUM> may be remotely configured to operate in the desired configuration.

<FIG> illustrates an example communication system <NUM>. The communication system <NUM> comprises the communication module <NUM> and machine <NUM> discussed herein. In addition, the system <NUM> comprises a monitoring server <NUM>.

The monitoring server <NUM> is connected to the communication module <NUM> via its telecommunications interface <NUM>. For example, the telecommunications interface <NUM> may connect to a telecommunications network W, which in turn connects to the Internet I, wherein the monitoring server <NUM> is also connected to the internet I. It will be appreciated that the network connection between the communication module <NUM> and server <NUM> may comprise additional links, including other wide area networks, local networks, leased lines, virtual private networks and so on. In one example, the monitoring server <NUM> is hosted in the cloud. However, in other examples the monitoring server <NUM> may be hosted as a private server.

The monitoring server <NUM> is configured to store data received from the communication module <NUM>. The monitoring server <NUM> may comprise a memory having a suitable database or other data storage structure in order to store the received data. The monitoring server <NUM> may also provide a GUI (e.g. a web site) to allow a user to view the received data, for example via a internet connected mobile device <NUM> or personal computer <NUM>.

The system <NUM> may also comprise a configuration portal <NUM>, via which an operator may input configuration information related to the communication module <NUM>. The portal <NUM> may be hosted by a suitable server connected to the internet I. The configuration information may include one or more of: linking the module to a mobile network operator data service for transmission over the telecommunications network; linking the module to a customer billing account for the data used by the module; indicating a storage location for the data on the server <NUM>; and indicating the type of machine <NUM> to which the communication module <NUM> is connected.

The operator may also select the mode of operation of the communication module <NUM> (e.g. active slave, passive slave, master), as well as the periodicity of the transmissions of the module <NUM>. Accordingly, a configuration message comprising configuration data may be sent from the configuration portal <NUM>, instructing the communication module <NUM> to operate in the desired mode, with the desired machine type and the desired periodicity.

The system <NUM> may also comprise a connection management portal <NUM>, via which an operator may manage and configure the wireless telecommunications link of the module <NUM>. This may include determining the connection status of the module <NUM> over the network.

In use, the communication module <NUM> is installed in the machine <NUM>. This may include connecting the serial interface <NUM> to a suitable serial port of the machine <NUM>, and connecting the power supply unit <NUM> to a suitable power source.

Once the communication module <NUM> is powered, the installer may use the configuration portal <NUM> to set up the module <NUM>. Particularly, the installer may indicate the type of the machine <NUM> to which the module is connected (e.g. one of a powered door, roller shutter, pumping station, dock leveller, car park barrier, walk-in freezer, solar panel, air conditioning unit, heating/ventilation unit, horticultural irrigations system etc). This configures the module <NUM> to retrieve the appropriate data from the machine <NUM> via the serial interface <NUM>. It will be appreciated that way in which the relevant data will be retrieved will depend on the operation mode of the module <NUM>. Accordingly, a mapping is provided between variables or fields used by machine <NUM> and storage locations (e.g. database fields) in the memory of the server <NUM>. The selection of the machine type may also cause the selection of an appropriate corresponding user interface for display via the server <NUM>.

The installer may also use the configuration portal <NUM> to link the module <NUM> to a particular data service, billing account and storage location on the server, as well as indicating the operation mode of the module <NUM>. This may cause instructions to be to be transmitted to the communication module <NUM> from the configuration portal <NUM> to cause the module <NUM> to operate in the specified mode.

In one example, the installer may also use the configuration portal <NUM> to set the periodicity of transmissions sent by the communication module <NUM>. More frequent transmissions may ensure that the data stored at the server <NUM> is more up to date, but that less frequent transmissions may reduce data consumption and associated charges.

Once installed, the communication module <NUM> receives data from the machine <NUM> via the serial interface <NUM>. The received data is then transmitted to the server <NUM> using the telecommunications interface <NUM>. Upon receipt at the server <NUM>, the data is stored.

Subsequently, a user seeking to monitor the machine <NUM> may access the server <NUM>, whereupon a GUI is displayed showing the data received from the module <NUM> in an appropriately labelled format. Accordingly, the data may allow the user to determine the current status of the machine <NUM>. Furthermore, the stored data may permit an analysis of the historic operation of the machine <NUM>, which may be useful in ensuring efficient operation of the machine, reducing energy costs and increasing throughput.

In some examples, once installed, the module <NUM> may be updated via the telecommunications interface <NUM>. That is to say, the module <NUM> may receive a software or firmware update via the telecommunications interface <NUM>, and the control unit <NUM> may be configured to install the update. In some examples, once installed, the module <NUM> may also receive and apply updates to the machine <NUM>, for example the PLC <NUM> of the machine.

Turning to <FIG>, an example communication method is illustrated. In block S51, data is received by a serial interface of a communication module from a machine. In block S52, the received data is sent by the communication module over a telecommunications network to a monitoring server. The communication module, machine and monitoring server may be as described herein. The method may comprise further steps as disclosed herein.

Advantageously, the above-described modules, systems and methods provide a means of providing network connectivity to a wide range of industrial machinery, thereby providing a means of remotely monitoring such machines. The module is low cost, and thus is appropriate for relatively low-cost standalone machines where providing network connectivity would otherwise be cost prohibitive. The module is capable of operating in a number of modes, which allow it to interface with a wide variety of machines, and permit it to be retrofitted to legacy machines which may not otherwise support network connectivity.

The module is advantageously easy to install and configure, allowing it to be allowing it to be installed by an operator without detailed knowledge of network configuration and programming. Particularly, the operator may simply select the type of machine to which the module is selected so as to retrieve an appropriate configuration profile indicating which variables are to be extracted from the machine, and the UI layout via which they are displayed to a user. Furthermore, the module may be readily updated over the air, and facilitate updates to the machine.

In addition, the above-described modules, systems and methods transmit data from the machine to a server hosted remotely from the machine, for example in the cloud. This ensures the data can be accessed, regardless of whether the machine is in operation.

At least some of the example embodiments described herein may be constructed, partially or wholly, using dedicated special-purpose hardware. Terms such as 'component', 'module' or 'unit' used herein may include, but are not limited to, a hardware device, such as circuitry in the form of discrete or integrated components, a Field Programmable Gate Array (FPGA) or Application Specific Integrated Circuit (ASIC), which performs certain tasks or provides the associated functionality. In some embodiments, the described elements may be configured to reside on a tangible, persistent, addressable storage medium and may be configured to execute on one or more processors. These functional elements may in some embodiments include, by way of example, components, such as software components, object-oriented software components, class components and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuitry, data, databases, data structures, tables, arrays, and variables. Although the example embodiments have been described with reference to the components, modules and units discussed herein, such functional elements may be combined into fewer elements or separated into additional elements.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same or equivalent purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent features.

Claim 1:
A communication module (<NUM>) for monitoring a machine (<NUM>), comprising:
a serial interface (<NUM>) connectable to a serial interface of the machine (<NUM>);
a telecommunications interface (<NUM>) connectable to a telecommunications network, wherein the telecommunications interface (<NUM>) is a GSM module configured to communicate over a GSM network; and
a control unit (<NUM>) configured to control operation of the communication module (<NUM>), the control unit (<NUM>) being further configured to transmit data received via the serial interface (<NUM>) to a monitoring server (<NUM>) via the telecommunications interface (<NUM>),
the control unit (<NUM>) being further configured to receive configuration data via the telecommunications interface (<NUM>), wherein the configuration data comprises:
machine type data indicating data items of the machine (<NUM>) to be monitored, retrieved from the machine (<NUM>) via the serial interface (<NUM>) and transmitted via the telecommunication interface (<NUM>);
periodicity data indicating a periodicity of transmissions of the retrieved data items to be made by the communication module (<NUM>) via the telecommunication interface (<NUM>); and
operating configuration data, indicating the desired operating configuration of the communication module (<NUM>) according to which the data items are to be retrieved.