Method and system for converting production process data into human-machine interface data

Abstract

A method (400) for converting production flow (PF) data (110) into human-machine interface (HMI) data (130) is proposed. The PF data (110) includes storage objects (112, 118) and processing objects (114, 116). The method includes: receiving (402) the PF data (110), identifying (404) the storage objects (112, 118) and processing objects (114, 116) in the PF data (110), for each processing object (114, 116) (406), identifying (408) the source object (112, 114), identifying (410) the destination object (116, 118), forming (412) a plurality of process sequences (120a-b) based on the PF data (110), identifying (414) the link objects (126a-b) present in two or more process sequences (120a-b), generating (416) an aggregated process sequence (128), and generating (418) the HMI data (130) based on the aggregated process sequence (128), such that the HMI data (130) can generate a rectangular array (134), wherein for each process sequence (120a-b), the destination object (142, 144) of the visual representation of the destination object (116, 118) is placed after the source object (138, 140) of the visual representation of the source object (112, 114) in the first direction (A) in the rectangular array (134).

Description

Technical Field

[0001] The present invention relates to a method and a system for controlling a food processing line. More specifically, the present invention relates to a method for converting production process data into human-machine interface data, and a system comprising a food processing line, an operator display, and a control unit. Background Art

[0002] Today's food processing lines are generally constructed such that they can be modified in different ways to meet different product characteristics or to produce different types of products. Configuring the processing lines to meet a wide variety of conditions and requirements comes at the cost of the food processing lines generally being very complex. In addition to being complex, generally most processing lines are different from each other. One reason for this may be that the food processing lines have been upgraded over time. This complexity, combined with the uniqueness of many food processing lines in their composition, makes it generally difficult for an operator to control the operation of a food processing line, especially in the case where he or she has little or no experience with the specific food processing line for which he or she is responsible.

[0003] To better understand the food processing line and to be able to monitor the progress of food processing, different SCADA (Supervisory Control And Data Acquisition) systems have been developed. Although these systems relieve the burden on the operator responsible for controlling the food processing line, setting up and implementing a new system is usually very time-consuming. In addition, even when the system has been set up, it may still be challenging for a new operator to understand how to interpret the information presented through the operator display. SCADA systems can be set up in different ways, and the information can be conveyed to the operator in different ways. Although this flexibility has the advantage of allowing the system to be customized, the disadvantage is that a new operator may need time to become familiar with the system.

[0004] Although existing SCADA systems provide the operator with information about the food processing line, setting up such a system requires an investment of time and money. In addition to the time and money required to set up the system, most systems can be set up according to the specific needs of the operator, which is advantageous in many ways but also brings the risk that a new operator may have difficulty understanding the information provided and may therefore control the food processing line in a non-optimal way. Summary of the Invention

[0005] An object of the present invention is to at least partially overcome one or more of the above limitations of the prior art. Specifically, an object is to provide a time-saving and efficient procedure for setting up a control system for a food processing line. Another object is to ensure that the information of different food processing lines is represented consistently, thereby reducing the risk of operator error.

[0006] According to a first aspect, a method for converting production flow (PF) data into human-machine interface (HMI) data is provided, wherein the PF data may include storage objects representing storage units in a food processing line and processing objects representing processing units in the food processing line. The method includes: receiving the PF data, identifying the storage objects and the processing objects in the PF data, for each processing object, identifying a source object of the processing object among the storage objects and the processing objects, identifying a destination object of the processing object among the storage objects and the processing objects, forming a plurality of process sequences based on the PF data, wherein each process sequence may include a process-sequence-specific source object and a process-sequence-specific destination object, identifying link objects present in two or more process sequences, generating an aggregated process sequence by linking the process sequences via the link objects, and generating the HMI data based on the aggregated process sequence such that once the HMI data is executed on an operator display, a rectangular array of screen area elements arranged in a first direction (A) can be generated, wherein for each process sequence, the destination object of the visualization representation of the destination object can be placed after the source object of the visualization representation of the source object in the first direction A in the rectangular array.

[0007] By adopting such a structured method, HMI data can be generated in a time-saving manner, and the time and cost for setting up or upgrading a food processing line can be reduced. In addition, by adopting the above-structured method, even if the food processing line is very complex, it can be consistently converted into a user interface, which can be intuitively used by operators and other personnel due to its consistency. One of the reasons for being able to handle complex processing lines is that each processing object is analyzed separately, and then the results of these individual evaluations are aggregated.

[0008] The rectangular array of screen area elements may be arranged in the first direction A and a second direction B, wherein the processing object of the visualization representation of the processing object can be placed after the storage object of the visualization representation of the storage object in the second direction B in the rectangular array.

[0009] The advantage of distinguishing between storage objects and processing objects on an operator display is that the operator can more easily understand how the different units of the food processing line are connected to each other.

[0010] The objects to be processed may include a first type of object to be processed and a second type of object to be processed, and the visualized objects to be processed may include a first type of visualized object to be processed and a second type of visualized object to be processed that are respectively linked to the first type of object to be processed and the second type of object to be processed, wherein the second type of visualized object to be processed may be placed after the first type of visualized object to be processed in the second direction B in the rectangular array.

[0011] The advantage of separating different types of objects to be processed in the second direction B is that the operator can more easily grasp how the food processing line is designed and how different food processing objects are related to each other.

[0012] The processing unit may be selected from the group consisting of: a temperature processing device, a homogenizer, a separator, a filtering device, a mixer, a cheese vat, an ice cream freezer, an ice cream extruder, a powder dryer, and a packaging machine.

[0013] The storage unit may be a tank.

[0014] The filling degree of the storage unit may be determined, and the filling degree may be displayed in the visualized storage object.

[0015] The inventory of the food processing line may be determined based on the filling degree of the storage unit, and the inventory of the food processing line may be displayed together with the visualized storage object.

[0016] According to a second aspect, a system is provided that includes a food processing line, an operator display, and a control unit configured to convert production flow (PF) data into human-machine interface (HMI) data. The PF data may include storage objects representing storage units in the food processing line and processing objects representing processing units in the food processing line. The control unit may include: a PF data receiver configured to receive the PF data, a storage and processing object identifier configured to identify the storage objects and the processing objects in the PF data, a source object identifier configured to, for each processing object, identify a source object of the processing object among the storage objects and the processing objects, a destination object identifier configured to identify a destination object of the processing object among the storage objects and the processing objects, a process sequence former configured to form a plurality of process sequences based on the PF data, where each process sequence includes a process-sequence-specific source object and a process-sequence-specific destination object, a linked object identifier configured to identify linked objects present in two or more process sequences, an aggregated process sequence generator configured to generate an aggregated process sequence by linking the process sequences via the linked objects, and an HMI data generator configured to generate the HMI data based on the aggregated process sequence such that, once the HMI data is executed on the operator display, a rectangular array of screen area elements arranged in a first direction A and a second direction B is generated, where, for each process sequence, a visual representation of the destination object of the destination object can be placed after a visual representation of the source object of the source object in the first direction A in the rectangular array.

[0017] A visual representation of the processing object of the processing object can be placed after a visual representation of the storage object of the storage object in the second direction B in the rectangular array.

[0018] The processing object may include a first type of processing object and a second type of processing object, and the visual representation of the processing object may include a first type of visual representation of the processing object and a second type of visual representation of the processing object respectively linked to the first type of processing object and the second type of processing object, where the second type of visual representation of the processing object is placed after the first type of visual representation of the processing object in the second direction B in the rectangular array.

[0019] The processing unit may be selected from the group consisting of: temperature processing equipment, a homogenizer, a separator, filtration equipment, a mixer, a cheese vat, an ice cream freezer, an ice cream extruder, a powder dryer, and a packaging machine.

[0020] The storage unit may be a tank.

[0021] The features and advantages presented in connection with the first aspect also apply to the second aspect.

[0022] Other objects, features, aspects, and advantages of the present invention will become apparent from the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Embodiments of the present invention will now be described by way of example with reference to the accompanying schematic diagrams, in which

[0024] Figure 1 generally shows how production process (PF) data is converted into human-machine interface (HMI) data.

[0025] Figure 2 shows an example of how a food processing line can be displayed on an operator display.

[0026] Figure 3 shows another example of how a food processing line can be displayed on an operator display.

[0027] Figure 4 is a flowchart showing the steps of a method for converting PF data 110 into HMI data 130.

[0028] Figure 5 generally shows a system including a food processing line, an operator display, and a control unit. DETAILED DESCRIPTION

[0029] Reference Figure 1 provides a general description, by way of example, of how information generated by a food processing line 100 can be converted so that an operator can access the current state of the food processing line 100 via an operator display 132.

[0030] As shown, the food processing line 100 includes a plurality of storage units 102, 108 and a plurality of processing units 104, 106. In the example shown, the storage units 102, 108 are a first tank 102 and a second tank 108, and the processing units 104, 106 are a plate heat exchanger 104 and a homogenizer 106. The first tank 102 is arranged to feed food to the plate heat exchanger 104. After temperature treatment, the food is fed from the plate heat exchanger 104 to the homogenizer 106, where the food can be processed to break fat globules. After homogenization, the food is fed to the second tank 108.

[0031] During production, production flow (PF) data 110 is generated by food processing line 100. This data can include, for example, data generated by valve devices, flow sensors, level sensors, and / or pressure sensors. This data can be generated by different storage units and the processing units themselves via built-in sensors, and / or this data can be generated by sensors that are external units (placed between two different processing units). PF data 100 can be transmitted directly via data communication modules included in different food processing units 104, 106, storage units 102, 108, and / or valve devices (not shown), or alternatively, PF data can be transmitted via a data communication module shared by several storage units 102, 108, processing units 104, 106, and / or valve devices.

[0032] Food processing line 100 can be reflected in PF data 110. For example, the first tank 102 can be represented as the first storage object 112, the first processing unit 104 can be represented as the first processing object 114, the second processing unit 106 can be represented as the second processing object 116, and the second tank 108 can be represented as the second storage object 118.

[0033] After identifying the storage objects and processing objects in PF data 110, the PF data 110 is processed such that for each processing object 114, 116, the source object of the processing object can be identified, and the destination object of the processing object can also be identified. In other words, for each processing object, it can be determined from which processing object or storage object the food is fed out, and it can also be determined to which processing object or storage object the food is fed. After identifying the source object and the destination object, a process sequence 120a-b can be formed. The process sequence 120a-b can include process sequence-specific source objects 122a-b and process sequence-specific destination objects 124a-b. Although the example shown includes two sequentially placed process sequences, this method can also be used for parallel process sequences and complex setups that include several sequentially placed process sequences and several parallelly placed process sequences.

[0034] As shown, the processing objects and / or storage objects can form part of more than one process sequence 120a-b. For example, as shown, the processing objects 114, 116 can form part of the two process sequences 120a-b shown. The processing objects 114, 116 and / or storage objects 112, 118 that form part of more than one process sequence 120a-b can be identified as linked objects 126a-b. By using these linked objects 126a-b, the process sequences 120a-b linked via the linked objects 126a-b can be combined into an aggregated process sequence 128.

[0035] Once the aggregation process sequence 128 is generated, human-machine interface (HMI) data 130 can be generated based on the aggregation process sequence. The aggregation process sequence 128 is generated in a structured manner by identifying the source object and the destination object of each processing object, making it possible to generate HMI data 130, so that the food processing line 100 is reflected on the operator display 132 in a consistent manner. This is advantageous because the operator can easily navigate himself or herself and thus easily grasp the information provided, which in turn leads to faster decision-making and also a lower risk of making decisions based on misreading the information provided via the operator display 132.

[0036] Once the HMI data 130 is received by the operator display 132, it can be transformed into graphical objects provided in a rectangular array 134, which has a plurality of screen area elements 136 and extends in a first direction A and a second direction B. As shown, the first storage object 112 (which is also the first process sequence dedicated source object 122a herein) can be represented by the source object 138 of the first visual representation, and the first processing object 114 (which is also the second process sequence dedicated source object 122b herein) can be represented by the source object 140 of the second visual representation. The second processing object 116 (which is also the first process sequence dedicated destination object 124a herein) can be represented by the destination object 142 of the first visual representation, and the second storage object 118 (which is also the second process sequence dedicated destination object 124b herein) can be represented by the destination object 144 of the second visual representation. In order to convey information to the operator in a way that reduces the risk of misreading, the way in which food can flow through the food processing line 100 can be represented as: for each process sequence 120a-b, the destination objects 142, 144 of the visual representation of the destination objects 116, 118 can be placed after the source objects 138, 140 of the visual representation of the source objects 112, 114 in the first direction A in the rectangular array 134. As shown, in the example shown, the first visual representation of the destination object 142 can be placed to the right of the first visual representation of the source object 138, i.e., in a subsequent position in the first direction A extending from left to right, and the second visual representation of the destination object 144 can be placed to the right of the second visual representation of the source object 138.

[0037] In addition, to enable an operator to easily distinguish between the visualized processing objects 140, 142 of the processing objects 114, 116 and the visualized storage objects 138, 144 of the storage objects 112, 118, the visualized processing objects 140, 142 can be placed in the matrix array 134 after the visualized storage objects 138, 144 in the second direction B. In this particular example, this approach results in the second visualized source object 140 and the first visualized destination object 142 being placed below the first visualized source object 138 and the second visualized destination object 144.

[0038] The processing objects 114, 116 can include a first type of processing object 114 (such as, for example, a plate heat exchanger in Figure 1 this example) and a second type of processing object 116 (such as, for example, a homogenizer). As an effect of there potentially being different types of processing objects, the visualized processing objects 140, 142 can include a first type of visualized processing object 140 and a second type of visualized processing object 142 that are respectively linked to the first type of processing object 114 and the second type of processing object 116. To enable an operator to easily identify the different types of processing objects, the second type of visualized processing object 142 can be placed in the rectangular array 134 after the first type of visualized processing object 140 in the second direction B.

[0039] The operator display 132 can be a touch screen. Area elements 146, 148, 150, 152 that support the touch screen can be provided such that additional information about the selected object is provided once the operator touches the visualized source object or destination object 138, 140, 142, 144.

[0040] Figure 2 An example 200 is shown of how a more complex food processing line can be displayed on the operator display 132. Similar to Figure 1 the food processing line 100 shown, Figure 2 the food processing line visualized in the operator panel 132 includes first and second tanks. However, different from Figure 1 the example shown, one of the processing objects - the "separator" - is set as a process sequence dedicated source object and is thus placed on the left side in the rectangular array 134. Also different from Figure 1In the illustrated example, there are three parallel processing objects that are visualized - "THE 1", "THE 2", and "PHE" - all of which are arranged to receive food from "Tank 1" or "Separator". By using the above method, namely identifying process sequences 120a-b and process sequence dedicated source objects 122a-b and generating an aggregated process sequence 128 based on these, the Figure 2 parallel arrangement shown can be efficiently identified, enabling the consistent generation of HMI data 130.

[0041] Figure 3 Another example is shown of how the food processing line can be visualized on the operator display 132. In this particular example, four storage objects are visualized. Additionally, in this particular example, the third processing object 302 forms the process dedicated source object for the process sequence of the fourth processing object 304 that is placed after the third processing object 302 in the first direction A, while the third storage object 306 can form the process dedicated destination object for this process sequence. Since the third processing object 302 does not constitute the process dedicated destination object for any other process sequence, the third processing object 302 can be provided with only one connection, as shown.

[0042] Figure 4 FIG. 400 is a flowchart showing a method 400 for transforming PF data 110 into HMI data 130. In a first step 402, PF data 110 can be received. Thereafter, in a second step 404, the storage objects 112, 118 and the processing objects 114, 116 in the PF data 110 can be identified. In a third step 406, for each processing object 114, 116, in a first sub-step 408, the source objects 112, 114 of the processing object 114, 116 can be identified among the storage objects 112, 118 and the processing objects 114, 116. Thereafter, in a second sub-step 410, the destination objects 116, 118 of the processing object 114, 116 can be identified among the storage objects 112, 118 and the processing objects 114, 116. In a third sub-step 412, a plurality of process sequences 120a-b can be formed based on the PF data 110, where each process sequence includes a process sequence dedicated source object 122a-b and a process sequence dedicated destination object 124a-b.

[0043] In a fourth step 414, the link objects 126a-b existing in two or more process sequences 120a-b can be identified.

[0044] In a fifth step 416, an aggregated process sequence 128 can be generated by linking the process sequences 120a-b via the link objects 126a-b.

[0045] In a sixth step 416, HMI data 130 may be generated based on the aggregated process sequences 128 such that once the HMI data 130 is executed on the operator display 132, a rectangular array 134 of screen area elements 136 arranged along a first direction A is generated, wherein for each process sequence 120a-b, the destination objects 142, 144 of the visual representations of the destination objects 116, 118 may be placed after the source objects 138, 140 of the visual representations of the source objects 112, 114 in the first direction A in the rectangular array 134.

[0046] Figure 5 The system 500 is shown by way of example and includes a food processing line 100, an operator display 132, and a control unit 502 configured to convert PF data 110 into HMI data 130. The control unit 502 may include a PF data receiver 504 configured to receive PF data 110. Based on the received PF data, the storage and processing object identifier 506 processes the PF data to identify the storage objects 112, 118 and the processing objects 114, 116 in the PF data 110. After identifying the storage objects and the processing objects, the source object identifier 508 may process each processing object 114, 116 based on this information to identify the source objects 112, 114 of the processing objects 114, 116 among the storage objects 112, 118 and the processing objects 114, 116. In a similar manner, the destination object identifier 510 may process the data to identify the destination objects 116, 118 of the processing objects 114, 116 among the storage objects 112, 118 and the processing objects 114, 116. After identifying the source objects and the destination objects, the process sequence former 512 may process the data such that a plurality of process sequences 120a-b are formed based on the PF data 110. After forming the plurality of process sequences, each process sequence includes a process-sequence-specific source object 122a-b and a process-sequence-specific destination object 124a-b. A linked object identifier 514 may be provided to identify the linked objects 126a-b present in two or more process sequences 120a-b. After identifying the linked objects 126a-b, an aggregated process sequence generator 516 may be used to generate an aggregated process sequence 128 by linking the respective process sequences 120a-b via the linked objects 126a-b. Finally, after having the aggregated process sequence 128, an HMI data generator 518 may be used to generate HMI data 130 based on the aggregated process sequence 128 such that a rectangular array 134 of screen area elements 136 may be generated once the HMI data 130 is executed on the operator display 132.

[0047] As can be seen from the above description, although various embodiments of the present invention have been described and illustrated, the present invention is not limited thereto, but can also be implemented in other ways within the scope of the subject matter defined by the following claims.

Claims

1. A method (400) for converting production process data (110) into human-machine interface data (130), wherein the production process data (110) includes storage objects (112, 118) representing storage units (102, 108) in a food processing line (100) and processing objects (114, 116) representing processing units (104, 106) in the food processing line (100), wherein the processing units (104, 106) are selected from the group consisting of: temperature treatment devices, homogenizers, separators, filtration devices, mixers, cheese vats, ice cream freezers, ice cream extruders, powder dryers, and packaging machines, and wherein the storage units (102, 108) are tanks, the method comprises: receiving (402) the production process data (110), identifying (404) the storage objects (112, 118) and the processing objects (114, 116) in the production process data (110), for each processing object (114, 116) (406), identifying (408) a source object (112, 114) of the processing object (114, 116) among the storage objects (112, 118) and the processing objects (114, 116), identifying (410) a destination object (116, 118) of the processing object (114, 116) among the storage objects (112, 118) and the processing objects (114, 116), forming (412) a plurality of process sequences (120a - b) based on the production process data (110), wherein each process sequence includes a process - sequence - specific source object (122a - b) and a process - sequence - specific destination object (124a - b), identifying (414) link objects (126a - b) present in two or more of the process sequences (120a - b), the link objects including at least one of the storage object and the processing object, generating (416) an aggregated process sequence (128) by linking the process sequences (120a - b) together via the link objects (126a - b), and generating (418) the human - machine interface data (130) based on the aggregated process sequence (128), such that once the human - machine interface data (130) is executed on an operator display (132), a rectangular array (134) of screen - area elements (136) arranged in a first direction (A) is generated, wherein for each process sequence (120a - b), a destination object (142, 144) of the visual representation of the destination object (116, 118) is placed after a source object (138, 140) of the visual representation of the source object (112, 114) in the first direction (A) in the rectangular array (134).

2. The method (400) according to claim 1, wherein the rectangular array (134) of the screen area elements (136) is arranged along the first direction (A) and the second direction (B), and the processing objects (140, 142) of the visual representation of the processing objects (114, 116) are placed after the storage objects (138, 144) of the visual representation of the storage objects (112, 118) in the second direction (B) in the matrix array.

3. The method (400) according to claim 1 or 2, wherein the processing objects (114, 116) include a first type of processing object (114) and a second type of processing object (116), and the processing objects (140, 142) of the visual representation include a first type of processing object (140) of the visual representation linked to the first type of processing object (114) and a second type of processing object (142) of the visual representation linked to the second type of processing object (116), wherein the second type of processing object (142) of the visual representation is placed after the first type of processing object (140) of the visual representation in the second direction (B) in the rectangular array (134).

4. The method according to any one of the preceding claims 1 or 2, wherein the filling degree of the storage units (102, 108) is determined, and the filling degree is displayed in the storage objects (138, 144) of the visual representation.

5. The method according to claim 4, characterized in that the inventory of the food processing line (100) is determined based on the filling degree of the storage units (102, 108), and the inventory of the food processing line (100) is displayed together with the storage objects (138, 144) of the visual representation.

6. A system (500) comprising a food processing line (100), an operator display (132) and a control unit (502), the control unit being configured to convert production process data (110) into human-machine interface (HMI) data (130), wherein the production process data (110) includes storage objects (112, 118) representing storage units (102, 108) in the food processing line (100) and processing objects (114, 116) representing processing units (104, 106) in the food processing line (100), wherein the processing units (104, 106) are selected from the group consisting of: temperature treatment devices, homogenizers, separators, filtration devices, mixers, cheese vats, ice cream freezers, ice cream extruders, powder dryers and packaging machines, and wherein the storage units (102, 108) are tanks, the control unit (502) comprises: a production process data receiver (504) configured to receive the production process data (110), A storage and processing object identifier (506) configured to identify the storage objects (112, 118) and the processing objects (114, 116) in the production process data (110), A source object identifier (508) configured to identify, for each processing object (114, 116), the source object (112, 114) of the processing object (114, 116) among the storage objects (112, 118) and the processing objects (114, 116), A destination object identifier (510) configured to identify, among the storage objects (112, 118) and the processing objects (114, 116), the destination object (116, 118) of the processing object (114, 116), A process sequence formulator (512) configured to form a plurality of process sequences (120a - b) based on the production process data (110), where each process sequence includes a process - sequence - specific source object (122a - b) and a process - sequence - specific destination object (124a - b), A linked object identifier (514) configured to identify linked objects (126a - b) present in two or more process sequences (120a - b), the linked objects including at least one of the storage object and the processing object, An aggregated process sequence generator (516) configured to generate an aggregated process sequence (128) by linking the process sequences (120a - b) via the linked objects (126a - b), A human - machine interface data generator (518) configured to generate the human - machine interface data (130) based on the aggregated process sequence (128), such that once the human - machine interface data (130) is executed on an operator display (132), a rectangular array (134) of screen - area elements (136) arranged in a first direction (A) and a second direction (B) is generated, where for each process sequence (120a - b), the destination object (142, 144) of the visual representation of the destination object (116, 118) is placed after the source object (138, 140) of the visual representation of the source object (112, 114) in the first direction (A) in the rectangular array (134).

7. The system according to claim 6, wherein the processing object (140, 142) of the visual representation of the processing object (114, 116) is placed after the storage object (138, 144) of the visual representation of the storage object (112, 118) in the second direction (B) in the matrix array (134).

8. The system according to claim 6 or 7, wherein the objects to be processed (114, 116) include a first type of object to be processed (114) and a second type of object to be processed (116), and the visualized objects to be processed (140, 142) include a first type of visualized object to be processed (140) and a second type of visualized object to be processed (142) that are respectively linked to the first type of object to be processed (114) and the second type of object to be processed (116), wherein the second type of visualized object to be processed (142) is placed after the first type of visualized object to be processed (140) in the second direction (B) in the rectangular array (134).

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