Composite system communication

Abstract

Systems and methods for improved production line control system communications are disclosed. The production line control system includes a plurality of components, such as a main component and a client component. At least one of the master component and the client component is configured to implement or execute a composite controller configured to: operatively communicate with each of the plurality of components; receiving information from each of the plurality of components; determining composite information of the production line control system based on information received from each of the plurality of components; generating a user interface that displays information related to each of the plurality of components and the composite production line control system; and a controller that transmits a command to each of the plurality of components.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 496,391, filed April 15, 2023, the entire disclosure of which is incorporated herein by reference as if set forth herein in its entirety. Technical Field

[0003] This disclosure relates generally to production line control, and more specifically to systems and methods for improved production line control and communication, such as for liquid dispensing systems. Background Technology

[0004] Liquid dispensing systems can be used in a variety of applications. For example, such systems can apply hot melt adhesives during the manufacture of disposable hygiene products. As another example, hot melt liquid dispensing systems can apply hot melt adhesives to assemble various types of packaging, such as paper-based packaging for food and beverages. Hot melt adhesives used in such applications can include moisture-curing hot melt polyurethane adhesives (“hot melt PUR”), which are typically used in situations where a stable surface-to-surface bond must be formed. Other conventional hot melt adhesives can be used to bond a variety of similar and dissimilar materials together in a mating relationship, such as wood, plastics, corrugated films, paper, cartons, metals, rigid polyvinyl chloride (PVC), fabrics, leather, etc. Hot melt adhesives are particularly useful in applications where rapid curing of the adhesive after melting and dispensing is desired.

[0005] In an example configuration of a hot melt liquid dispensing system, a solid or semi-solid form of hot melt adhesive is supplied to one or more melters or melter units. The melters heat the solid or semi-solid hot melt adhesive until it reaches a molten state. The molten hot melt adhesive can then be pumped to one or more applicators (also called applicator modules, dispensers, etc.). The applicators thus dispense the molten hot melt adhesive to the desired surface or substrate, typically as a series of points or lines. However, it is crucial to apply the adhesive within narrow tolerances for positioning, timing, and volume. For example, insufficient volume of dispensed adhesive once applied to the surface can result in ineffective bonding, while excessive adhesive can lead not only to wasted material but also to undesirable flow.

[0006] Proper operation of the melter within a hot melt liquid dispensing system is a crucial factor in achieving the desired dispensing results. For example, the temperature of the hot melt adhesive affects its viscosity. The viscosity of the hot melt adhesive, in turn, affects the volume of hot melt adhesive dispensed during each application, especially when the hot melt adhesive is pressure-driven. However, numerous operating parameters, settings, data measurements, hardware configurations, and so on must be carefully managed to ensure optimal melter performance. Clearly, effectively managing these many parameters presents a challenge.

[0007] To further complicate these challenges, hot melt liquid dispensing systems typically include multiple melters supporting a production line containing multiple applicators, or the production line may be supported by multiple hot melt liquid dispensing systems, each including one or more melters. Furthermore, a plant or production facility may have multiple production lines operating simultaneously, each associated with a separate hot melt liquid dispensing system, which in turn includes one or more melters.

[0008] Known production line systems typically require additional controllers (hardware and software) within the system for composite control, including controllers or human-machine interface (HMI) devices, usually on each component of the system, where each component is controlled individually. This often results in repetitive and time-consuming processes requiring operators to individually access each component to perform operations such as loading recipes or turning controls on / off. Therefore, it is desirable for operators to be able to perform this action once and then perform the same action on multiple connected machines designated for production.

[0009] These and other shortcomings are addressed in this disclosure. Summary of the Invention

[0010] This article discloses systems and methods for improving communication in production line control systems.

[0011] In one example, a production line control system is provided. The production line control system is configured to monitor and / or control at least one distribution device. The production line control system includes multiple components. The multiple components include a main component. The multiple components also include at least one client component. At least one of the main component and the at least one client component is configured to implement or execute a composite controller. The composite controller is configured to operatively communicate with each of the multiple components. The composite controller is also configured to receive the operating state of the main component. The composite controller is configured to receive the operating state of the main component from the controller of the main component. The composite controller is also configured to receive the operating state of the at least one client component. The composite controller is configured to receive the operating state of the at least one client component from the controller of the at least one client component. The composite controller is also configured to determine a composite operating state of the production line control system. The composite controller is configured to determine the composite operating state of the production line control system based at least in part on the operating state of the main component and the operating state of the at least one client component. The composite controller is also configured to generate a user interface. The user interface displays multiple control tiles. Each of the plurality of control tiles represents (a) one of the plurality of components and (b) at least one of the user-selectable component data of the plurality of components. The user interface also displays an indicator of the operating status of the master component. The user interface also displays an indicator of the operating status of the at least one client component. The user interface also displays an indicator of the combined operating status of the production line control system. The composite controller is also configured to transmit commands to the controller of the master component. The composite controller is also configured to transmit the commands to the controller of the at least one client component.

[0012] In another example, another production line control system is provided. The production line control system is configured to monitor and / or control at least one distribution device. The production line control system includes multiple components. The multiple components include a main component. The main component includes a controller. The multiple components also include at least one client component. The at least one client component includes a controller. The multiple components also include a backup main component. The backup main component includes a controller. The controller of the main component is configured to operatively communicate with each of the multiple components. The controller of the backup main component is also configured to operatively communicate with each of the multiple components. The controller of the main component is configured to implement or execute a composite controller. The controller of the backup main component is configured to determine whether the controller of the main component has lost operative communication with the at least one client component and the backup main component. If the controller of the backup main component determines that the controller of the main component has lost operative communication with the at least one client component and the backup main component for a predetermined minimum time, then the controller of the backup main component is also configured to implement or execute a composite controller. The composite controller is configured to receive the operating status of the main component. The composite controller is configured to receive the operating status of the main component from the controller of the main component. The composite controller is also configured to receive the operating status of the at least one client component. The composite controller is also configured to receive the operating status of a backup master component. The composite controller is configured to receive the operating status of the backup master component from its controller. The composite controller is configured to receive the operating status of the at least one client component from its controller. The composite controller is also configured to determine the composite operating status of the production line control system. The composite controller is configured to determine the composite operating status of the production line control system based at least in part on the operating status of the master component, the operating status of the at least one client component, and the operating status of the backup master component. The composite controller is also configured to generate a user interface. The user interface displays a plurality of control tiles. Each of the plurality of control tiles represents (a) one of the plurality of components and (b) at least one of user-selectable component data for the plurality of components. The user interface also displays an indicator of the operating status of the master component. The user interface also displays an indicator of the operating status of the at least one client component. The user interface also displays an indicator of the operating status of the backup master component. The user interface also displays an indicator of the composite operating status of the production line control system. The composite controller is also configured to transmit commands to the controller of the primary component. The composite controller is also configured to transmit the commands to the controller of the at least one client component. The composite controller is further configured to transmit the commands to the controller of the backup primary component.

[0013] In yet another example, a method is provided for transmitting commands to multiple components of a production line control system. The production line control system includes a main component. The production line control system also includes at least one client component. The method includes receiving the operating status of the main component. The operating status of the main component is received at a composite controller. The composite controller is implemented or executed by at least one of the main component and the at least one client component. At the composite controller, the operating status of the main component is received from the controller of the main component. The method also includes receiving the operating status of the at least one client component. At the composite controller, the operating status of the at least one client component is received from the controller of the at least one client component. The method also includes determining a composite operating status of the production line control system. The composite operating status of the production line control system is determined at least in part based on the operating status of the main component and the operating status of the at least one client component. The method also includes generating a user interface. The user interface displays multiple control tiles. Each of the multiple control tiles represents (a) one of the multiple components and (b) at least one of user-selectable component data of the main component or the at least one client component. The user interface also displays an indicator of the operating status of the main component. The user interface also displays an indicator of the operating status of the at least one client component. The user interface also displays an indicator of the combined operating status of the production line control system. The method also includes transmitting commands to the controller of the master component. The method further includes transmitting the commands to the controller of the at least one client component. Attached Figure Description

[0014] The accompanying drawings, which are incorporated in and form part of this specification, illustrate the embodiments and, together with the specification, serve to explain the principles of the methods and systems:

[0015] Figure 1 An example production line control system is shown;

[0016] Figure 2 An example schematic diagram of the composite system is shown;

[0017] Figure 3 An example schematic diagram of another composite system is shown;

[0018] Figure 4 An example diagram of the composite system is shown;

[0019] Figure 5 An example diagram of another composite system is shown;

[0020] Figure 6 A flowchart of an example method is shown;

[0021] Figure 7 Another example method flowchart is shown;

[0022] Figure 8 An example diagram of the user interface is shown;

[0023] Figure 9 Example diagrams of user interface elements are shown;

[0024] Figure 10 An example diagram of another user interface element is shown;

[0025] Figure 11 An example diagram of another user interface element is shown; and

[0026] Figure 12 An example schematic diagram of an automatic network switch is shown.

[0027] Various aspects of this disclosure will now be described in detail with reference to the accompanying drawings, wherein, unless otherwise stated, the same reference numerals always refer to the same elements. Detailed Implementation

[0028] The systems and methods disclosed herein relate to improved communication for production line systems. Although primarily referenced to hot melt adhesives, the techniques described herein are applicable to any type of liquid, including non-adhesive liquids.

[0029] Figure 1 An example production line control system 10 (e.g., a hot melt adhesive dispensing system or other type of production line control system) is shown, which enables the techniques described herein to be implemented. The production line control system 10 may include a melter unit 20, which may include an adhesive supply section 22 for receiving and melting solid or semi-solid adhesive 24a (e.g., granules), a manifold 26 connected to the adhesive supply section 22, a controller 28, and a user interface 29. The adhesive supply section 22 may be a can melter or a grid and reservoir melter, etc. During melting, the solid or semi-solid adhesive 24a stored in the adhesive supply section 22 can be transformed into liquid adhesive 24. The adhesive supply section 22 may include a sidewall 30, a removable cover 31, and a base 32, the base 32 of which may include one or more adhesive supply section heaters 34 for melting and heating the adhesive 24a and liquid adhesive 24 in the adhesive supply section 22. The adhesive supply outlet 36 near the base 32 can be connected to the channel 38, which can be connected to the inlet 40 of the manifold 26.

[0030] A volumetric pump 58 (such as a vertically oriented piston pump (as shown) or a gear pump) can be coupled to manifold 26 to pump liquid adhesive 24 from adhesive supply section 22 into manifold 26, where the liquid adhesive 24 can be split into separate streams. Pump motor 59 can drive pump 58. Through the operation of pump 58 (and thus also as a function of pump motor 59), adhesive can be supplied under pressure to manifold 26 and applicators 48, 50. This pressure can affect the volume of adhesive dispensed in one applicator cycle (also known as a gun cycle) of adhesive dispensing module 54, and generally affects the flow rate and velocity of adhesive entering, passing through, and / or leaving manifold 26.

[0031] Manifold 26 can be mounted to the sidewall 30 of adhesive supply section 22 using spacer 41 and can be spaced apart from adhesive supply section 22 by a distance 42 sufficient to provide thermal insulation between adhesive supply section 22 and manifold 26. Manifold 26 may include multiple outlet ports 44, which may be fitted with heated hoses 46 attached to one or more adhesive applicators 48, 50 to supply liquid adhesive 24 to the applicators 48, 50. Manifold 26 may include a manifold heater 56, which may be separate from adhesive supply section heater 34 and can be independently controlled by controller 28. In this example, a single heater may be used to heat both adhesive supply section 22 and manifold 26. Although Figure 1 The adhesive supply unit 22 is shown physically adjacent to the manifold 26, but other arrangements are possible, such as the adhesive source being physically distant from the manifold. In such arrangements, more than one pump can be used to move the adhesive from the adhesive supply unit 22 toward the final application point.

[0032] Manifold 26 can generate multiple flow streams, which can be delivered to applicators 48, 50 by corresponding heated hoses 46. The hoses 46 can be electrically connected to controller 28 via rope bundles 62 associated with each hose 46. Applicators 48, 50 may include one or more adhesive dispensing modules 54 configured to dispense and / or apply liquid adhesive 24 to products, such as cartons, packaging, or other objects. Adhesive dispensing modules 54 can be mounted to applicator bodies 51, which may have applicator heaters 53 and be supported on a frame 52. Production line control system 10 may include two applicators 48, 50, with one applicator positioned on each side of the melter unit 20, such as... Figure 1As shown, however, other embodiments of the production line control system 10 may use different numbers of applicators, dispensing modules, and other configurations to suit specific applications. For example, applicators 48 and 50 may each be configured with a single adhesive dispensing module 54, or may each be configured with a pair of adhesive dispensing modules 54. The adhesive dispensing modules 54 of applicators 48 and 50 may be jointly monitored, controlled, and / or actuated by a common air source. Alternatively, the adhesive dispensing modules 54 of applicators 48 and 50 may be independently monitored, controlled, and / or actuated by separate air sources. Applicators 48 and 50 and / or adhesive dispensing modules 54 may be referred to as applicators or dispensers, respectively.

[0033] Pump 58 may be located outside adhesive supply unit 22 and may be connected to air pressure regulator 70 that receives air from air source 61. More specifically, air pressure regulator 70 may be mounted to melter unit 20 and connected to air source 61. In some embodiments, pump 58 may be attached to manifold 26 and heated by manifold heater 56. This arrangement allows for a larger can opening 60, increasing can capacity and reducing the time required to heat pump 58. Furthermore, flow meter 80 may be attached to manifold 26 to measure the adhesive flow through it. Flow meter 80 may include a pair of sensors electrically connected to controller 28 via corresponding cords 63a, 63b associated with each sensor. At least one product detector 90, such as a light sensor, may also be electrically connected to controller 28.

[0034] Melter unit 20 may include controller 28. Controller 28 may house power supplies and electronic controls for the production line control system 10. Controller 28 may be configured to have one or more processors and a memory configured to store instructions that, when executed by one or more processors, cause controller 28 to perform the various operations described herein. Controller 28 may be configured to manage various types of data associated with the production line control system 10 and its components, including melter unit 20, applicators 48, 50, and / or controller 28 itself. Managing such data may include storing data, capturing data (e.g., measured by various sensors), modifying or setting data, receiving similar data from other melter units 20 or other controllers 28 of the production line control system 10, and / or providing data to other melter units 20 or other controllers 28 of the production line control system 10 (e.g., via a composite controller or cloud system as described herein).

[0035] Data managed by controller 28 (collectively referred to as control data) may include operating parameters, measurement data, and / or hardware configuration data. Example operating parameters may relate to temperature setpoint, control loop settings (e.g., temperature control loop), control loop type, pump speed, melter duty cycle (or its separate heater), applicator cycle rate, and pump and / or pump motor speed. Example measurement data may relate to liquid temperature (including at various points within melter unit 20, tank 22, manifold 26, applicators 48, 50, and heated hoses), liquid flow rate (e.g., from manifold 26), liquid flow rate (e.g., from manifold 26), and / or liquid pressure. Example hardware configuration data may include the number of pumps, pump type, holding capacity of tank 22, number of hose outlets of manifold 26, power capacity, control interface with controller 28, weight (e.g., of melter unit 20), external dimensions (e.g., of melter unit 20), liquid throughput from melter unit 20, and / or melting rate of melter unit 20.

[0036] Regarding the heating characteristics of the production line control system 10, the controller 28 can be electrically connected to heaters, including the adhesive supply heater 34, manifold heater 56, applicator heater 53, and / or any hose heater. The controller 28 can also be connected to various temperature sensors in the production line control system 10, which may be associated with or included in the adhesive supply heater 34, manifold heater 56, applicator heater 53, and / or any hose heater. The controller 28 can independently monitor and adjust the adhesive supply heater 34, manifold heater 56, applicator heater 53, and / or any hose heater to melt the solid or semi-solid adhesive 24a received in the adhesive supply section 22 and maintain the temperature of the (molten) adhesive 24 to ensure the appropriate viscosity of the adhesive 24 supplied to the applicators 48, 50 and dispensed by the adhesive dispensing module 54.

[0037] Figure 2 A schematic diagram of a composite system 200 comprising multiple melter units 202a-e at a production facility is shown. In several aspects, the composite system 200 may be an aggregation of all systems installed on a single production line to produce a product, an aggregation of all systems installed on multiple production lines to produce a product, an aggregation of all systems installed on multiple production lines to produce multiple products, etc. In several aspects, the composite system 200 may take many different forms, including: a homogeneous composite network comprising multiple systems on the same production line (e.g., a production line with multiple melters); and a heterogeneous composite system comprising multiple systems (e.g., melters, roller unloaders, and pattern controllers), at least one of which originates from a different production line. Although... Figure 2The melting units 202a-e are shown, but the data flow can be controlled using the production line control system 10 or any other component of the production line control system 10, as described below. Data flow within the composite system 200 can be performed according to a publish / subscribe communication model or architecture, such as Open Platform Communication (OPC) Unified Architecture (OPC / UA). Specifically, control data can be published by the melting unit 202 to the composite controller 210. As used herein, the term "composite controller" can refer to hardware, software, or a combination thereof. As a non-limiting example, the composite controller described herein is a software implementation, and in some non-limiting examples, this software implementation can be implemented or performed by a controller or cloud system, one of the components of the composite system described herein. Control data published to the composite controller 210 can be propagated by the composite controller 210 to select the melting unit 202 via subscription. As described herein, in examples, client components (e.g., melting units 202a-d) can submit data to the master component. (For example, melter unit 202e) publishes information (e.g., the operating status of the corresponding component). In other examples, the master component may (e.g., simultaneously) publish command or control messages to the client components, as described herein. As described herein, in some examples, the composite system may be a homogeneous system (e.g., comprising melter units of the same type), or in other examples, it may be a heterogeneous system (e.g., comprising melter units of different types or other components such as roller unloaders or pattern controllers). In any of the foregoing examples, the composite controller may be configured to decode information received from such components and publish command or control messages to any component, regardless of type. This advantageously allows a single composite controller to be configured to be operationally connected to any type of controller in the composite system to improve production line control and communication.

[0038] like Figure 2 As shown, the composite controller 210 can be implemented as part of the melter unit 202e, and in some examples, includes software implemented or executed by the controller 204 of the melter unit 202e. Alternatively, the composite controller 210 can be implemented or executed by a separate unit co-located with the melter units 202a-e. As another alternative, the composite controller 210 can be implemented as a cloud system or executed by a cloud system, as per the description of... Figure 3As discussed herein, in the example, each component of composite system 200 may be configured with software implemented or executable as a composite controller, such that composite controller 210 can be implemented or executed by any component of composite system 200 (i.e., each and any component may be configured to assume the role of a master component as needed to suit a particular application). Determining which component(s) of composite system 200 is implemented or executed as composite controller 210 may be based on predetermined hierarchical identifiers, such as the first component of composite system 200 being operatively connected to composite system 200, components of composite system 200 having a lowest sequence number, etc., including combinations thereof.

[0039] As needed, the melter units may be collectively referred to as a plurality of melter units 202 or a single melter unit 202, or suitably, the melter unit may be specifically referred to as one of a particular melter unit 202a-e. System 200 may be referred to as a composite system. System 200 may represent a single liquid (e.g., adhesive) dispensing system (e.g., Figure 1 The system 200 is a production line control system 10, which is constructed with multiple melter units 202 or other components. Alternatively, the system 200 may represent multiple production line control systems, each having a single melter unit 202. For example, melter unit 202a may belong to a first production line control system, melter unit 202b may belong to a second production line control system, and so on. Furthermore, the system 200 may include combinations of such systems, where some melter units 202 are all part of a common production line control system, while other melter units 202 each belong to a separate single melter unit production line control system. Although the system 200 is generally discussed with respect to the melter units 202, the techniques described herein can be applied to other components of the production line control system, such as the applicator or sub-components of the melter unit 202 (e.g., manifolds, adhesive cans, hoses, etc.).

[0040] Each melting unit 202 may include a controller 204 and / or be associated with a controller 204. The controller 204 of the melting unit 202 and / or the controller 204 associated with the melting unit 202 typically controls the operation of the melting unit 202 and communication to and from the melting unit 202. In some cases, the controller 204 may additionally control at least some aspects of the operation of a production line control system associated with the melting unit 202. The controller 204 may also manage control data stored at the controller 204, including receiving control data, modifying control data, and transferring control data to other systems or components. For example, the controller 204 may receive control data from a composite controller 210 as a subscriber. Conversely, the controller 204 may transfer control data to a composite controller 210 as a publisher. Control data may include operating parameters, measurement data, and hardware configuration. The controller 204 may be associated with... Figure 1 The controller 204 is the same as or similar to the controller 28. Controller 204 may include an OPC Unified Architecture (OPC / UA) controller.

[0041] Each controller 204 may be configured with a server 214 and a client 216. Server 214 and client 216 may be implemented as part of controller 204. Alternatively or additionally, server 214 and client 216 may be implemented at least partially as separate physical components. Server 214 and client 216 may be considered, respectively, an embedded server and an embedded client of melter unit 202 and / or its controller 204. Server 214 may include an embedded OPC / UA server, and client 216 may include an embedded OPC / US client. Server 214 may typically be configured to publish control data (i.e., control data messages) to composite controller 210. Client 216 may typically be configured to subscribe to and receive published control data (i.e., control data messages) from composite controller 210. In the publish-subscribe architecture of system 200, server 214 may be considered a publisher, and client 216 may be considered a subscriber.

[0042] As indicated, the melter unit 202e may include and / or be associated with a composite controller 210. The composite controller 210 may be configured to coordinate and direct various control data messages to and from the melter unit 202, particularly the controller 204 of the melter unit 202 (including the controller 204 of the melter unit 202e itself). For example, the composite controller 210 may receive published control data messages from a server 214 of the melter unit 202 and send control data messages to clients 216 of one or more other melter units 202 according to subscription criteria. In some examples, the composite controller 210 may act as a message broker for control data messages.

[0043] Composite controller 210 can filter published control data messages to determine which melter unit 202 (if any) should receive them. Composite controller 210 can filter published control data messages based on one or more classifications. In some examples, the classification (or category) of the published control data messages can be defined at least in part by the publishing server 214. Composite controller 210 can further filter published control data messages based on subscription profiles (e.g., subscription criteria) associated with other melter units 202. The subscription profiles associated with melter units 202 can be defined at least in part. The filtering by composite controller 210 can be performed based on a topic-based model, a content-based model, or a combination thereof.

[0044] In a topic-based model, classification can be about the type of component associated with control data (e.g., pump, heater, adhesive tank, applicator, manifold, heated hose, controller, etc.). Classification can also be about the type of operating parameters associated with control data (e.g., temperature setpoint, applicator circulation rate, melter / heater duty cycle, control loop setting, control loop type, pump speed, etc.). Classification can also be about the type of measurement data indicated in the control data (e.g., adhesive temperature, adhesive flow rate, adhesive flow rate, and adhesive pressure). Classification can also be about the type of hardware configuration data indicated in the control data (e.g., number of pumps, pump type, adhesive tank holding capacity, number of hose outlets in the manifold, power capacity, control interfaces to and from the controller, melter unit weight, melter unit external dimensions, adhesive throughput from the melter unit, and melter unit melting rate). Classification can also typically be based on the type of data: for example, operating parameter data, measurement data, or hardware configuration data.

[0045] In a content-based classification model, classification can be related to a specific melter unit 202 that publishes control data. Classification can further be related to the values ​​of operating parameters or measurement data. For example, classification can be based on operating parameter or measurement data values ​​that exceed a threshold, are below a threshold, are outside a threshold range, or are within a threshold range. For instance, based on the composite controller 210 determining that the adhesive temperature value is outside a threshold range, control data indicating the adhesive temperature from one melter unit 202 can be sent by the composite controller 210 to other melter units 202.

[0046] The melter unit 202e, including the composite controller 210, may be configured with a panel 206, also referred to as a control panel. One or more other melter units 202 may also be configured with panels 206. In some examples, panel 206 may be optionally excluded. Panel 206 may include a display (e.g., an LCD or LED display) and one or more user input devices (e.g., pointing devices, keyboards, or various control buttons). The display may be configured as a touchscreen display for user input. Panel 206 may output a graphical user interface, which may be configured to display the visual layout of the melter unit 202 and other components / units of the system 200. The graphical user interface may also be configured with one or more interface elements (e.g., “tiles”) to display various data associated with the system. Interface elements may be additionally or alternatively associated with the melter unit 202 or other components / units of the system 200. When an interface element of a particular production line control system is activated, data related to the system, such as system operating parameters, various measurement data, and / or aspects of the system's hardware configuration, may be displayed. The graphical user interface can also be used to input various changes to the production line control system and other components of system 200. For example, operators can typically use the graphical user interface and panel 206 to modify the operating parameters of the production line control system, and these modified operating parameters can be transmitted or transferred to components of the system as described herein.

[0047] The melting unit 202e (particularly the composite controller 210) can be configured to communicate with the computing device 222. The computing device 222 can communicate with the melting unit 202e via wired, fiber optic, wireless, or other means. For example, the computing device 222 can communicate via a WAN (Wide Area Network), LAN (Local Area Network), WLAN (Wireless LAN), intranet, Internet, communication channels as defined herein, and / or other means. The computing device 222 can be located in the same production facility as the melting unit 202. For example, an operator can move across the floor of the production facility equipped with the portable computing device 222 to monitor and manage production operations. Alternatively or additionally, the computing device 222 can be located remotely from the production facility. As some examples, the computing device 222 can be a personal computer (PC), laptop computer, mobile device, tablet computer, or smartphone. The computing device 222 can be configured to perform functions similar to those of the panel 206 of the melting unit 202e. In some examples, the melter unit 202e may be configured without panel 206, and the functions of panel 206 may instead be transferred to computing device 222.

[0048] The first and second control data messages 208a and 208b illustrate example publish / subscribe data flows within system 200. The first (“publish”) control message 208a is typically used to send information (e.g., operational status) from one or more client components (e.g., melter units 202a-d) of the composite system 200 to the master component (e.g., melter unit 202e). In the example, the first control data message 208a may additionally or alternatively include other information, such as user-selectable information about the corresponding component to be displayed on the user interface (e.g., as control tiles), as described herein. The second (“subscribe”) control message 208b is typically used to send information (e.g., command or control messages) from the master component (e.g., melter unit 202e) to one or more client components (e.g., melter units 202a-d) of the composite system 200. In the example, the second control data message 208b may be used to control one or more client components, such as by controlling their sub-components (e.g., pumps, heaters), loading recipes, etc., as described herein.

[0049] Regarding the first control data message 208a, the server 214 of the melter unit 202a can generate the first control data message 208a and publish it to the composite controller 210. The composite controller 210 can filter the first control data message 208a based on subscription profiles associated with other melter units 202 and aspects of the first control data message 208a. Aspects of the first control data message 208a may include one or more categories. Such categories may have been defined by the server 214 of the melter unit 202a. In this example, the first control data message 208a may indicate the heater duty cycle of the melter unit 202a. Subscription profiles associated with melter units 202b, 202c, and 202d may indicate that these melter units 202b, 202c, and 202d should receive control data related to the heater duty cycle (e.g., the category of the first control data message 208a) from other melter units 202. Additionally or alternatively, the subscription profiles associated with melter units 202b, 202c, and 202d may indicate that these melter units 202b, 202c, and 202d should receive control data (e.g., additional or alternative classifications of the first control data message 208a) published by melter unit 202a. In either case, the first control data message 208a may be sent via subscription to the respective client 216 of melter units 202b, 202c, and 202d.

[0050] Regarding the second control data message 208b, the server 214 of the melter unit 202b can generate the second control data message 208b and publish it to the composite controller 210. The composite controller 210 can filter the second control data message 208b based on subscription profiles associated with other melter units 202 and aspects of the second control data message 208b (e.g., one or more categories of the second control data message 208b). In this example, the second control data message 208b may indicate the temperature setpoint operating parameters of the melter unit 202b. Subscription profiles associated with melter units 202a and 202d may indicate that these melter units 202a and 202d should receive control data related to the temperature setpoint operating parameters (e.g., categories of the second control data message 208b) from other melter units 202. Therefore, the composite controller 210 can send the second control data message 208b to the corresponding clients 216 of the melter units 202a and 202d via subscription. Further, in this example, if the temperature setpoint operating parameters are outside the threshold range (e.g., another category of the second control data message 208b), the subscription profile associated with the melter units 202c and 202e can instruct these melter units 202c and 202e to only receive control data associated with the temperature setpoint operating parameters. In this example, the temperature setpoint operating parameters indicated in the second control data message 208b are not outside the threshold range. Therefore, in this example, the second control data message 208b is not sent to the melter units 202c and 202e.

[0051] The composite controller 210 can also be configured to coordinate at least some of the operations of the melter units 202. For example, the composite controller 210 can receive control data from one melter unit 202 and instruct a second melter unit 202 to operate accordingly. For example, the composite controller 210 can receive control data indicating that the first melter unit 202 is inoperable or suffers reduced molten binder output. Therefore, the composite controller 210 can instruct the second melter unit 202 to increase its molten binder output to compensate for the inoperability or reduced molten binder output of the first melter unit 202.

[0052] Figure 3 A schematic diagram of a system 300 constructed according to a cloud / edge architecture is shown. System 300 may be similar to, in at least some respects, a cloud architecture / edge architecture. Figure 2 System 200. Therefore, the same reference numerals denote the same parts or components. However, instead of the composite controller, it is implemented as part of the melter unit 202, as... Figure 2In the case of system 200, the composite controller 232 is implemented by server 230. Server 230 may be part of a cloud / edge system, and melter unit 202 may communicate with server 230 via network 250. Thus, server 230 may be located remotely from the production facility housing melter unit 202, but this disclosure is not limited thereto. For example, server 230 may be located in the same production facility as melter unit 202 and connected to melter unit 202 via a LAN (e.g., WLAN) and / or a communication channel defined at the production facility. Server 230 is not limited to a single computing device but may include multiple networked computing devices, storage units (e.g., databases), and / or networking devices.

[0053] The composite controller 232 implemented at server 230 can be similar to in at least some respects Figure 2 The composite controller 210. In practice, the composite controller 232 can be considered similar to the composite controller 210 in many functional aspects. For example, similar to the composite controller 210, the composite controller 232 can receive published control data messages from the server 214 of the melter unit 202. The composite controller 232 can filter the control data messages based on various aspects of the subscription profile associated with the melter unit 202 and the control data itself. The composite controller 232 can thus transmit the control data messages to the client 216 of the determined melter unit 202 (or not at all).

[0054] The computing device 222 can communicate with the server 230, and particularly with the composite controller 232. The computing device 222 can realize the functionality of... Figure 2 The panel 206 of the melter unit 202e provides at least some of the functions. For example, the computing device 222 can display a graphical user interface (GUI) that provides a visual layout of the production line control system and other components within the production facility. The GUI can display various data related to the production line control system, such as operating parameters, measurement data, and hardware configuration data. The data displayed by the GUI can be derived from control data messages published by or otherwise received from the melter unit 202. The GUI can provide various interactive interface elements (“tiles”) that can be activated to display further data of the production line control system associated with the interface elements. The GUI and computing device 222 can generally be used to control various aspects of the production line control system and other components of the system. For example, the computing device 222 can be used to adjust various operating parameters of the production line control system. This control can be implemented via server 230 and / or composite controller 232.

[0055] Figure 4At least a portion of an exemplary composite system 400 is shown, which includes four operatively connected melter units 402, labeled melter units 402a-402d. In at least some aspects, Figure 4 System 400 can be with Figure 1 Production line control system 10 Figure 2 System 200 and / or Figure 3 The system is the same as or similar to 300. Similarly, in at least some respects, Figure 4 The melter unit 402 can be with Figure 1 The melting unit 20 and / or Figure 2 and Figure 3 The melter unit 402 is identical or similar to the melter unit 202. Thus, the melter unit 402 may include a reservoir configured with one or more heaters to melt solid or semi-solid adhesive supplied to the melter unit 402. The melter unit 402 may also include a manifold for dispensing the molten adhesive to one or more applicators (e.g., applicators configured to dispense molten adhesive) via a connected hose (e.g., a heated hose). Additional heaters may be found throughout the system 400, either at or within the manifold, hose, or applicator associated with the respective melter unit 402. The system 400 may also include one or more sensors to measure the temperature of the molten adhesive at various points within the system 400, such as within the reservoir, manifold, hose, or applicator of the respective melter unit 402. Although they are not in Figure 4 As shown, however, one or more applicators, hoses, and any adhesive supply devices (e.g., hoppers) can be considered part of system 400. It is conceivable that each melter unit 402 of system 400 supplies molten adhesive to one or more applicators specifically associated with that melter unit 402.

[0056] Although system 400 is Figure 4 The system is depicted as having four melting units 402; however, it should be understood that the system 400 may have any suitable number of melting units 402, depending on the type of melting unit 402, the type of material to be dispensed, the amount of material to be melted and dispensed, and / or other manufacturing factors. Furthermore, the melting units 402 of the system 400 may include different types of melting units 402 (such as... Figure 5 The melter unit 406 shown) and / or melter units operating according to different operating parameters or configurations. Additionally or alternatively, it should be understood that system 400 may include any other components (referred to as client components, which may operate as a primary component or a backup primary component, as described herein), such as Figure 5 The pattern control device 408 shown.

[0057] The melter unit 402 (e.g., particularly the associated control device 410) may also include a communication interface, such as a wireless interface, to enable network communication with other devices, including another control device 410 or a cloud system. The wireless interface may communicate via, for example, Wi-Fi and / or other communication channels as defined herein. The wireless interface may additionally or alternatively include cellular communication devices.

[0058] System 400 may include one or more control devices 410 configured to display information related to system 400, such as information relating to one or more of the melter units 402 or other components of system 400. In at least some aspects, Figure 4 and Figure 5 The control device 410 can be with Figure 1 Controller 28 and / or Figure 2 and Figure 3 The composite controller 204 is the same as or similar to the composite controller 204. The control device 410 can be disposed on one or more melter units 402 or other components. For example, such a control device 410 can be embedded in a melter unit 402. In one aspect, only a single melter unit 402 of the system 400 is configured with the control device 410. For example, such a single melter unit 402a configured with the control device 410 can be similar to the one configured with the composite controller 210. Figure 2 The melter unit 202e is the same as or similar to that of the melter unit 202e. In fact, the composite controller 210 and the control device 410 can be implemented in the same computing module or device.

[0059] Additionally or alternatively, control device 420 may be a separate device that communicates (e.g., wirelessly or wired) with one or more individual melter units 402 or other components of system 400. Separate control device 420 may include a desktop computer, laptop computer, tablet computer, and / or mobile phone. In one aspect, system 400 may include multiple control devices 410, 420. For example, system 400 may have one or more control devices 410 that communicate directly with one or more other melter units 402 via wired means, and / or one or more separate control devices 420 that communicate wirelessly with one or more melter units 402. In some examples, separate control device 420 may communicate with... Figure 2 and Figure 3 The computing device 222 is the same as or similar to the independent control device 420. The control functions of the independent control device 420 can be facilitated by a cloud system; in some examples, the cloud system may include [the following]. Figure 3 Server 230 is the same as or similar to other servers.

[0060] As described herein, a composite controller can typically be implemented or executed by the controller of any component of the production line control system, thereby enabling such a component to assume the role of a master component, provided that such a component operates as a master component and its controller implements or executes the composite controller. For example, the composite control capabilities described herein can typically be included in software implemented or executed on or by each controller of each component of the production line control system, thereby allowing each component to assume any role within the composite system as described herein without requiring additional control hardware. As can be understood and as described herein, no control device and / or composite controller is required for each component of the production line control system; rather, the control device and / or composite controller can typically be located anywhere within the composite system as described herein, but it should be understood that the term "within" does not necessarily require the control device and / or composite controller to be physically located in the same location as other components of the production line control system. In the example, the master component may include the composite controller. In other examples, a cloud server located remotely from the location housing the production line control system may include the composite controller. In the example, an operator can navigate from any connected device (e.g., an HMI device) to a control screen associated with the production line control system or any of its components, as described herein. In the example, the controller of any component of the production line control system can implement or execute a composite controller, and can be determined based on predetermined hierarchical identifiers such as the first component of the production line control system to be operatively connected to the production line control system, the component of the production line control system with the lowest serial number, etc. (including combinations thereof).

[0061] Controllers (including composite controllers) for components of a production line system may be configured with one or more processors and a memory configured to store instructions that, when executed by one or more processors, cause the controller to perform the various operations described herein. Controllers may be configured to manage various types of data associated with the production line control system and its components. Managing such data may include storing data, capturing data (e.g., measured by various sensors), modifying or setting data, receiving similar data from other components or other controllers of the production line control system, and / or providing data to other components or other controllers of the production line control system (e.g., via composite controllers or cloud systems as described herein). In the examples, any controller (including composite controllers) may be a human-machine interface (HMI) device.

[0062] In this example, the production line control system may include a backup primary component. The backup primary component is typically configured to operate in a manner similar to other client components, provided the primary component maintains operational communication with the client components. For example, a composite controller may receive the operational status of the backup primary component, and the composite controller may transmit command and / or control messages to the backup primary component, similar to what is performed for other client components as described herein. In such an example, determining the composite operational status of the production line control system may include taking into account the operational status of the backup primary component, similar to what is performed for other client components as described herein. However, additionally, the backup primary component may receive and / or monitor command and control messages transmitted to, from, or between the primary and other components. For example, the backup primary component may monitor the reception of command and / or control messages issued by the primary component (e.g., at regular or predetermined intervals). Like the primary component, any component of the system can typically operate as a backup primary component. In this example, the system may include a single primary component, a single backup primary component, and one or more client components, but a backup primary component may also typically be referred to as one of the client components when it has not yet been converted to assume the role of a primary component.

[0063] A standby master component can be configured (e.g., via its controller) to determine whether a master component (e.g., particularly its controller) has lost operational communication with a client component and / or a standby master component. In an example, this determination can be performed by the standby master component (e.g., particularly its controller) by recognizing that the standby master component has not received any command and / or control messages issued by the master component within a predetermined minimum time period (e.g., approximately five seconds) or within a predetermined minimum number of lost frames. If such a determination is made indicating that the master component has lost operational communication with the client component and / or the standby master component, the standby master component can operate as the master controller, wherein the standby master controller's controller implements or performs a composite controller (e.g., by the standby master component transitioning to the role of the master component, wherein the standby master component's controller implements or performs a composite controller). During the period in which the standby master component operates as the master component and the standby master component's controller operates as a composite controller, the standby master component and its controller can operate as described herein with respect to the master component and the composite controller. Furthermore, the standby master component's controller (which then operates as a composite controller) can monitor whether the master component's controller has regained operational communication with the client component and / or the standby master component. Before regaining this operational communication, the backup master component's controller can continue to operate as a composite controller, as described herein. However, if this operational communication is regained (i.e., the master component's controller regains operational communication with the client component and / or the backup master component), the backup master component's controller can switch back to operating as a composite controller, as described herein. After such a switch, the backup master component's controller can resume operation as a backup "bookkeeper," including receiving and / or monitoring command and control messages transmitted to, from, or between the master and other components (e.g., including receiving and / or recording the composite operating status of the production line control system from the composite controller).

[0064] It is understood, and as described herein, that primary components, backup primary components, and other client components can be any component of the production line control system. Figure 4 As shown, the main component can be melter unit 402a, and other client components (any of which can operate as a backup main component) can also be melter units 402b-d, but other examples of this disclosure are not limited thereto. For example, as Figure 5 As shown, the main component can be the melter unit 402a, and other client components (any of which can operate as a backup main component) can include one type of melter unit 402b-d, another type of melter unit 406, and pattern control device 408, but other combinations may be used as needed to suit a particular application.

[0065] Figure 6 A data flow diagram is shown for a method 600 for transmitting commands to multiple components (such as melting units) in a production line control system or component. Specifically, method 600 can transmit commands (e.g., including control data) between a master component (e.g., a first melting unit among multiple melting units) and one or more client components (e.g., a second melting unit among multiple melting units). The production line control system may be, for example... Figure 1 The production line control system 10. Method 600 can, for example, in... Figure 2 System 200 and / or Figure 3 The system can operate within 300 units. Therefore, multiple production line control system melter units can be integrated with... Figure 2 and Figure 3 The melting unit 202 is the same as or similar to the melting unit 202. The melting unit may include a melting unit for a single production line control system, or a melting unit for multiple different production line control systems, or a combination thereof. For example, the first melting unit and the second melting unit may both belong to the same production line control system, or the first melting unit and the second melting unit may belong to different production line control systems.

[0066] At step 602, the main component (e.g., the first melter unit, such as...) is received. Figure 2 and Figure 3 The melter unit 202a and / or Figure 4 or Figure 5 The operating state of one of the melters 402a. As described herein, the operating state of the main component can be received at the composite controller. In the example where the composite controller is the controller of the main component, the operating state of the main component can be received by the controller of the main component, which operates as the composite controller.

[0067] In step 604, a client component (e.g., another melting unit, such as...) is received. Figure 2 and Figure 3 One of the melter units 202b-d and / or Figure 4 or Figure 5 The operating status of one of the melter units 402b-d or 406 or the pattern control device 408. As described herein, the operating status of the client component can be received at the composite controller. In the example where the composite controller is the controller of the main component, the operating status of the main component can be received by the controller of the main component that operates as the composite controller.

[0068] In the example, the operating state of the main component and / or the operating state of the client component may include the state of operating parameters associated with such component and / or its operating mode (e.g., production mode, setup mode, or maintenance mode). In the example, the operating state of the main component and / or the operating state of the client component may be in the form of signals generated by the respective components. These signals can typically be generated by the controller of the respective component (e.g., [missing information]). Figure 2 and Figure 3 The signal is generated by the controller 204. In an example, the controller may be a melter unit. For example, the signal may include a beacon signal. The signal may be detected by the composite controller on a network to which the composite controller is connected. As an example, the network may include a LAN (e.g., WLAN) at a production facility housing the composite system. Corresponding components may generate signals in response to their connection to the network. Each component may be configured to generate signals (e.g., signals indicating its operational status) at predetermined intervals.

[0069] In the example, the operating state of the main component and / or the client component may include control data messages or be in the form of control data messages, which may include control data related to the operating parameters of the respective components. For example, operating parameters may include temperature setpoint, temperature control loop setting, control loop type, pump speed, pump motor speed, heater duty cycle, or applicator cycle rate. Control data messages may include data about the component and / or measured by the component, such as liquid temperature, liquid flow rate, liquid flow volume, or liquid pressure. Control data messages may include the hardware configuration of the first melter unit, such as the number of pumps, pump type, liquid holding capacity, number of hose outlets, power capacity, number of control interfaces, melter unit weight, melter unit external dimensions, flow throughput, or melting rate. In the example, the operating state of one component (e.g., the state of operating parameters associated with this component and / or its operating mode) may affect the operating states of one or more other components. For example, one or more components may change their operating mode based on the operating states of one or more other components. As a non-limiting example, the pattern controller may not be configured to feed patterns until the melter has reached the temperature setpoint and / or the pump associated with the melter is set to turn on. As another non-limiting example, the melter may be placed in a temperature rollback (standby) state after an extension before the pattern controller's trigger is deactivated.

[0070] In step 606, the composite operating state of the production line control system is determined. As described herein, the composite operating state of the production line control system can be determined by a composite controller. The composite operating state of the production line control system can be determined at least in part based on the operating states of the main component and the client component (e.g., by the composite controller). As a general example, if the operating states of the main component and the client component are both determined to have a specific value or character (e.g., in production mode), then the composite controller can determine that the composite operating state of the production line control system has the same value or character (e.g., in production mode).

[0071] In the examples, the composite operating state of the production line control system can be determined (e.g., via a composite controller) at least in part based on the hierarchy of the operating states of the main components and the client components. For example, the hierarchy can be determined based on predefined user hierarchy settings or predetermined hierarchy settings. In some examples, it can be determined (e.g., via a composite controller) whether any component of the production line control system is required for production. Continuing with such examples, if a particular component is determined to be required for production but has an operating state indicating that such a component is not in production (such as the component being inoperable, or, in the case of a melter unit, suffering reduced melt binder output), the composite operating state can reflect that the composite system is not in production or otherwise indicates an error or alarm within the composite system. Conversely, if a particular component is determined not to be required for production, the operating state of such a component can be ignored when determining the composite operating state of the production line control system (e.g., via a composite controller).

[0072] At step 608, a user interface is generated (e.g., by a composite controller). In this example, it can be generated via, for example, via the control device 410 of the main component (e.g., Figure 4 or Figure 5The user interface is displayed on screen 412 of the first melter unit 402a. The user interface can display (e.g., simultaneously) multiple control tiles (e.g., user-selectable control tiles), as described herein. Each of the multiple control tiles can represent a component among multiple components of the production line control system. As a non-limiting example, the user interface can display control tiles representing a main component and additional control tiles representing client components. The user interface can also additionally display (e.g., simultaneously) indicators of the operating status of the main component, indicators of the operating status of the client components, and indicators of the combined operating status of the production line control system. Such indicators can typically take any form as needed to suit a particular application, such as text indicators (e.g., “Production,” “Setup,” “Maintenance”). In the example, the user interface can display information about the control tiles and any other displays based on predefined user display settings or predetermined display settings (such as the position and / or size of one or more control tiles).

[0073] In the example, the user interface can display indicators of the operational status of each of the multiple components determined to be required for production, as described herein. Additionally, as described herein, the user interface can display indicators of the operational status of each of the multiple components determined to be unnecessary for production, regardless of whether such operational status is ignored when determining the composite operational status of the production line control system.

[0074] It can display control data related to the production line control system (e.g., its components), including any control data included or indicated in commands transmitted by the composite controller. Such control data can be displayed via a user interface associated with the production line control system (e.g., Figure 8 User interface 800 and / or Figure 10 The user interface 1004 displays operating parameters, such as those of a production line control system or a distribution system comprising one or more melting units. In the example, control tiles may include one or more control tiles configured to display the status of operating parameters associated with the operating parameters as described herein. Also as described herein, via the user interface, an operator can control at least some aspects of the production line control system or the distribution system comprising one or more melting units. For example, the user interface may be configured to allow adjustment of operating parameters of the production line control system or any of its components (e.g., melting units) based on user input to the user interface.

[0075] The user interface can be one or more components of the production line control system (e.g., Figure 2 The melter unit 202e) outputs (e.g., a display). Any melter unit or other component may include a control panel (e.g., Figure 2 and Figure 3The control panel 206 can display a user interface. In this example, the composite system 200 may include a single user interface, but other examples are not limited to this. For example, in some examples, the composite system 200 may include multiple user interfaces. Each user interface provided in the composite system 200 may typically be configured to navigate to any component of the composite system (e.g., to display information related to any component of the composite system), and each user interface provided in the composite system 200 may typically be configured to monitor and / or control any component of the composite system (e.g., to transmit commands or control messages). Typically, the user interface can provide access to each component of the control system. The component displaying the user interface may or may not include the composite controller. The user interface may additionally or alternatively be provided by a computing device associated with the production line control system (e.g., Figure 2 and Figure 3 The computing device 222 outputs the data. The computing device can communicate with one or more components. For example, if one of the components includes a composite controller, the computing device can communicate with the composite controller of such component. The computing device can receive control data via such a component, which includes control data indicated in a command or control data message. This control data can be represented in a user interface output by the computing device.

[0076] Additionally or alternatively, the computing device may be located at a cloud / edge server (e.g., remotely from the location housing the production line control system) Figure 3 The computing device communicates with server 230 in the cloud / edge server. In cases where the cloud / edge server includes a composite controller, the computing device can communicate with the composite controller of the cloud / edge server. The computing device can receive control data via the cloud / edge server, including control data indicated in command or control data messages. This control data can be represented in a user interface output by the computing device. The computing device can be located remotely from the location housing the production line control system, such as a production facility, or the computing device can be located in the same location as the location housing the production line control system.

[0077] The user interface may include production line elements (e.g., representing production lines associated with components of the production line control system) Figure 8 Production line element 802). The user interface may also include multiple system elements (e.g., Figure 8System element 804). A system element among multiple system elements can represent a liquid distribution system of a production line control system. For example, a first system element can represent a first production line control system or liquid distribution system including a first melter, and a second system element can represent a second production line control system or liquid distribution system including a second melter. Production line elements and multiple system elements can be arranged on a user interface to reflect the relative positions of the production line and / or liquid distribution system represented by the multiple system elements at relevant locations (e.g., production facilities). The user interface may include composite state elements (e.g., representing composite operating states of the production line control system as described herein) that indicate a composite operating state of the production line control system. Figure 8 The composite state element 812). In the example, the composite state element may have a corresponding unique symbol or image according to the indicated composite operating state of the system, such as a checkmark indicating a positive composite operating state ( ). Figure 8 The composite status element (812) is shown. In other examples, the composite status element may include an "X" or other symbols or images indicating a negative composite operation status. Additionally or alternatively, in the example, the composite status element may be color-coded to indicate the composite operation status of the production line control system, such as a colored border or colored text "composite".

[0078] At least one of the multiple system elements may include an operation mode element (e.g., Figure 10 The operation mode element 1019 indicates the operation mode of the represented production line control system or liquid distribution system. For example, the operation mode element may indicate that the represented component or liquid distribution system is in production mode, setup mode, or maintenance mode. At least one of the multiple system elements may include a fill height element (e.g., Figure 10 The system element (1034) indicates the fill height associated with the represented production line control system or liquid dispensing system. For example, the fill height may be relative to the fill height of the liquid in the melter unit of the liquid dispensing system. The system element may be configured such that an interface element (e.g., a pop-up window) is displayed upon activation. The interface element may indicate control data associated with the production line control system or liquid dispensing system represented by the system element. For example, such control data may include multiple measured temperatures at various points within the production line control system or liquid dispensing system.

[0079] At step 610, a command (e.g., including a control message or in the form of a control message) is transmitted to the main component (e.g., by the composite controller). At step 612, a command (e.g., including a control message or in the form of a control message) is transmitted to the main component, and can also be transmitted to the client component. In the example, the commands transmitted to the main controller and client component may include instructions for operating the main component and / or client component, as described herein. In the example, the commands may include operating parameters of the production line control system or one or more of its components. As described herein, operating parameters can be set and modified via user input (e.g., via a user interface). Upon receiving such user input, a command (in some cases, a modified command) may be transmitted (e.g., via the composite controller) to the main component and / or client component to operate the component with the operating parameters (in some cases, modified operating parameters). After transmitting the command or modified command, Figure 6 The process can be repeated starting from receiving the operational status (e.g., updated status) of the master component and / or client component.

[0080] One component of the production line control system may include a composite controller, and in this example, may include a control panel (e.g., panel 206) configured to display at least a portion of any control data indicated in a command. Additionally or alternatively, a remote cloud / edge server (e.g., [missing information]) may be associated with the production line control system. Figure 3 The server 230 can implement a composite controller.

[0081] Computing devices (e.g., Figure 2 and Figure 3 The computing device 222 can access any control data indicated in the command via the composite controller. The computing device can be located outside the site housing multiple liquid dispensing system melter units, or it can be located in the same site housing the production line control system. The computing device can include at least one of a personal computer (PC), laptop computer, mobile device, tablet computer, or smartphone. In the example, the computing device or HMI device can utilize a web browser with a custom application to implement or perform any of the features or processes described herein.

[0082] In the example, the client component can be configured to switch between multiple modes, such as production mode, setup mode, and maintenance mode. In production mode, the controller of the client component in production mode can be configured to receive command and / or control messages from the composite controller and operate the component in response to such command and / or control messages as described herein. In maintenance mode, the controller of the client component in maintenance mode can be configured to be "read-only," such as by being configured to operate the component only by receiving command and / or control messages from the composite controller without responding to such command and / or control messages.

[0083] In some examples, it may be desirable for a user to quickly identify one of the components of a production line control system via a user interface. In some examples, the user interface may identify each component of the production line control system by name, photograph, or another unique identifier. For example, control tiles displayed at the user interface may display such unique identifiers, where the unique identifier corresponds to the corresponding component within the production line control system. It may also be desirable to identify specific components within the production line control system, such as by transmitting a command (e.g., via a composite controller) to the selected component to emit identifiers, such as audible identifiers (e.g., emitted by a horn of the user-selected component) and / or visual identifiers (e.g., emitted by a flashing indicator of the user-selected component and / or emitted by a beacon of the user-selected component, such as those for components with…). Figure 4 (As illustrated in the diagram of the melter unit 402c of the lighthouse 402d).

[0084] Figure 7 A data flow diagram of the decision-making method 700 adopted by the production line control system (particularly the spare main component) is shown.

[0085] Specifically, method 700 can determine which controller among several components of a production line control system should implement or execute a composite controller. Method 700 can, for example, serve as... Figure 6 The method 600 is executed by a subroutine, as described in this article.

[0086] In step 702, it can be determined (e.g., by the controller of the backup primary component) whether the controller of the primary component has lost operational communication with the client component and / or the backup primary component, as described herein. If it is determined in step 702 that the controller of the primary component has lost operational communication with the client component and / or the backup primary component (as indicated by the "Yes" arrow extending away from step 702), then in step 704a, the controller of the backup primary component can be configured to implement or perform a composite controller, as described herein. Thereafter, in step 706, it can be determined (e.g., by the controller of the backup primary component) whether the controller of the primary component has regained operational communication with the client component and / or the backup primary component, as described herein.

[0087] If it is determined at step 706 that the controller of the primary component has regained operational communication with the client component and / or the backup primary component (as indicated by the "Yes" arrow extending away from step 706), then in step 708a, the controller of the primary component can be configured to implement or perform a composite controller, as described herein. Thereafter, the controller of the primary component can operate as a composite controller and continue implementation. Figure 6 The steps of method 600 are as follows. However, if it is determined in step 706 that the controller of the primary component has not yet regained operational communication with the client component and / or the backup primary component (as indicated by the "No" arrow extending away from step 706), then in step 708b, the controller of the backup primary component can be configured to implement or perform a composite controller, as described herein. Thereafter, the controller of the backup primary component can operate as a composite controller and continue implementation... Figure 6 The steps of method 600. Additionally, the controller of the standby main component can continue to monitor the connection status of the main component's controller, such as by repeating step 706 (e.g., continuously or at predetermined intervals), until the main component's controller regains an operational connection with the client component and / or the standby main component.

[0088] However, if it is determined at step 702 that the controller of the primary component has not lost operational communication with the client component and / or the backup primary component (as indicated by the "No" arrow extending away from step 702), then in step 704b, the controller of the primary component may be configured to implement or execute (or continue to implement or execute) the composite controller as described herein. Thereafter, the controller of the primary component may implement or execute the composite controller and continue to implement... Figure 6 The method in step 600.

[0089] The controller of the backup main component can be configured to repeat. Figure 7 Method 700 (e.g., continuously or at predetermined intervals) is used to ensure that the production line control system remains operational without unnecessary interruptions.

[0090] Figure 8 A user interface 800 that can be used in conjunction with the system described herein is shown. The user interface 800 can display a visual representation of the production line and associated systems reflecting the actual layout at a production facility (i.e., site). The user interface 800 can indicate various data related to such a system. The user interface 800 can be composed of one or more components of the production line control system (e.g., Figure 2 and Figure 3 The controller of the melter unit 202) (e.g., Figure 2 and Figure 3 The controller 204) and the panel (e.g., Figure 2 and Figure 3 The user interface 800 can be implemented using panel 206. The user interface 800 may be additionally or alternatively implemented using a composite controller (e.g., panel 206). Figure 2 The composite controller 210) and components including the composite controller (e.g., Figure 2 The user interface 800 is implemented via a panel of the melting unit 202e. The user interface 800 may also be provided by a server (e.g., Figure 3 The composite controller at server 230 (e.g., Figure 3 The composite controller 232) is implemented. The user interface 800 may additionally or alternatively be implemented by a computing device (e.g., a computer that communicates with the composite controller). Figure 2 and Figure 3 This is achieved using a computing device 222.

[0091] User interface 800 may be associated with a production line (e.g., a production machine). The production line may include, for example, a line for manufacturing disposable hygiene products or assembling cardboard packaging. The production line may be represented in user interface 800 by production line element 802. User interface 800 may include multiple system elements 804a-f (generally referred to as system element 804 or multiple system elements 804). System element 804 can be considered as a “tile” of user interface 804. Each tile or system element 804 may be associated with a production line control system (e.g., Figure 1 The component is associated with and represents a component of the production line control system 10 or other types of systems. In the example, the component corresponding to system element 804 may be a melter unit, a pattern control device, or a similar component as described herein. The components corresponding to system element 804 may be associated with each other via a shared composite controller as described herein. For example, the composite controller may be configured to operatively communicate with each component of the production line control system, and in the example, the composite controller may operatively interconnect multiple components so that information (e.g., control data) can be transferred between them.

[0092] System element 804 can be labeled based on its function in the production line or by another type of indicator. Each system element 804 may include an operation mode element 806 configured to indicate the operating mode or status of the corresponding component. For example, Figure 9 The operating mode element 806f of the system element 804f indicates that the corresponding system is in production mode. As another example, the operating mode element can indicate that the corresponding component is in setup mode or maintenance mode. The operating mode element 806f can have a unique image corresponding to the indicated operating mode, such as 06814f for the system name. Figure 9 The operation mode element 806f of the system element 804f shown in the figure is shown.

[0093] System element 804 and production line element 802 are visually arranged on user interface 800 according to (e.g., reflecting or corresponding to) the relative positions of corresponding components and production lines at the production facility. For example, a component represented by system element 804 may be positioned at a specific point on the production line, and this position on the production line is reflected in the placement of system element 804 relative to production line element 802 in user interface 800. The relative positioning (and dimensions) of production line element 802 and system element 804 are not necessarily drawn to scale.

[0094] The position of system element 804 on the user interface can be adjusted. For example, a user can provide input to the user interface 800 to adjust the position of system element 804. Alternatively, the system implementing user interface 800 can automatically adjust the positioning of system element 804. As an example, when a new component or liquid dispensing system is installed on the production line, the component or liquid dispensing system can be automatically detected and inserted into the production architecture represented by user interface 800. System element 804 corresponding to the newly installed component or liquid dispensing system can be created in user interface 800. The user (or controller) can then position system element 804 according to the actual position of the new component or liquid dispensing system relative to the production line and other components. If the corresponding component moves from one position on the production line to another position on the production line, the user (or controller) can similarly adjust the position of system element 804.

[0095] Each system element 804 may also include a system status element 808 to indicate the status of the associated system, such as running, shut down, or faulty. Specifically, the system status element 808 may be color-coded to represent the system status of the associated system. For example, the green border of the system status element 808f for system name 06 (…) Figure 9 The system element 804f shown can indicate that system name 06 is running.

[0096] System element 804 may also include other elements, such as subsystem status and / or user-selectable data, such as Figure 9 The system element 804f is shown with subsystem status element 816f and data element 818f (e.g., user-selectable data element). In the example, data element 818f can display unique data for the component represented by system element 804f and can visually display up to ten or more different data points (e.g., temperature or pressure, pump speed, output, different zones or characteristics). Specific data displayed by data element 818f can be selected by the user or automatically populated based on user-defined display settings.

[0097] Figure 8 The user interface 800 and other user interfaces envisioned herein can advantageously provide increased ease of use, accessibility, and / or control. For example, Figure 8The user interface 800 (e.g., via composite state element 812) displays a "quick-read" view of the composite operating states of the production line control system, providing the operator with a quick and comprehensive way to identify the composite operating states of the production line control system (e.g., the states of all relevant components of the system used to determine the composite operating states as described herein). Additionally, as described herein, the operator can view the operating status of each individual component or sub-component by viewing the user interface 800 or by individually clicking or activating any component via the user interface 800. Accessibility is increased by providing the operator with an intuitive means of viewing and quickly navigating to the user interface screens of any component as described herein. Control is increased by providing the operator with a comprehensive means of controlling all components and sub-components (e.g., heater and pump controls) from a single set of controls (e.g., via control devices). Furthermore, in the example, the user interface 800 may allow recipes to be loaded from individual components to each component, thus providing a comprehensive and efficient means by which the operator can effectively control the production line control system. In the example, a recipe may be a set of product-specific settings for periodically producing the same product with consistent output. The recipe may include selection of enabled external areas and their setpoint temperature, pressure settings, pump selection, adhesive addition, etc. The composite recipe can be a master or central control used (e.g., globally and / or simultaneously) to specify all connected components used for production within the composite system. In the example, the composite recipe may contain product-specific settings for all such connected components, or a common recipe name or number may be loaded on each component, where the product-specific settings are stored locally within the component. Using such a composite recipe eliminates the repetitive and time-consuming process of requiring the operator to individually access each component to load the recipe. Additionally or alternatively, the user interface 800 may provide the operator with means to implement composite master control, such as a set of one or more command or control messages (e.g., globally and / or simultaneously) to issue such command or control messages to components specified for production within the composite system. As a non-limiting example, such composite master control includes main heater enable / disable, temperature backoff enable / disable, pump release enable / disable, etc. Using such a composite master control eliminates the repetitive and time-consuming process of requiring the operator to individually access each component to turn the master control on / off.

[0098] System element 804 can be interacted with or activated (e.g., clicked) to access further information and functions related to the corresponding system. For example, activation of system element 804 may cause a pop-up element to appear on user interface 800, or may present a new, different user interface to access further information and functions. Figure 10This shows that the operator has already selected... Figure 8 The user interface 1004 is displayed after system element 804a. Further information displayed when system element 804 is activated may include operating parameters of the corresponding component, current and / or past measurement data of the corresponding component, and / or hardware configuration data of the corresponding component. Pop-up windows or new user interfaces may include additional user interface elements or "tiles" corresponding to various data categories or compositions of the component, such as fill height monitoring tile 1034, pump monitoring tile 1035, pattern control or recipe tile 1036, and / or temperature monitoring tile 1040, as... Figure 10 As shown. For example, activation of the temperature monitoring tile 1040 can cause another pop-up window or user interface to display the temperature setpoint and measured temperature value of the display system, such as... Figure 11 As shown. As another example, activation of an interface element for a specific melter unit of the system can cause another pop-up window or user interface to be displayed, showing various aspects of the melter unit's hardware configuration, such as the number of hose outlets, flow rate, pump type, physical dimensions, and available control interfaces. The pop-up window or new user interface can be closed to return to the previous pop-up window or user interface within the hierarchy, including, as currently displayed... Figure 8 The user interface 800 shown in the image. Figure 10 The user interface 1004 and its elements shown are examples of such user interfaces, pop-ups, tiles, or windows that can be integrated with the user interface 800.

[0099] Figure 10 and Figure 11Various aspects of a user-customizable graphical user interface 1004, such as that output via screen 412 of control device 410, are illustrated. While the user interface 1004 and associated features are discussed generally with respect to the melter units, such disclosure is equally applicable to other components of system 400, including pattern control devices, applicators, dispensing modules, hoses, solid or semi-solid adhesive supply devices, or heaters disposed within such other components. Typically, user interface 1004 is configured to display control data (e.g., operating parameters or status information) for the multiple melter units 402 and other components of system 400. User interface 1004 is also configured to enable the user to set or adjust various operating parameters of melter units 402 and other components of system 400. It should be understood that the specific parameters that can be displayed and / or controlled via user interface 1004 will depend on the specific type of melter unit 402, the material to be dispensed, and / or the specific manufacturing protocols implemented in a given system 400. As an example, such parameters may include, but are not limited to, the temperature of various components, pump speed, material volume, pressure, dispensing pattern, amount of material dispensed, type of material dispensed, presence of gas, operating status of the melter, geographical and distance information, specific permit information, and the relative location of the melter unit 402 and other components of the system 400 at the production facility. In one aspect, the user interface 1004 is configured to display, set, modify, transmit, and otherwise manipulate control data, such as the control data discussed herein.

[0100] Control device 410 can allow access to multiple operating modes. For example, in "production" mode, certain parameters can be changed. Setpoints and operating modes can be changed while preventing alterations to other system configurations. In "setup" mode, control device 410 can allow system simulation, initial parameter setting, verification of component functionality, and system clearing. In "maintenance" mode, control device 410 can allow maintenance of the melter unit 402 or other components (e.g., replacement of pumps, filters, or other components).

[0101] The control device 410 allows one or more users to simultaneously monitor and / or change parameters of multiple melting units 402 or other components. This reduces the time required to monitor each individual melting unit 402 or other component individually. Furthermore, users can send commands to all melting units 402 or other components in the system 400 simultaneously, instead of having to modify the parameters of each individual melting unit 402 or other component individually.

[0102] Control unit 410 allows the user to compare individual melter units 402 to identify damage, defects, or other inconsistencies within system 400. By allowing control of all melter units 402 in system 400, the user can stop or pause one or more melter units 402 for any number of reasons (e.g., maintenance, overheating, material reloading, etc.) and ensure that the remaining melter units 402 within system 400 compensate for the stopped or paused melters. This helps maintain consistent production and reduce downtime.

[0103] As described above, the user interface 1004 is constructed for user customization. For example, many status / parameter information and control functions are presented via a series of interactive interface elements called "tiles". The specific configuration regarding which tiles are displayed on the user interface 1004, where they are displayed on the user interface 1004, and when they are displayed on the user interface 1004 can be determined at least in part by the user's preferences.

[0104] like Figure 10 As shown, the user interface 1004 can be divided into a status area 1030 and a dashboard area 1031. The dashboard area 1031 is typically the area for displaying and interacting with the aforementioned tiles.

[0105] Regarding status area 1030, element 1018 indicates the selected melter unit 402 or other component (in this case, "system name 01"), for which various information and control functions are presented at least partially within dashboard area 1031. The selected component indicated in the element can be accessed from... Figure 8 The user interface 800 can be selected from various components. Additionally or alternatively, the component indicated by element 1018 can be selected via a drop-down menu associated with element 1018. The operation mode element 1019 indicates the operation mode of the selected component, such as production, setup, or maintenance. The operation mode of the selected component can be controlled via the operation mode element 1019. The composite status element 1012 can indicate the status of the composite system 400, which can also be controlled via the composite status element 1012. The status area 1030 may also include interface elements 1038 that can be activated to initiate various user functions. For example, a user can enter their user ID and password to log in to the system and load user preference settings related to the user interface configuration.

[0106] The dashboard area 1031 is configured to display one or more tiles. Tiles can display various information relating to the status / operating parameters of system 400, selected components, and / or various subsystems or functions of the selected components. Tiles may additionally or alternatively enable the setting or adjustment of various operating parameters or settings. Some tiles may be configured to have multiple sub-tiles. Some tiles (including sub-tiles) may be configured to open other tiles or windows, which typically provide further information or access to additional settings or controls associated with the initial tile. Through user preferences, users can customize various attributes of the dashboard area 1031 applied when a user logs into user interface 1004 and / or control device 410. For example, user preferences can define which tiles are initially displayed in the dashboard area 1031. User preferences can further define the initial placement of tiles within the dashboard area 1031 and / or the relative size of the tiles. User preferences can also further define what action or function is performed when a specific tile or tile element is activated or interacted with (e.g., clicked or pressed). Users can additionally or alternatively change the arrangement or appearance of tiles when the user interface 1004 is displayed, such as turning off tiles, moving tiles (e.g., dragging and dropping), or minimizing tiles. Tiles can also be placed entirely or partially on top of another tile.

[0107] Continue to refer to Figure 10Select the “System Name 01” component. This will display the fill height monitoring tile 1034, pump monitoring tile 1035, pattern control or formulation tile 1036, and temperature monitoring tile 1040 in the dashboard area. The fill height monitoring tile 1034 visually and digitally indicates the current fill height percentage (72%) of the adhesive reservoir associated with the “System Name 01” melter unit. The user can directly set or adjust the parameters indicated in the fill height monitoring tile 1034. The pump monitoring tile 1035 includes one or more pump sub-tiles 1039, each corresponding to the pump of the selected “System Name 01” melter unit. Each pump tile 1039 indicates one or more of the name of the corresponding pump (e.g., “Pump 1”, “Pump 2”) and the current speed (rpm) of that pump. The pattern control or formulation tile 1036 can activate the loaded formulation or dispensing pattern selection function when activated. The loaded formulation or dispensing pattern can be used by one or more components of the selected "System Name 01" melter unit to prepare or dispense adhesives or other liquids. Temperature monitoring tiles 1040 typically indicate the temperature of the various parts of the selected "System Name 01" (including associated grids, reservoirs, hoses, and applicators). Such temperature points (e.g., temperature channels) each correspond to one of the temperature sub-tiles 1041 within the temperature monitoring tile 1040. Depending on the specific component or location for measuring the temperature, the status of the component, and / or various display settings, the temperature sub-tile 1041 may indicate the current measured temperature and the name of the heater or other component. As a non-limiting example, Figure 11 The temperature monitoring tile 1040 is shown after being activated so that additional information such as the temperature sub-tile 1041 of each part of the component is now shown, such as the temperature setpoint, the current measured temperature and the name of the part (e.g., "grid (T1)").

[0108] Typically, the controller for each component of a production line control system can have a fixed Ethernet address determined by that controller. However, in other examples, the controller for each component of the production line control system can be assigned an Ethernet address (e.g., by a composite controller using Dynamic Host Configuration Protocol (DHCP)). Now turn to Figure 12The production line control system may include an automated network switch 1220. The automated network switch 1220 may be configured to operatively connect each component of the production line control system to each other via a composite network, for example, by connecting to a network adapter 1210 (e.g., Wi-Fi). The automated network switch 1220 may also be configured to mechanically (e.g., via relays or switches) or electronically (e.g., via one or more integrated circuits) isolate selected components from the composite network. This can be useful when an operator expects to operate one of the components in a non-composite mode, such as by restoring the Ethernet address of such a component to its fixed address to avoid conflicts that might occur if the component remained connected to the composite network (e.g., leading to unexpected and unpredictable operation).

[0109] like Figure 12 As shown, the automatic network switch 1220 may include multiple ports. As a non-limiting example, the automatic network switch 1220 may include one or more of the following: a first port configured to operatively connect the automatic network switch 1220 to other components (not including...). Figure 12 The connection of the first port shown is as follows: a second port, configured to operatively connect the automated network switch 1220 to network adapter 1210 via port 1215; a third port, configured to operatively connect the automated network switch 1220 to the composite network via port 1225; a fourth port, configured to operatively connect the automated network switch 1220 to the controller and / or operator interface of client component 1230 via port 1235; and a fifth port, configured to operatively connect the automated network switch 1245 to other components. In this example, the automated network switch 1220 may be configured to isolate a component of the production line control system from the composite network by disabling the third port, thereby allowing the operator interface of that component to operatively communicate with the controller of that component. Additionally or alternatively, the controller of this component may be configured to disable the third port via software control. In this example, client component 1230 may be operatively connected via port 1255 to USB Ethernet adapter 1250 or other components.

[0110] The following are several non-limiting examples of various aspects of this disclosure. One example includes: Example 1A. A production line control system configured to monitor and / or control at least one distribution device, the production line control system comprising: a plurality of components including a main component and at least one client component, wherein at least one of the main component and the at least one client component is configured to implement or execute a composite controller, the composite controller being configured to operatively communicate with each of the plurality of components and being configured to: receive an operating state of the main component from a controller of the main component; receive an operating state of the at least one client component from a controller of the at least one client component; determine a composite operating state of the production line control system based at least in part on the operating state of the main component and the operating state of the at least one client component; generate a user interface displaying a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) component data of the plurality of components and (b) user-selectable component data of the plurality of components; an indicator of the operating state of the main component; an indicator of the operating state of the at least one client component; and an indicator of the composite operating state of the production line control system; transmit commands to the controller of the main component; transmit commands to the controller of the at least one client component. Example 1B.A production line control system configured to monitor and / or control at least one distribution device, the production line control system comprising: a plurality of components, the plurality of components including a main component including a controller, at least one client component including the controller, and a backup main component including the controller, wherein the controller of the main component and the controller of the backup main component are both configured to operatively communicate with each of the plurality of components, wherein the controller of the main component is configured to implement or execute a composite controller, wherein the controller of the backup main component is configured to: determine whether the controller of the main component has lost operative communication with the at least one client component and the backup main component; and if the controller of the backup main component determines that the controller of the main component has lost operative communication with the at least one client component and the backup main component for a predetermined minimum time, implement or execute the composite controller, and wherein the composite controller is configured to: receive from the controller of the main component The operation status of the main component; receiving the operation status of the at least one client component from the controller of the at least one client component; receiving the operation status of the backup main component from the controller of the backup main component; determining the composite operation status of the production line control system based at least in part on the operation status of the main component, the operation status of the at least one client component, and the operation status of the backup main component; generating a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing at least one of (a) a component among the plurality of components and (b) user-selectable component data of the plurality of components; an indicator of the operation status of the main component; an indicator of the operation status of the at least one client component; an indicator of the operation status of the backup main component; and an indicator of the composite operation status of the production line control system; transmitting commands to the controller of the main component; transmitting commands to the controller of the at least one client component; and transmitting commands to the controller of the backup main component. Example 1C.A method for transmitting commands to multiple components of a production line control system, the multiple components including a master component and at least one client component, the method comprising: receiving an operating state of the master component from a controller of the master component at a composite controller implemented or executed by at least one of the master component and the at least one client component; receiving an operating state of the at least one client component from a controller of the client component at the composite controller; determining a composite operating state of the production line control system based at least in part on the operating state of the master component and the operating state of the at least one client component; generating a user interface displaying: a plurality of control tiles, each of the plurality of control tiles representing (a) a component of the production line control system including the master component and the at least one client component and (b) at least one of user-selectable component data of the master component or the at least one client component; an indicator of the operating state of the master component; an indicator of the operating state of the at least one client component; and an indicator of the composite operating state of the production line control system; transmitting commands to the controller of the master component; and transmitting commands to the controller of the at least one client component.

[0111] All combinations (including the removal or addition of features or steps) in this and preceding paragraphs are contemplated in a manner consistent with the other parts of this disclosure. For the avoidance of doubt, the above Examples 1A, 1B, and 1C may also include any or more combinations of the following examples: Example 2. A production line control system according to any example of this document, wherein the composite controller is implemented or performed by a human-machine interface (HMI) device. Example 3. A production line control system according to any example of this document, wherein the controller of the main component is configured to implement or perform the composite controller. Example 4. A production line control system according to any example of this document, wherein a cloud server located remotely from the location housing the production line control system is configured to implement or perform the composite controller. Example 5. A production line control system according to any example of this document, wherein the main component is a melter unit or a pattern controller. Example 6. A production line control system according to any example of this document, wherein the at least one client component is a melter unit or a pattern controller. Example 7. A production line control system according to any example of this document, wherein the main component is a melter unit, and the at least one client component is a pattern controller. Example 8. A production line control system according to any example of this document, wherein the at least one client component comprises a plurality of client components. Example 9. A production line control system according to Example 8, wherein one of the plurality of components is a melting unit, and another of the plurality of components is of a type other than a melting unit (e.g., a pattern controller). Example 10. A production line control system according to Example 8, wherein a composite controller is configured to determine a composite operating state of the production line control system based at least in part on a hierarchy of operating states of a master component and operating states of at least one client component. Example 11. A production line control system according to Example 10, wherein the hierarchy is determined based on a predefined user hierarchy setting. Example 12. A production line control system according to Example 10, wherein the composite controller is further configured to determine whether any of the plurality of components is not required for production. Example 13. A production line control system according to Example 12, wherein the composite controller is further configured to ignore the operating states of any of the plurality of components that are not required for production when determining the composite operating state of the production line control system. Example 14. A production line control system according to Example 12, wherein the composite controller is further configured to output the user interface displaying an indicator of the operating state of each of the plurality of components required for production. Example 15. The production line control system according to Example 12, wherein the composite controller is further configured to output a user interface that displays an indicator of the operating status of a component that is not required for production among a plurality of components.Example 16. A production line control system according to any example of this document, wherein the composite controller is further configured to output a user interface displaying production line elements representing the production line associated with the plurality of components. Example 17. A production line control system according to Example 16, wherein the production line elements and the plurality of control tiles are arranged on the user interface to reflect the relative positions of the production line and the plurality of components represented by the plurality of control tiles in associated locations. Example 18. A production line control system according to any example of this document, wherein each of the plurality of control tiles includes a unique identifier corresponding to a specific component among the plurality of components. Example 19. A production line control system according to any example of this document, wherein the composite controller is further configured to transmit a command to a user-selected component among the plurality of components to emit an identifier. Example 20. A production line control system according to Example 19, wherein the identifier is an audible identifier. Example 21. A production line control system according to Example 20, wherein the audible identifier is configured to be emitted by a speaker of a user-selected component among the plurality of components. Example 22. A production line control system according to Example 19, wherein the identifier is a visual identifier. Example 23. A production line control system according to Example 22, wherein the visual identifier is configured to be emitted by a flashing indicator of a component selected by the user among the plurality of components. Example 24. A production line control system according to Example 22, wherein the visual identifier is configured to be emitted by a beacon of a component selected by the user among the plurality of components. Example 25. A production line control system according to any example herein, wherein the operating state of the at least one client component includes at least one of an operating mode of the at least one client component or a state of an operating parameter associated with the at least one client component. Example 26. A production line control system according to Example 25, wherein the operating state of the at least one client component includes an operating mode selected from a group consisting of a production mode, a setting mode, and a maintenance mode. Example 27. A production line control system according to any example herein, wherein the composite controller is configured to output the user interface of the plurality of control tiles based on predefined user display settings. Example 28. A production line control system according to Example 27, wherein at least one of the position of the control tile among the plurality of control tiles and the size of the control tile among the plurality of control tiles is based on predefined user display settings. Example 29. A production line control system according to any example herein, wherein the command includes operating parameters. Example 30. A production line control system according to Example 29, wherein a plurality of control tiles include control tiles configured to display the status of operating parameters associated with operating parameters. Example 31. A production line control system according to Example 29, wherein a plurality of control tiles include control tiles configured to receive user input to modify operating parameters.Example 32. A production line control system according to Example 31, wherein the composite controller is further configured, upon receiving the user input for modifying the operating parameters: transmits a modified command to at least one of the controllers of the main component and the at least one client component, wherein the modified command includes instructions for operating the at least one of the controllers of the main component and the at least one client component to which the modified command is transmitted to operate under the modified operating parameters; and receives an updated operating status from the at least one of the controllers of the main component and the at least one client component to which the modified command is transmitted. Example 33. A production line control system according to any example herein, wherein the command includes control data associated with operating parameters of the main component or the at least one client component, the operating parameters including at least one of temperature setpoint, temperature control loop setting, control loop type, pump speed, pump motor speed, heater duty cycle, or applicator cycle rate. Example 34. A production line control system according to any example herein, wherein the command includes control data associated with data measured by the main component or the at least one client component, the data including at least one of liquid temperature, liquid flow rate, liquid flow rate, or liquid pressure. Example 35. A production line control system according to any example of this document, wherein the command includes control data associated with hardware configuration data for the main component or the at least one client component, the hardware configuration data including at least one of the following: number of pumps, pump type, liquid holding capacity, number of hose outlets, power capacity, number of control interfaces, unit weight, unit external dimensions, flow rate, or melting rate. Example 36. A production line control system according to any example of this document, wherein the at least one client component is configured to switch between (a) a production mode and (b) a maintenance mode, wherein in the production mode, the controller of the at least one client component is configured to receive the command and operate the at least one client component in response to the command, and in the maintenance mode, the controller of the at least one client component is configured to receive the command only without operating the at least one client component in response to the command. Example 37. A production line control system according to any example of this document, wherein the plurality of components includes a backup main component. Example 38. A production line control system according to Example 37, wherein the backup main component includes a controller configured to operatively communicate with each of the plurality of components.Example 39. A production line control system according to Example 38, wherein the controller of the backup main component is configured to: determine whether the controller of the main component has lost operational communication with at least one client component and the backup main component; and if the controller of the backup main component determines that the controller of the main component has lost operational communication with at least one client component and the backup main component for a predetermined minimum time, then implement or execute a composite controller. Example 40. A production line control system according to Example 39, wherein the predetermined minimum time is approximately five seconds. Example 41. A production line control system according to Example 39, wherein if the controller of the backup main component determines that the controller of the main component has lost operational communication with at least one client component and the backup main component for a predetermined minimum time, the controller of the backup main component is further configured to: monitor whether the controller of the main component has regained operational communication with at least one client component and the backup main component; and if the controller of the backup main component determines that the controller of the main component has regained operational communication with at least one client component and the backup main component, then the controller of the main component is configured to implement or execute a composite controller. Example 42. A production line control system according to Example 39, wherein if the controller of the backup main component determines that the controller of the main component has not lost operational communication with the at least one client component and the backup main component within the predetermined minimum time amount: then the controller of the main component is configured to implement or execute the composite controller; and the controller of the backup main component is configured to receive the composite operating state of the production line control system from the composite controller. Example 43. A production line control system according to any example herein, wherein the controller of at least one client component has a fixed Ethernet address determined by the controller of at least one client component. Example 44. A production line control system according to any example herein, wherein the composite controller is further configured to assign Ethernet addresses to the controllers of the at least one client component. Example 45. A production line control system according to Example 44, further comprising an automatic network switch configured to operatively connect each of the plurality of components to each other via a composite network. Example 46. A production line control system according to Example 45, wherein the automatic network switch is configured to operatively connect each of the plurality of components to each other via a composite network using a Dynamic Host Configuration Protocol (DHCP). Example 47. A production line control system according to Example 45, wherein an automatic network switch is configured to mechanically isolate at least one client component from the composite network.Example 48. A production line control system according to Example 45, wherein the automatic network switch includes: a first port configured to operatively connect the automatic network switch to a network adapter; a second port configured to operatively connect the automatic network switch to a composite network; and a third port configured to operatively connect the automatic network switch to at least one of the controller and an operator interface of at least one client component. Example 49. A production line control system according to Example 48, wherein the automatic network switch is configured to electronically isolate the at least one client component from the composite network by disabling the third port, thereby allowing the operator interface of the at least one client component to operatively communicate with the controller of the at least one client component. Example 50. A production line control system according to Example 48, wherein the controller of the at least one client component is configured to disable the third port via software control.

[0112] Those skilled in the art will understand that the systems and methods disclosed herein can be implemented via a computing device, which may include, but is not limited to, one or more processors, system memory, and a system bus that couples various system components, including processors, to the system memory. In the case of multiple processors, the system can utilize parallel computing.

[0113] For illustrative purposes, applications and other executable program components (such as operating systems) are shown as discrete boxes herein; however, it should be understood that such programs and components reside in different storage components of a computing device at different times and are executed by the computer's data processor. Implementations of service software may be stored on or transmitted across some form of computer-readable medium. Any disclosed methods can be executed by computer-readable instructions implemented on a computer-readable medium. A computer-readable medium can be any available medium accessible to a computer. By way of example and not limitation, a computer-readable medium can include "computer storage media" and "communication media." "Computer storage media" includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information (such as computer-readable instructions, data structures, program modules, or other data). Exemplary computer storage media include, but are not limited to, RAM, ROM, EPROM, flash memory or other memory technologies, CD-ROM, digital versatile disc (DVD) or other optical storage devices, magnetic tape cassettes, magnetic tape, disk storage devices or other magnetic storage devices, or any other medium that can be used to store desired information and is accessible to a computer. Applications and / or storage media may be implemented at least partially at a remote system.

[0114] The aspects of this disclosure can be implemented via a communication channel in any type of computing device with wired / wireless communication capabilities, such as, for example, desktop computers, personal computers, laptop / mobile computers, personal data assistants (PDAs), mobile phones, tablet computers, cloud computing devices, etc.

[0115] Aspects of this disclosure may include communication channels, which may be any type of wired or wireless electronic communication network, such as, for example, wired / wireless local area networks (LANs), wired / wireless personal area networks (PANs), wired / wireless home area networks (HANs), wired / wireless wide area networks (WANs), campus networks, metropolitan area networks, enterprise private networks, virtual private networks (VPNs), internetworks, backbone networks (BBNs), global area networks (GANs), the Internet, intranets, extranets, overlay networks, near field communication (NFC), cellular telephone networks, personal communication services (PCS), using known protocols such as Global System for Mobile Communications (GSM), CDMA (Code Division Multiple Access), GSM / EDGE and UMTS / HSPA network technologies, Long Term Evolution (LTE), 5G (fifth-generation mobile network or fifth-generation wireless system), WiMAX, HSPA+, W-CDMA (Wideband Code Division Multiple Access), CDMA2000 (also known as C2K or IMT multi-carrier (IMT-MC)), Wi-Fi, Bluetooth, etc., and / or combinations of two or more of them. The NFC standard covers communication protocols and data exchange formats and is based on existing radio frequency identification (RFID) standards, including ISO / IEC 14443 and FeliCa. The standards include ISO / IEC 18092[3] and standards defined by the NFC Forum.

[0116] It should also be noted that the software implementations of this disclosure as described herein may optionally be stored on tangible storage media, such as: magnetic media, such as magnetic disks or magnetic tapes; magneto-optical or optical media, such as magnetic disks; or solid-state media, such as memory cards or other packages containing one or more read-only (non-volatile) memories, random access memories, or other rewritable (volatile) memories. Digital file attachments to emails or other self-contained archives or sets of archives are considered equivalent to distribution media of tangible storage media. Therefore, this disclosure is considered to include tangible storage media or distribution media as listed herein, and includes equivalents and successor media recognized in the art in which the software implementations of this disclosure are stored.

[0117] Furthermore, the various aspects of this disclosure can be implemented in non-general-purpose computer implementations. Additionally, the various aspects of this disclosure set forth herein improve the functionality of the system, as is apparent from its disclosure. Moreover, the various aspects of this disclosure relate to computer hardware specifically programmed to solve the complex problems addressed by this disclosure. Therefore, the various aspects of this disclosure generally improve the functionality of the system in their particular embodiments for performing the processes set forth in this disclosure and defined by the claims.

[0118] Various aspects of this disclosure may include servers that execute instances of applications or software configured to accept requests from clients and respond accordingly. Servers may run on any computer, including dedicated computers. A computer may include at least one processing element (typically a central processing unit (CPU)) and some form of memory. The processing element may perform arithmetic and logical operations, and a sorting and control unit may change the order of operations in response to stored information. Servers may include peripheral devices that allow retrieval of information from external sources and storage and retrieval of the results of operations. Servers may operate within a client-server architecture. Servers may perform tasks on behalf of clients. Clients may connect to the server via a network over a communication channel as defined herein. Servers may use memory with error detection and correction, redundant disks, redundant power supplies, etc.

[0119] As used in the specification and appended claims, the singular forms “a,” “an,” and “the” include plural indicators unless the context clearly specifies otherwise. A range herein may be expressed as from “about” one particular value and / or to “about” another particular value. When such a range is expressed, another embodiment includes from one particular value and / or to another particular value. Similarly, when a value is expressed as an approximation using the antecedent “about,” it should be understood that the particular value forms another embodiment. It should also be understood that each endpoint of a range is significant relative to and independent of the other endpoint.

[0120] Unless otherwise expressly stated, it is not intended to interpret any method described herein as requiring its steps to be performed in a particular order. Therefore, no inference is made in any respect of the order in which the method claims actually describe the order of their steps, or where the claims or specification do not otherwise specifically state that these steps will be limited to a particular order. This applies to any possible non-expressive basis used for interpretation, including: logical questions concerning the arrangement of steps or operational procedures; general meanings derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0121] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art upon consideration of the specification and practice disclosed herein. The specification and examples are intended to be considered exemplary only, and the true scope and spirit are indicated by the appended claims.

Claims

1. A production line control system configured to monitor and / or control at least one distribution device, the production line control system comprising: Multiple components, including a main component and at least one client component, Wherein the main component and at least one of the at least one client component are configured to implement or execute a composite controller, the composite controller being configured to operatively communicate with each of the plurality of components, and the composite controller being configured to: Receive the operating status of the main component from the controller of the main component; Receive the operation status of the at least one client component from the controller of the at least one client component; The combined operating state of the production line control system is determined at least in part based on the operating state of the main component and the operating state of the at least one client component; Generate a user interface, which displays: Multiple control tiles, each of the multiple control tiles representing (a) one of the multiple components and (b) at least one of the user-selectable component data of the multiple components; An indicator of the operating state of the main component; An indicator of the operational status of at least one client component; as well as The indicator of the composite operation status of the production line control system; The command is transmitted to the controller of the main component; as well as The command is transmitted to the controller of the at least one client component.

2. The production line control system of claim 1, wherein the controller of the main component is configured to implement or execute the composite controller.

3. The production line control system of claim 1, wherein at least one of the main component and the at least one client component configured to implement or execute the composite controller is determined based on a predetermined hierarchical identifier.

4. The production line control system according to claim 1, wherein the main component is a melting unit or a pattern controller, and the at least one client component is a melting unit or a pattern controller.

5. The production line control system according to claim 1, wherein the at least one client component comprises a plurality of client components.

6. The production line control system according to claim 5, wherein one of the plurality of components is a melter unit, and another of the plurality of components is a pattern controller.

7. The production line control system of claim 5, wherein the composite controller is configured to determine the composite operating state of the production line control system based at least in part on a hierarchy of the operating states of the master component and the operating states of the plurality of client components.

8. The production line control system of claim 7, wherein the level is determined based on a predefined user level setting.

9. The production line control system of claim 7, wherein the composite controller is further configured to determine whether any of the plurality of components is not required for production.

10. The production line control system of claim 9, wherein the composite controller is further configured to: when determining the composite operating state of the production line control system, ignore the operating state of any of the plurality of components that is not required for production.

11. The production line control system according to claim 1, wherein the command includes operating parameters.

12. The production line control system of claim 11, wherein the plurality of control tiles includes control tiles configured to receive user input for modifying the operating parameters.

13. The production line control system of claim 12, wherein the composite controller is further configured to, upon receiving the user input for modifying the operating parameters: The modified command is transmitted to at least one controller of the main component and the at least one controller of the at least one client component, wherein the modified command includes instructions for operating the at least one of the main component and the at least one client component to which the modified command is transmitted, thereby operating with the modified operation parameters; and The controller of at least one of the controllers of the main component and the at least one client component, to which the modified command is transmitted, receives the updated operation status.

14. The production line control system of claim 1, wherein the at least one client component is configured to switch between (a) a production mode and (b) a maintenance mode, wherein in the production mode, the controller of the at least one client component is configured to receive the command and operate the at least one client component in response to the command, and in the maintenance mode, the controller of the at least one client component is configured to receive the command only without operating the at least one client component in response to the command.

15. The production line control system of claim 1, wherein the composite controller is further configured to assign an Ethernet address to the controller of the at least one client component.

16. The production line control system of claim 15 further includes an automatic network switch configured to operatively connect the various components of the plurality of components to each other via a composite network.

17. The production line control system according to claim 16, wherein the automatic network switch comprises: A first port, configured to operatively connect the automatic network switch to a network adapter; A second port is configured to operatively connect the automatic network switch to the composite network; as well as A third port is configured to operatively connect the automatic network switch to at least one of the controller of the at least one client component and the operator interface of the at least one client component.

18. The production line control system of claim 17, wherein the automatic network switch is configured to isolate the at least one client component from the composite network electronics by disabling the third port, thereby allowing the operator interface of the at least one client component to operatively communicate with the controller of the at least one client component.

19. A production line control system configured to monitor and / or control at least one distribution device, the production line control system comprising: The system comprises multiple components, including a main component containing a controller, at least one client component containing a controller, and a backup main component containing a controller. The controller of the primary component and the controller of the backup primary component are both configured to operatively communicate with each of the plurality of components. The controller of the main component is configured to implement or execute a composite controller. The controller of the backup main component is configured to: Determine whether the controller of the main component has lost operational communication with the at least one client component and the backup main component; as well as If the controller of the backup primary component determines that the controller of the primary component has lost operational communication with the at least one client component and the backup primary component for a predetermined minimum amount of time, then the composite controller is implemented or executed, and The composite controller is configured as follows: Receive the operating status of the main component from the controller of the main component; The controller of the at least one client component receives the operation status of the at least one client component; Receive the operating status of the backup main component from the controller of the backup main component; The combined operating state of the production line control system is determined at least in part based on the operating state of the main component, the operating state of the at least one client component, and the operating state of the backup main component; Generate a user interface, which displays: Multiple control tiles, each of the multiple control tiles representing (a) one of the multiple components and (b) at least one of the user-selectable component data of the multiple components; An indicator of the operating state of the main component; An indicator of the operational status of at least one client component; An indicator of the operating status of the backup main component; as well as The indicator of the composite operation status of the production line control system; The command is transmitted to the controller of the main component; The command is transmitted to the controller of the at least one client component; as well as The command is transmitted to the controller of the backup master component.

20. A method for transmitting commands to multiple components of a production line control system, the production line control system including a master component and at least one client component, the method comprising: At a composite controller implemented or executed by at least one of the main component and the at least one client component, the operating state of the main component is received from the controller of the main component; At the composite controller, the operating status of the at least one client component is received from the controller of the client component; The combined operating state of the production line control system is determined at least in part based on the operating state of the main component and the operating state of the at least one client component; Generate a user interface, which displays: Multiple control tiles, each of the multiple control tiles representing (a) a component of the production line control system including the main component and the at least one client component and (b) at least one of the user-selectable component data of the main component or the at least one client component; An indicator of the operating state of the main component; An indicator of the operational status of at least one client component; as well as The indicator of the composite operation status of the production line control system; The command is transmitted to the controller of the main component; as well as The command is transmitted to the controller of the at least one client component.

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