INTEGRATED AND INTELLIGENT PAINT MANAGEMENT

Description

BACKGROUND OF THE INVENTION

[0001] Many modem industrial painting processes involve highly complex multistep processes. For example, automotive, commercial vehicle, aerospace, light & heavy industrial, marine, and others require highly consistent coatings film thickness, final paint colors, visual appearance equal to expectation, cured coatings performance properties equal to specification, across large product lines and over long periods of time. This is further complicated by modem painting methods that often involve multiple layers and complex chemistry.

[0002] For example, in some conventional systems, each of the coating layers can be additive and build upon one another. Additionally, many of the layers may be polychromatic color and clear finishes. As such, it is increasingly difficult and important to ensure that each layer is consistent across the process so that the final product has the correct coating attributes. For example, a single car may be painted with multiple different layers in order to provide significant corrosion protection and create a very specific final color and effect. A significant discrepancy within any of the layers may result in a final paint color that does not meet the specifications and that does not match the other cars, or final cure film performance does not meet quality or durability specifications.

[0003] Additionally, conventional systems often require unique paint formulations for different geographic locations or regional legislative requirements in order to create coatings that have the same specifications and / or attributes. Further, in some cases, significant changes in local environmental conditions can impact the paint application process. The unique formulations and the impacts of weather present multiple problems relating to color and appearance consistency and costs. For example, as conditions change at one facility the color may drift away from the color produced by the other facilities.

[0004] Further, due to the complexity of the paint application process, it can be extremely difficult to identify what parameters need to be adjusted in order to create a final paint coating that is within the specifications. Within conventional paint systems, when a problem is identified, a specialist at the facility relies upon their own personal experience and the "art" of the paint application process to identify the potential problem. This solution is undesirable because different specialists will have different experience and different exposure to the various paint application process. As such, different specialists may respond differently to the same problem and unintentionally create further problems within the paint application process.

[0005] Accordingly, there are many problems in the art to be addressed.

[0006] EP 0 915 401 A2 relates to a computer-implemented apparatus and method for coordinating paint-related process steps of at least one paint-related facility. The paint-related process steps exhibit paint-related characteristics. A data acquisition module is provided for acquiring paint characteristic data indicative of the paint-related characteristics. A paint process control data structure is provided for interrelating the acquired paint characteristic data with at least two of the paint-related process steps to produce interrelated paint process control data. A paint process control coordinator is connected to the data acquisition module for storing the acquired paint characteristic data in the paint process control data structure. A data display is connected to the paint process control data structure for remotely receiving and viewing the interrelated paint process control data.

[0007] US 6,528,109 B1 relates to an integrated paint quality control (IPQC) system for feedback control of paint process for painting vehicle bodies includes a film thickness sensor system for measuring paint film thickness of the painted bodies. The IPQC system also includes a control system communicating with the film thickness sensor system for receiving information of the paint film thickness and combining the paint film thickness information with paint automation parameters on a vehicle identification number (VIN) basis of the painted bodies to control the paint process.

[0008] US 2010 / 0033318 A1 to a system and method for selectively communicating data from a remote facility to a central computing device via one or more communication networks and / or protocols.BRIEF SUMMARY OF THE INVENTION

[0009] The present invention relates to a first system for monitoring a paint application process at a first facility and automatically adjusting paint parameters within a first multivariate paint application system based upon sensor data gathered from various first sensor modules receiving data from various points within the first multivariate paint application system, the system comprising: a quality assurance parameter database, the quality assurance parameter database being configured to provide an indication of an ideal range of a final paint product attribute; an electronic sensor module configured to automatically measure the final paint product attribute on a completed product; a quality assurance processing module configured to: receive the measured final paint product attribute from the electronic sensor module over a network, and determine that the measured final paint product attribute is outside of the ideal range; a paint application system configuration module configured to: access a first facility database of one or more operating parameters from one or more paint application machines that performed a step in the process of painting the completed product and one or more paint mixture ingredients that were used in the process of painting the completed product, and determine, using a first multivariate analysis, at least one of the one or more first operating parameters that if adjusted would place the final paint product parameter for future products within the ideal range, wherein the multivariate analysis accounts for at least (i) current environmental conditions, (ii) machine operation parameters, and (iii) paint ingredients; and a computing device comprising a screen that is configured to display a proposed adjustment to at least one operating parameter, wherein the proposed adjustment is received from the paint application system configuration module, wherein at least one of the paint application machines comprises a paint applicator that is associated with a plurality of adjustable operating parameters, wherein the quality assurance processing module is further configured to automatically adjusting at least one of the plurality of adjustable operating parameters associated with the paint applicator to align with the proposed adjustment.

[0010] Moreover, a computer-implemented method configured to be carried out in a system according to the present invention is provided.

[0011] Additional features and advantages of the present invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the present invention. The features and advantages of the present invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of the present invention as set forth hereinafter.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order to describe the manner in which the above recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to the present invention, which is illustrated in the appended drawings. Understanding that these drawings are not to be considered to be limiting of the scope of the present invention, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: Figure 1 illustrates a schematic diagram of a computer system in accordance with the present invention; Figure 2 illustrates a schematic diagram of a remote server communicating with geographically diverse paint facilities in accordance with the present invention; Figure 3 depicts a paint system user interface in accordance with the present invention; Figure 4 depicts another paint system user interface in accordance with the present invention; Figure 5 depicts another paint system user interface in accordance with the present invention; Figure 6A depicts another paint system user interface in accordance with the present invention; Figure 6B depicts another paint system user interface in accordance with the present invention; Figure 7A depicts another paint system user interface in accordance with the present invention; Figure 7B depicts another paint system user interface in accordance with the present invention; Figure 7C depicts another paint system user interface in accordance with the present invention; Figure 8 is a flowchart of an exemplary method implemented in accordance with the present invention; and Figure 9 is a flowchart of another exemplary method implemented in accordance with the present invention. DETAILED DESCRIPTION

[0013] The present invention extends to systems, and methods configured to automatically or with human interface gather diverse data from a paint facility and identify one or more paint or applications process parameter attributes that could place a final cured film painted product outside a desired range. In particular, the present invention can comprise various computing modules and / or sensor modules configured to receive sensor readings or human input device readings and then analyze all variables to validate current or create proposed adjusted operating parameter changes. The sensor or device readings can comprise both current operating parameters and environmental data. Additionally, data can be shared across multiple, geographically-diverse painting facilities such that paint formulations and output can be optimized.

[0014] Accordingly, the present invention can provide significant technical advances and address long felt needs within the field of large-scale paint application. For example, the present invention can provide an intuitive interface for managing a complex paint application process. Additionally, the present invention can provide automatic computer-based learning suggestions for preemptively correcting potential problems within the paint application process. Further, the present invention can provide methods for optimizing paint processes across a variety of geographically diverse paint facilities.

[0015] When applying paint and other coatings to a particular product, granular tracking and control of each independent step can be vital. For example, the final coating performance can be heavily dependent upon the process control and consistency with which each individual layer and coating is applied, dried, or otherwise cured. One will understand that if any step in the paint application process varies significantly outside of a threshold value, the finished paint coating may fall outside of desired specifications.

[0016] Identifying and maintaining the proper coating chemistry can be a critical step in deriving or achieving the desired final film performance properties. Coatings chemistry and painting processes, however, have grown ever more complex. The increased complexity has, at least in part, been due to more strenuous customer specifications, societal demand for lower total environmental impacts, cost driven toward lower consumption of energy, and high quality demands.

[0017] As coating specifications and complexity have increased, the conventional artisan-based approaches for managing paint facilities have become inadequate and inefficient. In particular, those of common knowledge in the painting industry recognize there are relationships between the coatings chemistry, the applications and processes applied, and the final painted product. Despite this recognition, conventional methods fail to demonstrate or utilize a dynamic understanding of paint controlling and monitoring of the diversity of variables within a paint facility. For instance, conventional methods may include a paint manager identifying a particular problem in the paint process and relying upon his own personal experience, guessing what process should be changed to correct the problem.

[0018] The present invention can incorporate multiple variables with respect to paint chemistry, including but not limited to chemistry type, solids, solvency, viscosity, rheologies, shear behavior, pressure, flow, temperature, and the like. Similarly, the present invention can incorporate multiple variables with respect to paint applications and cure processes. These variables can include, but are not limited to, painting process type, coating through-put rate, speed of coating deposit, climatic conditions, pressures, flows, voltages, temperatures, atomizers and atomization energies, evaporation energies, cure energies, and the like.

[0019] In particular, each of the aforementioned variables can be monitored to determine if they fall within one or more defined thresholds. The invention can comprise a mobile computing device, which can be configured to do the variable monitoring and analysis of input data to define the system health and paint process quality outcomes. The data collection can take a variety of different forms, including but not limited to human input, automatic communication from process control equipment, near field communication or data capture, input from measurement instruments, cameras, bar or QR readers, voice recording, or other input methods. Once entered, algorithms that can predict paint process outcome based on the range of multivariate inputs can analyze the data.

[0020] Along these lines, Figure 1 depicts a paint system that includes paint system software 100. As depicted, the paint system software 100 can comprise various modules and components. One will understand, however, that the modules and components shown and described herein are provided only for the sake of clarity and explanation and do not limit the system to any particular configuration. In particular, other paint system software 100 may otherwise divide, combine, or describe the various modules and still remain within the scope of the present invention. Additionally, in various implementations, modules can comprise hardware components, software components, or combinations of hardware and software components.

[0021] Figure 1 shows that the paint system software 100 can be in communication with a quality assurance database 112, various sensor units 122, various paint production machinery 132 (e.g., spray applicators, paint baths, ovens, etc.), various mobile computing devices 142, and various remote servers 144. When in use, the paint system software 100 can both receive information regarding a painting process and propose various changes and optimizations based upon the received information.

[0022] Figure 1 further shows that the paint system software 100 also comprises a quality assurance processing module 110. The quality assurance processing module 110 may further be in communication with various other modules 120, 130, 140 and components 112 within a paint system. For example, the quality assurance processing module 110 receives sensor data from various sensor modules 120. For instance, a sensor module maybe in communication with a camera or spectrophotometer 122. The camera or spectrophotometer may be configured to identify a final paint product attribute such as film thickness, color, or finish appearance attributes on a finished paint product. Additionally, the sensor module 120 may also be in communication with various other sensors including but not limited to thermometers, pressure sensors, depth sensors, chemical detection sensors, multi-meters, and other paint process related sensing devices.

[0023] Additionally, the quality assurance processing module 110 can receive input information from a user through a mobile computing device 142. For instance, a user can manually enter various data points and sensor readings into the mobile computing device 142 as the data points and sensor readings become available to the user. Instead of using a mobile computing device such as a tablet or a smartphone, a user can utilize a desktop computer, a server, or any other user operated computing device to interact with the paint system software 100.

[0024] Once the quality assurance processing module 110 has received one or more data points, the quality assurance processing module 110 can receive specific production information from a quality assurance database 112. For example, the quality assurance database 112 can comprise various paint specifications that describe desired or ideal final paint attributes. Additionally, the quality assurance database 112 may also comprise various operating threshold information that describes acceptable thresholds for various processes within the painting system. For example, it may be desirable to apply a certain thickness of a coating, a certain viscosity of a coating, or to apply a coating at a particular temperature.

[0025] The quality assurance processing module 110 can identify various problems within the paint application system. For example, the quality assurance processing module 110 can identify an undesirable trend detected by the sensor module 120. Similarly, the quality assurance processing module 110 can detect when a predetermined threshold has been breached.

[0026] Based upon the detected undesirable behavior or predicted undesirable outcome, the quality assurance processing module 110 can propose specific changes needed to correct the problem. For example, the quality assurance module 110 can send a proposal to input / output ("IO") module 140, which can then forward the proposal to the appropriate user. In relation to the present invention, multiple users may have access to different computing devices 142. The I / O module 140 may selectively send the proposed solution to a particular user that is associated with a particular point in the paint process. For example, a proposal may relate to a pre-paint process. The I / O module 140 may identify a user in charge of the pre-paint process and send the proposal only to that user.

[0027] The quality assurance processing module 110 automatically execute the proposed change by communicating directly with a paint application module 130. For example, the paint application module 130 may be in communication with a variety of different paint application machinery 132. The paint application module 130 is in communication with a paint applicator 132, such as an automated atomizer, a paint air gun, an electrostatic spray gun, a bell sprayer, or some other paint applicator. Accordingly, upon receiving the proposed change, the paint application module 130 automatically controls the paint applicator 132 to implement the proposed change. For example, the proposed change may comprise an increased spray rate. In this case, the paint application module 130 can increase the spray rate of the paint applicator 132. One will understand, however, that any machinery or system within the paint facility may also be operable by the paint application module 130.

[0028] Additionally, quality assurance processing module 110 can rely upon a multivariate analysis when determining proposed changes. For example, the quality assurance processing module 110 may rely upon current local meteorological conditions, multiple sensor readings, specific information relating to the type and make of various paint application machinery 132, and information relating to various components of a paint formulation. The quality assurance database 112 can provide the information relating to paint formulation, paint application machinery type, paint application machinery make and model, and other similar information.

[0029] Additionally, the quality assurance processing module 110 can adjust and revise one or more equations used within the multivariate analysis. For example, the multivariate analysis may comprise components that are weighted based upon historic feedback received by the paint system software 100. For example, based upon analyzed historic feedback data, the quality assurance processing module 110 may identify that a particular chemical component varies based upon heat and pressure. Using the identified relationship, the quality assurance processing module 110 can propose solutions and actions necessary to correct or modify various final paint product attributes.

[0030] Over time, however, as machinery within the paint facility is replaced or repaired, one or more paint application variables may intentionally or unintentionally vary from their historic value. The quality assurance processing module 110 can identify that one or more sensors are providing feedback that does not align with historical parameters. Based upon the unexpected feedback, the quality assurance processing module 110 can automatically learn and adjust the multivariate analysis to account for the adjusted parameters. Additionally, the present invention can determine when a particular sensor is inoperative or returning erroneous readings. For example, upon receiving a reading that significantly exceeds an expected threshold, the present invention can flag the associated sensor as needing inspection.

[0031] Additionally, the quality assurance module 110 can identify previously unknown associations and trends between paint production variables. For example, using machine-learning techniques, the quality assurance module 110 may identify previously unknown relationships between local humidity, particular chemicals within a paint formulation, and paint curing characteristics.

[0032] After identifying these relationships, the quality assurance module 110 can incorporate these relationships into future proposed changes. For instance, the quality assurance module 110 may identify that due to a change in humidity and its impact on a particular chemical within a paint formulation, that an atomizer should be adjusted to ensure the paint meets the required specifications. Accordingly, the present invention can automatically identify relationships that are unknown in the conventional art and can automatically propose changes to a paint application process based upon the identified relationships.

[0033] Additionally, the paint system software 100 may also communicate through the I / O module 140 with a remote server 144. Remote server 144 may, for example, comprise a central processing hub (e.g., Figure 2) that is in communication with multiple instances of paint system software 100 spread across multiple geographically diverse paint facilities.

[0034] For example, Figure 2 depicts a schematic diagram of a remote server 144 in communication with multiple paint facilities 200(a-e). The remote server 144 can receive various sensor readings, coating output quality data, and process data from the various paint facilities 200(a-e). Using this information, the remote server 144 can identify trends at each of the respective paint facilities 200(a-e). Additionally, remote server 144 can identify optimizations that can be pushed out to the various facilities. For example, remote server 144 can identify how to adjust the paint manufacturing and application process to accommodate for humidity changes at a particular paint facility 200e that is in a humid region. The remote server 144 can then automatically provide the adjustments to a different paint facility 200b within a second region that is experiencing uncommonly high humidity for the second region.

[0035] As such, the present invention can provide significant benefits over the conventional "artisan" approach to paint application. Specifically, the present invention can accommodate variation or limitations knowledge of the individual in charge of a shift. For example, the shift leader in one region versus another region may have little or no experience dealing with excessive humidity. Since, the present invention can share information across diverse geographic regions and climates, systems of the present invention can provide optimizations and adjustments that previously were not possible.

[0036] Additionally, the present invention provides systems and methods for consolidating paint formulations across multiple geographically diverse locations. For instance, a particular color of blue created at paint facility 200a may require a unique and different paint formulation than facility 200e to create the same color of blue. One will understand the significant technical and financial difficulties implicated in creating unique paint formulations for every paint facility so that uniform colors can be achieved across the facilities 200(a-e).

[0037] Further, the present invention provides high adaptation to changing weather patterns at the individual facilities, changing and upgrading machinery at the individual facilities in both the form of a piece-meal upgrade and an entire facility upgrade, and accurately tracking specific outcomes at the different facilities. In contrast to the shortcomings of the conventional art, present invention can automatically identify common trends and differences among the various different paint facilities 200(a-e) without regards to differences in machinery, weather, and other local variables. Using this information, significant improvements in paint coating quality and efficiency can be automatically implemented.

[0038] For example, the remote server 144 can identify paint formulations that can be commonly used by multiple paint facilities 200(a-e) to create coatings that meet the same final specifications or attributes. For instance, a particular paint formulation may be used in paint facility 200a to create a particular color of green. Using information received from both paint facility 200a and paint facility 200e, the remote server 144 can identify that paint facility 200e uses the same paint formulation as paint facility 200a but with different facility operating parameters to create the same color of green. As such, remote server 144 can save costs by sending the same paint formulation to both facilities 200a, 200e and allowing the local quality assurance processing modules 110 to make the necessary unique adjustments at each facility 200a, 200e to create the correct coating.

[0039] In addition, the remote server 144 can also automatically manage inventory at an inventory server 210 based upon the information received from the various paint facilities 200(a-e). For example, remote server 144 may identify that a particular chemical component at a particular paint facility is running low. The remote server 144 may be able to automatically initiate an order for that chemical before it runs out at the paint facility.

[0040] Additionally, the remote server 144 can automatically adjust paint production based upon detected changing weather patterns and / or other parameters. For example, the remote server 144 may receive weather forecast information for one or more of the locations of the paint facilities 200(a-e). Further, the remote server 144 may identify that a weather trend that is occurring or is forecasted to occur at a particular paint facility 200a, and will have a detrimental effect on a particular coating that the paint facility 200a is supposed to produce. Upon making this determination, the remote server 144 can automatically shift the paint orders from the paint facility 200a that is affected with the detrimental weather to another paint facility 200b that is not experiencing or otherwise affected by the detrimental effects.

[0041] The use of the remote server 144 within this description is meant to only indicate that a computing module is remote from at least one of the painting facilities. One of the paint facilities may host the remote server 144 such that the other paint facilities are all communicating with the single hosting facility. Alternatively, the remote server 144 may be simultaneously hosted by multiple paint facilities 200(a-e), or even all the paint facilities 200(a-e), through a distributed system.

[0042] As discussed above, the present invention can also include mobile computing devices 142. The mobile computing devices 142 can be both input devices and output devices. For example, a paint technician may input various paint variables into the mobile computing device 142. The input variables may then be provided to the paint system software 100.

[0043] Additionally, a mobile computing device 142 can be used to display proposed changes generated by the quality assurance processing module 110. For example, a technician working in the pre-paint portion of a paint facility may receive a proposed change to adjust a particular aspect of the pre-paint process. Accordingly, a mobile computing device 142 can provide unique and novel ways for technicians in charge of specific areas in a paint facility to receive proposed changes that account for conditions and variables throughout the entire paint facility process. Similarly, the present invention can provide paint facility managers with quick and easy access to information relating to the entire paint facility.

[0044] For example, Figure 3 depicts a user interface 300 composed of icons 310, 320, 330 representative of different aspects of a paint application process. The icons can include a lab icon 310, a pre-treatment set of icons 320, an electro deposition set of icons 330, and any number of other icons necessary to represent different portions of the paint process. As such, using the user interface 300 of Figure 3, a user can quickly and easily access information relating to any individual portion of a paint process.

[0045] For instance, upon selecting the lab icon 310, a lab interface 450 may be displayed to a user as depicted in Figure 4. The lab interface 450 may comprise various inputs and outputs relating to a paint formulation chemistry. For example, the exemplary lab interface 450 of Figure 4 comprises a solids chart 400, a PH chart 410, a conductivity chart for 20, a temperature chart 430, and other various information charts.

[0046] Figure 4 also displays an exploded view of the solids chart 400 depicting a current state number indicator 440 along with various thresholds 402, 404, 406, 408. The current state indicator 440 may indicate the current detected percentage of solids. Additionally, the current state indicator may also indicate a user-specified percentage of coating solids. For example, a user may select the current state indicator 440 and adjust the number to reflect a desired level of paint solids within the coating.

[0047] Figure 4 shows that as a user adjusts the requested solids amount 440, indicators relating to the other display variables 410, 420, 430 may automatically adjust themselves to reflect detected changes in each of the respective levels or to display calculated changes within each of the respective levels. Accordingly, the information displayed within the user interface 450 can be dynamically updated to reflect sensed data, dynamically updated to represent calculated data, and / or manually adjusted by a user.

[0048] As an example of a user adjusting a value within the user interface 450, the quality assurance processing module 110 may suggest that a user decrease the percentage of solids from 22.9% to 21.3%. The reason for the suggested change may not directly relate to an incorrect percentage of solids, but may instead relate to a causal relationship that is not apparent until further into the painting process. As such, the adjustment of the solid percentage may not have a discernible effect to the user actually making the adjustment, but may correct a potential problem further in the process.

[0049] The user interface can also comprise thresholds 402, 404, 406, 408. The thresholds may indicate limits for safety factors, quality factors, and other such limits. For example, a first upper threshold 404 may indicate a threshold that can only be crossed for a specific period of time. A second upper threshold limit 402 may indicate a level that should never be crossed due to safety concerns. Accordingly, a user viewing the sensed current indicator 440 can immediately determine whether the indicator is within a desired threshold. Similarly, a user adjusting a current indicator 440 can clearly and easily know acceptable ranges of adjustment.

[0050] Figure 5 depicts an action item user interface 500. As shown, the action item user interface 500 can comprise various warnings relating to current paint facility operation. The warnings can be filtered by the individual user who is accessing the action item interface 500. For instance, a user associated with the curing process will only be displayed warnings that are within the user's ability to control.

[0051] The action item interface 500 may also comprise an icon warning indicator 520 that visually displays to a user the importance of a particular indication. For instance, the action item interface 500 comprises exclamation marks for warnings and stop signs for critical items. Additionally, the action item interface may comprise a numerical indication 510 displaying the sensor reading that is a cause of concern. Further, the interface 500 may comprise a brief description 530 of the present problem. The brief description may further comprise graph or other numerical depiction of the previous sensor readings 540.

[0052] One will appreciate that the action item interface 500 may comprise warnings for readings of crossed thresholds 530, for readings that are trending towards thresholds 532, for statistical anomalies between concurrent readings, and for other problems analytically identified by the quality assurance processing module 110. A user can access further information relating to each warning by simply selecting the warning within the action item interface 500. Once a warning is selected, a user may be presented an interface similar to the interface of Figure 4 described above.

[0053] In addition to receiving warnings through the action item interface 500 a user can also input warnings and problems into the system. For example, Figure 6 depicts a problem reporting user interface 600 for reporting particular problems identified within a finished product. The finished product depicted in Figure 6 comprises an automobile. For example, upon identifying that a coating thickness for the roof of a car is insufficient, a user can select the roof of the car 610 and indicate on a graph 620 the detected problem. This and similar interfaces may be necessary to enter data that the sensors are unable to automatically gather. Additionally, this and similar interfaces may be necessary to further explain sensor data.

[0054] For example, Figure 6B depicts a user data entry interface 630. The user data entry interface 630 can comprise a sketch portion where a user can draw on a picture of a finished product and enter text regarding the finished product, a picture portion where user can take a picture of the problems with the finished product, a video portion, an audio recording portion, and other portions for any other data input means. Using the user input interface 630, a user can articulate a problem and submit the problem such that a paint facility manager or troubleshooter can review the user's notes.

[0055] In addition to providing users with trouble shooting abilities, paint system software 100 can also provide a paint facility manager with an overview of an entire paint facility. For example, Figure 7A depicts a paint facility schematic interface 700. A paint facility user interface 700 can be customized for any particular paint facility. For example, the user interface 700 can be designed to depict the physical layout of the paint facility, the product progression of the paint facility, or any other layout that is desired by the user.

[0056] Within the interface 700 of Figure 7A a user is provided with a physical map of a paint facility. Within the physical map a user can select a particular facility portion to access information relating to that portion. For example, Figure 7B depicts a zoomed in portion of the map shown in Figure 7A. The interface of Figure 7B depicts individual processes 710 that take place within that part of the paint facility. Additionally, a user can be provided with access options 712 to access additional information relating to each individual paint facility process. For example, upon selecting the passive spray process, a passive spray interface 720 as depicted in Figure 7C may be displayed to a user.

[0057] The present invention can provide a variety of task-specific user interfaces. For example, a user can access a user interface that provides the user information about and control of an entire paint facility processing line. Similarly, a user can access another user interface that provides the user with alerts relating to the current paint application process. As such, the present invention provides dynamic and novel methods for controlling and monitoring a paint facility and paint application process.

[0058] Accordingly, Figures 1-7C and the corresponding text illustrate or otherwise describe one or more methods, systems, and / or instructions stored on a storage medium for monitoring and managing one or more paint facilities. One will appreciate that the present invention can also be described in terms of methods comprising one or more acts for accomplishing a particular result. For example, Figures 8 and 9 and the corresponding text illustrate flowcharts of a sequence of acts in a method for monitoring and managing one or more paint facilities. The acts of Figures 8 and 9 are described below with reference to the components and modules illustrated in Figures 1 - 7C.

[0059] For example, Figure 8 illustrates that a flow chart for a method for receiving data and providing calculated adjustments to the paint application process can comprise an act 800 of receiving a first operating parameter. Act 800 can include receiving at the server, from a computing device, a first operating parameter associated with a first paint processing machine at a first painting facility. For example, Figure 1 and the accompanying description, illustrate that a quality assurance database 112 can comprises various operating parameters, such as thresholds, best practices, paint application machinery specifications, paint formulations, and other related data points. In particular, the quality assurance database 112 can comprise an operating parameter associated with a particular piece of paint application machinery.

[0060] Additionally, Figure 8 depicts that the method can include an act 810 of receiving a first quality control measurement. Act 810 can comprise receiving at the server a first quality control measurement from an analysis of a finished first paint product. For example, Figure 1 and the accompanying description, illustrates that a camera or spectrophotometer sensor 122 can communicate various quality control measurements to paint system software 100.

[0061] Figure 8 also depicts that the method can include an act 820 of accessing a set of historical operating parameters. Act 820 can comprise accessing from a database a set of historical operating parameters associated with the first painting processing machine. For example, Figure 1 and the accompanying description, illustrates a quality assurance processing module 110. The quality assurance processing module 110 can receive historical operating data from the quality assurance database 112. The historical operating parameters may comprise machinery operation parameters, previously made adjustments, historic output data, and other similar data.

[0062] Further, Figure 8 depicts that the method can include an act 830 of identifying a deficiency in a finished product. Act 830 can comprise automatically identifying a deficiency in the finished first paint product based upon the first quality control measurement. For example, Figure 1 and the accompanying description, illustrates that the quality assurance processing module 110 can identify a deficiency in a finished product based upon information received from the sensor module 120. For instance, the quality assurance module may determine that a film thickness is outside of specified thresholds.

[0063] Further still, Figure 8 depicts that the method can include an act 840 of transmitting a proposed adjustment. Act 840 can comprise transmitting to a computing device screen a proposed adjustment to the first operating parameter that will correct the deficiency. The proposed adjustment can account for the historical operating parameters associated with the first paint processing machine. For example, Figure 1 and the accompanying description illustrate an IO module 140 that communicates proposed adjustments to a computing device 142. For instance, the user interfaces 450, 500 of Figures 4 and 5 depict examples of suggested changes.

[0064] In addition to the foregoing, Figure 9 illustrates a flow chart for an additional or alternative method for receiving data and providing calculated adjustments to a paint application process. For example, Figure 9 shows that the method can comprise an act 900 of receiving one or more operating parameters from a plurality of facilities. Act 900 can comprise receiving at a server from a plurality of painting facilities one or more operating parameters that are unique to each respective painting facility. For example, Figure 2 and the accompany description illustrate a remote server 144 in communication with various paint facilities 200(a-e) spread out across a geographically diverse area. The remote server 144 can receive operating parameters from each of the unique paint facilities 200(a-e).

[0065] Additionally, Figure 9 shows that the method can include an act 910 of receiving a plurality of quality control measurements. Act 910 can comprise receiving a plurality of quality control measurements from analyses of finished paint products from each respective painting facility. For example, each paint facility 200(a-e) can comprise its own paint system software 100. Each respective paint system software 100 can comprise an IO module 140 that communicates with the remote server 144. Specifically, the IO module 140 can communicate to the remote server 144 information, such as quality control measurements.

[0066] Figure 9 also shows that the method can include an act 920 of analyzing relationships between the operating parameters and the quality control measurements. Act 920 can comprise automatically analyzing, with one or more processors, relationships between historic operating parameters and historic quality control measures at each of the painting facilities. For example, Figure 2 and the accompanying description, describe the remote server 144 as analyzing the information received the paint facilities 200(a-e) to identify various trends.

[0067] Further, Figure 9 shows that the method can include an act 930 of identifying one or more paint formulations that can be used by multiple facilities. Act 930 can comprise, based upon the analyzed relationships, identifying one or more initial paint formulas that can be utilized by at least two of the plurality of painting facilities and which are capable of creating a particular paint product that meets predetermined parameters. For example, Figure 2 and the accompanying description describe an example where the remote server 144 determines that the same paint formulation can be used by paint facility 200a and the paint facility 200e to create the same final coatings, albeit with different operating parameters at each facility 200a, 200e.

[0068] Accordingly, the present invention can provide significant advantages over conventional systems and methods, and address many long-felt needs. For example, the present invention can automatically identify negative trends within a paint application facility. Additionally, the present invention can perform multivariate analysis to identify potential changes that can be made to avoid negative outcomes. Further, the present invention can identify efficiencies that can be implemented across geographically diverse and operationally unique paint facilities.

[0069] Although the subject matter has been described in language specific to structural features and / or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the described features or acts described above, or the order of the acts described above. Rather, the described features and acts are disclosed as example forms of implementing the claims.

[0070] The present invention may comprise or utilize a special-purpose or general-purpose computer system that includes computer hardware, such as, for example, one or more processors and system memory, as discussed in greater detail below. The present invention may also include physical and other computer-readable media for carrying or storing computer-executable instructions and / or data structures. Such computer-readable media can be any available media that can be accessed by a general-purpose or special-purpose computer system. Computer-readable media that store computer-executable instructions and / or data structures are computer storage media. Computer-readable media that carry computer-executable instructions and / or data structures are transmission media. Thus, by way of example, and not limitation, the present invention can comprise at least two distinctly different kinds of computer-readable media: computer storage media and transmission media.

[0071] Computer storage media are physical storage media that store computer-executable instructions and / or data structures. Physical storage media include computer hardware, such as RAM, ROM, EEPROM, solid state drives ("SSDs"), flash memory, phase-change memory ("PCM"), optical disk storage, magnetic disk storage or other magnetic storage devices, or any other hardware storage device(s) which can be used to store program code in the form of computer-executable instructions or data structures, which can be accessed and executed by a general-purpose or special-purpose computer system to implement the disclosed functionality of the invention.

[0072] Transmission media can include a network and / or data links which can be used to carry program code in the form of computer-executable instructions or data structures, and which can be accessed by a general-purpose or special-purpose computer system. A "network" is defined as one or more data links that enable the transport of electronic data between computer systems and / or modules and / or other electronic devices. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a computer system, the computer system may view the connection as transmission media. Combinations of the above should also be included within the scope of computer-readable media.

[0073] Further, upon reaching various computer system components, program code in the form of computer-executable instructions or data structures can be transferred automatically from transmission media to computer storage media (or vice versa). For example, computer-executable instructions or data structures received over a network or data link can be buffered in RAM within a network interface module (e.g., a "NIC"), and then eventually transferred to computer system RAM and / or to less volatile computer storage media at a computer system. Thus, it should be understood that computer storage media can be included in computer system components that also (or even primarily) utilize transmission media.

[0074] Computer-executable instructions comprise, for example, instructions and data which, when executed at one or more processors, cause a general-purpose computer system, special-purpose computer system, or special-purpose processing device to perform a certain function or group of functions. Computer-executable instructions may be, for example, binaries, intermediate format instructions such as assembly language, or even source code.

[0075] Those skilled in the art will appreciate that the invention may be practiced in network computing environments with many types of computer system configurations, including, personal computers, desktop computers, laptop computers, message processors, hand-held devices, multi-processor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, mobile telephones, PDAs, tablets, pagers, routers, switches, and the like. The invention may also be practiced in distributed system environments where local and remote computer systems, which are linked (either by hardwired data links, wireless data links, or by a combination of hardwired and wireless data links) through a network, both perform tasks. As such, in a distributed system environment, a computer system may include a plurality of constituent computer systems. In a distributed system environment, program modules may be located in both local and remote memory storage devices.

[0076] Those skilled in the art will also appreciate that the invention may be practiced in a cloud-computing environment. Cloud computing environments may be distributed, although this is not required. When distributed, cloud computing environments may be distributed internationally within an organization and / or have components possessed across multiple organizations. In this description and the following claims, "cloud computing" is defined as a model for enabling on-demand network access to a shared pool of configurable computing resources (e.g., networks, servers, storage, applications, and services). The definition of "cloud computing" is not limited to any of the other numerous advantages that can be obtained from such a model when properly deployed.

[0077] A cloud-computing model can be composed of various characteristics, such as on-demand self-service, broad network access, resource pooling, rapid elasticity, measured service, and so forth. A cloud-computing model may also come in the form of various service models such as, for example, Software as a Service ("SaaS"), Platform as a Service ("PaaS"), and Infrastructure as a Service ("IaaS"). The cloud-computing model may also be deployed using different deployment models such as private cloud, community cloud, public cloud, hybrid cloud, and so forth.

[0078] A cloud-computing environment may comprise a system that includes one or more hosts that are each capable of running one or more virtual machines. During operation, virtual machines emulate an operational computing system, supporting an operating system and perhaps one or more other applications as well. Each host may include a hypervisor that emulates virtual resources for the virtual machines using physical resources that are abstracted from view of the virtual machines. The hypervisor also provides proper isolation between the virtual machines. Thus, from the perspective of any given virtual machine, the hypervisor provides the illusion that the virtual machine is interfacing with a physical resource, even though the virtual machine only interfaces with the appearance (e.g., a virtual resource) of a physical resource. Examples of physical resources including processing capacity, memory, disk space, network bandwidth, media drives, and so forth.

[0079] The above description should be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

[0080] The present invention may thus relate in particular, without being limited thereto, to the following aspects: An aspect provides a system for monitoring and controlling one or more paint application process(es), the system comprising: a first paint application system by which a first painted product is formed from an object to be painted in a first paint application process, one or more first measuring device(s) for determining at least one attribute of the first painted product; a first paint application process database which comprises historical data of the at least one attribute of the first painted product in relation to a plurality of operating parameters associated with the first paint application process including at least environmental conditions, paint ingredients, and operating parameters of the first paint application system; a quality assurance database which comprises data on an ideal range and / or an acceptable range for the at least one attribute of the first painted product; one computing device being configured to, or more than one communicatively linked computing devices being in their entirety configured to: automatically determine the at least one attribute of the first painted product by means of the one or more first measuring device; detect a deficiency in the first painted product by means of a quality assurance processing module, which is in communication with the one or more first measuring device, has access to the quality assurance database and is configured to detect said deficiency by determining if one or more of the determined at least one attribute of the first painted product falls outside of its ideal range and / or its acceptable range; provide a proposed adjustment to one or more operating parameter(s) associated with the first paint application process for correcting said deficiency in the first painted product by means of a paint application system configuration module, which is in communication with the quality assurance processing module and the first paint application system, has access to the first paint application process database and is configured to perform a first multivariate analysis based on the historical data from the first paint application process database for providing the proposed adjustment, wherein the multivariate analysis accounts for at least current environmental conditions, paint ingredients and operating parameters of the first paint application system of the first paint application process; and transmit the proposed adjustment to one or more operating parameter(s) associated with the first paint application process to a display device configured to display the proposed adjustment and / or automatically adjust one or more operating parameter(s) associated with the first paint application process according to the proposed adjustment by the paint application system configuration module, wherein at least one of the paint application machines comprises a paint applicator that is associated with a plurality of adjustable operating parameters, wherein the quality assurance processing module is further configured to automatically adjusting at least one of the plurality of adjustable operating parameters associated with the paint applicator to align with the proposed adjustment.

[0081] Preferably at least a portion of the historical data of the first paint application process database are related to operating parameters of the first paint application system that are specific to type and make of the at least one paint application device.

[0082] Preferably one or more first sensor(s) for determining one or more of the operating parameter(s) associated with the first paint application process are present, wherein the sensor module is in communication with the one or more first sensors and is configured to automatically measure one or more of the operating parameters associated with the first paint application process.

[0083] Preferably the paint application system configuration module is configured to repeatedly provide proposed adjustments and automatically adjust one or more operating parameter(s) associated with the first paint application process to align with the respective proposed adjustment for correction of a determined deficiency in the first painted product, the configuration module being configured to update the multivariate analysis on the basis of a feedback loop, which takes into account the measured one or more attribute(s) of a first painted product obtained by application of the adjusted one or more operating parameter(s) according to the respective last preceding proposed adjustment in the first paint application process.

[0084] Preferably a second paint application system by which a second painted product is formed from an object to be painted in a second paint application process is present, the second paint application system being in a geographically different location than the first paint application system; one or more second measuring device(s) for determining at least one attribute of the second painted product and a second paint application process database which comprises historical data of one or more second painted product attribute(s) in relation to a plurality of operating parameters associated with the second paint application process including at least environmental conditions, paint ingredients and operating parameters of the second paint application system, and one or more computing device(s) configured to provide the analogous functions as defined for the first paint application process with respect to the second paint application process; and a server in communication with the first paint application system and the second paint application system and having access to the first paint application process database and optionally to the second application process database, wherein the server is configured to: receive an indication of a target paint coating to be applied in the first paint application process and the second paint application process, the target paint coating being associated with a plurality of attribute requirements within predetermined thresholds, identify on the basis of data comprising the historical data from the first paint application process database and optionally the second paint application process database first operating parameters associated with the first paint application process and second operating parameters associated with the second paint application process for creating the target paint coating by the first paint application process as well as by the second paint application process such that said plurality of attribute requirements are fulfilled within the predetermined thresholds, wherein the identified first operating parameters are different from the identified second operating parameters.

[0085] Preferably the server is configured to identify a common paint formulation for the target paint coating that both the first paint application system and the second paint application system are capable of using to create the target paint coating such that said plurality of attribute requirements are fulfilled within the predetermined thresholds.

[0086] Preferably the server is configured to take into account local meteorological conditions in identifying the first operating parameters and the second operating parameters for creating the target paint coating by the first paint application process as well as by the second paint application process such that said plurality of attribute requirements are fulfilled within the predetermined thresholds. Furthermore, a computer-implemented method for implementing the system for monitoring and controlling one or more paint application processes is present.

Claims

1. A first system for monitoring a paint application process at a first facility and automatically adjusting paint parameters within a first multivariate paint application system based upon sensor data gathered from various first sensor modules receiving data from various points within the first multivariate paint application system, the system comprising: a quality assurance parameter database, the quality assurance parameter database being configured to provide an indication of an ideal range of a final paint product attribute; an electronic sensor module configured to automatically measure the final paint product attribute on a completed product; a quality assurance processing module configured to: receive the measured final paint product attribute from the electronic sensor module over a network, and determine that the measured final paint product attribute is outside of the ideal range; a paint application system configuration module configured to: access a first facility database of one or more operating parameters from one or more paint application machines that performed a step in the process of painting the completed product and one or more paint mixture ingredients that were used in the process of painting the completed product, and determine, using a first multivariate analysis, at least one of the one or more first operating parameters that if adjusted would place the final paint product parameter for future products within the ideal range, wherein the multivariate analysis accounts for at least (i) current environmental conditions, (ii) machine operation parameters, and (iii) paint ingredients; and a computing device comprising a screen that is configured to display a proposed adjustment to at least one operating parameter, wherein the proposed adjustment is received from the paint application system configuration module, wherein at least one of the paint application machines comprises a paint applicator that is associated with a plurality of adjustable operating parameters, wherein the quality assurance processing module is further configured to automatically adjusting at least one of the plurality of adjustable operating parameters associated with the paint applicator to align with the proposed adjustment.

2. The system as recited in claim 1, wherein at least a portion of the one or more operating parameters from the machinery database are specific to a type and make of the paint applicator.

3. The system as recited in claim 1, wherein: the paint application system configuration module is further configured to update the multivariate analysis; and the multivariate analysis is based upon a feedback loop indicating an updated final paint product parameter on a recently completed product that was painted using at least one adjusted parameter of the one or more adjustable operating parameters.

4. The system as recited in claim 1, further comprising: a second paint application system configured to monitor a paint application process at a second facility, wherein the second paint application system is in a geographically different location than the first paint application system; and a central data processing hub in communication with the first paint application system and the second paint application system, wherein the central processing hub is configured to: receive an indication of a particular paint coating, wherein the paint coating is associated with various threshold attribute requirements, and identify various first operating parameters from the first facility and various second operating parameters from the second facility required to respectively create the particular paint coating such that it falls within the various threshold attribute requirements, wherein the first operating parameters and the second operating parameters are different.

5. The system as recited in claim 4, wherein the central data processing hub is further configured to: identify various first operating parameters from the first facility and various second operating parameters from the second facility required to respectively create the particular paint coating, such that it falls within the various threshold attribute requirements, wherein both the first facility and the second facility utilize a common paint formulation to achieve the final paint product attribute, wherein preferably at least one of the first operating parameters and the second operating parameters are influenced by local meteorological conditions.

6. The system as recited in claim 4, wherein the central data processing hub is further configured to: identify a common paint formulation for the final paint product attribute that both the first facility and the second facility are capable of using to create the particular paint coating such that it falls within the various threshold attribute requirements.

7. A computer-implemented method configured to be carried out in a system according to any one of claims 1 to 6.