A method and system for controlling and managing machines of a production plant by means of on-board control devices

Abstract

There is described a method for controlling and / or managing, by means of on-board control electronic devices, the operation of machines a production plant. The above- mentioned machines M, M1, M2, Mn are provided with respective machine controllers PLC, PLC1, PLC2, PLCn and cooperate for the manufacturing of a product or object, according to a production process. The method comprises providing respective on-board control electronic devices ED, ED1, ED2, EDn to a plurality of the above-mentioned plant machines. Each of the on-board control electronic devices ED contains, stored, and is adapted to execute one or more software programs or modules, configured to carry out the following additional method steps: - communicating and interoperating with the machine controller PLC of the respective machine, based on a common general model of machine controller data structure, adapted to interoperate with different types of machine controllers, to provide machine operating instructions to the machine controller PLC and to receive machine operation monitoring information from the machine controller PLC; - communicating with an operator, through a computer interface, to provide machine monitoring information and receive, from the operator, operating instructions for the machine operation and / or machine configuration or re-configuration instructions; the computer interface schematically represents the production process, in which the machine cooperates; - processing the monitoring information received from the machine controller and / or the instructions received from the operator, based on a logical representation model of the aforesaid production process, said model being common to all said on-board control electronic devices ED, for determining real-time decisions concerning the machine operation; - controlling the machine operation in real-time, by providing instructions to the machine controller, based on said decisions determined in real-time, to dynamically and automatically manage the machine operation and evolution of the production process to which the machine contributes. An on-board control device ED and a control electronic system are further described, capable of performing the above-mentioned control method.

Description

[0001] “A method and system for controlling and managing machines of a production plant by means of on-board control devices”

[0002] DESCRIPTION

[0003] TECHNOLOGICAL BACKGROUND OF THE INVENTION

[0004] Field of application.

[0005] The present invention generally relates to the technical field of controlling and managing machines of a production plant by means of electronic / computerized means.

[0006] In particular, the invention relates to a method and system for controlling machines of a production plant by means of on-board control devices.

[0007] Description of the prior art.

[0008] In the aforesaid technical field, software is known for controlling and managing industrial machines.

[0009] More generally, software packages are widely known and commonly used for controlling and managing the single entities composing a factory, from the simplest level (e.g., sensors) to gradually more and more complex levels (devices, stations, machines, plants).

[0010] In view of the complexity of a production plant, the related control and management systems and methods are also complex, and they are structured into a plurality of elements, at different levels (e.g., programmable logic controllers at device or machine or “group of machines” levels), and with their own special features.

[0011] The interoperability of such a plurality of control elements, which are heterogeneous in many aspects, poses problems of complexity, cost, slowness, scarce reliability, which represent a challenge for production plant designers.

[0012] In order to overcome, at least in part, such problems, the so-called “edge” control devices are known, installable and operating “on-board” a machine, with the function of “mediating” between machine controllers and higher-level control units.

[0013] However, such “edge” devices do not fully solve the above problems. For example, they must nonetheless be implemented in a manner dependent on the machine on which they are installed, in order to communicate appropriately with the particular type of machine controller used in the machine.

[0014] Moreover, the programing, configuration and use of such “edge” devices require particularly qualified operators.

[0015] In addition, each modification or reconfiguration of the production process requires a reprograming of the “edge” devices by expert programmers.

[0016] Furthermore, any instructions to change the behaviour / operation of a machine require the intervention of the operator and cannot be managed in real time by the “edge” control device.

[0017] Moreover, with reference to a control system comprising the edge device and the programmable machine logic controller, the evolution of production plants and the introduction of “Internet of Things - loT” technologies set complex objectives and increasingly more stringent needs, including:

[0018] - allowing a product to be traced through all the steps of production, assembly and control in which it travels within the company adopting the system;

[0019] - allowing the production, assembly and control processes to be traced for each single order / batch / product for all the steps present within the company adopting the system;

[0020] - allowing real-time control of the correctness of the processing in terms of compliance with specific setpoint parameters, processing order, acceptability of the components of the bill of materials, thus integrating the concepts and management of recipes, bills of materials, rules and thresholds, technological processes.

[0021] Such objectives should be achieved simultaneously respecting the following requirements:

[0022] - a unique and modular management and control system to accommodate all the traceability functionalities in a single product;

[0023] - scalable system;

[0024] - flexible system;

[0025] - system with simple architecture, easy to install, easy to consult and easy to configure.

[0026] The above requirements are not fully met by the prior art known to date.

[0027] SUMMARY OF THE INVENTION

[0028] It is the object of the present invention to provide a method for controlling and / or managing the operation of machines of a production plant, which allows solving, at least in part, the drawbacks described above with reference to the prior art and responding to the aforesaid needs particularly felt in the considered technical field. Such an object is achieved by a method according to claim 1 .

[0029] Further embodiments of such a method are defined in claims 2-11.

[0030] It is also the object of the present invention to provide an electronic device for controlling and / or managing the operation of machines of a production plant. Such an object is achieved by a device according to claim 12.

[0031] It is also the object of the present invention to provide an electronic system for controlling and / or managing the operation of machines of a production plant, adapted to implement the above control and management method. Such a system is defined in claim 13. Further embodiments of such a system are defined in claims 14-16.

[0032] It is also the object of the present invention to provide an industrial production plant comprising the above-mentioned control and management system. Such an object is achieved by a plant according to claim 17.

[0033] It is also the object of the present invention to provide a computer program adapted to carry out said method for controlling and / or managing the operation of machines of a production plant. Such a computer program is defined in claim 18.

[0034] BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Further features and advantages of the method and system according to the invention will be apparent from the following description illustrating preferred embodiments, given by way of non-limiting indication, with reference to the accompanying drawings, in which:

[0036] - Figure 1A shows, in a diagrammatic and simplified form, a machine of an industrial plant to which an embodiment of the method is applied and comprising an onboard control electronic device according to an embodiment of the invention;

[0037] - Figure 1 B represents, in a diagrammatic and simplified form, an industrial plant controllable by means of an on-board control and / or management method according to an embodiment of the invention;

[0038] - Figure 2 illustrates a diagram of division of functionalities in architectural modules, adopted in an embodiment of the invention;

[0039] - Figures 3 and 4 illustrate further details of architecture and software modules, used in respective embodiments of the invention;

[0040] - Figure 5 illustrates an example of logical representation of a technological cycle, adopted in a representation model of the production process according to the present invention;

[0041] - Figure 6 illustrates an example of a configuration diagram, adopted in a representation model of the production process according to the present invention;

[0042] - Figure 7 illustrates a detail (“connector”) of a control and management graphical interface provided in an embodiment of the method according to the invention;

[0043] - Figure 8 illustrates an example of a communication scheme between on-board control electronic device and machine controller, also representative of a general model of machine controller data structure, adopted in an embodiment of the method according to the invention.

[0044] DETAILED DESCRIPTION.

[0045] A method is described for controlling and / or managing, by means of on-board control electronic devices, the operation of machines of a production plant 1. The above- mentioned machines (indicated as M in Figure 1A and as M1 , M2, Mn in Figure 1 B) are provided with respective machine controllers (indicated as PLC in Figure 1 A and as PLC1 , PLC2, PLCn in Figure 1 B) and cooperate for the manufacturing of a product or object according to a production process.

[0046] The method comprises providing respective on-board control electronic devices (indicated as ED in Figure 1A and as ED1 , ED2, EDn in Figure 1 B) to a plurality of machines from the aforesaid plant machines M, M1 , M2, Mn.

[0047] Each of the on-board control electronic devices ED, ED1 , ED2, EDn contains, stored, and is adapted to execute one or more software programs or modules configured to carry out the following additional method steps:

[0048] - communicating and interoperating with the machine controller PLC, PLC1 , PLC2, PLCn) of the respective machine, based on a common general model of machine controller data structure, adapted to interoperate with different types of machine controllers, to provide machine operating instructions to the machine controller PLC, PLC1 , PLC2, PLCn and to receive machine operation monitoring information from the machine controller PLC, PLC1 , PLC2, PLCn;

[0049] - communicating with an operator (or a user), through a computer interface, to provide machine monitoring information and receive from the operator operating instructions for the machine operation and / or machine configuration or re-configuration instructions; such a computer interface diagrammatically represents the production process, in which the machine cooperates;

[0050] - processing the monitoring information received from the machine controller and / or the instructions received from the operator, based on a logical representation model of said production process, said logical representation model being common to all on-board electronic control devices ED, ED1 , ED2, EDn, for determining real-time decisions concerning the machine operation;

[0051] - controlling the machine operation in real-time, by providing instructions to the machine controller, based on the aforesaid decisions determined in real-time, to dynamically and automatically manage machine operation and evolution of the production process to which the machine contributes.

[0052] It should be noted that a production plant (or factory, or production line), to which the method applies, comprises, for example a plurality of work-stations each comprising one or more machines M, M1 , M2, Mn, adapted to carry out one or more processing steps on one or more pieces to be processed, until obtaining the finished object or product, according to a production process.

[0053] The aforesaid work-stations and machines are mutually connected and interoperating according to a physical partition of the plant.

[0054] The production plant is governed by a plurality of different-level control and / or monitoring units mutually connected and interoperating according to a plant control physical architecture. In the method according to the present invention, such monitoring and control units crucially comprise the above-mentioned on-board control electronic devices (or “edge device” ED, ED1 , ED2, EDn) and, at a lower level, the above-mentioned machine controllers (e.g., programmable logic control units, PLC, PLC1 , PLC2, PLCn).

[0055] In the present description, the definition of “machine” is broadly understood to indicate any entity composing the production plant, in particular any electronic or mechanical device, anyway implemented and at any level of complexity, comprised in the production plant, for example, any type of “actuator”, i.e., device adapted to perform actions during the production process, and any type of “sensor”, i.e., device adapted to monitor and / or detect and / or measure one or more physical quantities.

[0056] The entities referred to as “controller” or “control and / or monitoring unit” or “control device” can be made, according to possible implementation options of the present invention, by means of electronic processors (e.g., micro-processors, processors or computers), operating in the production plant, adapted to control and / or govern and / or monitor one or more machines of the plant, by means of software programs or firmware, and configured to mutually communicate by means of data communication means and techniques known perse.

[0057] In the present description, by mentioning “software modules” reference will be made to “logical” software modules. According to different possible implementation options, each or each group of these “logical software modules” is implemented by any partition in one or more software programs, according to software development methods known perse.

[0058] According to an embodiment, the method comprises the additional step of allowing communication between the on-board control electronic devices ED, ED1 , ED2, EDn and / or between each of the on-board control electronic devices ED, ED1 , ED2, EDn and other higher-level plant control units.

[0059] According to an embodiment of the method, the above-mentioned step of providing respective on-board control electronic devices ED, ED1 , ED2, EDn to a plurality of plant machines comprises providing respective on-board control electronic devices ED, ED1 , ED2, EDn to all the machines composing the production plant or a production line of the production plant. According to an embodiment of the method, the above-mentioned general model of machine controller data structure allows each on-board control electronic device ED, ED1 , ED2, EDn to interoperate with every type of machine controller installed on the plant machines.

[0060] According to different possible implementations of the method, the above-mentioned machine operating instructions and machine operation monitoring information are related to machine quantities and / or variables and / or operation parameters and / or quantities or parameters associated with the piece to be processed.

[0061] According to an embodiment of the method, the aforesaid instructions provided by the operator comprise machine configuration or re-configuration instructions; in this case, said step of controlling the machine operation comprises providing instructions to modify the machine operation according to the above-mentioned machine configuration or reconfiguration instructions, without modifying the machine controller software.

[0062] According to an embodiment of the method, the aforesaid instructions provided by the operator comprise process re-configuration instructions; in this case, the above- mentioned step of controlling the machine operation comprises providing instructions to modify the machine operation according to the aforesaid process re-configuration instructions, without modifying the machine controller software.

[0063] According to an embodiment of the method, the above-mentioned step of controlling the machine operation comprises modifying machine operation in real-time, i.e., at the time when a piece to be processed enters or passes, before exiting, in the machine or in a work-station comprising the machine.

[0064] In this case, the modification of the machine operation is automatically and dynamically carried out by the on-board control electronic device ED, ED1 , ED2, EDn based on the real-time monitoring information of the machine operation provided by the machine controller, so that the piece processing is carried out based on the detection during the processing itself and without intervention by the operator.

[0065] According to an embodiment, the method comprises the further step of recording, by means of the on-board control electronic devices ED, ED1 , ED2, EDn, processing and production data comprising values describing, for every piece, processing progress and / or times of entrance and exit from every processing step for every piece.

[0066] In this case, the real-time monitoring information of machine operation comprises the above-mentioned processing and production data.

[0067] According to an implementation option of the method, the processing and response times of each of the on-board control electronic devices are in the order of tens of milliseconds, and / or are comprised in a range between 50 and 100 ms, so that such processing and response times can be considered in real-time with respect to the process and production times.

[0068] According to an embodiment, the method further provides configuring each of the on-board control electronic devices ED, ED1 , ED2, EDn, before the installation thereof in a respective machine. Such a configuring step comprises:

[0069] - storing the aforesaid software programs or modules in the on-board control electronic device ED;

[0070] - providing a general model of machine controller data structure, capable of allowing communication and interoperability with different types of machine controllers, and storing such a general model of machine controller data structure as provided;

[0071] - providing a re-configurable model of a logical representation or logical mapping of the production process implemented in the plant, and storing such a re-configurable model of a logical representation of the production process as provided.

[0072] The above-mentioned general model of machine controller data structure is common to all on-board electronic control devices intended to be installed in the production plant.

[0073] The above-mentioned re-configurable model of a logical representation of the production process is common to all on-board electronic control devices intended to be installed in the production plant.

[0074] An electronic device is described below for controlling and / or managing the operation of machines M, M1 , M2, Mn of a production plant 1 , provided with respective machine controllers PLC, PLC1 , PLC2, PLCn and adapted to cooperate for the manufacturing of a product or object, according to a production process.

[0075] The electronic device is an on-board control electronic device (also referred to as “edge device” - ED, ED1 , ED2, EDn), installable in a respective machine, and comprises one or more processors or calculators or electronic computers configured to store and execute one or more software programs or modules configured to carry out the following actions:

[0076] - communicating and interoperating with the machine controller PLC, PLC1 , PLC2, PLCn) of the respective machine, based on a common general model of machine controller data structure, adapted to interoperate with different types of machine controllers, to provide machine operating instructions to the machine controller PLC, PLC1 , PLC2, PLCn and to receive machine operation monitoring information from the machine controller PLC, PLC1 , PLC2, PLCn;

[0077] - communicating with an operator, through a computer interface, to provide machine monitoring information and receive from the operator operating instructions for the machine operation and / or machine configuration or re-configuration instructions; the computer interface diagrammatically represents the production process, in which the machine cooperates;

[0078] - processing the monitoring information received from the machine controller and / or the instructions received from the operator, based on a logical representation model of the production process common to all on-board electronic control devices ED, ED1 , ED2, EDn, for determining real-time decisions concerning machine operation;

[0079] - controlling the machine operation in real-time, by providing instructions to the machine controller, based on the determined real-time decisions, to dynamically and automatically manage the machine operation and evolution of the production process to which the machine contributes.

[0080] An electronic system is described below for controlling and / or managing the operation of machines M, M1 , M2, Mn of a production plant 1 , adapted to cooperate in the manufacturing of a product or object, according to a production process.

[0081] Such a system comprises a plurality of on-board control electronic devices ED, ED1 , ED2, EDn, according to the above description, where each of such electronic devices is installed and / or associated with a respective one of the above-mentioned machines; the system further comprises a plurality of machine controllers PLC, PLC1 , PLC2, PLCn, each installed and / or associated with a respective machine, and each in communication and interoperating with a respective on-board control electronic device ED, ED1 , ED2, EDn.

[0082] According to an embodiment of the system, the above-mentioned machine controllers comprise or consist of programmable logic control units PLC, PLC1 , PLC2, PLCn.

[0083] According to an embodiment, the system further comprises plant control units 3 and telecommunication means 2 configured to connect the on-board control electronic devices ED1 , ED2, EDn to one another and to the plant control units 3.

[0084] According to different possible implementation options, the system is configured to perform a control method according to any one of the embodiments of the method described above.

[0085] An industrial production plant 1 is described below for the production of a product or object, where a piece to be processed is processed through a plurality of work-stations according to a production process aimed at obtaining said product or object.

[0086] Such a plant, according to the invention, comprises a plurality of machines M1 , M2, Mn, operating in the work-stations, each adapted to carry out one or more steps of processing on the pieces entering it; the plant further comprises an electronic system for controlling and / or managing the operation of machines of a production plant, according to any one of the previously described embodiments of the system according to the invention.

[0087] The invention further includes a computer program, comprising at least one program instruction, which, when executed by a computer, causes the computer to execute a method for controlling and / or managing, by means of the on-board control electronic devices ED, ED1 , ED2, EDn, the operation of machines of a production plant, according to any of the embodiments of the method described above.

[0088] By way of non-limiting example, detailed examples of application of the control method and a control system according to the invention are described below with reference to figures 1-8.

[0089] In one of such examples, the control and traceability system has the following functional features.

[0090] (1) Connection to industrial instruments and machines by means of different configurable and extensible field protocols.

[0091] (2) Configurable reading and writing of data by industrial instruments and machines.

[0092] (3) “Edge”-type storage, on the on-board control electronic device (hereinafter also referred to as “Edge device”) of all the data needed within a first period (e.g., 6 months) and remote storage, on various “Local” or “Web” levels, until a second period (e.g., 10 years).

[0093] (4) Storage of recipes, machine setups, technological cycles and thresholds sharable with the machines, based on the current production on the machines.

[0094] (5) Interfacing with company computer systems (e.g., ERP / MES / other) for the exchange of acquisition and production data, recipes, setups, technological cycles and thresholds.

[0095] (6) Displaying of on-board machine modules (by means of the above-mentioned computerized interface) for accepting input from operators.

[0096] (7) Real-time processing of the data read at point (2) to evaluate logics and thresholds and return information to the machines referred to in point (1).

[0097] (8) Configurable displaying of the data stored at point (3) and possibility of carrying out analyses thereon and consulting the results of such analyses.

[0098] (9) Displaying the data stored at point (4) and possibility of configuring and entering new data.

[0099] (10) Device management functionality towards low-level devices interfacing with the machines. (11) Acquisition and displacement of the data between the different acquisition levels in point (3).

[0100] (12) Configurable displaying of the data of point (3) with a view to quality control with the possibility of carrying out analyses and seeing the results of such analyses.

[0101] At an architectural level, the control system can be split and described in terms of three levels:

[0102] - “Edge” level, near the machine and with high-performance requisites in terms of speed;

[0103] - “Local” level, intermediate level and operator access point;

[0104] - “Web” level, with high storage capacity.

[0105] Figure 2 represents the distribution of the functionalities in the different modules, according to the implementation example described herein.

[0106] The individual functionalities of the above list are now analyzed in greater detail.

[0107] (1) Connection to industrial instruments and machines by means of different configurable and extensible field protocols.

[0108] The system natively supports the most important industrial field protocols (e.g., Simatic S7, OPC-LIA and Modbus-TCP).

[0109] (2) Configurable reading and writing of data by industrial instruments and machines.

[0110] The process of reading the field data by the machines and the writing of possible results of the processing thereof is based on a data exchange system which does not impact the performance of the plant to which the control system is connected.

[0111] The target time for the complete reading and writing cycle, according to an implementation option, is 50 milliseconds.

[0112] (3) Local storage of all necessary data on various Edge or Web levels.

[0113] The control and management system ensures the storage / saving of all the relevant data generated by the machines and by the system itself (by means of operator input or rule processing) following different mechanisms.

[0114] For the data linked to the current productions (hereinafter defined as “active data”), required by the Edge device to make decisions and share them with the machines, a very high access speed is ensured, as well as the guarantee of continuous availability, because a lack thereof causes a stop in production. For the most recent data, for which it is consequently necessary to have an elevated availability and consultation speed, a local storage is guaranteed to ensure high consultation performance. A safe storage for the historical data and a great storage capacity which can shift in time are provided.

[0115] (4) Storage of recipes, machine setups, technological cycles and thresholds sharable with the machines, based on the current production.

[0116] The control and management system stores a series of technological and management information on the process under monitoring in order to correctly interpret the data from the field, provide analyses, representations, process logics and send feedback to the production system.

[0117] This data comprises detailed data on Stations, Products, technological Cycles, Recipes and setups, processing steps, Operators and authorizations, Rules and Thresholds.

[0118] (5) Interfacing with company computer systems for the exchange of acquisition and production data, recipes, setups, technological cycles and thresholds.

[0119] The control and management system exchanges data by means of a mechanism, which is open and integrable, with third-party company computer systems, such as ERP / MES systems, for example. The exchanged data must be both linked to the traceability of the process / product and to the configuration of new information.

[0120] (6) Display of on-board machine modules to accept operator input.

[0121] The control and management system allows displaying screens adapted to insert input by the operator. Such inputs are aimed at entering field data not deriving from sensor-fitted instruments or machines. Examples of this input include processing parameters, manual operating times, quality control results, and so on.

[0122] (7) Real-time processing of the data to evaluate logics and thresholds and return information to the machines.

[0123] The control and management system locally processes the data entering the system in real time to generate feedback for machines and / or operators based on the knowledge codified in the data structure referred to above in point (4).

[0124] Such analyses are based on three types of data: the data read from the field, the data stored in the database and linked to the current production and the information mentioned in the previous paragraph. Such analyses are made within the aforesaid cycle time.

[0125] (8) Configurable displaying of the stored data and possibility of carrying out analyses thereon and seeing the results of such analyses.

[0126] The control and management system ensures the possibility to consult the product and process traceability data, by means of an intuitive and reactive User Experience, both locally (factory network) and remotely (web). Such information is obtained by merging the data in the databases of all three of the above architectural levels.

[0127] (9) Displaying the data stored at point (4) and possibility of configuring and entering new data.

[0128] By means of protected access and local network, the control and management system provides the possibility of modifying and adding the data described in point (4). This functionality is protected by an authentication system and, optionally, the changes made, the identity of the person making the change and the casualization of the change are stored, since they are critical process data.

[0129] (10) Device management functionality towards low-level devices interfacing with the machines.

[0130] The control and management system monitors operation of the Edge devices by the factory network in real time and displays logs and errors to allow problems to be diagnosed.

[0131] (11) Acquisition and displacement of the data between the different acquisition levels mentioned in point (3).

[0132] The control and management system manages, by means of operations planned and / or initialized by the Edge device, the displacement of the data between the three aforesaid different storage levels, to ensure the permanence and availability of the data.

[0133] Moreover, the control and management system manages backup logics.

[0134] (12) Configurable displaying of the data with a view to quality control with the possibility of carrying out analyses and seeing the results of such analyses.

[0135] The control and management system ensures the possibility of carrying out and displaying quality control analyses, by means of an intuitive and reactive User Experience, which can be consulted both locally (factory network) and remotely (Web). Such information is obtained by merging the data in the databases of all three of the above architectural levels.

[0136] Further details about the general architecture of the control and management system are described below.

[0137] Edge Level: level close to the machine, consisting of an industrial mini-PC, for example, with a Linux Operating system on which a MySQL database is installed and the Edge software application.

[0138] Local Level: intermediate level represented by one or more Personal Computers, e.g., with Windows Operating System residing in LAN or VLAN, which allow communication with the Edge level. According to an implementation option, configuration, analytics (“Client App”) and database synchronization (“SyncDB”) applications are installed in these stations.

[0139] Web Level: level with high storage capacity, which allows exploiting the advantages of the web systems. According to possible implementation options, the Web level corresponds to an “On-premise” server (connected to a LAN / VLAN, which allows it to communicate with the Edge level) or “On-Cloud” server (the Edge level is connected to Internet so as to reach the server).

[0140] According to an implementation option, analytics (“Client App”) and database synchronization (“SyncDB”) applications are installed on the web level.

[0141] With reference to the “Edge level” detailed examples of the Edge level software, stored and executable by the above-mentioned on-board electronic control device, are described below

[0142] The Edge level software prioritizes performance. The objective is the exchange of process data (e.g., recipes) with field systems and the storage of data related to current operations.

[0143] The Edge level software is the module responsible for the data flow in the system, which acquires, interprets and saves the data from the different sources possible for the system (field protocols, operator input, company IT systems).

[0144] Therefore, the main functionalities of the Edge level software are:

[0145] - connection to industrial instruments and machines by means of configurable and extensible field protocols by means of third-party driver integration;

[0146] - configurable reading and writing of data by the machines with high performance;

[0147] - management of multiple data sources;

[0148] - high reading and writing performance;

[0149] - storage of traceability data, high-frequency data for graphics and images;

[0150] - real-time processing of data with rules engine;

[0151] - data exchange with other Edge modules to acquire data of other steps of the technological cycle;

[0152] - collection of images from machine level sources and storage in the internal memory of the Edge device.

[0153] According to an implementation option, the Edge level software contains a socket server TCP which deals with managing all the communications with the local level and interfacing with the Edge database (MySQL) and the configuration files. In this case the functionalities are:

[0154] - data exchange by means of specific protocol at Local and Web levels: this data is of a different nature and serves different modules: historical traceability data (passive) for storage at higher levels, or real-time traceability data (active) for the Client App, or configuration data for the Configurator; - reading and management of data from the Integration Module.

[0155] According to an implementation option, the Edge level software provides an interface for third-party systems requiring a specific communication protocol (API http, edge tables). In this case the functionalities are:

[0156] - receiving third-party information through the necessary specific protocol;

[0157] - formatting information in the specific communication protocol of the Socket Server;

[0158] - publication of information by means of the Socket TCP to the Socket server.

[0159] According to an implementation option, the Edge level software comprises an “identifier module” which serves to make the Edge device identifiable on the network, to allow the Configurator and Client Apps to access it. The functionalities of such a module are: listening for device search messages, response to the requester with specific information on the identity thereof to allow the connection and identification.

[0160] Details are now provided about a “local level” software provided in an embodiment.

[0161] Local level software manage all user interfaces, both for display and for configuration.

[0162] While maintaining a high level of performance, local level software programs take care of centralizing and merging the information to make the Edge system transparent for the user, storing the data for intermediate intervals of time, configuring and managing the Edge level.

[0163] According to an implementation option, the Local level modules are “Configurator”, “Client App”, “Operator Input”, “Centralized Database”.

[0164] The “Configurator” software module deals with managing the configurations of the Edge devices and monitoring the operation thereof. The main functionalities thereof are:

[0165] - automatic detection of Edge devices on the network;

[0166] - authentication and management of safety on the device;

[0167] - reading of configurations on the device;

[0168] - writing of new configurations on the device;

[0169] - modification of configurations on the device;

[0170] - device diagnostic consultation;

[0171] - log activities in Edge for a record of the changes.

[0172] The “Client App” software module allows the user to display the data stored and the data analyses. The main functionalities of the “Client App” module are:

[0173] - consultation RT and historical data and making queries with filtering, orderings, and so on;

[0174] - making the distribution of data on different modules transparent to the user;

[0175] - generation of analyses and reports on process quality;

[0176] - generation of product or process reports;

[0177] - displaying of images associated with production;

[0178] - displaying graphics associated with processing.

[0179] The software module “Operator Input” is a light and configurable module which allows opening an input interface on any device for communicating data to the Edge module and interacting with the traceability process. The main functionalities thereof are:

[0180] - app aimed at providing the operator with an interface for records: manual stations, stations requiring operator feedback;

[0181] - managing the automatic generation of codes for sorting stations;

[0182] - managing advancement of the process and the processing steps;

[0183] - it can be installed on any on-board machine device (PC, Tablet, touch panel, etc..).

[0184] The “local Database” contains all non-active data from the Edge devices connected on a local level. This database keeps a copy of the data for an intermediate time period, and is installed on all the local devices requiring the use of the Client App.

[0185] Details are now given for a “Web level” software provided in an embodiment.

[0186] The Web level software modules manage long-term storage of the data, they also provide access to the Local level analyses, but based on long-term historical data, and they allow further analysis relating to quality control. Finally, the Web level software modules ensure delocalized accessibility to the system.

[0187] According to possible implementation options, the Web modules are installed on “on-premise” or “on-cloud” servers.

[0188] According to an embodiment, the Web level software modules are “Web App”, “Web data transfer”, “Web Database”.

[0189] The “Web App” software module comprises all the functionalities of the local Client App module (mentioned above) with the addition of specific functionalities only possible with the historical data present in the Web database. The main functionalities thereof are:

[0190] - consultation RT and historical data and making queries with filtering, orderings, etc.;

[0191] - making the distribution of data on different modules and different plants / factories transparent to the user; - generation of product or process reports;

[0192] - displaying of images associated with production;

[0193] - displaying graphics associated with processing;

[0194] - management of users and authorizations;

[0195] - generation of analyses and reports on the quality of the process with statistics and indicators useful for assessing the process in the long term.

[0196] The “Web data Transfer” software module is symmetrical with the same local function and serves the purpose of periodically receiving, from the Edge level, the important data from the Edge database, transferring it into the web database.

[0197] The “Web Database” software module deals with storing the historical data (e.g., up to 10 years) on the web database, with a high level of availability and increased safety with respect to local storage. Moreover, it centralizes information from different local networks, allowing the same type of aggregation that the local level can establish by aggregating the Edge modules.

[0198] With reference to the “Edge Software Module”, note that, according to an embodiment, it is made as a quick, robust structure, open to external integrations and such as to ensure that the addition of external components does not compromise the “core” module.

[0199] Figure 4 represents an implementation option of the internal structure of the Edge software module. In such an embodiment, the main components are:

[0200] - “Native Drivers”, with two main field protocols implemented as natives in the module;

[0201] - “Other Drivers Hub”: by means of Socket TCP and a specific and documented integration language is given to third-party software access to the sending of data to the Edge module for supporting non-native protocols;

[0202] - “Event Manager”: component of the Edge module responsible for identifying the events (on the native drivers and on the Socket TCP) and orchestrating the core in the management thereof;

[0203] - “Edge Core”: the heart of the Edge module, based on the events managed by the event manager it manages the internal logics of the module;

[0204] - Socket server: provides an additional Socket TCP communication towards the top with the Edge Socket Server level module;

[0205] - Configuration & Db: the Edge module rests against configuration files, generated and exchanged with the Configurator to manage all the information on the configuration and a Database for saving the active data and being able to access it quickly. According to an implementation option, the above-mentioned software is developed as compiled stand-alone software, written in C++, executable on Linux machines.

[0206] The “Socket server” software module aims to allow the Edge level all the communications towards the local network to which the Edge level is connected. The functionalities of such a module are:

[0207] - it acts as a Socket server towards the top to ensure management of the messages entering the Edge;

[0208] - it acts as a Socket Client in communications towards the Edge Core module;

[0209] - it receives the authentication requests from the Configurator and validates them on the Edge device user list;

[0210] - it receives the authentication requests from the Client API and validates them on the Edge device user list;

[0211] - it reads the configuration files and returns them at the request of the Configurator;

[0212] - it receives the new configurations and updates them in the Edge device;

[0213] - it receives the requests for Real Time data from Client App and manages the flow of exiting active data;

[0214] - it initializes and manages the sending of the passive data from the device to the upper-level databases.

[0215] The identification software module is a module written in the same language as the Edge module and managed as a separate service.

[0216] It listens on a specific port for UDP broadcasts with a specific code and directly responds to the applicant with a message containing all the data deemed necessary for identification and connection to the Socket server of the Edge device.

[0217] The “Edge Database” software module, referring to a database for active data, provides the use of a Relational database.

[0218] An implementation option provides the use of a mySQL database, to ensure the management of the converging requests at the expense of increased installation difficulty and increased consumption of resources.

[0219] The “Configurator” software module, according to an implementation option, is a stand-alone software written in C++, executable on Windows, and transferable to other Operating Systems.

[0220] Access to the app takes place by user authentication. Users are defined and saved on a local Database level. Access and communication with the Edge level takes place by Socket TCP. The Edge module which manages communication is the Socket Server module, which also manages user authentication in the Edge module.

[0221] The “Client App” software module, according to an implementation option, is a stand-alone software developed using native web technologies (e.g., React) and encapsulated in Electron. It is executable on Windows, and can be carried to other Operating Systems. Access to the app takes place by user authentication.

[0222] The “Operator Interface” software module, according to an implementation option, is a stand-alone software developed using native web technologies (e.g., React) and encapsulated in Electron. It is executable on Windows, and can be carried to other Operating Systems.

[0223] The “Data acquisition on Web” software module, according to an implementation option, is a “back-end” developed in Python and executable on V.M. Linux.

[0224] The “Web App” software module is an App developed in React and executable on V.M. Linux.

[0225] According to an embodiment, the system provides an installation flexibility for different scenarios which allow a plurality of Hardware configurations.

[0226] According to three implementation options, the installation scenarios are “Only Edge Installation”, or “Edge and Local Installation” or “Web, local and Edge Installation”.

[0227] In the scenario of “Only Edge Installation” the presence of only the Edge device is provided, with the addition of peripheral devices (screen, mouse and keyboard) for allowing the Client app to be installed on the “Edge” device together with the native Edge modules.

[0228] In the “Edge and Local Installation” scenario, the Edge device and one or more local devices external to the Edge are present. In this scenario, the Client app and the Configurator reside in the local level and, in the Edge, only the own modules of the level are present.

[0229] In the scenario of “Local, Web and Edge Installation”, besides the configuration of the previous scenario, the web level is added with a specific database for increased permanence and data and with the possibility of enabling the functionalities typical of a web app in terms of easy access and easy distribution and updating.

[0230] According to an embodiment, the control and management system also comprises, in addition to the aforesaid “configurator” and Edge” software models, a “Client App” analysis software module.

[0231] The configurator is the application which allows management of the projects, definition of all logics and rules for production, of the recipe product list and, in general, of every possible operation option of the platform.

[0232] The Edge module is the platform portion which deals with communication with the “on field” data sources. It receives the configuration from the configurator and communicates with the machine controller to acquire data to be stored, sending production recipes, providing routing rules and coordinating the production process based on the rules specified in the project.

[0233] The “Client App” software module is responsible for displaying the data and the processing thereof. It requests the necessary data from the databases, groups and filters the data to offer the user a clear and precise representation of the production process, of the products and of the plant, both from a historical point of view and in real time.

[0234] For the traceability functions of the control and management system, the pieces produced or under production are separated into two macro-categories which are also reflected in the “Client App”: the pieces which have completed the production cycle thereof and for which historical-type information is displayed and the pieces currently under production for which Real-Time information is displayed.

[0235] Two macro-sections are also present within the “Client App”: the first one allows analyzing the record of the pieces produced and the second one allows displaying the state of the pieces in the plant in real time.

[0236] After logging in to the “Client App” a dashboard page is displayed.

[0237] According to an implementation option, the dashboard page is divided into three sections.

[0238] In the upper part of the dashboard page, the filters which allow searching for according to specific criteria are displayed. The filters present are a “time filter” and “specific filters”, which allow looking for specific types of piece, article codes, batches, orders, in order to allow the identification of specific categories of pieces.

[0239] The central part of the dashboard page shows, based on the selected filters, the respective number of pieces, products, batches and orders corresponding to the search. Clicking on each of the four zones takes to the relevant analysis page.

[0240] Cards are displayed in the lower section of the dashboard page, which allow access to specific analyses, such as quality analyses, for example, on the piece, the result of the current search.

[0241] According to different implementation options, such specific analyses comprise the following analyses (each corresponding to one or more pages reachable from the dashboard page”). Piece analysis.

[0242] It shows a summary of all the pieces produced corresponding to the selected filters, e.g., by displaying in order of numerousness the article codes present in the search, the average processing time for each article code and the average lead time for each article code.

[0243] The processing time is understood to mean the amount of time spent by a piece in the processing steps that it has passed through, while the lead time is understood to be the time spent since the piece began the first processing step until the last step is complete. Thus, all the waiting times between one processing and the other are also included in the crossing time.

[0244] The list of all the pieces corresponding to the given filter is also shown in a table. Clicking on a line in the table takes to the analysis page specific for that piece.

[0245] Article Analysis

[0246] It shows a summary of all the product article codes corresponding to the selected filters, e.g., by displaying in order of numerousness the article codes present in the search, the average processing time for each article code and the average lead time for each article code.

[0247] The list of all article codes corresponding to the given filter is also shown in a table. Clicking on a line in the table takes to the piece analysis page relating to all the pieces contained in the article code for which the line was selected and also corresponding to the initial search filters.

[0248] Batch Analysis

[0249] It shows a summary of all the batches produced corresponding to the selected filters, e.g., by displaying in order of numerousness the article codes present in the search, the average processing time for each article code and the average lead time for each article code.

[0250] The list of all batches corresponding to the given filter is also shown in a table. Clicking on a line in the table takes to the piece analysis page relating to all the pieces contained in the batch for which the line was selected and also corresponding to the initial search filters.

[0251] Order Analysis

[0252] It shows a summary of all the orders produced corresponding to the selected filters, e.g., by displaying in order of numerousness the article codes present in the search, the average processing time for each article code and the average lead time for each article code. The list of all the orders corresponding to the given filter is also shown in a table. Clicking on a line in the table takes to the piece analysis page relating to all the pieces contained in the order for which the line was selected and also corresponding to the initial search filters.

[0253] It displays in detail all the data relating to the production of a single piece. The related page is divided into two sections.

[0254] At the top section, in the cards, the summary data of the processing of the piece is shown, and the master data thereof.

[0255] At the bottom section, a table shows all the processing steps, to which the piece has been subjected and relevant data is shown for each one so that they can be characterized.

[0256] Real-Time Analysis

[0257] This section allows viewing the current state of the plant to which the Edge device is connected.

[0258] The top section shows all the steps in the plant and for each of them, if present, the piece currently under production in the step with some important data relating thereto: piece code, article code, batch, order, time of entering the step and permanence time of the piece in the step.

[0259] In the bottom section, the list of pieces currently in the buffer is reported in the form of a table. A “piece in buffer” is understood to mean a piece which is in the production cycle thereof, and has thus completed at least the first step of the cycle thereof, but which has not been completed yet and is not currently in a processing step. Therefore, the buffer pieces include all those pieces currently in transit between one step and another, as well as all those pieces which, for some reason, have been removed from the normal production cycle to run checks or other operations.

[0260] Some important features are listed for each of the buffer pieces and moreover, the time of completing the last traced operation of the piece is the dwell time in the buffer.

[0261] All the Real Time page information is automatically updated once a second.

[0262] Details relating to the configuration of a plant, made possible by an embodiment of the method and system according to the invention, are reported below by way of nonlimiting example, as well as information relating to the logical representation reconfigurable model of the production process, used in an embodiment of the method according to the invention.

[0263] The configuration of the plant consists of different steps in relation to the different entities required to be configured.

[0264] The first step is the definition of the Edge modules present on the plant. Each Edge module can be connected to one or more data sources but to a single plant.

[0265] The second step is to configure all the data sources present and with which it is necessary to interact, and associate each of the sources to the corresponding Edge module. For each data source, besides personal information, information on the communication protocol and the general configurations of such a protocol are required.

[0266] For each data source all the variables of interest are configured, identifying them with a variable identifier Var_id and entering all the parameters needed to access the variable depending on the protocol of the data source in question, such as address, type of data, and so on.

[0267] Then, the Steps are defined for each plant. One step represents a specific operation carried out by the plant and logically separated from the others. All the variables relating to the specific processing that the plant is capable of implementing are incorporated in the Step.

[0268] The variables can be categorized into three categories: variables representing parameters to be communicated to the machine, variables representing results to be acquired for the machine, variables representing the signals needed for the communication between the machine and Edge (e.g., Flag, Ack, or other).

[0269] Each step also has an additional tag / parameter referred to as Station. The station allows identifying and grouping the steps according to the physical station on which they are carried out. A set of operations can be physically carried out on the machine (station) but can be modelled as a sequence of steps for tracing the single operations in greater detail.

[0270] The presence of the Station tags allows implementing different logics for steps in sequence on the same station.

[0271] The machine parameters represent a series of special parameters of the steps which are globally configured and inherited by all the technological cycle instances independently of the product codes or steps.

[0272] The recipe is a collection of process parameters which are specific for the step and characterize the processing. Therefore, the specific recipe, like the line, must carry out the various steps. The recipes are defined in association with the steps. One step can have several different recipes. The association of the recipe with the step takes place in the technological cycle instance. The list of the values of the specific parameters for the recipe is defined within the recipe. Details relating to the technological cycle and to the aggregation methods of the information are reported below by way of non-limiting example with reference to the logical representation reconfigurable model of the production process, used in an embodiment of the method according to the invention.

[0273] The technological cycle represents the graph with the relationships between the various steps in the production process. Therefore, it serves to specify the order between the steps and the possible branches in the production flow which can be followed in the process.

[0274] An example of a technological cycle is shown in Figure 5.

[0275] The technological cycle, in itself, does not contain the rules relating to the routing on the various branches depending on the instantiation. By combining the technological cycle and the recipes, all the elements for creating the technological cycle instance are available.

[0276] After defining the functional features of the production line, proceed with configuring the master data of the products.

[0277] Each product is understood as a possible production typology on the line combining the steps thereof and it is characterized by a technological cycle instance and, optionally, a bill of materials.

[0278] The bill of materials, ordered into bill lines, indicates the components needed to create the product code. The bill of materials can be used for checks on the correctness of the components during the step of tracing the production.

[0279] The technological cycle instance represents the heart of the information on a product code. Several product codes can share the same technological cycle instance, if they only differ in the bill of materials, or if they follow the same production process.

[0280] The technological cycle instance combines the information of the technological cycle with that of the recipes for defining the organization of the steps, and the recipe of each step. It also allows adding, to each single step, all the additional configurations for the processing of the specific product, such as rules on the reprocessing, on the buffers, routing logics based on the reject codes or other, for example.

[0281] On completion of the technological cycle instance there are two more information families: the Product Parameters and the reject reasons.

[0282] With reference to the Product Parameters, note that the recipes of the steps can be shared between multiple technological cycle instances, to ensure easy reconfigurability of the resulting technological cycle instances. If there are unique recipe parameters for a single product code which do not have to be shared with other technological cycle instances, they are defined within the product parameters.

[0283] Figure 6 illustrates an example of a general configuration diagram, adopted in a representation model of the production process according to the present invention.

[0284] The “Exit state code master data” allows associating a description with the exit State codes, which facilitates the comprehension thereof in the report step.

[0285] The “Connectors” are one aspect of the graphical interface for managing the production flows.

[0286] The concept of connector, with the respective graphical representation, is introduced to manage a jump in the flow and connect two sequences logically, but not graphically.

[0287] A connector is the equivalent of a JumpTo, which signals the start of a path based on a specific exit with a specific state.

[0288] Figure 7 shows the graphical representation of a connector: the left part represents the exit from step C with state 20, the right part represents the entrance which accepts the outputs from C with states comprised between 15 and 30 and the outputs from D with state 4 or 5.

[0289] On start-up of the production of a product (unique serial number) the type of product currently under production is identified to “baptize” the serial number and associate it with the corresponding article code (and with the technological flow).

[0290] This occurs, according to two implementation options, according to two different logics: commanded by the Edge or commanded by the machine.

[0291] In the case of a command from the machine (in situations where the machine directly manages production) the following data is written on specific variables:

[0292] - OrderCode: identifies the production order;

[0293] - BatchCode: identifies the production batch;

[0294] - ArticleCode: identifies the typology of product under production.

[0295] This data is acquired by the Edge and associated with all the new piece serial numbers entering the first processing step.

[0296] In the case of a command by the Edge, it is the latter that knows the production specifications and communicates them to the machine. In this case the Edge writes, on three variables different to those mentioned above, the data of the Order, Batch and Article to be produced and the machine limits itself to reporting the information received in the 3 above-mentioned variables for the re-reading and verification by the edge module.

[0297] The variables involved in this specification are 6 in total per plant, divided into blocks of 3: - [OrderCode, BatchCode, Article Code]: written by the Edge and read by the machine;

[0298] - [OrderCode, BatchCode, ArticleCode]: written by the machine and read by the Edge.

[0299] A few illustrative details of the configuration of the steps of the technological cycle instance is provided hereinafter.

[0300] At the time of instantiation of a technological cycle, each step belonging thereto can require further configurations depending on the specific product code and not residing in the configuration of the step or in the recipe. Such configurations comprise the routing rules on the various paths based on outcomes and results of the step.

[0301] The specifications of the communications between data Source (machine / PLC) and the Edge device are detailed hereinafter, according to an embodiment. Such information (as reported, for example, in Figure 8) is also representative of the general model of machine controller data structure, adopted in an embodiment of the method according to the invention.

[0302] Piece input.

[0303] The information linked to the exchange of data entering a step is: unique piece identifier “Piece Id (serial number)”; new piece command, i.e. , communication of new piece present in step.

[0304] If, from the assessment of the rules for entering the step for the piece by the Edge, it were impossible to process the piece in the specific step, the following data would be returned to the data source:

[0305] - Nack Code: code that identifies the reason for the non-processability (these codes are defined at a program level and cannot be modified, documented separately);

[0306] - log steps: in the master data step each step has a unique numeric identifier; “log steps” is a vector which is filled when the piece passes in the step; each element of the vector is filled with the step exit state.

[0307] - Nack: indicates the impossibility of the station to process the piece.

[0308] If, from the assessment of the rules for entering the step for the piece by the Edge, it were possible to process the piece in the specific step the following data would be returned to the data source:

[0309] - recipe parameters: all the parameters linked to the specific recipe for the article code of the piece written in the machine;

[0310] - product parameters: all the specific parameters of the step are written in the machine, but defined at a product level and not a recipe level; - Ack: notification to the machine that it can accept the piece and process it according to the recipe.

[0311] Acceptation logics for a product entering a step.

[0312] - piece present in the master data: if the number is new if the step is the first of the technological cycle, it is associated with Order, Batch and Article according to the previously described rules and scenarios;

[0313] - previous step completed: check that the order of the steps defined in the technological cycle is respected;

[0314] - re-entry checks;

[0315] - check pending;

[0316] - buffer downstream.

[0317] Based on the logics and state of a piece the Edge device determines whether it can or cannot be processed in the step.

[0318] The information connected to the exit of the piece from the step, according to an implementation option, is:

[0319] - exit state code: state of the exiting piece determined by the data source;

[0320] - exit request command: signals to the Edge that the instructions for causing the piece to exit are requested;

[0321] - exit number: identifies the code of the path for the exit of the piece (logical path in the technological flow);

[0322] - exiting action: identifies a code (from those available for the step and programmed in the machine) to specify the physical action to be carried out to cause the piece to exit correctly;

[0323] - Ack / Nack exit Choice: notifies the machine that the data requested has been written or that the operation has failed;

[0324] - exiting action (feedback) & exit Number (feedback): if these values have been provided by the Edge, following a machine request, they are copied here; if they have been decided autonomously by the machine they are entered for the first time;

[0325] - exit command: requests the Edge to verify the possibility of causing the piece to come out of the step by performing the exiting action;

[0326] - Ack / Nack Exit: signals the possibility / lmpossibility of causing the piece to come out of the step.

[0327] It is worth noting that the object of the present invention is fully achieved by the control method, by the control device and by the control system disclosed above by virtue of the functional features thereof. In fact, the aforesaid control and management method and system are capable of providing an integrated, efficient and flexible control of a production plant.

[0328] In particular, with reference to the operations of the method described above in the application example, and with reference to the previously shown different embodiments of the method, it is possible to identify the following advantages, amongst others.

[0329] The solution described above allows providing the machines with a “process intelligence”. It provides a software stored and run on an Edge device on board the machine which communicates with the machine controller in real time.

[0330] The technical solution described above allows configuring the logics governing the machines without writing lines of code. The production process is represented by a flow diagram which can have many variants.

[0331] In an embodiment, all the production data is recorded, and, for every piece, times of entrance and exit from every step are saved, values describing the processing progress. The recorded data is used to take decisions in real time concerning machine operation.

[0332] The technical solution described above is based on a standardized data structure model which allows interfacing any PLC machine controller model with the on-board control electronic device (“Edge Device”), and therefore, advantageously, it imposes no hardwaretype constraints with the machine.

[0333] The on-board control electronic device, provided in the invention, allows a dynamic update of the performance of the machine, and allows i.e. , “modifying” the machine operation without acting on the machine controller (e.g., PLC). Advantageously, such a feature allows causing the production process of a product to evolve, entering new instructions for the processing of the semi-finished product.

[0334] The technical solution, described above, uses a high-level definition and description of the production process. Thereby, it allows mapping the production processes through a simple and intuitive interface (e.g., block diagrams), ensuring objectification of the processes. The entire management of the process can therefore be assigned to figures who do not strictly need to possess technical skills.

[0335] The above technical solution authorizes “atomic” decisions in real time, i.e., decisions on the operation to be imposed on the machine are taken piece by piece in real time, i.e., both when the piece enters the station for processing and before it exits. The processing and response times ensured by the method and system according to the invention are very low (about 50-100ms).

[0336] The production process of the piece evolves according to the detection during the processing without the intervention of the operator. The objectives of the system have been identified as the following ones:

[0337] - allowing a product to be traced through all the steps of production, assembly and control in which it travels within the company adopting the system;

[0338] - allowing the production, assembly and control processes to be traced for each single order / batch / product for all the steps present within the company adopting the system;

[0339] - allowing real-time control of the correctness of the processing in terms of compliance with specific setpoint parameters, processing order, acceptability of the components of the bill of materials, thus integrating the concepts and management of recipes, bills of materials, rules and thresholds, technological processes.

[0340] Such objectives are achieved simultaneously respecting the following requirements (by virtue of the functional features of the control and management system described above):

[0341] - a unique and modular management and control system to accommodate all the traceability functionalities in a single product;

[0342] - scalable system;

[0343] - flexible system;

[0344] - system with simple architecture, easy to install, easy to consult and easy to configure.

[0345] Those skilled in the art may make changes and adaptations to the embodiments of the method, device and system described above or can replace elements with others which are functionally equivalent in order to meet contingent needs, without departing from the scope of the following claims. Each of the features described as belonging to a possible embodiment can be made irrespective of the other embodiments described.

Claims

CLAIMS1. A method for controlling and / or managing, by means of on-board control electronic devices, the operation of machines of a production plant, wherein said machines (M, M1 , M2, Mn) are provided with respective machine controllers (PLC, PLC1 , PLC2, PLCn) and cooperate for the manufacturing of a product or object according to a production process, wherein the method comprises:- providing respective on-board control electronic devices (ED, ED1 , ED2, EDn) to a plurality of said plant machines (M, M1 , M2, Mn), wherein each of the on-board control electronic devices (ED, ED1 , ED2, EDn) contains, stored, and is adapted to execute one or more software programs or modules configured to carry out the following additional method steps:- communicating and interoperating with the machine controller (PLC, PLC1 , PLC2, PLCn) of the respective machine, based on a common general model of machine controller data structure, adapted to interoperate with different types of machine controllers, to provide machine operating instructions to the machine controller (PLC, PLC1 , PLC2, PLCn) and to receive machine operation monitoring information from the machine controller (PLC, PLC1 , PLC2, PLCn);- communicating with an operator, through a computer interface, to provide machine monitoring information and receive, from the operator, operating instructions for the machine operation and / or machine configuration or re-configuration instructions, wherein said computer interface diagrammatically represents said production process, in which the machine cooperates;- processing the monitoring information received from the machine controller and / or the instructions received from the operator, based on a logical representation model of said production process, said logical representation model being common to all said on-board control electronic devices (ED, ED1 , ED2, EDn), for determining real-time decisions concerning the machine operation;- controlling the machine operation in real-time, by providing instructions to the machine controller, based on said determined real-time decisions, to dynamically and automatically manage machine operation and evolution of the production process to which the machine contributes.

2. A method according to claim 1 , comprising the additional step of allowing communication between the on-board control electronic devices (ED, ED1 , ED2, EDn) and / or between each of the on-board control electronic devices (ED, ED1 , ED2, EDn) andother higher-level plant control units (3).

3. A method according to any one of the preceding claims, wherein said step of providing respective on-board control electronic devices (ED, ED1 , ED2, EDn) to a plurality of plant machines comprises providing respective on-board control electronic devices (ED, ED1 , ED2, EDn) to all the machines composing the production plant or a production line of the production plant.

4. A method according to any one of the preceding claims, wherein said general model of machine controller data structure allows each on-board control electronic device (ED, ED1 , ED2, EDn) to interoperate with every type of machine controller installed on the plant machines.

5. A method according to any one of the preceding claims, wherein said machine operating instructions and machine operation monitoring information are related to machine quantities and / or variables and / or operation parameters and / or quantities or parameters associated with the piece to be processed.

6. A method according to any one of claims 1-5, wherein said instructions provided by the operator comprise machine configuration or re-configuration instructions, and wherein said step of controlling the machine operation comprises providing instructions to modify the machine operation according to said machine configuration or re-configuration instructions, without modifying the machine controller software.

7. A method according to any one of claims 1-5, wherein said instructions provided by the operator comprise process re-configuration instructions, and wherein said step of controlling the machine operation comprises providing instructions to modify machine operation according to said process re-configuration instructions, without modifying the machine controller software.

8. A method according to any one of the preceding claims, wherein said step of controlling the machine operation comprises modifying machine operation in real-time, i.e., at the time when a piece to be processed enters or passes, before exiting, in the machine or in a work-station comprising the machine, wherein the modification of machine operation is automatically and dynamically carried out by the on-board control electronic device (ED,ED1 , ED2, EDn) based on the real-time monitoring information of the machine operation provided by the machine controller, so that the piece processing is carried out based on what is detected during the processing itself and without intervention by the operator.

9. A method according to any one of the preceding claims, comprising the step of recording, by means of the on-board electronic control devices (ED, ED1 , ED2, EDn), processing and production data comprising values describing, for every piece, processing progress and / or times of entrance and exit from every processing step for every piece, and wherein said real-time monitoring information of machine operation comprises said processing and production data.

10. A method according to any one of the preceding claims, wherein the processing and response times of each on-board control electronic device are in the order of tens of milliseconds, and / or are encompassed in a range between 50 and 100 ms, so that such processing and response times can be considered in real-time with respect to process and production times.

11. A method according to any one of the preceding claims, further comprising configuring each of the on-board control electronic devices (ED, ED1 , ED2, EDn), before the installation thereof in a respective machine, wherein said configuration step comprises:- storing said software programs or modules in the on-board control electronic device (ED, ED1 , ED2, EDn);- providing a general model of machine controller data structure, capable of allowing communication and interoperability with different types of machine controllers, and storing said provided general model of machine controller data structure;- providing a re-configurable model of a logical representation or logical mapping of the production process implemented in the plant, and storing said provided reconfigurable model of a logical representation of the production process; wherein said general model of machine controller data structure and said reconfigurable model of a logical representation of the production process are common to all the on-board control electronic devices to be installed in the production plant.

12. An electronic device for controlling and / or managing the operation of machines of a production plant, wherein said machines (M, M1 , M2, Mn) are provided with respective machine controllers (PLC, PLC1 , PLC2, PLCn) and cooperate for the manufacturing of aproduct or object, according to a production process, wherein the electronic device is an on-board control electronic device or “edge device” (ED, ED1 , ED2, EDn), installable in a respective machine, and comprising one or more processors or calculators or electronic computers configured to store and execute one or more software programs or modules configured to carry out the following actions:- communicating and interoperating with the machine controller (PLC, PLC1 , PLC2, PLCn) of the respective machine, based on a common general model of machine controller data structure, adapted to interoperate with different types of machine controllers, to provide machine operating instructions to the machine controller (PLC, PLC1 , PLC2, PLCn) and to receive machine operation monitoring information from the machine controller (PLC, PLC1 , PLC2, PLCn);- communicating with an operator, through a computer interface, to provide machine monitoring information and receive, from the operator, operating instructions for the machine operation and / or machine configuration or re-configuration instructions, wherein said computer interface diagrammatically represents said production process, in which the machine cooperates;- processing the monitoring information received from the machine controller and / or the instructions received from the operator, based on a logical representation model of said production process, said logical representation model being common to all said on-board control electronic devices (ED, ED1 , ED2, EDn), for determining real-time decisions concerning the machine operation;- controlling the machine operation in real-time, by providing instructions to the machine controller, based on said determined real-time decisions, to dynamically and automatically manage machine operation and evolution of the production process to which the machine contributes.

13. An electronic system for controlling and / or managing the operation of machines (M, M1 , M2, Mn) of a production plant, adapted to cooperate in the manufacturing of a product or object, according to a production process, wherein the system comprises:- a plurality of on-board control electronic devices (ED, ED1 , ED2, EDn), according to claim 12, each of said control electronic devices being installed and / or associated with a respective one of said machines;- a plurality of machine controllers (PLC, PLC1 , PLC2, PLCn), each installed and / or associated with a respective machine, and each communicating and interoperating with a respective on-board control electronic device (ED, ED1 , ED2, EDn).

14. A system according to claim 13, wherein said machine controllers (PLC, PLC1 , PLC2, PLCn) comprise or are composed of programmable logic control units (PLC, PLC1 , PLC2, PLCn).

15. A system according to claim 13 or claim 14, further comprising plant control units (3) and telecommunication means (2) configured to connect the on-board control electronic devices (ED, ED1 , ED2, EDn) to one another and to the plant control units (3).

16. A system according to any one of claims 13-15, configured to execute a control method according to any one of claims 1-12.

17. An industrial production plant (1) for the production of a product or object, wherein a piece to be processed is processed through a plurality of work-stations according to a production process aimed at obtaining said product or object, comprising:- a plurality of machines (M1 , M2, Mn), operating in said plurality of workstations, each adapted to perform one or more processing steps on the pieces entering;- an electronic system for controlling and / or managing the operation of machines of a production plant, according to any one of claims 13-16.

18. A computer program comprising at least one program instruction, which, when executed by a computer, causes the computer to execute a method for controlling and / or managing, by means of the on-board control electronic devices (ED, ED1 , ED2, EDn), the operation of machines of a production plant, as claimed in any one of claims 1 to 11.

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