Method and system for converting production flow data into human-machine interface data
Patent Information
- Application Number
- JP2023577395
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2021-06-15
- Filing Date
- 2022-04-27
- Publication Date
- 2025-05-09
AI Technical Summary
Modern food processing lines are complex and unique, leading to difficulties in setting up SCADA systems and interpreting information for new operators, which can result in suboptimal control and increased time and cost.
A method and system for converting production flow data into human-machine interface data by identifying storage and processing objects, forming process sequences, and generating a structured HMI data representation in a rectangular array to facilitate intuitive operator understanding.
This approach reduces setup time and cost while ensuring consistent information display across different food processing lines, minimizing operator errors and enabling quick decision-making.
Smart Images
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Abstract
Description
[Technical field]
[0001] The present invention relates to a method and a system for controlling a food processing line, more particularly to a method for converting production flow data into human machine interface data and a system comprising a food processing line, an operator display and a control unit. [Background technology]
[0002] Modern food processing lines are often built so that they can be adapted in a variety of ways to produce different product characteristics or different types of products. Having a processing line configured to meet a wide variety of conditions and requirements comes at the cost of the food processing line being often complex. In addition to being complex, most processing lines are typically different from one another, in part because food processing lines have improved over time. This complexity, combined with the fact that many food processing lines are unique in their configuration, typically makes it a challenging task for operators to manage the operation of a food processing line, especially if they have little or no experience working with the particular food processing line they are responsible for.
[0003] To better understand food processing lines and monitor the progress of food processing, various SCADA (Supervisory Control And Data Acquisition) systems have been developed. Although these systems reduce the burden on the operators responsible for controlling the food processing line, it generally takes time to set up and implement a new system. Furthermore, even when the system is set up, it can be difficult for a new operator to understand how to interpret the information displayed via the operator display. SCADA systems can be set up in different ways and can communicate information to operators in various ways. This flexibility has the advantage of being able to customize the system, but the disadvantage is that it takes time for a new operator to understand the system.
[0004] Even though current SCADA systems provide operators with information about the food processing line, setting up such a system requires investment, both financially and in time. In addition to the time and expense required to set up the system, most systems can be set up according to the specific needs of the operator, which, although advantageous in many ways, can mean that new operators have difficulty understanding the information provided, resulting in the risk that the food processing line will be controlled in a suboptimal way. Summary of the Invention [Problem to be solved by the invention]
[0005] It is an object of the present invention to at least partially overcome one or more of the limitations of the prior art mentioned above. In particular, it is an object to provide a time-efficient procedure for setting up a control system of a food processing line. Another object is to ensure that information is consistently represented for different food processing lines, thereby reducing the risk of operator error. [Means for solving the problem]
[0006] According to a first aspect, there is provided a method for converting production flow (PF) data into human machine interface (HMI) data, the PF data may include storage objects representing storage units of a food processing line and processing objects representing processing units of the food processing line, the method comprising: receiving the PF data; identifying the storage objects and the processing objects in the PF data; for each processing object, identifying a source object for the processing object from among the storage objects and the processing objects; identifying a destination object for the processing object from among the storage objects and the processing objects; forming a number of process sequences based on the PF data, each process sequence comprising a process sequence specific and process sequence specific source objects and destination objects, identifying link objects present in two or more of the process sequences and generating an aggregated process sequence by linking the process sequences via the link objects, and generating HMI data based on the aggregated process sequences such that, once executed on an operator display, the HMI data generates a rectangular array of screen area elements arranged in a first direction (A), wherein the visually represented destination objects of the destination objects are positioned following the visually represented source objects of the source objects for each of the process sequences in the first direction (A) in the rectangular array.
[0007] By having such a structured approach, HMI data is generated in a time-efficient manner, reducing the time and cost involved in starting up a food processing line or upgrading a food processing line. Moreover, by having such a structured approach, even if a food processing line is very complex, it can be translated into a consistent and therefore intuitive user interface for operators and other personnel. One of the reasons that makes it possible to handle complex processing lines is that each process item is analyzed individually and then the results of these individual evaluations are aggregated.
[0008] A rectangular array of screen area elements may be arranged in a first direction A and a second direction B, and a visual representation of a processing object may be arranged following a visual representation of a storage object in the second direction B of the rectangular array.
[0009] The advantage of distinguishing between storage and processing objects on the operator display is that operators can more easily see how the different units of a food processing line are connected to each other.
[0010] The processing objects may comprise a first type processing object and a second type processing object, and the visually represented processing objects may comprise a visually represented first type processing object and a visually represented second type processing object linked to the first type processing object and the second type processing object, respectively, and the visually represented second type processing object may be arranged following the visually represented first type processing object in a second direction B in the rectangular array.
[0011] The advantage of separating the different types of workpieces in the second direction B is that it makes it easier for the operator to understand how the food processing line is designed and how the different food workpieces relate to each other.
[0012] The processing unit may be selected from the group consisting of a temperature processor, a homogenizer, a separator, a filter device, a mixer, a cheese tank, an ice cream freezer, an ice cream extruder, a powder dryer, a packaging machine.
[0013] The storage unit may be a tank.
[0014] The fill level of the storage unit may be determined and the fill level displayed on a visual representation of the storage object.
[0015] Inventory for the food processing line may be determined based on the fill level of the storage units, and inventory for the food processing line may be displayed with a visual representation of the storage object.
[0016] According to a second aspect, a system is provided, comprising a food processing line, an operator display, and a control unit configured to convert production flow (PF) data into human machine interface (HMI) data. The PF data may comprise storage objects representing storage units of the food processing line, and processing objects representing processing units of the food processing line. The control unit comprises a PF data receiving unit configured to receive the PF data, a storage object / processing object identifying unit configured to identify the storage objects and the processing objects in the PF data, a source object identifying unit configured to identify, for each processing object, a source object identifying unit configured to identify a source object of the processing object among the storage objects and the processing objects, and a destination object identifying unit configured to identify a destination object of the processing object among the storage objects and the processing objects, and a process sequence forming unit configured to form a number of process sequences based on the PF data, each process sequence comprising a process sequence specific source object and a process sequence specific destination object, and wherein the two or more process sequences are connected to the HMI data. the link object identification unit configured to identify link objects present in the process sequences of the process sequences; an aggregated process sequence generation unit configured to generate an aggregated process sequence by linking the process sequences via the link objects; and an HMI data generation unit configured to generate HMI data based on the aggregated process sequence, the HMI data, once executed on an operator display, generating a rectangular array of screen area elements arranged in a first direction A and a second direction B, wherein destination objects, visual representations of destination objects, are arranged following visual representations of source objects, for each of the process sequences in the first direction A within the rectangular array.
[0017] The visual representation of the processing object may be positioned following the visual representation of the storage object in a second direction B of the rectangular array.
[0018] The processing objects may comprise a first type processing object and a second type processing object, and the visually represented processing objects may comprise a visually represented first type processing object and a visually represented second type processing object linked to the first type processing object and the second type processing object, respectively, and the visually represented second type processing object is arranged following the visually represented first type processing object in the second direction B in the rectangular array.
[0019] The processing unit may be selected from the group consisting of a temperature processing device, a homogenizer, a separator, a filtering device, a mixer, a cheese tank, an ice cream freezer, an ice cream extruder, a powder dryer, a packaging machine.
[0020] The storage unit may be a tank.
[0021] The features and advantages mentioned in relation to the first aspect also apply to the second aspect.
[0022] Further objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and drawings.
[0023] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. [Brief description of the drawings]
[0024] [Figure 1] Generally showing how Production Flow (PF) data is transformed into Human Machine Interface (HMI) data. [Diagram 2]An example of how a food processing line can be displayed on an operator display is shown. [Diagram 3] Another example of how a food processing line can be displayed on an operator display. [Figure 4] 1 shows a flow chart illustrating steps of a method for converting PF data 110 to HMI data 130. [Diagram 5] Generally, a system is shown that includes a food processing line, an operator display, and a controller. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to FIG. 1, there is a generalized diagram of how information generated by food processing line 100 can be translated so that an operator can access the current status of food processing line 100 via operator display 132.
[0026] As shown, the food processing line 100 includes a number of storage units 102, 108 and a number of processing units 104, 106. In the illustrated example, the storage units 102, 108 are a first tank 102 and a second tank 108, and the processing units 104, 106 are a plate heat exchanger 104 and a homogenizer 106. The first tank 102 is arranged to supply food to the plate heat exchanger 104. From the plate heat exchanger 104, the food is temperature treated and then supplied to the homogenizer 106 where the food is treated to break down fat globules. After being homogenized, the food is supplied to the second tank 108.
[0027] During production, production flow (PF) data 110 is generated by the food processing line 100. This data may comprise data generated, for example, from valve arrangements, flow sensors, level sensors and / or pressure sensors. This data may be generated by the different storage and processing units themselves via built-in sensors and / or by sensors that are external units, for example located between two different processing units. The PF data 110 may be directly transferred via data communication modules included in the different food processing units 104, 106, in the storage units 102, 108 and / or in the valve arrangements (not shown), or alternatively, the PF data may be transferred via a data communication module shared by multiple storage units 102, 108, processing units 104, 106 and / or valve arrangements.
[0028] The food processing line 100 can be reflected in the PF data 110. For example, the first tank 102 may be represented as a first storage object 112, the first processing unit 104 may be represented as a first processing object 114, the second processing unit 106 may be represented as a second processing object 116, and the second tank 108 may be represented as a second storage object 118.
[0029] After identifying the storage objects and processing objects in the PF data 110, the PF data 110 is processed to identify, for each processing object 114, 116, a source object for the processing object and a destination object for the processing object. In other words, for each processing object, determine which processing object or storage object the food is supplied from and determine which processing object or storage object the food is supplied to. After identifying the source and destination objects, a process sequence 120a-b is formed. The process sequence 120a-b comprises a process sequence specific source object 122a-b and a process sequence specific destination object 124a-b. Although the illustrated example comprises two process sequences arranged in a sequence, this approach can also be used for complex setups with process sequences arranged in parallel or multiple process sequences arranged in sequence or multiple process sequences arranged in parallel.
[0030] As shown, processing objects and / or storage objects may form part of multiple process sequences 120a-b. For example, as shown, processing objects 114, 116 may form part of two process sequences 120a-b as shown. Processing objects 114, 116 and / or storage objects 112, 118 that form part of one or more process sequences 120a-b may be identified as link objects 126a-b. By using these link objects 126a-b, the process sequences 120a-b linked via the link objects 126a-b may be combined into an aggregated process sequence 128.
[0031] Once the aggregated process sequence 128 has been generated, Human Machine Interface (HMI) data 130 may be generated based on the aggregated process sequence. Having the aggregated process sequence 128 generated in a structured manner, with source and destination objects identified for each process object, allows the food processing line 100 to generate HMI data 130 that is reflected in a consistent manner on the operator displays 132. This is advantageous in that the operator can easily navigate himself and thus grasp the information provided, thereby making decisions faster and with less risk that the decisions made are based on a misinterpretation of the information provided via the operator displays 132.
[0032] Once received by the operator display 132, the HMI data 130 can be transformed into a graphical object having a plurality of screen area elements 136 and presented in a rectangular array 134 extending in a first and second direction A, B. As shown, the first storage object 112, here the first process sequence specific source object 122a, can also be represented by a first visually represented source object 138, and the first processing object 114, here the second process sequence specific source object 122b, can also be represented by a second visually represented source object 140. The second processing object 116, here also the first process sequence specific destination object 124a, can be represented by a first visually represented destination object 142, and the second storage object 118, here also the second process sequence specific destination object 124b, can be represented by a second visually represented destination object 144. To convey information to the operator in a manner that reduces the risk of misidentification, how food products may flow through the food processing line 100 may be represented by arranging the visually represented destination objects 142, 144 of the processing objects 116, 118 following the visually represented source objects 138, 140 of the source objects 112, 114 for each of the process sequences 120a-b in a first direction A within the rectangular array 134. As shown, in the presented example, the first visually represented destination object 142 may be arranged to the right of the first visually represented source object 138, i.e., following the first direction A extending from left to right, and the second visually represented destination object 144 may be arranged to the right of the second visually represented source object 140.
[0033] Further, to allow an operator to easily distinguish the visually represented processing objects 140, 142 of the processing objects 114, 116 from the visually represented storage objects 138, 144 of the storage objects 112, 118, the visually represented processing objects 140, 142 may be positioned following the visually represented storage objects 138, 144 in the second direction B of the rectangular array 134. In this particular example, this approach results in the second visually represented source object 140 and the first visually represented destination object 142 being positioned below the first visually represented source object 138 and the second visually represented destination object 144.
[0034] The processing objects 114, 116 may include a first type processing object 114, which is exemplified as a plate heat exchanger in Fig. 1, and a second type processing object 116, which is exemplified as a homogenizer. As an effect of the possible existence of different types of processing objects, the visually represented processing objects 140, 142 may include a first type processing object 140 and a second type processing object 142, which are linked to the first type processing object 114 and the second type processing object 116, respectively. In order to allow the operator to easily identify different types of processing objects, the visually represented second type processing object 142 may be arranged following the first type processing object 140 in the second direction B of the rectangular array 134.
[0035] The operator display 132 may be a touch screen. Touch screen active area elements 146, 148, 150, 152 may be provided so that when the operator touches a visually represented source or destination object 138, 140, 142, 144, additional information about the selected object is provided.
[0036] FIG. 2 illustrates an example 200 of a method for displaying a more complex food processing line on the operator display 132. Similar to the food processing line 100 illustrated in FIG. 1, the food processing line visualized on the operator panel 132 as illustrated in FIG. 2 includes a first tank and a second tank. However, unlike the example illustrated in FIG. 1, one of the processing objects, “Separator”, is configured as a process sequence specific source object and is therefore positioned on the left side of the rectangular array 134. Also unlike the example illustrated in FIG. 1, three parallel processing objects, “THE 1”, “THE 2”, and “PHE”, are visualized, all of which are positioned to receive food from “Tank 1” or “Separator”. By using the approach described above, i.e., identifying process sequences 120a-b and process sequence specific source objects 122a-b and generating an aggregate process sequence 128 based on them, a parallel arrangement such as that illustrated in FIG. 2 can be efficiently identified so as to generate HMI data 130 consistently.
[0037] FIG. 3 shows yet another example of how a food processing line can be visualized on the operator display 132. In this particular example, four storage objects are visualized. Furthermore, in this particular example, a third processing object 302 may form a process-specific source object of a process sequence for a fourth processing object 304 that is placed following the third processing object 302 in the first direction A, and a third storage object 306 may form a process-specific destination object of this process sequence. Since the third processing object 302 does not constitute a process-specific destination object of other process sequences, the third processing object 302 may only comprise one connection as shown.
[0038] 4 is a flow chart showing a method 400 for converting PF data 110 to HMI data 130. In a first step 402, the PF data 110 is received. Then, in a second step 404, the storage objects 112, 118 and the processing objects 114, 116 in the PF data 110 are identified. In a third step 406, for each processing object 114, 116, in a first sub-step 408, the source objects 112, 114 of the processing object 114, 116 are identified from among the storage objects 112, 118 and the processing objects 114, 116. Then, in a second sub-step 410, the destination objects 116, 118 for the processing object 114, 116 are identified from among the storage objects 112, 118 and the processing objects 114, 116. In a third sub-step 412, multiple process sequences 120a-b are formed based on the PF data 110, each process sequence being composed of a process sequence specific source object 122a-b and a process sequence specific destination object 124a-b.
[0039] A fourth step 414 is to identify link objects 126a-b that are present in two or more process sequences 120a-b.
[0040] In a fifth step 416, an aggregated process sequence 128 is generated by linking the process sequences 120a-b via link objects 126a-b.
[0041] In a sixth step 416, HMI data 130 is generated based on the aggregated process sequences 128 and the HMI data 130, once executed on the operator display 132, generates a rectangular array 134 of screen area elements 136 arranged in a first direction A, where visual representations 142, 144 of the destination objects 116, 118 are positioned following the visual representations 138, 140 of the source objects 112, 114 for each of the process sequences 120a-b in the first direction A within the rectangular array 134.
[0042] 5 shows an example of a system 500 including a food processing line 100, an operator display 132, and a control unit 502 configured to convert the PF data 110 into the HMI data 130. The control unit 502 includes a PF data receiving unit 504 configured to receive the PF data 110. Based on the received PF data, a storage / processing object identifying unit 506 processes the PF data to identify the storage objects 112, 118 and the processing objects 114, 116 in the PF data 110. After identifying the storage objects and the processing objects, a source object identifying unit 508 processes each processing object 114, 116 based on this information to identify the source objects 112, 114 of the processing objects 114, 116 among the storage objects 112, 118 and the processing objects 114, 116. Similarly, the destination object specification unit 510 processes the data to specify destination objects 116, 118 of the processing objects 114, 116 among the storage objects 112, 118 and the processing objects 114, 116. After specifying the source objects and the destination objects, the process sequence formation unit 512 processes the data so that a number of process sequences 120a-b based on the PF data 110 are formed. After the number of process sequences are formed, each process sequence includes a process sequence-specific source object 122a-b and a process sequence-specific destination object 124a-b. A link object specification unit 514 is provided to specify link objects 126a-b that exist in two or more process sequences 120a-b. After specifying the link objects 126a-b, an aggregated process sequence generation unit 516 is provided to generate an aggregated process sequence 128 by linking the process sequences 120a-b via the link objects 126a-b.Finally, after having the aggregated process sequence 128, an HMI data generator 518 is used to generate HMI data 130 based on the aggregated process sequence 128, which, once executed on the operator display 132, generates a rectangular array 134 of screen area elements 136.
[0043] From the foregoing description, while various embodiments of the present invention have been described and illustrated, the present invention is not limited thereto and may be embodied in other ways within the scope of the subject matter defined in the following claims.
Claims
1. A method (400) for converting production flow (PF) data (110) into human machine interface (HMI) data (130), the PF data (110) including storage objects (112, 118) representing storage units (102, 108) of a food processing line (100) and processing objects (114, 116) representing processing units (104, 106) of the food processing line (100); The method comprises: receiving (402) the PF data (110); Identifying (404) the storage objects (112, 118) and the processing objects (114, 116) in the PF data (110); For each processed object (114, 116) (406), identifying (408) a source object (112, 114) of the processing object (114, 116) from among the storage object (112, 118) and the processing object (114, 116); Identifying (410) a destination object (116, 118) of the processing object (114, 116) from among the storage object (112, 118) and the processing object (114, 116); forming (412) a plurality of process sequences (120a-b) based on the PF data (110), each process sequence comprising a process sequence-specific source object (122a-b) and a process sequence-specific destination object (124a-b); Identifying (414) link objects (126a-b) that exist in two or more of said process sequences (120a-b); generating (416) an aggregated process sequence (128) by linking (120a-b) the process sequences (120a-b) via the link objects (126a-b); generating (418) the HMI data (130) based on the aggregated process sequence (128) such that, when executed on an operator display (132), the HMI data (130) generates a rectangular array (134) of screen area elements (136) arranged in a first direction (A); a destination object (142, 144) which is a visual representation of the destination object (116, 118) is arranged following a source object (138, 140) which is a visual representation of the source object (112, 114) for each of the process sequences (120a-b) in a first direction (A) in the rectangular array (134); Method (400).
2. the rectangular array (134) of screen area elements (136) is arranged in the first direction (A) and in the second direction (B), and the visual representations (140, 142) of the processing objects (114, 116) are arranged in the second direction (B) of the rectangular array (134) subsequent to the visual representations (138, 144) of the storage objects (112, 118); 2. The method of claim 1 (400).
3. the processing objects (114, 116) comprise a first type processing object (114) and a second type processing object (116); and the visually represented processing objects (140, 142) comprise a visually represented first type processing object (140) and a visually represented second type processing object (142); a second type of visually represented processing object (142) linked to the first type of processing object (114) and the second type of processing object (116), respectively, is arranged in the rectangular array (134) in the second direction (B) following the first type of visually represented processing object (140); The method of claim 1.
4. said processing units (104, 106) being selected from the group consisting of temperature processing equipment, homogenizers, separators, filter equipment, mixers, cheese tanks, ice cream freezers, ice cream extruders, powder dryers and packaging machines; The method of claim 1.
5. The storage units (102, 108) are tanks; The method of claim 1.
6. a degree of filling of said storage unit (102, 108) is determined and said degree of filling is displayed on said visually represented storage object (138, 144); The method according to claim 5.
7. an inventory of the food processing line (100) is determined based on the degree of filling of the storage units (102, 108), and the inventory of the food processing line (100) is displayed together with the visually represented storage objects (138, 144); The method according to claim 6.
8. A system (500) comprising a food processing line (100), an operator display (132) and a control unit (502) configured to convert production flow (PF) data (110) into human machine interface (HMI) data (130), the PF data (110) comprising storage objects (112, 118) representing storage units (102, 108) of the food processing line (100) and processing objects (114, 116) representing processing units (104, 106) of the food processing line (100); The control unit (502) A PF data receiving unit (504) configured to receive the PF data (110); a storage and processing object identification unit (506) configured to identify the storage object (112, 118) and the processing object (114, 116) in the PF data (110); a source object identifier (508) configured to identify, for each processing object (114, 116), a source object (112, 114) of the processing object (114, 116) among the storage object (112, 118) and the processing object (114, 116); a destination object specification unit (510) configured to specify a destination object (116, 118) of the processing object (114, 116) among the storage object (112, 118) and the processing object (114, 116); a process sequence former (512) configured to form a number of process sequences (120a-b) based on said PF data (110), each process sequence comprising a process sequence specific source object (122a-b) and a process sequence specific destination object (124a-b); a link object identifier (514) configured to identify link objects (126a-b) present in two or more of said process sequences (120a-b); an aggregated process sequence generator (516) configured to generate an aggregated process sequence (128) by linking the process sequences (120a-b) together via the link objects (126a-b); an HMI data generator (518) configured to generate the HMI data (130) based on the aggregated process sequence (128) such that, once executed on an operator display (132), the HMI data (130) generates a rectangular array (134) of screen area elements (136) arranged in a first direction (A) and a second direction (B); a destination object (142, 144) which is a visual representation of the destination object (116, 118) is arranged following a source object (138, 140) which is a visual representation of the source object (112, 114) for each of the process sequences (120a-b) in the first direction (A) within the rectangular array (134); System (500).
9. the visual representations (140, 142) of the processing objects (114, 116) are arranged in the rectangular array (134) in a second direction (B) subsequent to the visual representations (138, 144) of the storage objects (112, 118); The system of claim 8.
10. the processing objects (114, 116) comprise a first type processing object (114) and a second type processing object (116); and the visually represented processing objects (140, 142) comprise a visually represented first type processing object (140) and a visually represented second type processing object (142); a second type of visually represented processing object (142) linked to the first type of processing object (114) and the second type of processing object (116), respectively, is arranged in the rectangular array (134) in the second direction (B) following the first type of visually represented processing object (140); The system of claim 8.
11. said processing units (104, 106) being selected from the group consisting of temperature processing equipment, homogenizers, separators, filter equipment, mixers, cheese tanks, ice cream freezers, ice cream extruders, powder dryers and packaging machines; The system of claim 8.
12. the storage unit (102, 108) is a tank; The system of claim 8.