Integrated Systems Communications

Abstract

A system and method for improved production line control system communication are disclosed. The production line control system includes a plurality of components, such as a master component and client components. At least one of the master component and client components is configured to implement or run a composite controller. The composite controller is configured to communicate effectively with each of the plurality of components, to receive information from each of the plurality of components, to determine composite information of the production line control system based on the information received from each of the plurality of components, to generate a user interface that displays information about each of the plurality of components and the composite production line control system, and to send commands to the controllers of each of the plurality of components.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 496,391, filed Apr. 15, 2023, the entire disclosure of which is incorporated herein by reference in its entirety.

[0002] This disclosure relates generally to production line control, and more particularly to systems and methods for improved production line control and communication, such as in liquid ejection systems.

Background Art

[0003] Liquid ejection systems are used in a variety of applications. For example, such systems may apply hot melt adhesives during the manufacture of disposable hygiene products. As another example, hot melt liquid ejection systems may apply hot melt adhesives to assemble various types of packaging, such as paper - based packaging for food and beverages. Examples of hot melt adhesives used in such applications include moisture - curable hot melt polyurethane adhesives (“hot melt PUR”), which are often used when stable face - to - face joints must be formed. Other conventional hot melt adhesives may be used when fitting and fixing various homogeneous and heterogeneous materials, such as wood, plastic, corrugated film, paper, carton stock, metal, rigid polyvinyl chloride (PVC), cloth, leather, etc., in a mating relationship. Hot melt adhesives can be particularly useful in applications where it is desirable to quickly solidify the adhesive after melting and ejecting it.

[0004] In an example configuration of a hot melt liquid dispensing system, a hot melt adhesive in solid or semi-solid form is supplied to one or more melters or melter units. The melters heat the solid or semi-solid hot melt adhesive until it reaches a molten state. The molten hot melt adhesive can then be pumped to one or more applicators (also referred to as applicator modules, dispensers, etc.). The applicators then dispense the molten hot melt adhesive onto a desired surface or substrate, often as a series of dots or lines. However, applying the adhesive within limited positioning, timing, and quantity tolerances is almost always difficult. For example, if the amount of adhesive dispensed is insufficient, the bond may not be effective, while if the amount of adhesive is excessive, not only is the material wasted, but the adhesive may also flow undesirably once applied to the surface. [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] The proper operation of the melter(s) in a hot melt liquid dispensing system is a crucial factor in achieving the desired dispensing results. For example, the temperature of the hot melt adhesive affects its viscosity. This viscosity, in turn, affects the amount of hot melt adhesive dispensed during each application, especially if the hot melt adhesive is pressure-driven. Furthermore, numerous operating parameters, settings, data measurements, hardware configurations, etc., must be carefully managed to ensure optimal melter performance. Clearly, effectively managing these many parameters presents a significant challenge.

[0006] Further complicating these challenges is the fact that hot melt dispensing systems often consist of multiple melters supporting a production line with multiple applicators, or that a production line may be supported by multiple hot melt dispensing systems, each having one or more melters. Furthermore, a factory or production facility may have multiple production lines operating simultaneously, each associated with a separate hot melt dispensing system, each having one or more melters.

[0007] In known production line systems, each component of the system is often controlled individually, and consequently, additional controllers (hardware and software) are usually required within the system for combined control, including controllers or human-machine interaction (HMI) devices for each component. This often results in repetitive and other time-consuming processes that require the operator to access each component individually to perform actions such as loading manufacturing processes or switching controls on and off. Therefore, it is desirable that the operator be able to perform this action once, and that the same action be performed for multiple connected machines designated for production.

[0008] This disclosure addresses these and other shortcomings. [Means for solving the problem]

[0009] This specification discloses systems and methods for improved production line control system communication.

[0010] In one example, a production line control system is provided. This production line control system is configured to monitor and / or control at least one dispensing device. This production line control system includes a plurality of components. The plurality of components includes a master component. The plurality of components further includes at least one client component. The master component and at least one of the at least one client component are configured to implement or run a composite controller. The composite controller is configured to communicate effectively with each of the plurality of components. The composite controller is further configured to receive the operating state of the master component. The composite controller is configured to receive the operating state of the master component from the controller of the master component. The composite controller is further configured to receive the operating state of at least one client component. The composite controller is configured to receive the operating state of at least one client component from the controller of at least one client component. The composite controller is further configured to determine the composite operating state of the production line control system. The composite controller is configured to determine the composite operating state of the production line control system at least in part based on the operating state of the master component and the operating state of at least one client component. The composite controller is further configured to generate a user interface. This user interface displays multiple control tiles. Each of the multiple control tiles represents at least one of (a) a component of a plurality of components, and (b) user-selectable component data of the plurality of components. The user interface further displays an indicator of the operating status of the master component. The user interface further displays an indicator of the operating status of at least one client component. The user interface further displays an indicator of the composite operating status of the production line control system. The composite controller is further configured to send commands to the controller of the master component.The composite controller is further configured to send commands to the controller of at least one client component.

[0011] In a further example, another production line control system is provided. This production line control system is configured to monitor and / or control at least one dispensing device. This production line control system includes a plurality of components. The plurality of components includes a master component. The master component includes a controller. The plurality of components further includes at least one client component. At least one client component includes a controller. The plurality of components further includes a backup master component. The backup master component includes a controller. The controller of the master component is configured to communicate effectively with each of the plurality of components. The controller of the backup master component is also configured to communicate effectively with each of the plurality of components. The controller of the master component is configured to implement or run a composite controller. The controller of the backup master component is configured to determine whether the controller of the master component has lost effective communication with at least one client component and the backup master component. If the controller of the backup master component determines that the controller of the master component has lost effective communication with at least one client component and the backup master component for a predetermined minimum amount of time, the controller of the backup master component is further configured to implement or run a composite controller. The composite controller is configured to receive the operating status of the master component. The composite controller is configured to receive the operating status of the master component from the controller of the master component. The composite controller is further configured to receive the operating status of at least one client component. The composite controller is further configured to receive the operating status of the backup master component. The composite controller is configured to receive the operating status of the backup master component from the controller of the backup master component.The composite controller is configured to receive the operating status of at least one client component from the controller of at least one client component. The composite controller is further configured to determine the composite operating status of the production line control system. The composite controller is configured to determine the composite operating status of the production line control system at least partially based on the operating status of the master component, the operating status of at least one client component, and the operating status of the backup master component. The composite controller is further configured to generate a user interface. This user interface displays a plurality of control tiles. Each of the plurality of control tiles represents at least one of (a) a component of the plurality of components, and (b) user-selectable component data of the plurality of components. The user interface further displays an indicator of the operating status of the master component. The user interface further displays an indicator of the operating status of at least one client component. The user interface further displays an indicator of the operating status of the backup master component. The user interface further displays an indicator of the composite operating status of the production line control system. The composite controller is further configured to send commands to the controller of the master component. The composite controller is further configured to send commands to the controller of at least one client component. The composite controller is further configured to send commands to the controller of the backup master component.

[0012] In yet another example, a method is provided for sending commands to multiple components of a production line control system. The production line control system includes a master component. The production line control system further includes at least one client component. The method includes receiving the operating status of the master component. The operating status of the master component is received in a composite controller. The composite controller is implemented or run by at least one of the master component and at least one client component. The operating status of the master component is received in the composite controller from the controller of the master component. The method further includes receiving the operating status of at least one client component. The operating status of at least one client component is received in the composite controller from the controller of at least one client component. The method further includes determining the composite operating status of the production line control system. The composite operating status of the production line control system is determined at least in part on the operating status of the master component and the operating status of at least one client component. The method further includes generating a user interface. This user interface displays multiple control tiles. Each of the multiple control tiles represents at least one of (a) a component of the multiple components, and (b) user-selectable component data of a master component or at least one client component. The user interface further displays an indicator of the operating status of the master component. The user interface further displays an indicator of the operating status of at least one client component. The user interface further displays an indicator of the combined operating status of the production line control system. The method further includes sending a command to the controller of the master component. The method further includes sending a command to the controller of at least one client component.

[0013] The accompanying drawings, which by reference form part of this specification, illustrate embodiments and, together with this specification, are helpful in explaining the principles of the methods and systems. [Brief explanation of the drawing]

[0014] [Figure 1] This diagram shows an example of a production line control system. [Figure 2] This is a schematic diagram illustrating an example of a composite system. [Figure 3] This is a schematic diagram illustrating an example of another complex system. [Figure 4] This is a diagram illustrating an example of a composite system. [Figure 5] This is a diagram illustrating an example of another complex system. [Figure 6] This is an example of a method flowchart. [Figure 7] Here is another example flowchart. [Figure 8] This is a diagram illustrating an example of a user interface. [Figure 9] This is a diagram illustrating an example of a user interface element. [Figure 10] This is a diagram illustrating an example of another user interface element. [Figure 11] This is a diagram illustrating an example of another user interface element. [Figure 12] This is a schematic diagram illustrating an example of an automatic network switch. [Modes for carrying out the invention]

[0015] Hereinafter, aspects of this disclosure will be described in detail with reference to the drawings, and unless otherwise specified, the same reference numerals throughout the drawings refer to the same elements.

[0016] The systems and methods of this disclosure relate to improved production line system communication. While primarily referring to hot melt adhesives, the techniques described herein may be applicable to any type of liquid, including non-adhesive liquids.

[0017] FIG. 1 shows, as an example, a production line control system 10 (e.g., a hot melt adhesive dispensing system or other types of production line control systems) that can implement the techniques described herein. The production line control system 10 can include a melter unit 20 that can include an adhesive supply 22 for containing and melting a solid or semi-solid adhesive 24a, such as pellets, a manifold 26 connected to the adhesive supply 22, a controller 28, and a user interface 29. The adhesive supply 22 can be, in particular, a tank-type melter or a grid and reservoir melter. The solid or semi-solid adhesive 24a stored in the adhesive supply 22 can change to a liquid adhesive 24 when melted. The adhesive supply 22 can include a side wall 30, a removable cover 31, and a base 32 that can include one or more adhesive supply heaters 34 for melting and heating the adhesive 24a and the liquid adhesive 24 within the adhesive supply 22. An adhesive supply outlet 36 proximate to the base 32 can be coupled to a passage 38 that can connect to an inlet 40 of the manifold 26.

[0018] A positive displacement pump 58, such as a vertical piston pump or a gear pump (as shown), can be coupled to the manifold 26 to pump the liquid adhesive 24 from the adhesive supply 22 into the manifold 26, where the liquid adhesive 24 can be divided into separate streams. A pump motor 59 can drive the pump 58. By the operation of the pump 58 (and thus according to the function of the pump motor 59), the adhesive can be supplied under pressure to the manifold 26 and the applicators 48, 50. Such pressure can generally affect the flow rate and velocity of the adhesive entering, passing through, and / or exiting the manifold 26, along with the amount of adhesive dispensed in one applicator cycle (also referred to as a gun cycle) of the adhesive dispensing module 54.

[0019] The manifold 26 can be attached to the side wall 30 of the adhesive supply part 22 by the spacer 41 and can be arranged at a distance 42 sufficient to provide insulation from the adhesive supply part 22 from the manifold 26 of the adhesive supply part 22. The manifold 26 can comprise a plurality of outlet ports 44 into which a heated hose 46 can be fitted, and the hose 46 is attached to one or more adhesive applicators 48, 50 to supply, for example, the liquid adhesive 24 to the applicators 48, 50. The manifold 26 can comprise a manifold heater 56, and the manifold heater 56 can be separate from the adhesive supply part heater 34 and can be independently controlled by the controller 28. In some examples, a single heater can be used to heat the adhesive supply part 22 and the manifold 26. FIG. 1 shows the adhesive supply part 22 in physical proximity to the manifold 26, but other arrangements are possible, such as an arrangement in which the source of the adhesive is physically remote from the manifold. In such arrangements, two or more pumps can be used to move the adhesive from the adhesive supply part 22 towards the final application point.

[0020] The manifold 26 can provide multiple flow streams that can be delivered to applicators 48, 50 by corresponding heated hoses 46. The hoses 46 can be electrically coupled to the controller 28 by a set of cords 62 associated with each hose 46. The applicators 48, 50 may include one or more adhesive dispensing modules 54 configured to dispense / apply liquid adhesive 24 to products such as cartons, packages, or other objects. The adhesive dispensing modules 54 can be mounted on the applicator body 51, which may have an applicator heater 53 and may be supported by a frame 52. The production line control system 10 may include two applicators 48, 50, with one applicator located on each side of the melter unit 20 as shown in Figure 1, but other embodiments of the production line control system 10 may use different numbers of applicators, dispensing modules, and other configurations as desired to suit a particular application. For example, applicators 48 and 50 may each be configured to have a single adhesive dispensing module 54, or they may each be configured to have a pair of adhesive dispensing modules 54. The adhesive dispensing modules 54 of applicators 48 and 50 may be commonly monitored, controlled, and / or operated by a common air supply unit. Alternatively, the adhesive dispensing modules 54 of applicators 48 and 50 may be independently monitored, controlled, and / or operated by separate air supply units. Applicators 48 and 50 and / or adhesive dispensing modules 54 may be referred to as applicators or dispensers, respectively.

[0021] The pump 58 can be located outside the adhesive supply unit 22 and can be connected to a pneumatic regulator 70 that receives air from the air supply unit 61. More specifically, the pneumatic regulator 70 can be mounted on the melter unit 20 and connected to the air supply unit 61. In some embodiments, the pump 58 can be mounted on the manifold 26 and heated by a manifold heater 56. This configuration allows for a larger tank opening 60, increases the tank capacity, and reduces the time required to heat the pump 58. Furthermore, a flow meter 80 can be mounted on the manifold 26 to measure the flow rate of adhesive passing through the manifold 26. The flow meter 80 may comprise a pair of sensors electrically coupled to the controller 28 by their respective codes 63a, 63b associated with each sensor. At least one product detector 90, such as an optical sensor, can also be electrically coupled to the controller 28.

[0022] The melter unit 20 may include a controller 28. The controller 28 may house a power supply and an electronic control unit for the production line control system 10. The controller 28 may be configured to include one or more processors and a memory configured to store instructions, when executed by the one or more processors, that cause the controller 28 to perform various operations as described herein. The controller 28 may be configured to manage various types of data related to the production line control system 10 and its components, including the melter unit 20, applicators 48, 50 and / or the controller 28 itself. Managing such data may include storing data, taking in data (e.g., measured by various sensors), modifying or setting data, receiving similar data from other melter units 20 or other controllers 28 of the production line control system 10, and / or providing data to other melter units 20 or other controllers 28 of the production line control system 10 (e.g., via a composite controller or cloud system as described herein).

[0023] The data managed by the controller 28 (collectively referred to as control data) may include operating parameters, measurement data, and / or hardware configuration data. Examples of operating parameters may relate to temperature setpoints, control loop settings (e.g., temperature control loop), control loop type, pump speed, melter duty cycle (or its individual heaters), applicator cycle rate, and pump and / or pump motor speed. Examples of measurement data may relate to liquid temperature (including liquid temperature at various points in the melter unit 20, tank 22, manifold 26, applicators 48, 50, and heated hoses), liquid flow rate (e.g., from manifold 26), liquid flow rate (e.g., from manifold 26), and / or liquid pressure. Examples of hardware configuration data may include the number of pumps, the type of pumps (which may be multiple), the holding capacity of the tank 22, the number of hose outlets on the manifold 26, the power capacity, the control interface to and from the controller 28, the weight (of, for example, the melter unit 20), the external dimensions (of, for example, the melter unit 20), the liquid throughput from the melter unit 20, and / or the melting rate of the melter unit 20.

[0024] With respect to the heating mechanism of the production line control system 10, the controller 28 can be electrically coupled to heaters including the adhesive supply heater 34, the manifold heater 56, the applicator heater 53, and / or any hose heaters. The controller 28 can also be coupled to various temperature sensors within the production line control system 10, which can be associated with or included in the adhesive supply heater 34, the manifold heater 56, the applicator heater 53, and / or any hose heaters. The controller 28 can individually monitor and adjust the adhesive supply heater 34, the manifold heater 56, the applicator heater 53, and / or any hose heaters and maintain the temperature of the (molten) adhesive 24 to ensure the appropriate viscosity of the adhesive 24 contained in the adhesive supply unit 22, which is then supplied to the applicators 48, 50 and dispensed by the adhesive dispensing module 54.

[0025] Figure 2 shows a schematic diagram of a composite system 200 comprising multiple melter units 202a to 202e in a production facility. In some embodiments, the composite system 200 can be a collection of all systems installed on a single production line to produce a product, a collection of all systems installed on multiple production lines to produce a product, a collection of all systems installed on multiple production lines to produce multiple products, and so on. In some embodiments, the composite system 200 can take several different forms, these different forms including a homogeneous composite network including multiple systems on the same product line, e.g., a production line with multiple melters; and a heterogeneous composite system that may include multiple systems, e.g., melters, drum unloaders, and pattern controllers, where at least one system is from a different product line. Figure 2 shows melter units 202a to 202e, but as will be described later, a production line control system 10 or any other component of multiple production line control systems 10 can be used to control the data flow. The data flow within the composite system 200 can be implemented according to a publish / subscribe type communication model or architecture such as the Open Platform Communications (OPC) Integrated Architecture (OPC / UA). In particular, control data can be published to the composite controller 210 by the melter unit 202. As used herein, the term “composite controller” may refer to hardware, software, or a combination thereof. In non-limiting examples, the composite controller described herein is a software embodiment that can be implemented or run by one of the controllers among the components of the composite system or cloud system, as described herein, in some specific non-limiting examples. Control data published to the composite controller 210 can be propagated by the composite controller 210 to select the melter unit 202 via subscription.As described herein, in some examples, client components (e.g., melter units 202a-202d) can publish information (e.g., the operating status of each component) to a master component (e.g., melter unit 202e). In further examples, the master component can publish commands or control messages to client components (e.g., simultaneously) as described herein. As described herein, the composite system may, in some examples, be a homogeneous system (e.g., including the same type of melter unit), or in other examples, a heterogeneous system (e.g., including different types of melter units, or other components such as a drum unloader or pattern controller). In any of the above examples, the composite controller can be configured to decode information received from these components and to publish commands or control messages to any component of any type. This advantageously enables a single composite controller configured to be operably connected to any type of controller in the composite system in order to obtain improved production line control and communication.

[0026] As shown in Figure 2, the composite controller 210 can be implemented as part of the melter unit 202e, including implementation as executable software, by the controller 204 of the melter unit 202e, in some specific examples. Alternatively, the composite controller 210 can be implemented or run as a standalone unit located in the same location as the melter units 202a-202e. As a further alternative, the composite controller 210 can be implemented or run as a cloud system, as considered with respect to Figure 3. As described herein, in some examples, the composite controller 210 can be implemented or run by any component of the composite system 200 (i.e., each component and any component can be configured to play the role of a master component as desired to suit a particular application), and each component of the composite system 200 can be configured to have software that can be implemented or run as a composite controller. Determining which of the components (which may be multiple) of the composite system 200 will be implemented or run as the composite controller 210 can be based on a predetermined hierarchical identifier, such as the first component of the composite system 200 that is operationally connected to the composite system 200, the component of the composite system 200 having the lowest serial number, or a combination thereof.

[0027] A melter unit can be referred to as a melter unit 202 as a whole, or a melter unit can be specifically referred to as one of the particular melter units 202a to 202e, as appropriate. System 200 can be referred to as a composite system. System 200 can represent a single liquid (e.g., adhesive) dispensing system (e.g., production line control system 10 in Figure 1) configured to include multiple melter units 202 or other components. Alternatively, system 200 can represent multiple production line control systems, each having a single melter unit 202. For example, melter unit 202a may belong to a first production line control system, melter unit 202b may belong to a second production line control system, and so on. Furthermore, system 200 can include combinations thereof, in which case some melter units 202 all belong to a common production line control system, while other melter units 202 each belong to a separate single-melter unit production line control system. While System 200 is generally considered in relation to the melter unit 202, the techniques described herein can be applied to other components of the production line control system, such as the applicator or sub-components of the melter unit 202 (e.g., manifold, adhesive tank, hose, etc.).

[0028] Each melter unit 202 may be equipped with and / or associated with a controller 204. The controller 204 of a melter unit 202 and / or associated with a melter unit 202 can generally control the operation of the melter unit 202 and communication to and from the melter unit 202. In some cases, the controller 204 can further control the operation of at least some aspects of the production line control system associated with the melter unit 202. The controller 204 can further manage the control data stored in it, such as receiving control data, modifying control data, and transmitting control data to other systems or components. For example, the controller 204 can receive control data from a composite controller 210 as a subscriber. Conversely, the controller 204 can transmit control data to the composite controller 210 as a publisher. The control data may include operating parameters, measurement data, and hardware configuration. The controller 204 may be the same as or similar to the controller 28 in Figure 1. Controller 204 may include an OPC Integrated Architecture (OPC / UA) controller.

[0029] Each controller 204 can be configured to include a server 214 and a client 216. The server 214 and client 216 can be implemented as part of the controller 204. Alternatively, the server 214 and client 216 can be implemented, at least in part, as separate physical components. The server 214 and client 216 can be considered as the embedded server and embedded client of the melter unit 202 and / or its controller 204, respectively. The server 214 may include an embedded OPC / UA server, and the client 216 may include an embedded OPC / US client. The server 214 can generally be configured to publish control data (i.e., control data messages) to the composite controller 210. The client 216 can generally be configured to subscribe to and receive the published control data (i.e., control data messages) from the composite controller 210. In the publish-subscribe architecture of system 200, server 214 can be considered a publisher and client 216 can be considered a subscriber.

[0030] As stated, the melter unit 202e may include and / or be associated with a composite controller 210. The composite controller 210 can be configured to coordinate various control data messages and direct them to and from the melter units 202, particularly the controllers 204 of the melter units 202 (including the controller 204 of the melter unit 202e itself). For example, the composite controller 210 may receive published control data messages from the server 214 of the melter unit 202 and send control data messages to one or more clients 216 of other melter units 202 according to subscription criteria. In some specific examples, the composite controller 210 may act as a message broker for control data messages.

[0031] The composite controller 210 can filter published control data messages to determine which of the melter units 202 should receive the published control data messages, if any. The composite controller 210 can filter published control data messages according to one or more classifications of the control data messages. In some examples, the classification (or class) of the published control data messages can be defined at least in part by the publish server 214. The composite controller 210 can further filter published control data messages based on subscription profiles (e.g., subscription criteria) associated with other melter units 202. A melter unit 202 can define a subscription profile associated with it at least in part. Filtering by the composite controller 210 can be performed according to a topic-based model, a content-based model, or a combination thereof.

[0032] In topic-based models, classification can relate to the type of component associated with the control data (e.g., pump, heater, adhesive tank, applicator, manifold, heated hose, controller, etc.). Classification can further relate to the type of operating parameter associated with the control data (e.g., temperature setpoint, applicator cycle rate, melter / heater duty cycle, control loop setting, control loop type, pump speed, etc.). Classification can further relate to the type of measured data indicated in the control data (e.g., adhesive temperature, adhesive flow rate, adhesive flow rate, and adhesive pressure). Classification can further relate to the type of hardware configuration data indicated in the control data (e.g., number of pumps, type of pump(s), adhesive tank capacity, number of hose outlets on the manifold, power capacity, control interface to the controller, melter unit weight, melter unit external dimensions, adhesive throughput from the melter unit, and melting rate of the melter unit). Classification can further generally be based on the type of data, e.g., operating parameter data, measured data, or hardware configuration data.

[0033] In a content-based classification model, classification can relate to a specific melter unit 202 that published control data. Separation can further relate to operating parameters or measured data values. For example, classification can be based on whether the operating parameter or measured data value is above a threshold, below a threshold, outside the threshold range, or within the threshold range. For example, control data from one melter unit 202 indicating adhesive temperature can be transmitted by the composite controller 210 to another melter unit 202 based on the composite controller 210 determining that the adhesive temperature value is outside the threshold range.

[0034] A melter unit 202e equipped with a composite controller 210 may be configured to include a panel 206, also referred to as a control panel. One or more of the other melter units 202 may also be configured to include a panel 206. The panel(s) 206 may be optionally omitted in some specific examples. The panel 206 may include a display (e.g., an LCD or LED display) and one or more user inputs (e.g., a pointing device, a keyboard, or various control buttons). The display may be configured as a touchscreen display for user input. The panel 206 may output a graphical user interface that can be configured to display a visual layout of the melter unit 202 and other components / units of the system 200. The graphical user interface may also be configured to include one or more interface elements (e.g., "tiles") that display various data related to the system. The interface elements may be further or alternatively associated with the melter unit 202 or other components / units of the system 200. Activating an interface element for a specific production line control system allows the display of data related to that system, such as the system's operating parameters, various measurement data, and / or the configuration of the system's hardware. This graphical user interface can also be used to input various changes to the production line control system and other components of system 200. For example, an operator can generally use the graphical user interface and panel 206 to change the operating parameters of the production line control system, and the changed operating parameters can be communicated or transmitted to the system components as described herein.

[0035] The melter unit 202e (in particular, the composite controller 210) can be configured to communicate with a computing device 222. The computing device 222 can communicate with the melter unit 202e via wired connections, fiber optic connections, and / or wireless connections, etc. For example, the computing device 222 can communicate with the melter unit 202e via a WAN (Wide Area Network), LAN (Local Area Network), WLAN (Wireless LAN), intranet, Internet, and / or communication channels as defined herein, etc. The computing device 222 can be located in the same production facility as the melter unit 202. For example, an operator can carry a portable computing device 222 around the floor of the production facility to monitor and manage production operations. Alternatively, the computing device 222 can be located remotely from the production facility. As some examples, the computing device 222 may be a personal computer (PC), laptop computer, mobile device, tablet computer, or smartphone. The computing device 222 can be configured to perform functions similar to those of panel 206 of the melter unit 202e. In some cases, the melter unit 202e can be configured without panel 206, and instead, the functions of panel 206 can be transferred to the computing device 222.

[0036] The first control data message 208a and the second control data message 208b illustrate an example of publish / subscribe data flow within system 200. The first ("publish") control message 208a can generally be used to send information (e.g., operating status) from one or more client components of the composite system 200 (e.g., melter units 202a-202d) to a master component (e.g., melter unit 202e). In some examples, the first control data message 208a may further or alternatively include other information, such as user-selectable information of the corresponding component displayed on the user interface (e.g., as a control tile), as described herein. The second ("subscribe") control message 208b can generally be used to send information (e.g., a command or control message) from a master component (e.g., melter unit 202e) to one or more client components of the composite system 200 (e.g., melter units 202a-202d). In some examples, the second control data message 208b can be used to control one or more of the client components, such as by controlling a subcomponent of the client component (e.g., a pump, a heater) and / or reading a manufacturing process, as described herein.

[0037] With respect to the first control data message 208a, the server 214 of the melter unit 202a can generate the first control data message 208a and publish it to the composite controller 210. The composite controller 210 can filter the first control data message 208a according to the subscription profile associated with other melter units 202 and the form of the first control data message 208a. The form of the first control data message 208a can include one or more classifications of the first control data message 208a. Such classifications may be defined by the server 214 of the melter unit 202a. In this example, the first control data message 208a may indicate the heater duty cycle of the melter unit 202a. The subscription profiles associated with melter units 202b, 202c, and 202d may indicate that these melter units 202b, 202c, and 202d should receive control data from other melter units 202 with respect to the heater duty cycle (e.g., classification of the first control data message 208a). Furthermore or alternatively, the subscription profiles associated with melter units 202b, 202c, and 202d may indicate that these melter units 202b, 202c, and 202d should receive control data published by melter unit 202a (e.g., additional or alternative classification of the first control data message 208a). In either or both cases, the first control data message 208a may be sent via subscription to the respective clients 216 of melter units 202b, 202c, and 202d.

[0038] With respect to the second control data message 208b, the server 214 of the melter unit 202b can generate the second control data message 208b and publish it to the composite controller 210. The composite controller 210 can filter the second control data message 208b according to the subscription profile for the other melter units 202 and the form of the second control data message 208b (e.g., one or more classifications of the second control data message 208b). In this example, the second control data message 208b may indicate the temperature setpoint operating parameters of the melter unit 202b. The subscription profiles associated with the melter units 202a and 202d may indicate that these melter units 202a and 202d should receive control data from the other melter units 202 with respect to the temperature setpoint operating parameters (e.g., classifications of the second control data message 208b). Therefore, the composite controller 210 can send the second control data message 208b to each client 216 of the melter units 202a and 202d via the subscription. Furthermore, for this example, the subscription profiles associated with melter units 202c and 202e can indicate that these melter units 202c and 202e should only receive control data related to the temperature setpoint operating parameter when the temperature setpoint operating parameter is outside the threshold range (e.g., another classification of the second control data message 208b). In this example, the temperature setpoint operating parameter shown in the second control data message 208b is not outside the threshold range. Therefore, in this example, the second control data message 208b is not sent to the melter units 202c and 202e.

[0039] The composite controller 210 can also be configured to coordinate at least some operations of the melter units 202. For example, the composite controller 210 can receive control data from one melter unit 202 and instruct a second melter unit 202 to operate accordingly. For example, the composite controller 210 may receive control data indicating that the first melter unit 202 is inoperable or that the amount of molten adhesive being discharged is decreasing. The composite controller 210 can therefore instruct the second melter unit 202 to increase its amount of molten adhesive to compensate for the inoperability or decrease in the amount of molten adhesive being discharged by the first melter unit 202.

[0040] Figure 3 shows a schematic diagram of system 300 configured according to a cloud / edge architecture. System 300 may be similar to system 200 in Figure 2 in at least some aspects. Thus, similar reference numerals indicate similar components or parts. However, instead of the composite controller being implemented as part of the melter unit 202, as in the case of system 200 in Figure 2, the composite controller 232 is implemented by a server 230. The server 230 may be part of a cloud / edge system, and the melter unit 202 may communicate with the server 230 via a network 250. Thus, the server 230 may be located remotely from the production facility housing the melter unit 202, but this disclosure is not limited in that way. For example, the server 230 may be located in the same production facility as the melter unit 202 and connected to the melter unit 202 via a LAN (e.g., WLAN) and / or a communication channel defined in that production facility. The server 230 is not limited to a single computing device and may comprise multiple networked computing devices, storage units (e.g., databases) and / or networking devices.

[0041] The composite controller 232 implemented in server 230 may be similar to the composite controller 210 in Figure 2 in at least some aspects. In fact, the composite controller 232 can be considered similar to the composite controller 210 in many aspects of its functionality. For example, like the composite controller 210, the composite controller 232 can receive published control data messages from the server 214 of the melter unit 202. The composite controller 232 can filter the control data messages according to the subscription profile associated with the melter unit 202 and the nature of the control data itself. This allows the composite controller 232 to send control data messages to (or not send to) a given melter unit 202 client 216.

[0042] The computing device 222 can communicate with the server 230, in particular with the composite controller 232. The computing device 222 can perform at least some of the functionality provided by panel 206 of the melter unit 202e in Figure 2. For example, the computing device 222 can display a graphical user interface that provides a visual layout of the production line control system and other components within the production facility. The graphical user interface can display various data related to the production line control system, such as operating parameters, measurement data, and hardware configuration data. The data displayed by the graphical user interface can be derived from control data messages published by or otherwise received from the melter unit 202. The graphical user interface can provide various interactive interface elements ("tiles") that can be activated to display further data of the production line control system related to the interface elements. The graphical user interface and the computing device 222 can generally be used to control various aspects of the production line control system and other components of the system. For example, the computing device 222 can be used to adjust various operating parameters of the production line control system. Such control can be implemented via the server 230 and / or the composite controller 232.

[0043] Figure 4 shows at least a portion of an exemplary composite system 400, which includes four operably connected melter units 402 labeled as melter units 402a to 402d. The system 400 in Figure 4 can be the same as or similar to the production line control system 10 in Figure 1, the system 200 in Figure 2, and / or the system 300 in Figure 3, in at least some embodiments. Similarly, the melter unit 402 in Figure 4 can be the same as or similar to the melter unit 20 in Figure 1, and / or the melter unit 202 in Figures 1 and 3, in at least some embodiments. Thus, the melter unit 402 may include a reservoir configured to have one or more heaters for melting solid or semi-solid adhesive supplied to the melter unit 402. The melter unit 402 may further include a manifold for distributing the molten adhesive via connected hoses (e.g., heated hoses) to one or more applicators (e.g., applicators configured to dispense the molten adhesive). Further heaters may be found throughout the system 400, including in or within the manifolds, hoses, or applicators associated with each melter unit 402. The system 400 may also include one or more sensors for measuring the temperature of the molten adhesive at various locations within the system 400, such as in the reservoirs, manifolds, hoses, or applicators of each melter unit 402. Although not shown in Figure 4, one or more applicators, hoses, and optional adhesive supply devices (e.g., hoppers) can be considered part of the system 400. Each melter unit 402 of the system 400 may, in particular, supply molten adhesive to one or more applicators associated with that melter unit 402.

[0044] Although the system 400 is depicted in Figure 4 as having four melter units 402, it will be understood that it can have any suitable number of melter units 402 depending on the type of melter unit 402, the type of material to be extruded, the amount of material to be melted and extruded, and / or other manufacturing factors. Furthermore, the melter units 402 of the system 400 may include different types of melter units 402 (such as the melter unit 406 shown in Figure 5) and / or melter units that operate according to different operating parameters or operating configurations. Furthermore or alternatively, it will be understood that the system 400 may include any other components (referred to as client components, which may be able to operate as master components or backup master components, as described herein), such as the pattern control device 408 shown in Figure 5.

[0045] The melter unit 402 (for example, in particular the associated control device 410) may further comprise a communication interface, such as a wireless interface, for performing network communication with another control device 410 or other devices including a cloud system. The wireless interface may communicate, for example, via Wi-Fi and / or other communication channels as defined herein. The wireless interface may further or alternatively comprise a cellular communication device.

[0046] The system 400 may include one or more control devices 410 configured to display information about the system 400, such as information about one or more of the melter units 402 or other components of the system 400. In at least some embodiments, the control devices 410 in Figures 4 and 5 may be the same as or similar to the controller 28 in Figure 1 and / or the composite controller 204 in Figures 2 and 3. The control devices 410 may be located in one or more of the melter units 402 or other components. For example, such control devices 410 may be incorporated into the melter units 402. In one embodiment, only a single melter unit 402 of the system 400 is configured to include the control devices 410. For example, such a single melter unit 402a configured to include the control devices 410 may be the same as or similar to the melter unit 202e in Figure 2 configured to include the composite controller 210. In fact, the composite controller 210 and the control devices 410 may be implemented in the same computing module or computing device.

[0047] Furthermore, or alternatively, the control device 420 may be a standalone device that communicates (e.g., wirelessly or via wired communication) with one or more of the individual melter units 402 or other components of the system 400. The standalone control device 420 may include a desktop computer, a portable computer, a tablet, and / or a mobile phone. In one embodiment, the system 400 may include a plurality of control devices 410, 420. For example, the system 400 may have one or more control devices 410 that communicate directly via wired communication with one or more other melter units 402, and / or one or more standalone control devices 420 that communicate wirelessly with one or more melter units 402. In some examples, the standalone control device 420 may be the same as or similar to the computing device 222 in Figures 2 and 3. The control functions of the standalone control device 420 may be facilitated by a cloud system, which in some examples may include the same as or similar to the server 230 in Figure 3.

[0048] As described herein, a composite controller can generally be implemented or run by any one controller of the components of a production line control system, thereby assuming the role of a master component, insofar as such component acts as a master component and its controller implements or runs the composite controller. For example, the composite control capabilities described herein can generally be included in software implemented on or run by each controller of each component of a production line control system, thereby enabling each component to assume any role in the composite system as described herein without requiring additional control hardware. As can be understood and as described herein, a control device and / or composite controller is not required for each component of a production line control system; instead, a control device and / or composite controller can generally be located anywhere in the composite system as described herein. However, the term "within" should be understood as not necessarily requiring the control device and / or composite controller to be located on the same premises as the other components of the production line control system. In some examples, the master component may include a composite controller. In other examples, a cloud server located remotely from the premises housing the production line control system may include a composite controller. In some examples, the operator can navigate from any connected device (e.g., an HMI device) into a control screen associated with the production line control system or any of its components, as described herein. In some examples, any one controller among the components of the production line control system can implement or run a composite controller, which can be determined based on a predetermined hierarchical identifier, such as the first component of the production line control system operably connected to the production line control system, the component of the production line control system having the lowest serial number, or a combination thereof.

[0049] A controller of a production line system component, including a composite controller, may be configured to include one or more processors and a memory configured to store instructions that, when executed by the one or more processors, cause the controller to perform various operations described herein. The controller may be configured to manage various types of data related to the production line control system and its components. Managing such data may include storing data, taking in data (e.g., measured by various sensors), modifying or setting data, receiving similar data from other components or other controllers of the production line control system, and / or providing data to other components or other controllers of the production line control system (e.g., via a composite controller or cloud system, as described herein). In some examples, any of the controllers, including a composite controller, may be a human-machine interaction (HMI) device.

[0050] In some examples, a production line control system may include a backup master component. The backup master component is generally configured to operate in the same manner as other client components, as long as the master component is in a valid communication state with the client components. For example, a composite controller may receive the operating status of the backup master component, and the composite controller may send commands and / or control messages to the backup master component in the same way as they are performed for other client components, as described herein. In such examples, determining the composite operating state of the production line control system may include considering the operating status of the backup master component in the same way as they are performed for other client components, as described herein. In addition, the backup master component may receive and / or monitor commands and control messages communicated to and from the master component or between the master component and other components. For example, the backup master component may monitor the receipt of commands and / or control messages published by the master component (e.g., at regular or predetermined intervals). Similar to the master component, any component of the system can generally operate as a backup master component. In some examples, a system may include a single master component, a single backup master component, and one or more client components, although a backup master component may also be referred to as one of the client components when it has not transitioned to the role of a master component.

[0051] A backup master component can be configured (e.g., via its controller) to determine whether the master component (e.g., in particular its controller) has lost valid communication with the client components (which may be multiple) and / or the backup master component. In some examples, such determination can be made by the backup master component (e.g., in particular its controller) by recognizing that the backup master component has not received any commands and / or control messages published by the master component for a predetermined minimum amount of time (e.g., about 5 seconds) or a predetermined minimum number of missing frames. If such determination indicates that the master component has lost valid communication with the client components (which may be multiple) and / or the backup master component, the backup master component can operate as the master controller, and the controller of the backup master controller implements or operates the composite controller (e.g., by the backup master component transitioning to the role of the master component and the controller of the backup master component implementing or operating the composite controller). During the period in which the backup master component operates as the master component and the controller of the backup master component operates as the composite controller, the backup master component and its controller can operate with respect to the master component and the composite controller as described herein. In addition, the controller of the backup master component (which is then operating as a composite controller) can monitor whether the controller of the master component has restored valid communication with the client component(s) and / or the backup master component. Until such valid communication is restored, the controller of the backup master component may continue to operate as a composite controller as described herein.On the other hand, once such effective communication is restored (i.e., the controller of the master component restores effective communication with the client component(s) and / or the backup master component), the controller of the backup master component can transition back to operating as a composite controller, as described herein, by causing the controller of the master component to resume operation as a composite controller. After such a transition, the controller of the backup master component can resume operation as a backup “bookkeeper,” including receiving and / or monitoring commands and control messages communicated to or from the master component or between the master component and other components (e.g., receiving and / or recording the composite operating status of a production line control system from the composite controller).

[0052] As can be understood and as described herein, the master component, backup master component, and other client components can be any component of the production line control system. As shown in Figure 4, the master component may be a melter unit 402a, and the other client components (any of which may be able to operate as a backup master component) may similarly be melter units 402b-402d. However, other examples of the present disclosure are not limited thereto. For example, as shown in Figure 5, the master component may be a melter unit 402a, and the other client components (any of which may be able to operate as a backup master component) may include one type of melter unit 402b-402d, another type of melter unit 406, and a pattern control device 408. However, other combinations may be used as desired to suit a particular application.

[0053] Figure 6 shows a data flow diagram of method 600 for sending commands to multiple components of a production line control system or to components such as melter units. Specifically, method 600 can send commands (e.g., control data) between a master component (e.g., a first melter unit among multiple melter units) and one or more client components (e.g., a second melter unit among multiple melter units). The production line control system may be, for example, the production line control system 10 in Figure 1. Method 600 can be implemented, for example, within system 200 in Figure 2 and / or system 300 in Figure 3. Thus, multiple production line control system melter units may be the same as or similar to melter unit 202 in Figures 2 and 3. A melter unit may include a melter unit of a single production line control system, or it may include melter units of multiple different production line control systems, or a combination thereof. For example, the first melter unit and the second melter unit may both belong to the same production line control system, or they may each belong to different production line control systems.

[0054] In step 602, the operating status of the master component (for example, a first melter unit such as melter unit 202a in Figures 2 and 3 and / or melter unit 402a in Figure 4 or 5) is received. As described herein, the operating status of the master component can be received by a composite controller. In an example where the composite controller is the controller of the master component, the operating status of the master component can be received by the controller of the master component acting as the composite controller.

[0055] In step 604, the operating status of a client component (for example, another melter unit such as one of the melter units 202b to 202d in Figures 2 and 3 and / or one of the melter units 402b to 402d or 406 or pattern control device 408 in Figures 4 or 5) is received. As described herein, the operating status of the client component(s) may be received by the composite controller. In an example where the composite controller is the controller of the master component, the operating status of the master component may be received by the controller of the master component acting as the composite controller.

[0056] The operating status of the master component and / or the operating status of the client component(s) may, in some examples, include the status of operating parameters associated with these components and / or the operating modes of these components, such as production mode, setup mode, or maintenance mode. In some examples, the operating status of the master component and / or the operating status of the client component(s) may be in the form of signals generated by each component. These signals can generally be generated by the controller of each component (e.g., controller 204 in Figures 2 and 3). In some examples, the controller may be a melter unit. The signals may include, for example, beacon signals. The signals can be detected by a composite controller on a network to which the composite controller is connected. For example, the network may include a LAN (e.g., WLAN) in a production facility housing the composite system. Each component may generate a signal in response to its connection to the network. Each component may be configured to generate a signal (e.g., its operating status) at predetermined intervals.

[0057] In some examples, the operating status of a master component and / or client components(s) may include, or be in the form of, control data messages, which may include control data relating to the operating parameters of each component. For example, operating parameters may include temperature setpoints, temperature control loop settings, control loop types, pump speeds, pump motor speeds, heater duty cycles, or applicator cycle rates. Control data messages may include data about and / or measured by components, such as liquid temperature, liquid velocity, liquid flow rate, or hydraulic pressure. Control data messages may include hardware configuration of a first melter unit, such as the number of pumps, pump types, liquid holding capacity, number of hose outlets, power capacity, number of control interfaces, melter unit weight, melter unit external dimensions, flow throughput, or melting rate. In some examples, the operating status of one component (e.g., the state of operating parameters associated with that component and / or the operating mode of that component) may affect the operating status of one or more other components. For example, one or more components may change their operating mode based on the operating status of one or more other components. As one non-limiting example, the pattern controller may be configured not to discharge the pattern until the melter reaches a temperature setpoint and / or until the pump associated with the melter is turned on. As another non-limiting example, the melter may be placed in a temperature setback (standby) state after a prolonged period of inactivity of the pattern controller.

[0058] In step 606, the combined operating state of the production line control system is determined. As described herein, the combined operating state of the production line control system can be determined by the combined controller. The combined operating state of the production line control system can be determined (e.g., by the combined controller) at least in part based on the operating states of the master components and the operating states of the client components (which may be more than one). As a general example, if the operating states of the master components and the operating states of the client components (which may be more than one) are all determined to be operating states of a specific value or string (e.g., in production mode), the combined controller can determine that the combined operating state of the production line control system is the same operating state (e.g., in production mode).

[0059] In some cases, the combined operating state of a production line control system can be determined (e.g., by the combined controller) at least partially based on a hierarchy of operating states of the master component and the client component(s) (which may be multiple). For example, this hierarchy can be determined based on a default user hierarchy setting or a predetermined hierarchy setting. In some cases, it can be determined (e.g., by the combined controller) whether any of the components of the production line control system are required for production. Continuing these examples, if a particular component is determined to be required for production, but has an operating state indicating that it is not operational (e.g., the component is inoperable or, in the case of a melter unit, is experiencing a decrease in the discharge of molten adhesive), the combined operating state may reflect that the combined system is not operational, or it may otherwise indicate an error or alert within the combined system. Conversely, if a particular component is determined not to be required for production, its operating state can be ignored when determining the combined operating state of the production line control system (e.g., via the combined controller).

[0060] In step 608, a user interface is generated (for example, by a composite controller). In some examples, the user interface can be displayed via the screen 412 of the control device 410 of the master component (for example, the first melter unit 402a in Figure 4 or 5). The user interface can display multiple control tiles (for example, user-selectable control tiles) (for example, simultaneously) as described herein. Each of the multiple control tiles can represent one of multiple components of the production line control system. In a non-limiting example, the user interface can display control tiles representing the master component and additional control tiles representing client components (there may be more). The user interface can also additionally display indicators of the operating status of the master component, indicators of the operating status of client components (there may be more) and indicators of the combined operating status of the production line control system (for example, simultaneously). These indicators can generally take any form, such as text indicators (e.g., "Production", "Setup", "Service"), as desired to suit a particular application. In some examples, the user interface may display control tiles and other arbitrary display information based on default user display settings or predetermined display settings, such as the location and / or size of one or more of the control tiles.

[0061] In some examples, the user interface may display indicators of the operating status of each component of a plurality of components that are determined to be necessary for production, as described herein. In addition, the user interface may display indicators of the operating status of each component of a plurality of components that are determined not to be necessary for production, as described herein, regardless of whether such operating statuses are ignored when determining the combined operating status of the production line control system.

[0062] Control data relating to a production line control system (e.g., its components), including any control data contained in or indicated by commands transmitted by a composite controller, can be displayed. Such control data may include operating parameters of a production line control system or dispensing system (which may include more) comprising one or more melter units, and can be displayed via a user interface associated with the production line control system (e.g., user interface 800 in Figure 8 and / or user interface 1004 in Figure 10). In some examples, the control tiles may include one or more control tiles configured to display operating parameter states relating to operating parameters, as described herein. Similarly, via the user interface, as described herein, an operator can control at least some aspects of a production line control system or dispensing system (which may include more) comprising one or more melter units. For example, the user interface may be configured to allow adjustment of operating parameters of the production line control system or any of its components (e.g., melter units) based on user input to the user interface.

[0063] The user interface can be output (e.g., displayed) by one or more components of the production line control system (e.g., the melter unit 202e in Figure 2). The melter unit or any of the other components may include a control panel (e.g., panel 206 in Figures 2 and 3), which may display the user interface. In some examples, the composite system 200 may include a single user interface, but other examples are not limited thereto. For example, in some examples, the composite system 200 may include multiple user interfaces. Each user interface provided in the composite system 200 can generally be configured to navigate to any component of the composite system (e.g., to display information about that component), and each user interface provided in the composite system 200 can generally be configured to monitor and / or control any component of the composite system (e.g., to send commands or control messages). Generally, user interfaces(s) can provide access to each component of the control system. The components that display the user interface may or may not include the composite controller. The user interface can be further or alternatively output by a computing device associated with the production line control system (e.g., computing device 222 in Figures 2 and 3). The computing device can communicate with one or more of the components. For example, if one of the components includes a composite controller, the computing device can communicate with the composite controller of those components. The computing device can receive control data through these components, including control data indicated in command or control data messages. This control data can be displayed in the user interface output by the computing device.

[0064] Alternatively, the computing device can communicate with a cloud / edge server (e.g., server 230 in Figure 3) located remotely from the premises housing the production line control system. If the cloud / edge server includes a composite controller, the computing device can communicate with the composite controller of the cloud / edge server. The computing device can receive control data, including control data indicated in command or control data messages, via the cloud / edge server. This control data can be displayed on a user interface output by the computing device. The computing device may be located remotely from the premises housing the production line control system, such as a production facility, or it may be located on the same premises as the production line control system.

[0065] The user interface may include production line elements (e.g., production line element 802 in Figure 8) that represent a production line related to the components of the production line control system. The user interface may further include a plurality of system elements (e.g., system element 804 in Figure 8). One of the plurality of system elements may represent a liquid dispensing system of the production line control system. For example, a first system element may represent a first production line control system or liquid dispensing system comprising a first melter, and a second system element may represent a second production line control system or liquid dispensing system comprising a second melter. The production line elements and the plurality of system elements may be arranged on the user interface to reflect the relative positions within the relevant premises (e.g., production facility) of the production line and / or liquid dispensing system represented by the plurality of system elements. The user interface may include a composite state element (e.g., composite state element 812 in Figure 8) that represents a composite operating state of the production line control system, as described herein. A composite state element may have a corresponding unique symbol or image depending on the composite operating state of the system, such as a checkmark (composite state element 812 in Figure 8) indicating a positive composite operating state in some examples. In other examples, a composite state element may include an "×" or other symbol or image indicating a negative composite operating state. Furthermore or alternatively, a composite state element may be color-coded in some examples to represent the composite operating state of the production line control system, such as a colored border or colored text "Composite".

[0066] At least one of the multiple system elements may include an operating mode element (e.g., operating mode element 1019 in Figure 10) indicating the operating mode of the represented production line control system or liquid dispensing system. For example, the operating mode element may indicate that the represented component or liquid dispensing system is in production mode, setup mode, or maintenance mode. At least one of the multiple system elements may include a filling level element (e.g., filling level element 1034 in Figure 10) indicating the filling level related to the represented production line control system or liquid dispensing system. The filling level may, for example, relate to the liquid filling level in the melter unit of the liquid dispensing system. The system element may be configured to display an interface element (e.g., a pop-up) when activated. The interface element may display control data related to the production line control system or liquid dispensing system represented by the system element. For example, such control data may include multiple measured temperatures at various points within the production line control system or liquid dispensing system.

[0067] In step 610, a command (e.g., a command containing a control message, or a command in the form of a control message) is sent to the master component (e.g., by a composite controller). In step 612, the command sent to the master component (e.g., a command containing a control message, or a command in the form of a control message) is sent to the client component(s) (e.g., by a composite controller). The commands sent to the master controller and the client component(s) (e.g., may include instructions to operate the master component and / or client component(s) (e.g., as described herein). In some examples, the command may include operating parameters of the production line control system or one or more of its components. As described herein, operating parameters can be set and modified by user input (e.g., via a user interface). Upon receiving such user input, a command (in some cases, a modified command) may be sent to the master component and / or client component(s) (e.g., by a composite controller) (e.g., by a composite controller) to operate the master component and / or client component(s) (e.g., with the modified operating parameters). After sending a command or a modified command, the method flow in Figure 6 can be repeated, starting with receiving the operating status (e.g., updated status) of the master and / or client components(s).

[0068] One of the components of a production line control system may include a composite controller, which in some examples may include a control panel (e.g., panel 206) configured to display at least a portion of any control data indicated in a command. Alternatively, a remote cloud / edge server associated with the production line control system (e.g., server 230 in Figure 3) may implement the composite controller.

[0069] A computing device (for example, computing device 222 in Figures 2 and 3) can access any control data indicated in a command via a composite controller. The computing device may be located outside the premises housing multiple liquid discharge system melter units, or it may be located within the same premises housing the production line control system. The computing device may include at least one of a personal computer (PC), laptop computer, mobile device, tablet computer, or smartphone. In some examples, the computing device or HMI device may utilize a custom application web browser to implement or perform any of the features or processes described herein.

[0070] In some examples, client components(s) may be configured to transition between multiple modes, such as production mode, setup mode, and maintenance mode. In production mode, the controller of the client component in production mode may be configured to receive commands and / or control messages from the composite controller and to operate the component in response to such commands and / or control messages, as described herein. In maintenance mode, the controller of the client component in maintenance mode may be configured as "read-only," for example, by being configured to receive commands and / or control messages from the composite controller without operating the component in response to such commands and / or control messages.

[0071] In some cases, it may be desirable for the user to quickly identify one of the components of the production line control system via a user interface. In some cases, the user interface can identify each component of the production line control system by name, photograph, or other unique identifier. For example, control tiles displayed on the user interface may display such unique identifiers, each corresponding to a component of the production line control system. It may also be desirable to identify a specific component of the production line control system by sending a command that emits an identifier to one of the selected components of the production line control system (e.g., via a composite controller). This identifier may be an audible identifier (e.g., emitted by a horn on a user-selected component of the production line control system) and / or a visible identifier (e.g., emitted by a flashing indicator on a user-selected component of the production line control system, and / or emitted by a light tower on a user-selected component of the production line control system, as shown for the melter unit 402c with light tower 402d in Figure 4).

[0072] Figure 7 shows a data flow diagram of the decision method 700 used by the production line control system, particularly the backup master component.

[0073] Specifically, Method 700 can determine which controller of several components of a production line control system should implement or run the composite controller. Method 700 can be run, for example, as a subroutine of Method 600 in Figure 6, as described herein.

[0074] In step 702, as described herein, it can be determined (for example, by the controller of the backup master component) whether the controller of the master component has lost valid communication with the client component(s) and / or the backup master component. If, in step 702, it is determined that the controller of the master component has lost valid communication with the client component(s) and / or the backup master component (indicated by the arrow "Yes" extending away from step 702), then in step 704a, the controller of the backup master component may be configured to implement or run a composite controller as described herein. Subsequently, in step 706, as described herein, it can be determined (for example, by the controller of the backup master component) whether the controller of the master component has restored valid communication with the client component(s) and / or the backup master component.

[0075] If, in step 706, it is determined that the controller of the master component has restored valid communication with the client component(s) and / or the backup master component (indicated by the arrow "Yes" extending away from step 706), then in step 708a, the controller of the master component may be configured to implement or run a composite controller as described herein. The controller of the master component can then operate as a composite controller and subsequently perform the steps of method 600 in Figure 6. On the other hand, if, in step 706, it is determined that the controller of the master component has not restored valid communication with the client component(s) and / or the backup master component (indicated by the arrow "No" extending away from step 706), then in step 708b, the controller of the backup master component may be configured to implement or run a composite controller as described herein. The controller of the backup master component can then operate as a composite controller and subsequently perform the steps of method 600 in Figure 6. In addition, the controller of the backup master component can continue to monitor the connection status of the master controller by repeating step 706 (for example, continuously or at predetermined intervals) until the controller of the master component restores a valid connection with the client component(s) and / or the backup master component.

[0076] On the other hand, if in step 702 it is determined that the controller of the master component has not lost valid communication with the client component(s) and / or backup master component (indicated by the arrow “No” extending away from step 702), then in step 704b the controller of the master component may be configured to implement or run (or continue to implement or run) the composite controller as described herein. The controller of the master component may then implement or run the composite controller and subsequently carry out the steps of method 600 in Figure 6.

[0077] The backup master controller can be configured to repeat the method 700 in Figure 7 (for example, continuously or at predetermined intervals) to generally ensure that the production line control system continues to operate without unnecessary interruption.

[0078] Figure 8 shows a user interface 800 that can be used with the system described herein. The user interface 800 can display a visual representation of the production line and associated systems that reflect the actual layout in the production facility (i.e., premises). The user interface 800 can display various data about such systems. The user interface 800 can be implemented by a controller (e.g., controller 204 in Figures 2 and 3) and panel (e.g., panel 206 in Figures 2 and 3) of one or more components of the production line control system (e.g., melter unit 202 in Figures 2 and 3). The user interface 800 can further or alternatively be implemented by a composite controller (e.g., composite controller 210 in Figure 2) and a panel of a component equipped with a composite controller (e.g., melter unit 202e in Figure 2). The user interface 800 can further or alternatively be implemented by a composite controller (e.g., composite controller 232 in Figure 3) in a server (e.g., server 230 in Figure 3). The user interface 800 can be implemented by a computing device (e.g., computing device 222 in Figures 2 and 3) that communicates with the composite controller, either further or alternatively.

[0079] The user interface 800 can be associated with a production line (e.g., production machinery). A production line may include, for example, a production line for manufacturing disposable hygiene products or assembling corrugated cardboard packaging boxes. A production line can be represented in the user interface 800 by a production line element 802. The user interface 800 may include a plurality of system elements 804a to 804f (collectively referred to as one or more system elements 804). A system element 804 can be considered a "tile" of the user interface 804. Each tile or system element 804 can be associated with and represent a component of a production line control system (e.g., the production line control system 10 in Figure 1) or other types of systems. In some examples, the component corresponding to a system element 804 may be a melter unit, a pattern control device, or similar component, as described herein. The components corresponding to system elements 804 can be associated with each other via a common composite controller, as described herein. For example, a composite controller can be configured to communicate effectively with each component of a production line control system, and in some examples, the composite controller can interconnect the components in an operable manner so that information (e.g., control data) can be communicated between the components.

[0080] System elements 804 can be labeled according to their function in the production line or by another type of indicator. Each system element 804 may include an operating mode element 806 configured to indicate the operating mode or operating state of the corresponding component. For example, the operating mode element 806f of system element 804f shown in Figure 9 indicates that the corresponding system is in production mode. As another example, an operating mode element may indicate that the corresponding component is in setup mode or maintenance mode. The operating mode element 806 may have a corresponding unique image according to the indicated operating mode, as shown for the operating mode element 806f of system name 06 814f (system element 804f shown in Figure 9).

[0081] The system element 804 and the production line element 802 are visually positioned on the user interface 800 according to the relative positions of the corresponding components and production lines in the production facility (for example, to reflect or coincide with the relative positions). For example, a component represented by the system element 804 can be positioned at a specific location on the production line, and this position on the production line is reflected in the positioning of the system element 804 on the user interface 800 relative to the production line element 802. The relative positioning (and sizing) of the production line element 802 and the system element 804 is not necessarily to an exact scale.

[0082] The position of system element 804 on the user interface can be adjusted. For example, a user can provide input to the user interface 800 to adjust the position of system element 804. Alternatively, the system implementing the user interface 800 can automatically adjust the positioning of system element 804. As an example, when a new component or liquid dispensing system is installed on the production line, this component or liquid dispensing system can be automatically detected and inserted into the production architecture represented by the user interface 800. A system element 804 corresponding to the newly installed component or liquid dispensing system can be created on the user interface 800. The user (or controller) can then position the system element 804 according to the actual position of the new component or liquid dispensing system relative to the production line and other components. If the corresponding component is moved from one position on the production line to another on the production line, the user (or controller) can similarly adjust the position of system element 804.

[0083] Each system element 804 may further include a system state element 808 that indicates the state of the associated system, such as running, off, or faulty. In particular, the system state elements 808 can be color-coded to represent the system state of the associated system. For example, the green border of the system state element 808f of system name 06 (system element 804f shown in Figure 9) can indicate that system name 06 is running.

[0084] System element 804 may further include other elements such as subsystem states and / or user-selectable data, as shown in the subsystem state element 816f and data element 818f (e.g., user-selectable data element) of system element 804f shown in Figure 9. In some examples, data element 818f may represent unique data of a component represented by system element 804f, and can be intuitively represented by 10 or more different data points (e.g., temperature or pressure, pump speed, output of different zones or feature parts). The specific data displayed by data element 818f can be selected by the user or automatically set based on user-defined display settings.

[0085] The user interface 800 in Figure 8 and other user interfaces discussed herein can advantageously provide improved usability, accessibility, and / or control. For example, the user interface 800 in Figure 8 displays a "state list" display of the combined operating state of the production line control system (e.g., via the combined state element 812), which provides the operator with a quick and comprehensive way to recognize the combined operating state of the production line control system (e.g., the state of all relevant components of the system used when determining the combined operating state as described herein). In addition, as described herein, the operator can view the operating state of each individual component or subcomponent by browsing the user interface 800 or by individually clicking or activating any of the components via the user interface 800. Accessibility is improved by providing an intuitive means for the operator to browse the user interface screen of any component and quickly navigate to that screen, as described herein. Control (e.g., heater control and pump control) is improved by providing a comprehensive means for the operator to control all components and subcomponents from a single set of controls (e.g., via a control device). Furthermore, in some examples, the user interface 800 can enable the loading of a process from a single component to each component, thereby providing a comprehensive and efficient means by which the operator can effectively control the production line control system. In some examples, a process can be a collection of product-specific settings used to perform periodic production runs of the same product with consistent output. A process can include the selection of enabled external zones and the set values ​​for those zones, such as temperature, pressure settings, pump selection, adhesive application, etc. A composite process can be a master control or central control used (e.g., overall and / or simultaneously) for all connected components designated for production within the composite system.In some examples, a composite process may include product-specific settings for all such connected components, or it may load a common process name or process number for each component if the product-specific settings are stored locally within the components. The use of such a composite process can eliminate repetitive and other time-consuming processes that require the operator to individually access each component to load the process. In addition to or as an alternative to the above, the user interface 800 may provide means for the operator to perform composite master control, such as a set of one or more commands or control messages used to issue commands or control messages to all connected components designated for production within the composite system (e.g., globally and / or simultaneously). In non-limiting examples, such composite master control may include turning the master heater ON / OFF, turning the temperature setback ON / OFF, or turning the pump release ON / OFF. The use of such composite master control can eliminate repetitive and other time-consuming processes that require the operator to individually access each component to switch the master control ON / OFF.

[0086] To access further information and functions related to the corresponding system, the system element 804 can be interacted with or activated (e.g., clicked). For example, activation of the system element 804 can display a popup interface element on the user interface 800, or present a new and different user interface for accessing further information and functions. For example, Figure 10 shows the user interface 1004 displayed after the operator selects the system element 804a in Figure 8. Further information displayed when the system element 804 is activated may include the operating parameters of the corresponding component, current and / or past measurement data of the corresponding component, and / or hardware configuration data of the corresponding component. The popup or new user interface may include additional user interface elements corresponding to various data categories or data components of the component, or “tiles” such as the filling level monitoring tile 1034, pump monitoring tile 1035, pattern control or manufacturing process tile 1036, and / or temperature monitoring tile 1040 as shown in Figure 10. For example, activating the temperature monitoring tile 1040 may display another pop-up or user interface showing the system's temperature setpoint(s) and measured temperature values, as shown in Figure 11. As another example, activating an interface element of a specific melter unit in the system may display another pop-up or user interface showing various aspects of the melter unit's hardware configuration, such as the number of hose outlets, flow throughput capacity, pump type, physical dimensions, and available control interfaces. The pop-up or new user interface can be closed to return to a previous pop-up or user interface in the hierarchy. The previous pop-up or user interface includes user interface 800, as it is currently shown in Figure 8.The user interface 1004 and its elements shown in Figure 10 are examples of such user interfaces, pop-ups, tiles, or windows that can be integrated with user interface 800.

[0087] Figures 10 and 11 illustrate various aspects of the user-customizable graphical user interface 1004 output by the control device 410, such as via the screen 412 of the control device 410. While the user interface 1004 and its associated features are generally considered in relation to the melter unit, these disclosures are equally applicable to other components of the system 400, including pattern control devices, applicators, dispensing modules, hoses, and solid or semi-solid adhesive dispensers, or to heaters located within such other components. Generally, the user interface 1004 is configured to display control data (e.g., operating parameters or status information) for multiple melter units 402 and other components of the system 400. The user interface 1004 is further configured to allow the user to set or adjust various operating parameters of the melter units 402 and other components of the system 400. It will be understood that the specific parameters that can be displayed and / or controlled via the user interface 1004 will depend on the particular type of melter unit 402, the material to be dispensed, and / or the specific manufacturing protocol implemented in a given system 400. Examples of such parameters include, but are not limited to, the temperature of various components, pump rotation speed, material quantity, pressure, discharge pattern, amount of material discharged, type of material discharged, presence of gas, operating status of the melter, geographical and distance information, specific permission information, and the relative positioning of the melter unit 402 and other components of the system 400 in the production facility. In one embodiment, the user interface 1004 is configured to display, set, change, communicate and otherwise manipulate control data, such as the control data discussed herein.

[0088] The control device 410 can provide access to multiple operating modes. For example, in "production" mode, certain parameters can be changed. Setpoints and operating modes can be changed, but other system configurations can remain unchanged. In "setup" mode, the control device 410 can enable system simulation, initial parameter setup, verification of component functionality, and system purging. In "maintenance" mode, the control device 410 can enable maintenance of the melter unit 402 or other components (e.g., replacement of pumps, filters, or other components).

[0089] The control device 410 can enable one or more users to simultaneously monitor and / or change the parameters of multiple melter units 402 or other components. This reduces the time required to monitor each individual melter unit 402 or other component separately. Furthermore, instead of having to individually change the parameters for each separate melter unit 402 or other component, the user can send commands to all melter units 402 or other components of the system 400 simultaneously.

[0090] The control device 410 can enable the user to compare individual melter units 402 to determine damage, defects, or other inconsistencies within the system 400. By enabling control of all melter units 402 in the system 400, the user can stop or pause one or more melter units 402 for any number of reasons (e.g., maintenance, overheating, material reloading, etc.) and ensure that the remaining melter units 402 in the system 400 compensate for the stopped or paused melter. This can help maintain consistent production and reduce downtime.

[0091] As described above, the user interface 1004 is configured to be user-customizable. For example, most of the state / parameter information and control functions are presented through a series of interactive interface elements called "tiles." Specific configurations regarding which tiles are displayed in the user interface 1004, where the tiles are displayed in the user interface 1004, and when the tiles are displayed in the user interface 1004 can be determined, at least in part, by the user's preference settings.

[0092] As shown in Figure 10, the user interface 1004 can be divided into a state area 1030 and a dashboard area 1031. The dashboard area 1031 can generally be the area where the aforementioned tiles are displayed and interacted with.

[0093] With respect to the state area 1030, element 1018 indicates a selected melter unit 402 or other component (in this case, "system name 01") in which various information and control functions are presented at least partially within the dashboard area 1031. The selected component indicated by this element can be selected from various components represented in the user interface 800 shown in Figure 8. Furthermore, or alternatively, the component indicated by element 1018 can be selected via a dropdown menu associated with element 1018. The operation mode element 1019 indicates the operation mode of the selected component, such as production, setup, or maintenance. The operation mode of the selected component can be controlled via the operation mode element 1019. The composite state element 1012 can indicate the state of the composite system 400, which can also be controlled via the composite state element 1012. The state area 1030 may also include an interface element 1038 that can be activated to start various user functions. For example, a user can log in to the system by entering their user ID and password and load user preference settings regarding the user interface configuration.

[0094] The dashboard area 1031 is configured to display one or more tiles. The tiles can display various information about the system 400, the selected component, and / or the status / operational parameters of various subsystems or functions of the selected component. The tiles can further or alternatively allow various operation parameters or settings to be set or adjusted. Some tiles can be configured to have multiple subtiles. Some tiles (including subtiles) can be configured to open other tiles or windows that typically provide further information or access to additional settings or controls related to the initial tile. Through user preference settings, the user can customize various attributes of the dashboard area 1031 that are applied when logging into the user interface 1004 and / or the control device 410. For example, user preference settings can define which tiles are displayed first in the dashboard area 1031. User preference settings can further define the initial placement of tiles within the dashboard area 1031 and / or the relative sizes of the tiles. User preference settings can further define what action or function is performed when a particular tile or tile element is activated or interacted with (e.g., clicked or pressed). The user can also, or alternatively, change the arrangement or appearance of tiles while the user interface 1004 is displayed, such as closing tiles, moving tiles (e.g., dragging and dropping), or minimizing tiles. Tiles can also be positioned overlapping other tiles, either entirely or partially.

[0095] Referring to Figure 10 again, the "System Name 01" component is selected. This allows the filling level monitoring tile 1034, pump monitoring tile 1035, pattern control or manufacturing method tile 1036, and temperature monitoring tile 1040 to be displayed in the dashboard area. The filling level monitoring tile 1034 visually and numerically displays the current filling level percentage (72%) of the adhesive reservoir associated with the "System Name 01" melter unit. The user can directly set or adjust the parameters shown on the filling level monitoring tile 1034. The pump monitoring tile 1035 contains one or more pump subtiles 1039, each corresponding to the pump of the selected "System Name 01" melter unit. Each pump subtile 1039 displays one or more of the following: the name of the corresponding pump (e.g., "Pump 1", "Pump 2") and the current pump speed (rpm). When activated, the pattern control or manufacturing method tile 1036 can start the loaded manufacturing method or discharge pattern selection function. The loaded manufacturing process or dispensing pattern can be used by one or more components of the selected "System Name 01" melter unit to prepare or dispensing adhesive or other liquids. The temperature monitoring tile 1040 generally shows the temperatures of various parts of the selected "System Name 01," including the associated grid, reservoir, hose, and applicator. Each of these temperature points (e.g., temperature channels) corresponds to one of the temperature subtiles 1041 within the temperature monitoring tile 1040. Depending on the specific component or location where the temperature is measured, the state of the component, and / or various display settings, the temperature subtile 1041 may show the current measured temperature and name of the heater or other component. As a non-limiting example, Figure 11 shows the temperature monitoring tile 1040 after activation to immediately show additional information in the temperature subtile 1041 for each part of the component (e.g., "Grid (T1)"), such as the temperature setpoint, current measured temperature, and name of that part.

[0096] Typically, the controllers of each component of a production line control system may have a fixed Ethernet address determined by such controller. However, in other examples, the controllers of each component of a production line control system may be assigned an Ethernet address (for example, by a composite controller using Dynamic Host Configuration Protocol (DHCP)). Next, referring to Figure 12, the production line control system may include an automatic network switch 1220. The automatic network switch 1220 can be configured to connect each component of the production line control system to each other operably on a composite network, for example, by connecting to a network adapter 1210 (e.g., Wi-Fi). The automatic network switch 1220 can be further configured to isolate selected components from the composite network mechanically (e.g., by relays or switches) or electronically (e.g., by one or more integrated circuits). This can be useful in avoiding collisions (e.g., resulting in unexpected and unpredictable behavior) that may occur when an operator wants to operate one of the components in a non-composite mode, for example, by changing the Ethernet address of that component back to its fixed address, while that component remains connected to the composite network.

[0097] As shown in Figure 12, the automatic network switch 1220 may include multiple ports. As a non-limiting example, the automatic network switch 1220 may include one or more of the following: a first port configured to operably connect the automatic network switch 1220 to other components (there is no connection to the first port shown in Figure 12); a second port configured to operably connect the automatic network switch 1220 to the network adapter 1210 (1215); a third port configured to operably connect the automatic network switch 1220 to a composite network (1225); a fourth port configured to operably connect the automatic network switch 1220 to the controller and / or operator interface of the client component 1230 (1235); and a fifth port configured to operably connect the automatic network switch to other components (1245). In some examples, the automatic network switch 1220 can be configured to isolate components of the production line control system from the composite network by disabling a third port, thereby enabling the operator interface of such components to communicate operably with the controller of such components. Alternatively, the controller of such components can be configured to disable the third port via software control. In some examples, the client component 1230 can be operably connected to a USB Ethernet adapter 1250 or other components (1255).

[0098] The following are some non-limiting examples of aspects of the present disclosure. One example is: Example 1A. A production line control system configured to monitor and / or control at least one dispensing device, the production line control system comprising a plurality of components, including a master component and at least one client component, wherein the master component and at least one of the at least one client component are configured to implement or run a composite controller, the composite controller being configured to communicate effectively with each of the plurality of components, and to receive the operating status of the master component from the controller of the master component, and to receive the operating status of at least one client component from the controller of at least one client component, and the operating status of the master component and the operating status of at least one client component The production line control system includes: determining the combined operating state of the production line control system based at least in part on the rotation state; generating a user interface that displays a plurality of control tiles, each of which controls the control tile representing at least one of (a) one of a plurality of components and (b) user-selectable component data of the plurality of components; an indicator of the operating state of a master component; an indicator of the operating state of at least one client component; and an indicator of the combined operating state of the production line control system; sending commands to the controller of the master component; and sending commands to the controller of at least one client component. Example 1B. A production line control system configured to monitor and / or control at least one discharger, wherein the production line control system comprises a plurality of components, including a master component including a controller; at least one client component including a controller; and a backup master component including a controller, wherein both the controller of the master component and the controller of the backup master component are configured to communicate effectively with each of the plurality of components.The controller of the master component is configured to implement or run a composite controller, and the controller of the backup master component is configured to determine whether the controller of the master component has lost valid communication with at least one client component and the backup master component, and if the controller of the backup master component determines that the controller of the master component has lost valid communication with at least one client component and the backup master component for a predetermined minimum amount of time, implement or run the composite controller, and the composite controller is configured to receive the operating status of the master component from the controller of the master component, receive the operating status of at least one client component from the controller of at least one client component, receive the operating status of the backup master component from the controller of the backup master component, and the operating status of the master component A production line control system configured to: determine the combined operating state of the production line control system based at least partially on the operating state of at least one client component and the operating state of a backup master component; generate a user interface that displays a plurality of control tiles, each of which controls the control tile represents at least one of (a) one component from the plurality of components and (b) user-selectable component data of the plurality of components; an indicator of the operating state of the master component; an indicator of the operating state of at least one client component; an indicator of the operating state of a backup master component; and send commands to the controller of the master component; send commands to the controller of at least one client component; and send commands to the controller of the backup master component. Example 1C. Master component and,A method for sending commands to multiple components of a production line control system, including at least one client component, comprising: receiving the operating status of a master component from the controller of the master component in a composite controller implemented or executed by the master component and at least one of the at least one client component; receiving the operating status of at least one client component from the controller of the client component in the composite controller; determining the composite operating status of the production line control system at least partially based on the operating status of the master component and the operating status of at least one client component; generating a user interface that displays a plurality of control tiles, each of which represents at least one of (a) a component of the production line control system including a master component and at least one client component, and (b) user-selectable component data of the master component or at least one client component; an indicator of the operating status of the master component; an indicator of the operating status of at least one client component; and an indicator of the composite operating status of the production line control system; sending a command to the controller of the master component; and sending a command to the controller of at least one client component.

[0099] All combinations of this paragraph and the preceding paragraph (including the removal or addition of features or steps) are considered in a manner consistent with the other parts of this disclosure. To avoid doubt, Examples 1A, 1B and 1C described above may further include any one or more combinations of the following examples: Example 2. A production line control system of any example herein, in which the composite controller is implemented or executed by a human-machine interaction (HMI) device. Example 3. A production line control system of any example herein, in which the controller of the master component is configured to implement or execute the composite controller. Example 4. A production line control system of any example herein, in which a cloud server located remotely from the premises housing the production line control system is configured to implement or execute the composite controller. Example 5. A production line control system of any example herein, in which the master component is a melter unit or a pattern controller. Example 6. A production line control system of any example herein, in which at least one client component is a melter unit or a pattern controller. Example 7. A production line control system of any example herein, in which the master component is a melter unit and at least one client component is a pattern controller. Example 8. A production line control system of any example herein, wherein at least one client component comprises multiple client components. Example 9. The production line control system of Example 8, wherein one of the multiple components is a melter unit and another of the multiple components is of a type other than a melter unit (e.g., a pattern controller). Example 10. The production line control system of Example 8, wherein the composite controller is configured to determine the composite operating state of the production line control system at least partially based on a hierarchy of the operating states of the master component and the operating states of at least one client component. Example 11. The production line control system of Example 10, wherein the hierarchy is determined based on a default user hierarchy setting.Example 12. The production line control system of Example 10, further configured in which the composite controller determines whether any of the multiple components are not required for production. Example 13. The production line control system of Example 12, further configured in which the composite controller ignores the operating status of any of the multiple components that are not required for production when determining the composite operating status of the production line control system. Example 14. The production line control system of Example 12, further configured in which the composite controller outputs a user interface that displays an indicator of the operating status of each of the multiple components that are required for production. Example 15. The production line control system of Example 12, further configured in which the composite controller outputs a user interface that displays an indicator of the operating status of any of the multiple components that are not required for production. Example 16. The production line control system of any example herein, further configured in which the composite controller outputs a user interface that displays production line elements representing a production line associated with multiple components. Example 17. The production line elements and multiple control tiles are arranged on the user interface to reflect the relative positions of the production line and multiple components represented by the multiple control tiles within the associated premises. Example 18. A production line control system of any example herein, in which each of a plurality of control tiles contains a unique identifier corresponding to one of a plurality of components. Example 19. A production line control system of any example herein, in which the composite controller is further configured to send a command to one of the plurality of components selected by the user to send the identifier. Example 20. The production line control system of Example 19, in which the identifier is an audible identifier. Example 21. The production line control system of Example 20, in which the audible identifier is configured to be sent by one of the plurality of components selected by the user. Example 22. The production line control system of Example 19, in which the identifier is a visible identifier.Example 23. A production line control system from Example 22, in which a visible identifier is transmitted by a user-selected flashing indicator among multiple components. Example 24. A production line control system from Example 22, in which a visible identifier is transmitted by a user-selected light tower among multiple components. Example 25. A production line control system from any example herein, in which the operating state of at least one client component includes at least one of the operating mode of at least one client component or the state of an operating parameter associated with at least one client component. Example 26. A production line control system from Example 25, in which the operating state of at least one client component includes an operating mode selected from the group consisting of production mode, setup mode, and maintenance mode. Example 27. A production line control system from any example herein, in which a composite controller is configured to output a user interface that displays multiple control tiles based on a default user display setting. Example 28. A production line control system from Example 27, in which at least one of the location of one of the multiple control tiles and the size of one of the multiple control tiles is based on a default user display setting. Example 29. A production line control system from any example herein, in which a command includes an operating parameter. Example 30. The production line control system of Example 29, which includes multiple control tiles, each configured to display the operating parameter state related to the operating parameter. Example 31. The production line control system of Example 29, which includes multiple control tiles, each configured to receive user input to change the operating parameter.Example 32. A production line control system of Example 31, further configured to: receive user input to change operating parameters, send a changed command to at least one of the controllers of the master component and at least one client component, the changed command including an instruction to operate at least one of the controllers of the master component and at least one client component to which the changed command is sent, in order to operate with the changed operating parameters; and receive an updated operating state from at least one of the controllers of the master component and at least one client component to which the changed command is sent. Example 33. A production line control system of any example herein, the command including control data relating to operating parameters of the master component or at least one client component, the operating parameters including at least one of a temperature setpoint, temperature control loop setting, control loop type, pump speed, pump motor speed, heater duty cycle, or applicator cycle rate. Example 34. A production line control system of any example herein, the command including control data relating to data measured by the master component or at least one client component, the data including at least one of liquid temperature, liquid flow rate, liquid flow rate, or hydraulic pressure. Example 35. A production line control system in any example herein, in which a command includes control data relating to hardware configuration data of a master component or at least one client component, the hardware configuration data including at least one of the following: number of pumps, pump type, liquid holding capacity, number of hose outlets, power capacity, number of control interfaces, unit weight, unit external dimensions, flow throughput, or melting rate.Example 36. A production line control system of any example herein, wherein at least one client component is configured to transition between (a) a production mode in which the controller of at least one client component is configured to receive commands and operate at least one client component in response to commands, and (b) a maintenance mode in which the controller of at least one client component is configured to receive commands only, without operating at least one client component in response to commands. Example 37. A production line control system of any example herein, wherein the multiple components include a backup master component. Example 38. The production line control system of Example 37, wherein the backup master component includes a controller configured to maintain valid communication with each of the multiple components. Example 39. The production line control system of Example 38, wherein the controller of the backup master component is configured to determine whether the controller of the master component has lost valid communication with at least one client component and the backup master component, and to implement or execute a composite controller if the controller of the backup master component determines that the controller of the master component has lost valid communication with at least one client component and the backup master component for a predetermined minimum amount of time. Example 40. The production line control system of Example 39, wherein the predetermined minimum time is approximately 5 seconds.Example 41. The production line control system of Example 39, wherein the controller of the backup master component is further configured to monitor whether the controller of the master component has regained valid communication with at least one client component and the backup master component if the controller of the backup master component has lost valid communication with at least one client component and the backup master component for a predetermined minimum amount of time, and the controller of the master component is configured to implement or run a composite controller if the controller of the backup master component has regained valid communication with at least one client component and the backup master component. Example 42. The production line control system of Example 39, wherein the controller of the backup master component is configured to implement or run a composite controller if the controller of the master component has not lost valid communication with at least one client component and the backup master component for a predetermined minimum amount of time, and the controller of the backup master component is configured to receive the composite operating status of the production line control system from the composite controller. Example 43. A production line control system of any example herein, wherein the controller of at least one client component has a fixed Ethernet address determined by the controller of at least one client component. Example 44. A production line control system of any example herein, wherein the composite controller is further configured to assign the Ethernet address of the controller of at least one client component. Example 45. The production line control system of Example 44, further comprising an automated network switch configured to operably connect each of several components to each other on a composite network. Example 46. The production line control system of Example 45, wherein the automated network switch is configured to operably connect each of several components to each other on a composite network using Dynamic Host Configuration Protocol (DHCP). Example 47. The production line control system of Example 45, wherein the automated network switch is configured to mechanically isolate at least one client component from the composite network. Example 48. The production line control system of Example 45, wherein the automated network switch includes a first port configured to operably connect the automated network switch to a network adapter, a second port configured to operably connect the automated network switch to a composite network, and a third port configured to operably connect the automated network switch to at least one of the controller and / or operator interfaces of at least one client component. Example 49. The production line control system of Example 48, wherein the automatic network switch is configured to electronically isolate at least one client component from the composite network by disabling a third port, thereby allowing the operator interface of at least one client component to communicate operably with the controller of at least one client component. Example 50. The production line control system of Example 48, wherein the controller of at least one client component is configured to disable a third port via software control.

[0100] Those skilled in the art will understand that the systems and methods disclosed herein can be implemented via a computing device comprising, but is not limited to, one or more processors, system memory, and a system bus connecting various system components, including the processors, to the system memory. In the case of multiple processors, the system can utilize parallel computing.

[0101] For illustrative purposes, application programs such as operating systems and other executable program components are shown herein as individual blocks, but it is understood that such programs and components reside at different points in time within different storage components of a computing device and are executed by the computer's data processor(s). Embodiments of service software may be stored in any form of computer-readable medium or transmitted through any form of computer-readable medium. Any of the disclosed methods may be executed by computer-readable instructions embodied in a computer-readable medium. The computer-readable medium may be any available medium accessible by a computer. For example, and without limitation, the computer-readable medium may include “computer storage medium” and “communication medium.” “Computer storage medium” includes volatile and non-volatile media, removable and non-removable media, implemented by any method or technique for storing information such as computer-readable instructions, data structures, program modules, or other data. Examples of computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disk (DVD) or other optical storage devices, magnetic cassettes, magnetic tapes, magnetic disk storage devices or other magnetic storage devices, or any other media that can be used to store desired information and can be accessed by a computer. Application programs and / or storage media can be implemented, at least in part, on a remote system.

[0102] Embodiments of this disclosure can be implemented, for example, in any type of computing device having wired / wireless communication capabilities via the above-mentioned communication channel, such as desktop computers, personal computers, laptop / mobile computers, personal data assistants (PDAs), mobile phones, tablet computers, and cloud computing devices.

[0103] Aspects of this disclosure may include communication channels that can be any type of wired or wireless electronic communication network. This electronic communication network may use known protocols such as, for example, Global System for Mobile Communications (GSM), CDMA (Code Division Multiple Access), GSM / EDGE and UMTS / HSPA network technologies, Long-Term Evolution (LTE), 5G (Fifth Generation Mobile Network or Fifth Generation Wireless System), WiMAX, HSPA+, W-CDMA (Wideband Code Division Multiple Access), CDMA2000 (also known as C2K or IMT Multi-Carrier (IMT-MC)), Wireless Fidelity (Wi-Fi), Bluetooth, and / or combinations of two or more of these, and may be wired / wireless local These include wide area networks (LANs), wired / wireless personal area networks (PANs), wired / wireless home area networks (HANs), wired / wireless wide area networks (WANs), campus networks, metropolitan networks, enterprise private networks, virtual private networks (VPNs), internetworks, backbone networks (BBNs), global area networks (GANs), the internet, intranets, extranets, overlay networks, near-field communication (NFC), mobile phone networks, and personal communication services (PCS). The NFC standard encompasses communication protocols and data exchange formats and is based on existing radio frequency identification (RFID) standards, including ISO / IEC 14443 and FeliCa. These standards include those defined by ISO / IEC 18092[3] and the NFC Forum.

[0104] It should also be noted that the software embodiments of this disclosure described herein may optionally be stored on tangible storage media such as magnetic media like disks or tapes; magneto-optical media or optical media like disks; or solid media such as memory cards or other packages containing one or more read-only (non-volatile) memories, random-access memories, or other rewritable (volatile) memories. Digital file attachments to emails or other self-contained information archives or sets of archives are considered equivalent distribution media to tangible storage media. Accordingly, this disclosure is deemed to include tangible storage media or distribution media such as those enumerated herein, including equivalents and successor media approved in the art on which the software embodiments described herein are stored.

[0105] In addition, various aspects of this disclosure can be implemented in non-general-purpose computer embodiments. Moreover, as is evident from the disclosure, various aspects of this disclosure improve the functionality of a system. Furthermore, various aspects of this disclosure involve computer hardware specifically programmed to solve the complex problems addressed by this disclosure. Thus, various aspects of this disclosure improve the functionality of a system overall in their particular embodiments that perform the processes described by this disclosure and defined by the claims.

[0106] Aspects of this disclosure may include a server running an instance of an application or software configured to receive requests from a client and provide responses accordingly. This server may run on any computer, including a dedicated computer. The computer may include at least one processing element, typically a central processing unit (CPU), and some form of memory. The processing element may perform arithmetic and logical operations, and an ordering and control unit may change the order of operations according to stored information. The server may include peripheral devices that enable the retrieval of information from external sources and the storage and retrieval of calculation results. The server may operate within a client-server architecture. The server may perform several tasks on behalf of a client. A client may connect to the server over a network on a communication channel defined herein. The server may use memory with error detection and correction, redundant disks, redundant power supplies, etc.

[0107] Where used herein and in the appended claims, terms that do not specify a quantity include multiple subjects unless the context clearly indicates otherwise. Where such a range is given herein, it may be given as "about" a particular value and / or "about" another particular value. Where such a range is given, another embodiment includes this particular value and / or this other particular value. Similarly, where a value is indicated as an approximation by the use of "about" before it, it will be understood that this particular value forms another embodiment. It will be further understood that each endpoint of these ranges is significant, whether in relation to or independent of the other endpoints.

[0108] Unless expressly otherwise specified, none of the methods described herein are ever intended to be construed as requiring their steps to be performed in a particular order. Therefore, if a method claim does not actually describe the order in which its steps should be followed, or if it is not specifically stated in the claims or specification that the steps should be limited to a particular order, no order is ever intended to be inferred. This applies to any possible implicit grounds for interpretation, including logical matters relating to the arrangement of steps or operational flows, obvious meanings derived from grammatical structure or punctuation, and the number or type of embodiments described in the specification.

[0109] Those skilled in the art will see that various modifications and variations can be made without departing from the scope or spirit. Other embodiments will also be apparent to those skilled in the art from considering the details and practices disclosed herein. The details and examples are intended to be considered illustrative only, and the true scope and spirit are shown by the appended claims.

Claims

1. A production line control system configured to monitor and / or control at least one dispensing device, The production line control system comprises a plurality of components, including a master component and at least one client component. The master component and at least one of the at least one client component are configured to implement or run a composite controller, the composite controller is configured to communicate effectively with each of the plurality of components, The operating status of the master component is received from the controller of the master component, The operating status of the at least one client component is received from the controller of the at least one client component. The combined operating state of the production line control system is determined at least partially based on the operating state of the master component and the operating state of the at least one client component. It is a user interface, Each of the multiple control tiles represents at least one of (a) one component of the multiple components, and (b) user-selectable component data of the multiple components. The indicator of the operating status of the master component, The indicator of the operating status of the at least one client component, The indicator of the combined operation state of the production line control system, To generate a user interface that displays, Sending a command to the controller of the master component, Sending the command to the controller of the at least one client component, A production line control system configured to perform the following actions.

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

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

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

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

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

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

8. The production line control system according to claim 7, wherein the hierarchy is determined based on a default user hierarchy setting.

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

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

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

12. The production line control system according to claim 11, wherein the plurality of control tiles include a control tile configured to receive user input to change the operating parameters.

13. When the composite controller receives the user input to change the operating parameters, Sending a modified command to at least one of the controllers of the master component and the at least one of the controllers of the at least one client component, wherein the modified command includes an instruction to operate the master component and the at least one of the at least one client component to which the modified command is sent, in order to operate with the modified operating parameters. The updated operating status is received from at least one of the controllers of the master component and the at least one client component, to which the modified command is sent. The production line control system according to claim 12, further configured to perform the following:

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

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

16. The production line control system according to claim 15, further comprising an automatic network switch configured to connect each of the plurality of components in an operable manner to one another on a composite network.

17. The aforementioned automatic network switch is The automatic network switch is configured to have a first port that is operablely connected to a network adapter, A second port configured to connect the aforementioned automatic network switch to the aforementioned composite network in an operable manner, The automatic network switch is configured to operably connect to at least one of the controller of the at least one client component and the operator interface of the at least one client component, A production line control system according to claim 16, including the above.

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

19. A production line control system configured to monitor and / or control at least one dispensing device, The production line control system comprises a plurality of components, including a master component including a controller, at least one client component including a controller, and a backup master component including a controller. Both the controller of the master component and the controller of the backup master component are configured to communicate effectively with each of the plurality of components. The controller of the master component is configured to implement or run a composite controller. The controller of the backup master component is The controller of the master component determines whether it has lost effective communication with the at least one client component and the backup master component. If the controller of the backup master component determines that the controller of the master component has lost effective communication with at least one client component and the backup master component for a predetermined minimum amount of time, the composite controller is implemented or executed. It is configured to do the following: The aforementioned composite controller is The operating status of the master component is received from the controller of the master component, The operating status of the at least one client component is received from the controller of the at least one client component. The operating status of the backup master component is received from the controller of the backup master component, The combined operating state of the production line control system is determined at least partially based on the operating state of the master component, the operating state of the at least one client component, and the operating state of the backup master component. It is a user interface, Each of the multiple control tiles represents at least one of (a) one component of the multiple components, and (b) user-selectable component data of the multiple components. The indicator of the operating status of the master component, The indicator of the operating status of the at least one client component, The indicator of the operating status of the backup master component, The indicator of the combined operation state of the production line control system, To generate a user interface that displays, Sending a command to the controller of the master component, Sending the command to the controller of the at least one client component, Sending the command to the controller of the backup master component, A production line control system configured to perform the following actions.

20. A method for sending commands to multiple components of a production line control system, which includes a master component and at least one client component, The operating status of the master component from the controller of the master component is received by a composite controller implemented or executed by the master component and at least one of the at least one client component. The composite controller receives the operating status of at least one client component from the controller of the client component, The combined operating state of the production line control system is determined at least partially based on the operating state of the master component and the operating state of the at least one client component. It is a user interface, Each of the plurality of control tiles represents at least one of the following: (a) a component of the production line control system including the master component and the at least one client component, and (b) user-selectable component data of the master component or the at least one client component. The indicator of the operating status of the master component, The indicator of the operating status of the at least one client component, The indicator of the combined operation state of the production line control system, To generate a user interface that displays, Sending a command to the controller of the master component, Sending the command to the controller of the at least one client component, Methods that include...

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