Method and system for machine visualization and control

Abstract

A method for cooling visualization and control in a casting die includes: measuring temperature and flow rate of a cooling fluid in each of a plurality of coolant passages in the casting die and to generate cooling data; capturing at least one thermal image of the casting die; integrating each of the thermal image and the cooling data with a three-dimensional (3D) model of the casting die to generate an integrated model; and generating a 3D visualization of the casting die including at least one of a heat map visualization and a flow visualization using the integrated model.

Description

Attorney Docket No. 18402-05307 (713507PCT)METHOD AND SYSTEM FOR MACHINE VISUALIZATION AND CONTROLCROSS REFERENCE TO RELATED APPLICATIONS[00011 This PCT International Patent Application claims the benefit of U.S. ProvisionalPatent Application No. 63 / 688,453, filed August 29, 2024, and U.S. Provisional Patent Application No. 63 / 739,750, filed December 30, 2024, the contents of which are incorporated herein by reference in their entirety.FIELD

[0002] The present disclosure relates generally to human-machine interfaces for user interaction with automation equipment, such as machine cells. The present disclosure also relates to visualizing and controlling liquid cooling in machines, such as casting dies.BACKGROUND

[0003] A casting die, such as a High Pressure Die Casting (HPDC) production cell, may include several different sub-systems with limited ability to combine data and to derive process improvements.

[0004] Automation equipment on a factory floor may be divided into machine cells for performing one or more manufacturing operations, such as casting, machine, finishing, etc. Stakeholders, such as engineers, technicians, maintenance personal, etc. may need to review numerous data regarding such automation equipment. Presenting such data regarding automation equipment in a way that is both intuitive and useful for the stakeholders can present challenges.

[0005] Simulation Software may be used to simulate data regarding automation equipment, such as thermals and material flows in a casting die. However, conventional simulation software does not provide an ability to integrate live data and generally has significant simulationAttorney Docket No. 18402-05307 (713507PCT) lead times. For example, a conventional simulation may take substantially longer to execute than the process being simulated. Thus, conventional simulation software is unsuitable for real-time die casting applications. Generic digital twin software may be employed for modeling processes performed by the automation equipment, such as cooling in a casting die. However, such generic digital twin software is limited in its ability to integrate and fuse live data.SUMMARY

[0006] The present disclosure provides a method for cooling visualization and control in a casting die. The method includes: measuring temperature and flow rate of a cooling fluid in each of a plurality of coolant passages in the casting die; calculating cooling data based on the flow rate and the temperature of the cooling fluid in each of the plurality of coolant passages; capturing at least one thermal image of the casting die; integrating each of the thermal image and the cooling data with a three-dimensional (3D) model of the casting die to generate an integrated model; and generating a 3D visualization of the casting die including at least one of a heat map visualization and a flow visualization using the integrated model.

[0007] The present disclosure also provides a system for cooling visualization and control. The system includes: a casting die having one or more dies and a plurality of coolant passages; a thermal imaging camera configured to measure surface temperatures of the casting die; a plurality of temperature sensors each configured to measure a temperature of one of the dies or a cooling fluid in a corresponding one of the coolant passages; a plurality of flow sensors each configured to measure a flow rate of the cooling fluid in the corresponding one of the coolant passages; and a visualization controller. The visualization controller is configured to: acquire thermal imaging data from the thermal imaging camera; acquire temperature data from the plurality of temperature sensors and flow data from the plurality of flow sensors; calculate cooling data based on the flowAttorney Docket No. 18402-05307 (713507PCT) data and the temperature data; integrate each of the thermal imaging data and the cooling data with a three-dimensional (3D) model of the casting die to generate an integrated model; and generate a 3D visualization of the casting die including at least one of a heat map visualization and a flow visualization using the integrated model.|0008[ The present disclosure also provides a system for visualization and control of automation equipment for manufacturing. The system comprises: a machine cell including one or more automation devices and / or machines; and a visualization controller. The visualization controller is configured to: receive data regarding the one or more automation devices and / or machines; and generate a 3D visualization of the one or more automation devices and / or machines.

[0009] The present disclosure also provides a method for visualization and control of automation equipment for manufacturing.

[0010] These and other aspects of the present disclosure are disclosed in the following detailed description of the embodiments, the appended claims, and the accompanying figures.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Further details, features and advantages of designs of the invention result from the following description of embodiment examples in reference to the associated drawings.

[0012] FIGS. 1A - IB each show a schematic block diagram of a digital twin.

[0013] FIG. 2 shows a block diagram of a system for visualization and control of automation equipment for manufacturing, in accordance with the present disclosure.

[0014] FIG. 3 shows a user interface screen including controls, tabular data, and a 3D visualization of the casting die, including graphic representations of temperature therein, in accordance with the present disclosure.Attorney Docket No. 18402-05307 (713507PCT)(0015] FIG. 4 shows a user interface screen including a 3D visualization of the casting die with six coolant circuits highlighted and illustrating temperatures therein, in accordance with the present disclosure.

[0016] FIG. 5 shows a user interface screen including a 3D visualization of the casting die with six coolant circuits highlighted and illustrating flow therein, in accordance with the present disclosure.

[0017] FIG. 6 shows a user interface screen including a 3D visualization of four coolant circuits in the casting die and illustrating temperatures therein, and with the dies not visible, in accordance with the present disclosure.

[0018] FIG. 7 shows a schematic flow diagram illustrating steps in a method for cooling visualization and control in a casting die.

[0019] FIG. 8 shows a schematic block diagram of a cooling sub-system for a casting die, in accordance with an aspect of the present disclosure.

[0020] FIG. 9 shows a first user interface screen including a grid view with several machine cells, according to an aspect of the present disclosure.

[0021] FIG. 10 shows a second user interface screen including a grid view with several machine cells, and showing performance data, according to an aspect of the present disclosure.

[0022] FIG. 11 shows a third user interface screen including a 3D perspective view of a machine cell, according to an aspect of the present disclosure.

[0023] FIG. 12 shows a fourth user interface screen including a 3D front view of a machine cell, and with details for a selected machine, according to an aspect of the present disclosure.Attorney Docket No. 18402-05307 (713507PCT)DETAILED DESCRIPTION

[0024] Referring to the drawings, the present invention will be described in detail in view of following embodiments.

[0025] The systems and methods of the present disclosure provide a unique approach to combining live process data for thermal images with temperature and / or flow data from a cooling system and projecting data on a three-dimensional (3D) model of a High Pressure Die Casting (HPDC) tool. The systems and methods of the present disclosure leverages the MQTT standards- based messaging protocol on the Internet of Things (loT) side to ensure event-driven nature of approach and facilitate immediate problem resolution process.

[0026] It is an objective of the present disclosure to identify relevant process parameters for thermal management in the HPDC tool, live-stream data into an adequate digital twin environment and fuse data from different sensors and sources into a single application (“Die Inspector”)(0027] FIGs. 1A and IB each show a schematic block diagram of a digital twin 10. As shown, the digital twin 10 bridges a physical space 12, which may also be called a physical reality, with a virtual space 14, which may also be called a virtual representation or a simulated reality. A data interconnection 16 provides bi-directional transfer of data between the physical space 12 and the virtual space 14. FIG. IB includes some additional detail, with the physical space 12 including an action 20 that impacts an operation 22 and which leads to a measurement 24. For example, the action 20 may include a setting for a machine that impacts a machining operation 22 and which is measured at 24. The measurement 24 regarding the physical space is interpreted at 25 to describe one or more features of a model in the virtual space 14. The virtual space 14 includes updating, at 26, the model based on interpreted data from the interpretation 25. The virtual space 14 includesAttorney Docket No. 18402-05307 (713507PCT) analyzing the updated model at 28 and making a decision at 30. The decision 30 is communicated back to the physical space 12 to cause or modify the action 20, thereby completing a feedback control loop.

[0028] FIG. 2 shows a block diagram of a system 100 for visualization and control of automation equipment for manufacturing, including a machine cell 110. The machine cell 110 includes one or more pieces of manufacturing equipment, such as a casting die 140, and one or more pieces of material transfer equipment, such as conveyors and robots. The machine cell 110 shown on FIG. 2 includes a pick-and-place robot 112 having an end effector 114 that is configured to move workpieces. The machine cell 110 may also include numerous different monitoring devices, such as limit switches, proximity switches, light curtains, and / or cameras. The machine cell 110 shown on FIG. 2 includes a thermal imaging camera 150 that is configured to monitor temperatures of the casting die 140.10029] The system 100 includes a visualization controller 120 having a first processor 122 operably connected to a first storage memory 124. The first storage memory 124 stores instructions, such as program code for execution by the first processor 122. The first storage memory 124 also holds data to be used by the first processor 122. A user interface 130, such as a PC monitor or a tablet is functionally connected to the visualization controller 120. The user interface 130 includes a display screen 132 configured to graphically display images, and an input control device 134, such as a keyboard, a mouse, a trackpad, a touch screen, etc. The display screen 132 may include, for example, a computer monitor, a screen on a tablet or smartphone, a projector, or a head-mounted display, such as a virtual reality (VR) or augmented reality (AR) headset. An operator may interact with the input control device 134 to command the visualization controller 120 to present various different items and graphical information on the display screen 132. In someAttorney Docket No. 18402-05307 (713507PCT) embodiments, the visualization controller 120 may be combined in a same physical unit with the user interface 130. However, the visualization controller 120 may be physically separate from the user interface 130. For example, the visualization controller 120 may stream image data to the user interface 130 via a remote network connection.|0030| The casting die 140 includes a moving die 142, and a fixed die 143. The moving die 142 has a plurality of first coolant passages 144a extending therethrough for conducting cooling fluid, and the fixed die 143 has a plurality of second coolant passages 144b extending therethrough for conducting cooling fluid. The cooling fluid may include water, glycol, a mixture thereof and / or another fluid, such as a liquid and / or a phase change material (PCM). A plurality of temperature sensors 146 each measure temperatures of the moving die 142, the fixed die 143, and / or the cooling fluid in corresponding ones of the coolant passages 144a, 144b. A plurality of flow sensors 148 each measure flow rates of the cooling fluid in corresponding ones of the coolant passages 144a, 144b. The casting die 140 is in functional communication with the visualization controller 120 for transmitting data regarding, at least, readings from the temperature sensors 146 and the flow sensors 148.

[0031] The thermal imaging camera 150 has a field of view 152 that includes the casting die 140. The thermal imaging camera 150 may measure surface temperatures of various parts of the casting die 140. The thermal imaging camera 150 is also in functional communication with the visualization controller 120 for transmitting data regarding, at least, readings from the temperature sensors 146 and the flow sensors 148.

[0032] The system 100 also includes a server 160, which may include one or more computers, and which are located remotely from the visualization controller 120. The server 160 includes a second processor 162 operably coupled to a second storage memory 164. The serverAttorney Docket No. 18402-05307 (713507PCT)160 is configured to communicate with the visualization controller 120 via one or more data networks 156. The server 160 may store data regarding the operation of the casting die 140, such as temperature and flow data, for offline or later review and analysis. In some embodiments, the temperature and / or flow data may be communicated from the casting die 140 to the visualization controller 120 and / or the server 160 using the MQTT standards-based messaging protocol. However, other data transmission protocols may be used. Alternatively or additionally, data may be communicated between the server 160 and the visualization controller 120 using the MQTT standards-based messaging protocol or using a different protocol for data transmission.(0033) FIG. 3 shows a user interface screen 200 including controls 202, a tabular data section 204, and a 3D visualization 210 of the casting die 140, including graphic representations of temperature therein. The 3D visualization 210 may enable an operator to more quickly diagnose and correct issues with the casting die 140, such as an issue causing insufficient cooling in one or more areas of the casting die 140. For example, the 3D visualization 210 may indicate a particular cooling circuit of the casting die 140 causing a biggest problem (such as a particularly high temperature or low flow rate), enabling an operator to quickly address the problem by increasing a flow rate and / or otherwise reducing a temperature associated with that particular cooling circuit. (0034] FIG. 4 shows a user interface screen 200 including a 3D visualization 210 of the casting die 140 with six coolant circuits highlighted and illustrating temperatures therein. FIG. 5 shows a user interface screen 200 including a 3D visualization of the casting die 140 with six coolant circuits highlighted and illustrating flow therein.

[0035] FIG. 6 shows a user interface screen 200 including a 3D visualization of four coolant circuits in the casting die 140, and illustrating temperatures therein, and with the dies not visible. The user interface screen 200 may be presented on the display screen 132 of the userAttorney Docket No. 18402-05307 (713507PCT) interface 130. The user interface screen 200 may be presented on a factory floor, physically near the casting die 140. Alternatively or additionally, the user interface screen 200 may be presented remotely.

[0036] As shown in FIGs. 3-6, the controls 202 include options to select either of the moving die 142 or the fixed die 144. The controls 202 include sliders for adjusting values that change how a heatmap is presented. The controls 202 also include options to select either of temperature or flow to be displayed. The tabular data section 204 includes a listing of coolant circuits that comprise the coolant passages 144a, 144b, together with temperature and flow rate data regarding the cooling fluid in each of those coolant circuits. In some embodiments, and as shown in FIG. 4, individual ones of the coolant circuits can be selected within the tabular data section 204, and the selected coolant circuits can be highlighted or otherwise indicated in the 3D visualization.[0037| As also shown in FIGs. 3-5, the 3D visualization 210 of the casting die 140 includes a heatmap 212 showing temperatures at various locations of the moving die 142 and / or the fixed die 143, with different colors and / or brightness representing different temperatures. The 3D visualization 210 also includes pipes 214 representing the coolant passages 144a, 144b.

[0038] In some embodiments, the view of the 3D visualization 210 may be adjustable using the input control device 134. For example, a user may rotate, translate, zoom, or otherwise manipulate the 3D visualization 210 of the casting die 140 in 3D space.

[0039] FIGs 3-6 also show a historical / live indicator 220 on the user interface screen 200. The historical / live indicator 220 indicates whether the data presented on the tabular data section 204 and / or the 3D visualization 210 presents a live or real-time representation of the casting die 140 or whether it presents historical data regarding the casting die 140 in the past.Attorney Docket No. 18402-05307 (713507PCT)(0040] FIG. 7 shows a schematic flow diagram illustrating steps in a method 300 for cooling visualization and control in a casting die. Various steps in the method 300 can be performed by the visualization controller 120, in accordance with some embodiments of the present disclosure. As can be appreciated in light of the disclosure, the order of operation within the method 300 is not limited to the sequential execution as illustrated in FIG. 7, but may be performed in one or more varying orders as applicable and in accordance with the present disclosure.100411 The method 300 starts at step 302. Step 302 may include starting up a digital twin system and / or initializing hardware and software components.100421 The method 300 proceeds with initializing, at step 304, a digital twin. Step 304 may include loading 3D models of stationary and moving die parts, such as models of the moving die 142 and the fixed die 143. Step 304 may also include connecting to a MQTT broker for data streaming.(0043] The method 300 proceeds with acquiring, at step 306, data. Step 306 may include acquiring thermal imaging data at step 308.1 044] Step 308 may further include activating, at step 310, one or more thermal cameras, such as by powering on the thermal imaging camera 150. Additionally or alternatively, step 310 may include calibrating the one or more thermal cameras, if necessary.(0045] Step 308 may also include streaming, at step 312, data from the one or more thermal cameras. Step 312 may include streaming the thermal image data via MQTT. In some embodiments, the data from the one or more thermal cameras may be first converted to a text file. The text file based on the data from the one or more thermal cameras may then be transmitted via MQTT. Step 312 may include establishing a MQTT connection between the visualizationAttorney Docket No. 18402-05307 (713507PCT) controller 120 and the one or more thermal cameras. Step 312 may also include streaming realtime thermal images from the one or more thermal cameras and to a digital twin running on the visualization controller 120 or on one or more other processors.

[0046] Additionally or alternatively, step 306 may include acquiring cooling channel data at 314, such as temperature and / or flow rate data regarding flow of the cooling fluid in the coolant passages 144a, 144b. Acquiring the cooling channel data may include measuring, at 316, the temperature of the cooling fluid by one or more of the temperature sensors 146. Additionally or alternatively, step 316 may include measuring a flow rate of the cooling fluid by one or more of the flow sensors 148. Acquiring the cooling channel data may also include streaming, at 318, data from the temperature sensors 146 and / or from the flow sensors 148. Step 318 may include streaming the temperature and / or flow rate data via MQTT. Step 312 may include establishing a MQTT connection between the visualization controller 120 and the temperature sensors 146 and / or the flow sensors 148. Step 312 may also include streaming real-time temperature and / or flow rate data from the temperature sensors 146 and / or the flow sensors 148 and to a digital twin running on the visualization controller 120 or on one or more other processors.10047] The method 300 proceeds with processing and integrating, at step 320, the thermal imaging data and the cooling channel data. Step 320 may include receiving, at step 322, and by the digital twin, the MQTT data streams having the imaging data and the cooling channel data. Step 322 may include subscribing, by the digital twin, thermal image and cooling data topics in order to receive the thermal imaging data and the cooling channel data. Additionally, step 322 may include the digital twin buffering the incoming data streams in order to acquire the thermal imaging data and the cooling channel data. By first converting the thermal image data to text, the thermalAttorney Docket No. 18402-05307 (713507PCT) image data can be more easily transmitted via the MQTT data streams and subsequently integrated with one or more other MQTT data streams having the cooling channel data.

[0048] The method 300 proceeds with integrating, at step 324, the thermal images with a 3D model. The 3D model may be used, for example, to generate the 3D visualization 210 shown on FIGs. 2-6. Step 324 may include mapping the thermal image data onto the 3D model. Additionally or alternatively, step 324 may include dynamically updating a texture 2D heatmap using the thermal image data.100491 The method 300 proceeds with integrating, at step 326, the cooling channel data with the 3D model. Step 326 may include overlaying the temperature and flow data on cooling channels. Step 326 may also include updating a visual representation of the coolant passages 144a, 144b in the 3D model and in real-time based on the temperature and / or flow rate data.

[0050] The method 300 proceeds with setting-up, at step 328, a visualization. For example, the 3D visualization 210 shown on FIGs. 2-6 may be generated based on the 3D model and / or based on additional data.

[0051] Step 328 may include generating, at step 330, a 3D representation of the casting die 140. Step 330 includes displaying, at step 331, a 3D Model of one or more stationary die parts and / or one or more moving die parts. Step 331 may include rendering the static parts of the die in a 3D view. The static parts may include the fixed die 143 and / or other static components, such as a frame or housing of the casting die 140. Step 331 may also include rendering the moving or dynamic parts of the die, such as the moving die 142 and / or animations showing fluid flow.

[0052] Step 328 may include generating, at step 332, a heatmap visualization. Step 332 may include overlaying, at step 333, a Texture2D Heatmap on the visualization of the die. Step 333 may include applying the thermal data as a heatmap texture on the 3D model. In someAttorney Docket No. 18402-05307 (713507PCT) embodiments, a temperature cutoff may be adjustable for controlling brightness or intensity of the heatmap texture or which portions of the heatmap texture are visible. The user may adjust a temperature threshold for the heatmap display, for example using the controls 202 on the user interface screen 200. In some embodiments, the user may adjust a feathering effect setting using the controls 202 on the user interface screen 200 for smoothing the heatmap gradients.

[0053] Step 328 may include visualizing, at step 334, flow in the coolant passages 144a, 144b. Step 334 may include activating a flow visualization mode and / or switching a visualization mode to show flow data. Step 334 may include displaying, at step 335, a flow visualization to indicate fluid flow in the coolant passages 144a, 144b. The flow visualization may include, for example, coloration and / or animations of graphic elements that visually resemble and / or schematically represent the coolant passages 144a, 144b. With the flow visualization activated, the pipes 214 may be colored based on a flow rate in the corresponding coolant passages 144a, 144b. Color coding may be applied to the pipes based on flow rate of fluid therein and based on one or more threshold values. For example, the pipes 214 may be colored red if the flow in a corresponding one of the coolant passages 144a, 144b is below a predetermined low-flow threshold value. The pipes 214 may be colored yellow if the flow in a corresponding one of the coolant passages 144a, 144b is above a minimum operating flow threshold value, and green if the flow is above a preferred operating flow threshold value. In some embodiments, the threshold values impacting the coloration of the pipes 214 may be adjusted using a threshold adjustor of the controls 202 on the user interface screen 200.

[0054] The method 300 proceeds with receiving, at step 336, a user interaction. The user interaction may include, for example, a command to view the thermal images on the 3D Model. The user interaction may include commands to spin the 3D Model on one or more different axes,Attorney Docket No. 18402-05307 (713507PCT) to translate the 3D model in one or more dimensions, and / or to change a magnification in order to zoom in or out on particular part of the 3D model.

[0055] The system 100 may cause the user interface screen 200 to display real-time thermal images integrated with the 3D model in response to the user command to view the thermal images on the 3D Model. The user interaction may include a command to adjust the heatmap settings. For example, the controls 202 on the user interface screen 200 may present an interface for adjusting the temperature cutoff and feathering settings. The user interaction may include a command to switch to a flow visualization mode. For example, the controls 202 on the user interface screen 200 may include a button for toggling between heatmap and flow visualization modes. The user interaction may include a command to adjust flow threshold settings. For example, the controls 202 on the user interface screen 200 may include a control interface, such as a slider, for setting flow thresholds and color coding.

[0056] The method 300 proceeds with displaying, at step 338, real-time monitoring data. Step 338 may include the user interface screen 200 continuously updating the thermal images. For example, the thermal data may be refreshed on the 3D model in real-time. Step 338 may include the user interface screen 200 continuously updating the cooling channel data. For example, the temperature and flow data may be refreshed on the 3D model in real-time. Step 338 may include the user interface screen 200 continuously updating the 3D model to display real-time changes. For example, all updates, including indicators, flow, temperature, and positioning information may be indicated visually on the 3D representation and in real-time based on corresponding real-world characteristics of the casting die 140.

[0057] In some embodiments, a temperature or a flow rate of the cooling fluid in at least one of the coolant passages in the casting die 140 may be adjusted based on the 3D visualizationAttorney Docket No. 18402-05307 (713507PCT) of the casting die. For example, a user may manually adjust one or more control devices, such as a valve, a heater, or a motor, and to cause the temperature or the flow rate to be maintained at a predetermined setpoint value or in accordance with a corresponding operating threshold value. In some embodiments, a manually adjusting the one or more control devices may include changing a setting using the user interface 130. Alternatively or additionally, the system 100 may implement an automated process to automatically adjust at least one of the temperature or the flow rate of the cooling fluid. The casting die 140 may include automated controls to maintain a corresponding temperature and / or flow setpoint value. For example, one or more proportion-integral-derivative (PID) loops may be used to generate corresponding command signals for controlling an actuator, such as a valve, a heater, or a motor and to cause the temperature or the flow rate of the cooling fluid to be maintained at the corresponding setpoint value. The automated process may further include changing a corresponding temperature and / or flow setpoint value within a range of values and based on an integrated model that takes into account thermal image data from the thermal imaging camera 150 in addition to temperature and / or flow data from the from the temperature sensors 146 and / or the flow sensors 148.100581 The method 300 proceeds with shutting-down at step 340. Step 340 may include stopping the data streams. Stopping the data streams may include gracefully disconnecting from the MQTT streams. Step 340 may proceed with shutting-down the system by powering-down one or more hardware and / or software components.

[0059] FIG. 8 shows a schematic block diagram of a cooling sub-system 400 for a casting die 140, in accordance with an aspect of the present disclosure. As shown, the casting die 140 includes a plurality of cooling circuits 452, 454, 456, 458. For simplicity of discussion, only four cooling circuits are shown. However, the casting die 140 may have any number of the coolingAttorney Docket No. 18402-05307 (713507PCT) circuits 452, 454, 456, 458. Each of the cooling circuits 452, 454, 456, 458 may circulate the cooling fluid through one or more of the coolant passages 144a, 144b in the casting die 140.

[0060] A cooling controller 420 is configured to controllably supply the cooling fluid through each of the cooling circuits 452, 454, 456, 458. The cooling controller 420 includes a supply header 422 that is connected to a cooling water supply 428 via a supply piping 423. The cooling water supply 428 may include, for example, a heat exchanger or a chiller that provides water at a predetermined temperature. The cooling controller 420 also includes a return header 424 and return piping 425 through which the cooling water is returned to the cooling water supply 428 at a higher temperature than a temperature of the cooling water in the supply header 422.[00611 The cooling controller 420 also includes a plurality of proportionating control valves 430 each configured to regulate a flow of the cooling fluid between the supply header 422 and a corresponding one of the cooling circuits 452, 454, 456, 458. The cooling controller 420 also includes a plurality of temperature sensors 432 each configured to measure a temperature of the cooling fluid returning from a corresponding one of the cooling circuits 452, 454, 456, 458 and to the return header 424. The cooling controller 420 also includes a cooling electronic control unit (ECU) 440 that is configured to monitor the temperatures of the cooling fluid returning from each of the cooling circuits 452, 454, 456, 458, via signals from the corresponding temperature sensors 432 and to send corresponding command signals to each of the proportionating control valves 430.

[0062] In some embodiments, and as shown in FIG. 8, the cooling ECU 440 is in functional communication with the visualization controller 120 to send temperature data and / or flow data to the visualization controller 120. The temperature data may include temperatures measured by the temperature sensors 432. The flow data may include position data regarding the proportionatingAttorney Docket No. 18402-05307 (713507PCT) control valves 430 and / or a flow rate data corresponding to the position data of the proportionating control valves 430.

[0063] FIG. 9 shows a first user interface screen 500 including a grid view with several machine cells 504. The grid view may represent a schematic arrangement of the machine cells 504 to easily and simply show a sequence manufacturing operations and / or a corresponding material flow on a factory floor. The first user interface screen 500 also includes a selection menu 502 that enables an operator to show data for one or more different parameters, such as Overall Equipment Effectiveness (OEE), equipment performance, equipment availability, and / or quality.

[0064] The first user interface screen 500 includes a status indicator 506 adjacent to and associated with each of the machine cells 504 to quickly show the status of the machine cells 504. The status indicators 506 may each show a particular color and / or pattern to represent the status of the corresponding machine cell 504. For example, the status indicators 506 may flash red if the corresponding machine cell 504 is down or faulted. The status indicators 506 may be solid green when the corresponding machine cell 504 is operating properly.

[0065] The first user interface screen 500 also includes a factory performance overlay 510 with numeric and / or graphical representations of various metrics regarding the entire factory performance. The factory performance overlay 510 may include data regarding Overall Equipment Effectiveness (OEE), equipment performance, equipment availability, quality, and throughput, such as net jobs per hour (JPH).

[0066] FIG. 10 shows a second user interface screen 550 including a grid view with several machine cells 504. The second user interface screen 550 includes arrows 552 indicating a manufacturing workflow. The second user interface screen 550 also includes workflow data overlays 554 adjacent to one or more of the arrows 552 and to indicate a parameter of the workflow.Attorney Docket No. 18402-05307 (713507PCT)The workflow data overlays 554 may indicate, for example, a number of jobs per hour or a cumulative number of parts in a given period of time that moved along a given path or conveyor segment.[0(167] FIG. 11 shows a third user interface screen 600 including a 3D perspective view of a machine cell, according to an aspect of the present disclosure. The third user interface screen 600 may include animations and / or positioning to indicate status of machines within the machine cell. The animations and / or positioning may represent real-world conditions of the machines. Alternatively or additionally, the animations and / or positioning shown on the third user interface screen 600 may represent non-visible characteristics of the machines, such as temperatures, faults or warning status information.

[0068] The third user interface screen 600 includes an equipment selector interface 512 that enables an operator to select a particular piece of equipment within the machine cell for additional details. The third user interface screen 600 also includes a live data indicator 514 that denotes the third user interface screen 600 showing current real-time status (i.e. live) data or nonlive status information. The non-live status information may indicate a historical status of the machine cell at some time in the past. Alternatively or additionally, the non-live status information may indicate a simulated future status of the machine cell.

[0069] FIG. 12 shows a fourth user interface screen 650 including a 3D front view of a machine cell, and with details for a selected machine, according to an aspect of the present disclosure. The fourth user interface screen 650 includes a data pop-out 652 showing overview data about the selected machine, including machine identifier numbers and / or names, type of material the machine is configured to use, e.g. Aluminum, and number of cavities that the machine includes. The data pop-out 652 also shows operating parameters regarding the selected machine,Attorney Docket No. 18402-05307 (713507PCT) such as numeric data for cycle times, material thickness, pressures, etc. The data pop-out 652 also includes icons associated with each of the operating parameters to indicate a status of the associated operating parameters. The icons may include a green check to represent, for example, the operating parameter being within a nominal or “good” range of values. The icons may include a yellow triangle to represent, for example, the operating parameter being within an alarm range, outside of the nominal range of values or trending toward a non-nominal value. The icons may include a red X to represent, for example, the operating parameter being having a value indicative of a non-conforming or faulted condition.(0070) The system, methods and / or processes described above, and steps thereof, may be realized in hardware, software or any combination of hardware and software suitable for a particular application. The hardware may include a general purpose computer and / or dedicated computing device or specific computing device or particular aspect or component of a specific computing device. The processes may be realized in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable device, along with internal and / or external memory. The processes may also, or alternatively, be embodied in an application specific integrated circuit, a programmable gate array, programmable array logic, or any other device or combination of devices that may be configured to process electronic signals. It will further be appreciated that one or more of the processes may be realized as a computer executable code capable of being executed on a machine readable medium.|0071| The computer executable code may be created using a structured programming language such as C, an object oriented programming language such as C++, or any other high- level or low-level programming language (including assembly languages, hardware descriptionAttorney Docket No. 18402-05307 (713507PCT) languages, and database programming languages and technologies) that may be stored, compiled or interpreted to run on one of the above devices as well as heterogeneous combinations of processors, processor architectures, combinations of different hardware and software, or any other machine capable of executing program instructions.|0072| Thus, in one aspect, each method described above and combinations thereof may be embodied in computer executable code that, when executing on one or more computing devices performs the steps thereof. In another aspect, the methods may be embodied in systems that perform the steps thereof, and may be distributed across devices in a number of ways, or all of the functionality may be integrated into a dedicated, standalone device or other hardware. In another aspect, the means for performing the steps associated with the processes described above may include any of the hardware and / or software described above. All such permutations and combinations are intended to fall within the scope of the present disclosure.10073] The foregoing description is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

Attorney Docket No. 18402-05307 (713507PCT)CLAIMSWhat is claimed is:

1. A method for cooling visualization and control in a casting die, comprising: measuring temperature and flow rate of a cooling fluid in each of a plurality of coolant passages in the casting die; calculating cooling data based on the flow rate and the temperature of the cooling fluid in each of the plurality of coolant passages; capturing at least one thermal image of the casting die; integrating each of the thermal image and the cooling data with a three-dimensional (3D) model of the casting die to generate an integrated model; and generating a 3D visualization of the casting die including at least one of a heat map visualization and a flow visualization using the integrated model.

2. The method of Claim 1, wherein the 3D visualization of the casting die includes the heat map visualization.

3. The method of Claim 1, wherein the 3D visualization of the casting die includes the flow visualization.

4. The method of Claim 1, further comprising presenting, on a display screen, the 3D visualization of the casting die including the at least one of the heat map visualization and the flow visualization using the integrated model.Attorney Docket No. 18402-05307 (713507PCT)5. The method of Claim 4, further comprising modifying, based on a user control, a presentation of the 3D visualization of the casting die and to change at least one of a perspective view of the 3D visualization or to show or hide at least one component of the casting die.

6. The method of Claim 5, further comprising: receiving, via an input control of a user interface, a command to show or hide at least one component of the casting die; and revising the presentation of the 3D visualization of the casting die in accordance with the command to show or hide the at least one component of the casting die.

7. The method of Claim 1, further comprising adjusting at least one of a temperature or a flow rate of the cooling fluid in at least one of the coolant passages in the casting die and based on the 3D visualization of the casting die.

8. The method of Claim 7, wherein adjusting the at least one of the temperature or the flow rate of the cooling fluid includes automatically adjusting the at least one of the temperature or the flow rate by an automated process and to cause the at least one of the temperature or the flow rate of the cooling fluid to maintain a corresponding setpoint value.

9. The method of Claim 1, further including adjusting a color of a feature of the casting die on the 3D visualization based on a difference between one of the temperature or the flow rate of the cooling fluid in a corresponding one of the coolant passages and a corresponding threshold value.Attorney Docket No. 18402-05307 (713507PCT)10. The method of Claim 9, further including receiving, via an input control of a user interface, a command to change the corresponding threshold value for adjusting the color of the feature of the casting die.11 . The method of Claim 1, further including comparing the cooling data to a set of known parameters to determine a need for additional cooling in one or more coolant passages of the plurality of coolant passages in the casting die.

12. A system for cooling visualization and control, comprising: a casting die having one or more dies and a plurality of coolant passages; a thermal imaging camera configured to measure surface temperatures of the casting die; a plurality of temperature sensors each configured to measure a temperature of one of the dies or a cooling fluid in a corresponding one of the coolant passages; a plurality of flow sensors each configured to measure a flow rate of the cooling fluid in the corresponding one of the coolant passages; and a visualization controller, wherein the visualization controller is configured to: acquire thermal imaging data from the thermal imaging camera; acquire temperature data from the plurality of temperature sensors and flow data from the plurality of flow sensors; calculate cooling data based on the flow data and the temperature data; integrate each of the thermal imaging data and the cooling data with a three- dimensional (3D) model of the casting die to generate an integrated model; andAttorney Docket No. 18402-05307 (713507PCT) generate a 3D visualization of the casting die including at least one of a heat map visualization and a flow visualization using the integrated model.

13. The system of Claim 12, wherein the 3D visualization of the casting die includes the heat map visualization.

14. The system of Claim 12, wherein the 3D visualization of the casting die includes the flow visualization.

15. The system of Claim 12, further comprising a display screen, wherein the display screen is configured to present the 3D visualization of the casting die.

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