A production control system

Abstract

A production control system There is provided a production control system for a batch production facility, the production control system comprising: one or more automation components, each component comprising an RFID reader; one or more ground plates configured for installation on a production line of the batch production facility, each ground plate comprising one or more RFID tags, each tag having a unique identifier; and a controller configured to communicate with the RFID reader. Each of the automation components is configured to attach to each of the ground plates. Upon attachment of an automation component to a ground plate, the RFID reader of the automation component is arranged to read a unique identifier of the one or more RFID tags of the ground plate. The RFID reader is configured to send to the controller the unique identifier of the one or more RFID tags.

Description

[0001] A production control system

[0002] Field

[0003] The invention relates to a production control system for a batch production facility, and a method of controlling production in a batch production facility.

[0004] Background

[0005] In contract manufacturing one or more production lines may be used for the batch processing of a number of different products. The production lines therefore need to be reconfigurable, to accommodate different orders.

[0006] Traditionally the reconfiguration is physical and labour-intensive, wherein different types of automation equipment are manually installed and configured for each order, or equipment in-situ is re-configured. Industrial automation has been difficult to implement due to the level of product variation on each production line.

[0007] Recently machine-learning technologies have enabled industrial robots to relocate and perform different tasks with increasing autonomy and awareness, however such solutions are complex and expensive. It would be desirable to provide a more accessible automation system, that would accommodate different batch orders, but be simple and inexpensive compared to machine learning-enabled technologies.

[0008] Other solutions involve automation equipment with a degree of flexibility, wherein the equipment can accommodate different sizes of items of a certain product type, however this equipment tends to be stationary and cannot easily be deployed to another location on the production line.

[0009] Further improvements in production line automation equipment and / or methods of use are required, particularly to provide a system which is adaptable / reconfigurable for different batch orders without being complex or expensive.

[0010] SummaryIn a first aspect of the invention there is provided a production control system for a batch production facility. The production control system comprises: one or more automation components, each component comprising an RFID reader; one or more ground plates configured for installation on a production line of the batch production facility, each ground plate comprising one or more RFID tags, each tag having a unique identifier; and a controller configured to communicate with the RFID reader. Each of the automation components is configured to attach to each of the ground plates. Upon attachment of an automation component to a ground plate, the RFID reader of the automation component is arranged to read a unique identifier of the one or more RFID tags of the ground plate. The RFID reader is configured to send to the controller the unique identifier of the one or more RFID tags.

[0011] There may be a plurality of different automation components. Thus according to the invention, the production control system is reconfigurable, with each one of the different automation components being configured to attach to all of the ground plates. It is therefore possible to quickly reconfigure the production line by moving automation components around to new locations between tasks. Moreover, the system can detect whether the correct equipment is installed in the correct location by reading at each RFID reader, the unique identifier of an RFID tag associated with the nearby ground plate (i.e. the ground plate on which the automation component is situated). It will be appreciated by the person skilled in the art that the other ground plates are too far away to read. The system according to the present invention therefore provides a production line facility that is easily reconfigurable in a fail-safe manner by determining whether the set-up is suitable before commencing production.

[0012] Each automation component may comprise an adaptor plate, each adaptor plate having a first attachment face configured to attach to each of the ground plates, and a second attachment face configured to attach to the automation component. As such, the adaptor plates provide a generic interface meaning that the ground plates do not need to be bespoke to each automation component. The RFID readers may be comprised in the adaptor plates.Each ground plate may comprise four RFID tags, for example situated at different locations around the perimeter of the ground plate.

[0013] Each ground plate may comprise a plurality of locating pins configured to engage a corresponding plurality of locating holes in each adaptor plate. Thus the automation components can be quickly attached with high precision. Alternatively, each adaptor plate may comprise a plurality of locating pins configured to engage a corresponding plurality of locating holes in each ground plate.

[0014] The RFID reader may be configured to send to the controller an automation component identifier associated with the RFID reader of the automation component.

[0015] The RFID reader may be configured to communicate wirelessly with the controller.

[0016] The production control system may further comprise a product database accessible by the controller, wherein the product database includes, for each of a plurality of automation tasks, a list of one or more required automation components and ground plates. The product database may for example be stored in the cloud and be accessed via an internet connection. The product database may therefore contain for each automation task, a recipe for the automation task including the types of automation components (i.e. automation equipment) required and their locations on the production line or lines. It will be appreciated that the ground plates can be fixed to the production line in known (i.e. permanent) locations, and therefore each recipe can reference specific ground plates in known locations.

[0017] During use, the controller may be configured to compare the unique identifier of the one or more RFID tags and the automation component identifier against the product database to determine for a selected automation task whether the ground plate and automation component are in the list of required automation components and ground plates. Therefore, a first check may be performed to see if the detected equipment is of the correct type and in the correct location. A second check may additionally beperformed to check that all of the equipment in the recipe has been identified as correctly installed before production commences.

[0018] The production control system may further comprise a user interface configured to communicate with the controller, the user-interface being configured to enable the selection of an automation task from a plurality of automation tasks. The user interface mayfor example be provided on a tablet configured to communicate wirelessly with the controller.

[0019] The automation tasks may be pre-programmed. In embodiments, the user interface may be configured to enable a new automation task to be generated by the user and added to the plurality of automation tasks.

[0020] Each ground plate may be configured to enable removable attachment to the production line, for example each ground plate may include a plurality of bolt holes to enable removable attachment of the ground plate to the production line.

[0021] The ground plate may comprise one or more distance sensors. In such embodiments, the distance sensors can be used to calibrate the automation components when installed, for example enabling a user to adjust various different positions of the equipment (i.e. adjust position offsets).

[0022] In a second aspect of the invention there is provided a method of controlling production in a batch production facility. The method comprises the steps of: attaching an automation component to a ground plate installed on a production line of the batch production facility, wherein the automation component comprises an RFID reader and the ground plate comprises one or more RFID tags, each tag having a unique identifier; reading at the RFID reader a unique identifier of the one or more RFID tags of the ground plate; and sendingto a controller the unique identifier of the one or more RFID tags.

[0023] The method may further comprise the step of powering the automation component.The method may further comprise the step of sending to the controller an automation component identifier associated with the RFID reader of the automation component.

[0024] The method may further comprise the step of comparin the unique identifier of the one or more RFID tags and the automation component identifier against a product database to determine for a selected automation task whether the ground plate and automation component are in a list of one or more required ground plates and automation components.

[0025] The method may further comprise the steps of: selecting via a user interface the automation task from a plurality of automation tasks, and sending the selected automation task to the controller wirelessly.

[0026] The method may further comprise the step of removably installing the ground plate at one of a plurality of attachment sites on a production line in the batch production facility. The method may further comprise the step of removably installing the ground plate at one of a plurality of attachment sites on a plurality of production lines in the batch production facility.

[0027] The method may comprise repeating the method for one or more further automation components.

[0028] The method may further comprise the steps of checking whether all of the required automation components and ground plates for the selected automation task have been identified, and commencing production if all of the required automation components and ground plates have been identified.

[0029] The method may comprise measuring at the ground plate at least one distance to a known location on the automation component.

[0030] The further automation components may be installed on the same production line.Drawings

[0031] An example embodiment of the invention will now be described by way of example only with reference to the following drawings:

[0032] Figure 1 is a schematic representation of a production control system according to the example embodiment;

[0033] Figure 2 is a perspective view of a ground plate of the system of Figure 1 ;

[0034] Figure 3 is a perspective view of an automation component of the system of Figure 1 ; Figure 4 is a high-level flow diagram of a method of controlling production in a batch production facility; and

[0035] Figure 5 is a more detailed flow diagram of a method of controlling production in a batch production facility.

[0036] Detailed Description

[0037] According to the example embodiment of the invention, Figure 1 shows a production control system 1 for a batch production facility.

[0038] The system 1 includes a plurality of ground plates 3, each ground plate being configured for installation on a production line of a batch production facility. In use, the ground plates are installed at production stations alongthe production line (or lines). Each ground plate can support an automation component. In another embodiment there may be only one ground plate.

[0039] The system 1 further includes a plurality of automation components 5, for example industrial robots. Each automation component 5 is configured for attachment to each of the ground plates 3. Therefore, the automation components 5 can be fixed interchangeably on the different ground plates 3 providing flexibility in the set up, so that the production line can be easily adapted depending on the specific order. In another embodiment there may be only one automation component.Each of the ground plates 3 includes at least one embedded RFID tag 7 (i.e. RFID chip), where each RFID tag 7 is encoded with a unique hexadecimal identifier so that each ground plate can be uniquely identified.

[0040] Each of the automation components 5 includes an RFID reader 9. Each RFID reader is configured to read the unique identifier of an RFID tag in close proximity. Therefore, each RFID reader 9 can read the unique identifiers of one or more RFID tags 7 of the ground plate 3 to which the automation component 5 is attached, but not tags of other ground plates 3 in other locations on the production line.

[0041] The system 1 further includes a controller 11 in wireless communication with the RFID readers 9 of the automation components 5, and a user interface 13 in wireless communication with the controller 11.

[0042] A set of automation tasks are pre-programmed into the system 1 and stored in a memory associated with the controller 11. In the example embodiment, the automation tasks are also backed up a cloud storage facility. Each production station along the production line has a ground plate installed. In use, the automation components are attached (manually) to the ground plates as deemed to be correct for a particular automation task selected by a user via the user interface 13.

[0043] The automation components 5 are then individually powered by a power supply associated with each production station / ground plate location. Upon powering up of the automation components, the respective RFID readers 9 detect the RFID tags 7 of the corresponding ground plates 3 (in another example embodiment the RFID readers may be battery powered or otherwise have their own power supply). The other RFID tags are too far away to read.

[0044] The RFID readers 9 then each communicate over Wi-Fi with the controller 11 by sending a Json packet containingthe RFID reader number (i.e. an automation component identifier) and the RFID tag number (i.e. a ground plate identifier). The controller 11 can then determine which component is situated on which ground plate alongtheproduction line or lines. The controller then compares the received identifiers with expected identifiers according to a local database accessible by the controller which contains lists of identifiers required for different automation tasks. The database is backed up to the customer account in the cloud so that it can be transferred between controllers on different production lines if required. Therefore the system has the capability to run the same product across multiple production lines without needin to configure the automation components each time. Instead, the automation components can be relocated to appropriate ground plates on the other production lines and the verification cycle can be performed as described.

[0045] The controller checks for a selected automation task, firstly, whether the received identifiers are in the list of required identifiers, and secondly, whether all required identifiers are present. The controller then signals that production can commence.

[0046] In the example embodiment, the selected automation task is “triple filling jars” with the required identifiers being a filling robot at ground plate 1 (which is known and recorded to be installed at a first production station on production line 1 ), a filling robot at ground plate 2 (which is known and recorded to be installed at a second production station on production line 1), and a filling robot at ground plate 3 (which is known and recorded to be installed at a third production station on production line 1 ). One by one, the required filling robots are attached to the appropriate ground plates, and read the signals from the RFID tags of the ground plates, before communicating the information identifying each automation component and its associated ground plate to the controller. The controller can therefore determine the types and locations of the automation components which have been set up. In a different embodiment, the ground plates may be located on different production lines within the same batch production facility. In a different embodiment, the automation components may have different functions, for example, one may be a filling robot, whilst another may be a packaging robot, whilst another may be a stacking robot.

[0047] Each ground plate 3 comprises a plurality of floor fixing holes through which anchor bolts can be inserted to secure the ground plate to the floor (i.e. of the productionstation on the production line). As shown in Figure 2, each anchor bolt is covered by a bolt cover 23 which is flush with the upper surface 24 of the ground plate. Each ground plate 3 further comprises four embedded RFID tags, one at each corner of the ground plate, in the example embodiment, the tags being visible through a plurality of RFID tag holes 17. Having a plurality of RFID tags embedded in or on the ground plate enables detection of the orientation of the automation component when connected.

[0048] Each ground plate further comprises a plurality of component fixing holes 15 for connecting an automation component 5 or a suitable intermediary adaptor plate to the ground plate 3. The ground plate 3 further comprises a plurality of locating pins 21 which protrude from the upper surface of the ground plate, for engaging with corresponding locating holes in the underside of the automation component 5 or intermediary adaptor plate. The ground plate further comprises a plurality of inner attachment holes 19. The inner attachment holes 19 enable the attachment of a plastic sleeve that covers an inner channel of the automation component and enables the routing through of wiring required forthe specific application. In the example embodiment, all of the ground plates have the same pattern of holes. In the example embodiment all of the ground plates are identical although in other embodiments some ground plates may have additional adaptations for other purposes.

[0049] Accordingto the example embodiment, and as shown in Figure 3, each automation component 5 is attached to a ground plate 3 via an adaptor plate 25. The adaptor plate has a standard lower side having a pattern of fixing holes and locating holes to correspond with the component fixing holes 15 and locating pins 21 of the ground plate so that the adaptor plate can attach to any of the ground plates. The adaptor plate has a unique upper side which is bespoke to the automation component 5. Therefore, through the use of an adaptor plate 25, each automation component 5 can be fixed to any of the ground plates 3. In the example embodiment each adaptor plate 25 comprises an RFID reader 9. In use when the automation component is attached to the ground plate, the RFID reader 9 faces down towards the ground plate 3. The RFID holes 17 in the ground plate 3 enable the RFID reader of the adaptor plate 25 to be situated on the RFID tags.In the example embodiment, each adaptor plate 25 comprises a single RFID reader 9 positioned non-centrally on the adaptor plate underside. For example, in the example embodiment wherein the adaptor plate is substantially square-shaped, the RFID reader 9 is positioned towards one corner of the square. The RFID reader 9 is in a fixed, known location on the adaptor plate. Moreover, the adaptor plate is situated on the automation component in a fixed position (i.e. it cannot be re-positioned on the automation component). Therefore, the RFID tag which is detected by the RFID reader out of the four possibilities gives an indication of the orientation of the automation component with respect to the ground plate 3.

[0050] The system additionally comprises one or more PLC agents (not shown) wherein the controller is configured to communicate with the PLC agents to enable them to implement the actual machine automation control of the automation components via OPC-UA.

[0051] A method of controlling production in a batch production facility generally comprises, at a high level, as illustrated in Figure 4, the steps of: attaching (27) an automation component to a ground plate installed on a production line of the batch production facility, wherein the automation component comprises an RFID reader and the ground plate comprises an RFID tag; reading (29) at the RFID reader the unique identifier of the RFID tag of the attached ground plate; and sending (31 ) to a controller information correspondingto the unique identifier.

[0052] In more detail, as illustrated in Figure 5, and according to the example embodiment the method comprises an initial step of installing (51) three ground plates on a production line, in the example embodiment, each ground plate at a different production station on the production line. The ground plates are anchored into the floor of each production station. In a next step a user selects (53) (or alternatively could create and save) on a user interface an automation task from a plurality of displayed automation tasks. The automation task selected is the task of triple filling jars. The user can input further information to tailor the task, for example specifying the size and shape of the jars, andthe relative amounts of each of three filler materials to be discharged into the jars. In a next step (55) a suitable automation component (i.e. in the example embodiment a filling robot configured to fill jars) is attached to each ground plate. Each automation component is attached with bolts to an adaptor plate, which is then placed on the ground plate so that locating pins on the upper surface of the ground plate engage with locating holes in the underside of the adaptor plate. As such, the automation component can be precisely positioned on the production station. The adaptor plate is then fixed with bolts to the ground plate.

[0053] In a next step (57) each automation component is powered from a power supply at each production station. In a next step (59) the RFID reader of each automation component scans for a local RFID signal (within a radius of about 5cm). In a next step (61 ) the RFID reader of each automation component detects a signal from the RFID tag of the corresponding ground plate. In a next step (63) each RFID reader determines a ground plate identifier from the RFID tag signal. In a next step (65) each RFID reader creates a Json packet containing the ground plate identifier (i.e. identifying the location on the production line) and an identifier of the RFID reader (i.e. identifying the automation component attached). In a next step (67) each RFID reader transmits to the controller the Json packet over Wi-Fi. In a next step (69) the controller sends to each RFID reader an acknowledgement signal.

[0054] In a next step (71 ) the user interface transmits the selected task to the controller. In a next step (73) the controller searches in a database (in the example embodiment stored in the cloud but alternatively in an associated local memory) for a list of ground plate and automation component / RFID reader identifiers required forthe selected task. The controller checks firstly whether the received identifiers are in the list (i.e. as pairs of RFID reader and ground plate identifiers), and secondly whether all of the required pairs of identifiers have been received. In a next step (75a) if all of the required pairs of identifiers have not been received, the user is prompted via the user interface to reconfigure the necessary production station. Alternatively, in a next step (75b) if all of the required pairs of identifiers have been received, the user is alerted via the userinterface that configuration was successful and production can commence. The controller then signals to the PLC agents to commence operations via OPC-UA.

[0055] The steps of the method may be undertaken in a different order, for example the user interface may transmit to the controller prior to attachment of the automation components. It will be appreciated that one or more ground plates could be located on a given production line. The system is configured such that one controller is present per production line.

Claims

Claims1. A production control system for a batch production facility, the production control system comprising:one or more automation components, each component comprising an RFID reader;one or more ground plates configured for installation on a production line of the batch production facility, each ground plate comprising one or more RFID tags, each tag having a unique identifier; anda controller configured to communicate with the RFID reader;wherein each of the automation components is configured to attach to each of the ground plates;wherein upon attachment of an automation component to a ground plate, the RFID reader of the automation component is arranged to read a unique identifier of the one or more RFID tags of the ground plate, and the RFID reader is configured to send to the controller the unique identifier of the one or more RFID tags.

2. The production control system of claim 1 , wherein each automation component comprises an adaptor plate, each adaptor plate having a first attachment face configured to attach to each of the ground plates, and a second attachment face configured to attach to the automation component.

3. The production control system of claim 2, wherein each ground plate comprises a plurality of locating pins configured to engage a corresponding plurality of locating holes in each adaptor plate.

4. The production control system of any preceding claim, wherein the RFID reader is configured to send to the controller an automation component identifier associated with the RFID reader of the automation component.

5. The production control system of any preceding claim, wherein the RFID reader is configured to communicate wirelessly with the controller.

6. The production control system of any preceding claim, further comprising a product database accessible by the controller, wherein the product database includes, for each of a plurality of automation tasks, a list of one or more required automation components and ground plates.

7. The production control system of claims 4 and 6, wherein during use, the controller is configured to compare the unique identifier of the one or more RFID tags and the automation component identifier against the product database to determine for a selected automation task whether the ground plate and automation component are in the list of required automation components and ground plates.

8. The production control system of any preceding claim, further comprising a user interface configured to communicate with the controller, the user-interface being configured to enable the selection of an automation task from a plurality of automation tasks.

9. The production control system of claim 8, wherein the automation tasks are preprogrammed.

10. The production control system of any preceding claim, wherein each ground plate includes a plurality of bolt holes to enable removable attachment of the ground plate to the production line.

11. A method of controlling production in a batch production facility, comprising the steps of:attaching an automation component to a ground plate installed on a production line of the batch production facility, wherein the automation componentcomprises an RFID reader and the ground plate comprises one or more RFID tags, each tag having a unique identifier;reading at the RFID reader the unique identifier of the one or more RFID tags of the ground plate;sending to a controller the unique identifier of the one or more RFID tags.

12. The method of claim 11 , further comprising the step of powering the automation component.

13. The method of any of claims 11-12, further comprising the step of sending to the controller an automation component identifier associated with the RFID reader of the automation component.

14. The method of claim 13, further comprising the step of:comparingthe unique identifier of the one or more RFID tags and the automation component identifier against a product database to determine for a selected automation task whether the ground plate and automation component are in a list of one or more required ground plates and automation components.

15. The method of claim 14, further comprising the steps of:selecting via a user interface the automation task from a plurality of automation tasks, and sending the selected automation task to the controller wirelessly.

16. The method of any of claims 11-15, further comprising the step of:removably installing the ground plate at one of a plurality of attachment sites on a plurality of production lines in the batch production facility.

17. The method of any of claims 11-16, comprising repeating the method for one or more further automation components.

18. The method of claim 17, further comprising the steps of:checking whether all of the required automation components and ground plates for the selected automation task have been identified;Commencing production if all of the required automation components and ground plates have been identified.

19. The method of claim 17 or 18, wherein the further automation components are installed on the same production line.

20. The method of any of claims 11-19, further comprising the steps of: measuring at the ground plate at least one distance to a known location on the automation component.

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