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Claims  |
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The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. An apparatus for facilitating support, maintenance and management of a
plurality of operator-supervised industrial machines that are located in a
given plant area which is serviced in common by operator support and
machine maintenance personnel, and which is characterized by an
environment having a high audible noise level and low operator visibility,
and a high electrical noise level such that common forms of audible,
visual and electrical signal communication are unsuitable, comprising:
an operator-controlled input module for each machine, each said module
incorporating a machine computer means and operator-actuated means for
inputting into the associated machine computer means digitally encoded
call data for requesting operator support assistance, and status data
representing a condition of the operation or nonoperation of the
associated machine;
first and second local computer means, said first local computer means
being associated with a first group of said machines preselected from the
total plurality of machines, and said second local computer means being
associated with a second and different group of said machines preselected
from the total plurality of machines, said first local computer means
being jointly linked to all of said machine computer means in said input
modules of said first group of machines and including means for
sequentially polling said machine computer means so as to receive the
digitally encoded call and status data therefrom, and said second local
computer means being jointly linked to all of said machine computer means
in said input modules of said second group of machines and including means
for sequentially polling said machine computer means so as to receive the
digitally encoded call and status data therefrom;
first and second electrical signal controlled visual paging display means
mounted in the plant area and being respectively associated with said
first and second groups of machines;
first and second display computer means for receiving and decoding the
digitally encoded call data and for respectively controlling said first
and second visual paging display means so as to cause the call data to be
visually displayed in the plant area, said first display computer means
being linked to said first local computer means and including interrupt
means for causing the call data in said first local computer means to be
transmitted to said first display computer means, and said second display
computer means being linked to said second local computer means and
including interrupt means for causing the call data in said second local
computer means to be transmitted to said second display computer means;
front end computer means, each of said first and second local computer
means being linked to said front end computer means over separate digital
data transmission paths, said front end computer means including means for
sequentially polling each of said first and second local computer means
for call and status data originating at the first and second groups of
machines respectively, and means for receiving and storing such call and
status data developed in response to said means for polling, and said
front end computer means further including interrupt means for
transmitting said call data received and stored in said front end computer
means to each of said first and second local computer means such that call
data received by said front end computer means from both said first and
second local computer means is routed back to each of said first and
second local computer means and hence to the associated first and second
display computer means for causing said first and second display means to
visually present call data originating in either said first or second
groups of machines; and
data processing means for utilizing said call and status data stored in
said front end computer means.
2. The apparatus of claim 1, wherein each of said input modules comprises
feedback indicator light means mounted so as to be visible by the machine
operator, and each of said machine computer means includes means for
energizing said indicator light means in response to the associated
operator-actuated means so as to acknowledge to the operator that the
digitally encoded call and status data has been entered into the
associated machine computer means.
3. The apparatus of claim 1, wherein said machine computer means, display
computer means, and local computer means comprise identical
microprocessors.
4. The apparatus of claim 1, wherein said machine computer means, display
computer means, local computer means and said front end computer means
comprise identical microprocessors.
5. The apparatus of claim 1, wherein said front end computer means
comprises a microprocessor based microcomputer and said data processing
means comprises a general purpose programmable computer linked to said
front end computer means for receiving, compiling and report formatting of
call and status data collected by said front end computer means.
6. The apparatus of claim 1, further comprises a party line serial data
transfer means for jointly linking said first local computer means to all
of said machine computer means of the first group of machines.
7. The apparatus of claim 6 wherein said party line serial data transfer
means comprises at least one common current data loop extending from said
first local computer means and separate means for coupling each of said
machine computer means of said first group of machines to said common
current data loop.
8. The apparatus of claim 7, wherein said first display computer means is
jointly linked, along with said machine computer means of said first group
of machines to said first local computer means, and further comprising
means for coupling said first display computer means to said common
current data loop.
9. The apparatus of claim 7, wherein each of said means for coupling said
machine computer means to said common current data loop comprises an
optical isolator.
10. The apparatus of claim 1 wherein said first and second local computer
means are disposed at separate locations on the plant floor respectively
adjacent the first and second groups of machines, and further comprising
CRT and keyboard terminal means for at least said first local computer
means for retrieving and displaying call and status data from said front
end computer means via said first local computer means.
11. In an industrial machine support system that has a plurality of
operator-actuated input modules, one at each of a corresponding plurality
of industrial machines, for generating digitally encoded call signals that
represent requests for operator assistance, and that has a plurality of
signal controlled visual paging displays disposed in a plant area where
the industrial machines are located, the improvement comprising:
a separate machine microcomputer means for each of said input modules for
receiving and storing said call signals;
first and second local microcomputer means, said first local microcomputer
means being associated with a first group of said machines and their
corresponding input modules, said second local microcomputer means being
associated with a second and different group of said plurality of machines
and their corresponding input modules;
first and second display microcomputer means for receiving, decoding and
displaying digitally encoded call signals and for controlling separate
ones of said displays so as to cause said call signals received by said
first and second display microcomputer means to be visually displayed in
the plant area;
first digital signal linking means for jointly linking said first local
microcomputer means with each of said machine microcomputer means for said
first group of machines and with said first display microcomputer means,
and second digital signal linking means for jointly linking said second
local microcomputer means with each of said machine microcomputer means
for said second group of machines and with said second display
microcomputer means;
said first local microcomputer means including means for sequentially
polling said machine microcomputer means for said first group of machines
so as to receive and store the digitally encoded call signals held in such
machine microcomputer means, and said second local microcomputer means
including means for sequentially polling said machine microcomputer means
for said second group of machines so as to receive and store the digitally
encoded call signals held in such machine microcomputer means;
said first and second display microcomputer means each including means for
receiving the call signals stored in said first and second local
microcomputer means, respectively, and said first and second local
microcomputer means each including interrupt means for transmitting call
signals stored therein to said first and second display microcomputer
means respectively;
and front end computer means linking each of said first and second local
microcomputer means, said front end microcomputer means including means
for sequentially polling each of said first and second local microcomputer
means for call signals originating at machines in the first and second
groups of machines, respectively, and including means for receiving and
storing such call signals developed in response to said means for polling,
and said front end computer means further including interrupt means for
transmitting call signals stored therein to each of said first and second
local microcomputer means.
12. In an industrial machine support system that has a plurality of
operator-actuated input modules, one at each of a corresponding plurality
of operator-supervised machines, for generating digitally encoded call
signals that represent requests for operator assistance, and that has a
signal controlled visual paging display disposed in a plant area where
operator support personnel are located, the improvement comprising:
a distributed microcomputer network interconnecting said operator-actuated
input modules and said paging display, said network comprising:
a separate machine microcomputer for each of said input modules for
receiving and storing said call signals;
a display microcomputer means for receiving and decoding said call signals,
and including means for operating said paging display so as to cause calls
represented by said call signals to be visually displayed thereon;
local microcomputer means;
digital data linking means for linking said local microcomputer means
jointly to said machine microcomputer means and to said display
microcomputer means, said digital data linking means comprising at least
one common current data loop extending from said local microcomputer means
serially to said machine and display PG,38 microcomputer means and a
plurality of separate coupling means each connected in series with said
loop for coupling each of said machine and display microcomputer means to
said digital data linking means; and
said local microcomputer means including means for sequentially polling
said machine microcomputer means for call signals held therein and means
for accumulating and storing said call signals developed in response to
said means for polling, and said local microcomputer means including
interrupt means for transmitting call signals held in said local
microcomputer means to said display microcomputer means.
13. The improvement in claim 12, wherein each of said separate coupling
means is a photo-optical isolator. |
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Claims |
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Description |
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BACKGROUND OF THE INVENTION
This invention is directed to systems for improving the productivity of
operator-supervised industrial machines, such as systems of the type
disclosed in U.S. Pat. No. 4,017,831 for N/C MACHINE PAGING, STATUS AND
REPORT SYSTEM, issued Apr. 12, 1977, by Jansey D. Tieden and Forrester E.
Woodruff, Jr.
While the herein-disclosed embodiment of the invention is directed to a
system for use with N/C machines, it will be appreciated that the
invention has utility as a support system for other types of industrial
machines. In general, the invention is useful in conjunction with
operator-supervised industrial machines that are arranged close together
within a given plant area, and that are operated in an environment
characterized by a high level of audible noise and limited operator
visibility, such that audible and visual communication between the
operator and support personnel is very difficult, if not possible, and in
an environment characterized by the presence of high level electrical
noise due to stray electromagnetic fields such that many common forms of
electrical signal communication are unsatisfactory. As discussed more
fully in the above referenced U.S. Pat. No. 4,017,831, the disclosure of
which is incorporated herein by reference, these and other difficulties in
monitoring the performance of N/C machines led to the development of the
system disclosed in that patent for enabling the machine operator to
effectively call for support personnel, such as tool kitters, supervisors,
etc., immediately when needed, and provide performance monitoring
capability, such as real time knowledge of machine status, and compilation
of historical operating data for each machine. While a paging, status and
report system constructed in accordance with the disclosure in U.S. Pat.
No. 4,017,831 has served its intended purpose in markedly improving the
productivity of a plurality of N/C machines, the implementation and online
operation of the prior system has revealed some shortcomings.
One of these shortcomings is attributed to the overall architecture of the
computer network employed in the prior system. As disclosed in the above
cited U.S. patent, the prior system used one central computer for
collecting data and for operating the various display devices and
input/output terminals. Thus, a failure of the central computer would
cause the entire system to shut down.
Another practical, but perplexing, difficulty was encountered in the
installation and maintenance of the prior system. Because of the
architecture of the system, input modules for each N/C machine require
separate cables (a set for each N/C machine module), extending from the
numerous machine modules to the central computer in a remote control room.
Moreover, each visual paging board of the system required separate,
multiwire cabling between the central computer in the control room and the
plurality of paging boards disposed at various locations throughout the
shop area. As a result, the prior system required a very substantial
amount of wiring between its variously located components, thereby
rendering the system expensive to install, both in terms of material and
labor, and costly to maintain.
Even apart from the cost of the additional wiring there are numerous
situations in which existing conduits for routing wiring and cables to and
from the N/C machines are already filled to capacity and will, at best,
accommodate only a limited amount of additional control cabling for
installation of a system of the above-characterized type. Such limited
cabling capacity severely constrains the use of the prior machine support
system.
In addition to the above, other shortcomings of the existing system include
its susceptibility to total system shutdown upon the occurrence of certain
hardware failures at the operator controlled input modules; a limitation
on the expansion of the system to accommodate additional machines and in
general a lack of flexibility; and, the inability of the prior system to
automatically diagnose and flag specific hardware component failures.
Accordingly, an object of the present invention is to provide an industrial
machine paging, status monitoring and report compiling system using a
computer network design that facilitates the transmission of data between
the operator-controlled imput modules located on each machine and the
various computing, visual display, permanent record storage and printout
devices.
Another object of the invention is to provide such a system in which the
computer network is configured so that the system is tolerant of certain
component failures. In other words, a malfunction of certain of the system
components will not necessarily cause the entire system to shut down,
rather the system will continue to operate in a limited but useful
capacity.
A further object of the invention is to provide such a system with
flexibility in terms of being readily expanded, or reduced, to accommodate
a greater or lesser number of monitored machines.
Still a further object of the invention is to provide such a system with
the capability of automatically detecting and signalling a hardware
failure within certain components of the system.
SUMMARY OF THE INVENTION
In accordance with the principles of this invention, a distributed
microcomputer network is employed in a paging, status monitoring and
report compiling system to collect CALL and STATUS data at each of a
plurality of operator-supervised industrial machines, operating in the
kind of environment characterized above, and to communicate operator
assistance CALL data with a plurality of visual paging boards
strategically located in the plant and maintenance CALL data with a
printer located in the maintenance crib, and to communicate both the CALL
and STATUS data with a central data processor located in a central control
room. The total number of industrial machines, which for example may be
N/C machines, in a given plant area, are divided into at least first and
second groups. Each machine in each such group is provided with an
operator-controlled input module, which in turn incorporates a
microcomputer, referred to as a machine microcomputer, for accumulating
and temporarily storing digitally encoded CALL and STATUS data, entered by
the machine operator via the input module. At a next higher level of the
distributed microcomputer network, the first and second groups of machines
are each assigned another microcomputer, called a local microcomputer
which is jointly coupled to each of the machine microcomputers belonging
to the same group by a party line data link. The first and second group
local microcomputers each request and receive, by sequential polling
operation, data that is stored in the machine microcomputers within the
associated group, thus further concentrating the CALL and STATUS data.
Also, each of the first and second machine groups is provided with a
visual display microcomputer acting in association with a local
microcomputer, for controlling the operation of a visual paging board
assigned to the group. At a still higher level in the distributed
microcomputer network, a front end microcomputer is provided for
communicating with each of the first and second local microcomputers. The
front end microcomputer in general functions to request and receive stored
data from each of the local microcomputers, by carrying out a sequential
polling operation; route CALL data, regardless of which local
microcomputer originated such data back down the computer network to all
the local microcomputers for causing all operator assistance CALL data to
be displayed on every paging board; and route CALL and STATUS data to a
central data processor for processing into reports and where desired, into
permanent storage; and route CALL data requiring maintenance action to an
output terminal in the maintenance crib.
In the present preferred form of the invention, the above mentioned party
line data link that couples the group of machine microcomputers to the
associated local microcomputer is provided by a common serial transfer
data link in which a common, interruptable loop current is jointly coupled
to each of the machine microcomputers. This form of data transmission is
immune to the presence of high level electrical noise, and is capable of
being conducted over readily installed transmission paths such as twisted
pair conductors. Furthermore, in the preferred form of this invention, the
local microcomputers are coupled to the front end microcomputer by
separate, independent serial transfer data links so that a loss of one of
the links will not prevent the other local microcomputers from
communicating with the front end microcomputer.
Other features provided in the presently preferred embodiment include:
feedback indicator lights on the operator input module that assist the
operator in entering CALL and STATUS data self diagnostic capability in
which malfunction in certain components of the system is automatically
detected and responsive maintenance CALLs are generated; CRT and keyboard
access terminals at each local microcomputer (which is preferably located
on the plant floor) so as to permit floor area supervisors and maintenance
personnel to request machine data and other reports from the central data
processor without leaving the plant floor; and the provision of a complete
central data processor unit (which need not be a microcomputer) that is
separate from the front end microcomputer and that serves to compile
format and permanently record CALL and STATUS data received from the front
end microcomputer, issue regular periodic and special request reports, and
display current CALL and STATUS data on a CRT terminal.
To provide a complete disclosure of the invention, reference is made to the
appended drawings and following description of one particular and
currently preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial diagram illustrating one embodiment of the paging,
status monitoring and report compiling system of the invention used in
conjunction with N/C machines.
FIG. 2 is a generalized block diagram of the distributed microcomputer
network that interconnects the plurality of N/C machines and the various
computation, visual display, report compiling and terminal printers that
comprise the system.
FIG. 3 is a more detailed block diagram of a machine microcomputer and the
associated operator-controlled input module for entering the CALL and
STATUS data into the memory of the machine microcomputer.
FIG. 4 is a block diagram of detail similar to that of FIG. 3 showing the
visual display microcomputer and the associated row drivers which
responsively energize selected lights on the visual display paging board
to visually form the operator-originated CALLs which include the
associated machine location.
FIG. 5 is a block diagram of similar detail to that of FIGS. 3 and 4,
depicting one of the local microcomputers that is used at an intermediate
level in the distributed microcomputer network of FIG. 2.
FIG. 6 is a block diagram showing the serial transmit and receive data
paths employed for linking each local microcomputer (FIG. 5) with the
associated group of machine microcomputers (FIG. 3) and the associated
visual display microcomputer (FIG. 4).
FIG. 7 is a block diagram, of detail similar to that of FIGS. 3 through 5,
depicting the front end microcomputer which is situated, along with a
central data processor, at the highest level within the distributed
computer network shown in FIG. 2.
FIGS. 8A and 8B are flow diagrams of the program governing the operation of
the central data processor of FIGS. 1 and 2.
FIGS. 9A and 9B are flow diagrams of the program governing the operation of
the front end microcomputer of FIGS. 1 and 2.
FIGS. 10a and 10B are flow diagrams of the program governing the operation
of each of the local microcomputers of FIGS. 1, 2 and 5.
FIGS. 11A, 11B and 11C are flow diagrams of the program governing the
operation of each of the machine microcomputers shown in FIGS. 2 and 3.
FIGS. 12A and 12B are flow diagrams of the program governing the operation
of each of the visual display microcomputers shown in FIGS. 1, 2 and 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, each of a plurality of N/C machines 15 is linked
with a plurality of visual display boards 16 for paging support personnel
in the plant area, with a maintenance printer 17 located in the
maintenance crib for requesting certain maintenance actions, and with a
central data processor unit 18 located in a central control room, by means
of a distributed microcomputer network including a plurality of machine
microcomputers and operator input modules 20, a plurality of local
microcomputer units 30 including associated CRT/keyboard terminals, a
plurality of visual display microcomputers 40, and a front end
microcomputer 50.
Each of the plurality of N/C machines 15 is provided with a machine
microcomputer and operator input module 20 packaged in a common housing 21
and mounted on or adjacent to machine 15 so as to permit an operator,
stationed at machine 15 for supervising its operation, to input CALL and
STATUS data using a set of CALL selector switches 22 and STATUS selector
switches 24. A CALL feedback light 26 and a STATUS feedback light 28 are
selectively energized by the microcomputer within module 20 in a manner,
as described more fully hereinafter, that assists the operator in entering
the CALL and STATUS data using switches 22 and 24. It is noted that module
20 does not contain any of the numerical control circuitry for operating
the machine 15, and such control circuitry is not specifically disclosed
herein and operates independently of the paging monitoring and report
compiling system of the invention.
The total number of machines 15 connected to the system is divided into a
plurality of groups. Each group of machines 15 and their associated
machine microcomputers and input modules 20 are linked to one of the
plurality of local microcomputer units 30. Each such local microcomputer
receives and concentrates CALL and STATUS data from the plurality of
machine microcomputers and input modules 20 belonging to that group. An
associated visual display microcomputer 40 is provided for each machine
group for controlling one of the paging boards 16 in response to CALLs
held in memory by the corresponding local microcomputer unit 30.
Front end microcomputer 50, serving as the next higher level of the
distributed computer system, polls each of the plurality of local
microcomputer units 30 to receive and concentrate CALL and STATUS data
from all of the machine microcomputers 20. The thusly consolidated data
representing CALLs and STATUS are channeled by the front end microcomputer
50 to various parts of the system as follows. CALLs are routed by
microcomputer 50 back down the network to the plurality of local
microcomputers 30, which in turn distribute the consolidated CALL data to
each paging board 16 via the associated visual display microcomputer 40.
Thus, paging boards 16 serve to visually page the support personnel at all
locations in the plant area where boards 16 are visible. Maintenance CALLs
are additionally transmitted to the maintenance crib for printout on the
maintenance printer 17. CALLs and STATUS data are also routed by front end
microcomputer 50 to the central data processor unit 18 which displays
current CALL and STATUS data for each machine on an associated CRT and
compiles periodic reports and stores such reports permanently on a floppy
disc recording. Additionally, upon request, processor unit 18 acts through
high speed line printer 19 to print out previously compiled reports.
With reference to FIG. 2, it is seen that front end microcomputer 50 is
interconnected by a plurality of separate serial data transfer channels
100 to each of a plurality of local microcomputer units 30. Each unit 30
includes a local microcomputer (designated microcomputers #1-6
corresponding to the six local units that are employed in the
herein-disclosed embodiment), a local CRT 302 and a local keyboard 304.
Each local unit 30 is associated with a separate group of N/C machines 15,
which group will typically be located in a subsection of the overall plant
area. In this instance, each local microcomputer #1-6 handles the CALL and
STATUS information originating at 20 N/C machines 15. As mentioned above,
each N/C machine is equipped with a machine microcomputer and operator
input module 20, which is physically located on or adjacent to the
associated machine for enabling the operator to input CALL and STATUS data
into the microcomputer network. Thus, under the charge of local
microcomputer #1, 20 such machine microcomputers and input modules 20 are
provided, one for each of machines #1-20. Modules 20 are coupled to
microcomputer #1 by a party line serial data transfer link 110 which, as
more fully described hereinafter, greatly reduces the amount of physical
wiring required between the various machine mounted modules 20 and the
associated local microcomputer.
Additionally, as shown for local microcomputer #1, each local unit is
coupled over party line link 110 to one visual display microcomputer 40,
which in turn is connected for operating one of the visual display paging
boards 16. It is observed that the visual display microcomputer 40
communicates with the local microcomputer #1 over the same party line data
link 110 that serves to communicate the machine microcomputers in modules
20 with local microcomputer #1.
Similarly, local microcomputer #2 has its associated CRT and keyboard, and
is linked to another group of up to 20 N/C machines and associated machine
microcomputer and input modules, and to a visual display microcomputer and
associated paging board.
Each local unit 30 and its associated group of machines 15, modules 20,
visual display microcomputer 40 and paging board 16 is capable, as
described more fully hereinafter, of functioning in a limited capacity as
a separate, independent subdivision of the overall system depicted in FIG.
2. In the disclosed embodiment, front end microcomputer 50 is capable of
accommodating up to six local units 30, however, it will be appreciated
that the computing and memory capacity of microcomputer 50 may be readily
extended to handle a larger number of local units.
To correlate the CALL and STATUS data that originates at the operator
inputs of modules 20 with the date and time of day (shift time), front end
microcomputer 50 receives as an input thereto time and date data from a
time/date module 118. Central data processor unit 18 coupled to front end
microcomputer 50 includes in addition to the central data processor 182 a
CRT 184 and a floppy disc storage 186. Processor 182, CRT 184 and storage
186 may be packaged as an integrated console as depicted by unit 18 in
FIG. 1.
The machine microcomputer used in each of modules 20, the local
microcomputer used in each local unit 30 and the front end microcomputer
50 may all be provided by identical, commercially available
microprocessors, each complemented by various input/output and memory | | |
