The present invention generally relates to systems and methods for remotely controlling apparatuses. In particular, the present invention relates to systems and methods for remotely controlling apparatuses using dynamic association of controls to one or more apparatuses.
The processing of lumber in the wood processing industry is typically performed in mills comprising multiple large production lines. The production lines are typically vast with multiple machines and apparatus operating complex processing tasks on lumber passing therethrough.
While many lumber production lines are automated, manual operations are sometimes required, such as when a lumber remains is jammed or is an operation was not performed correctly. In such cases, some of the systems and/or apparatus of the production lines are controlled by an operator using one or more consoles comprising numerous switches, dials, and other controls with similar or related production lines commonly assembled into a sector (referred to as an “outfeed sector”) being controlled by a console. Preferably, multiple outfeed sectors are controlled by a single operator having a global view of all the processes to better predict or react to the specific requirements of the production lines.
Understandably, the control of multiple outfeed sectors, and therefore numerous machines or apparatus, results in consoles having a substantially high number of controls. This vast array of controls is suitable for initiating the automatic operation of the production lines but may prove challenging when a manual intervention is required as the high number of controls and possible directions can prove confusing and difficult to operate while reacting to a situation. Their complexity further requires that the operator obtains highly specific, technical and expensive training leaving production mills vulnerable in the event of staffing absence or departure.
Referring now to
There is therefore a need for an apparatus and method of simply and efficiently operating multiple outfeed sectors manually thus reducing the complexity of traditional mill consoles.
The shortcomings of the prior art are generally mitigated by a computer-implemented method to remotely operate one or more apparatuses which may comprise selecting a group of the apparatuses, dynamically and operatively associating a control to each of the apparatuses of the group of apparatuses and remotely controlling each of the associated apparatus using the control associated to the said associated apparatus.
In one aspect of the invention, the selection of the group of apparatuses may trigger the association of the controls to each of the apparatuses of the group of apparatuses. Moreover, the method may comprise displaying at least one video feed of the group of apparatuses with the selection of a group of apparatuses comprising selecting the video feed. A graphical overlay may further be added to the selected video feed with the graphical overlay showing boundaries of the group of apparatuses, comprising identification of the control associated to one of the apparatuses of the group and/or comprising a visual identification of each of the apparatuses displayed in the video feed. The visual identification of each of the apparatuses displayed in the video feed may further match a visual identification of the associated control.
In another aspect of the invention, the remote control of each of the associated apparatus may further comprise the control communicating with the associated apparatus through a data network.
In yet another aspect of the invention, the method may further comprise automatically selecting a group of apparatuses having an emergency and automatically associating the controls to each of the apparatuses of the selected group of apparatuses in response to an emergency from the group of apparatuses and automatically displaying at least one video feed of the group of apparatuses being the origin of the emergency
A system to remotely control a plurality of apparatuses is also provided. The system may comprise a user interface configured to select a group of apparatuses from the plurality of apparatuses and execute actions to control an apparatus as well as a controller in communication with the user interface, the controller being configured to dynamically and operatively connect the user interface to one of the apparatuses of a group of apparatuses, the connection allowing the user interface to operatively control the apparatus.
In one aspect of the invention, the system may comprise at least one sensor configured to capture a video feed of the group of apparatuses, the sensor being in communication with the controller. The controller may further be configured to add one or more graphical overlays to the captured video feed with the user interface further comprising a display configured to display the video feed with added graphical overlays. The user interface may comprise a plurality of displays, each display displaying a video feed of a group of apparatuses.
In another aspect of the invention, the user interface may comprise a plurality of controls, each of the controls being associable to one of the apparatuses of the selected group. The controls may be joysticks and the user interface may further comprise a display configured to display the association between the apparatuses and the controls.
In yet another aspect of the invention, the controller may a human-machine interface and the apparatuses may be adapted to convey bundles of wood.
Other and further aspects and advantages of the present invention will be obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
The above and other aspects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:
5B is an exemplary screenshot of a video feed of a second group of apparatuses captured by the system of
5C is an exemplary screenshot of a video feed of a third group of apparatuses captured by the system of
5D is an exemplary screenshot of a video feed of a fourth group of apparatuses captured by the system of
A novel system and method to manually control bundle outfeed apparatuses will be described hereinafter. Although the invention is described in terms of specific illustrative embodiments, it is to be understood that the embodiments described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.
Referring to
Broadly speaking, the apparatus management system 100 is adapted to operate the one or more apparatus 30 of the one or more production lines 15 in the lumber mill 10 and to manually intervene in operations when necessary, by providing an operator an overview of the one or more production lines 15 while selectively and easily associating controls to a desired apparatus 30. In typical embodiments, the operations are automatic but the system 100 overrides the automatic operation when needed or in case of a problem. In particular, the apparatus management system 100 may be configured to dynamically associate the controls of an input or user interface 140 to control or operate various apparatus 30. To that end, the apparatus management system 100 may comprise a controller unit (not shown), such as a CPU or a computer or any computerized device.
Understandably, the present invention is not limited to production lines 15 of lumber mills 10 but may be used in other industries requiring conveying articles or bundles of articles from one production station to another.
Referring now to
Broadly, the apparatus management system 100 provides an operator the ability to select one or more apparatus 30 using the mapping controller 130. The mapping controller 130 is configured to store the apparatuses 30 of a zone 40 of the production line 15 in memory. The mapping controller 130 is further configured to associate or match in memory each apparatus 30 of the zone 40 to a control 142 of the input interface 140. Upon associating the apparatus 30 to the control 142, the control 142 will be operatively connected to the apparatus 30. Therefore, a user manipulating a control 142 shall manually operate the associated apparatus 30.
Referring now to
Referring now to
In embodiments comprising a plurality of controls 142, each control 142 may be mapped to an apparatus 30. For example, in the embodiment illustrated in
The controls 142 may comprise unique visual identifiers or colors such as to be easily visibly discernible from one another to an operator. The visual identifiers may further comprise a colour overlay, symbols, lighting or any other suitable visual identification means.
In certain embodiments, the apparatus management system 100 may be adapted to provide control or operation of one or more zones 40 of the lumber mill 10. Each zone 40 may encompass an aspect or characteristic of an apparatus 30, one or more apparatus 30 or one or more production lines 15. Preferably, the zones 40 are assigned to encompass elements of the lumber mill 10 which operate in unison to perform a specific task. To that end, the input interface 140 may control one or more zones 40 thereby providing an operator a more intuitive control of a single or multiple apparatus 30 in unison for performing any desired process. In other embodiments, each of the controls 142 may be associated to more than one apparatus 30 of a zone 40.
The apparatus management system 100 generally allows the control of a plurality of zones or groupings 40. As such, a user selects a zone 40, typically by selecting one of the zones 40 shown on the display 120. The system 100 maps the control or operation of each of the apparatus 30 comprised in zone 40 to a control 142. As a result, the operator may simultaneously control or operate the apparatuses 30 being part of the selected zone 40 using the plurality of mapped controls 142. Understandably, some zones 40 may comprise a plurality of apparatuses 30 being lower than the number of available controls 142, as such, some of the controls 142 may remain unmapped and thus inactive in the context of the selected zone.
In certain embodiments, the mapping controller 130 is in operative communication with the apparatuses 30 of the production line 15. The mapping controller 130 is thus adapted to send commands and/or requests to the apparatuses, such as a command to activate movement of the apparatus 30. The mapping controller 130 is further configured to store the apparatuses 30 forming a group of apparatuses 40. The mapping controller 130 is further in operative communication with the controls 142. As such, the mapping controller 130 is configured to receive signals from the controls 142 triggered by an input of an operator. The mapping controller 130 is configured to store the association between a control 142 and one or more apparatuses 30. Thus, upon receiving a signal from the control 142, the mapping controller 130 fetches the apparatus 30 associated to the control 142 and sends a command to the associated apparatus 30 as a function of the received input signal.
The mapping controller 130 is further in communication with the display 120 and the sensors 60. In such embodiment, each sensor 60 communicates to the mapping controller 130 a video feed of a group 40 of apparatuses 30, also referred as a zone. The mapping controller 130 transmits or communicates the one or more video feeds to the display 120 to be viewed by the operator. The mapping controller 130 is further configured to receive the selection of a group 40. In some embodiments, the selection may be performed using a touch screen displaying the groups 40 or through any other interface to select a group, such as a drop down, an input box, a button, etc. Upon receiving the selected group 40 of apparatuses 30, the mapping controller 130 fetches the information to communicate with the apparatuses 30 comprised in the selected group 40. The mapping controller 130 further performs an association of the controls 142 with the fetched apparatuses 30.
In some embodiments, the mapping controller 130 is embodied as a HMI. The mapping controller 130 may comprise a central processing unit (CPU), a memory unit, a storage unit, input/output ports and a data communication unit. The storage unit is typically configured to store the network addresses or communication information of the apparatuses 30 of the production line 15, the information required to communicate with the controls 142 and/or the information required to obtain or get the stream of the cameras 60. The input/output ports may comprise one or more video ports, data ports and/or any other know input/output ports. The data communication unit may be embodied as wired or wireless communication module, such as, ethernet, WIFI, mobile communication unit, etc.
In certain embodiments, when the user selects another zone 40, the system 100 is configured to map the apparatuses 30 of the newly selected zone 40 to each of the controls 142.
The mapping or association controller 130 typically comprises a selection interface 132. The selection interface 132 generally allows an operator to select and assign one or more zones 40 to the controls 142. The selection interface 132 may further comprise one or more selectors 134 configured to operate the mapping controller 130. The selectors 134 may comprise one or more joysticks, switches, knobs, rolling balls, keys, touchscreens, trackpads, or any other suitable input means. Referring to
Referring now to
In certain embodiments, the display 120 may be configured to display a visualization or information regarding the production lines 15. As stated above, the display 120 may comprise one or more displays 122 adapted to visually present information regarding different zones 40 or apparatuses 30 of the production lines 15. The displays 122 may be embodied as a CRT monitor, a LCD monitor, a segment display or any other display suitable for presenting visual information.
Referring to
Referring now to
In certain embodiments, the mapping controller 130 may be used in collaboration with the display 120 to assign the controls 142 to the zones 40. To that end, the display 120 may comprise a user interface allowing an operator to select one zone 40 and to assign them to one or more control 142. Upon selection, the mapping controller 130 is configured to map the apparatuses of the selected zone 40 to different controls 142.
The display 120 may be configured to display one or more graphical overlays 126 atop the video feeds 124. The graphical overlays 126 may illustrate the physical boundaries of the zones 40. The overlays 126 may further identify each of the one or more apparatus 30 forming part of the grouping 40 and the association of each of the apparatuses 30 to a specific control 142, the production directional flow or any other data or information regarding the operations performed within each of the apparatuses 30 or the grouping 40.
Referring to
In certain embodiments, the mapping controller 130 may be configured to dynamically associate all the apparatuses 30 of the zone 40. For example, when an operator assigns a zone 40 via the selection interface 132, the mapping controller 130 automatically assigns the selected zone 40 to each of the controls 142. The mapping controller 130 may be configured to automatically determine the control 142 to associate to the apparatus 30 based on the physical position of the different apparatuses in the zone 40. As such, as shown in
The mapping controller 130 may dynamically map one or more controls 142 to one or more apparatuses 30 based on any suitable criterion such as, but not limited to, a predetermined association pattern, the relative placement between the adjacent apparatuses 30, the sequence of the production line 15, the relationship between adjacent apparatuses 30 or any other suitable criterion. For example, referring to
The mapping controller 130 may further be adapted to automatically assign one or more controls 142 to one or more apparatuses 30 of a selected zone 40 when specific conditions are met. For example, a control 142 may be automatically assigned to an apparatus 30 in the event of an emergency or when the system 100 receives an error or warning code requiring immediate intervention thereby eliminating the use of the manual use of the mapping controller 130 by the operator. In such embodiment, the system 100 may automatically select the zone 40 from where an apparatus 30 requires manual intervention and map said zone 40 to a control 142.
The controls 142 may comprise a status indicator 149 adapted to inform an operator whether the control 142 has been associated to an apparatus 30 and is therefore operational. The status indicator 149 may accordingly offer a quick visual confirmation whether a control 142 is operational. The status indicator 149 may comprise an LED, an incandescent bulb, a switch or any other suitable visual indicator.
The mapping controller 130 may be in communication with a graphical module 136 configured to communicate the display feeds 124 to the display 120. The graphical module 136 may be configured to change the feeds to dynamically add the overlays 126. As such, the mapping controller 130 may configured to dynamically update the association tags 129 upon a new selection of a zone 40. The mapping controller 130 may additionally be in communication with the display 120 such as to automatically display the video feed 124 associated to a zone 40 having been selected.
In certain embodiments, the display 120 and the mapping controller 130 may form a unitary system (not shown).
In yet other embodiments, the mapping controller 130 and the display 120 may be a mobile computerized device adapted to receive the video feeds comprising a graphical user interface, such as a tablet or mobile device. In such embodiments, the computerized device may be further configured to display visual and interactive controls 142 which may be used to remotely operate the apparatuses 30 of selected zone 40.
In certain embodiments, the mapping controller 130 may be operated without use of the display 120. Referring now to
The identifiers 150 may comprise a unique tag 154 allowing the operator to identify the identifiers 150. For example, the unique tag 154 may comprise a name, a number, an alphanumeric code, a light, a symbol or any other suitable identification means. Accordingly, the mapping controller 130 may be adapted to receive an input indicating the identifier 150 to be associated to a control 142.
In certain embodiments, the identifiers 150 may further comprise an association indicator 156 adapted to visibly indicate the control 142 associated to said identifier 150. The association indicator 156 may comprise a display, a lighting system or any other suitable system for visually displaying information from a distance. Still referring to
In certain embodiments, the graphical module 136 may be adapted to present a graphical overlay 126 having a characteristic (such as a colour) similar to that of the association indicator 156 for the same apparatus 30. For example, an apparatus 30 viewed in a video feed 124 may comprise a graphical overlay 126 having the same colour as a lighting system of the association indicator 156 thereby allowing the operator to quickly relate a positioning within the video feed 124 to a position within the lumber mill 10.
The console 110 may additionally comprise one or more general controls 112 configured to control or regulate global functions of the lumber mill 10 or a production line 15. The general controls 112 may operate, for example, power to the entire lumber mill 10, a production line 15 or an apparatus 30, an emergency stop, a system reset or any other suitable system. Preferably, the general controls 112 always remain accessible to the operator without the possibility of reassigning them to a specific grouping 40. Referring to
Referring now to
The method 200 may further comprise capturing image or video feeds of one or more zones 40, 230 and displaying the captured feeds 124 to the operator 240. The selection of the zone 40, 210 may further comprise selecting a displayed zone 40.
The method 200 may further comprise adding an overlay 232 to the video feeds 124. The displayed overlay 126 may comprise data relating to the apparatus 30, such as but not limited to the flow direction, the name tag, the identification number, control associated to the apparatus 30, etc.
The method 200 may further comprise automatically associating one of the inputs to one of the apparatus in response to an emergency 250.
While illustrative and presently preferred embodiments of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.
The present patent application claims the benefits of priority of U.S. Patent Application No. 63/030,946, entitled “BUNDLE OUTFEED MANAGEMENT METHOD AND APPARATUSES”, and filed at the United States Patent Office on May 28, 2020, the content of which is incorporated herein by reference.
Number | Date | Country | |
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63030946 | May 2020 | US |