# US 11,305,937 B2 · Process control system

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- Number: US 11,305,937 B2
- Document ID: US11305937B2
- Status: Granted
- Kind: B2
- Application number: 16/618,715
- Filed: 2018-05-25
- Published: 2020-05-21
- Granted: 2022-04-19
- Earliest claimed: 2017-06-02
- Assignees: KUKA Systems GmbH
- Applicants: KUKA Systems GmbH
- Inventors: Andreas Bauer; Horst-Moritz Maus
- Web page: https://patentgrep.com/patent/US11305937B2

## CPC

- B65G 1/1375: {the orders being assembled on a commissioning stacker-crane or truck}
- G05B 19/41865: {characterised by job scheduling, process planning, material flow}
- G05B 19/41895: {using automatic guided vehicles [AGV] (control of position or course of AGV's G05D1/00)}
- G05B 2219/32283: Machine scheduling, several machines, several jobs
- G05B 2219/50393: Floor conveyor, AGV automatic guided vehicle
- Y02P 90/02: Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
- B65G: TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS (packaging B65B; handling thin or filamentary materials, e.g. paper sheets or thread, B65H; cranes B66C; portable mobile or lifting or hauling appliances, e.g. hoists, B66D; devices for lifting or lowering goods for loading or unloading purposes, e.g. fork-lift trucks, B66F9/00; emptying bottles, jars, casks, barrels or similar containers, not otherwise provided for, B67C9/00; delivering or transferring liquids B67D; filling or discharging vessels for liquefied, solidified or compressed gases F17C; pipe-line systems for fluids F17D)
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A process control system for a facility that has a station arrangement including at least one at least partially automated working station and a vehicle arrangement including at least one at least partially automated transport vehicle for transporting material to be conveyed to, in and/or from the station arrangement. The process control system includes a process means for planning, implementing and/or observing, particularly monitoring processes of the station arrangement, a fleet means for planning, implementing and/or observing, particularly monitoring movements of the vehicle arrangement, and a working means arrangement with at least one working means for controlling and/or monitoring at least one working station of the station arrangement. The process and fleet means and/or the process means and the working means arrangement and/or the fleet means and the working means arrangement are configured to communicate with each other.

## Claims

### Claim 1

A process controller for a facility having a station arrangement including at least one workstation that is automated, at least in part, and a vehicle arrangement including at least one transport vehicle that is automated, at least in part, and is intended for transporting goods to be conveyed to, in, and/or from the station arrangement, the process controller comprising:
a processing means for at least one of planning, executing, or observing processes of the station arrangement;
a fleet means for at least one of planning, executing, or observing movements of the vehicle arrangement; and
a work means arrangement comprising at least one work means for communication with at least one workstation of the station arrangement;
wherein at least one of:
the processing means and fleet means,
the processing means and work means arrangement, or
the fleet means and work means arrangement, are configured for at least one of communication or synchronization with one another;
wherein the fleet means comprises means for communication with the vehicle arrangement via at least one fleet manager;
wherein the fleet means is configured to at least one of:
communicate with at least one transport vehicle of the vehicle arrangement alternatively via a selected one of several designated fleet managers, or
communicate with at least one first transport vehicle of the vehicle arrangement via a first fleet manager and with at least one second transport vehicle of the vehicle arrangement via a further fleet manager.

### Claim 2 (depends on 1)

The process controller of claim 1, wherein at least one of:
executing by the processing means comprises commanding processes of the station arrangement;
observing by the processing means comprises monitoring processes of the station arrangement;
executing by the fleet means comprises commanding movements of the vehicle arrangement; or
observing by the fleet means comprises monitoring movements of the vehicle arrangement.

### Claim 3 (depends on 1)

The process controller of claim 1, further comprising:
a user means for at least one of inputting data by a user or outputting data to a user;
wherein at least one of:
the user means and processing means,
the user means and fleet means, or
the user means and work means arrangement,
are configured for communication with one another.

### Claim 4 (depends on 3)

The process controller of claim 3, wherein at least one of:
the processing means and fleet means;
the processing means and work means arrangement;
the fleet means and work means arrangement;
the user means and processing means;
the user means and fleet means; or
the user means and work means arrangement;
are designed for communication with one another on the basis of a protocol.

### Claim 5 (depends on 4)

The process controller of claim 4, wherein communication is based on a service-oriented protocol, in particular an OPC protocol, an OPC-UA protocol or an OPC-UA-like protocol.

### Claim 6 (depends on 1)

The process controller of claim 1, wherein at least one workstation of the station arrangement comprises at least one robot.

### Claim 7 (depends on 1)

The process controller of claim 1, wherein at least one of:
the processing means comprises at least one of:
means for planning of processes of the station arrangement on the basis of at least one of starting products, end products, or process step sequences,
means for allocating different workstations of the station arrangement for carrying out processes of the station arrangement, or
means for allocating transport vehicles of the vehicle arrangement for carrying out processes of the station arrangement; or
the processing means is at least one of:
configured for centralized planning, executing, or observing processes of at least two workstations of the station arrangement that are automated at least in part,
configured for planning, executing, or observing processes of the station arrangement by means of Artificial Intelligence, or
is superordinate to at least one of the fleet means or the work means arrangement.

### Claim 8 (depends on 7)

The process controller of claim 7, wherein at least one of:
the means for planning processes of the station arrangement are configured for at least one of temporal planning or reverse planning;
at least one of the planning means, workstation allocating means, or transport vehicle allocating means operates while the station arrangement carries out processes;
execution by the processing means comprises commanding processes of the station arrangement or the at least two workstations of the station arrangement; or
observation by the processing means comprises monitoring processes of the station arrangement or the at least two workstations of the station arrangement.

### Claim 9 (depends on 1)

The process controller of claim 1, wherein the fleet means comprises:
means for planning of stops of transport vehicles of the vehicle arrangement at various specified locations of the facility.

### Claim 10 (depends on 9)

The process controller of claim 9, wherein at least one of:
the stop planning means is configured for temporal planning of stops;
the specified locations are at least one of workstations or charging stations; or
at least one of the communication means or the stop planning means operates while the station arrangement carries out processes.

### Claim 11 (depends on 1)

The process controller of claim 1, wherein at least one work means of the work means arrangement is configured for communication with a station controller that is configured for at least one of controlling or monitoring at least one workstation of the station arrangement.

### Claim 12 (depends on 11)

The process controller of claim 11, wherein at least one of:
the station controller is a programmable logic controller; or
the at least one work means is configured for communication with the station controller while the station arrangement carries out processes.

### Claim 13 (depends on 1)

The process controller of claim 1, wherein means for communication with the vehicle arrangement via at least one fleet manager communicates with the vehicle arrangement while the station arrangement is carrying out processes.

### Claim 14 (depends on 1)

A system, comprising:
a facility that comprises a station arrangement comprising:
at least one workstation that is automated at least in part, and
a vehicle arrangement comprising at least one transport vehicle that is automated at least in part and is intended for transporting goods to be conveyed to, in, and/or from the station arrangement; and
a process controller according to claim 1 for controlling the facility.

### Claim 15

A method for controlling a facility that includes a station arrangement, the station arrangement including at least one workstation that is automated at least in part, and a vehicle arrangement comprising at least one transport vehicle that is automated at least in part and is intended for transporting goods to be conveyed to, in, and/or from the station arrangement, the method comprising:
providing at least one of communication or synchronization between at least one of:
a processing means and a fleet means,
the processing means and a work means arrangement, or
the fleet means and the work means arrangement,
wherein:
the processing means is configured for at least one of planning, execution, or observation of processes of the station arrangement,
the fleet means is configured for at least one of planning, execution, or observation of movements of the vehicle arrangement, and
the work means arrangement includes at least one work means configured for communication with at least one workstation of the station arrangement; and
communicating, by the fleet means, with the vehicle arrangement via at least one fleet manager;
wherein the fleet means is configured to at least one of:
communicate with at least one transport vehicle of the vehicle arrangement alternatively via a selected one of several designated fleet managers, or
communicate with at least one first transport vehicle of the vehicle arrangement via a first fleet manager and with at least one second transport vehicle of the vehicle arrangement via a further fleet manager.

### Claim 16 (depends on 15)

The method of claim 15, wherein the facility further includes a user means for inputting and/or outputting data by or to a user, the method further comprising:
providing communication between at least one of:
the user means and processing means,
the user means and fleet means, or
the user means and work means arrangement.

### Claim 17 (depends on 16)

The method of claim 16, wherein at least one of the communication or synchronization is based on a service-oriented, protocol, in particular an OPC protocol, an OPC-UA protocol, or an OPC-UA-like protocol.

### Claim 18 (depends on 15)

The method of claim 15, further comprising at least one of:
planning processes of the station arrangement using the processing means and based on at least one of starting products, end products, or process step sequences;
allocating, with the processing means, different workstations of the station arrangement for carrying out processes of the station arrangement; or
allocating, with the processing means, transport vehicles of the vehicle arrangement for carrying out processes of the station arrangement.

### Claim 19 (depends on 18)

The method of claim 18, wherein at least one of:
planning processes of the station arrangement comprises at least one of temporal planning or reverse planning; or
allocating the transport vehicles occurs while the station arrangement carries out processes.

### Claim 20 (depends on 15)

The method of claim 15, further comprising:
planning, by the fleet means, of stops of transport vehicles of the vehicle arrangement at various specified locations of the facility.

### Claim 21 (depends on 20)

The method of claim 20, wherein at least one of:
planning the stops comprises temporal planning;
the specified locations comprise at least one of workstations or charging stations; or
planning the stops occurs while the station arrangement carries out processes.

### Claim 22 (depends on 15)

The method of claim 15, further comprising:
communicating, by at least one work means of the work means arrangement, with a station controller that is configured to at least one of control or monitor at least one workstation of the station arrangement.

### Claim 23 (depends on 22)

The method of claim 22, wherein communicating occurs while the station arrangement carries out processes.

### Claim 24 (depends on 15)

The method of claim 15, wherein the processing means is at least one of:
configured for centralized planning, executing, or observing processes of at least two workstations of the station arrangement that are automated at least in part,
configured for planning, executing, or observing processes of the station arrangement by means of Artificial Intelligence, or
is superordinate to at least one of the fleet means or the work means arrangement.

### Claim 25

A computer program product for controlling a facility having at having a station arrangement including at least one workstation that is automated, at least in part, and a vehicle arrangement including at least one transport vehicle that is automated, at least in part, and is intended for transporting goods to be conveyed to, in, and/or from the station arrangement, the computer program product having program code stored in a non-transitory computer-readable medium that, when executed by a computer, causes the computer to:
provide at least one of communication or synchronization between at least one of:
a processing means and a fleet means,
the processing means and a work means arrangement, or
the fleet means and the work means arrangement;
wherein:
the processing means is configured for at least one of planning, execution, or observation of processes of the station arrangement,
the fleet means is configured for at least one of planning, execution, or observation of movements of the vehicle arrangement, and
the work means arrangement includes at least one work means configured for communication with at least one workstation of the station arrangement; and
communicate, by the fleet means, with the vehicle arrangement via at least one fleet manager;
wherein the fleet means is configured to at least one of:
communicate with at least one transport vehicle of the vehicle arrangement alternatively via a selected one of several designated fleet managers, or
communicate with at least one first transport vehicle of the vehicle arrangement via a first fleet manager and with at least one second transport vehicle of the vehicle arrangement via a further fleet manager.

### Claim 26

A process controller for a facility having a station arrangement including at least one workstation that is automated, at least in part, and a vehicle arrangement including at least one transport vehicle that is automated, at least in part, and is intended for transporting goods to be conveyed to, in, and/or from the station arrangement, the process controller comprising:
a processing means for at least one of planning, executing, or observing processes of the station arrangement;
a fleet means for at least one of planning, executing, or observing movements of the vehicle arrangement; and
a work means arrangement comprising at least one work means for communication with at least one workstation of the station arrangement;
wherein the processing means and the fleet means are configured for at least one of communication or synchronization with one another.

### Claim 27

A process controller for a facility having a station arrangement including at least one workstation that is automated, at least in part, and a vehicle arrangement including at least one transport vehicle that is automated, at least in part, and is intended for transporting goods to be conveyed to, in, and/or from the station arrangement, the process controller comprising:
a processing means for at least one of planning, executing, or observing processes of the station arrangement;
a fleet means for at least one of planning, executing, or observing movements of the vehicle arrangement; and
a work means arrangement comprising at least one work means for communication with at least one workstation of the station arrangement;
wherein at least one of:
the processing means and fleet means,
the processing means and work means arrangement, or
the fleet means and work means arrangement,
are configured for communication with one another on the basis of a service-oriented protocol, in particular an OPC protocol, an OPC-UA protocol or an OPC-UA-like protocol.