WO1999041649A1

WO1999041649A1 - Interactive remote control system of manufacturing equipment

Info

Publication number: WO1999041649A1
Application number: PCT/US1999/002800
Authority: WO
Inventors: Brandon Zemlo
Original assignee: Sierra Concepts Corporation
Priority date: 1998-02-13
Filing date: 1999-02-09
Publication date: 1999-08-19
Also published as: EP1055161A1; CA2322310C; US6393380B1; CA2322310A1

Abstract

Interactive access to a machine from a personal computer at a remote location is provided by connecting the machine and the computer to a communication network by modems which have digital data and analog audio input/output circuits. A point-to-point communication link is established between the machine and the remote location. Data and video are transmitted over the communication link using software that is configured to use a TCPIP network protocol. Voice transmission is handled by the audio circuits in the modems. The creation of a TCPIP network on the point-to-point communication link enables simultaneous access to the link by a plurality of programs and devices that separately handle the exchange of data, voice and video images over a shared communication medium.

Description

INTERACΗVE REMOTE CONTROL SYSTEM OF MANUFACTURING EQUIPMENT

Field of the Invention

The present invention relates to the trouble shooting,

training and configuration of computer controlled machinery,

such as machine tools in a factory, and more particularly to

providing those support services from a remote location via a

communication link.

Background of the Invention

Machine tools, that once were purely mechanical devices

controlled by a human operator, now are being controlled by

computer systems which have been programmed to operate the

machine tool in a prescribed manner to process a part being

manufactured. As the complexity of the computer control

grew, so did the ability to trouble shoot problems that arose

with the operation of the computerized machine tool.

Presently trouble shooting requires that a service

technician come to the premises at which the machine tool is

located and interface with the machine ' s computer to execute

diagnosis routines. In many instances, the technician must

observe the operation of the machine tool to determine how it is performing in response to specific manually entered

commands. In addition, the technician usually discusses the

errors and historical performance with the operator of the

machine. Once the source of the problem has been identified,

the technician then enters commands into a terminal for the

machine tool's computer which correct the situation. This

process requires that a technician with a high level of skill

in diagnosing and solving the problems come to the machine

tool. Therefore, a large number of skilled technicians are

required in order to timely service machine tools located

throughout a large geographical area.

As a result, it is desirable to enable a technician

to perform the trouble shooting and problem solving from

a central location, such as the office of an equipment

distributor or manufacturer, without having to go the

location of the machine tool. This would enable a single

technician to service machines throughout a large territory

and service a greater number of machines as travel time is

eliminated. Although it is feasible to remotely control the

machine tool's computer, such a data communication link would

not enable the service technician to observe the physical

movement of the machine or to conduct real time discussions

with the machine tool operator. As used herein the terms

"remote control" and "remote location" relate to a physical separation of the machine tool and a control station at

different locations, which precludes a person in one location

from directly observing events at the other location or from

speaking unaided to someone at the other location.

Although software presently exists for communicating

either data, audio or video via a computer over a dial-up

telephone line, the individual programs for each type of

information have been considered incompatible for simultaneous

execution so that all three types of information could be sent

over the same telephone connection together in real-time.

Each program typically requires exclusive control of the

telephone line and thus can not share access with the other

programs as each one expects to have the full bandwidth of

the telephone line available to it. Thus the conventional

approach would be to use separate telephone lines for each

modality, which doubles or triples the communication expense,

the number of lines and the connection effort.

An alternative proposal involves interconnecting the

service technician's office with the machine tool computer by

the Internet which would permit the transmission of audio and

video along with the digital information. However, the rate

of information transmission over the Internet between any

given pair of computers varies greatly depending upon the

amount of communication between other computers that is being carried at the same time. In addition, the Internet may send

the packets of information via different paths. As a result,

the Internet information transfer encounters unpredictable

time delays which does not facilitate real-time control of the machine tool .

Summary of the Invention

The present invention provides an interactive tool that

facilitates remote support, such as diagnosis and virtual

training, for the operation of machinery. This system

utilizes a real-time, fully interactive graphical interface

in conjunction with simultaneous transmission of at least

audio or video, preferably both, to accomplish this inter¬

activity. The mechanism behind this technology is a TCPIP

network that is established between a remote control computer

and the host control for the machine. The conduit for this

network is a point- to-pomt modem connection that is

established using a single conventional communication link,

such as a dial-up telephone line.

The present invention allows the limited bandwidth of a

standard telephone line to simultaneously carry data for

controlling the machine, voice communication between a remote

technician and the machine operator, and video images of the

people and the machine's operation. The simultaneous transmission of these three distinct types of information

occurs in a time division multiplex manner.

Brief Description of the Drawing

Figure 1 schematically illustrates a remote interactive

support system for providing service to a computer controlled

machine tool .

Detailed Description of the Invention

With reference to Figure 1, a machine tool 11 includes

a personal computer (PC) based controller 10, such as a

model 2100 Acramatic control system manufactured by Vickers,

Inc., Electronic Systems, Lebanon, Ohio, U.S.A. This type

of controller is a computer system which utilizes a Pentium

microprocessor that executes either a Windows 95, Windows

98 or Windows NT operating system, licensed by Microsoft

Corporation of Redmond, Washington, U.S.A. The controller

10 displays operational information to the machine operator

on a video monitor 13. A conventional color video camera 12

for computers is connected to a parallel port on controller

10. The controller 10 contains a serial port connected to a

high speed, simultaneous voice-data modem 14, such as a DSVD

modem, which may be an Accra model from Hayes Microcomputer Products, Inc. of Atlanta, Georgia, U.S.A. In addition to

providing an interface for the exchange of digital data

between a computer and a communication link, this type of

modem 14 also has analog audio connections for the ear piece

and microphone of a headset 16. The DSVD modem 14 includes

analog/digital circuitry that provides bidirectional

conversion between analog signals for the headset and

digitized audio signals sent over the communication link. A

DSVD modem typically is used to enable persons at opposite

ends of a telephone connection to play a video game and talk

to one another at the same time. The modem 14 is connected to

a standard dial-up telephone line which is part of telephone

network 18.

Although the exemplary embodiment of the interactive

support system in Figure 1 has the machine tool controller 10

connected directly to the modem 14, one skilled in the art

will appreciate that the present inventive concept can be

implemented by separate personal computer interfacing the

machine tool controller 10 to the modem 14 to handle

communication over the telephone network. In this latter

embodiment, the personal computer is considered to be part of

the machine, even if it is used to perform other functions.

The dial-up telephone network 18 connects the machine

tool controller 10 to a remote site where a technician is located. This establishes a poin -to point communication link between the two computer systems 10 and 20 which once

established provides a continuous path that is dedicated to

communication between those computer systems. This is in

contrast to the Internet which is not a point-to-point

communication link in that a given transmission is broken up

into a plurality of data packets, which may be routed via

different paths through the network along with packets from a

vast number of other computers at any given time. Thus the

Internet inherently has random delays of indeterminate length

which affect transmission of information between the sender

and receiver, which indeterminate delays are not present in

pomt-to-pomt communication links.

A standard personal computer 20, executing either the

Microsoft Windows 95, Windows 98 or Windows NT operating

system, is located at the remote site, which may be the

office of a distributor or manufacturer of the machine tool

11. This remote personal computer 20 has a parallel port to

which a conventional video camera 22 is connected and a

serial port connected to a simultaneous voice-data modem 24,

similar to modem 14. Another headset 26 is connected to the

modem 24 for use by the technician.

The hardware configuration shown in Figure 1 supports a

simultaneous bidirectional exchange of data, video and audio signals over the point-to-point communication link formed by

the telephone network. Those skilled in the art will

appreciate the transmission of these three modalities of

data, video and audio is not truly simultaneous, but occurs

in a high speed, time division multiplex mode in which each

modality is broken into packets that are sent over the

network interleaved in time. However, the interleaving

occurs so rapidly that it appears to the user as though the

three different types of information are being communicated

at the same time.

To accomplish this exchange of information, controller

10 and remote personal computer 20 are each loaded with a

commercially available data communication program, such as

"PC Anywhere" licensed by Symantec Corp. of Cupertino,

California, U.S.A. which allows a remote personal computer

to access another computer system. The images produced by

the video cameras 12 and 22 are sent to the associated modem

14 and 24 by a separate commercially available video

communication program, such as Microsoft's "NetMeeting" .

Although "NetMeeting" is a conferencing program which also

handles audio, that capability is not utilized in the

preferred embodiment of the present system. These

communication programs also handle receipt and display of

data and video images from the telephone network 18. The communication programs in both the machine tool

controller 10 and personal computer 20 are configured to

establish a Transport Control Protocol/Internet Protocol

(TCPIP) network by employing an augmentation of a standard

Remote Access Service (RAS) setup in the Microsoft Windows

9X/NT operating systems. Thus the software is configured as

though it is to communicate over the Internet, instead of a

standard dial-up telephone line, even though that latter

medium is being used to provide an autonomous pomt-to-pomt

communication link between the two computer systems. In

effect, the communication system is configured as a

"mini -Internet" with each computer system 10 and 20 being

assigned a pseudo Internet address. Specifically, the

communication software in the machine tool 11 acts as a

server, while the existing software for controlling the

machine tool acts as a server and a client. By creating a

pseudo Internet server, neither the data communication

program nor the video transmission program attempts to exert

exclusive control over the associated modem 14 or 24 and both

programs can operate simultaneously in exchanging data and

video via that modem. In additional these programs can

co-exist with the voice communication provided by the audio

circuitry in the DSVD modems 14 and 24 Tne TCPIP protocol also arbitrates among the programs

when collisions occur as both programs attempt to send

information over the telephone network at the same time.

In addition to configuring the data and video

communication programs for the TCPIP protocol, each program

and the voice channel of the DSVD modem in both computer

systems 10 and 20 is set up to minimize the telephone line

bandwidth which it requires for acceptable communication.

Th s allows all three modalities, data, voice and video to

share the same dial-up telephone connection. Specifically,

the DSVD modem is configured for maximum audio compression

and the delay is also set to the maximum value which still

provides real-time audio. These settings optimize the

modem's throughput of digital data (data and video

information) .

In the data communication program, the "color palette"

is set to a small number (e.g. 16 colors) which reduces the

amount of data being transmitted to replicate the display

screen 13 of the machine tool operator panel . In addition

the area of the desktop also is reduced to reduce the

quantity of data being transferred.

The video communication program may be one that is

limited to processing only video from the camera, such as

"Cu-Seeme" which is licensed by White Pines Software of

10 Nashua, New Hampshire, U.S.A. However the preferred program,

Microsoft NetMeeting, is teleconferencing software which is

intended to handle both video and audio. Teleconferencing

software may offer greater flexibility m controlling the

amount of video data being sent and the image quality.

Nevertheless, sending the voice communication via the audio

channel of the DSVD modems is more efficient than using the

audio capability of the teleconferencing software, as the

latter approach requires significantly greater bandwidth.

Therefore, the video communication program is configured with

the audio capability disabled. The video compression is set

to the maximum value which will preserve color transmission

and a realistic image refresh rate. It should be noted that

the configuration of each communication program and the voice

channel of the modem involve tradeoffs between acceptable

quality of its information transfer and the effects on the

remaining bandwidth that will be available to the transfer of

the other types of information.

When a technician desires to access the machine tool 11

at a remote factory, that person signs on to the personal

computer 20. The data communication program is executed to

instruct the modem 24 to dial the telephone number of the

modem 14 connected to the controller 10 for that machine tool

It also is possible with the TCPIP protocol to establish a

11 three-way conference call via telephone network 18 so that

persons at both the machine tool distributor and manufacturer

can provide interactive support for a remotely located machine

tool. When the communication link has been established

between controller 10 and personal computer 20 via the dial-up

telephone network 18, the data communication program being

executed by the machine tool controller 10 transmits the

digital machine operational data being displayed the

controller monitor 13 to the technician's computer 20. The

data communication program executing m the personal compuert

20 displays that data on monitor 28. Thus the remotely

located technician sees a replica of the machine controller

display.

Once the communication link has been established, the

video communication software begins executing in the machine

tool controller 10 and personal computer 20 to enable

personnel at both ends of the link to observe one another on

their respective monitors 13 and 28. The video communication

software inserts a small video image 30 and 32 m the monitors

13 and 28, respectively. The machine tool operator also can

aim the camera 12 so that the technician is able to observe

the machine tool on the personal computer monitor 28. The

size of the video display 32 can be changed by altering the

parameters of the video communication program executing m the

12 personal computer 20. The operator at the machine tool 11

wears headset 16 for voice communication with the remotely

located technician, who is wearing headset 26.

The technician uses the keyboard of personal computer 20

to send commands to the machine tool controller 10 which

replicate the commands that the operator can enter into the

machine's input device 15. This enables the technician to

view the present configuration of the machine tool, call up

historical logs containing machine tool error information and

instruct the machine tool to perform operations as though the

commands were entered into the input device 15. The

technician also may call for execution of diagnostic routines

stored in the machine tool controller and have the data

produced by those routines sent over the telephone network 18

for display on the personal computer monitor 28. In response

to viewing the results of the diagnostic routines, the

technician is able to send instructions either directly to

the machine tool controller 10 or verbally to the operator,

via headsets 16 and 26, to correct any operational errors.

The present system creates a TCPIP network between the

machine tool 11, which acts as the host controller, and the

technician's personal computer, which acts as a remote

computer. This TCPIP network enables simultaneous access to

the communication link 18 by the plurality of programs and

13 devices that separately handle the exchange of data, voice

and video over tne common communication link. It should be

understood that while a dial-up telephone network is utilized

to describe the present invention, other types of point-to- -

point communication links are feasible.

This interactive support system permits remote trouble

shooting to be performed with real time input/output machine

state and logic level analysis. In addition, error log

analysis and machine configuration determination of enabled

options can be carried out. The present system also can be

employed to transfer software updates from the distributor's

or manufacturer's computer to each machine tool in the field.

Such updating eliminates the need to duplicate and mail out

computer diskettes containing the software. The system also

provides the capability to update problematic machine tools

on-demand.

In addition to trouble shooting machine tool operation,

this remote interactive support system can be used to teach

the operator about machine tool function using audio and

video communication and actual interactive data transmission

from the teacher at a remote location.

Although it is preferable that both audio and video be

communicated for a full interactive exchange between the

remote technician location and the machine tool, either audio

14 or video alone can be combined with the data transmission for an enhanced interactive support.

The foregoing description was primarily directed to a

preferred embodiment of the invention. Although some

attention was given to various alternatives within the scope

of the invention, it is anticipated that one skilled in the

art will likely realize additional alternatives that are now

apparent from disclosure of embodiments of the invention.

Accordingly, the scope of the invention should be determined

from the following claims and not limited by the above

disclosure .

15

Claims

CLAIMSI claim:

1. A method for interactive access to a machine from a remote location, which method comprises the steps of:

establishing a pomt-to-pomt communication link between

the machine and the remote location;

executing communication software, in the machine and m

a computer at the remote location, to form a TCPIP network on

the pomt-to-pomt communication link;

exchanging, over the pomt-to-pomt communication link,

data regarding operation of the machine; and

exchanging audio over the pomt-to-pomt communication

link.

2. The method recited m claim 1 further comprising:

connecting a first modem to the machine;

connecting a second modem to the computer at the remote

location, wherein each of the first and second modems has a

digital data mput/output circuit and an analog audio

mput/output circuit; and

the step of exchanging audio comprises employing the

analog audio mput/output circuits of the first and second

modems .

16

3. The method recited m claim 1 further comprising

transmitting a video image over the pomt-to-pomt

communication link.

4. The method recited m claim 1 further comprising:

connecting a video camera to the machine, wherein the

video camera produces a video image;

processing the video image by the machine with video

communication software which is configured to transmit images

over a TCPIP network;

transmitting the video image over the pomt-to-pomt

communication link;

the computer receiving the video image from the point -

to-pomt communication link; and

displaying the video image at the computer.

5. The method recited in claim 1 further comprising:

connecting a first video camera to the machine;

connecting a second video camera to the computer;

executing, in the machine and in the computer, video

communication software which is configured for a TCPIP

network protocol ; and exchanging video signals from the first and second

cameras over the pomt-to-pomt communication link.

17

6. The method recited m claim 1 wherein the step of

exchanging audio comprises transmitting digitized audio over

the pomt-to-pomt communication link.

7. The method recited in claim 1 wherein exchanging

data utilizes a TCPIP network protocol.

8. The method recited m claim 1 wherein exchanging

data and exchanging audio occur in a time division multiplex

mode .

9. The method recited in claim 1 further comprising

diagnosismg operational problems of the machine in response

to the exchanging data and the exchanging audio.

10. The method recited in claim 1 further comprising

training personnel at the machine by means of exchanging data

and exchanging audio.

11. A method for interactive access to a machine from a

remote location, which method comprises the steps of:

establishing a point-to-point communication link between

the machine and the remote location;

executing communication software, in the machine and in

a computer at the remote location, to form a TCPIP network on

the point-to-point communication link; and

exchanging, over the point-to-point communication link, data regarding operation of the machine; and

exchanging video images over the point-to-point

communication link.

12. The method recited in claim 11 further comprising

exchanging audio over the point-to-point communication link.

13. The method recited in claim 11 further comprising

exchanging digitized audio over the point-to-point

communication link.

14. The method recited in claim 11 wherein exchanging

data and exchanging audio utilize a TCPIP network protocol.

19

15. The method recited m claim 11 further comprising:

connecting a first modem to the machine;

connecting a second modem to the computer at the remote

location, wherein each of the first and second modems has a

digital data input/output circuit and an analog audio

input/output circuit; and

employing the audio input/output circuits of the first

and second modems to transmit audio over the point-to-point

communication link.

16. The method as recited in claim 11 wherein executing

communication software comprises executing a first program in

each of the machine and the computer to exchange the data

over the point-to-point communication path using a TCPIP

protocol; and executing a second program in each of the

machine and the computer to exchange the video images over

the point-to-point communication path using a TCPIP protocol.

17. The method recited in claim 11 wherein exchanging

data and exchanging video occur in a time division multiplex

mode .

20

18. A method for interactive access to a machine from

a remote location, which method comprises the steps of:

connecting the machine to a communication network by

means of a first modem which includes a digital data input/

output circuit and an analog audio input/output circuit;

connecting a computer at the remote location to the

communication network by means of a second modem which

includes a digital data input/output circuit and an analog

audio input/output circuit;

establishing a point-to-point communication path between

the first and second modems;

executing communication software, in the machine and in

the computer, to form a TCPIP network on the point-to-point

communication path for the exchanging digital data, video and

audio;

exchanging, over the TCPIP network, digital data related

to operation of the machine;

exchanging digitized video over the TCPIP network, ; and

exchanging digitized audio over the TCPIP network.

19. The method recited in claim 18 wherein exchanging digital data and exchanging digitized video utilize a TCPIP network protocol .

21

20. The method recited in claim 18 wherein executing communication software comprises executing a first program in each of the machine and the computer to exchange the data over the pomt-to-pomt communication path using a TCPIP protocol; and executing a second program in each of the machine and the computer to exchange the video images over the pomt-to-pomt communication path using a TCPIP protocol.

21. The method recited in claim 17 wherein exchanging

digital data, exchanging digitized video and exchanging

digitized audio occur in a time division multiplex mode.

22