WO2008131381A1

WO2008131381A1 - Configuration of a can coating system using one button

Info

Publication number: WO2008131381A1
Application number: PCT/US2008/061143
Authority: WO
Inventors: James M. Khoury; Mark J. Ignatius
Original assignee: Nordson Corporation
Priority date: 2007-04-23
Filing date: 2008-04-22
Publication date: 2008-10-30
Also published as: WO2008131381A8

Abstract

A one button recipe change feature allows for simplified recipe changes across an entire coating line for coating systems. An optional hierarchy concept may be used to facilitate the one button recipe change feature.

Description

CONFIGURATION OF A CAN COATING SYSTEM USING O _^

Related Applications

[0001] This application claims to benefit of co-pending United States Provisional

Patent Application serial no. 60/925,805 filed on April 23, 2007, for ONE BUTTON RECIPE CONTROL, the entire disclosure of which is fully incorporated herein by reference including all attachments thereto.

Technical Field Of The Disclosure

[0002] The disclosure relates generally to apparatus and methods for spraying or otherwise applying coating material onto a surface, such as, for example, the interior surfaces of a rotating can. More particularly, the disclosure relates to monitoring and control functions useful for coating operations.

Background of the Disclosure

[0003] Spraying or applying a coating material onto the surface of a body is commonly done. For example, interior surfaces of metal beverage cans are coated to preserve the flavor of the contents from being changed due to contact with a metal surface. A variety of spray systems have been developed over the years. In the can industry, can interiors are sprayed using one or more spray applicator devices or spray guns having one or more nozzles positioned near the can interior. Material is sprayed onto the can surfaces typically while the can is rotated. Can surfaces may include interior and exterior surfaces. [0004] In most applications it is important to assure that the entire surface is coated.

The amount of material that is applied to a surface is usually measured in terms of coating weight. In an ongoing effort to reduce costs, coating weights have also been reduced. However, lower coating weights necessitate tighter control over the coating process. There are many process variables that affect coating weight, including temperature, pressure, viscosity, spray duration, nozzle design, nozzle flow rate and pattern control, and spray applicator position, to name just a few. The parameters that set forth a coating process are generally known as a recipe or coating recipe. A recipe may specify a wide variety of parameters, settings, values, limits, operational criteria, warnings and so on. [0005J Coating systems can become quite complex and large. A coating system may include a number of coating lines, and for each coating line there may be a large number of coating stations such as a spray machine for example. For example, a facility may have any number of coating lines, and each coating line may have_s for example, thirty spray or coating machines or coating stations, with each spray machine or coating station having one or more material applicators such as spray guns for example. It is easy to understand that such large facilities quickly present a time and manpower burden when it is desired to change a coating line from, for example, a beer can coating line to another beverage can. An operator needs to input large amounts of data and information, not only for each spray machine, but then must repeat the same entries for all spray machines that will use the same recipe in the line or lines. Even for facilities that are not so complex or high in production volume, even to change recipes for one coating line involves an extensive amount of data and information input. [0006] An existing system for monitoring and controlling the coating of a can on a spray machine is the Nordson iTrax^® brand System. This system is available for purchase from Nordson Corporation, Araherst, Ohio and is described, at least in part, in International Publication Number WO 2005/016552 A2, published February 24, 2005 that is hereby incorporated by reference in its entirety.

Summary of the Disclosure

10007] Methods and apparatus for recipe control are provided, including in one embodiment a single step selection of a recipe for one or more coating or spray machines in a coating line, with a coating or spray machine having one or more components that are electronically configurable. In another embodiment, a hierarchy may be used to relate various components with a particular coating or spray machine and coating line. [0008] These and other aspects and advantages of the inventions disclosed herein will be readily apparent to those skilled in the art from a reading of the following detailed description of the exemplary embodiments in view of the accompanying drawings.

Brief Description of the Drawings

[0009] Fig. 1 is a functional block diagram of a coating line;

[0010] Fig. IA is a functional block diagram of a spray machine control arrangement such as may be used with the coating line of Fig. 1 ;

[0011] Fig. 2 is a console that may be used as part of the Fig. 1 and Fig. IA embodiments;

[0012] Fig. 3 is an exemplary recipe selection screen;

[0013] Fig. 3A is an exemplary user interface screen;

[0014] Fig. 3 B is an exemplary user interface screen with a recipe selection drop down menu;

[001 SJ Fig. 3C is an exemplary screen for current running recipes;

[0016] Fig. 4 is an exemplary acknowledgement screen;

[0017] Fig. 5 is an exemplary SETUP screen and exemplary embodiment of a hierarchy arrangement.

Detailed Description Of The Exemplary Embodiments 1. INTRODUCTION

[0018] The present disclosure is directed to apparatus and methods for application of material onto a work piece surface, such as, for example, the rotating surfaces of a can. In an exemplary embodiment, the inventions are illustrated herein for use with a spray coating process and apparatus for spraying a coating material, such as for example water based and/or solvent borne coating material, to the interior surface of a rotating can body. For example, coating material may be applied to the interior surface of a two piece or three piece can body or outside dome spray.

[0019] While the inventions are described and illustrated herein with particular reference to various specific forms and functions of the apparatus and methods thereof, it is to be understood that such illustrations and explanations are intended to be exemplary in nature and should not be construed in a limiting sense. For example, the inventions may be utilized in any material application system involving the application of material to a rotating surface, and some inventions may find useful application to other coating application systems in which the coated surface is not rotating. The surface need not be a can surface, and need not be an interior surface, but may include exterior surfaces, generally planar, curvilinear and other surface geometries, end surfaces, and so on. The application system illustrated herein is a spray application system, however the word "spray" is not intended to be limiting. The inventions may be similarly applied to other application or coating techniques such as deposition, coating, brushing and other contact and non-contact application systems, as well as for liquid and non-liquid coating materials. The surface being coated may be rotated by a number of different techniques and apparatus and the various inventions are not necessarily limited to any particular rotation technology. Although the exemplary embodiments illustrate a modular type distributed control system, it will be readily appreciated that many of the inventive aspects described herein may be implemented in a system that is neither modular nor networked.

[0020] While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions— such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated. 2. DETAILED DESCRIPTION [0021] With reference to Pig. 1, an exemplary embodiment of a single coating line

500 is represented in a system level functional block diagram form. This coating line 500 may be, for example, a line for applying coating material to surfaces of a rotating workpiece such as a can. The present inventions may also be used with facilities having multiple coating lines. But the present disclosure is not limited in any manner to the end use of the coating line, and may well find application in other coating lines outside the art of coating surfaces by spraying or other application techniques,

[0022] The line 500 may include one or more spray machines 502 (up to N), and in this example each spray machine 502 may include one or more components, such as for example, one or more coating applicators such as spray guns, a mechanism for feeding product or workpieces that are being coated to the spray guns, and a supply of the coating material. In typical can coating systems, a local controller 504 may be used to overall control the product feed and coating material feed, as well as issuing appropriate spray gun trigger window signals and other control functions as needed.

[0023] Additional components that may be associated with each spray machine 502 may include a monitoring and control system 506. In this example, each monitoring and control system 506 is modular in design, meaning that there is a set of modules associated with each spray machine 502, wherein each module carries out various functions and operations as designed. Non-modular configurations may alternatively be used as needed. In the exemplary embodiment, there is a spray monitor module 508, a gun control module 510 and a pressure control module 512. Additional and/or different modules 514 may be provided as needed. For example, if a spray machine contains two spray guns, then there may be two gun control modules 510. In the exemplary embodiments, the modules are electronically configurable meaning that parameters, data and information relating to the operation and control of the modules may be performed via software, circuits or hardware or any combination thereof.

[0024] The specific functions of the system components such as the monitoring and control system 506 modules are not critical to the present disclosure and are only provided as exemplary, however, a more detailed description of an exemplary system is provided herein below. Also included as part of this disclosure is copending International Application No. PCT/US2007/009725 entitled CONTROL SYSTEM FOR CAN COATING filed on April 23, 2007, and published under No. WO 2007/133386 that is fully incorporated herein by reference and may be read in combination with this disclosure. This additional disclosure provides even more detail as to the functional and operational aspects of the various modules and their interaction with the spray machines.

[0025] With continued reference to Fig. 1, each of the monitoring and control system

506_I-_N modules may communicate with each other and with an operator interface 516 over a network 518. A suitable network is a CAN bus such as in a daisy-chain configuration (not shown), however, any network may be used as required. Alternatively, a network need not be used and the modules connected by hardwiring, hardware and so forth. The operator interface 516 may be any input device, with a personal computer being a typical but not required example. In the case of a personal computer, a USB to CAN converter 520 may be used if required. As will be further explained herein, basic functions for the interface 516 may be a means for presenting a choice of recipes, such as for example a visual or audio presentation or light tower, and a means for selecting an available recipe, such as an electronic switch for example. These are but a few examples of many choices for realizing both these means.

[0026] In this example, the computer 516 may also be used as an input device to load various recipes and operational information into the monitoring and control system 506 modules across the network 518. The interface 516 may have other functions such as data logging, calibration and so on, and if so desired may also carry out control functions. Operation of these aspects of the interface 516 is not a significant part of the present disclosure other than to understand that the interface allows recipes to be downloaded to the modules and such recipes prescribe the operational parameters for each coating operation. Conventional networking processes may be used to communicate between devices connected to the network as are well known to those in the art.

[00271 Although not a required configuration, in the present disclosure the interface

516, converter 520 and the spray monitor modules 508 may be part of a previously installed or available system model under the brand iTrax^® System available from Nordson Corporation, Westlake, Ohio. In an iTrax^® brand system, the spray monitor 515 such as may be associated for example with the interface 516, includes a visual display by which an operator may observe various operational features of the various spray machines. For example, the spray monitor may display flow rate data, spray duration times, pressure values, temperature values, production rates and so on. An iTrax model system may be configured for up to sixty- four spray stations or machines for example.

[0028] With reference to Fig. IA, we show a more detailed system level functional block diagram of a spray machine monitor and control system embodiment such as may be used, for example, with the spray machines of Fig. 1. Fig. IA is illustrated for a single spray machine, it being understood that additional monitor and control systems may be added to the network bus 518 as required for a complete coating line or multiple coating lines. Fig. IA thus is a more detailed layout of exemplary components such as various control modules for a single spray machine as previously illustrated in Fig. 1 herein above.

[0029] The basic system of Fig. IA may be an original build, or may be a modified system based on a previously installed or available system such as an iTrax^® brand system. [0030] In Fig. IA, the computer or other suitable interface device 516 may be provided as an operator interface, such as a personal computer running on a WINDOWS PC Operating System™ platform, for example, as noted above. The computer 516 stores or can be used to input one or more recipes that an operator may select based on the type of coating material to be applied and the type of work piece W. A recipe may be used on a single spray machine, multiple spray machines, a single coating line, multiple coating lines and so on. A typical recipe may include a variety of parameters such as, for example, coating material base and fire pressures, gun trigger timing, flow rates, temperature, rotation speed and so on. [0031] Also communicating with the network 518 may be one or more modules 202.

These modules correspond to the modules illustrated in Fig. 1 hereof. Each module 202 may receive all or a portion of a particular recipe that will be executed by the associated spray machine. In the Fig. IA embodiment, each spray machine has an associated spray monitor circuit module 508, gun control circuit module 510 and a multifunction spray machine monitor module 512. For spray machines having two spray guns or spray stations, additional gun control circuit modules 510 may be added to the network 518. Alternatively, a single gun module may contain circuitry for multiple spray guns in the spray machine. [0032] It is important to recognize that Fig. IA, as well as the other system block diagrams herein, are exemplary and intended to show functional relationships. The drawings do not necessarily imply or require a specific physical embodiment of the various circuits. For example, the block diagrams herein are based on a configuration that may be used to modify or add functionality to an existing system such as an iTrax^® brand system. But such need not be the case, and the physical embodiment of, for example, Fig. IA may be realized with an original design and build, Thus, various functions may be carried out by different modules, either those shown or others, or a module type system would not be required in all cases, but for example, a single circuit system could be connected to the network. An advantage of a modular system is that it allows a designer to choose what functionality is to be included in a particular system, and also allows for ease of expansion to a larger system. [0033] The spray monitor circuit 18 may include power relay contacts 206 that open when the spray monitor circuits 18 determines that the spray machine should be shut down. For example, the spray monitor circuit 18 may receive a control signal 22 from the multifunction spray machine monitor circuit 512. If the control signal 22 indicates the spray machine is not ready, the spray monitor circuit 508 may hold the contacts 206 open until the fault conditions are fixed. Operator overrides may also be provided if so required. The spray monitor circuit 508 also receives a pressure signal 46 from a pressure regulation and controller circuit 42 that relates to base and/or fire pressure of the coating material at the spray gun. The spray monitor circuit 508 may interrupt the spray machine via the contacts 206 if an out of range pressure condition is detected. The spray monitor circuit 508 may also use the pressure signal 46 to provide a real time gun trigger feedback signal 208 to the gun control circuit 510 for controlling actual spray duration time on a real time basis. The spray monitor module 18 may also be used to receive a gun trigger monitor signal 210 from the gun control circuit 510 so that an operator can visually note if the spray gun is firing correctly, and compare that to the actual spray duration time. The spray monitor module 508 may also monitor flow parameters based on the received pressure signals.

[0034] The gun control circuit module 510 may be used to generate appropriate gun drive signals 212 as well as to adjust the trigger and drive signals to achieve the commanded spray duration based on the real time feedback signal 208. The gun control circuit may also be used to operate a clean spray gun operation.

[0035] In addition to the control signal 22, the multifunction spray machine monitor circuit module 512 may be used to carry out pressure regulation and temperature control. [00361 Still another module 202 may be a remote display 70 (not shown in Fig. 1).

The remote display 70 for example may be used to display the same data that is placed on the bus 518, but at a location proximate the spray machine. In the exemplary embodiment, the remote display 70 communicates via the multifunction spray monitor 512, but alternatively may communicate through different modules or directly to the bus 518 as represented by phantom line 214 in Fig. IA.

[0037] Further description and explanation of the operational features of the various modules and spray machine are provided in the above incorporated disclosure, but such descriptions are not necessary for understanding the inventive aspects of the present disclosure.

[0038] Each spray gun or coating applicator may have a recipe associated with it that governs its operation. Each recipe also may include additional parameters for monitoring and controlling a particular spray machine. An exemplary recipe may specify, for example, base pressure of the coating material at the spray gun, fire pressure of the coating material at the spray gun, trigger alarm values and ranges, spray duration times, fault tolerances, sampling rates, calibration criteria and general configuration criteria. Many other pieces of information and data may form a recipe. While it is common for all spray guns in a single coating line or spray machine to use the same recipe, such is not necessarily required. And different coating lines within a coating system may use different recipes from one another or some may use the same recipe. Moreover, individual guns within a single coating line, and even within a single spray machine (such as top and bottom guns) may use different recipes. An example recipe for just one gun is attached to the provisional application referenced above and incorporated herein as Attachment 1 and exemplifies the complexity of data and information that goes into configuring even one gun with a recipe. It will be readily apparent that there typically is a large amount of data and information that must be incorporated into a recipe, even for a single gun. When a coating line or machine is going to have a change over to a different recipe (for example, changing a spray machine from a beer can coating operation to an isotonic coating operation), it becomes very tedious and time consuming for an operator to input or otherwise modify the recipes for each gun. Multiply this by potentially hundreds of guns and the change over time can become not only significant but very costly as system downtime means that product is not being made. This complexity and extensive operator interaction can significantly increase the likelihood of human error and increase the difficulty in maintaining adequate quality control of the recipes being run. Moreover, as more functionality is added to systems, such as the modular concepts disclosed herein, a large number of different modules must also be programmed for a recipe change. Different modules may receive entirely different data set from machine to machine for example. Even though networked systems somewhat address the issue in terms of data and information communication, nonetheless using a network does not overcome the complexity of loading in new data and information related to the recipe changes for each of the many individual components of a system, which without the present inventions represents a tremendous time and cost inefficiency.

[0039] In accordance with an inventive aspect of the present disclosure, recipe changes may be effected by a few simple actuations or selections made by buttons, switches or other means, even a single actuation or single step selection. Such recipe changes may be effected for all guns in a single line for example, individual guns within a line or spray machine, or even all guns in all the lines if they all will use the same recipe. This simplified or single step selection process greatly reduces the downtime to change any number of guns, spray machines or coating lines from one recipe to another by substantially reducing the amount of time it takes for an operator to assign the recipe to the various system components including the spray machines and associated control and monitoring modules. Thus an operator need not waste time programming each spray machine component individually, oftentimes repeating the same data entries over and over again. Thus with minimal programming or configuration effort an operator can select among available recipes that specify operational and monitoring parameters for the spray machine. An available recipe is a recipe that has already been previously determined and preset during a set up process. The simplified recipe selection routine also allows for effective use of built-in security measures to prevent recipes from being changed without proper authorization level of the user. Once the operator has made the recipe selection for a coating line or spray machine or gun, the recipe may be automatically downloaded or transferred to each module and spray machine in the selected coating line as needed to effect the changeover. This recipe change or selection process can in effect allow for changeover of the recipe for all the electronically configurable components at the same expected time, or simultaneously, that use the recipes, although simultaneous changes are not required.

[0040] Fig. 2 represents an operator interface 400 such as a console for example that may be used to carry out the present disclosure, although many different types of input devices and display or presentation techniques may be used alternatively. The console 400 may be part of an iTrax^® brand system, although some of the data and information displayed may also be in accordance with the present disclosure. The console 400 may include a color touch sensitive screen 402 that presents operational data and information of interest to an operator via a set of 'windows' or panels 404 with each window, for example, presenting data and information for a particular and preferably selectable spray gun or guns. [0041] Fig. 3 illustrates an exemplary screen presented to an operator. This screen includes two windows or faceplates, one for gun one (window 406) and the other for gun 4 (window 408). Within each window the operator can observe performance data for the spray gun such as base and fire pressures. An expand button 410 may be provided to allow another drop down screen to appear that presents even more data to the operator. An example of such an expanded window 405 is shown in Fig. 2.

[0042] Fig. 3A illustrates another embodiment of an operator interface screen. This example illustrates the level of complexity that coating systems may have. Each coating line may have a unique identifier, such as LSMl 1 for coating line 1, spray machine 1. Then each optional module may have a unique identifier such as SM3 for the spray monitor associated with LSM 12 top gun, SC4 for the spray controller associated with LSM 12 bottom gun, and PRXl for the pressure control module associated with the top gun of LSMIl, and so on. In Fig. 3 A, a top row of windows or faceplates 300a- f visually represent spray monitor 18 (Fig. IA) information for various spray guns. This information may include, for example, pressure data, spray duration, base pressure 301a, fire pressure 301b, delta pressure 301c, a spray counter 30 Id, and so on. The next row down 302a-f visually represent spray controller or gun control 204 (Fig. IA) information for the various guns. This information may include spray gun timing 303 a and clean spray gun timing 303b. A third row of windows 304a-f (partially shown in Fig. 3A) visually represent pressure control module 42 information. This information may include base pressure, temperature, belt speed and so on. In all the examples of Fig. 3 A, each window or faceplate may provide real time operating information or other formatted data about the coating line, as set forth, for example, in a typical iTrax™ brand system.

[0043] It should be noted that for all the exemplary screens and functions associated herewith, these screens and function may be executed according to a software system suitably programmed to carry out the tasks and control functions. In one embodiment, the software may generally be realized using an iTrax^® brand program running on a WINDOWS PC Operating System™ platform, with suitable software enhancements using convention programming techniques to implement the functions and controls described herein that extend beyond the iTrax^® brand system. These may include the one button recipe or single step selection process, and the hierarchy configuration for the system components, as will be further described herein. All of the software may be stored in suitable memory such as a hard disk or in volatile memory or both. Alternatively, the control and processing functions may be implemented through hardware and firmware and circuits rather than primarily software. [0044] The interface screens shown in Figs. 3 and 3A may include a toolbar 412.

This toolbar 412 may be for example as generally provided for the Nordson iTrax^® brand system. In accordance with an inventive aspect of the present disclosure, a new 'recipe' button is included that is labeled Rx or 414. When this button is actuated, such as for example by hovering a cursor over the button and clicking a mouse, or simply touching the button for a touch sensitive screen, a drop down menu 416 appears that provides a list of available recipes for the operator to select for a particular spray line. In the example presented in Fig. 3, coating line 1 may be configured for beer, isotonic or special coating recipes. Coating line 2 may have similar or different choices and so on for all available coating lines based on the design of the overall system. It will also be noted that the drop down Rx menu 416 may also include a 'SETUP' option 417. This SETUP selection option only appears if the person accessing the system has security authorization to create or modify a recipe. Such authorization may be implemented through any number of security measures such as login usernames and passwords for example. The drop down menu 416 of available recipes is also illustrated in Fig. 3B for the Fig. 3 A embodiment.

[0045] Assuming an operator is only changing recipes or selecting from among a set of available recipes, and not using the setup feature, the operator selects the coating line number and recipe type that will become the new current recipe for that particular coating line replacing the prior recipe that was being used. For example, suppose an operator is changing coating line 2 from isotonic to beer. The operator selects Line 2 Beer (selection 418) from the drop down menu 416 and an acknowledgement screen 422, such as illustrated in Figs. 4 and 4A as an example, is then presented. In this acknowledgement screen 422, the line recipe is identified at 310, and a time stamp and operator log as at 311 may be used for quality control purposes so that an inspector can determine when and by whom a line recipe was changed. This screen may also present information in a text field about the line that relates to line change parameters that in some cases cannot be automatically or electronically changed by a recipe command. For example, the exemplary acknowledgement screen 422 shows parameters in a text field 420 for the operator to carry out such as the gun angle position, which spray nozzle to use and which controlled orifice plate to use for the selected recipe. Many times these parameters and machine configuration criteria will not change between recipes but in some cases they may need to be changed. And in some cases, within a single recipe or coating line, different guns may have different or the same criteria as indicated with the text field 421. However, some systems may be designed for an automatic gun position apparatus, in which case the gun position may become part of the recipe function rather than an operator manual function.

[0046] Assuming the operator indeed wants Line 2 Beer and has carried out the required machine configuration, the operator may click on the accept button 423 thus causing the selected recipe to be loaded up as the new current recipe. If a different line or recipe had been intended, the operator may cancel the change with the cancel button 424 which may return the operator to the operating screen drop down menu 416 of Figs. 3 or 3B for example. Note that just because there is a general recipe instruction 'Line 1 Beer' does not imply or require that every gun in spray line 1 will have the same identical parameters within a recipe. More commonly, recipes will vary from spray machine to spray machine and even gun to gun. But in accordance with this disclosure, all such changes can be selected by the single step selection, without the operator having to individually program or change every gun and related module in the coating line.

[0047] Note that in Fig. 3, a rather simplified version is illustrated wherein, for example, line 1 may be programmed or changed to one of three selectable recipes (e.g. beer, isotonic and special). However, one of the advantages of the present system is that there is no practical restriction on how many unique recipes and configurations may be programmed into the available recipe list presented in the drop down menu 416. There may be, for example, any number of "Beer" recipes (each would have its own unique identifier name on the drop down list 416) for an operator to choose from, for example, for different types of cans or customers and so on. Because the present inventions allow for easy selection and implementation of recipe changes, the number of available choices may be expanded however a customer may want. This greatly increases the flexibility of the can coating system without compromising at all the time needed to effect such changes. Also, these recipes can be made secure from unwanted modification and change since the recipes may be implemented as read-only type files unless the necessary security authorization to create or modify recipes is provided by the user.

[0048] In the Fig. 3B embodiment, additional exemplary options are presented to the operator. For example, an option 426 to view the current running recipes may be selected which, as shown in Fig. 3C, opens a window 427 that identifies the recipes currently being used on each coating line. For example, coating line 1 is indicated at 428 as being isotonic 12 oz. and includes spray machines LSMIl and LSM 12_f while line 2 is indicated at 429 and being beer 12 oz. and running spray machines LSM21, LSM22 and LSM23. Additional lines and machines may be presented as are being used, such as the re-spray machine LSM 13 for line 1. [0049] Thus, by simply making a single step selection such as by clicking one button to select from the available recipe list such as window 416 (Figs. 3, 3B) or a new or different recipe for an entire spray line which will become the current recipe for that line, an operator can change the coating operation instructions and parameters in the form of recipes for all the guns and modules in a coating line. This may include pressure and temperature changes, spray duration times, fault limits and so on, which heretofore required an extensive amount of data transfer and input by an operator. This reduces operator errors since the recipes are automatically changed and electronic documentation is provided as to when and by whom the changes were made. In terms of Figs. 1 and IA, when the recipe is changed from a prior recipe to the current recipe, the selected recipe can be downloaded from the PC 516 or from the spray monitor module 508, or alternatively and preferably, when the operator accepts the recipe change, a signal is communicated to each of the modules 506 to reset and load in the new recipe parameters that may be, for example, already locally stored in each module. [0050] It is important to note that the simplified recipe change concept herein may be carried out in a wide variety of ways, and need not depend on any particular technique of presenting the available recipes or for selecting and effecting such changes in the spray machines. A window type drop down menu of available recipe choices is but one of many ways to carry out such a process. For example, audio presentation may be available to assist visually impaired operators. Therefore, a significant feature is the ability to select a recipe change including all data, information, coating parameters and so on for all guns and modules associated in a particular grouping—in the exemplary embodiment a coating line having a plurality of spray machines and spray guns and associated modules— by a single selection. There may be provided additional steps to actually effect the recipe change into the system, but the recipe selection and change may be as simple as a single selection step. And in some cases, the single selection may also result in an automatic change so that a true one button recipe change may be realized. However, in many production facilities it is desired to have an acknowledgement or verify prompt (such as the accept button 423 of Fig. 4) prior to effecting such changes. However,, as an alternative the verify prompt may be used after the changeover is made, thus effecting a one button change with subsequent verification. [0051] It may also be desired in some systems to have the flexibility to enable and disable the one step recipe selection function. This may be easily implemented from a configuration window (not shown) that allows an operator who has adequate security authorization level to decide whether to enable the one step recipe selection function. If the function is disabled, then module recipes may be effected individually such as by cut and paste techniques. This might be done, for example, by Quality Control personnel to determine optimum configurations at setup.

[00521 If the user or operator has sufficient security authorization to also perform a setup routine, the user clicks on 'SETUP' option 417 in Fig. 3 or 3B for example and is presented with a setup screen such as shown in an exemplary embodiment in Fig. 5. In this example, a number of windows may be presented to the operator to allow for selection of options as part of a setup routine, Typically SETUP will relate to recipe changes or coating line configuration changes so that the coating line will be down during a SETUP procedure, but not all lines need be down, and optionally a line may operate up to the time a recipe change is actually to be effected. Window 430 presents a choice of coating line recipes that may be modified, window 432 presents the spray machines associated with a selected coating line (in Fig. 5 the selected coating line is Line 2 Beer), and window 434 presents the modules assigned to the selected spray machine. Selection buttons 430a,b 432a,b 434a,b under each of these main windows allow an operator to add or delete line recipes, spray machines and associated modules as needed. Once the operator has selected the modules in the modules window 434 and the spray machines in the spray machines window 432, the operator may use the Rx button 436 to assign a selected recipe to a respective module or to the line. [0053] When the Rx button 436 is actuated, a drop down list of available recipes will appear. These recipes may be, for example, default recipes provided by the system manufacturer, or they may be predetermined recipes developed by the customer for their particular needs. The creation of these recipes is not within the scope of the present disclosure but rather may be implemented by known techniques, for example, as is presently done with an iTrax^® brand system.

(0054] A memo window 438 may be used for special instructions for a particular recipe, such as for example, to instruct an operator on spray line configuration features that cannot be done automatically as discussed herein above. For example, instructions on gun position, nozzle selection and controlled orifice plate selection. The setup operator completes a recipe assignment for each module in the selected line recipe. A save button 440 may then be used to store the new recipe associated with the selected coating line with a unique recipe identifier name, and additional coating lines may be configured in a similar manner if so desired. A print button 442 may be provided so that a new or modified recipe may be printed for quality control verification and tracking, for example.

[0055] Thus in accordance with the present disclosure, a hierarchy is created and used that establishes the recipe relationships and system component relationships for a coating system. This hierarchy is illustrated in an exemplary manner in Fig. 5 in that for each coating line recipe {window 430) a number of spray machines are associated with that recipe (window 432) and for each spray machine a number of modules and spray guns are associated with each spray machine. Alternatively, a hierarchy may be used that implements a different grouping schema or defines different associations as needed for a particular system. Thus, once a recipe has been created and stored, the recipe defines the operating and monitoring parameters for every gun and module in the coating line associated with the recipe, so that when an operator subsequently selects that recipe for a line changeover, all the modules and guns are automatically configured according to the recipe without the risk of human error in setting up the equipment wrong. As implemented in software, for example, the hierarchy is realized as an electronic association of one or more modules and guns with a respective spray machine, and an electronic association of one or more spray machines for a respective coating line.

(0056) Attachment 2 to the above referenced provisional application is a detailed description of an exemplary setup and one button recipe process such as can be used with the above described system and is incorporated herein by reference. Again, the particular implementation and process, either through software, hardware, circuits, firmware or a combination thereof or other techniques, is largely a matter of design choice, with a salient feature being the ability to select a recipe for a particular grouping of components by a single selection step.

[0057] The inventions have been described with reference to the exemplary embodiments. Modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. ^"

Claims

CLAIMSHaving thus described the invention, we claim:

1. A method for changing recipes in a coating system having at least one coating line that has one or more spray machines associated therewith and each spray machine has a plurality of electronically configurable components associated therewith, comprising the steps of: from an electronic list of available recipes, electronically selecting one of said available recipes for a selected coating line, wherein said selected recipe provides operational parameters and information for electronically configurable components of one or more spray machines associated with said selected coating line.

2. The method of claim 1 comprising the step of electronically changing a prior recipe for a spray machine to said selected recipe to become the current recipe for said spray machine.

3. The method of claim 1 wherein said selecting step consists of an electronic single step selection that selects a recipe as a current recipe that will be used by said one or more spray machines.

4. The method of claim 3 wherein said selected recipe is transferred to a plurality of modules over a communication network to implement said recipe selection.

5. The method of claim 3 wherein said electronic single step selection is performed by a one button actuation.

6. The method of claim 5 wherein said one button actuation comprises an electronically actuated option in a visually presented list of options.

7. The method of claim 6 wherein said visually presented list of options comprises a drop down menu on a visual display.

8. The method of claim 3 comprising a second actuation step that causes said selected recipe to become the current recipe.

9. The method of claim 1 wherein each recipe comprises a hierarchy of relationships between said electronically configurable components, said one or more spray machines and each coating line.

10. The method of claim 9 wherein said hierarchy comprises electronic associations between a group of configurable components and an associated spray machine, and a group of said spray machines and an associated coating line.

11. The method of claim 10 wherein said hierarchy comprises electronic associations for a plurality of coating lines each having an associated plurality of spray machines and a associated plurality of configurable components.

12. The method of claim 1 wherein said electronically configurable components comprise at least one control module that operates in accordance with information provided by said selected recipe.

13. The method of claim 12 wherein said control module comprises one or more of the following: spray monitor, spray controller, pressure control.

14. A method for controlling a can coating line having one or more coating machines, comprising the steps of: associating electronically a plurality of components of each coating machine, presenting electronically at least two available recipes, each available recipe being distinct from each other available recipe, each available recipe having one or more coating machines electronically associated therewith, each available recipe comprising coating operation instructions for said components of each of its associated coating machines, and selecting electronically one of said available recipes for a coating machine.

15. The method of claim 14 comprising the step of changing electronically a coating machine recipe to said selected recipe after said step of selecting electronically one of said available recipes is performed.

16. The method of claim 15 wherein said selected recipe is electronically transferred to said components of its associated coating machine.

17. The method of claim 14 wherein said step of selecting electronically one of said available recipes comprises a single step selection.

18. The method of claim 14 wherein said available recipes comprise recipes for a plurality of can coating lines with each can coating line comprising one or more coating machines, each coating machine having a plurality of components electronically associated therewith.

19. The method of claim 14 wherein said components comprise at least one of the following: coating applicator, spray gun, gun control module, pressure control module, spray monitor module.

20. The method of claim 17 wherein said single step selection comprises a one button actuation.

21. The method of claim 20 wherein said one button actuation comprises a single mouse click, single keystroke, single input actuation or single touch screen actuation.

22. The method of claim 14 wherein said step of presenting electronically at least two available recipes comprises the step of presenting a drop down menu that lists said available recipes and a setup option.

23. The method of claim 22 wherein said recipes are created and stored only during a setup operation.

24. Control system for a can coating line, comprising: at least one spray machine, each spray machine comprising a respective plurality of components that operate according to a recipe, a control system that executes control instructions that: electronically associate each said respective plurality of components with a spray machine, electronically associates available recipes with said at least one spray machine, each available recipe being distinct, electronically presents at least two available recipes, enables electronic selection of one of said recipes for a selected spray machine.

25. Control apparatus for a can coating line comprising: a controller that executes a programmable set of instructions, an operator interface, and an information storage device, said instructions comprising: storing and accessing a plurality of available recipes with said information storage device, each said recipe comprising configuration and parameter information for one or more spray machines on the line, presenting said available recipes to an operator by said interface, enabling selection of one of said recipes for use by the spray machine, said selection being a single step selection.

26. The control apparatus of claim 25 wherein said instructions enable selection of one of said available recipes for use by a plurality of spray machines.

27. The control apparatus of claim 25 wherein each spray machine comprises a plurality of modules that operate according to said selected recipe.

28. The control apparatus of claim 25 wherein each available recipe comprises a hierarchy relationship between a plurality of coating lines, a plurality of spray machines used on said coating lines and a plurality of modules used by said spray machines.

29. The method of claim 3 wherein said selected recipe is transferred to a plurality of modules at the same time over a communication network to implement said recipe selection,

30. The method of claim 23 wherein said setup operation is restricted by authorized access.

31. hi a can coating system of the type including at least one coating line, at least one or more coating machines and a plurality of electronically configurable components for each coating machine, comprising: a hierarchy stored on an electronically accessible device, said hierarchy being organized as electronic associations between one or more coating lines, one or more coating machines for a coating line, and a plurality of electronically configurable components for a coating machine associated with a coating line.

32. The system of claim 31 wherein a selected recipe for a coating line is applied to all said electronically configured components associated with said coating line as defined by said hierarchy.