FAQ about SIMATIC BATCH€¦ · Task/motivation . The SIMATIC BATCH scaling functionality allows...
Transcript of FAQ about SIMATIC BATCH€¦ · Task/motivation . The SIMATIC BATCH scaling functionality allows...
FAQ about SIMATIC BATCH
How do I Configure Scaled Recipe Parameters?
FAQ
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
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Table of Contents
Table of Contents ......................................................................................................... 2
1 General Information ...................................................................................... 3
1.1 Task/motivation ............................................................................................. 3
1.2 Definitions...................................................................................................... 3
2 Configuring Scaled Recipe Parameters in practical Operation ................ 4
2.1 Practical example 1 ....................................................................................... 4
2.2 Practical example 2 ....................................................................................... 8
3 Interpretation of the Messages .................................................................. 10
3.1 Interpretation of the messages when releasing the recipe ..................... 10 3.1.1 “High limit violated” message.......................................................................... 11 3.1.2 “Maximum quantity too large” message.......................................................... 12
3.2 Behavior when creating and releasing a batch ........................................ 13
4 History .......................................................................................................... 15
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Question
How do I configure scaled recipe parameters?
Answer
The information, instructions and notes listed in this document provide a detailed answer to this question.
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
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1 General Information
1.1 Task/motivation
The SIMATIC BATCH scaling functionality allows the user to formulate unit-independent recipes for a standard quantity – thus completely independent of the quantities actually to be produced.
It is only when a batch is released that the setpoints are adjusted accordingly and only those units are offered in which the production can be realized with the adjusted selections.
This document uses two examples to describe how the system provides optimum support in creating recipes and in using scaled recipe parameters.
1.2 Definitions
Reference quantity “Reference quantity for quantity scaling” characterizes the reference quantity to which all values to be scaled refer.
“Reference quantity” is frequently used synonymously with “standard quantity”. This can be handled accordingly on a plant-specific basis. However, these things are completely independent of the system and a “standard quantity” is not defined for SIMATIC BATCH.
Recipe limits The reference quantity is completely independent of the recipe limits “Minimum quantity of a batch” or “Maximum quantity of a batch”. These are the limits that have to be defined for a recipe in the “Product” tab.
Quantity The quantity is neither checked for the recipe limits when creating nor when releasing a batch. To the operator it serves as an orientation or is considered when using the “Create batches automatically” option.
Consequently, batches whose quantity is outside the recipe limit can be created, released and started.
Scaled setpoints When using scaled setpoints, a check whether the scaled setpoints are within the limits defined by the object (RPH, ROP) is performed when a batch is released. Candidates that are no longer permissible are removed from the candidate list. It may also occur that a valid candidate for the batch no longer exists.
The system supports the planner already in the work in the Recipe Editor and shows possible conflicts for the specified quantities.
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
2 Configuring Scaled Recipe Parameters in practical Operation
The following sections use the example of two practical examples to show the configuration of scaled recipe parameters.
2.1 Practical example 1
The selections of this example are listed in the following table: Table 2-1
Designation Value
Reference quantity Reference quantity for quantity scaling REFRecipe 120kg Minimum quantity Minimum quantity of a batch LLRecipe 80kg Maximum quantity Maximum quantity of a batch HLRecipe 150kg
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Figure 1 Recipe parameters
The setpoint of the phase considered here has the following unit-specific setpoint limits:
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
Table 2-2
Unit Setpoint low limit Setpoint high limit
LLSP HLSP Unit_A 30 70 Unit_B 0 100 Lowest / highest value 0 100
If several candidates (units) are possible for the Recipe Unit Procedure (RUP) (for example, for “Operator selection”, “Process parameters” or “The longest out of use”), the lowest low limit (0, 30 => 0) or the highest high limit (100, 70 => 100) of all candidates is indicated for the setpoint to be scaled. To illustrate this, the setpoints are shown in green. (See also Figure 2-2).
sf SP SPscal ∗=
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When modifying the batch quantity between minimum and maximum quantity, the following scaled setpoints (SPscal_xx) would ensue for the phase (SP = setpoint in the master recipe).
• Quantity = minimum quantity
3.33666.050sf SP SP scal_LLscal_LL =∗=∗=
• Quantity = maximum quantity
5.62250.150sf SP SP scal_HLscal_HL =∗=∗=
sfscal_xx being the scaling factor for quantity = minimum quantity or maximum quantity.
For linear scaling • Quantity = minimum quantity
666.0kg120kg80
REFLL
sfRecipe
Recipescal_LL ===
• Quantity = maximum quantity
25.1kg120kg150
REFHL
sfRecipe
Recipescal_HL ===
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386 For quadratic scaling
• Quantity = minimum quantity
444.0666.0kg120kg80
REFLL
sf 222
Recipe
Recipescal_LL ==⎥
⎦
⎤⎢⎣
⎡=
⎥⎥⎦
⎤
⎢⎢⎣
⎡=
• Quantity = maximum quantity
563.125.1kg120kg150
REFHL
sf 222
Recipe
Recipescal_HL ==⎥
⎦
⎤⎢⎣
⎡=
⎥⎥⎦
⎤
⎢⎢⎣
⎡=
The scaled values are checked when releasing the recipes or batch and messages are generated or candidates are removed.
Calculated setpoint limits as tooltip text
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To facilitate recipe design for the recipe writer, the limits within which the sepoint may be without violating the setpoint limits for quantities between minimum and maximum quantity are displayed as tooltip text. They are calculated from the conversion of the above-listed formula as follows:
scal_LL
SPSP_Tooltip sf
LL LL = scal_HL
SPSP_Tooltip sf
HL HL =
Figure 2-2, Display of the setpoint limits for several candidates, here Unit_A or Unit_B (in green and associated tooltip text)
0 666 , 0 0
sf LL
LL skal_LL
SP SP_Tooltip = = = 80
25 , 1 100
sf HL
HLskal_HL
SP SP_Tooltip = = =0
666 , 0 0
sf LL
LL scal_LL
SP SP_Tooltip = = = 80
25 , 1 100
sf HL
HLscal_HL
SP SP_Tooltip = = =
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386 Figure 2-3, Display of the setpoint limits for one candidate, here Unit_A (in black and associated tooltip
text)
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45 666 , 0 30
sf LL
LL skal_LL
SP SP_Tooltip = = = 56
25 , 1 70
sf HL
HLskal_HL
SP SP_Tooltip = = =45
666 , 0 30
sf LL
LL scal_LL
SP SP_Tooltip = = = 56
25 , 1 70
sf HL
HLscal_HL
SP SP_Tooltip = = =
The ratios are again to be shown in a chart. Unit_A and Unit_B have the “real” setpoint limits.
Figure 2-4
Unit_A
Unit_B
0 10 20 30 40 50 60 70 80 90 100 110
If the quantity was at the permissible high limit HLRecipe, the allowed setpoint range Unit_x_scal_HL would ensue for the corresponding unit or, analogously, Unit_x_scal_LL for the low limit LLRecipe.
This is combined in the Unit_x_range bar. When selecting setpoints from the green section, each quantity between LLRecipe and HLRecipe can be selected, whereas the selection of setpoints in the yellow section is limited.
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386 Figure 2-5
Unit_A_scal_L
Unit_A_scal_H
Unit_B_scal_L
Unit_B_scal_H
Unit_B_range
Unit_A_range
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
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If the setpoint is outside the limits calculated in the tooltip text, this causes a warning when releasing the recipe (see also chapter 3.1 Interpretation of the messages when releasing the recipe), although it is within the setpoint limits, e.g.
HLSP_Tooltip (= 56) < SP (= 60) < HLSP (= 70)
2.2 Practical example 2
The same parameters as in the first example are used. Merely the reference quantity has been reduced from 120kg to 1kg.
Table 2-3
Designation Value
Reference quantity Reference quantity for quantity scaling REFRecipe 1kg Minimum quantity Minimum quantity of a batch LLRecipe 80kg Maximum quantity Maximum quantity of a batch HLRecipe 150kg
In this example, the reference quantity is even outside the recipe limits and thus certainly not identical to a standard quantity. This enables the user to standardize recipes to, for instance, 1kg of final product, the real production volumes deviating considerably from this value.
80kg1kg80
REFLL
sfRecipe
Recipescal_LL === 150
kg1kg150
REFHL
sfRecipe
Recipescal_HL ===
The tooltip text then displays the following recommended setpoint limits for several candidates (e.g., operator selection) or one candidate:
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386 Figure 6 Display of the setpoint limits for several candidates, here Unit_A or Unit_B, in green and tooltip
text
0 80 0
sf LL
LLskal_LL
SP SP_Tooltip = = = 666 , 0
150 100
sf HL
HLskal_HL
SP SP_Tooltip = = =0
80 0
sf LL
LLscal_LL
SP SP_Tooltip = = = 666 , 0
150 100
sf HL
HLscal_HL
SP SP_Tooltip = = =
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Figure 7 Display of the setpoint limits for one candidate, here only Unit_A, in black and tooltip text
375, 0 80 30
sf LL
LL skal_LL
SP SP_Tooltip = = = 466 , 0
150 70
sf HL
HLskal_HL
SP SP_Tooltip = = =375, 0
80 30
sf LL
LL scal_LL
SP SP_Tooltip = = = 466 , 0
150 70
sf HL
HLscal_HL
SP SP_Tooltip = = =
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
3 Interpretation of the Messages
3.1 Interpretation of the messages when releasing the recipe
If the Recipe Editor detects possible conflicts, it displays corresponding warnings. In our example, two different warnings are generated that examine different views:
The same recipe as before is used; setpoint SP = 60; several candidates (Unit_A, Unit_B)
Figure 8 Setpoint parameters for which the messages shown below are generated.
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How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
3.1.1 “High limit violated” message
Figure 9 Details on the “High limit violated” message
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SPHL HLRecipe REFRecipe SP SPskal_HLSPHLSPHL HLRecipeHLRecipe REFRecipeREFRecipe SP SP SPskal_HLSPscal_HL
The setpoint for the indicated unit (here Unit_A) SPHL= 70 triggers the warning.
For a recipe limit HLRecipe = 150 and reference quantity REFRecipe = 120kg the scaled setpoint would result from the unscaled setpoint SP = 60;
75kg120kg15060
REFHL
SP sf SP SPRecipe
Recipescal_HLscal_HL =∗=∗=∗=
this scaled setpoint exceeeds the upper setpoint limit. The recipe is still released!
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
3.1.2 “Maximum quantity too large” message
Figure 10 Details on the “Maximum quantity too large” message
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In this case, the upper recipe limit HLRecipe = 150 triggers the warning. If the setpoints SP (and their limits LLSP or HLSP) are assumed as given or valid, the upper recipe limit HLRecipe must not exceed the value
140kg60kg70*120
SPHLREF HL SP
RecipeRecipe_max ==∗=
to ensure that there are no restrictions when releasing the batch.
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
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3.2 Behavior when creating and releasing a batch
In the master recipe, several units (here Unit_A, Unit_B) are to be possible as, for instance, for the “Operator selection” strategy.
A batch with a quantity of 145 is to be created.
Figure 11 Details of the created batch
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
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When releasing the batch, the following message is displayed: Figure 12 Dialog box to inform you that candidates have been deactivated
Select “Display Results” to obtain more details:
Figure 13 Details on the deactivation of candidates
Unit_A cannot be used since the upper setpoint limit HLSP is violated by the scaled setpoint
5.72kg120kg14560
REFQuantitySP SP
Recipescal =∗=∗=
How do I Configure Scaled Recipe Parameters?
ID Number: 26686386
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4 History Table 4-1 History
Version Date Modification
V1.0 10/10/07 First edition