SW_Platform

SOFTWARE PLATFORM SPECIFICATION Document #: SW_Platform.doc

Equipment: Machines based on Rockwell or Siemens systems. Project #: 100xxx Customer: EEDpt

File: ...\SW_Platform.doc Révision: 1.13 Page: 1 / 104

SOFTWARE

PLATFORM SPECIFICATION

Supplier

Komax Medtech

Allée du Quartz, 12

2301 La Chaux de Fonds

Switzerland

Equipment

Machines based on Rockwell or Siemens systems.




Table of Contents 1. Introduction ..................................................................................................................................................... 9

1.1. Account of modifications ......................................................................................................................................... 9 1.2. Signatures ............................................................................................................................................................... 10 1.3. Reference documents ............................................................................................................................................. 11

1.3.1. Standards & References ........................................................................................................................................................ 11 1.3.2. Working Documents.............................................................................................................................................................. 11

2. Executive Summary ....................................................................................................................................... 12 2.1. Preliminary ............................................................................................................................................................. 12 2.2. Objective ................................................................................................................................................................. 12

2.2.1. One Goal ............................................................................................................................................................................... 12 2.2.2. Three Needs .......................................................................................................................................................................... 12

2.2.2.1. Standard & References (State of the Art) ............................................................................................................................................. 12 2.2.2.2. Good Automation Practices .................................................................................................................................................................. 12 2.2.2.3. Rapid Application Development .......................................................................................................................................................... 12

2.2.3. Five E2ASY Paths ................................................................................................................................................................. 12 2.2.3.1. Emulation for early de-risking + Fail Safe for auto-recovery ............................................................................................................... 12 2.2.3.2. Effectiveness for ahead diagnostics ...................................................................................................................................................... 12 2.2.3.3. Agility for last minute changes ............................................................................................................................................................. 12 2.2.3.4. Simplicity always in mind .................................................................................................................................................................... 12 2.2.3.5. Yes we comply ..................................................................................................................................................................................... 12

2.2.4. Key points Summary ............................................................................................................................................................. 13 2.2.4.1. Three major needs ................................................................................................................................................................................ 13 2.2.4.2. 5 outstanding features........................................................................................................................................................................... 13 2.2.4.3. 4 elementary managers manage the following features ........................................................................................................................ 13 2.2.4.4. 4 elementary actuators incorporate the following features ................................................................................................................... 13 2.2.4.5. In addition ............................................................................................................................................................................................ 13

2.3. Document Summary .............................................................................................................................................. 14 2.3.1. Gamp Guide Lines ................................................................................................................................................................ 14 2.3.2. Design Guide Lines ............................................................................................................................................................... 14 2.3.3. Hardware Interfaces .............................................................................................................................................................. 14 2.3.4. Admin Details ....................................................................................................................................................................... 14 2.3.5. Machine Details..................................................................................................................................................................... 14 2.3.6. Asynchronous Stations Details .............................................................................................................................................. 14 2.3.7. Synchronous Stations Details ................................................................................................................................................ 14 2.3.8. Actuators Details ................................................................................................................................................................... 14

3. Gamp Guide Lines ......................................................................................................................................... 15 3.1. V Life Cycle ............................................................................................................................................................ 15 3.2. Tests Overview ....................................................................................................................................................... 16

3.2.1. Objectives .............................................................................................................................................................................. 16 3.2.2. Modules ................................................................................................................................................................................. 16 3.2.3. Box ........................................................................................................................................................................................ 16

3.2.3.1. Black .................................................................................................................................................................................................... 16 3.2.3.2. White .................................................................................................................................................................................................... 16

3.2.4. Komax Rules ......................................................................................................................................................................... 17 3.2.5. Software Architecture ............................................................................................................................................................ 17 3.2.6. Architecture & Scope ............................................................................................................................................................ 17

3.2.6.1. "Out of scope" ...................................................................................................................................................................................... 17 3.2.6.2. "In the scope" ....................................................................................................................................................................................... 17 3.2.6.3. Risky Station ........................................................................................................................................................................................ 17 3.2.6.4. Black Box Scope .................................................................................................................................................................................. 17 3.2.6.5. White Box Scope.................................................................................................................................................................................. 17

3.3. Tests Procedures .................................................................................................................................................... 18 3.3.1. Black Tests ............................................................................................................................................................................ 18

3.3.1.1. "State transition" .................................................................................................................................................................................. 18 3.3.1.2. Imperative vs Sequencing Logic .......................................................................................................................................................... 18

3.3.2. White Tests ............................................................................................................................................................................ 19 3.3.2.1. "Data Flow".......................................................................................................................................................................................... 19 3.3.2.2. "Branch/Decision" ................................................................................................................................................................................ 19 3.3.2.3. Standard Model .................................................................................................................................................................................... 19

3.4. Software Plan ......................................................................................................................................................... 20 3.4.1. Design ................................................................................................................................................................................... 20 3.4.2. Code ...................................................................................................................................................................................... 20 3.4.3. Setup...................................................................................................................................................................................... 20 3.4.4. Debug .................................................................................................................................................................................... 20 3.4.5. Test-Up .................................................................................................................................................................................. 20

3.5. Categories ............................................................................................................................................................... 21




3.5.1. Operational system ................................................................................................................................................................ 21 3.5.2. Firmware ............................................................................................................................................................................... 21 3.5.3. Standard software package .................................................................................................................................................... 21 3.5.4. Configurable software package ............................................................................................................................................. 21 3.5.5. Fitted software ....................................................................................................................................................................... 21

3.6. Changes Control ..................................................................................................................................................... 21 3.6.1. Revisions Numbering ............................................................................................................................................................ 21 3.6.2. Revisions Traceability ........................................................................................................................................................... 21 3.6.3. Program Header Update ........................................................................................................................................................ 21

3.7. Check lists ............................................................................................................................................................... 22 3.7.1. Software ................................................................................................................................................................................ 22 3.7.2. Hardware ............................................................................................................................................................................... 22

4. Design Guide Lines ........................................................................................................................................ 23 4.1. ISA-IEC's Models .................................................................................................................................................. 23

4.1.1. S88 / 61512 ........................................................................................................................................................................... 23 4.1.2. TR88 / PackML ..................................................................................................................................................................... 23

4.1.2.1. Line ...................................................................................................................................................................................................... 24 4.1.2.2. Machine ............................................................................................................................................................................................... 24 4.1.2.3. Station .................................................................................................................................................................................................. 24 4.1.2.4. Actuator ............................................................................................................................................................................................... 24

4.1.3. Physics .................................................................................................................................................................................. 25 4.1.4. Configuration ........................................................................................................................................................................ 25 4.1.5. Programs ............................................................................................................................................................................... 25 4.1.6. Machine Modes ..................................................................................................................................................................... 26

4.1.6.1. Producing ............................................................................................................................................................................................. 26 4.1.6.2. Maintenance ......................................................................................................................................................................................... 26 4.1.6.3. Manual-Emulation................................................................................................................................................................................ 26 4.1.6.4. Purge .................................................................................................................................................................................................... 26 4.1.6.5. Dry Cycle ............................................................................................................................................................................................. 26 4.1.6.6. Single Cycle ......................................................................................................................................................................................... 26 4.1.6.7. Limp Track........................................................................................................................................................................................... 26 4.1.6.8. Limp Nest............................................................................................................................................................................................. 26

4.1.7. Machine States ...................................................................................................................................................................... 27 4.1.7.1. Aborting ............................................................................................................................................................................................... 27 4.1.7.2. Aborted ................................................................................................................................................................................................ 27 4.1.7.3. Stopping-Clearing ................................................................................................................................................................................ 27 4.1.7.4. Stopped ................................................................................................................................................................................................ 28 4.1.7.5. Resetting .............................................................................................................................................................................................. 28 4.1.7.6. Idle ....................................................................................................................................................................................................... 28 4.1.7.7. Starting ................................................................................................................................................................................................. 28 4.1.7.8. Execute................................................................................................................................................................................................. 28 4.1.7.9. Holding ................................................................................................................................................................................................ 28 4.1.7.10. Held...................................................................................................................................................................................................... 28 4.1.7.11. Suspending ........................................................................................................................................................................................... 28 4.1.7.12. Suspended ............................................................................................................................................................................................ 28

4.1.8. Station States ......................................................................................................................................................................... 29 4.1.8.1. Aborting ............................................................................................................................................................................................... 29 4.1.8.2. Resetting .............................................................................................................................................................................................. 29 4.1.8.3. Idle ....................................................................................................................................................................................................... 29 4.1.8.4. Execute................................................................................................................................................................................................. 29

4.1.9. Actuator States ...................................................................................................................................................................... 29 4.1.9.1. Cmd:=1 ................................................................................................................................................................................................ 29 4.1.9.2. Alm1=1 ................................................................................................................................................................................................ 29 4.1.9.3. Sts=1 .................................................................................................................................................................................................... 29 4.1.9.4. Cmd:=0 ................................................................................................................................................................................................ 29 4.1.9.5. Alm0=1 ................................................................................................................................................................................................ 29 4.1.9.6. Sts=0 .................................................................................................................................................................................................... 29

4.2. UML's Models ........................................................................................................................................................ 30 4.2.1. Object Oriented ..................................................................................................................................................................... 30 4.2.2. UML's Quatuor ...................................................................................................................................................................... 30 4.2.3. Objects Diagram .................................................................................................................................................................... 31 4.2.4. States Diagram ...................................................................................................................................................................... 31 4.2.5. Sequential Diagram ............................................................................................................................................................... 31 4.2.6. Class Diagram ....................................................................................................................................................................... 32

4.2.6.1. Hierarchy ............................................................................................................................................................................................. 32 4.2.6.2. Specialization ....................................................................................................................................................................................... 32 4.2.6.3. Main Class ........................................................................................................................................................................................... 32 4.2.6.4. Interfaces .............................................................................................................................................................................................. 32

4.2.7. Class & Interfaces ................................................................................................................................................................. 33 4.2.7.1. Mgr_Adm ............................................................................................................................................................................................. 33 4.2.7.2. Mgr_Prog ............................................................................................................................................................................................. 34 4.2.7.3. Mgr_Track ........................................................................................................................................................................................... 35 4.2.7.4. Mgr_Nest ............................................................................................................................................................................................. 36




4.2.7.5. Act_Bin ................................................................................................................................................................................................ 37 4.2.7.6. Act_Cam .............................................................................................................................................................................................. 38 4.2.7.7. Act_Num .............................................................................................................................................................................................. 39 4.2.7.8. Act_Pls ................................................................................................................................................................................................. 40 4.2.7.9. Typ_Batch ............................................................................................................................................................................................ 41 4.2.7.10. Typ_Recipe .......................................................................................................................................................................................... 41 4.2.7.11. Typ_Nest .............................................................................................................................................................................................. 42

4.3. Embedded Features ............................................................................................................................................... 43 4.3.1. Real Time OEE for Ahead Diagnosis .................................................................................................................................... 43

4.3.1.1. TR88 Theory ........................................................................................................................................................................................ 43 4.3.1.2. Mgr_Adm ............................................................................................................................................................................................. 45 4.3.1.3. Mgr_Track ........................................................................................................................................................................................... 45 4.3.1.4. Mgr_Nest ............................................................................................................................................................................................. 45 4.3.1.5. Act_??? ................................................................................................................................................................................................ 45 4.3.1.6. OEEs Supervision ................................................................................................................................................................................ 45

4.3.2. Emulation for Early De-risking + Fail-Safe for Auto-recovery ............................................................................................. 46 4.3.2.1. Response Time ..................................................................................................................................................................................... 46 4.3.2.2. Principle ............................................................................................................................................................................................... 46 4.3.2.3. Binary................................................................................................................................................................................................... 46 4.3.2.4. Came .................................................................................................................................................................................................... 46 4.3.2.5. Numeric ............................................................................................................................................................................................... 46 4.3.2.6. Pulse ..................................................................................................................................................................................................... 46

4.3.3. Agility for Last Minute Changes ........................................................................................................................................... 47 4.3.3.1. Double solenoid cylinder...................................................................................................................................................................... 47 4.3.3.2. Linear axis with limit switches ............................................................................................................................................................. 47 4.3.3.3. Rotary table .......................................................................................................................................................................................... 47

4.4. Configuration Conventions ................................................................................................................................... 48 4.4.1. Keys Codes Meanings ........................................................................................................................................................... 48

4.4.1.1. Ack ....................................................................................................................................................................................................... 48 4.4.1.2. Act_...................................................................................................................................................................................................... 48 4.4.1.3. Adm, Admin ........................................................................................................................................................................................ 48 4.4.1.4. Alm ...................................................................................................................................................................................................... 48 4.4.1.5. Bin........................................................................................................................................................................................................ 48 4.4.1.6. Cam ...................................................................................................................................................................................................... 48 4.4.1.7. Cfg ....................................................................................................................................................................................................... 48 4.4.1.8. Clr ........................................................................................................................................................................................................ 48 4.4.1.9. Cmd...................................................................................................................................................................................................... 48 4.4.1.10. Ctl ........................................................................................................................................................................................................ 48 4.4.1.11. Ctr ........................................................................................................................................................................................................ 48 4.4.1.12. ...ID ...................................................................................................................................................................................................... 48 4.4.1.13. Inp ........................................................................................................................................................................................................ 48 4.4.1.14. Log ....................................................................................................................................................................................................... 48 4.4.1.15. Man ...................................................................................................................................................................................................... 48 4.4.1.16. Mode .................................................................................................................................................................................................... 49 4.4.1.17. Nak ....................................................................................................................................................................................................... 49 4.4.1.18. Nest ...................................................................................................................................................................................................... 49 4.4.1.19. NestInt ................................................................................................................................................... Error! Bookmark not defined. 4.4.1.20. Num ..................................................................................................................................................................................................... 49 4.4.1.21. Out ....................................................................................................................................................................................................... 49 4.4.1.22. Par ........................................................................................................................................................................................................ 49 4.4.1.23. Pls ........................................................................................................................................................................................................ 49 4.4.1.24. Prog ...................................................................................................................................................................................................... 49 4.4.1.25. Rep ....................................................................................................................................................................................................... 49 4.4.1.26. ...s ......................................................................................................................................................................................................... 49 4.4.1.27. Safe ...................................................................................................................................................................................................... 49 4.4.1.28. State ..................................................................................................................................................................................................... 49 4.4.1.29. Sts ........................................................................................................................................................................................................ 49 4.4.1.30. Tmr ...................................................................................................................................................................................................... 49 4.4.1.31. Track .................................................................................................................................................................................................... 49 4.4.1.32. Typ ....................................................................................................................................................................................................... 49

4.4.2. Tags Configuration ................................................................................................................................................................ 49 4.4.2.1. Description ........................................................................................................................................................................................... 49 4.4.2.2. Name .................................................................................................................................................................................................... 49 4.4.2.3. Domain................................................................................................................................................................................................. 49 4.4.2.4. DataType .............................................................................................................................................................................................. 49 4.4.2.5. TagType ............................................................................................................................................................................................... 49 4.4.2.6. TagReference ....................................................................................................................................................................................... 49

4.4.3. Programs Names ................................................................................................................................................................... 50 4.4.3.1. Machine ............................................................................................................................................................................................... 50 4.4.3.2. Station .................................................................................................................................................................................................. 50 4.4.3.3. Actuator ............................................................................................................................................................................................... 50

4.4.4. Controller Tags ...................................................................................................................................................................... 50 4.4.4.1. Admin .................................................................................................................................................................................................. 50 4.4.4.2. Programs .............................................................................................................................................................................................. 51 4.4.4.3. Machine ............................................................................................................................................................................................... 51 4.4.4.4. Station .................................................................................................................................................................................................. 51 4.4.4.5. Actuator ............................................................................................................................................................................................... 51




4.4.5. Programs Tags ....................................................................................................................................................................... 51 4.4.5.1. Machine ............................................................................................................................................................................................... 51 4.4.5.2. Station .................................................................................................................................................................................................. 52 4.4.5.3. Actuator ............................................................................................................................................................................................... 52

4.5. Design Process ........................................................................................................................................................ 53 4.5.1. Machine ................................................................................................................................................................................. 53

4.5.1.1. Machine Overview ............................................................................................................................................................................... 53 4.5.1.2. Machine Configuration ........................................................................................................................................................................ 53 4.5.1.3. Machine Data ....................................................................................................................................................................................... 53 4.5.1.4. Stations Configuration.......................................................................................................................................................................... 53 4.5.1.5. Admin Configuration ........................................................................................................................................................................... 54 4.5.1.6. Admin Data .......................................................................................................................................................................................... 54

4.5.2. Asynchronous Station............................................................................................................................................................ 55 4.5.2.1. Sample, Pick & Place ........................................................................................................................................................................... 55 4.5.2.2. Horizontal Time Diagram Reference .................................................................................................................................................... 55 4.5.2.3. Vertical Time Diagram with Transients Choices .................................................................................................................................. 55 4.5.2.4. Transients to Matrix ............................................................................................................................................................................. 56 4.5.2.5. Station Configuration ........................................................................................................................................................................... 56 4.5.2.6. Station Sequencer ................................................................................................................................................................................. 57 4.5.2.7. Sequences Details................................................................................................................................................................................. 57 4.5.2.8. Tags List .............................................................................................................................................................................................. 57

4.5.3. Synchronous Station .............................................................................................................................................................. 58 4.5.3.1. Sample, Build & Check Time Diagram Reference ............................................................................................................................... 58 4.5.3.2. Vertical Time Diagram with Transients ............................................................................................................................................... 58 4.5.3.3. Transients to Matrix ............................................................................................................................................................................. 58 4.5.3.4. Station Configuration ........................................................................................................................................................................... 59 4.5.3.5. Station Sequencer ................................................................................................................................................................................. 59 4.5.3.6. Sequences Details................................................................................................................................................................................. 59 4.5.3.7. Tag List ................................................................................................................................................................................................ 59

4.5.4. Actuator ................................................................................................................................................................................. 60 4.5.4.1. Configuration ....................................................................................................................................................................................... 60 4.5.4.2. Actuators List ....................................................................................................................................................................................... 60 4.5.4.3. Programming ........................................................................................................................................................................................ 61

4.5.5. Design Workflow .................................................................................................................................................................. 61 5. Hardware Interfaces ...................................................................................................................................... 62

5.1. Topology.................................................................................................................................................................. 62 5.1.1. Physical Interface .................................................................................................................................................................. 62 5.1.2. Human Interface .................................................................................................................................................................... 62

5.2. Components ............................................................................................................................................................ 63 5.3. Operator Panel ....................................................................................................................................................... 64

5.3.1. E-Stop .................................................................................................................................................................................... 64 5.3.2. Stop ....................................................................................................................................................................................... 64 5.3.3. Start ....................................................................................................................................................................................... 64 5.3.4. Jog - ....................................................................................................................................................................................... 64 5.3.5. Jog + ...................................................................................................................................................................................... 64

5.4. Lights ....................................................................................................................................................................... 64 5.4.1. Red Light Flashing ................................................................................................................................................................ 64 5.4.2. Red Light Steady ................................................................................................................................................................... 64 5.4.3. Amber Light Flashing ........................................................................................................................................................... 64 5.4.4. Amber Light Steady .............................................................................................................................................................. 64 5.4.5. Green Light Flashing ............................................................................................................................................................. 64 5.4.6. Green Light Steady ................................................................................................................................................................ 64 5.4.7. White Light Flashing ............................................................................................................................................................. 64 5.4.8. White Light Steady ................................................................................................................................................................ 64 5.4.9. Buzzer 2 sec .......................................................................................................................................................................... 64 5.4.10. Stop Button Flashing ............................................................................................................................................................. 64 5.4.11. Stop Button Steady ................................................................................................................................................................ 64 5.4.12. Start Button Flashing ............................................................................................................................................................. 64 5.4.13. Start Button Steady ................................................................................................................................................................ 64

5.5. H M I ....................................................................................................................................................................... 65 5.5.1. Screens Map .......................................................................................................................................................................... 65 5.5.2. Screens Header ...................................................................................................................................................................... 65

5.5.2.1. Recipe .................................................................................................................................................................................................. 65 5.5.2.2. Batch .................................................................................................................................................................................................... 65 5.5.2.3. Modes................................................................................................................................................................................................... 65 5.5.2.4. States .................................................................................................................................................................................................... 65 5.5.2.5. Date & Time ........................................................................................................................................................................................ 65

5.5.3. Screenshots ............................................................................................................................................................................ 66 5.5.3.1. Machine Overview ............................................................................................................................................................................... 66 5.5.3.2. Machine Recipe & Batch ..................................................................................................................................................................... 66 5.5.3.3. Machine Modes .................................................................................................................................................................................... 67 5.5.3.4. Machine States ..................................................................................................................................................................................... 67




5.5.3.5. Machine Stops Reasons ........................................................................................................................................................................ 68 5.5.3.6. Machine Stations .................................................................................................................................................................................. 68 5.5.3.7. Stations States ...................................................................................................................................................................................... 69 5.5.3.8. Station Overview .................................................................................................................................................................................. 69 5.5.3.9. Actuator States ..................................................................................................................................................................................... 70 5.5.3.10. Actuator Overview ............................................................................................................................................................................... 70 5.5.3.11. Touch Screen Cleaning ........................................................................................................................................................................ 70 5.5.3.12. On line Users Guides............................................................................................................................................................................ 70 5.5.3.13. On Line Design References .................................................................................................................................................................. 70

5.5.4. Alarms Severities Levels ....................................................................................................................................................... 71 5.5.4.1. vs Colors .............................................................................................................................................................................................. 71 5.5.4.2. vs Stations ............................................................................................................................................................................................ 71 5.5.4.3. Single Acknowledgement..................................................................................................................................................................... 71 5.5.4.4. Double Acknowledgement ................................................................................................................................................................... 71

5.5.5. User Access ........................................................................................................................................................................... 72 5.5.5.1. User Login ........................................................................................................................................................................................... 72 5.5.5.2. Access Matrix ...................................................................................................................................................................................... 72

6. Admin Details ................................................................................................................................................. 73 6.1. Header ..................................................................................................................................................................... 73

6.1.1. MainType .............................................................................................................................................................................. 73 6.1.2. Main_ID ................................................................................................................................................................................ 73 6.1.3. SubType ................................................................................................................................................................................ 73

6.2. States & Modes ....................................................................................................................................................... 73 6.2.1. E-Stop .................................................................................................................................................................................... 73 6.2.2. Stop ....................................................................................................................................................................................... 73 6.2.3. Start ....................................................................................................................................................................................... 73

6.3. Public Data ............................................................................................................................................................. 74 6.3.1. Current State .......................................................................................................................................................................... 74 6.3.2. Command State ..................................................................................................................................................................... 74 6.3.3. Current Mode ........................................................................................................................................................................ 74 6.3.4. Command Mode .................................................................................................................................................................... 74 6.3.5. Login Identifier ..................................................................................................................................................................... 74 6.3.6. Safety Identifier ..................................................................................................................................................................... 74 6.3.7. Acknowledge Identifier ......................................................................................................................................................... 74 6.3.8. Alarms Identifier ................................................................................................................................................................... 74

6.3.8.1. Alarm to Abort ..................................................................................................................................................................................... 74 6.3.8.2. Alarm to Stop ....................................................................................................................................................................................... 74 6.3.8.3. Alarm to Idle ........................................................................................................................................................................................ 74 6.3.8.4. Alarm to Suspend ................................................................................................................................................................................. 74 6.3.8.5. Alarm to Hold ...................................................................................................................................................................................... 74 6.3.8.6. Alarm to Warn ..................................................................................................................................................................................... 74 6.3.8.7. Alarm to Help....................................................................................................................................................................................... 74

6.3.9. Clear Identifier ...................................................................................................................................................................... 74 6.3.9.1. Oper's Stats Clear ................................................................................................................................................................................. 74 6.3.9.2. Shift's Stats Clear ................................................................................................................................................................................. 74 6.3.9.3. Batch's Stats Clear ................................................................................................................................................................................ 74

6.3.10. Admin Array ......................................................................................................................................................................... 74 6.3.10.1. Admin Operator ................................................................................................................................................................................... 74 6.3.10.2. Admin Shift .......................................................................................................................................................................................... 74 6.3.10.3. Admin Batch ........................................................................................................................................................................................ 74

6.3.11. Alarms Array ......................................................................................................................................................................... 74 6.3.12. Camshafts Array .................................................................................................................................................................... 74 6.3.13. Parameters Array ................................................................................................................................................................... 74 6.3.14. Parameters Length ................................................................................................................................................................. 74 6.3.15. Reports Array ........................................................................................................................................................................ 74 6.3.16. Tracks Manager ..................................................................................................................................................................... 74 6.3.17. Nests Manager ....................................................................................................................................................................... 74 6.3.18. Nests Empty .......................................................................................................................................................................... 74 6.3.19. Nest Identifier ........................................................................................................................................................................ 75 6.3.20. Part Identifier ........................................................................................................................................................................ 75 6.3.21. Pulse per Second ................................................................................................................................................................... 75 6.3.22. Batch Interface ...................................................................................................................................................................... 75 6.3.23. Recipes Array ........................................................................................................................................................................ 75 6.3.24. Recipe Name ......................................................................................................................................................................... 75 6.3.25. Recipe ID .............................................................................................................................................................................. 75

6.4. Diagram .................................................................................................................................................................. 75 6.5. Interfaces Configuration ....................................................................................................................................... 76

6.5.1. Admin Statistics .................................................................................................................................................................... 76 6.5.2. Alarms vs Stations & Severities ............................................................................................................................................ 76 6.5.3. Parameters / Cams vs Stations ............................................................................................................................................... 76 6.5.4. Reports vs Stations ................................................................................................................................................................ 76 6.5.5. Tracks vs Station's Sides ....................................................................................................................................................... 76




6.5.6. Nests Managers vs Fixture's Sides......................................................................................................................................... 76 6.6. PLC Files................................................................................................................................................................. 77

6.6.1. Programs Tags ....................................................................................................................................................................... 77 6.6.2. Program_Logic ...................................................................................................................................................................... 77 6.6.3. Actuators_Sub ....................................................................................................................................................................... 77 6.6.4. AlmScan_Sub ........................................................................................................................................................................ 77

6.7. HMI Screen ............................................................................................................................................................. 77 7. Machine Details ............................................................................................................................................. 78

7.1. Header ..................................................................................................................................................................... 78 7.1.1. MainType .............................................................................................................................................................................. 78 7.1.2. Main_ID ................................................................................................................................................................................ 78 7.1.3. MainName ............................................................................................................................................................................. 78 7.1.4. MaindT .................................................................................................................................................................................. 78 7.1.5. SubType ................................................................................................................................................................................ 78 7.1.6. Sub_ID .................................................................................................................................................................................. 78 7.1.7. SubName ............................................................................................................................................................................... 78 7.1.8. SubdT#### ............................................................................................................................................................................ 78 7.1.9. _Adm ..................................................................................................................................................................................... 78

7.2. States ....................................................................................................................................................................... 78 7.2.1. Abort ..................................................................................................................................................................................... 78 7.2.2. Reset ...................................................................................................................................................................................... 78 7.2.3. Exec ....................................................................................................................................................................................... 78

7.3. Diagram .................................................................................................................................................................. 79 7.4. Public Data ............................................................................................................................................................. 79

7.4.1. Program Manager .................................................................................................................................................................. 79 7.4.2. Program Track ....................................................................................................................................................................... 79 7.4.3. Motions Group ...................................................................................................................................................................... 79 7.4.4. Motions Array ....................................................................................................................................................................... 79 7.4.5. Outputs Array ........................................................................................................................................................................ 79 7.4.6. Inputs Array .......................................................................................................................................................................... 79

7.5. Interfaces Configuration ....................................................................................................................................... 80 7.5.1. Motions Interfaces vs Stations ............................................................................................................................................... 80 7.5.2. Outputs- & Inputs vs Stations ................................................................................................................................................ 80

7.6. PLC Files................................................................................................................................................................. 80 7.6.1. Programs Tags ....................................................................................................................................................................... 80 7.6.2. Program_Logic ...................................................................................................................................................................... 80 7.6.3. Actuators_Sub ....................................................................................................................................................................... 80

7.7. HMI Screen ............................................................................................................................................................. 80 8. Asynchronous Stations Details ...................................................................................................................... 81

8.1. Header ..................................................................................................................................................................... 81 8.1.1. MainType .............................................................................................................................................................................. 81 8.1.2. Main_ID ................................................................................................................................................................................ 81 8.1.3. MainName ............................................................................................................................................................................. 81 8.1.4. MaindT .................................................................................................................................................................................. 81 8.1.5. SubType ................................................................................................................................................................................ 81 8.1.6. Sub_ID .................................................................................................................................................................................. 81 8.1.7. SubName ............................................................................................................................................................................... 81 8.1.8. SubdT#### ............................................................................................................................................................................ 81 8.1.9. Sub Details ............................................................................................................................................................................ 81

8.2. States ....................................................................................................................................................................... 81 8.2.1. Abort ..................................................................................................................................................................................... 81 8.2.2. Reset ...................................................................................................................................................................................... 81 8.2.3. Exec ....................................................................................................................................................................................... 81

8.3. Diagram .................................................................................................................................................................. 82 8.4. Public Data ............................................................................................................................................................. 82

8.4.1. Prog ....................................................................................................................................................................................... 82 8.4.2. Track0 ................................................................................................................................................................................... 82 8.4.3. Track1 ................................................................................................................................................................................... 82 8.4.4. Nest0 ..................................................................................................................................................................................... 82 8.4.5. Nest1 ..................................................................................................................................................................................... 82

8.5. PLC Files................................................................................................................................................................. 83 8.5.1. Programs Tags ....................................................................................................................................................................... 83 8.5.2. Program_Logic ...................................................................................................................................................................... 83 8.5.3. Actuators_Sub ....................................................................................................................................................................... 84 8.5.4. Motion_Sub ........................................................................................................................................................................... 84

8.6. HMI Screen ............................................................................................................................................................. 84 9. Synchronous Stations Details ........................................................................................................................ 85




9.1. Header ..................................................................................................................................................................... 85 9.2. States ....................................................................................................................................................................... 85 9.3. Diagram .................................................................................................................................................................. 85 9.4. Public Data ............................................................................................................................................................. 85 9.5. PLC Files................................................................................................................................................................. 85

9.5.1. Programs Tags ....................................................................................................................................................................... 85 9.5.2. Program_Logic ...................................................................................................................................................................... 86 9.5.3. Actuators_Sub ....................................................................................................................................................................... 86 9.5.4. Motion_Sub ........................................................................................................................................................................... 86

9.6. HMI Screen ............................................................................................................................................................. 86 10. Actuators Details ............................................................................................................................................ 87

10.1. Overview ................................................................................................................................................................. 87 10.1.1. Principle ................................................................................................................................................................................ 87 10.1.2. Behaviour .............................................................................................................................................................................. 87 10.1.3. Programming Style ................................................................................................................................................................ 87

10.2. Binary ...................................................................................................................................................................... 88 10.2.1. Single Solenoid - Single Sensor ............................................................................................................................................ 88 10.2.2. Single Solenoid - Double Sensors ......................................................................................................................................... 88 10.2.3. Double Solenoids - Double Sensors ...................................................................................................................................... 88 10.2.4. Operator Button with Lamp ................................................................................................................................................... 88 10.2.5. Emergency Stop .................................................................................................................................................................... 88 10.2.6. Light / Lamp .......................................................................................................................................................................... 89 10.2.7. Recipe Confirm ..................................................................................................................................................................... 89 10.2.8. Batch Confirm ....................................................................................................................................................................... 89

10.3. Camodulo ................................................................................................................................................................ 90 10.3.1. Rotary Indexer ....................................................................................................................................................................... 90 10.3.2. Came Follower ...................................................................................................................................................................... 90 10.3.3. Master Came ......................................................................................................................................................................... 91

10.4. Numeric ................................................................................................................................................................... 91 10.4.1. Probe ..................................................................................................................................................................................... 91 10.4.2. Axis ....................................................................................................................................................................................... 91

10.5. Pulse ........................................................................................................................................................................ 92 10.5.1. Flip-Flop ................................................................................................................................................................................ 92 10.5.2. Feeder Level .......................................................................................................................................................................... 92

A. Appendices ..................................................................................................................................................... 93 A.1. Overall Model ......................................................................................................................................................... 93 A.2. Structured Text ...................................................................................................................................................... 94 A.3. Glossary .................................................................................................................................................................. 97 A.4. French Summary.................................................................................................................................................. 103




1. Introduction The purpose of this document is to describe and specify the machine software platform.

1.1. Account of modifications

Version Date Modified by Description of modification

0.01 28 August 2011 JC Pourchet Creation of the document

0.02 29 August 2011 JC Pourchet §3. Gamp Guide Lines

§4. Design Guide Lines

§7. Machine Details

0.03 30 August 2011 JC Pourchet §4. Design Guide Lines

§5. Hardware Interfaces

§8. Stations Details

0.04 11 Sept. 2011 JC Pourchet §3. Gamp Guide Lines

§4. Design Guide Lines

§6. Admin Details

§10. Actuators Details

0.05 1st Oct. 2011 JC Pourchet §4. Design Guide Lines

§5. Hardware Interfaces

§A.1. Overall Model

0.06 8th Dec. 2011 JC Pourchet §5.1. Hardware Topology

§5.2. Hardware Components

§5.5. Screens Map

0.07 19th Dec. 2011 JC Pourchet §A.2. Structured Text

§A.3. Glossary

0.08 24th Feb 2012 JC Pourchet §8. Asynchronous Station Details

§9. Synchronous Station Details

0.09 04th April 2012 JC Pourchet §4.2.6. Class Diagram

§4.2.7. Class & Interfaces

§5.5.2. Screens Header (Recipe, Batch, Mode, ...)

§5.5.3.1. Machine Overview Screenshot

§5.5.3.6. Stations View Screenshot

§6.4. Public Data (Recipe and Batch information)

1.00 17th July 2012 JC Pourchet §4.2.6. Class Diagram

§4.2.7.4. Mgr_Nest

§4.2.7.11 Typ_Nest (not used anymore)

§10.1. Actuators Detail, Overview

1.01 1st Dec. 2012 JC Pourchet §4.1.7. Machine States witch Hold & Suspend) §4.3.1.2. Mgr_Adm §4.5.1.5. Admin Configuration §5.4. Lights

§5.5.4. Screens Header §6.4. Admin Diagram

1.11 30th Jan. 2013 JC Pourchet §3.7. Check Lists §4.4. Configuration Conventions

1.12 06th Feb. 2013 JC Pourchet §5.5.4. Alarms Severities Levels §6.5.2. Alarms vs Stations & Severities

1.13 02th Dec. 2014 JC Pourchet §3.7. Checklist




1.2. Signatures

KOMAX MEDTECH

Role1 Name Function Date Signature

Preparer JC Pourchet Electrical Engineering Lead

Reviewer T. Perret D&D Software Engineer

Reviewer T. Sordel Validation Engineer

Approver

1ROLES DESCRIPTION

Preparer: Your signature indicates that you prepared this document.

Reviewer: Your signature indicates that, as a subject matter expert, you have reviewed the content of this document and agree its contents are accurate.

Approver: Your signature indicates that this document respects regulation requirements of Good Manufacturing Practices and Good Documentation Practices. You agree with its structure and its relations with others validation documents




1.3. Reference documents

1.3.1. Standards & References

Component Testing Standard for Software Component Testing

Fisher-Pillai S88 Batch Control - Applying the S88.01 / IEC 61512-1 by G. Fisher.

IEC-61131-3 Normalisation des langages de programmations.

IEEE-1008;1987 Standard for Software Unit Testing

ISA-S88-01 (IEC-61512-1) Batch Control, Models and Terminology.

ISA-S88-02 (IEC-61512-2) Batch Control, Data Structure & Guideline for Languages.

ISA-S88-05 (IEC-61512-5) Batch Control, Automated Equipment Control Models.

ISA-S88, Commissioning Models and Commissioning / Qualification Mapping.

ISA-TR88.00.03 Machine and Unit States: ISA-S88 Implementation Example.

ISO 13849-1 Safety of machinery – Part 1. General principles for design.

ISPE-Gamp 5 Risk Based Approach to Comply GxP Computerized Systems.

Matrice Asynchrone Logique séquentielle asynchrone, Uni-Marseille - J. Guizol.

Matrice d'Huffman Synthèse des systèmes séquentiels.

Rockwell IA-RM001C-EN-P Integrated Architecture: Modular Programming Foundations.

Siemens S88, 2007 La norme S88 selon Siemens, Bernard E. Cubizolles.

SoftwareTesting Canergie Mellon University

UML II Unified Modelling Language.

1.3.2. Working Documents

SW_Checklist.xls Software Tasks check lists sample.

SW_Platform.L5K PLC's project sample (RSLogix).

SW_Platform.ppt Slides show with all attached figures.

SW_Platform.xls Machine-Stations-Actuators configuration sample.

SW_Platform_ActBinCheck.xls Tests Protocols for each Binary Actuator.

SW_Platform_ActCamCheck.xls Tests Protocols for each Camshaft Actuator.

SW_Platform_ActNumCheck.xls Tests Protocols for each Numeric Actuator.

SW_Platform_ActPlsCheck.xls Tests Protocols for each Pulse Actuator.

SW_Platform_IQCheck.xls Check-list for IQ (I/O, Parameters, Alarms, Reports, etc...).

SW_PlatformDDETest.xls Tracks and Nests data tracking through DDE link.




Rapid

Application

Development

Standards

&

References

Good

Automation

Practices

2. Executive Summary

2.1. Preliminary

Automated machine programming is typically done by software engineers, machine designers, and system integrators. The form and style of the machine software ranges from modular, to monolithic in nature. The objective of this project is to specify the application of a common software methodology that is consistent with the modular programming of automated machinery as described in the ISA-88 standard. This project enables a consistent method of machine interconnection and operability.

2.2. Objective

In pharmaceutical industry the most required systems are Rockwell or Siemens.

2.2.1. One Goal

The SW_Platform defines 1 design guide lines for 2 PLC so only one HMI should comply with anyone.

2.2.2. Three Needs

Beside the unique HMI goal, there are 3 targets to keep in mind:

2.2.2.1. Standard & References (State of the Art)

versus ISA-S88, ISA-TR88.02 and ISO-13849

2.2.2.2. Good Automation Practices

with specifications, tests and validation

2.2.2.3. Rapid Application Development

"Time is money", "Ready early", ...

2.2.3. Five E2ASY Paths

After few technical performance tests, activity based costing analysis and normative references studies, the 5 following matters appear to be the right paths to achieve the 3 main targets.

2.2.3.1. Emulation for early de-risking + Fail Safe for auto-recovery

To pre-test and failure-compensate process sequences

2.2.3.2. Effectiveness for ahead diagnostics

Detailed real-time OEE at every level for ahead diagnosis and to identify predictable failures

2.2.3.3. Agility for last minute changes

Through combination of specialization ability and flexible aggregation, "lego mindstorm"

2.2.3.4. Simplicity always in mind

To make programs running earlier and faster with less files, data, code, bugs, pain, money...

2.2.3.5. Yes we comply

With standards & references so we reuse supplier's codes without reinventing wheel.

Only One

HMI-SCADA

For Two

Hardwares

Effectivenessahead diagnosis

with O.E.E.

Emulationfor de-risking

& Fail Safe

Simplicityalways

in mind

Yeswe comply

to standards

Agilityfor "last minute"

changes




2.2.4. Key points Summary

This platform is ready in ladder and structured-text (two PLC prototypes are coded). It applies the rules promoted by ISA-TR88. 8 reusable routines are defined (Admin, Prog, Track, Nest, Bin, Num, Cam and Pls) and the task "Admin" contains 3 routines (logic-actuators-alarm). Compared with the 1200 instructions lines of the 60 routines of current platforms, these 11 basic routines requires around 100 lines that give technical and economical affordable "modular testing". By testing three instructions lines at a time, this platform is validated in white box after 35 hr of effort (with prior written tests).

2.2.4.1. Three major needs

• Compliance TR88, 1st model for mecatronics iAssembly and Packaging industries.

• Rapid application development software, "ARD" to reduce costs.

• Adoption of best automation practices (Gamp 5).

2.2.4.2. 5 outstanding features

• Emulation with actuators included for offline de-risking and online safe mode ability.

• Real-time OEE included in each module for self-diagnostic and preventive maintenance.

• Agility by recombination of the 4 elementary actuators already established on PDS, and EQW1 RAI01.

• Simplicity with only 3 routines per station (logic-actuators-motions) and only 1 config file per machine.

• Compatibility with TR88 and Gamp5 (modes, states, alarms, data-in, data-out, mnemonics, etc. ...)

2.2.4.3. 4 elementary managers manage the following features

• The OEE in real-time in the three managers (Admin, Track and Nest).

• Enhanced limp mode by selecting Nests and / or Tracks.

• Synchronous and asynchronous sequencer (program).

• Management of operating modes and states (Admin).

• Part-ID and Shift-Register data monitoring.

• Management of multiple recipes (Admin).

• Batch Management (Admin).

• Consecutive errors.

• etc ...

2.2.4.4. 4 elementary actuators incorporate the following features

• Single or dual acknowledgement for alarm (HMI and / or Enclosure).

• The safety and self-recovery after operator acknowledgement.

• Manual controls without any additional programming.

• The real-time OEE calculations in the 4 actuators.

• The actuators time response emulation.

• Fail Safe Mode by emulation.

• Mirroring (probe mode).

• etc ...

2.2.4.5. In addition

The automatic generation of "test cases" and modelling "control activity" (HMI, SCADA, Recipe, Batch, etc. ...) is still in progress. The configuration file defining sequencers and data of one machine with its stations have a macro that generates the symbols and instructions lines directly into a Rockwell PLC; the same configuration file also contains all the required information for a machine SDS.

To terminate and by joining the actual software platform activity based costing, Komax should be able to save between 30% and 40% of software development cost while complying to medical requirements.




2.3. Document Summary

The main purpose of this document is to describe how to implement the E2ASY paths to achieve the 3 main targets (State of the Art, Good Automation Practices and Rapid Application Development); to do so, the first chapter summarizes the Gamp advises while the second proposes a design process that comply with the normative references; the latest chapters give practices details for hardware interfaces, administration, machine, station and actuator software design.

2.3.1. Gamp Guide Lines

Gamp guidance aims to achieve computerized systems that fit for intended use and meet current regulatory requirements, by building upon existing industry good practice in an efficient and effective manner. It promotes the system V life cycle approach; it synthesizes the goals of tests and gives some typical procedures for modular testing. This chapter gives also the standard software project plan, it lists the software categories and our changes control practices.

2.3.2. Design Guide Lines

The design guide lines goes quickly through the ISA-S88 / IEC-61512 models that have initiated the ISA-TR88 (PackML); it shows how it could be structured in matter of physics, configurations, programs, machine modes, machine states, station states and actuator states. Then it reminds UML's analysis that confirms the ISA's arguments wisdom; the analysis feedbacks objects, states, sequential and class diagrams. It depicts the specifics features embedded into every main class such as effectiveness calculations, time response emulation, components agility and simplicity. The configuration conventions are covered by following the TR88 organization through controller administration, machine and station scopes. The last part proposes a design process for software engineer as development guide lines.

2.3.3. Hardware Interfaces

There is no automation software without hardware; this chapter gives a standard topology that complies with machine directive 2006/42/CE. It proposes a classified list of standard components that could be used with this platform and how to drive them from a software point of view. Then it gives short descriptions of operator panel uses, lights tree behaviour and HMI screens requirements.

2.3.4. Admin Details

This chapter gives to the software engineer the keys to configure admin programs; It explains how to size the machine stations, "tracks side" quantity and "nests side" quantity; It goes again through every public tags that have been considered as "Admin" components; It reminds the "Admin" components could be locally or remotely controlled; It describes the dedicated HMI screen.

2.3.5. Machine Details

This chapter gives to the software engineer the keys to configure a machine programs; it shows how to configure station tags, private and public; it describes the dedicated HMI screen.

2.3.6. Asynchronous Stations Details

This chapter gives to the software engineer the keys to configure asynchronous (or transactional) station programs; it explains how to configure actuators, its "tracks side" quantity and "nests side" quantity; It gives clues to make the sequencer that manage the chosen actuators; It shows how to configure station tags, private and public; It describes the dedicated HMI screen.

2.3.7. Synchronous Stations Details

This chapter gives to the software engineer the keys to configure camshaft synchronous station programs; most of it is the same as asynchronous station but it explains how to merge the standard sequencer to the camshaft follower.

2.3.8. Actuators Details

This chapter gives to the software engineer the keys to configure actuators instructions;

It shows some examples how to choose, instance and configure the right actuator class.




3. Gamp Guide Lines

3.1. V Life Cycle

The V Life Cycle principle structures the development by coordinating the design, implementation and validation phases; successive versions of Gamp have continued to strengthen this model.

PerformanceTesting

User Requirements

Specification

ModulesSpecification

DesignSpecification

FunctionalSpecification

Integration &Modules Test

InstallationTesting

OperationalTesting

MachineMachine

ActuatorsActuators

StationStation

Black BoxBlack Box

BlackBox

BlackBox

WhiteBox

WhiteBox

Configuration _00

–

+Configuration _01

Main form _01Tags List _01

+ Sub form _01_00

Sub form _01_01

Sub form _01_02• Actuators List• Station Sequences

–

–

Project _A

Project _B

+

Sub form _01_010++

• Stations List• Mach. Sequences

The downswing starts with the customer's specifications that the supplier translates into multidisciplinary functional specifications, which means they are common to all trades that the provider must implement to achieve the final product.

These functional approaches are then taken up sector by sector (mechanical design, hardware and software) to prepare design specifications, those ones, because of their too high level of abstraction, are again taken to be detailed to establish concrete references to the implementation phase.

The design phase ends with the jobs (mechanics, hardware & software) specifications writing of the modules, these specifications are translated into mechanical drawings, electrical diagrams and software diagrams (states, objects, sequences or classes).

The upswing is completely symmetric in terms of tests, so from Gamp, a different type of test is required for each phase of implementation, so the pre-integration tests validate the modular testing achievements, the installation validate the jobs requirements, the operational tests confirm the choices and finally the functional performance tests qualify the final product relative to customer specifications.




3.2. Tests Overview

3.2.1. Objectives

Ensure proper operation on the specifications of a portion of the program (called "unit" or "module"):

o A test procedure for each module.

o A test module independent from the rest of the program.

o Ensure that performance correlates the specification of that module.

o All tests must be replayed after a code change to ensure the absence of instabilities.

The Extreme Programming advocates writing the test procedure at the same time that the function of the module is coded.

3.2.2. Modules

All software studio providers offers a standard way of viewing the project organization and may be called "Program Organization", "Project Explorer" or "POU", they all have the purpose to show a tree to determine the overall software modules nesting into each other or with each other ...

Therefore each of the icons listed in the Explorer is a module that can be tested with the exception of modules that contain only data ("tags") is still the case because most controllers are not yet fully object-oriented and continue to separate data programming instructions or code.

3.2.3. Box

3.2.3.1. Black

Example: the transistor

A "black box" is a module of unknown internal composition (voluntarily or not).

The black box test is used to verify that the results are the expected ones for given conditions. It is therefore appropriate as soon as the test is more important than the code behind.

3.2.3.2. White

Example: the bicycle

A "white box" is a module which can forecast every feature because all components are visible.

The white box testing is done by scanning the source code of the module during its own execution; the online stepping mode could be a mean to achieve this test.




3.2.4. Komax Rules

Unit tests take place before the installation tests stage: they are part of the integration testing stage; the protocols contents of these tests are based on modules specifications.

ModulesSpecification

Integration &Modules Test

MachineMachine

ActuatorsActuators

StationsStations

Black BoxBlack Box

BlackBox

BlackBox

WhiteBox

WhiteBox

Code In Scope:-Custom Process-Parts Information-Batch Supervision

Tests applicable on functions identified as critical on the pFMEA

Tests applicable on actuators identified as high-risk class in the SRA

pFMEA

S R A

3.2.5. Software Architecture

Unit testing is necessarily dependent on the chosen software architecture, in the field of assembly or packaging automatic machines, the latest standards require the following architecture: a machine is divided into stations and each station is an aggregate of actuators.

These standards describe only how to structure portions of program support to automate processes, parts of program schedules related to "Firmware" or "Fieldbus" commonly called "Platforms" are not affected.

3.2.6. Architecture & Scope

For the validation of a machine and only in case the base system comes from a recognized provider (Siemens or Rockwell the platform testing are not required; at most, the end customer may request a certificate respect of the recommendations of use ("good practices") established by the provider after an audit of our PLC platform using Komax guide lines.

3.2.6.1. "Out of scope"

We consider "beside" codes related to the systems (Siemens or Rockwell) integration in our platform does not fall within the scope of unit testing.

3.2.6.2. "In the scope"

We consider the specifically written code to automate processes required to assemble, process or trace the product for the custom application enters in the scope of unit testing.

3.2.6.3. Risky Station

In fact, all modules are tested more or less by programmers, electricians and mechanics between the machine power-up, configuration and tune-up. Therefore some unit tests are probably not needed on the whole modules in charge of the process of a machine, a machine would not consider every station as risky for the product. For unit tests, we consider only the modules belonging to stations where a risky process is identified.

3.2.6.4. Black Box Scope

Modules and sub-modules of a "risky station" identified by the "Software Risk Analysis" black box

are tested, including the main module when its white box testing is done.

3.2.6.5. White Box Scope

Only the main module of a "risky station" is subject of a white box test.




3.3. Tests Procedures

3.3.1. Black Tests

To describe a black box, we recommend the "State Transition Testing".

Test cases must execute transitions between states and require the following information:

- The initial state and the existing entries.

- The expected results and / or the final state expected.

Test cases are designed to execute valid transitions between states.

They can also be designed to test unspecified transitions.

3.3.1.1. "State transition"

StationMachine

Black Box(dT, Step, ...)

Safe

Ack.Alarm

Emulate

Act#1

Ab

ort

Ex

ec

Idle

Go

od

Step-by-Step

Act#2 Act#3

Equations:

_Alarm = Act#1.AlmOff+Act#1.AlmOn+...

_Good = Act#1.Sts x Act#2.Sts x ~Act#3.Sts

_Idle = ~Act#1.Sts x ~Act#2.Sts x Act#3.Sts

_Step = Abort + Exec x 10

Actuator

Black Box(dT, ...)

Ack

. . .

Alm OFF

Alm ON

Command Status

Input Output

Equations:

_Status = Input + Emulate x dT.Done

_AlmOn = Cmd x ~Sts x dT.Done

_AlmOff = ~Cmd x Sts x dT.Done

_Output = Cmd x ~Ack x ~AlmOn

Em

ula

te

3.3.1.2. Imperative vs Sequencing Logic

Black tests are enough for the components programmed under imperative logic (low level).

StationMachine

White Box

Safe

Ack.Alarm

Emulate

Ab

ort

Ex

ec

En

d

Go

od

Step-by-Step 'Header:

_If Abort=1 thenSeq:=1

_If Exec=1 thenSeq:=10

'Sequences:_If Seq=1 then

Act#1.Cmd:=0Seq:=2

_If Step=2 and Act#1.Sts=0 then Seq:=3

_If Seq=3 then ..._. . .

StationMachine

Black Box(dT, Step, ...)

Safe

Ack.Alarm

Emulate

Act#1

Ab

ort

Ex

ec

Idle

Go

od

Step-by-Step

Act#2 Act#3

Equations:

_Alarm = Act#1.AlmOff+Act#1.AlmOn+...

_Good = Act#1.Sts x Act#2.Sts x ~Act#3.Sts

_Idle = ~Act#1.Sts x ~Act#2.Sts x Act#3.Sts

_Step = Abort + Exec x 10

Once a component is programmed in sequential logic, a blank test is required.




a Clean...

b Load...

c Shift...

d Unload...

x Open...

y Down...

z Close...

Load...

Machine...

x ...

Clean...

x ...

Shift...

x ...

Unload...

Act#

b1

Act#

b2

Act#

b3

Act#

d1

Act#

d2

Act#

c1

Act#

c2

Act#

a1

Act#

a2

Process Machine Process Stations and Actuators

Pro

ced

ure

sIm

pera

tif

3.3.2. White Tests

To qualify a white box, we recommend the "Branch / Decision Testing" in cases of logical sequenced and the "Data Flow Testing" in other cases (i.e. "Part Info" or "Shift-Register").

3.3.2.1. "Data Flow"

This analysis identifies the interactions between components connected by data flow and / or flow control. The test cases are designed to perform transfers between variables or values of components and require the following information:

The input variables.

Places of definition of variables and pairs of uses.

The subsets of control flow (s) to run.

Expected results.

3.3.2.2. "Branch/Decision"

The source code analysis make possible the branches identification with their expected results. A branch is an instruction executed in a conditional expression. Test cases are designed to execute combinations of values in the branches and require the following information:

Identification and inputs of each branch.

The identification of combinations of values to run.

The expected results and / or identification of the next branch.

Under sequential logic, this technique requires a "step by step" mode of operation.

3.3.2.3. Standard Model

Here the number of programs to be tested in white boxes is the number of existing stations.




FDS.doc

URS.doc

SDS.doc

HDS.doc Draw

.dwg

Diag..xls Code

.plc

FDS.doc

HDS.doc

SDS.docTest

.xls

FDS.doc

Install.IQ

Oper..OQ

HDS.doc

SDS.doc

Perf.PQ

Alpha

or Beta

Release

Candidate

Release

Candidate

Gold

Release

Gold

Release

.plcCode

.xlsTest.xls

Conf.

.drwDraw

Design Code Debug Test-up

upSet

3.4. Software Plan

The following plan is booked to any software project and is coordinated with specifications.

3.4.1. Design

FDS alpha.

o Machine modelling by breaking machine to stations and then stations to actuators.

o Configuration of .machine & stations

o Risk analysis under pFMEA method.

o Design review.

Configuration alpha.

FDS release candidate.

3.4.2. Code

HDS + SDS alpha.

o Configuration of Inputs and outputs data (alarms, parameters, reports, outputs, inputs, etc....).

o PLC programming, start with tags importation and then sequences encoding.

o HMI screens, Displays design for machine and station(s).

o Code review.

Code alpha.

3.4.3. Setup

Configuration release candidate.

o Electrical booting, machine power-up.

o Hardware configuration, field bus setup, motion axis tune, distributed I/O mapping, etc...

o Physical Input/Output check, hardware control of electrical signals from PLC.

o Parameters initialization, machine and stations configurable data typing.

o Camshafts initialization, configurable cam angles typing.

HDS release candidate.

3.4.4. Debug

Code release candidate.

o Maintenance items, every manual function tests.

o Nominal speed cycle, complete automatic cycle station by station.

o Statistics displays, pre-test correctness of displayed data updates on HMI.

o Alarms displays, inputs forcing to pre-test alarms (number and descriptions).

o Branch tests, step-by-step pre-test control versus configuration spreadsheets.

SDS release candidate.

3.4.5. Test-Up

FDS gold release.

o Inputs check, final test for inputs and alarms

o Modules tests, final black box tests (only for categories 5 software parts)

o Installation tests, i.e. validation plan.

o Operational tests, i.e. validation plan.

o Performance tests, i.e. validation plan.

Configuration + Code + Test + HDS + SDS gold release.




"EQW1_M12_V106_06jun2011.ACD"

Project

Name

Machine

Name

Revision

Number

Revision

Date

3.5. Categories

To agree with Gamp guide lines, the following list is filled for every software project.

3.5.1. Operational system

3.5.2. Firmware

3.5.3. Standard software package

3.5.4. Configurable software package

3.5.5. Fitted software

GAMP – Software categories

Software parts Cat. Software parts Cat.

Komax PLC Software 5 Komax HMI Software 4 or 5

PLC – Design tools (Studio) 3 HMI – Design tools (Studio) 3

3.6. Changes Control

The software revision number is a part of the PLC project naming convention.

It defines the file name (with the date).

It defines the controller name (without the date).

3.6.1. Revisions Numbering

_.xx while the software project is controlled by the software engineer in charge of coding.

0.00 Right after "Inputs Check" at the beginning of "Test-Up" (see §5.1).

0.xx while "Modules Tests" without "Revisions Traceability" but with "Program header update".

1.00 right after "Integration Tests"

1.xx while "Operational and Performance Tests" with "Revisions Traceability".

2.00 right after the FAT.

2.xx after the FAT with "Revisions Traceability".

3.6.2. Revisions Traceability

A word document is attached to each revision; it describes each change with screenshots of codes changes (before and after) and with a comment of the modification; this makes the change historics, which includes "Test Reference", "Modification Title", "Why" reason, date and author.

3.6.3. Program Header Update

To be described...




3.7. Check lists

The checklist are used to check versus the predefined workflow and also to update the project status.

3.7.1. Software

The software project is divided in 3 main phases: Offline, Online and Release

# # #

## Main + Stations

∞ Mainframe

00 Transport

01 Damping Cup Load

02 Damping Cup Check

03 Damping Compound Disp.1

07 Damping Compound Vision

08 Retraction Assembly Load

09 Retraction Assembly Check

18 Damping Cup Nest A Check

19 Damping Cup 1080° Rotation

24 Good Part Unload

25 Empty Nest Check 100% 1

100% 1

never edit - read only

90% 1

70% 1

edit at sheet initialization

100% 1

100% 1

100%

100%

100%

100%

1

1

100%

100%

100%

Software Owner

Tom & Jerry

Fields Edition Colors Legend edit and also Risk [1-3]

1

100% 1

Current Date

7 sept. 14

Work Hr per 7 days week

20

7280655 Assembly Machine

M24Machine Description

SOFTware CHECKUP

RAI02

Project Number

Machine Name

100120

Project Name

70%

PL

C C

od

ing

HM

I S

etu

p

SD

S D

raft

Tu

ne-u

p S

up

po

rt

Dry

-ru

n S

uccess

Tests

Pre

req

uis

ites

1

100%

1

70%

100%

22

90%

90%

70%

90%

1

Risk [1-3]

1

1

1

1

1

1

1

1

70%

1

100%

1 100%

1

1

70% 1

190%

11

70%

1

1

Done %

100%

100%

Risk [1-3]

1

Risk [1-3]

100%

1

1

100%

100% 1

100% 1

100%

0 0

Expected Hr Risk [1...]

30 juin 14 240

Due Date

7 sept. 14

Expected Date Rated Hr

0

Due Hr

641 oct. 145Risk [1...]

6

Expected Hr

64

Expected DateRated Hr

9 sept. 14

Done %

100%

Done %

30 sept. 14 240

Expected Hr Risk [1...]

Rated HrExpected Date

PL

C D

eb

ug

I/O

Deb

ug

Due Hr

9 sept. 14 240

RELEASE

Due HrDue Date

Tests

Su

pp

ort

s

SD

S R

ele

ase

Due Date

OFFLINE ONLINE

UR

S+

FD

S A

naly

sis

SD

S C

on

fig

ura

tio

n

SD

S U

pd

ate

Bo

ot-

Up

20%+20%+20%+20%+20% 20%+20%+20%+20%+20%

HM

I D

eb

ug

3.7.2. Hardware

The hardware project is divided in 3 main phases: Standard, Specific and Release

5 # 5

## Main + Stations

∞ Mainframe

00 Transport

01 Damping Cup Load

02 Damping Cup Check

03 Damping Compound Disp.1

07 Damping Compound Vision

08 Retraction Assembly Load

09 Retraction Assembly Check

18 Damping Cup Nest A Check

19 Damping Cup 1080° Rotation

24 Good Part Unload

25 Empty Nest Check

0

20%+20%+20%+20%+20% 20%+20%+20%+20%+20%

Risk [1...]

7 sept. 140

13 juin 14

Ris

k A

naly

sis

200

Due Date

I/O

Revie

w

B.O

.M.

Sta

nd

ard

UR

S+

FD

S A

naly

sis

Ord

ers

Sta

nd

ard

HD

S D

raft

I/O

Lis

t +

Dis

trib

.

RELEASE

Due HrDue Date

Ord

ers

Rem

ain

ing

Bin

der

Rele

ase

HD

S R

ele

ase

Dra

win

gs R

ele

ase

SPECIFIC

Due Hr

20%+20%+20%+20%+20%

100

100%

1930 sept. 14

Rated Hr

30 sept. 14

Expected Hr Expected Hr

Done %

1

Risk [1-3]

100%

1

1

1100%

1

1

1100%

0

1

Done %

Expected Date

Due Date

5 févr. 14 100

Due Hr

100%

0

1

100%

1

100%

100%

100%

100%

80%

80% 1

80% 1

80%

1

10

90%

90%

80%

Risk [1-3]

1

1

1

80%

80%

1

1

1

1

80% 1

1

Current Date

7 sept. 14

Work Hr per 7 days week

Risk [1...]Risk [1...]

Rated Hr

20

RAI02

Project Number

Machine Name

100120

Hardware Owner

Jean-Noel Picaud

7280655 Assembly Machine

HARDware CHECKUP

Project Name

100%100%

M24Machine Description

B.O

.M.

Rem

ain

ing

Wir

ing

Su

pp

ort

Dra

win

gs U

pd

ate

s

STANDARD

100%

10

100%

Done %

100%

100%

100%

Expected Hr

1

100%

7 sept. 14

0

100% 1

1

100%

Fields Edition Colors Legend edit and also Risk [1-3]

1

100% 1

1

1

edit at sheet initialization never edit - read only

Expected Date Rated Hr Expected Date

100% 1 100% 1

100% 1

Tests

Pre

req

uis

ites

Risk [1-3]

1

80% 1

80% 1

1




4. Design Guide Lines

4.1. ISA-IEC's Models

4.1.1. S88 / 61512

The diagram shown here are specific in terms of the functionality they provide but can be implemented in various ways to fit most automated machinery and machine controllers; therefore the figures do not follow the standard UML guidelines for depiction of software flow.

Procedural

Model

Operation (s)

Recipe

Procedure (s)

Phases

Procedural

Model

Operation (s)

Recipe

Procedure (s)

Phases

Operation (s)

Process

Stage (s)

Actions

Process

Model

Operation (s)

Process

Stage (s)

Actions

Process

Model

Unit (s)

Area (s)

Cell (s)

Equipments

Modules

Physical

Model

Plant (s)

Enterprise

Unit (s)

Area (s)

Cell (s)

Equipments

Modules

Physical

Model

Plant (s)

Enterprise

Activity

Model

Process Management

Unit (s) Supervision

Process

ControlP

roduction,

Pla

nnin

g a

nd

Schedu

ling

Recip

es

Managem

ent

Info

rmation

Managem

ent

Activity

Model

Process Management


Process

ControlP

roduction,

Pla

nnin

g a

nd

Schedu

ling

Recip

es

Managem

ent

Info

rmation

Managem

ent

4.1.2. TR88 / PackML

If automated machinery is modelled in an ISA-S88 physical hierarchy, it is possible that a machine can represent the unit level in this hierarchy; It also known as PackML standard.

Procedural

Model

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲▼ ▲▼ ▲▼ ▲▼ ▲

Stations

▼ ▲▼ ▲

▼ ▲▼ ▲▼ ▲▼ ▲

Stations

▼ ▲▼ ▲▼ ▲ ▼ ▲

Machine(s)

▼ ▲ ▼ ▲

▼ ▲ ▼ ▲

Machine(s)

▼ ▲ ▼ ▲▼ ▲▼ ▲

Line(s)

▼ ▲▼ ▲

▼ ▲▼ ▲

Line(s)

▼ ▲▼ ▲

Activity

Model

Process Management


Process

Control

Pro

duction,

Pla

nnin

g a

nd

Schedulin

g

Recip

es

Managem

ent

Info

rmation

Managem

ent

Unit (s)

Area (s)

Cell (s)

Equipments

Modules

Physical

Model

Plant (s)

Enterprise

Unit (s)

Area (s)

Cell (s)

Equipments

Modules

Physical

Model

Plant (s)

Enterprise




4.1.2.1. Line

A Line (Cell) contains all of the Machines (Unit), Station (equipment) and Actuator (module) required to make one or more batches.

Process control activities must respond to a combination of control requirements using a variety of methods and techniques. Requirements that cause physical control actions may include responses to process conditions or to comply with administrative requirements.

A frequently recognized subdivision of a Line (Cell) is the train. A train is composed of all Machines (Unit) and other Stations (equipment) that may be utilized by a specific batch. A batch does not always use all the Stations (equipment) in a train. Furthermore, more than one batch and more than one product may use a train simultaneously. The order of equipment actually used or expected to be used by a batch is called the path. Although a Line (Cell) may contain more than one train, no train may contain equipment outside the boundaries of the Line (Cell).

A Line is a logical grouping of equipment that includes the equipments required for production of one or more batches. It defines the span of logical control of one set of process equipments within an area. The existence of the Line allows for production scheduling on a Line basis, and also allows for Line-wide control strategies to be designed. These Line-wide control strategies might be particularly useful in emergency situations.

4.1.2.2. Machine

A Machine (unit) is made up of Stations (equipment) and Actuators (module). The Actuators (module) that make up the Machine (unit) may be configured as part of the Machine (unit) or may be acquired temporarily to carry out specific tasks.

One or more major processing activities can be conducted in a Machine (unit). It combines all necessary physical processing and control Stations (equipment) required to perform those activities as an independent Station (equipment) grouping. It is usually centred on a major piece of processing Stations (equipment). Physically, it includes or can acquire the services of all logically related Stations (equipment) necessary to complete the major processing task(s) required of it. Machines (unit) operate relatively independently of each other.

A Machine (unit) frequently contains or operates on a complete batch of material at some point in the processing sequence of that batch. However, in other circumstances it may contain or operate on only a portion of a batch. This standard presumes that the Machine (unit) does not operate on more than one batch at the same time.

4.1.2.3. Station

Physically, the Station (equipment) may be made up of Actuators (module) and subordinate Stations (equipment). A Station (equipment) may be part of a Machine (unit) or a stand-alone Stations (equipment) grouping within a line. If engineered as a stand-alone Station (equipment) grouping, it can be an exclusive-use resource or a shared-use resource.

A Station (equipment) can carry out a finite number of specific minor processing activities such as dosing and weighing. It combines all necessary physical processing and Actuators (module) required to perform those activities. Functionally, the scope of the Station (equipment) is defined by the finite tasks it is designed to carry out.

4.1.2.4. Actuator

An Actuator (module) is typically a collection of sensors, probes, valves, motors, other Actuators (module), and associated Stations (equipment) interlocks that, from the point of view of control, is operated as a single entity. An Actuator (module) can also be made up of other Actuator (module). For example, a header Actuator (module) could be defined as a combination of several on/off automatic block valve.

Some examples of Actuators (module) are

a regulating device consisting of a transmitter, a controller, and a control valve that is operated via the set point of the device;

a state-oriented device that consists of an on/off automatic block valve with position feedback switches, that is operated via the set point of the device;

A header that contains several on/off automatic block valves and that coordinates the valves to direct flow to one or several destinations based upon the set point directed to the header actuator.

Note: Actuators (module) do not perform procedural control, only imperative (ISA-S88 §5.2.2.4.2).




4.1.3. Physics

The hierarchy's process tree complies with the P&ID tagging:

Line, 1 project title.

Machine, _Mn, 3 digits.

Station _Mn_Ss, 6 digits.

Actuators, _Mn_Ss_Aa, 9 digits.

The result is a total discrimination on each component based on their hierarchy level. This open approach makes also possible to treat sub-machine(s) and sub-station(s).

4.1.4. Configuration

There is no difference between the physical components and the project written data:

Line, 1 directory

Machine, 1 file.

Station, 1 machine file form.

Actuator, 1 station form column.

One to one link between physical components and configured components.

4.1.5. Programs

There is no difference between the physical components, the project written data and the PLC's programs organization of use (POU's):

Line, 1 PLC.

Machine, 1 PLC's task.

Station, 1 task program.

Actuator, 1 program rung.

One to one link between physical components, written components and coded items.

...

–

+ Machine _00

Machine _01

+ Station _01_00

Station _01_01–

Station _01_02 • Program Tags• Program Logic

–Station _01_02 • Program Tags• Program Logic

–

–

Line _A

Line _B

+

Sub. _01_010+

▼ ▼ ▲embedded within stations

▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲▼ ▲▼

▲ ▼ ▼ ▲ ▲▼ ▲▼ ▲▲

Stations

▼ ▲▼ ▲▼ ▲ ▼ ▲

Machine (s)

▼ ▲ ▼ ▲▼ ▲▼ ▲

Line (s)

▼ ▲▼ ▲

Configuration _00

–

+Configuration _01

Main form _01Tags List _01

+ Sub form _01_00

Sub form _01_01

Sub form _01_02• Actuators List• Station Sequences

–

–

Project _A

Project _B

+

Sub form _01_010+

▼ ▼ ▲

embedded within stations

▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲▼ ▲▼

▲ ▼ ▼ ▲ ▲▼ ▲▼ ▲▲

Stations

▼ ▲▼ ▲▼ ▲ ▼ ▲

Machine (s)

▼ ▲ ▼ ▲▼ ▲▼ ▲

Line (s)

▼ ▲▼ ▲

+

• Stations List• Mach. Sequences

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲▼ ▲▼ ▲▼ ▲▼ ▲

Stations

▼ ▲▼ ▲▼ ▲ ▼ ▲

Machine (s)

▼ ▲ ▼ ▲▼ ▲▼ ▲

Line (s)

▼ ▲▼ ▲




▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲▼ ▲▼ ▲▼ ▲▼ ▲

Stations

▼ ▲▼ ▲▼ ▲ ▼ ▲

Machine (s)

▼ ▲ ▼ ▲▼ ▲▼ ▲

Line (s)

▼ ▲▼ ▲

Maintenance

Manual

Emulation

Producing

Process Management

Pro

duction,

Pla

nnin

g a

nd

Schedulin

g

Recip

es

Managem

ent

Info

rmation

Managem

ent

4.1.6. Machine Modes

A Unit/Machine control mode is an ordered subset of states, state commands, and state transitions that determines the strategy for carrying out a unit/machine’s process. Typical Unit control modes are Automatic, Semi-Auto, Manual, Index, Jog, Purge, Clean, Dry Cycle, etc. The distinguishing elements between these Unit control modes are the selected subset of states, state commands, and state transitions.

4.1.6.1. Producing

This represents the mode which is utilized for routine production. The machine executes relevant logic in response to commands which are either entered directly by the operator or issued by another supervisory system. The Base State model below can be used to define a Producing mode that is used in order to deliver control of routine processing and production. It is recognized that machines also require maintenance, calibration, and setting up. To address this requirement two example modes of operation are shown below: Maintenance and Manual.

4.1.6.2. Maintenance

This mode may allow suitably authorized personnel the ability to run an individual machine independent of other machines in a production line. This mode would typically be used for alarm-finding, machine trials, or testing operational improvements. This mode would also allow the speed of the machine to be adjusted (where this feature is available).

It is expected that, because the machine will generally operate in its usual manner, it will need to undergo some or all of its routine starting up procedures. Maintenance mode will follow a recognized unit state model.

4.1.6.3. Manual-Emulation

Manual mode provides suitably authorized personnel the ability to operate individual subordinate equipment controls (such as actuator) within the machine under manual pushbutton control. Such controls in this mode may be on a "hold-to-run" basis such that removal of the run signal will cause the actuator to be stopped. The ability to perform specific functions will be dependent upon mechanical constraints and interlocks. Manual mode will be of particular use for setting up the machine to work.

This provides direct control of individual machine modules. This feature is available depending upon the mechanical constraints of the mechanisms being exercised. This feature may be used for the commissioning of individual actuators, verifying the operation of synchronized actuators, testing the actuator as a result of modifying parameters, etc...

Emulation refers to the ability of a program to emulate (imitate) physical device, in this mode, the time response emulation that is embedded in every actuator could be enabled; it means some machine equipments tune-up could be done even with some missing parts.

4.1.6.4. Purge

User mode to empty the machine (i.e. for cleaning).

4.1.6.5. Dry Cycle

User mode to execute without parts entering in the machine.

4.1.6.6. Single Cycle

User mode to execute only one cycle and ask operator for next one.

4.1.6.7. Limp Track

User mode to execute only on some track(s) (i.e. disable one or more up).

4.1.6.8. Limp Nest

User mode to execute only on some nest(s) (i.e. disable one or more nest).




4.1.7. Machine States

A Unit/Machine state completely defines the current condition of a machine. A Machine state is expressed as an ordered procedure, or programming routine, that can consist of one or more commands to other procedural elements or equipment entities, or consist of the status of a procedural element or equipment entity, or both. In performing the function specified by the state the machine state will issue a set of commands to the machine procedural elements or equipment entities which in turn can report status. The machine state will perform conditional logic which will either lead to further execution within the current machine state or cause a transition to another state. The machine state is the result of previous activities that had taken place in the machine to change the previous state.

Only one major processing activity may be active in one machine at any time. The linear sequence of major activities will drive a strictly sequentially ordered flow of control from one state to the next state – no parallel states operating on the same equipment entity are allowed to be active in one machine at the same time.

▼ ▲ ▼ ▲

Machine(s)

▼ ▲ ▼ ▲

▼ ▲▼ ▲

Line(s)

▼ ▲▼ ▲

Suspend

Stopped ExecuteStarting

Reseting Susping

Mo

des

Ch

ang

e

Held HoldingAborting

Idle

Stoping

Aborted

Suspend


Reseting Susping

Mo

des

Ch

ang

e


Idle

Stoping

Aborted

Types of States, For the purposes of understanding three machine state types are defined:

o Acting State: A state which represents some processing activity. It implies the single or repeated execution of processing steps in a logical order, for a finite time or until a specific condition has been reached. In ISA-88 these are referred to transient states, those states ending in “-ing”.

o Wait State: A state used to identify that a machine has achieved a defined set of conditions. In such a state, the machine is maintaining a status until transitioning to an Acting state or the Dual state. In ISA-88 this was referred to as a Final or Quiescent state.

o Dual State: A Wait state that is causing the machine to behave as in an Acting state. The Dual state is representative of a Machine state that can be continuously transitioning between Acting and Waiting, and Looping, as defined by the logical sequence required. As noted in ISA-88, the Execute, or Running state, is a Transient state. This Machine state has been re-characterized to also include the diversity of operation found in packaging and discrete machines.

4.1.7.1. Aborting

This acting state can be entered at any time in response to E-Stops, Unsafe-Enclosures or on the occurrence of a machine alarm defined in the abort range. The aborting logic will bring the machine to a rapid safe stop. It will also provide a signal to initiate the ABORTED State.

4.1.7.2. Aborted

This wait state maintains machine to be tripped by its safety system; all high energy equipments are powered-off and the enclosures are unlocked; subsequently any manual intervention by opening enclosures to correct and reset the detected machine alarm could take place here. The machine can only exit the ABORTED state after an explicit STOP command; this is the way to lock enclosures.

4.1.7.3. Stopping-Clearing

This acting state can be entered at any time in response to Stop-Button or on the occurrence of a machine alarm defined in the stop range. This stopping state executes the logic which brings the machine to safe conditions by checking-locking enclosures and then power-on every component. When complete or after pending alarms acknowledgment (i.e. "CLEAR" command made by Start-button), it provides a signal to initiate the STOPPED State.




4.1.7.4. Stopped

This wait state means machine is powered, safe and stationary after completing the STOPPING state (Enclosures locked). All communications with other systems are functioning (if applicable). A START command will cause the acknowledgement of pending alarms and an exit from STOPPED to the RESETTING state. An ABORT command will cause an exit from STOPPED to ABORTING; this is the way to unlock enclosures.

4.1.7.5. Resetting

This acting state is the result of a START command from the STOPPED state. RESETTING will typically place the machine in a kind of "HOME" state where components are ready to execute process. When complete, it provides a signal to initiate IDLE state.

4.1.7.6. Idle

This wait state indicates that RESETTING is complete ("HOMED"). This state maintains the machine conditions which were achieved during the RESETTING state, and performs operations required when the machine is in IDLE.

4.1.7.7. Starting

This acting state is the result of a maintained START command (local or remote) from the IDLE, SUSPENDED or HELD states that causes machine to sound a horn during few second before providing a signal to bring machine to EXECUTE; if the maintained START command is shortened then it will provide a signal to initiate the IDLE state instead.

4.1.7.8. Execute

This dual state means machine is processing materials it is deemed to be executing or in the EXECUTE state. Different machine modes will result in specific types of EXECUTE activities. For example, if the machine is in the Production mode, the EXECUTE will result in products being produced, while in Purge mode the EXECUTE state refers to the action of cleaning the machine.

4.1.7.9. Holding

This acting indicates machine detects an internal equipment alarm or any internal material in-feeds lack (i.e., container feed, beverage feed, crown feed, lubricant feed, etc.) or when the HOLD command is used to start HOLDING logic which brings the machine to a controlled stop or to a state which represents HELD for the particular unit control mode. The HOLD command offers the operator a safe way to intervene manually in the process (such as removing a broken bottle from the in-feed) and restarting execution when conditions are safe. To be able to restart production correctly after the HELD state, all relevant process set-points and return status of the procedures at the time of receiving the HOLD command must be saved in the machine controller when executing the HOLDING procedure.

4.1.7.10. Held

The wait HELD state holds the machine's operation while material blockages are cleared, or to stop throughput while a downstream problem is resolved, or enable the safe correction of an equipment alarm before the production may be resumed.

4.1.7.11. Suspending

This acting state is a result of a change in monitored conditions due to process conditions or factors. The trigger event will cause a temporary suspension of the EXECUTE state. SUSPENDING is typically the result of starvation of machine upstream incoming or downstream outgoing blocked that prevents the machine from EXECUTE continued steady production. During the controlled sequence of SUSPENDING the machine will transition to a SUSPENDED state. The SUSPENDING state might be forced by the operator.

4.1.7.12. Suspended

This wait state indicates machine may be running at a relevant set point speed, but there is no product being produced while the machine is waiting for external process conditions to return to normal. When the offending process conditions return to normal, the SUSPENDED state will transition to STARTING and hence continue towards the normal EXECUTE state.




▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Cmd:=1

Cmd:=0Sts=0

Alm1=1

Alm0=1

Sts=1Cmd:=1

Cmd:=0Sts=0

Alm1=1

Alm0=1

Sts=1Cmd:=1

Cmd:=0Sts=0

Alm1=1

Alm0=1

Sts=1

4.1.8. Station States

▼ ▲▼ ▲▼ ▲▼ ▲

Stations

▼ ▲▼ ▲ Reseting

Exec.

Aborting Idle

Reseting

Exec.

Aborting Idle

4.1.8.1. Aborting

This acting state can be entered at any time in response to E-Stops, Unsafe-Enclosures or on the occurrence of any alarm. The aborting logic will bring the station to a rapid safe stop. When complete it provides a signal to initiate IDLE State.

4.1.8.2. Resetting

This acting state is the result of a RESET command from the IDLE state. RESETTING will typically place the station in a kind of "HOME" state where components are ready to execute process. When complete, it provides a signal to initiate IDLE state.

4.1.8.3. Idle

This wait state maintains the stations conditions which were achieved in previous acting state, and performs operations required when the station is in IDLE.

4.1.8.4. Execute

This acting state means the station is processing one material cycle and when complete providing a signal to initiate IDLE state.

4.1.9. Actuator States

4.1.9.1. Cmd:=1

This acting state Enables the actuator output in conjunction with time-out control; if input feedback is right then it provides signal to initiate "Sts=1" state; however if time is over before actuator input feedback is right then it provides signal to initiate "Alm1=1" state.

4.1.9.2. Alm1=1

This wait state maintains actuator to be in safe position by DISABLING the actuator physical output; the only way to leave the "Alm1=1" state is the "Cmd_Ack" command to go back to "Cmd:=1" state.

4.1.9.3. Sts=1

This wait state maintains the actuator output enabled and performs operations required to check actuators input feedback PRESENCE; The "Cmd:=0" command can end "Sts=1".

4.1.9.4. Cmd:=0

This acting state Disables the actuator output in conjunction with time-out control; if input feedback is right then it provides signal to initiate "Sts=0" state; however if time is over before actuator input feedback is right then it provides signal to initiate "Alm0=1" state.

4.1.9.5. Alm0=1

This wait state maintains actuator to be in safe position by DISABLING the actuator physical output; the only way to leave the "Alm0=1" state is the "Cmd_Ack" command to go back to "Cmd:=0" state.

4.1.9.6. Sts=0

This wait state maintains the actuator output disabled and performs operations required to check actuators input feedback ABSENCE; The "Cmd:=1" command can end "Sts=0".




Programs(Machines, Stations, etc...)

Global

Local

Platform

4.2. UML's Models

4.2.1. Object Oriented

Structured Programming:

With this architecture most of the code instructions takes place in the so called "Platform"; most of this instructions are used in functions called by machines and stations programs; it is very difficult to delimit the data context so any test is painful; this architecture means big efforts to comply to any customer required exception with high risk in side effects; the worst constraint is the jarring to heterogeneous programs mix (multi sources providers direct integration).

Object Oriented Programming

The basic result of an object oriented software platform is the tremendous reduction of the code instructions used by the platform itself; most of the codes take place in objects directly instantiated in the machines or stations programs; it means light interdependence between programs and platform; it means easy customisation and heterogeneous programs mixing.

4.2.2. UML's Quatuor

The Komax SW_Platform complies with Object Oriented Programming principles in order to implement Gamp guide lines while ISA-S88 figures do not follow the standard UML guidelines; the following paragraphs depict SW_Platform with 4 UML perspectives:

The object diagram in UML is a diagram that shows a complete or partial view of the structure of a modelled system at a specific time.

The state diagram describes the behaviour of a programmed device or other process works such that an entity or each of its sub-entities are always in exactly one of a number of possible states and where there are well-defined conditional transitions between these states.

The sequence diagram is a kind of interaction diagram that shows how processes operate with one another and in what order. It is a construct of a Message Sequence Chart. A sequence diagram shows object interactions arranged in time sequence. It depicts the objects and class involved in the scenario and the sequence of messages exchanged between the objects needed to carry out the functionality of the scenario. Sequence diagrams typically are associated with use case realizations in the Logical View of the system under development.

The class diagram is the main building block in object oriented modelling. It is used both for general conceptual modelling of the systematic of the application and for detailed modelling translating the models into programming code. The classes in a class diagram represent both the main objects and/or interactions in the application and the objects to be programmed.

There are others UML's diagrams that could be used to depict software, but those four could make it.

Public

Private

Programs(Machines, Stations, etc...)

Platform




4.2.3. Objects Diagram

A machine is an aggregation of stations; and the stations are also aggregation of actuators.

Machine and stations contain the "Administration" data, while actuators do not.

Those "Administration" data are the machine "Public" commands, parameters, status, reports, statistics, accumulators, etc...

Those can be attached to tracks (machine side) and/or nests (on fixture side or conveyed pucks or pallets)

4.2.4. States Diagram

The m achine specific program only contains instructions to drive connected stations; so it only needs the same states as any stations programs.

The "Administration" program for a machine is driven by the machine states diagram that interacts with the "rest of the world" including the operator, see "Machine States" §5.1.7.

The stations programs could do their job with 3 acting states and 1 wait state; see "Station States" §5.1.8.

The actuators could do their job with 2 acting states and 4 wait states: see §5.1.9.

4.2.5. Sequential Diagram

Depending on the command "Exec" sent by the upper machine program, the station program initiates sequences that would send commands to relevant actuators, then switches to next sequence regarding actuators status, and so on to go through every defined sequence up to the completion of the current cycle that initiates the status "Idle".

_Mn_00_00 : Act _Mn_00_01 : Act _Mn_00_AA : Act



_Mn_Ss_00 : Act _Mn_Ss_01 : Act _Mn_SS_AA : Act

_Mn_00 : Station

_Mn_01 : Station

_Mn_02 : Station_Mn_02 : Station

_Mn_Ss : Station

_Mn_Machine

Admin

Admin

Admin

Admin

Admin

_Mn_AdminAdmin Admin

_Tracks _Nests

_Mn_SS : Station

_Mn_SS_00 : Act _Mn_SS_01 : Act _Mn_SS_AA : Act

_Mn_Machine

Sts_On

Cmd_On Cmd_Off

Cmd_On Cmd_On

Cmd_OffCmd_Off

ÊxecÊxec

Idle

Sts_Off

Sts_On Sts_On

Sts_OffSts_Off

_Mn_Xx : Station

_Mn_Ss_00 : Act _Mn_Ss_01 : Act _Mn_Ss_Aa : Act

_Mn_Machine

Aborting

Reseting

Idle

Exec.

Aborting

Reseting

Idle

Exec.

Aborting

Reseting

Idle

Exec.

Aborting

Reseting

Idle

Exec. Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

_Mn_AdminSuspend


Reseting Susping

Mo

des

Ch

ang

e


Idle

Stoping

Aborted

Suspend


Reseting Susping

Mo

des

Ch

ang

e


Idle

Stoping

Aborted

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On




4.2.6. Class Diagram

The result of the 3 previous analyses on objects, states and sequential diagrams is this class diagram.

Act_Cam

main classspecialization

Act_Cam


Machine

0...0...

Act_Num


Act_Num


Act_Bin


Act_Bin


Act_Pls


Act_Pls


Act_AA Came0...

Act_AA Came0...

0...0...

Act_AA Numeric0...1

Act_AA Numeric0...1

Act_AA Binary0...

1...

Act_AA Binary0...

1...

Act_AA Pulse0...

Act_AA Pulse0...

specialization

specialization

main class

Man_Prog

specialization

specialization

main class

Man_Prog

main class

Man_Prog

main class

Man_Nest[Up]1...up

main class

Man_Nest[Up]1...up

1...

Station

1...

Station

main class

Man_Adm

1...main class

Man_Adm

1...

main class

Man_Track[Up]

1...up main class

Man_Track[Up]

main class

Man_Track[Up]

1...up

Typ_Batch

Interface

Typ_Recip

Interface

Typ_Batch

Interface

Typ_Recip

Interface

4.2.6.1. Hierarchy

Machine is an Admin(s), sub-machine(s) or station(s) aggregation.

Station is a sub-station(s) or actuator(s) aggregation.

Actuators are some main class specializations.

4.2.6.2. Specialization

Machine and Stations are "Mgr_Prog" and "Mgr_Adm" main class specialization.

Stations are "Mgr_Track" and "Mgr_Nest" main class specialization.

Actuators are "Act_xxx" main class specializations.

4.2.6.3. Main Class

Mgr_Adm is statistics and efficiency calculations for "oper", "shift" and "batch" real time OEE.

Mgr_Prog is states and sequences manager of any program (machine and station).

Mgr_Track is statistics and effectiveness calculations for track (track's real time OEE).

Mgr_Nest is statistics and effectiveness calculations for nest (nest's real time OEE).

Act_Bin is states control for binary component (cylinder, gate, conveyor, etc...)

Act_Cam is states control for camshaft component (angular axis, came follower, etc...)

Act_Num is states control for numeric component. (Linear axis, heater, flow meter, etc...)

Act_Pls is states control for hysteretic component. (Feeder level, flip-flop, tick control, etc...).

4.2.6.4. Interfaces

Typ_Recip is a user defined type for storing and restoring parameters and camshaft arrays.

Typ_Batch is a user defined type for manufacturing execution system to control multiple machines.




4.2.7. Class & Interfaces

4.2.7.1. Mgr_Adm

Manager for Statistics (Machine only); it includes logic to calculate real time OEE.

The tag naming conventions took place in §5.4.1.

Mgr_Prog, as reference to program manager.

Cfg_TrackQty, config. to define tracks quantity per station.

Cfg_OEEOff, config. to disable or reset rtOEE calculation.

Cmd_State, command to give current machine state.

Cmd_Sec, command to trig second pulse.

Rep_TmrTotal, report to view total time accumulation.

Rep_TmrExec, report to view operating time accumulation.

Rep_CtrBad, report to view aborting sequence quantity.

Rep_CtrTotal, report to view total sequence quantity.

Rep_CtrGood, report to view good sequence quantity.

Rep_Availability, report to view current OEE availability.

Rep_Performance, report to view current OEE performance.

Rep_Quality, report to view current OEE quality.

Rep_OEE, report to view current real time OEE value.

Sts_GoodID, status to indicate last execution was good (ID.0 for track #0, ID.1 for track #1, etc...).

Sts_BadID, status to indicate last execution was aborted (ID.0 for track #0, ID.1 for track #1, etc...).

...

Sample of an admin with "Oper", "Shift" and "Batch" defined.

Man_Adm

main class

Man_ProgPar_TimeIdealCfg_TrackQtyCfg_OEEOff Cmd_StateCmd_Sec

Rep_TmrTotalRep_TmrExecRep_CtrTotalRep_CtrGood

Sts_GoodIDSts_BadID

Rep_Avail.Rep_Perf.Rep_QlityRep_OEE




4.2.7.2. Mgr_Prog

Manager for Program (Machine or Station); it includes a states and a sequences logic.


Cfg_Safe, config. is safe means module in safety conditions.

Cfg_ActExe, config. to enable actuators subroutine.

Cfg_Emulate, config. to enable emulation.

Cfg_SeqStep, config. to enable step-by-step sequences.

Par_TimeIdeal, parameter to define exec. ideal cycle time.

Cmd_SeqOns, command one shot under Step-by-Step.

Cmd_State, command to request state change:

o 1 = Abort

o 2 = Reset

o 4 = Exec

o n = Custom

Sts_State, status to indicate current state:

o 1 = Abort

o 2 = Reset

o 4 = Exec

o n = Custom

Sts_Seqp, status to indicate sequence previously executed.

Sts_Seq, status to indicate current sequence.

Sts_StateOns, status to indicate state change request.

Sts_SeqOns, status to indicate sequence change threshold.

Sts_SeqExe, status to indicate sequence is free to execute.

Sts_Emulate, status to indicate program under emulation mode.

Sts_NakAlm, status to indicate no alarm acknowledgement pending.

Sts_NoAlm, status to indicate no alarm pending.

Sts_dTing, status to indicate acting state not complete.

Sts_Abort, status to indicate abort is pending.

Sts_Safe, status to indicate sequence in safe mode.

Sts_Idle, status to indicate acting state complete.

Rep_dT, report to view acting state duration value.

...

Sample of a program defined.

Man_Prog

main class

Cfg_SafeCfg_ActExeCfg_EmulatePar_TimeIdealCmd_SeqOnsCfg_SeqStepCmd_State

Sts_StateSts_SeqpSts_Seq

Sts_StateOnsSts_SeqOnsSts_SeqExe

Sts_EmulateSts_NakAlmSts_NoAlmSts_dTingSts_Abort

Sts_SafeSts_IdleRep_dT




4.2.7.3. Mgr_Track

Manager for Tracks (Machine or Station); it includes logic to calculate real time OEE and consecutive errors test. The tag naming conventions took place in §5.4.1.


Par_MaxCons, parameter to define consecutive maximum.


Cfg_ConsOff, ccnfig. to disable or reset consecutive test.

Rep_TmrAbort, report to view aborting time accumulation.

Rep_TmrExec, report to view executing time accumulation.



Rep_CtrExec, report to view executing sequence quantity.

Rep_Consec, report to view current consecutive value.


Sts_Enable, status to indicate current track is enable.

Sts_AlmCons, status to indicate consecutive alarm.

Sts_Good, status to indicate last execution was good.

Sts_Bad, status to indicate last execution was aborted.

...

Sample of a station with Track0 on Side0 and Track1 on Side1 defined.

Man_Track

main class

Man_ProgPar_MaxConsCfg_ConsOffCfg_OEEOff

Rep_TmrAbortRep_TmrExecRep_CtrGoodRep_CtrExecRep_CtrBad

Sts_EnableSts_AlmCons

Sts_GoodSts_Bad

Rep_ConsecRep_OEE




4.2.7.4. Mgr_Nest

Manager for Nest statistics (Station); it includes logic to calculate real time OEE.

The tag naming conventions took place in §5.4. 1.


Adm_NestID, Admin reference that gives nest ID offset.

Cfg_Station, config to define the current station number.








Sts_Station, status to indicate last good execution station.

Sts_NestID, status to indicate last good execution.

Sts_PartID, status to indicate the nested part ID number.

Sts_Enable, status to indicate current nest is enable.

Sts_Nesty, status to indicate nest filled with some part.

Sts_Good, status to indicate last execution was good.


...

Sample of a station with only one nest defined.

Man_Nest

main class

Man_ProgAdm_NestIDCfg_StationCfg_OEEOff

Rep_TmrAbortRep_TmrExecRep_CtrGoodRep_CtrExecRep_CtrBad

Sts_EnableSts_NestySts_Good

Sts_Bad

Sts_StationSts_NestIDSts_PartIDRep_OEE




4.2.7.5. Act_Bin

Act_Bin is states control for binary components (cylinder, gate, conveyor, etc...).


Par_TimeOut, parameter to define movement timeout.

Cfg_Emulate, config. to enable or disable emulation.


Cfg_NoAlm, config. to disable or enable alarming.

Cfg_Mirror, config. to make command mirroring input; Probe or Gauge behaviour instead of real active actuator.

Cmd_Nak, reverse command to acknowledge pending alarm.

Cmd_Ack, command to acknowledge pending alarm.

Cmd_Out, command to enable/disable output.

Cmd_Inp, command to read from physical input.

Rep_TmrExec, report to view acting state time accumulation.

Rep_CtrExec, report to view acting states quantity.

Rep_CtrAlm, report to view alarming states quantity.


Rep_dT, report to view movement duration value.

Sts_Alm0, status to indicate Alarm because of input not OFF

Sts_Alm1, status to indicate Alarm because of input not ON

Sts_Done, status to indicate time out over.

Sts_Out, status to indicate what should be send to physical output

Sts_Inp, status to indicate what is the status of physical input when not in emulation

...

Sample of a binary actuator specialization.

Act_Bin

main class

Par_TimeOutCfg_EmulateCfg_OEEOffCfg_NoAlmCfg_MirrorCmd_NakCmd_AckCmd_OutCmd_InpRep_TmrExecRep_CtrExecRep_CtrAlm

Sts_Alm0Sts_Alm1Sts_Done

Sts_OutSts_Inp

Rep_OEERep_dT




4.2.7.6. Act_Cam

Act_Cam is states control for camshaft components (angular axis, came follower, etc...).



Cfg_CamRng, config. to define the came range (360°).

Cfg_CamAnte, config. to define the angular value to anticipate.

Cfg_CamPost, config to define the angular value to postpone.

Cfg_SlowPar, config for slow timeout ratio vs normal timeout.




Cfg_Mirror, config. to make command mirroring input; Probe or came follower behaviour instead of real active actuator.

Cmd_Loop, command to request a full revolution cycle.

Cmd_Hold, command to request an immediate motion stop.



Cmd_Out, command to set value for output.

Cmd_Sp, command to switch between different setpoints.

Cmd_Inn, command to read from physical input.




Rep_Ante, report to indicate current anticipated window angle.

Rep_Post, report to indicate current postponed window angle.



Sts_Alm0, status to indicate Alarm because of angular value still before CamAnte

Sts_Alm1, status to indicate Alarm because of angular value still after CamPost.


Sts_Rev, status to indicate reverse motion.

Sts_Slow, status to indicate slow motion.

Sts_Out, status to indicate what should be send to physical output.

Sts_Inp, status to indicate the "in position" Boolean flag when not in emulation.

Sts_Inn, status to indicate the physical input value when not in emulation.

...

Sample of a camshaft follower specialization.

Act_Cam

main class

Par_TimeOutCfg_CamRngCfg_CamAnteCfg_CamPostCfg_SlowParCfg_EmulateCfg_OEEOffCfg_NoAlmCfg_MirrorCmd_LoopCmd_HoldCmd_NakCmd_AckCmd_OutCmd_SpCmd_Inn

Rep_TmrExecRep_CtrExecRep_CtrAlm

Sts_Alm0Sts_Alm1Sts_DoneSts_SlowSts_RevSts_OutSts_InpSts_Inn

Rep_AnteRep_PostRep_OEE

Rep_dT




4.2.7.7. Act_Num

Act_Num is states control for numeric component. (Linear axis, heater, flowmeter, etc...).



Cfg_Minimum, config. to define the minimum range value.

Cfg_Maximum, config. to define the maximum range value.

Cfg_InpWitdh, config to define the "in position" bandwidth.

Cfg_SlowPar, config for slow timeout ratio vs normal timeout.





Cmd_Hold, command to request an immediate motion stop.



Cmd_Out, command to set value for output.

Cmd_Sp, command to switch between different setpoints.

Cmd_Inn, command to read from physical input.






Sts_Alm0, status to indicate Alarm because of angular value still before CamAnte

Sts_Alm1, status to indicate Alarm because of angular value still after CamPost.


Sts_Slow, status to indicate slow motion.

Sts_Out, status to indicate what should be send to physical output.

Sts_Inp, status to indicate the "in position" Boolean flag when not in emulation.

Sts_Inn, status to indicate the physical input value when not in emulation.

...

Sample of a numeric actuator specialization.

Act_Num

main class

Par_TimeOutCfg_MinimumCfg_MaximumCfg_InpWitdhCfg_SlowParCfg_EmulateCfg_OEEOffCfg_NoAlmCfg_MirrorCmd_HoldCmd_NakCmd_AckCmd_OutCmd_SpCmd_Inn

Rep_TmrExecRep_CtrExecRep_CtrAlm

Sts_Alm0Sts_Alm1Sts_DoneSts_Slow

Sts_OutSts_InpSts_Inn

Rep_OEERep_dT




4.2.7.8. Act_Pls

Act_Pls is states control for hysteretic component (Feeder level, flip-flop, tick control, etc...).


Par_TimeOut, parameter to define threshold absence timeout.

Par_TmrOff, parameter to define down threshold delay.

Par_TmrOn, parameter to define up threshold delay.







Cmd_Out, command to enable/disable output.

Cmd_Inp, command to read from physical input.






Sts_Alm0, status to indicate Alarm because of input not OFF

Sts_Alm1, status to indicate Alarm because of input not ON


Sts_Tick, status to indicate tick state (1/3 of Par_TmrOff), the tick feature gives additional pulses while Sts_Out is off.

Sts_Out, status to indicate what should be send to physical output

Sts_Inp, status to indicate what is the status of physical input when not in emulation

...

Sample of a pulse actuator specialization.

Act_Pls

main class

Par_TimeOutPar_TmrOffPar_TmrOnCfg_EmulateCfg_OEEOffCfg_NoAlmCfg_MirrorCmd_NakCmd_AckCmd_OutCmd_InpRep_TmrExecRep_CtrExecRep_CtrAlm

Sts_Alm0Sts_Alm1Sts_DoneSts_DoffSts_TickSts_OutSts_Inp

Rep_OEERep_dT




Typ_Batch

interface

StoreID

DateProductDescript

MaterialID

AbortStopIdleExecHold

Typ_Recip

interface

RestoreStore

NamePars

Cams

4.2.7.9. Typ_Batch

User Defined Type for manufacturing execution system to control multiple machines.

Abort, request for quick end of batch.

Stop, request for clean end of batch.

Idle, request to activate batch and wait for confirmation from every machine.

Exec, request to enable batch after confirmation from every machine.

Hold, request for storing data and free machines before next exec request.

Store, container to memorize data that would be restored when restarting.

ID, batch ID.

Date, batch date.

Recipe, batch recipe.

Descript, batch description.

MaterialID, raw material ID.

Batch.Idle:=1

Batch.Exec:=1

BatchConf.Alm_Off = 1

Mach.Idle:=1

BatchConf.Cmd_On = 1Recipe Loaded

Mach.Hold:=1

BatchConf.Alm_On = 1

Mach.Exec:=1

BatchConf.Alm_On = 0BatchConf.Alm_Off = 0

Reset Count

Load Recips[ID]

Batch.Idle:=1

Batch.Exec:=1

BatchConf.Alm_Off = 1

Mach.Idle:=1

BatchConf.Cmd_On = 1Recipe Loaded

Mach.Hold:=1

BatchConf.Alm_On = 1

Mach.Exec:=1

BatchConf.Alm_On = 0BatchConf.Alm_Off = 0

Reset Count

Load Recips[ID]

Batch.Hold = 1Batch.Exec = 0

Mach.Hold:=1


Mach.Exec:=1

Batch.Stop = 1 Batch.Abort = 1Batch.Idle = 0

Mach.Idle:=1

Store Count

Restore Count

Reset Count

Mach.Exec = 1

Mach. is free



Mach.Hold:=1


Mach.Exec:=1

Batch.Stop = 1 Batch.Abort = 1Batch.Idle = 0

Mach.Idle:=1

Store Count

Restore Count

Reset Count

Mach.Exec = 1

Mach. is free


4.2.7.10. Typ_Recipe

User Defined Type for storing and restoring parameters and camshaft arrays.

Restore, request to upload memorized parameters and camshafts.

Store, request to download and memorizing parameters and camshafts.

Name, recipe name.

Pars, container to memorize parameters array.

Cams, container to memorize camshaft array.

ID:=n

Recips[ID].Store = 1

Recips[ID] := ParamsRecips[ID].Store:=0

ID:=n

Recips[ID].Restore = 1

Params := Recips[ID]Recips[ID].Restore:=0




Typ_Nest

interface

Rep_TmrExecRep_CtrAbortRep_CtrGoodRep_CtrExec

Rep_OEESts_EnableSts_NestySts_AbortSts_Good

Sts_StationSts_NestIDSts_PartID

4.2.7.11. Typ_Nest

On this platform, there is no need for User Defined Type for nests "shift-register" or "Part-Info" data.







Sts_Enable, status to indicate current nest is enable.

Sts_Nesty, status to indicate nest filled with some part.


Sts_Good, status to indicate las execution was good.

Sts_Station, status to indicate last good execution station.

Sts_NestID, status to indicate last good execution.

Sts_PartID, status to indicate the nested part ID number.

as it is required in structured programming where code and data are splitted:

Lookup[1]

_01_00 : Station_00

_01_01 : Station_01

_01_04 : Station_04

Shift Event

Shift Lookup

Update Reg.

Update Reg.

Nest[1]

Nest[2]

Nest[3]

Nest[4]

Nest[5]

Nest[6]

Nest[7]

Nest[8]

Lookup[2]

Lookup[3]

Lookup[4]

Lookup[5]

Lookup[6]

Lookup[7]

Lookup[8]

Nests Array

(Structure)

On this platform, a collection of nests object could reach the same goal without Typ_Nest.

Under Object Oriented Programming code and data are merged:

_01_00 : Station_00

_01_01 : Station_01

_01_04 : Station_04

Position Update

Station Event

Station Event

Nest[1]

Nest[2]

Nest[3]

Nest[4]

Nest[5]

Nest[6]

Nest[7]

Nest[8]




4.3. Embedded Features

The object oriented programming incites to integrate or to embed most often required features:

Efficiencies calculation.

Software emulation.

Fail safe feature.

Some other could be added in the future...

4.3.1. Real Time OEE for Ahead Diagnosis

Every SW_Platform components embed their own real time Overall Equipment Effectiveness calculation based on real time TR88 OEE normative reference. This feature lets user find out when the machine is low in efficiency, which station is involved and finally which actuator is making trouble; it helps more than making diagnosis from alarms messages waterfalls.

4.3.1.1. TR88 Theory

From ISA-TR88, Overall Equipment Effectiveness (OEE) is a measure comparing how well manufacturing equipment is running compared to the ideal plant. The resulting measurement is expressed as the ratio of the actual output of the equipment divided by the maximum possible output of the equipment under ideal conditions. OEE is calculated by multiplying three independently measured values: Availability, Performance Rate, and Quality Rate. The fundamental OEE definition is defined as an availability ratio multiplied by a performance ratio multiplied by a quality ratio.

OEE is often displayed as a waterfall object in which the major components of Availability, Performance, and Quality are displayed graphically. Losses are further subdivided into categories within the OEE sections.

Total Time

Scheduled Stops

Planed Production Time

Fault Stops

Operating Time

Suspending

Reduced Speed

Unscheduled Stops

Total Pieces Time Credit

Startup Rejects

Good Pieces Time Credit

Processed Rejects

Curtailment

Performance = Total Pieces / (Operating Time x Rate)

Availability = Operating Time / Planned Production Time

Quality = Good Pieces / Total Pieces

O E E = (Good_Pieces x 60) / (Planed_Production_Time x Machine_Rate_per_Min)

Calculating a Real-Time OEE in a Machine Controller or HMI

This example is a simple real-time calculation based upon Pack Tags with data originating from the machine controller. This example will not require historical tracking of information and will show a calculation of OEE since the last time the machine counts and timers were reset in the machine controller. This example is recommended for machine builders and control vendors that want to show a basic OEE on their HMI systems.

The limitation of this calculation will be that it will only be valid for the time period since the last time the counts and times were reset in the machine controller. It will also be invalid if the setup or product of the machine causes the design speed of the machine to change.

OEE = Availability x Performance x Quality




Availability = Operating_Time / Planned_Production_Time

o Planned Production Time is defined as the amount of time that the machine is scheduled to run production. This includes time such as changeover time, unplanned maintenance time, and major breakdowns. For this implementation, it will be assumed that the machine is always scheduled to run. The number of total seconds since the last reset occurred can be obtained using the following tag: UnitName.Admin.AccTimeSinceReset

o Operating Time is defined as the time the machine has been attempting to run production. This should be linked to the time that the machine has been in production mode. The number of seconds in production mode since the last reset occurred can be typically obtained using the following tag:

Performance = Total_Pieces / (Operating_Time x Ideal_Run_Rate / 60)

o Total Pieces is defined as the total pieces that have been brought into the machine from the primary production path. The number of units that have been brought into the machine since the last reset can typically be obtained through the following tag:

o Ideal Run Rate is defined as the maximum rate the machine can run given the current product and setup of the machine. This number may change based upon a product being run on the machine. Should this number change, then the OEE calculation will become invalid. It is suggested that if this number ever change, that a reset on the count and timers should occur. The number of units per minute for the ideal run rate can be obtained using the following tag:

NOTE: Because the unit of time for MachDesignSpeed is in minutes and the operating time is in seconds, there needs to be a unit correction factor in the above equation. We have chosen to divide the MachDesignSpeed by 60 to convert it into units per second. This will keep units consistent in the above equation.

Quality = Good_Pieces / Total_Pieces

o Good Pieces includes only good pieces during the production run. This is the main production processed count of the machine. If a filler, this should be bottles out of the filler. The number of good pieces of production that have been run since the last count reset can be obtained by subtracting the total products processed minus the products that were defective: UnitName.Admin.ProdProcessedCount[#].Count - UnitName.Admin.ProdDefectiveCount[#].Count where the # is typically 0 for both counters as a default. If multiple products are being tracked the index may change.

o Total Pieces is defined as the total pieces that have been brought into the machine from the primary production path. The number of units that have been brought by the following UnitName.Admin.ProdProcessedCount[#].Count tag that could give the last reset time: where the # is typically 0 as a default. If multiple products are being tracked the index may change.

Overall Real-Time OEE Calculation When multiplying Availability, Performance, and Quality the following equation for OEE is produced:

O.E.E. = (Good_Pieces x 60) / (Planned_Production_Time x Ideal_Run_Rate)

or

O.E.E. = Good_Pieces x Ideal_Cycle_Time.01sec / Planned_Production_Time.sec

Limitations of Real-Time OEE Equation

o The above real-time OEE equation is only valid for the time period since the times and counts were last reset in the machine controller. It also becomes invalid if the MachDesignSpeed is ever changed.




4.3.1.2. Mgr_Adm

With SW_Platform, the Mgr_Adm instances located in Admin program is in charge of machine OEE report. The following waterfall diagram shows where state elapsed times are putting in account.

Elapsed time since last clear

Operating Time

Aborting

Total Parts Time Credit

Good Parts Time Credit

Performance = Total Parts Time Credit / Op. Time

Availability = Operating Time / Accumulated Time since last reset

Quality = Good Parts / Total Parts

O E E = Good_Parts x Cycle_Time_Ideal_msec / Time_Since_Last_Clear_dsec

Aborted

Stopping

Stopped

Resetting

Idle

Suspending

Suspended

Starting

Bad Parts

Holding

Held

The upper formula only covers the machine effectiveness and is coded in Mgr_Adm class; this means by default, the effectiveness could be spread in "Oper", "Shift" or "Batch" or more instances. The Cycle_Time_Ideal is in msec and the Time_Since_Last_Clear is in dsec for result in %.

4.3.1.3. Mgr_Track

With SW_Platform, the Mgr_Track instances in station program are in charge of OEE report for one of the station track side. This formula covers station effectiveness and is embedded in Mgr_Track class.

O E E = (Ctr_Good x Cycle_Time_Ideal) / Tmr_Exec

4.3.1.4. Mgr_Nest

With SW_Platform, the Mgr_Nest instances in station program are in charge of OEE report for one of the fixture side. This formula covers nest effectiveness and is embedded in Mgr_Nest class.

O E E = (Ctr_Good / Ctr_Exec) x (1 - (Tmr_Abort / Tmr_Exec) )

4.3.1.5. Act_???

With SW_Platform, every Act_??? instance in actuators sub-programs are in charge of OEE report for each elementary module. This formula is embedded in Act_Bin, Act_Cam, Act_Num and Act_Pls class.

O E E = Time_Out x (Ctr_Exec - Ctr_Alarm) / Tmr_Exec

4.3.1.6. OEEs Supervision

The detailed real-time OEE at every level gives useful information to identify predictable failures. RSLinx Topic Name

SW_Platform

Tag Name Get Value Tag Name Get Value Tag Name Get Value Tag Name Get Value

Diagnostics Station 00 Effectivenenss Operator (User) Effectivenenss Shift Effectivenenss Batch

_01_00_Track.Rep_OEE 75 _01_Admin_Oper.Rep_TmrTotal 9674 _01_Admin_Shift.Rep_TmrTotal 9673 _01_Admin_Batch.Rep_TmrTotal 9672

_01_00_00_RotCam.Rep_OEE 189 _01_Admin_Oper.Rep_CtrTotal 2048 _01_Admin_Shift.Rep_CtrTotal 2048 _01_Admin_Batch.Rep_CtrTotal 2048

_01_00_01_Secu.Rep_OEE 116 _01_Admin_Oper.Rep_Availability 99 _01_Admin_Shift.Rep_Availability 99 _01_Admin_Batch.Rep_Availability 99

_01_00_02_Index.Rep_OEE 116 _01_Admin_Oper.Rep_Performance 106 _01_Admin_Shift.Rep_Performance 106 _01_Admin_Batch.Rep_Performance 106

_01_Admin_Oper.Rep_Quality 75 _01_Admin_Shift.Rep_Quality 75 _01_Admin_Batch.Rep_Quality 75

_01_Admin_Oper.Rep_OEE 78 _01_Admin_Shift.Rep_OEE 78 _01_Admin_Batch.Rep_OEE 78

Diagnostics Station 01 Diagnostics Station 02 Diagnostics Station 03 Diagnostics Station 04

_01_01_Track0.Rep_OEE 100 _01_02_Track0.Rep_OEE 75 _01_03_Track0.Rep_OEE 112 _01_04_Track0.Rep_OEE 88

_01_01_Track1.Rep_OEE 100 _01_02_Track1.Rep_OEE 75 _01_03_Track1.Rep_OEE 112 _01_04_Track1.Rep_OEE 88

_01_01_00_ArmGrip0.Rep_OEE 101 _01_02_00_ArmGrip0.Rep_OEE 101 _01_03_00_RotCam.Rep_OEE 199 _01_04_00_ArmGrip0.Rep_OEE 101

_01_01_01_ArmGrip1.Rep_OEE 101 _01_02_01_ArmGrip1.Rep_OEE 101 _01_03_01_Build0.Rep_OEE 101 _01_04_01_ArmGrip1.Rep_OEE 101

_01_01_02_ArmDown.Rep_OEE 101 _01_02_02_ArmDown.Rep_OEE 101 _01_03_02_Build1.Rep_OEE 101 _01_04_02_ArmDown.Rep_OEE 101

_01_01_03_ArmNum.Rep_OEE 168 _01_02_03_ArmNum.Rep_OEE 168 _01_03_03_Check0.Rep_OEE 101 _01_04_03_ArmNum.Rep_OEE 168

_01_01_04_BodyGate.Rep_OEE 101 _01_02_04_ScrewGate.Rep_OEE 101 _01_03_04_Check1.Rep_OEE 101 _01_04_04_PartConvoy.Rep_OEE 101

_01_01_05_BodyFeed.Rep_OEE 101 _01_02_05_ScrewFeed.Rep_OEE 101

Diagnostics Nest 01 Diagnostics Nest 02 Diagnostics Nest 03 Diagnostics Nest 04

_01_01_Nest0.Rep_OEE 100 _01_02_Nest0.Rep_OEE 45 _01_03_Nest0.Rep_OEE 100 _01_04_Nest0.Rep_OEE 100

_01_01_Nest1.Rep_OEE 100 _01_02_Nest1.Rep_OEE 100 _01_03_Nest1.Rep_OEE 100 _01_04_Nest1.Rep_OEE 44

_01_01_Nest0.Sts_PartID 0 _01_02_Nest0.Sts_PartID 2111 _01_03_Nest0.Sts_PartID 2109 _01_04_Nest0.Sts_PartID 2107

_01_01_Nest1.Sts_PartID 0 _01_02_Nest1.Sts_PartID 2112 _01_03_Nest1.Sts_PartID 2110 _01_04_Nest1.Sts_PartID 2108

24.01.2012SW_Platform DDE DiagnosticsKOMAX MEDTECH Set DiagGet Diag




4.3.2. Emulation for Early De-risking + Fail-Safe for Auto-recovery

Also use as "Fail Safe" feature due to its automatic and safe ability to compensate a failure.

4.3.2.1. Response Time

In signal processing, the impulse response of a dynamic system is its output when presented with an input command signal. More generally, an impulse response refers to the reaction of any dynamic system in response to some external change. In both cases, the impulse response describes the reaction of the system as a function of time (or possibly as a function of some other independent variable that parameterizes the dynamic behaviour of the system).

4.3.2.2. Principle

The SW_Platform integrates the emulation ability directly in the actuator functions; the concept is based on the "embedded time response" where the embedded timer is used to manage the movement time out while not being in emulation mode, or it is used to simulate the input feedback while being in emulation mode.

Additional benefits:

Automatic and safe ability to compensate a failure.

Simulate a part presence for "dry-cycle" purpose for instance.

4.3.2.3. Binary

See the top right sketch that applies to binary components such as cylinder, gate, conveyor, etc...

4.3.2.4. Came

Same as Numeric that applies to camshaft components such as angular axis came follower, etc...

4.3.2.5. Numeric

See the bottom right sketch that applies to numeric components such as linear axis, heater, flow-meter, etc...

4.3.2.6. Pulse

Same As Binary that applies to hysteretic components such as feeder level, flip-flop, tick control, etc...

dT►

╓╜dT►

╓╜ &

& &╖╙&╖╙

Cmd_Out

Sts_Alm

Sts_Inp

Sts_Out Cmd_InpCfg_Emulate

Sts_Done

Cmd_Ack

Cfg_NoAlm

0ff

On

t1 t2dT0ff

On

t1 t2dTOff

On

t1 t2dTOff

On

t1 t2dT

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

%T ►

╓╜%T ►

╓╜ &

Sts_Alm

Cmd_%Out Cmd_%InCfg_Emulate

Sts_Done

dT

Cmd_%Out

&

Sts_%InCmd_Ack

&╖╙&╖╙

Cfg_NoAlm

α

β

t1 t2%T2

min

max

t3 t4 t5

γ

%T3 %T4 %T5

α

β

t1 t2%T2

min

max

t3 t4 t5

γ

%T3 %T4 %T5Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On




4.3.3. Agility for Last Minute Changes

Agility in automation means a combination of specialization ability and flexible aggregation.

4.3.3.1. Double solenoid cylinder

▼▲

▼

▼

▼▼

▼▲ ▲▼

•Open

•Close

•Opened

•Closed

•OpenErr

•ClosErr

▼

▼

▲▼

▼▼

▼▲

▼

▼

▼▼

▼▲ ▲▼

•Open

•Close

•Opened

•Closed

•OpenErr

•ClosErr

▼

▼

▲▼

▼▼

4.3.3.2. Linear axis with limit switches

▼

▼

▼▲

▼

▼

▼▲

•Home

•Setpoint

•Homed

▲

▼

▼

▼

▼

▼

▼

•Getpoint

▲

▼

▼

▼▲

▼

▼

▼▲

•Home

•Setpoint

•Homed

▲

▼

▼

▼

▼

▼

▼

•Getpoint

▲

4.3.3.3. Rotary table

▼

▼

▼▲

▼

▼

▼ ▲

▲

▼

▼

▼▲

▼

▼ ▲▼

▼

▼

▼

▼

▼ ▲

•Start

•Stopped

▼

•Stopping

•Accelerate

•Cruise

•Indexing

•Indexed

•Index

▼

▼

▼▲

▼

▼

▼ ▲

▲

▼

▼

▼▲

▼

▼ ▲▼

▼

▼

▼

▼

▼ ▲

•Start

•Stopped

▼

•Stopping

•Accelerate

•Cruise

•Indexing

•Indexed

•Index




4.4. Configuration Conventions

Private definition (Program tags declaration) FunctionName_KeyCode_Description Ex: "Vision1_Cmd_Abort"

Public definition (Controller tags declaration) _Mn_Sn_Aa_PrivateDefinition (a public tag is a private tag + _Machine_Station_Actuator_ heading) Ex: "_11_26_01_Vision1_Cmd_Abort"

4.4.1. Keys Codes Meanings

Key Code Meaning Description Type(s)

4.4.1.1. Ack Acknowledge Used to send acknowledgement to instruction / function, typically used alarms acknowledgments.

DINT, BOOL

4.4.1.2. Act_ Actuator Used to specify an actuator instruction/function. Act_...

4.4.1.3. Adm, Admin

Administration Used at the machine level beside Cmd and Sts.

"Adm" is the short form of "Admin" that is the short form of "Administration.

Any

4.4.1.4. Alm Alarm Which alarm is occurring within process. This can be either a bit-level or value-level indication. Value-based alarm annunciation allows for a large quantity of alarms to be supported within a single indicator. Bit-level alarming can support multiple alarms simultaneously, but can require a large number of indicators to support all alarm states.

DINT, BOOL

4.4.1.5. Bin Binary Used to specify a binary actuator instruction/function

Act_Bin

4.4.1.6. Cam Camshaft Used to specify a camshaft actuator instruction / function

Act_Cam

4.4.1.7. Cfg Configuration Generally used to designate a value used in configuring how the process within the instruction / functions. This is only occasionally changed. It can be entered from the HMI or as part of a recipe or batch.

DINT, BOOL

4.4.1.8. Clr Clear Generally used to designate a command used to clear accumulators, report or parameters of the process within the instruction/functions.

DINT, BOOL

4.4.1.9. Cmd Command Generally used to as a command input of the instruction/function, either from the operator via the HMI or from the program.

DINT, BOOL

4.4.1.10. Ctl Control Complex PLC 's data structures used to control PLC's specific instruction/function.

CONTROL

4.4.1.11. Ctr Counter Used to accumulate or increment any value. DINT

4.4.1.12. ...ID Identifier Used to merge some Boolean status within an integer.

DINT

4.4.1.13. Inp Input Real-time data used to drive the process within an instruction / function. Generally used to designate a connection to a real input point or a control device (local or external).

DINT, BOOL

4.4.1.14. Log Login "User" User Login status of machine. DINT, BOOL

4.4.1.15. Mgr Manager Used to specify a manager instruction/function Mgr_...




Key Meaning Description Type(s)

4.4.1.16. Mode Mode Mode of the process within the machine DINT

4.4.1.17. Nak None Acknowledge

Used to send none acknowledgement to instruction / function, typically used alarms double acknowledgments (none single).

Act_...

4.4.1.18. Nest Fixture Side Used to specify nest statistics manager instruction / function

Mgr_Nest

4.4.1.19. Num Numeric Used to specify a numeric actuator instruction / function

Act_Num

4.4.1.20. Out Output Real-time data driven from the process within an instruction/function. Generally used to designate a connection to a real output point, a control device, or to data sent to other process.

DINT, BOOL

4.4.1.21. Par Parameter Parameters are variables that are received from an external source, such as a batch or a recipe management system that can be internal or external to the program

REAL, DINT

4.4.1.22. Pls Pulse Used to specify a pulse (flip-flop) actuator instruction / function

Act_Pls

4.4.1.23. Prog Program Used to specify a machine/station manager instruction / function

Mgr_Prog

4.4.1.24. Rep Report Reported value designates a value (calculated inside the instruction) that is typically used for batch reporting.

REAL, DINT

4.4.1.25. ...s Array of ... Used to specify an array of data (one or more dimensions).

REAL[ ], DINT[ ]

4.4.1.26. Safe Safety Safety status of machine/station DINT, BOOL

4.4.1.27. State State State of the process within the machine/station DINT

4.4.1.28. Sts Status Status of the process within the instruction / function

DINT, BOOL

4.4.1.29. Tmr Timer Timer driven by system clock or by custom ticks DINT, TIMER

4.4.1.30. Track Station Side Used to specify machine/station tracks statistics manager instruction/function

Mgr_Track

4.4.1.31. Typ Type definition

Complex data structures made up of a combina-tion of input and output data. These structures are used to pass data in an instruction/function.

UDT

4.4.2. Tags Configuration

4.4.2.1. Description

The description is equivalent to the tag comment.

4.4.2.2. Name

The name defines the tag name.

4.4.2.3. Domain

This field could be filled with "Public" for controller tags (global) or "Private" for program tag (local).

4.4.2.4. DataType

This field defines the PLC data type related to the tag under configuration.

4.4.2.5. TagType

This field could be filled with "Alias" for referenced tags or "Tag" for unreferenced tag.

4.4.2.6. TagReference

In case of "Alias" tag type and if reference has to be defined manually, this is the right field.




4.4.3. Programs Names

In the controller main task, the programs names are related to their TR88 types.

4.4.3.1. Machine

_<Machine-ID>_<Machine-Name> (should be placed at the beginning of the task).

_<Machine-ID>_<Admin> (should be at the end of the task).

4.4.3.2. Station

_<Machine-ID>_<Station-ID>_<Station-Name>

4.4.3.3. Actuator

The Admin actuators are embedded in "Actuators_Sub" routine under "_Mn_Adm" programs.

4.4.4. Controller Tags

4.4.4.1. Admin

At the controller level, there are tags related to the TR88 Admin features; all off them belong to the machine and can be internally or remotely controlled.




4.4.4.2. Programs

At the controller level, the tags are related to their TR88 owners.

4.4.4.3. Machine

_<Machine-ID>_<Tag-Name>

_<Machine-ID>_<Admin>_<Tag-Name>

4.4.4.4. Station

_<Machine-ID>_<Station-ID>_<Tag-Name>

4.4.4.5. Actuator

_<Machine-ID>_<Station-ID>_<Actuator-ID>_<Actuator-Name>

4.4.5. Programs Tags

At the program level, the tags are related to their TR88 owners.

4.4.5.1. Machine

<Tag-Name>




4.4.5.2. Station

<Tag-Name>

4.4.5.3. Actuator

<Actuator-Name>_<Actuator-subtag>

_<Alm0> means actuator not OFF

_<Alm1> means actuator not ON

_<Inp> means actuator physical input

_<Out> means actuator physical output

_<Par> means actuator parameter

_<Rep> means actuator report




4.5. Design Process

4.5.1. Machine

4.5.1.1. Machine Overview

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Actuators

▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲ ▼ ▼ ▲ ▲

Actuators_01_SS_AA

Stations_01_SS

Fibro

▼ ▲ ▼ ▲

P&P Build

▼ ▲ ▼ ▲ ▼ ▲ ▼ ▲

•Reset•Start

•Idle•Exec.

•Reset•Start

•Idle•Exec

•Reset•Start

•Idle•Exec.

Stations_01_SS

Fibro

▼ ▲ ▼ ▲

P&P Build

▼ ▲ ▼ ▲ ▼ ▲ ▼ ▲

•Reset•Start

•Idle•Exec.

•Reset•Start

•Idle•Exec

•Reset•Start

•Idle•Exec.

Machine_01

▼ ▲▼ ▲

•Reset•Start

•Idle•Exec.

X-00

E-01

X-01

E-02

X-02

E-03

E-nd

.

[nop]

[nop]

[nop]

[nop]

(L) Done

[ ] Cycle

[ ] Home

.

(U) Grip

[ ] Opened

[nop]

[nop]

[nop]

[nop]

.

.

[nop]

[nop]

(U) Vert.

[ ] Up

[nop]

[nop]

.

.

[nop]

[nop]

[nop]

[nop]

(U) Horiz.

[ ] Picked

.

.

E-00

X-00

E-01

X-01

E-02

X-02

.

.

NextMode"Gripper""Vertical""Horizontal"Steps

X-00

E-01

X-01

E-02

X-02

E-03

E-nd

.

[nop]

[nop]

[nop]

[nop]

(L) Done

[ ] Cycle

[ ] Home

.

(U) Grip

[ ] Opened

[nop]

[nop]

[nop]

[nop]

.

.

[nop]

[nop]

(U) Vert.

[ ] Up

[nop]

[nop]

.

.

[nop]

[nop]

[nop]

[nop]

(U) Horiz.

[ ] Picked

.

.

E-00

X-00

E-01

X-01

E-02

X-02

.

.


4.5.1.2. Machine Configuration

MainType Machine SubType Station Station Station Station Station Station Revision V001_110810

Main_ID _01 Sub_ID _00 _01 _02 _03 _04 _Admin Abort Sts_Seq:=01

MainName Machine SubName BaseFibro LoadBody LoadScrew BuildPart UnloadPart _ Reset Sts_Seq:=11

MaindT#### 7300 SubdT#### 800 6000 6500 6500 6500 2000 Exec Sts_Seq:=21

Cmd_State:=1 Cmd_State:=1 Cmd_State:=1 Cmd_State:=1 Aborting=1 Sts_Safe:=0

Sts_Idle=1 Sts_Idle=1 Sts_Idle=1 Sts_Idle=1

Cmd_State:=1 Sts_Safe:=1

Sts_Idle=1 Aborted:=1 Sts_Idle:=1

Resetting=1

Cmd_State:=2 Cmd_State:=2 Cmd_State:=2 Cmd_State:=2 Sts_Safe:=0



Sts_Idle=1 Idle:=1 Sts_Idle:=1

Cmd_State:=4 Cmd_State:=4 Cmd_State:=4 Cmd_State:=4 Execute=1 Sts_Safe:=0



Sts_Idle=1 Sts_Idle:=1

Name Domain DataType TagType Ctrl+Shift+D = Double Click

Prog Public Man_Prog Alias Ctrl+Shift+S = Update Sheet

Track Public Man_Track Alias Ctrl+Shift+W = Update Workbook

Motions Public MOTION_GROUP Tag

Mots Public REAL[5,2] Tag

Outs Public DINT[5] Tag

Inps Public DINT[5] Tag

Outputs Array _01_Outs

Inputs Array _01_Inps

Motions Group _01_Motions

Motions Array _01_Mots

Mode=1-Producing, Mode=2-Maintenance, Mode=4-Manual

Mode=8-Purge, Mode=16-DryCycleSts_Seq=11 Cmd_Seq:=12

Reset every process Station

Reset Base Fibro Sts_Seq=13

Exec every process Station Sts_Seq=21 Cmd_Seq:=22

Exec Base Fibro Sts_Seq=22

Sts_Seq=12 Cmd_Seq:=13

Abort every process station Sts_Seq=01 Cmd_Seq:=02

Abort BaseFibro Sts_Seq=02

Config Tracks vs Mode

Manage Track Statistics

Description TagReference

Manage Prog Logic

The first form in the machine document is dedicated to the machine as the main.

MainType, could be Machine or Sub_Machine.

Main_ID, should be between _00 to _99.

MainName, the convenient machine name description.

MaindT####, Ideal expected time response.

4.5.1.3. Machine Data

The "Machine" program merges every machine private data. Description Name Domain DataType TagType TagReference

Manage Prog Logic Prog Public Mgr_Prog Alias

Manage Track Statistics Track Public Mgr_Track Alias

Motions Array Mots Public REAL[5,2] Tag _01_Mots

Outputs Array Outs Public DINT[5] Tag _01_Outs

Inputs Array Inps Public DINT[5] Tag _01_Inps

Sized for 5 x Stations with 2 x Tracks.

4.5.1.4. Stations Configuration

The stations are declared in the machine form; one station is equivalent to one column.

SubType, could be Station or Sub-Station.

Sub_ID, should be after _Mn (_<MachineID>) identifier from _00 to _99.

SubName, the convenient station name description.

SubdT####, Ideal expected time response

The latest "station" is dedicated for the "_Adm" program declaration that is always attached to any machines; for this one, no "_ID" number, just "_Adm" statement.




4.5.1.5. Admin Configuration

The "_Adm" program is always attached to a machine and "Administrate" as defined in TR88; the sequencer takes care of the machine state model, the operator panel buttons and the lights tree.

MainType Station SubType Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Revision V001_110810

Main_ID _01_Adm Sub_ID _00 _01 _02 _03 _04 _05 _06 _07 Abort n/a

MainName _ SubName SafeGuard Alm_Buzz Alm_White Alm_Green Alm_Amber Alm_Red But_Stop But_Start Reset n/a

MaindT#### 2000 SubdT#### 1000 1000 1000 1000 1000 1000 30 30 Exec n/a

Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Flashing Flashing Flash if Alm Mach_Abort:=1 State:=01

Sts_Inp=0 AlmAbort=1 Sts_Inp=1 Mach_Idle=0

Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Steady Flashing Flash if Alm Sts_Safe:=00 State:=02


Cmd_Out:=1 Cmd_Out:=0 Cmd_Out:=0 Flashing Cmd_Out:=0 Flashing Flash if Alm State:=03

Sts_Inp=1 AlmStop=1 Sts_Inp=1

Cmd_Out:=0 Cmd_Out:=0 Steady Cmd_Out:=0 Steady Flash if Alm Sts_Safe:=FF State:=04

Sts_Inp=1 AlmStop=1 Sts_Inp=0 Sts_Inp=0

State=04 Sts_Inp=0 Sts_Inp=1 Mach_Reset:=1 State:=05

Cmd_Out:=0 Flashing Flashing Cmd_Out:=0 Flashing Steady State:=06

AlmIdle=0 Mach_Idle=1

Cfg_NoAlm:=0 Cmd_Out:=0 Flashing Steady Cmd_Out:=0 Steady Flashing State:=07

Sts_Inp=1

Cmd_Out:=1 Cmd_Out:=0 Flashing Cmd_Out:=0 Cmd_Out:=0 Flashing Steady State:=06

Cfg_NoAlm=0 Sts_Inp=0

Sts_Inp=1 Sts_Inp=1 State:=08

Cfg_NoAlm:=1 Cmd_Out:=0 Steady Cmd_Out:=0 Cmd_Out:=0 Flashing Flash if Alm Mach_Exec:=1 State:=05

AlmIdle=1

AlmHold=1 State:=09

AlmSusp=1 State:=11

Flashing Steady Cmd_Out:=0 Cmd_Out:=0 Flashing Flash if Alm State:=10

Mach_Idle=1

Steady Flashing Cmd_Out:=0 Cmd_Out:=0 Flashing Flash if Alm State:=07

AlmHold=0

Flashing Cmd_Out:=0 Steady Cmd_Out:=0 Flashing Flash if Alm State:=12

Mach_Idle=1

Staedy Cmd_Out:=0 Flashing Cmd_Out:=0 Flashing Flash if Alm State:=07

AlmSusp=0Suspended, 12 State=12

Suspending, 11

State=09

State=11

State=07

Held, 10

State=08

Holding, 09

State=10

Aborting, 01State

Any

Stopping, 03

Execute, 08

Starting, 07

State=06

Aborted, 02

Stopped, 04

State=05

State

Any

Resetting, 05

Idle, 06

State

Any

State

Any

4.5.1.6. Admin Data

The "_Adm" program merges every machine public data

Description Name Domain DataType TagType TagReference Current State Sts_State Public DINT Tag _01_Adm_Sts_State

Command State Cmd_State Public DINT Tag _01_Adm_Cmd_State

Current Mode Sts_Mode Public DINT Tag _01_Adm_Sts_Mode

Command Mode Cmd_Mode Public DINT Tag _01_Adm_Cmd_Mode

Login Identifier LogID Public DINT Tag _01_Adm_LogID Safety Identifier SafeID Public DINT Tag _01_Adm_SafeID

Acknow. Identifier AckID Public DINT Tag _01_Adm_AckID

Alarms Identifier AlmID Public DINT Tag _01_Adm_AlmID

Alarm to Abort Alm_Abort Public BOOL Alias _01_Adm_AlmID.1

Alarm to Stop Alm_Stop Public BOOL Alias _01_Adm_AlmID.2

Alarm to Idle Alm_Idle Public BOOL Alias _01_Adm_AlmID.3

Alarm to Hold Alm_Hold Public BOOL Alias _01_Adm_AlmID.4

Alarm to Suspend Alm_Susp Public BOOL Alias _01_Adm_AlmID.5

Alarm to Warn Alm_Warn Public BOOL Alias _01_Adm_AlmID.6

Alarm to Help Alm_Help Public BOOL Alias _01_Adm_AlmID.7

Stats Clear Identifier ClrID Public DINT Tag _01_Adm_ClrID

Oper's Stats Clear Clr_Oper Public BOOL Alias _01_Adm_ClrID.0

Shift's Stats Clear Clr_Shift Public BOOL Alias _01_Adm_ClrID.1

Batch's Stats Clear Clr_Batch Public BOOL Alias _01_Adm_ClrID.2

Admin Array Adms Public Mgr_Adm[3] Tag _01_Adm_Adms

Admin Oper Adm_Oper Public Mgr_Adm Alias _01_Adm_Adms[0] Admin Shift Adm_Shift Public Mgr_Adm Alias _01_Adm_Adms[1] Admin Batch Adm_Batch Public Mgr_Adm Alias _01_Adm_Adms[2] Alarms Array Alms Public DINT[5,10] Tag _01_Adm_Alms

Camshafts Array Cams Public DINT[5,10] Tag _01_Adm_Cams

Parameters Array Pars Public DINT[5,10] Tag _01_Adm_Pars

Reports Array Reps Public DINT[5,10] Tag _01_Adm_Reps

Tracks Manager Tracks Public Mgr_Track[5,2] Tag _01_Adm_Tracks

Nests Manager Nests Public Mgr_Nest[5,2] Tag _01_Adm_Nests

Nests Empty NestEmpty Public DINT Tag _01_Adm_NestEmpty

Nest Identifier NestID Public DINT Tag _01_Adm_NestID

Part Identifier PartID Public DINT Tag _01_Adm_PartID

Pulse per Second PlsSec Public Act_Pls Tag _01_Adm_PlsSec

Motions Group Motions Public MOTION_GROUP Tag _01_Motions

Motions Array Mots Public REAL[5,2] Tag _01_Mots

Outputs Array Outs Public DINT[5] Tag _01_Outs

Inputs Array Inps Public DINT[5] Tag _01_Inps

Sized for 5 x Stations with 2 x Tracks.




Gri

pD

own

Req

uest

Pic

k-P

lace

Gri

pD

own

Req

uest

Pic

k-P

lace

4.5.2. Asynchronous Station

An asynchronous or transactional process individuates each of its activities so that each one commits its operation before execution continues.

4.5.2.1. Sample, Pick & Place

▼ ▼▲ ▲

Grip

▼ ▲ ▼ ▲

▼ ▼▲ ▲

Grip

▼ ▲ ▼ ▲

▼ ▼ ▲ ▲

Down

▼ ▲ ▼ ▲

▼▼▲ ▲ ▼ ▼ ▲ ▲

Pick

▼ ▲ ▼ ▲

Place

▼ ▲ ▼ ▲

▼▼▲ ▲ ▼ ▼ ▲ ▲

Pick

▼ ▲ ▼ ▲

Place

▼ ▲ ▼ ▲

Actuators_01_01_00_Grip

_01_01_01_Down

_01_01_02_P&P

P&P

▼ ▲▼ ▲

•Reset•Start

•Idle•Exec.

Station_01_01_Prog

Machine_01_Prog

▼ ▲▼ ▲

•Reset•Start

•Idle•Exec.

X-00

E-01

X-01

E-02

X-02

E-03

E-nd

.

[nop]

[nop]

[nop]

[nop]

(L) Done

[ ] Cycle

[ ] Home

.

(U) Grip

[ ] Opened

[nop]

[nop]

[nop]

[nop]

.

.

[nop]

[nop]

(U) Vert.

[ ] Up

[nop]

[nop]

.

.

[nop]

[nop]

[nop]

[nop]

(U) Horiz.

[ ] Picked

.

.

E-00

X-00

E-01

X-01

E-02

X-02

.

.


X-00

E-01

X-01

E-02

X-02

E-03

E-nd

.

[nop]

[nop]

[nop]

[nop]

(L) Done

[ ] Cycle

[ ] Home

.

(U) Grip

[ ] Opened

[nop]

[nop]

[nop]

[nop]

.

.

[nop]

[nop]

(U) Vert.

[ ] Up

[nop]

[nop]

.

.

[nop]

[nop]

[nop]

[nop]

(U) Horiz.

[ ] Picked

.

.

E-00

X-00

E-01

X-01

E-02

X-02

.

.


4.5.2.2. Horizontal Time Diagram Reference

4.5.2.3. Vertical Time Diagram with Transients Choices

4.5.2.4.




4.5.2.4. Transients to Matrix

_Seq:=01

_Seq:=02

_Seq:=03

_Seq:=04

_Seq:=05

_Seq:=06

_Seq:=07

_Seq:=08

_Seq:=00

Request=1

Request:=0

Place:=1

Place=1

Pick:=1

Pick=1

Down:=1

Down=1

Down:=0

Down=0

Down:=1

Down=1

Down:=0

Down=0

Grip:=1

Grip=1

Grip:=0

Grip=0

_Seq=00

_Seq=01

_Seq=02

_Sep=03

_Seq=04

_Seq=05

_Seq=06

_Seq=07

_Seq=08

Cmd_RequestPick-PlaceDownGripSts_

_Seq:=01

_Seq:=02

_Seq:=03

_Seq:=04

_Seq:=05

_Seq:=06

_Seq:=07

_Seq:=08

_Seq:=00

Request=1

Request:=0

Place:=1

Place=1

Pick:=1

Pick=1

Down:=1

Down=1

Down:=0

Down=0

Down:=1

Down=1

Down:=0

Down=0

Grip:=1

Grip=1

Grip:=0

Grip=0

_Seq=00

_Seq=01

_Seq=02

_Sep=03

_Seq=04

_Seq=05

_Seq=06

_Seq=07

_Seq=08

Cmd_RequestPick-PlaceDownGripSts_

"Sts_Seq=nn" if Sequence number "nn"

"Actuator:=1" Set Act.Cmd_Out to ON

"Actuator=1" if Act.Sts_Inp is ON

"Cmd_Seq:=nn" Set Sequence number to "nn"

"Actuator:=0" Set Act.Cmd_Out to OFF

"Actuator=0" if Act.Sts_Inp is OFF

4.5.2.5. Station Configuration

Type, Prog.. Type

##, Program ID Nbr

Name, Description

dT####, Exp. time Out

Type, Actuator Type

##, Actuator ID Nbr

Name, Description


Cm

d_S

eq

:=xx

Next

sequence

Date, Year-Month-Day

Version, Revision number

Reset,

Seq.

for

rese

ttin

g

Ho

me,

Seq.

for

hom

ing

Cycle

, S

eq.

for

cyclin

g

Request

Station versus

sequence

Module #00

activity versus

sequence

Module #01

activity versus

sequence

Module #02

activity versus

sequence

Sts_Seq=xx

Current

sequence

sequence

description




4.5.2.6. Station Sequencer

Header = Manager of Program LogicHeader = Manager of Program Logic

4.5.2.7. Sequences Details

The sequence branch start with the test on the current sequence value.

Then it is splitted in two branches:

o The first one is conditioned by "Prog.Sts_SeqOns" that gives the up threshold and where the commands to the actuators take place.

o The second one is conditioned by "Prog.Sts_SeqExe" that enable the sequence to be executed and where the status from the actuators are tested.

At the right, if the second half branch conditions are all good, then the command to next sequence is written with some other station instructions such as "Prog.Sts_Safe" for instance.

4.5.2.8. Tags List

With the spreadsheet embedded macro, every station tag is merged in the tags list form.

MainType Machine Revision V001_110810

Main_ID _01 Made Komax

MainName Machine by SW

Scope _ID Name Domain DataType TagType TagReference Description

T a g s L i s t

_01_01_LoadBody _01_01_ArmAxis ArmAxis Public AXIS_GENERIC Tag _01_01_03_ArmAxis _01_01, Arm Axis

_01_01_LoadBody _01_01_ArmAxisCtl ArmAxisCtl Private MOTION_INSTRUCTION[10] Tag _01_01, Arm Axis Control

_01_01_LoadBody _01_01_ArmAxisSts ArmAxisSts Private DINT Tag _01_01, Arm Axis Status

_01_01_LoadBody _01_01_Nest0 Nest0 Public Man_Nest Alias _01_Admin_Nests[1,0] _01_01, Statistics

_01_01_LoadBody _01_01_Nest1 Nest1 Public Man_Nest Alias _01_Admin_Nests[1,1] _01_01, Statistics

_01_01_LoadBody _01_01_Prog Prog Public Man_Prog Alias _01_01, Program

_01_01_LoadBody _01_01_Track0 Track0 Public Man_Track Alias _01_Admin_Tracks[1,0] _01_01, Statistics

_01_01_LoadBody _01_01_Track1 Track1 Public Man_Track Alias _01_Admin_Tracks[1,1] _01_01, Statistics

_01_02_LoadScrew _01_02_ArmAxis ArmAxis Public AXIS_GENERIC Tag _01_02_03_ArmAxis _01_02, Arm Axis




4.5.3. Synchronous Station

A synchronous process is invoked by a request based on camshaft angle.

4.5.3.1. Sample, Build & Check Time Diagram Reference

4.5.3.2. Vertical Time Diagram with Transients

4.5.3.3. Transients to Matrix

_Seq:=01

_Seq:=02

_Seq:=03

_Seq:=04

_Seq:=05

_Seq:=06

_Seq:=00

Request=1

Request:=0

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=1

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=1

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=330

Rep_Ante≥060

Rep_Ante≥180

Rep_Ante≥270

Rep_Ante≥330

Cmd_Out:=000

_Seq=00

_Seq=01

_Seq=02

_Sep=03

_Seq=04

_Seq=05

_Seq=06

Cmd_RequestCheckBuildCamShaftSts_

_Seq:=01

_Seq:=02

_Seq:=03

_Seq:=04

_Seq:=05

_Seq:=06

_Seq:=00

Request=1

Request:=0

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=1

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=1

Cmd_Out:=0

Sts_Inp=0

Cmd_Out:=330

Rep_Ante≥060

Rep_Ante≥180

Rep_Ante≥270

Rep_Ante≥330

Cmd_Out:=000

_Seq=00

_Seq=01

_Seq=02

_Sep=03

_Seq=04

_Seq=05

_Seq=06

Cmd_RequestCheckBuildCamShaftSts_

"Sts_Seq=nn" if Sequence number "nn"

"Actuator:=1" Set Act.Cmd_Out to ON

"Actuator=1" if Act.Sts_Inp is ON

"Cmd_Seq:=nn" Set Sequence number to "nn"

"Actuator:=0" Set Act.Cmd_Out to OFF

"Actuator=0" if Act.Sts_Inp is OFF

Ca

ms

ha

ftB

uil

dR

eq

uest

Ch

ec

k

000°

060°

180°

270°

000°

330°

Camshaft Build RequestCheck




4.5.3.4. Station Configuration Type, Prog.. Type

##, Program ID Nbr

Name, Description


Type, Actuator Type

##, Actuator ID Nbr

Name, Description


Date, Year-Month-Day

Version, Revision number

Request

Station versus

sequence

Module #00

activity versus

sequence

Module #01

activity versus

sequence

Module #02

activity versus

sequence

Sts_Seq=xx

Current

sequence

sequence

description

MainType Station SubType Act_Cam Act_Bin Act_Bin Revision V001_110810

Main_ID _01_03 Sub_ID _00 _01 _02 Abort Sts_Seq:=01

MainName BuildPart SubName RotCam Build0 Check0 Reset Sts_Seq:=01

MaindT#### 10000 SubdT#### 9000 1000 1000 Exec Sts_Seq:=02

Cmd_Out:=0 Cmd_Out:=0

Sts_Inp=0 Sts_Inp=0

Sts_Seq=02 Cmd_Out:=330 Sts_Safe:=0 Cmd_Seq:=03

Sts_Seq=03 Rep_Ante≥090 Cmd_Out:=1 Cmd_Seq:=04

Sts_Seq=04 Rep_Ante≥190 Cmd_Out:=1 Cmd_Seq:=05


Sts_Inp=0 Sts_Inp=0 Sts_Safe:=1

Rep_Ante≥330

Cmd_Out:=000Sts_Seq=06

Disable Builds

Disable ChecksSts_Seq=01 Cmd_Seq:=06

Sts_Idle:=1

Disable All Sts_Seq=05 Rep_Ante≥270

Cam Exec

Enable Build

Enable Check

Cmd_Seq:=06

Cam Up

4.5.3.5. Station Sequencer

Header = Manager of Program LogicREQUEST WAIT

CAM UP

DISABLE BUILD

DISABLE CHECK

DISABLE BUILD

DISABLE CHECK

CAM EXEC

ENABLE BUILD

ENABLE CHECK

Cam Exec

Enable Build

Enable Check

Cam Up

Disable Builds

Disable Checks

Disable All

Cam Exec

Enable Build

Enable Check

Cam Up

Disable Builds

Disable Checks

Disable All

Cam Exec

Enable Build

Enable Check

Cam Up

Disable Builds

Disable Checks

Disable All

Header = Manager of Program LogicREQUEST WAIT

CAM UP

DISABLE BUILD

DISABLE CHECK

DISABLE BUILD

DISABLE CHECK

CAM EXEC

ENABLE BUILD

ENABLE CHECK

Cam Exec

Enable Build

Enable Check

Cam Up

Disable Builds

Disable Checks

Disable All

Cam Exec

Enable Build

Enable Check

Cam Up

Disable Builds

Disable Checks

Disable All

Cam Exec

Enable Build

Enable Check

Cam Up

Disable Builds

Disable Checks

Disable All

4.5.3.6. Sequences Details

Header rungs exactly the same codes between synchronous and asynchronous.

The synchronous sequence (#2 for instance) starts by defining the came setpoint (330° for instance). Then each rung uses a "LIM" instruction that checks if predefined angle is between "_CamAnte" and "_CamPost". The last "camshafted" rung checks reached last angle to request the next sequence #3.

4.5.3.7. Tag List

As Asynchronous station...




4.5.4. Actuator

4.5.4.1. Configuration

The actuators are declared in the station form; one actuator is equivalent to one column.

SubType, could be Act_Bin, Act_Cam, Act_Num or Act_Pls.

Sub_ID, should be after _Mn_Ss (_<MachineID>_<StationID>) identifier from _00 to _99.

SubName, the convenient function name description.

SubdT####, Ideal expected time response

4.5.4.2. Actuators List

With the spreadsheet embedded macro, every station actuator are merged in the actuators list form where definitions extensions could added such as physical output / inputs, parameters or reports.

Scope, should be the name of the program where the actuator take place.

_ID, should be the actuator ID seen from the controller point of view (_Mn_Ss_Aa means _<MachineID>_<StationID>_<ActuatorID>).

Name, the convenient function name description.

DataType, could be Act_Bin, Act_Cam, Act_Num, Act_Pls or Alias

DataValue, expected time response or any additional parameter value.

Parameter Definition, Admin reference that gives ID number in parameters array.

Parameter Description, the text to add after _Mn_Ss_Aa_Name...

Report Definition, Admin reference that gives ID number in repoerts array.

Report Description, the text to add after _Mn_Ss_Aa_Name...

Alarm OFF Definition, Admin reference that gives ID number in alarms array.

Alarm OFF Description, the text to add after _Mn_Ss_Aa_Name...

Alarm ON Definition, Admin reference that gives ID number in alarms array.

Alarm ON Description, the text to add after _Mn_Ss_Aa_Name...

Output Definition, Physical reference that gives ID number in outputs array.

Input Definition, Physical reference that gives ID number in inputs array.

...




4.5.4.3. Programming

4.5.5. Design Workflow

HDS.doc

SDS.doc

Install.IQ

Perf.PQ

Alpha

or Beta

Alpha

or Beta

Release

Candidate

Release

Candidate

Gold

Release

Gold

Release

Imagine Achieve Check

HDS.doc

Oper..OQ

SDS.doc

FDS.doc

URS.doc

SDS.doc

HDS.doc Draw

.dwg

FDS.doc

Diag..xls.xls

Conf.Diag..xls.xls

Conf.

.drwDraw

Code.plc

Test.xls.plc

Code.xls

Test

Test.xls.drw

Wire

Test.xls.dwg

MountSupply.doc

Design.dwg

FDS.doc

N°

Test.xls

.doc

User's

Guide

N°




5. Hardware Interfaces

5.1. Topology

There is no automation software without hardware; this document gives a typical topology that complies with machine directive 2006/42/CE (ISO 13849-1).

5.1.1. Physical Interface

Clean Air

Safe

Actuators

Unsafe Cylinders

Safe Cylinders

Unsafe

Actuators

Main Switch

E-Stop

Light

Curtain

Safety Stop

MainValve

Safety Switches

Safety Servo

SafetyValve

Safety Speed

5 / 3 Valves

5 / 2Valves

Door

Key

5.1.2. Human Interface




5.2. Components

It proposes a classified list of standard components that could be used with this platform and how to drive them from a software point of view.

Designation Supplier Reference

Power supply MOELLER ELECTRIC SN3-100-EU8

E-Stop luminous. Head MOELLER ELECTRIC M22-PVLT

E-Stop Block Contact MOELLER ELECTRIC M22-CK01

E-Stop Led MOELLER ELECTRIC M22-CLED-R

Door Switch SIEMENS 3SE5322-0SBS1 / 24VDC

Safety Security Unit PILZ PNOZ E1.1P

Safety Contactor ROCKWELL 100S*

Drive controller BOSCH REXROTH HCS02.1E-W0070-A-03-NNNN

Board basic single-axis BOSCH REXROTH CSB01.1C-PB-ENS-EN1-NN-S-NN-FW

Motor cable BOSCH REXROTH IKG4118/005.0

Encoder cable BOSCH REXROTH IKS4042/005.0

Multi-axis Servo Drive ROCKWELL Kinetix 6500*

Control module Ethernet IP ROCKWELL 2094-EN02D-M01-S1

Ethernet cable ROCKWELL 1595J-M8CBJM-x

Ethernet cable / 0.3m ROCKWELL 1585J-M8CBJM-0M3

Vision camera COGNEX In-sight

2D Matrix readers COGNEX To be defined

Bar code guns DATALOGIC DS2100N-1214

Optic Sensors KEYENCE To be defined

Cylinder Sensors BALLUF To be defined

Inductive Sensors CONTRINEX To be defined

Optic Sensors BAUMER To be defined

Cylinder Sensors FESTO To be defined

Single Solenoid Valve (360 l/min) FESTO VMPA1-M1H-M-PI

Double Solenoid Valve (360 l/min) FESTO VMPA1-M1H-J-PI

Centre Closed Solenoid Valve (320 l/min) FESTO VMPA1-M1H-G-PI

Centre Exhaust Solenoid Valve (240 l/min) FESTO VMPA1-M1H-E-PI

Vacuum Solenoid Valve (200 l/min) FESTO MHE3-M1H-3/2G-1/8

Vacuum Solenoid Valve (900 l/min) FESTO CPE14-M1BH-3GLS-1/8

Head BP bright white MOELLER ELECTRIC M22-DL-W

Head BP bright green MOELLER ELECTRIC M22-DL-G

Head BP bright blue MOELLER ELECTRIC M22-DL-B

Head BP bright red MOELLER ELECTRIC M22-DL-R

Head BP bright yellow MOELLER ELECTRIC M22-DL-Y

Module led white MOELLER ELECTRIC M22-CLEDC-W or M22-CLED-W

Module led green MOELLER ELECTRIC M22-CLEDC-G or M22-CLED-G

Module led blue MOELLER ELECTRIC M22-CLEDC-B or M22-CLED-B

Module led red MOELLER ELECTRIC M22-CLEDC-R or M22-CLED-R

Block contact NC MOELLER ELECTRIC M22-CK01 or M22-CKC01

Block contact NO MOELLER ELECTRIC M22-CK10 or M22-CKC10

Red Light MOELLER ELECTRIC SL-L-R & SL-LED-R

Amber Light MOELLER ELECTRIC SL-L-Y & SL-LED-Y

Green Light MOELLER ELECTRIC SL-L-G & SL-LED-G

White Light MOELLER ELECTRIC SL-L-W & SL-LED-W

Buzzer MOELLER ELECTRIC SL-A24

...

...




5.3. Operator Panel

°°

StopStop StartStart Jog -Jog - Jog +Jog +

5.3.1. E-Stop

Anytime, this button requests machine state "Aborting".

Then when machine state is "Aborted", the doors are unlocked.

5.3.2. Stop

If machine state is "Stopped", this button requests machine state "Aborting".

If machine state is different than "Stopped", this button requests machine state "Stopping".

Then when machine state is "Stopped", the doors are locked.

5.3.3. Start

If machine state is "Stopped", this button requests machine state "Resetting".

Then when machine state is "Idle", this button requests machine state "Starting".

If machine state keeps "Starting" for 2 seconds, then machine state goes to "Execute".

Anytime, the button requests an acknowledgement on pending alarm(s).

5.3.4. Jog -

If machine mode is "Manual", this button requests a negative slow motion on selected axis.

5.3.5. Jog +

If machine mode is "Manual", this button requests a positive slow motion on selected axis.

5.4. Lights

Machine States vs

Lights States

Ab

ort

ing

Ab

ort

ed

Sto

pp

ing

Sto

pp

ed

Re

sett

ing

Idle

Sta

rtin

g

Exe

cute

Ho

ldin

g

He

ld

Su

spe

nd

ing

Su

spe

nd

ed

5.4.1. Red Light Flashing F F F

5.4.2. Red Light Steady S S S

5.4.3. Amber Light Flashing F F

5.4.4. Amber Light Steady S S

5.4.5. Green Light Flashing F F F F F F

5.4.6. Green Light Steady S S S S

5.4.7. White Light Flashing F F

5.4.8. White Light Steady S S

5.4.9. Buzzer 2 sec F

5.4.10. Stop Button Flashing F F F F F F F F F F

5.4.11. Stop Button Steady S S S

5.4.12. Start Button Flashing Any time an alarm message is pending

5.4.13. Start Button Steady S S




5.5. H M I

5.5.1. Screens Map

Machine Na

vig

atio

n R

ibb

on

Modes

Select

Recipe &

Batch

Station

Actuator

Overview

Reports

System

Param.

Process

Param. Overview

Reports

Overview

Reports

System

Param.

System

Param.

States

Control

States

Control

States

Control

Bo

ttom

User Login

Part-InfoAlarms

Historic

Stops

Causes

Screen

Cleaning

Machine Na

vig

atio

n R

ibb

on

Modes

Select

Recipe &

Batch

Station

Actuator

Overview

Reports

System

Param.

Process

Param. Overview

Reports

Overview

Reports

System

Param.

System

Param.

States

Control

States

Control

States

Control

Bo

ttom

User Login

Part-InfoAlarms

Historic

Stops

Causes

Screen

Cleaning

Machine Na

vig

atio

n R

ibb

on

Modes

Select

Recipe &

Batch

Station

Actuator

Overview

Reports

System

Param.

Process

Param. Overview

Reports

Overview

Reports

System

Param.

System

Param.

States

Control

States

Control

States

Control

Bo

ttom

User Login

Part-InfoAlarms

Historic

Stops

Causes

Screen

Cleaning

5.5.2. Screens Header

5.5.2.1. Recipe

Stored

Dark Grey

Recipe Control

Color

Restored

Light Grey

Stored

Dark Grey

Recipe Control

Color

Restored

Light Grey

5.5.2.2. Batch

Execute

Starting

Green

N / A

N / A

Dark Grey

Idle

Resetting

Yellow

Aborted

Aborting

Red

HoldingStoppingFlashing

Stopped

Amber

Batch

Control

Color

Held

Light Grey

Steady Execute

Starting

Green

N / A

N / A

Dark Grey

Idle

Resetting

Yellow

Aborted

Aborting

Red


Stopped

Amber

Batch

Control

Color

Held

Light Grey

Steady 5.5.2.3. Modes

Producing

Prod. Single

Green

Maintenance

Maint. Single

Dark Grey

Dry Cycle

Dry Single

Yellow

ManualClearLimp NestFlashing

Limp Track

Amber

Machine

Modes

Color

Purge

Light Grey

N / ASteady

Blue

Producing

Prod. Single

Green

Maintenance

Maint. Single

Dark Grey

Dry Cycle

Dry Single

Yellow

ManualClearLimp NestFlashing

Limp Track

Amber

Machine

Modes

Color

Purge

Light Grey

N / ASteady

Blue

5.5.2.4. States

Execute

Starting

Green

Suspended

Suspending

Dark Grey

Idle

Resetting

Yellow

Aborted

Aborting

Red


Stopped

Amber

Machine

States

Color

Held

Light Grey

Steady Execute

Starting

Green

Suspended

Suspending

Dark Grey

Idle

Resetting

Yellow

Aborted

Aborting

Red


Stopped

Amber

Machine

States

Color

Held

Light Grey

Steady 5.5.2.5. Date & Time

The date and time to the PLCs is given by the HMI Data-Server with "Clock Update Tools". For the HMI PC clients, the date time is synchronized with Windows W32 time service.




5.5.3. Screenshots

5.5.3.1. Machine Overview

5.5.3.2. Machine Recipe & Batch




5.5.3.3. Machine Modes

5.5.3.4. Machine States




5.5.3.5. Machine Stops Reasons

5.5.3.6. Machine Stations




5.5.3.7. Stations States

5.5.3.8. Station Overview




5.5.3.9. Actuator States

5.5.3.10. Actuator Overview

5.5.3.11. Touch Screen Cleaning

Just a black screen during few second to let clean the touch screen.

5.5.3.12. On line Users Guides

Operator and Maintenance Guides.

5.5.3.13. On Line Design References

Mechanical drawings, Hardware diagrams, Software diagrams and Validation protocols




5.5.4. Alarms Severities Levels

If "Alarms" tab is enable, the bottom of any screen display the "Alarms Banner".

5.5.4.1. vs Colors

Lights Tree

Help information

Warning information

Suspend Alarms

Hold Alarms

Idle Alarms

Stop Alarms

Abort Alarms

Description

StopAmber2

IdleYellow3

HoldLight Grey4

SuspendDark Grey5

AbortRed1

WarnGreen6

HelpBlue7

MeaningLevel Color Lights Tree

Help information

Warning information

Suspend Alarms

Hold Alarms

Idle Alarms

Stop Alarms

Abort Alarms

Description

StopAmber2

IdleYellow3

HoldLight Grey4

SuspendDark Grey5

AbortRed1

WarnGreen6

HelpBlue7

MeaningLevel Color

5.5.4.2. vs Stations

Alms[4,7].nAlms[4,6].nAlms[4,5].nAlms[4,4].nAlms[4,3].nAlms[4,2].nAlms[4,1].nStation #04




Alms[0,6].n

Warn

6

HelpSuspendHeldIdleStopAbortMeaning

Alms[0,7].nAlms[0,5].nAlms[0,4].nAlms[0,3].nAlms[0,2].nAlms[0,1].nStation #00

. . .

Level 531 2 4 7





Alms[0,6].n

Warn

6

HelpSuspendHeldIdleStopAbortMeaning

Alms[0,7].nAlms[0,5].nAlms[0,4].nAlms[0,3].nAlms[0,2].nAlms[0,1].nStation #00

. . .

Level 531 2 4 7

5.5.4.3. Single Acknowledgement

When an alarm requires just a single acknowledgment to be reset

5.5.4.4. Double Acknowledgement

When an alarm requires more than a single acknowledgment to be reset, it could be made by:

Opening and closing the relevant enclosure.

Double signature from the HMI.




5.5.5. User Access

Access to user login by pressing the "Right Bottom Corner".

5.5.5.1. User Login

User's names and passwords are managed via the customer domain; it allows to:

Login or logout authorized users.

Change passwords.

5.5.5.2. Access Matrix

Function(s) A

View Only B

Operator C

Supervisor

D

Maintenance

E

Administrator

Allow Machine Overview

Allow Machine Control, STOP Button Yes Yes Yes Yes Yes

Allow Machine Control, START Button No Yes Yes Yes Yes

Allow "Recipe & Batch" Display

Allow "Recipe & Batch" Change

Allow Machine Stop Causes Selection

Allow Machine Modes Selection

Allow Station Selection

Allow Station Control

Allow Actuator Selection

Allow Actuator Control

Allow "System Parameters" Display

Allow "System Parameters" Change

Allow "Overview Reports" Display

Allow "Overview Reports" Reset

Allow "Process Parameters" Display

Allow "Process Parameters" Change

Allow Alarms Display

Allow "Abort" Alarms Acknowledgement

Allow "Stop" Alarms Acknowledgement

Allow "Idle" Alarms Acknowledgement

Allow Touch Screen Cleaning

Allow Parts Information Display

Allow User Login




6. Admin Details

6.1. Header

6.1.1. MainType

Could be "Machine" or "Sub-Machine".

6.1.2. Main_ID

"_Mn_Adm" if machine, should be from _00 to _99.

"_Mnn_Adm" if sub-machine, should be from _000 to _999.

6.1.3. SubType

All actuators required for machines or sub-machines administration are controlled in "Actuators_Sub".

EStopsOFF checks emergency stops.

DoorsClosed checks the enclosures safety feedbacks.

DoorsLock controls the enclosures interlocks.

Alm_Buzz manages the alarms and 2sec buzzer while starting.

Alm_White manages the white lamp in lights tree.

Alm_Green manages the green lamp in lights tree.

Alm_Amber manages the amber lamp in lights tree.

Alm_Red manages the red lamp in lights tree.

But_Stop manages the stop button with its lamp.

But_Start manages the start button with its lamp.

6.2. States & Modes

The normal access goes through reactions to operator panel (E-Stop, Stop and Start buttons); however, a remote access is available through Cmd_State. Another feature manages by admin logic is Sts_Mode versus Cmd_Mode only when Sts_State=Stopped; keep in mind that a mode change make state switch to Sts_State=Aborting.

6.2.1. E-Stop

"E-Stop" button or alarms initiate the "Aborting" acting state from any current state.

6.2.2. Stop

"Stop" button or alarms initiate the "Stopping" acting state from any current state if no abort pending.

"Stop" button initiates the "Aborting" acting state from "Stopped" state to unlock the doors.

6.2.3. Start

"Start" button initiates the "Resetting" acting state from "Stopped" state.

"Start" button initiates the "Starting" acting state from "Idle" state.

"Start" button acknowledges pending alarm versus current user login.

Suspend


Reseting Susping

Mo

des

Ch

ang

e


Idle

Stoping

Aborted

Suspend


Reseting Susping

Mo

des

Ch

ang

e


Idle

Stoping

Aborted




6.3. Public Data

The "_Adm" program merges every machine public "_Mn_Adm_..." data:

Name Tag Description

6.3.1. Current State Sts_State 1=Aborting, 2=Aborted, 3-Stopping, 4=Stopped, 5=Resetting, 6=Idle, 7=Starting, 8=Execute, 9=Holding, 10=Held, 11=Suspending, 12=Suspended.

6.3.2. Command State Cmd_State 1=Aborting, 2=Aborted, 3-Stopping, 4=Stopped, 5=Resetting, 6=Idle, 7=Starting, 8=Execute, 9=Holding, 10=Held, 11=Suspending, 12=Suspended.

6.3.3. Current Mode Sts_Mode 1=Producing, 2=Maintenance, 4=Manual, 8=Purge, 16=DryCycle, 32=SingleCycle, 64=LimpLeft, 128=LimpRight

6.3.4. Command Mode Cmd_Mode 1=Producing, 2=Maintenance, 4=Manual, 8=Purge, 16=DryCycle, 32=SingleCycle, 64=LimpLeft, 128=LimpRight

6.3.5. Login Identifier LogID Up to 32 user access groups.

6.3.6. Safety Identifier SafeID Up to 32 enclosures to discriminate.

6.3.7. Acknowledge Identifier AckID Update from LogID if Start button pressed and pending alarm.

6.3.8. Alarms Identifier AlmID Up to 7 different types of alarms.

6.3.8.1. Alarm to Abort Alm_Abort To request Aborting

6.3.8.2. Alarm to Stop Alm_Stop To request Stopping

6.3.8.3. Alarm to Idle Alm_Idle To request Resetting

6.3.8.4. Alarm to Suspend Alm_Susp To request Suspending

6.3.8.5. Alarm to Hold Alm_Hold To request Holding

6.3.8.6. Alarm to Warn Alm_Warn To warn operator

6.3.8.7. Alarm to Help Alm_Help To help operator

6.3.9. Clear Identifier ClrID To discriminate which statistics counters needs to be cleared.

6.3.9.1. Oper's Stats Clear Clr_Oper To clear Oper's statistics

6.3.9.2. Shift's Stats Clear Clr_Shift To clear Shift's statistics

6.3.9.3. Batch's Stats Clear Clr_Batch To clear Batch's statistics

6.3.10. Admin Array Adms To manage any statistics for real time OEE

6.3.10.1. Admin Operator Adm_Oper To manage Oper's statistics (real time OEE)

6.3.10.2. Admin Shift Adm_Shift To manage Shift's statistics (real time OEE)

6.3.10.3. Admin Batch Adm_Batch To manage Batch's statistics (real time OEE)

6.3.11. Alarms Array Alms Alarms array is in 2D, one for stations and the second for severities; so a 4 stations machine would be [05,10].

6.3.12. Camshafts Array Cams Camshafts array is in 2D, one for stations and the second for camshafts; so a 4 stations machine would be [05,10]

6.3.13. Parameters Array Pars Parameters array is in 2D, one for stations and the second for parameters; so a 4 stations machine would be [05,10]

6.3.14. Parameters Length ParsLen Parameters and Camshafts Length use by "Recipe Confirm"

6.3.15. Reports Array Reps Reports array is in 2D, one for stations and the second for reports; so a 4 stations machine would be [05,02]

6.3.16. Tracks Manager Tracks Tracks managers array is in 2D, one for stations and the second for sides; so a 4 stations with 2 tracks would be [05,02]

6.3.17. Nests Manager Nests Nests managers array is in 2D, one for stations and the second for sides; so a 4 stations with 2 tracks would be [05,02]

6.3.18. Nests Empty NestEmpty Indicates when every nest are empty





6.3.19. Nest Identifier NestID 1= Nest#1 in front of station #01, 2= Nest#2 in front of station #01

etc...

6.3.20. Part Identifier PartID 1= Part ID #00001, 2= Part ID #00002,

etc...

6.3.21. Pulse per Second PlsSec Second heart beat...

6.3.22. Batch Interface Batch MES to control multiple machines vs batch

6.3.23. Recipes Array Recips Storable and restorable parameters and camshafts collections

6.3.24. Recipe Name Recipe Name of active parameters and camshafts collection

6.3.25. Recipe ID RecipeID ID of active parameters and camshafts collection

...

6.4. Diagram

All sequences defined in the configuration admin form are coded in the "Program_Logic". MainType Station SubType Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Act_Bin Revision V001_110810

Main_ID _01_Adm Sub_ID _00 _01 _02 _03 _04 _05 _06 _07 Abort n/a

MainName _ SubName SafeGuard Alm_Buzz Alm_White Alm_Green Alm_Amber Alm_Red But_Stop But_Start Reset n/a

MaindT#### 2000 SubdT#### 1000 1000 1000 1000 1000 1000 30 30 Exec n/a

Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Flashing Flashing Flash if Alm Mach_Abort:=1 State:=01


Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Steady Flashing Flash if Alm Sts_Safe:=00 State:=02


Cmd_Out:=1 Cmd_Out:=0 Cmd_Out:=0 Flashing Cmd_Out:=0 Flashing Flash if Alm State:=03

Sts_Inp=1 AlmStop=1 Sts_Inp=1

Cmd_Out:=0 Cmd_Out:=0 Steady Cmd_Out:=0 Steady Flash if Alm Sts_Safe:=FF State:=04

Sts_Inp=1 AlmStop=1 Sts_Inp=0 Sts_Inp=0

State=04 Sts_Inp=0 Sts_Inp=1 Mach_Reset:=1 State:=05

Cmd_Out:=0 Flashing Flashing Cmd_Out:=0 Flashing Steady State:=06

AlmIdle=0 Mach_Idle=1

Cfg_NoAlm:=0 Cmd_Out:=0 Flashing Steady Cmd_Out:=0 Steady Flashing State:=07

Sts_Inp=1

Cmd_Out:=1 Cmd_Out:=0 Flashing Cmd_Out:=0 Cmd_Out:=0 Flashing Steady State:=06

Cfg_NoAlm=0 Sts_Inp=0

Sts_Inp=1 Sts_Inp=1 State:=08

Cfg_NoAlm:=1 Cmd_Out:=0 Steady Cmd_Out:=0 Cmd_Out:=0 Flashing Flash if Alm Mach_Exec:=1 State:=05

AlmIdle=1

AlmHold=1 State:=09

AlmSusp=1 State:=11

Flashing Steady Cmd_Out:=0 Cmd_Out:=0 Flashing Flash if Alm State:=10

Mach_Idle=1

Steady Flashing Cmd_Out:=0 Cmd_Out:=0 Flashing Flash if Alm State:=07

AlmHold=0

Flashing Cmd_Out:=0 Steady Cmd_Out:=0 Flashing Flash if Alm State:=12

Mach_Idle=1

Staedy Cmd_Out:=0 Flashing Cmd_Out:=0 Flashing Flash if Alm State:=07

AlmSusp=0Suspended, 12 State=12

Suspending, 11

State=09

State=11

State=07

Held, 10

State=08

Holding, 09

State=10

Aborting, 01State

Any

Stopping, 03

Execute, 08

Starting, 07

State=06

Aborted, 02

Stopped, 04

State=05

State

Any

Resetting, 05

Idle, 06

State

Any

State

Any

The admin program is a mix between procedural and imperative logic; the Sts_State is the key; the related actuators reacts on the Sts_State values.




6.5. Interfaces Configuration

The configuration of the data seen in "Admin" are based on a matrix approach where rows could be related to stations and columns to station's components.

6.5.1. Admin Statistics

Admin Statistics Operator Shift Batch . . .

Machine #01 Adms[0] Adms[1] Adms[2] . . .

. . .

6.5.2. Alarms vs Stations & Severities

Level 1 2 3 4 5 6 7

Meaning Abort Stop Idle Held Suspend Warn Help

Station #00 _Alms[0,1].n _Alms[0,2].n _Alms[0,3].n _Alms[0,4].n _Alms[0,5].n _Alms[0,6].n _Alms[0,7].n

Station #01 _Alms[1,1].n _Alms[1,2].n _Alms[1,3].n _Alms[1,4].n _Alms[1,5].n _Alms[1,6].n _Alms[1,7].n

. . .

6.5.3. Parameters / Cams vs Stations

Parameters Param. 0 Param. 1 Param. 2 . . .

Station #00 Pars[0,0] / Cams[0,0] Pars[0,1] / Cams[0,1] Pars[0,2] / Cams[0,2] . . .





. . .

6.5.4. Reports vs Stations

Reports Report 0 Report 1 Report 2 . . .

Station #00 Reps[0,0] Reps[0,1] Reps[0,2] . . .





. . .

6.5.5. Tracks vs Station's Sides

Statistics First Side Second Side . . .

Station #00 Tracks[0,0] N/A . . .

Station #01 Tracks[1,0] Tracks[1,1] . . .




. . .

6.5.6. Nests Managers vs Fixture's Sides

Nests Manager First Side Second Side . . .

Station #00 N/A N/A . . .

Station #01 Nests[1,0] Nests[1,1] . . .




. . .




6.6. PLC Files


This folder contains every tags defined as private and every tags defined as alias to public references.

6.6.2. Program_Logic

This program contains the logic to manage Sts_State and Sts_Mode versus operator panel (or remote).

6.6.3. Actuators_Sub

This subroutine merges every instruction in charge of actuators related to the machine administration.

6.6.4. AlmScan_Sub

This subroutine scans _Mn_Adm_Alms array to find out the kind of alarm that could be pending

6.7. HMI Screen

See §7.5.3 ...




7. Machine Details

7.1. Header

The header configures the machine organization.

MainType Machine SubType Station Station Station Station Station Station

Main_ID _01 Sub_ID _00 _01 _02 _03 _04 _Admin

MainName Machine SubName BaseFibro LoadBody LoadScrew BuildPart UnloadPart _

MaindT#### 9500 SubdT#### 800 6500 6500 8500 6500 2000

7.1.1. MainType

Could be "Machine" or "Sub-Machine".

7.1.2. Main_ID

"_Mn" if machine, should be from _00 to _99.

"_Mnn" if sub-machine, should be from _000 to _999.

7.1.3. MainName

The convenient machine or sub-machine name description.

7.1.4. MaindT

The ideal expected time response in msec.

7.1.5. SubType

Could be sub_machine or station; the stations are declared in the machine form; one station is equivalent to one column. Usually machine or sub-machine do not need actuator; if not, the routine "Actuators_Sub" would be added.

7.1.6. Sub_ID

If station, should be "M" (_<Sub_MachID>) identifier from 0 to 9.

If station, should be "_Ss" (_<StationID>) identifier from _00 to _99.

7.1.7. SubName

The convenient sub-machine or station name description.

7.1.8. SubdT####


7.1.9. _Adm

If it's not a sub-machine, the latest "station" is dedicated for the "_Adm" program declaration that is always attached to any machines; for this one, no "_ID" number, just "_Adm" statement.

7.2. States

▼ ▲▼ ▲▼ ▲▼ ▲

Stations


Exec.

Aborting Idle

Reseting

Exec.

Aborting Idle

7.2.1. Abort

When Prog.Cmd_State = 1 and Admin_State = 1 (Aborting) then set sequence #01.

7.2.2. Reset

When Prog.Cmd_State = 2 and Admin_State = 5 (Resetting) then set sequence #11.

7.2.3. Exec

When Prog.Cmd_State = 4 send And Admin_State = 8 (Execute) then set sequence #21.

Revision V001_110810

Abort Sts_Seq:=01

Reset Sts_Seq:=11

Exec Sts_Seq:=21




7.3. Diagram

MainType Machine SubType Station Station Station Station Station Station Revision V001_110810

Main_ID _01 Sub_ID _00 _01 _02 _03 _04 _Admin Abort Sts_Seq:=01

MainName Machine SubName BaseFibro LoadBody LoadScrew BuildPart UnloadPart _ Reset Sts_Seq:=11


Cmd_State:=1 Cmd_State:=1 Cmd_State:=1 Cmd_State:=1 Aborting=1 Sts_Safe:=0



Sts_Idle=1 Aborted:=1 Sts_Idle:=1

Resetting=1

Cmd_State:=2 Cmd_State:=2 Cmd_State:=2 Cmd_State:=2 Sts_Safe:=0



Sts_Idle=1 Idle:=1 Sts_Idle:=1

Cmd_State:=4 Cmd_State:=4 Cmd_State:=4 Cmd_State:=4 Execute=1 Sts_Safe:=0



Sts_Idle=1 Sts_Idle:=1

Abort every process station Sts_Seq=01 Cmd_Seq:=02

Abort BaseFibro Sts_Seq=02

Reset Base Fibro Sts_Seq=13

Exec every process Station Sts_Seq=21 Cmd_Seq:=22

Exec Base Fibro Sts_Seq=22

Mode=1-Producing, Mode=2-Maintenance, Mode=4-Manual

Mode=8-Purge, Mode=16-DryCycleSts_Seq=11 Cmd_Seq:=12

Reset every process Station Sts_Seq=12 Cmd_Seq:=13

Config Tracks vs Mode

All sequences defined in the configuration machine form are coded in the "Program_Logic".

The sequence #01 to #02 control "Abort" stations requests.

o Abort station #01 to #04 and check their completion.

o Abort station #00 (the transport) and go to idle.

The sequence #11 to #14 control "Reset" stations requests.

o Configure StationID versus current mode.

o Reset station #01 to #04 versus StationID and check their completion.

o Reset station #00 versus StationID (the transport) and go to idle.

The sequence #21 to #24 controls "Exec" stations requests.

o Exec station #01 to #04 versus StationID and check their completion.

o Exec station #00 versus StationID (the transport) and go to idle.

7.4. Public Data


7.4.1. Program Manager Prog The instance of class Mgr_Prog to manage states and sequences.

7.4.2. Program Track Track The instance of class Mgr_Track to manage statistics and consecutives errors.

7.4.3. Motions Group Motions Motions Group (depends on the PLC's technology).

7.4.4. Motions Array Mots Motions Real array [#,0] = Servo Number, Output Value (Setpoints) [#,1] = Servo Number, Input Value (Position)

7.4.5. Outputs Array Outs Outputs Boolean array

7.4.6. Inputs Array Inps Inputs Boolean array

...




7.5. Interfaces Configuration

7.5.1. Motions Interfaces vs Stations

Motions Interfaces

Setpoints #1 Output

Position #1 Input

Setpoints #2 Output

. . .

Station #00 Mots[0,0] Mots[0,1] Mots[0,2] . . .





. . .

7.5.2. Outputs- & Inputs vs Stations

Interfaces Output Input . . .

Station #00 Outs[0] Inps[0] . . .





. . .

7.6. PLC Files




This program contains the logic to manage the stations.


Usually not applicable at the machine level.

7.7. HMI Screen

See §7.5.3 ...




8. Asynchronous Stations Details An asynchronous process or transactional process individuates each of its activities so that each one commits its operation before execution continues.

8.1. Header

8.1.1. MainType

Could be "Station" or "Sub-station".

8.1.2. Main_ID

"_Mn_Ss" if machine's station, should be from _00_00 to _99_99.

"_Mnn_Ss" if sub-machine's station, should be from _000_00 to _999_99.

"_Mn_Sss" if machine's sub-station, should be from _00_000 to _99_999.

"_Mnn_Sss" if sub-machine's sub-station, should be from _000_000 to _999_999.

8.1.3. MainName

The convenient station or sub-station name description.

8.1.4. MaindT


8.1.5. SubType

Could be station or sub-station; the actuators are declared in the machine form; one actuator is equivalent to one column. All actuators required for stations or sub-stations are controlled in "Actuators_Sub".

8.1.6. Sub_ID

If station, should be "S" (_<Sub_StationID>) identifier from 0 to 9.

If station, should be "_Aa" (_<ActuatorID>) identifier from _00 to _99.

8.1.7. SubName

The convenient sub-station or actuator name description

8.1.8. SubdT####


8.1.9. Sub Details

The actuator #00 is an "Act_Bin" named "ArmGrip" with a 500 msec timeout.

The actuator #01 is an "Act_Bin" named "ArmDown" with a 1000 msec timeout.

The actuator #02 is an "Act_Num" named "ArmMotion" with a 2000 msec timeout.

The actuator #03 is reserved...

The actuator #04 is an "Act_Bin" named "BodyGate" with a 1000 msec timeout.

The actuator #05 is an "Act_Bin" named "BodyFeed" with a 1000 msec timeout.

...

8.2. States

8.2.1. Abort

When Prog.Cmd_State = 1 and Prog.Sts_State = 1 (Aborting) then set sequence #01.

8.2.2. Reset

When Prog.Cmd_State = 2 and Prog.Sts_State = 2 (Resetting) then set sequence #01.

8.2.3. Exec

When Prog.Cmd_State = 4 send And Prog.Sts_State = 4 (Execute) then set sequence #2.

▼ ▲▼ ▲▼ ▲▼ ▲

Stations


Exec.

Aborting Idle

Reseting

Exec.

Aborting Idle

MainType Station SubType Act_Bin Act_Bin Act_Bin Act_Num Act_Bin Act_Bin Revision V001_110810

Main_ID _01_01 Sub_ID _00 _01 _02 _03 _04 _05 Abort Sts_Seq:=01

MainName LoadBody SubName ArmGrip0 ArmGrip1 ArmDown ArmMotion BodyGate BodyFeed Reset Sts_Seq:=01


Cmd_Out:=0 Cmd_Out:=0 Sts_Safe:=0

Sts_Inp=0 Sts_Inp=0


Sts_Inp=1 Sts_Inp=1


Sts_Inp=1 Sts_Inp=0


Sts_Inp=1 Sts_Inp=1

Cmd_Out:=0

Sts_Inp=0

Cmd_Sp:=06 Sts_Safe:=0

Sts_Inp=0

Cmd_Out:=1

Sts_Inp=1


Sts_Inp=0 Sts_Inp=0

Cmd_Out:=0

Sts_Inp=0


Sts_Inp=1 Sts_Idle:=1

Name Domain DataType TagType

Prog Public Man_Prog Alias

Track0 Public Man_Track Alias


Nest0 Public Man_Nest Alias


ArmAxe Public AXIS_GENERIC Tag

ArmCtl Private MOTION_INSTRUCTION[10] Tag

ArmSts Private DINT Tag

Manage Nest0 Statistics _01_Admin_Nests[1,0]

Manage Track1 Statistics _01_Admin_Tracks[1,1]

Sts_Seq=02

Disable Feeder + Close Gate Sts_Seq=01 Cmd_Seq:=08

Armp Up on pick Sts_Seq=05 Cmd_Seq:=06

Arm Down on pick

Close GateSts_Seq=03 Cmd_Seq:=04

Close Gripper on pick

Arm Down on place Sts_Seq=07 Cmd_Seq:=08

Cmd_Seq:=03


Arm Up to place Sts_Seq=06 Cmd_Seq:=07

Enable Feeder + Open Gate

Open Gripper Sts_Seq=08 Cmd_Seq:=09

Arm Up Sts_Seq=09 Cmd_Seq:=10

Arm Up to pick Sts_Seq=10


Motion Axis _01_01_ArmAxe


Manage Prog Logic


Motion Control

Motion Status




8.3. Diagram

All sequences defined in the configuration station form are coded in the "Program_Logic".

The sequence #01 controls actuators #04 and #05 to reset "Sts_Safe" and command sequence #08.

The sequence #02 controls actuators #04 and #05 to command sequence #03.

...

The sequence #10 controls actuators #02 to set "Sts_Safe" and "Sts_Idle" to complete sequencer.

MainType Station SubType Act_Bin Act_Bin Act_Bin Act_Num Act_Bin Act_Bin Revision V001_110810

Main_ID _01_01 Sub_ID _00 _01 _02 _03 _04 _05 Abort Sts_Seq:=01

MainName LoadBody SubName ArmGrip0 ArmGrip1 ArmDown ArmMotion BodyGate BodyFeed Reset Sts_Seq:=01


Cmd_Out:=0 Cmd_Out:=0 Sts_Safe:=0

Sts_Inp=0 Sts_Inp=0


Sts_Inp=1 Sts_Inp=1


Sts_Inp=1 Sts_Inp=0


Sts_Inp=1 Sts_Inp=1

Cmd_Out:=0

Sts_Inp=0


Sts_Inp=0

Cmd_Out:=1

Sts_Inp=1


Sts_Inp=0 Sts_Inp=0

Cmd_Out:=0

Sts_Inp=0


Sts_Inp=1 Sts_Idle:=1







ArmAxe Public AXIS_GENERIC Tag

ArmCtl Private MOTION_INSTRUCTION[10] Tag

ArmSts Private DINT Tag



Sts_Seq=02

Disable Feeder + Close Gate Sts_Seq=01 Cmd_Seq:=08

Armp Up on pick Sts_Seq=05 Cmd_Seq:=06

Arm Down on pick

Close GateSts_Seq=03 Cmd_Seq:=04

Close Gripper on pick

Arm Down on place Sts_Seq=07 Cmd_Seq:=08

Cmd_Seq:=03


Arm Up to place Sts_Seq=06 Cmd_Seq:=07

Enable Feeder + Open Gate

Open Gripper Sts_Seq=08 Cmd_Seq:=09

Arm Up Sts_Seq=09 Cmd_Seq:=10

Arm Up to pick Sts_Seq=10


Motion Axis _01_01_ArmAxe


Manage Prog Logic


Motion Control

Motion Status

8.4. Public Data

8.4.1. Prog

The instance of class Mgr_Prog to manage states and sequences.

8.4.2. Track0

The instance of class Mgr_Track to manage statistics and consecutives errors of 1st side [station,up].

8.4.3. Track1

The instance of class Mgr_Track to manage statistics and consecutives errors of 2nd side [station,up].

8.4.4. Nest0

The instance of class Mgr_Nest to manage statistics of pointed nest on 1st side [station,up].

8.4.5. Nest1

The instance of class Mgr_Nest to manage statistics of pointed nest on 1st side [station,up].




8.5. PLC Files




This program contains the logic to manage actuators in an ASYNCHRONOUS manner.





This subroutine merges every instruction in charge of actuators related to the station.

8.5.4. Motion_Sub

In case of motion (servo-motor) presence, this subroutine contains the instructions to manage it.

8.6. HMI Screen

See §7.5.3 ...




9. Synchronous Stations Details A synchronous process is invoked by a request based on camshaft angle.

9.1. Header

As §9.1.

9.2. States

As §9.2.

9.3. Diagram

All sequences defined in the configuration station form are coded in the "Program_Logic", and the first actuator has to be an "Act_Cam" that would be in charge of checking the right angles at the right time.

The sequence #01 resets every actuators and command sequence #03.

The sequence #02 executes camshaft:

o Request camshaft rotation up to angle 330°.

o Check Sts_Cam to set or reset the related actuators versus camshaft angle.

o When camshaft rotation reaches 330° angle, check actuators and commands sequence #03.

The sequence #03 ends camshaft and set "Sts_Idle" to complete sequencer.

MainType Station SubType Act_Cam Act_Bin Act_Bin Act_Bin Act_Bin Revision V001_110810

Main_ID _01_03 Sub_ID _00 _01 _02 _03 _04 Abort Sts_Seq:=01

MainName BuildPart SubName RotCam Build0 Build1 Check0 Check1 Reset Sts_Seq:=01

MaindT#### 10000 SubdT#### 9000 1000 1000 1000 1000 Exec Sts_Seq:=02

Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0

Sts_Inp=0 Sts_Inp=0 Sts_Inp=0 Sts_Inp=0

Sts_Seq=02 Cmd_Out:=330 Sts_Safe:=0 Cmd_Seq:=03

Sts_Seq=03 Rep_Ante≥090 Cmd_Out:=1 Cmd_Out:=1 Cmd_Seq:=04

Sts_Seq=04 Rep_Ante≥190 Cmd_Out:=1 Cmd_Out:=1 Cmd_Seq:=05

Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0 Cmd_Out:=0

Sts_Inp=0 Sts_Inp=0 Sts_Inp=0 Sts_Inp=0 Sts_Safe:=1

Rep_Ante≥330

Cmd_Out:=000







RotAxis Public AXIS_GENERIC Tag

RotAxisCtl Private MOTION_INSTRUCTION[10] Tag

RotAxisSts Private DINT Tag

RotAxisSts Private DINT Tag

CamAnte Public DINT Alias

CamBuild Public DINT Alias

CamCheck Public DINT Alias

CamDisab Public DINT Alias

Rot Axis Status

Rot Axis Control

Rot Axis Status

Cmd_Seq:=06

Sts_Idle:=1

Disable All Sts_Seq=05 Rep_Ante≥270

Cam Exec

Enable Build

Enable Check

Cmd_Seq:=06

Cam Up

Head Axis _01_03_00_RotAxis

Disable Builds

Disable ChecksSts_Seq=01

Statistics

Description

Program

_01_Admin_Tracks[3,0]

_01_Admin_Tracks[3,1]

_01_Admin_Nests[3,0]

Cam to Disable _01_Admin_Cams[3,3]

Cam to Build

_01_Admin_Cams[3,0]Cam Anticipate

_01_Admin_Cams[3,1]

Cam to Check _01_Admin_Cams[3,2]

Sts_Seq=06

Statistics

Statistics

Full Path TagReference

_01_Admin_Nests[3,1]

Statistics

9.4. Public Data

As §9.4.

Plus additional information about required camshaft angles.

9.5. PLC Files


As §9.5.1.

▼ ▲▼ ▲▼ ▲▼ ▲

Stations


Exec.

Aborting Idle

Reseting

Exec.

Aborting Idle





This program contains the logic to manage actuators in SYNCHRONOUS manner.

Header rungs exactly the same codes between synchronous and asynchronous.

The synchronised sequences starts by defining the came setpoint (330° for instance).

Then each rung starts with a test on sequence followed with by "GEQ" instructions that check if

predefined angle is greater than or equal to "_CamAnte". The last rung of this sequence checks if camshaft reaches the setpoint with every actuators in idle state to request the next sequence #3.


As §9.5.3.

9.5.4. Motion_Sub

As §9.5.4.

9.6. HMI Screen

See §7.5.3 ...




10. Actuators Details The actuators for one station are merged in the subroutine Actuators_Sub in the station sub task.

10.1. Overview

10.1.1. Principle

The actuators embed a timer that is used to control the timeout or to manage the emulation

10.1.2. Behaviour

The actuators behaviour should follow this states diagram

Cmd:=1, this acting state Enables the actuator output in conjunction with time-out control.

Alm1=1, this wait state maintains actuator to be in safe position by DISABLING the actuator physical output.

Sts=1, this wait state maintains the actuator output enabled and performs operations required to check actuators input feedback PRESENCE.

Cmd:=0, this acting state Disables the actuator output in conjunction with time-out control.

Alm0=1, this wait state maintains actuator to be in safe position by DISABLING the actuator physical.

Sts=0, this wait state maintains the actuator output disabled and performs operations required to check actuators input feedback ABSENCE.

10.1.3. Programming Style

The look and feel should be consistent through out all the programming projects...

▼▼

▼▼

▼▼

▼▼

Commands

Cmd_

Configurations

Cfg_

Parameters

Par_

Reports

Rep_

Status

Sts_

Actuator

▼▼

▼▼

▼▼

▼▼

> Incoming Data > > Outgoing Data >

dT►

╓╜dT►

╓╜ &

& &╖╙&╖╙

Cmd_Out

Sts_Alm

Sts_Inp

Sts_Out Cmd_InpCfg_Emulate

Sts_Done

Cmd_Ack

Cfg_NoAlm

%T ►

╓╜%T ►

╓╜ &

Sts_Alm

Cmd_%Out Cmd_%InCfg_Emulate

Sts_Done

dT

Cmd_%Out

&

Sts_%InCmd_Ack

&╖╙&╖╙

Cfg_NoAlm

0ff

On

t1 t2dT0ff

On

t1 t2dTOff

On

t1 t2dTOff

On

t1 t2dT

α

β

t1 t2%T2

min

max

t3 t4 t5

γ

%T3 %T4 %T5

α

β

t1 t2%T2

min

max

t3 t4 t5

γ

%T3 %T4 %T5Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd_On

Cmd_Off

Sts_Off

Alm_On

Alm_Off

Sts_On

Cmd:=1

Cmd:=0Sts=0

Alm1=1

Alm0=1

Sts=1Cmd:=1

Cmd:=0Sts=0

Alm1=1

Alm0=1

Sts=1Cmd:=1

Cmd:=0Sts=0

Alm1=1

Alm0=1

Sts=1




10.2. Binary

Act_Bin is states control for binary component (cylinder, gate, conveyor, etc...)

10.2.1. Single Solenoid - Single Sensor

▼ ▼▲ ▲

Grip

▼ ▲ ▼ ▲

▼ ▼▲ ▲

Grip

▼ ▲ ▼ ▲

10.2.2. Single Solenoid - Double Sensors

▼ ▼ ▲ ▲

Down

▼ ▲ ▼ ▲

▼ ▼ ▲ ▲

Down

▼ ▲ ▼ ▲

10.2.3. Double Solenoids - Double Sensors

▼▼

▲▲

▼▼

▲▲

Pic

k

▼▲

▼▲

Pla

ce

▼▲

▼▲

▼▼

▲▲

▼▼

▲▲

Pic

k

▼▲

▼▲

Pla

ce

▼▲

▼▲

10.2.4. Operator Button with Lamp

StopStop

10.2.5. Emergency Stop




10.2.6. Light / Lamp

10.2.7. Recipe Confirm

10.2.8. Batch Confirm




10.3. Camodulo

Act_Cam is states control for camshaft component (angular axis, came follower, etc...)

10.3.1. Rotary Indexer

10.3.2. Came Follower




10.3.3. Master Came

10.4. Numeric

Act_Num is states control for numeric component. (linear axis, heater, flow meter, etc...)

10.4.1. Probe

10.4.2. Axis




10.5. Pulse

Act_Pls is states control for hysteretic component.(feeder level, flip-flop, tick control, etc...).

10.5.1. Flip-Flop

10.5.2. Feeder Level




A. Appendices

A.1. Overall Model

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Program_Logic Actuators_Sub

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Latecomer_Sub

Trackser_Sub

Motions_Sub

Visions_Sub




A.2. Structured Text

Machine Example :

(* PROGRAM HEADER, Check _01_Adm_SafeID AND Update Status_Abort *)

Prog.Cfg_ActExe:=_01_Adm_SafeID.0; Track.Sts_Abort:=(Prog.Cfg_Safe & Prog.Sts_State.2 & Prog.Sts_Abort);

(* Call Manager_Program, Call Manager_Tracks AND IF State_Once THEN First Sequence *)

Mgr_Prog(Prog);

Mgr_Track(Track,Prog,1,10800);

Track.Cfg_ConsOff:=_01_Adm_ClrID.0; Track.Cfg_OEEOff:=_01_Adm_ClrID.0;

IF _01_Adm_AckID.0 & NOT Prog.Sts_NoAlm THEN Prog.Cmd_State.0:=1; END_IF;

IF Prog.Sts_StateOns THEN

IF Prog.Sts_State.0 THEN Prog.Sts_Seq:=01; END_IF;



END_IF;

(* PROGRAM SEQUENCER, Process Control *)

CASE Prog.Sts_Seq OF

01: (* Abort every process station *)

IF Prog.Sts_SeqOns THEN _01_01_Prog.Cmd_State:=1; _01_02_Prog.Cmd_State:=1; _01_03_Prog.Cmd_State:=1;

_01_04_Prog.Cmd_State:=1; Prog.Sts_Safe:=0; END_IF;

IF NOT Prog.Sts_SeqOns & _01_01_Prog.Sts_Idle & _01_02_Prog.Sts_Idle & _01_03_Prog.Sts_Idle &

_01_04_Prog.Sts_Idle & Prog.Sts_SeqExe THEN Prog.Cmd_Seq:=2; END_IF;

02: (* Abort BaseFibro *)

IF Prog.Sts_SeqOns THEN _01_00_Prog.Cmd_State:=1; END_IF;

IF NOT Prog.Sts_SeqOns & _01_00_Prog.Sts_Idle & Prog.Sts_SeqExe THEN Prog.Sts_Safe:=1; Prog.Sts_Idle:=1;END_IF;

11: (* Config Tracks vs Mode *)

JSR(ProgMode_Sub); Prog.Cmd_Seq:=12;

12: (* Reset every process station *)





13: (* Reset BaseFibro *)



21: (* Exec every process station *)





22: (* Exec BaseFibro *)



IF Prog.Sts_Idle THEN

IF NOT Prog.Sts_Abort THEN Track.Sts_Good:=1; END_IF;

IF _01_03_Nest0.Sts_Abort THEN _01_Adm_Oper.Sts_AbortID.0:=1; _01_Adm_Shift.Sts_AbortID.0:=1;

_01_Adm_Batch.Sts_AbortID.0:=1; END_IF;

IF _01_03_Nest0.Sts_Good THEN _01_Adm_Oper.Sts_GoodID.0:=1; _01_Adm_Shift.Sts_GoodID.0:=1;

_01_Adm_Batch.Sts_GoodID.0:=1; END_IF;

IF _01_03_Nest1.Sts_Abort THEN _01_Adm_Oper.Sts_AbortID.1:=1; _01_Adm_Shift.Sts_AbortID.1:=1;

_01_Adm_Batch.Sts_AbortID.1:=1; END_IF;

IF _01_03_Nest1.Sts_Good THEN _01_Adm_Oper.Sts_GoodID.1:=1; _01_Adm_Shift.Sts_GoodID.1:=1;

_01_Adm_Batch.Sts_GoodID.1:=1; END_IF;

END_IF;

ELSE Prog.Sts_Seq:=0;

END_CASE;

(* PROGRAM FOOTER, IF Config_ActExe THEN Merge every reuiqred Actuators Alarms to update Status_NoAlarm *)

IF Prog.Cfg_ActExe THEN Prog.Sts_NoAlm:=(_01_00_Prog.Sts_NoAlm OR NOT _01_00_Prog.Cfg_ActExe) &

(_01_01_Prog.Sts_NoAlm OR NOT _01_01_Prog.Cfg_ActExe) &



(_01_04_Prog.Sts_NoAlm OR NOT _01_04_Prog.Cfg_ActExe);

END_IF;

(* IF NO Status_NoAlarm THEN check each station IDLE or Alarm to Set Sts_Idle (i.e. alarm pending management) *)

IF NOT Prog.Sts_NoAlm & (NOT _01_00_Prog.Sts_NoAlm OR _01_00_Prog.Sts_Idle) &

(NOT _01_01_Prog.Sts_NoAlm OR _01_01_Prog.Sts_Idle) &



(NOT _01_04_Prog.Sts_NoAlm OR _01_04_Prog.Sts_Idle) THEN Prog.Sts_Idle:=1;

END_IF;




Station Example :

(* PROGRAM HEADER, Check _01_Adm_SafeID AND Update Status_Abort *)

Prog.Cfg_ActExe:=1; Prog.Cfg_Emulate:=1; Prog.Cfg_Safe:=_01_Adm_SafeID.0;

Track0.Sts_Abort:=(Prog.Cfg_Safe & Prog.Sts_State.2 & Prog.Sts_Abort); Track1.Sts_Abort:=Track0.Sts_Abort;

Nest0.Sts_Abort:=Track0.Sts_Abort; Nest1.Sts_Abort:=Track0.Sts_Abort;

(* Call Manager_Program, Call Manager_Tracks AND IF State_Once THEN First Sequence *)

Mgr_Prog(Prog);

Mgr_Track(Track0,Prog,3,9000); Mgr_Nest(Nest0,Prog,_01_Adm_NestID,_01_Adm_NestInt);

Mgr_Track(Track1,Prog,3,9000); Mgr_Nest(Nest1,Prog,_01_Adm_NestID,_01_Adm_NestInt);

Track0.Cfg_ConsOff:=_01_Adm_ClrID.0; Track0.Cfg_OEEOff:=_01_Adm_ClrID.0; Nest0.Cfg_OEEOff:=_01_Adm_ClrID.0;

Track1.Cfg_ConsOff:=_01_Adm_ClrID.0; Track1.Cfg_OEEOff:=_01_Adm_ClrID.0; Nest1.Cfg_OEEOff:=_01_Adm_ClrID.0;

IF _01_Adm_AckID.0 & NOT Prog.Sts_NoAlm THEN Prog.Cmd_State.0:=1; END_IF;

IF Prog.Sts_StateOns THEN


IF NOT Prog.Sts_State.0 THEN Prog.Sts_Seq:=2; END_IF;

END_IF;

(* PROGRAM SEQUENCER, Process Control *)

CASE Prog.Sts_Seq OF

01: (* Disable Feeder + Close Gate *)

IF Prog.Sts_SeqOns THEN BodyGate.Cmd_Out:=0; BodyFeed.Cmd_Out:=0; Prog.Sts_Safe:=0; END_IF;

IF Prog.Sts_SeqExe & NOT BodyGate.Sts_Inp & NOT BodyFeed.Sts_Inp THEN Prog.Cmd_Seq:=8; END_IF;

02: (* Enable Feeder + Open Gate *)

IF Prog.Sts_SeqOns THEN BodyGate.Cmd_Out:=1; BodyFeed.Cmd_Out:=1; END_IF;

IF Prog.Sts_SeqExe & BodyGate.Sts_Inp & BodyFeed.Sts_Inp THEN Prog.Cmd_Seq:=3; END_IF;

03: (* Arm Down on pick Close Gate *)

IF Prog.Sts_SeqOns THEN ArmDown.Cmd_Out:=1; BodyGate.Cmd_Out:=0; END_IF;

IF Prog.Sts_SeqExe & ArmDown.Sts_Inp & NOT BodyGate.Sts_Inp THEN Prog.Cmd_Seq:=4; END_IF;

04: (* Close Gripper on pick *)

IF Prog.Sts_SeqOns THEN ArmGrip0.Cmd_Out:=(Track0.Cfg_Enable & NOT Nest0.Sts_Nesty); END_IF;

IF Prog.Sts_SeqOns THEN ArmGrip1.Cmd_Out:=(Track1.Cfg_Enable & NOT Nest1.Sts_Nesty); END_IF;

IF Prog.Sts_SeqExe & (ArmGrip0.Sts_Inp OR NOT ArmGrip0.Cmd_Out) &

(ArmGrip1.Sts_Inp OR NOT ArmGrip1.Cmd_Out) THEN Prog.Cmd_Seq:=5; END_IF;

05: (* Arm Up on pick *)

IF Prog.Sts_SeqOns THEN ArmDown.Cmd_Out:=0; END_IF;

IF Prog.Sts_SeqExe & NOT ArmDown.Sts_Inp THEN Prog.Cmd_Seq:=6; END_IF;

06: (* Arm Up to place *)

IF Prog.Sts_SeqOns THEN ArmMotion.Cmd_Sp.6:=1; Prog.Sts_Safe:=0; END_IF;

IF NOT Prog.Sts_SeqOns & ArmMotion.Sts_Inp THEN Prog.Cmd_Seq:=7; END_IF;

07: (* Armp Down on place *)


IF Prog.Sts_SeqExe & ArmDown.Sts_Inp THEN Prog.Cmd_Seq:=8; END_IF;

08: (* Open Gripper *)

IF Prog.Sts_SeqOns THEN ArmGrip0.Cmd_Out:=0; ArmGrip1.Cmd_Out:=0; END_IF;

IF Prog.Sts_SeqExe & NOT ArmGrip0.Sts_Inp & NOT ArmGrip1.Sts_Inp THEN Prog.Cmd_Seq:=9; END_IF;

09: (* Arm Up on place *)


IF Prog.Sts_SeqExe & NOT ArmDown.Sts_Inp THEN Prog.Cmd_Seq:=10; END_IF;

10: (* Arm Up to pick *)

IF Prog.Sts_SeqOns THEN ArmMotion.Cmd_Sp.10:=1; END_IF;

IF NOT Prog.Sts_SeqOns & ArmMotion.Sts_Inp THEN Prog.Sts_Safe:=1; Prog.Sts_Idle:=1; END_IF;

IF Prog.Sts_Idle & Prog.Sts_State.2 THEN Track0.Sts_Good:=(Track0.Cfg_Enable & NOT Prog.Sts_Abort);

Nest0.Sts_Good:=Track0.Sts_Good; Nest0.Sts_Nesty:=Track0.Sts_Good; END_IF;

IF Prog.Sts_Idle & Prog.Sts_State.2 THEN Track1.Sts_Good:=(Track1.Cfg_Enable & NOT Prog.Sts_Abort);

Nest1.Sts_Good:=Track1.Sts_Good; Nest1.Sts_Nesty:=Track1.Sts_Good; END_IF;

ELSE Prog.Sts_Seq:=0;

END_CASE;

(* PROGRAM FOOTER, IF Config_ActExe THEN Call Actuators_Sub AND Merge Actuators Alarms to update Status_NoAlarm *)

IF Prog.Cfg_ActExe THEN

JSR(Actuators_Sub);

Prog.Sts_NoAlm:=NOT ArmGrip0.Sts_AlmOff & NOT ArmGrip0.Sts_AlmOn & NOT ArmGrip1.Sts_AlmOff &

NOT ArmGrip1.Sts_AlmOn & NOT ArmDown.Sts_AlmOff & NOT ArmDown.Sts_AlmOn &

NOT ArmMotion.Sts_AlmOff & NOT ArmMotion.Sts_AlmOn & NOT BodyGate.Sts_AlmOff &

NOT BodyGate.Sts_AlmOn & NOT BodyFeed.Sts_AlmOff & NOT BodyFeed.Sts_AlmOn;

END_IF;




Actuators Example :

(* Actuator Arm Grip 0 *)

ArmGrip0.Cmd_Inp:=ArmGrip0_Inp;

ArmGrip0.Cmd_Ack:=_01_Adm_AckID.0;

ArmGrip0.Cfg_OEEOff:=_01_Adm_ClrID.0;

ArmGrip0.Cfg_Emulate:=Prog.Sts_Emulate;

Act_Bin(ArmGrip0,ArmGrip0_Par);

ArmGrip0_AlmOff:=ArmGrip0.Sts_AlmOff;

ArmGrip0_AlmOn:=ArmGrip0.Sts_AlmOn;

ArmGrip0_Out:=ArmGrip0.Sts_Out;

(* Actuator Arm Grip 1 *)

ArmGrip1.Cmd_Inp:=ArmGrip1_Inp;

ArmGrip1.Cmd_Ack:=_01_Adm_AckID.0;

ArmGrip1.Cfg_OEEOff:=_01_Adm_ClrID.0;

ArmGrip1.Cfg_Emulate:=Prog.Sts_Emulate;

Act_Bin(ArmGrip1,ArmGrip1_Par);

ArmGrip1_AlmOff:=ArmGrip1.Sts_AlmOff;

ArmGrip1_AlmOn:=ArmGrip1.Sts_AlmOn;

ArmGrip1_Out:=ArmGrip1.Sts_Out;

(* Actuator Arm Down *)

ArmDown.Cmd_Inp:=ArmDown_Inp OR (NOT ArmDown_Inp & NOT ArmUp_Inp);

ArmDown.Cmd_Ack:=_01_Adm_AckID.0;

ArmDown.Cfg_OEEOff:=_01_Adm_ClrID.0;

ArmDown.Cfg_Emulate:=Prog.Sts_Emulate;

Act_Bin(ArmDown,ArmDown_Par);

ArmDown_AlmOff:=ArmDown.Sts_AlmOff;

ArmDown_AlmOn:=ArmDown.Sts_AlmOn;

ArmDown_Out:=ArmDown.Sts_Out;

(* Actuator Arm Motion *)

ArmMotion.Cmd_In:=ArmMotion_Inp;

ArmMotion.Cmd_Ack:=_01_Adm_AckID.0;

ArmMotion.Cfg_OEEOff:=_01_Adm_ClrID.0;

ArmMotion.Cfg_Emulate:=Prog.Sts_Emulate;

ArmMotion.Cfg_Minimum:=0; ArmMotion.Cfg_Maximum:=10000; ArmMotion.Cfg_InpWidth:=10;

IF ArmMotion.Cmd_Sp.6 THEN ArmMotion.Cmd_Out:=ArmPlace_Par; END_IF;

IF ArmMotion.Cmd_Sp.10 THEN ArmMotion.Cmd_Out:=ArmPick_Par; END_IF;

Act_Num(ArmMotion,ArmMotion_Par);

ArmMotion_AlmOff:=ArmMotion.Sts_AlmOff;

ArmMotion_AlmOn:=ArmMotion.Sts_AlmOn;

ArmMotion_Out:=ArmMotion.Sts_Out;

JSR (Motions_Sub);

(* Actuator Body Gate *)

BodyGate.Cmd_Inp:=BodyGate_Inp;

BodyGate.Cmd_Ack:=_01_Adm_AckID.0;

BodyGate.Cfg_OEEOff:=_01_Adm_ClrID.0;

BodyGate.Cfg_Emulate:=Prog.Sts_Emulate;

Act_Bin(BodyGate,BodyGate_Par);

BodyGate_AlmOff:=BodyGate.Sts_AlmOff;

BodyGate_AlmOn:=BodyGate.Sts_AlmOn;

BodyGate_Out:=BodyGate.Sts_Out;

(* Actuator Body Feed *)

BodyFeed.Cmd_Inp:=BodyFeed_Inp;

BodyFeed.Cmd_Ack:=_01_Adm_AckID.0;

BodyFeed.Cfg_OEEOff:=_01_Adm_ClrID.0;

BodyFeed.Cfg_Emulate:=Prog.Sts_Emulate;

Act_Bin(BodyFeed,BodyFeed_Par);

BodyFeed_AlmOff:=BodyFeed.Sts_AlmOff;

BodyFeed_AlmOn:=BodyFeed.Sts_AlmOn;

BodyFeed_Out:=BodyFeed.Sts_Out;




A.3. Glossary

A.

Aborting Rapid safe stop acting state

Aborted Safe stop complete state, doors are unlocked

Ack Acknowledge used to send acknowledgement

Act_ Actuator used to specify an actuator instruction/function

Act_Bin Actuator class for binary asset (cylinder, gate, conveyor, ...)

Act_Cam Actuator class for camshaft asset (angular axis, came follower, ...)

Act_Num Actuator class for numeric asset (linear axis, heater, flowmeter, ...)

Act_Pls Actuator class for hysteretic asset (feeder, flip-flop, tick, ...)

Activity Model Tasks hierarchy description of procedural items control

Actuator 9 digits - 1 station form column - 1 program rung

Actuator States Cmd_On - Alm_On - Sts_On - Cmd_Off - Alm_Off - Sts_Off

Adm, Admin Administration used at the machine level beside Cmd and Sts.

Adm_NestID Admin reference that gives nest ID offset.

Adm_Update Admin request to update status after a shift.

Agility for last minute changes Combination of "specialization ability" and "flexible aggregation"

Alm Alarm which alarm is occurring within the process

Alpha revision First version or Draft

ANSI American National Standard for Instruments.

Asynchronous Station Single request so each one commits before execution goes on

Availability Operating_Time / Planned_Production_Time

B.

Batch MES to control multiple machines vs batch

Beta revision Second version

Bin Binary used to specify a binary actuator instruction/function

Black Box Outside Scope software module (see states transition testing)

Branch / Decision Testing Test each command and transition step by step (branch accuracy)

C.

Cam Camshaft used to specify a camshaft actuator instruction/function

Categories vs Gamp System - Firmware - Standard - Configured - Fitted software types

Cfg Configuration used to designate a value used in configuring

Cfg_ActExe Config. to enable actuators subroutine.

Cfg_CamAnte Config. to define the angular value to anticipate.

Cfg_CamPost Config to define the angular value to postpone.

Cfg_CamRng Config. to define the came range (360°).

Cfg_SlowPar Config. for slow timeout ratio vs normal timeout.

Cfg_Emulate Config. to enable emulation.

Cfg_InpWitdh Config to define the "in position" bandwidth.

Cfg_Maximum, Config. to define the maximum range value.

Cfg_Mirror Config. to make command mirroring input

Cfg_NoAlm Config. to disable alarming.

Cfg_OEEOff Configuration to disable or reset real-time OEE

Cfg_Safe Config. is safe means the context is under safety conditions.

Cfg_SeqStep Config. to enable step-by-step sequences.

Cfg_Station Config to define the current station number.




Cfg_TrackQty Configuration to define tracks quantity per station

Change Control Software change traceability (revisions numbering)

Check list "Dry-Run" check - "Test-Up" check - "To Do" list

Class diagram Represent main objects and/or interactions in the application

Clr Clear used to designate a command used to clear

Cmd To command input of the instruction/function

Cmd_Ack Command to acknowledge pending alarm.

Cmd_Hold Command to request an immediate motion stop.

Cmd_Inn Command to read from physical input.

Cmd_Inp Command to read from physical input.

Cmd_Loop Command to request a full revolution cycle.

Cmd_Nak Reverse command to acknowledge pending alarm.

Cmd_Out Command to enable/disable output.

Cmd_SeqOns Command one shot under Step-by-Step.

Cmd_Sp Command to switch between different setpoints.

Cmd_State Command to request state change:

Configuration Software modules specification

Code 2nd development phase completed with configuration and code

Ctl Control, Complex PLC 's data structures used to control PLC's

Ctr Counter used to accumulate or increment any type of value

D.

Debug 4th development phase completed with modular testing

Data Flow Testing Test interactions between components connected by data flow

Data In Configuration, Parameters, Options, ...

Data Out Reports, Counters, Tracks, Nests, Effectiveness, ...

DataType Could be Boolean, Integer, Real, String, etc...

Design 1st development phase completed with specification

Diagnostics / Effectiveness real-time OEE on each items to predict and diagnose failures

Domain Applied to tags as public (global) or private (local)

E.

E2ASY Emulation-Effectiveness-Agility-Simplicity-Yeswe comply.

Effectiveness / Diagnostics real-time OEE on each items to predict and diagnose failures

Emulation for early de-risking to pre-test process sequences as soon as possible

E-Stop Emergency stop initiates a Abort request

Execute Running dual state (machine is processing parts)

Extreme Programming Writing the test procedure at the same time the function is coded

F. G. H.

Fail Safe Automatic & safe ability to compensate a failure

FDS Functional Design Specification

Gamp Good Automation Manufacturing Practices.

Gold Release revision Qualified version

HDS Hardware Design Specification

Held Temporary stop complete, wait for operator action

Hierarchy Representation of "above", "below" or "at the same level as" items

HMI Human Machine Interface

Holding Temporary stop acting state, usually to require operator action




I.

...ID Identifier used to merge some Boolean status within an integer

Idle Homing complete state, ready to start !

IEC International Electrotechnical Commission

IEC-61131-3 Normalisation des langages de programmations

IEEE Institute of Electrical and Electronics Engineers

Imperative Logic Considered as an algorithmic declarative programming

Inp Input, Real-time data used to drive the process

Interface Data structure to interconnect software items (object)

IQ Installation Qualification

ISA-S88-01 (IEC-61512-1) Batch Control, Models and Terminology.

ISA-S88-02 (IEC-61512-2) Batch Control, Data Structure & Guideline for Languages.

ISA-S88-05 (IEC-61512-5) Batch Control, Automated Equipment Control Models.

ISA-S88, Commissioning Models and Commissioning / Qualification Mapping.

ISA-TR88.00.02 Machine and Unit States: ISA-S88 Implementation Example.

ISA Instrument Society of America.

ISO International Organization for Standardization

ISO 13849-1 Safety of machinery – Part 1. General principles for design.

ISPE International Society for Pharmaceutical Engineering.

J. K. L.

Jog- In manual mode, negative slow motion request

Jog+ In manual mode, positive slow motion request

Line 1 project title - 1 directory - 1 PLC

Log User Login status of machine.

Logic Could be Imperative or Sequencing Logic

M. N.

Machine 3 digits - 1 file - 1 PLC's task program

Machine Modes Producing - Maintenance - Manual - Purge - Dry cycle - etc...

Machine States Aborting - Aborted - Stopping - Stopped - Resetting - Idle - etc...

MainType Could be machine or sub-machine

Main_ID should be between _00 to _99.

MainName the convenient machine name description.

MaindT#### Ideal expected time response.

Man Manager used to specify a manager instruction/function

MES Manufacturing Execution System

Mgr_Adm Manager for machine statistics

Mgr_Nest Manager for nest statistics

Mgr_Prog Manager for program (mode, states & sequences)

Mgr_Track Manager for track statistics

Mode Mode of the process within the machine

Model A representation of components and their relationships

Modular Testing To test software modules (see Testing).

Module Software Every PLC's explorer files (see POU).

Module Specification Software Configuration

Nest Fixture side or up

Num Numeric used to specify a numeric actuator instruction/function




O.

Object diagram UML diagram that shows the structure of a modelled system.

OEE Overall Equipment Effectiveness

OMAC Organization for Machine Automation & Control

OOP Object Oriented Programming (see UML)

OQ Operational Qualification

Out Output Real-time data driven from the process

P. Q.

PackML Packaging Modeling Language.

Par Parameters are variables that are from an external source

Par_MaxCons Parameter to define consecutive maximum.

Par_TimeIdeal Parameter to define execute ideal cycle time.

Par_TmrOff Parameter to define down threshold delay.

Par_TmrOn Parameter to define up threshold delay.

Par_TimeOut Parameter to define movement timeout.

Performance Total_Pieces / (Operating_Time x Ideal_Run_Rate / 60)

Physics The hierarchy's process tree complying to P&ID tagging

Physical Model A description of physical assets involved in manufacturing

Platform PLC's architecture, coding rules and related user interface

PLC Program Logic Controller

Pls Pulse used to specify a pulse (flip-flop) actuator

POU Program Organization Unit (PLC's Explorer Hierarchy)

PQ Performance Qualification

Procedural Model A logic description required to accomplish a batch

Process Model A batch description required to manufacture something

Prog - Program Task dedicated to a machine and / or station

Qualification Ensure the performance correlates the specification

Quality Good_Pieces / Total_Pieces

R.

RAD Rapid Application Development

Recipe Name of active parameters and camshafts collection

RecipID ID of active parameters and camshafts collection

Recips Storable and restorable parameters and camshafts collections

References PLC's supplier guide lines

Release Candidate Revision Ready to start testing

Rep Reported value designates a value

Rep_Ante Report to indicate current anticipated window angle

Rep_Availability Report to view current OEE availability.

Rep_Consec Report to view current consecutive value.

Rep_CtrAlm Report to view alarming states quantity.

Rep_CtrAbort Report to view aborting sequence quantity.

Rep_CtrGood Report to view good sequence quantity.

Rep_CtrExec Report to view executing sequence quantity.

Rep_CtrTotal Report to view total sequence quantity.

Rep_dT Report to view acting state duration value.

Rep_OEE Report to view current real time OEE value.

Rep_Performance Report to view current OEE performance.

Rep_Post Report to indicate current postponed window angle




Rep_Quality Report to view current OEE quality.

Rep_TmrAbort Report to view aborting time accumulation.

Rep_TmrExec Report to view executing time accumulation.

Rep_TmrTotal Report to view total time accumulation.

Resetting Kind of homing acting state

Revisions Numbering Software change traceability (Change Control)

S.

...s Array of ...used to specify an array of data

S88. 1988's Standard, Batch Control, Models and Terminology.

Safe Safety status of machine/station

SCADA Supervisory Control and Data Acquisition

SDS Software Design Specification

Sequence Procedural action followed by wait condition transition (step).

Sequence diagram Interaction diagram that shows how processes operate

Sequencing logic Considered as a step towards declarative programming

Setup 3rd development phase started with power-up.

Software Programs of instructions for telling a computer what / how to do

Software Plan Design - Code -Debug -Test-up

Specialization Main class subtype also known as the "child" derived class

Standards GAMP, S88, TR88.02, IEC-61131, IEC-61512 and ISO-13849

Start / Re-start Acting state request from wait states or alarm reset in acting states

Starting Previous to execute acting state, usually horning for a while...

State State of the process within the machine/station

State diagram Describes the behaviour of a programmed device

States transition testing Execute valid transitions between module states (see black box)

Station 6 digits - 1 machine file form - 1 task program

Station States Aborting - Resetting - Execute - Idle

Step Procedural action followed by wait condition transition (sequence).

Stop Stop request from any state or Abort request from stopped state

Stopped Standard stop complete state, doors are closed and locked

Stopping Standard stop acting state, also check for doors closed

Sts Status of the process within the instruction/function

Sts_Abort High when abort is pending.

Sts_AlmCons High when consecutive alarm.

Sts_Alm0 High when Alarm because of input not OFF

Sts_Alm1 High when Alarm because of input not ON

Sts_Bad High when execution was bad.

Sts_BadID High when last execution was aborted.

Sts_Done High when time out over.

Sts_dTing High while Prog.Rep_dT is less than Par_TimeIdeal

Sts_Emulate High when program under emulation mode.

Sts_Enable High when current track or nest is enable.

Sts_Good High when las execution was good.

Sts_GoodID High when last execution was good

Sts_Idle High when acting state complete.

Sts_Inn High when the physical input analogical value.

Sts_Inp High when what is the status of physical input

Sts_NakAlm High when no alarm acknowledgement pending




Sts_NestID High when last good execution

Sts_Nesty High when nest filled with some part.

Sts_NoAlm High when no alarm pending.

Sts_Out High when what should be send to physical output

Sts_PartID High when the nested part ID number

Sts_Rev High when reverse motion.

Sts_Safe High when sequence in safe mode.

Sts_Seq High when current sequence.

Sts_SeqExe High when sequence is free to execute.

Sts_SeqOns High when sequence change threshold.

Sts_Seqp High when sequence previously executed.

Sts_Slow High when slow motion.

Sts_State High when current state:

Sts_StateOns High when state change request.

Sts_Station High when last good execution station.

Sts_Tick High when tick state (1/3 of Par_TmrOff)

..._Sub Subroutine dedicated to specific sub-task in a task.

SubType Could be Station or Sub-Station.

Sub_ID Should be after _Mn (_<MachineID>) identifier from _00 to _99.

SubName The convenient station name description.

SubdT#### Ideal expected time response

Suspended Wait state while Incoming starved or outgoing blocked conditions

Suspending Incoming starved or outgoing blocked acting state

Synchronous Station Invoked by a request based on camshaft angle

T.

Tag Index term assigned to a piece of information

TagReference In case of Aliased tag defines the reference tag

TagType Could be "Tag" or "Alias" to another tag

Testing Ensure the performance correlates the specification

Test-Up Last development phase completed with qualification

Tmr Timer driven by system clock or by custom ticks

Topology Hardware model

TR88 S88 Technical Report for Packaging and Assembly Machines.

Track Station side or up

Transition Status condition to step over a sequence.

Typ Complex data structures made up of a data combination

Typ_Batch UDT for MES to control multiple machines vs batch.

Typ_Nest UDT for the nests array for "shift-register" or "Part-Info".

Typ_Recip UDT for storing and restoring parameters and camshaft arrays.

U. V. W. X. Y. Z.

UDT User Defined Type (data structure)

UML Unified Modeling Language (see OOP)

URS User Requirements Specifications

V Life Cycle Methodology to coordinate design, implementation and validation

White Box Inside Scope software module

Yes we comply with standards So we reuse supplier's codes without reinventing wheels




Rapid

Application

Development

Standards

&

References

Good

Automation

Practices

Effectivenessahead diagnosis

with O.E.E.

Emulationfor de-risking

& Fail Safe

Simplicityalways

in mind

Yeswe comply

to standards

Agilityfor "last minute"

changes

A.4. French Summary

La programmation d'une machine automatique est réalisée par des programmeurs, des concepteurs et des intégrateurs. Les formes et les styles de cette programmation peuvent être à la fois monolithique et modulaire. L'objet de ce projet est de spécifier une méthode de programmation compatible avec l'approche modulaire recom-mandée par le standard ISA-S88 (TR-88). Ce projet propose un modèle cohérent d'utilisation et d'interconnexion des machines d'assemblage.

Objectif

Dans l'industrie pharmaceutique, les systèmes les plus demandés sont Rockwell et Siemens.

o But La SW_Platform définit 1 guide de conception pour 2 PLC afin qu'1 seul HMI suffise à les interfacer.

o Besoins En plus du HMI unique, il faut garder 3 fondamentaux à l'esprit:

Standard & Références (State of the Art). versus ISA-S88, ISA-TR88.02 et ISO-13849

Bonne Pratiques d'Automation. avec spécifications, tests et validations

Développement Rapide d'Applications. "Time is money", "Ready early", ...

Aucun d'entre eux n'est facile à mettre en oeuvre.

Pistes E2ASY

Après divers tests de performances, analyse des prix de revient et études des dernières normes, les 5 pistes suivantes semblent offrir les moyens d'atteindre les 3 cibles précédemment citées.

o Emulation pour un de-risking anticipé & un mode sans-échec de reprise automatique

Pour pré-tester et consolider le séquençage des processus.

o Efficience pour le diagnostique avancé

OEE temps-réel détaillée pour chaque élément offrant diagnostique et maintenance préventive.

o Orienté Agilité

Par la combinaison de spécialisations et d'agrégations flexibles, "lego mindstorm"

o Privilégier la Simplicité

Pour coder plus vite des routines plus rapides en réduisant fichiers, données, codes, bugs...

o Yes nous respectons les normes

La compatibilité permet de réutiliser les codes des fournisseurs sans avoir à réinventer la roue.

Only One

HMI-SCADA

For Two

Hardwares




Conclusion

En résumé cette plateforme est prête en contacts-ladder et en structured-text (2 prototypes PLC sont codés). Elle respecte les règles promues par ISA-TR88. 8 routines réutilisables sont définies (Admin, Prog, Track, Nest, Bin, Num, Cam et Pls) et 3 routines (logic-actuators-alarm) constituent la tâche "Admin". Comparées aux 1200 lignes d'instructions des 60 routines des plateformes actuelles, ces 11 routines élémentaires totalisent une 100taine de lignes permettant un "modular testing" économiquement et techniquement abordable; en testant 3 lignes d'instructions à l'heure, cette plateforme est validée en boîte blanche après 35 hr d'efforts (avec des tests préalablement rédigés).

3 besoins majeurs

o Conformité TR88, 1ier modèle mécatronique pour l'industrie Assembly et Packaging.

o Développement rapide d'applications software, "RAD" pour réduire les coûts.

o Adoption de bonnes pratiques d'automation (Gamp 5).

5 pistes tangibles

o Emulation incluse aux actuateurs pour dé-risquer offline et disposer d'un mode sans échec online.

o OEE temps réel incluse dans chaque module pour l'auto-diagnostique et la maintenance préventive.

o Agilité par recombinaison des 4 actuateurs élémentaires déjà implantée sur PDS, EQW1 et RAI01.

o Simplicité avec 3 routines par station (logic-actuators-motions) et 1 fichier de config par machine.

o Compatibilité avec TR88 et Gamp5 (modes, états, alarmes, data-in, data-out, mnémoniques, etc...)

4 managers élémentaires avec les caractéristiques suivantes

o L'OEE temps réel dans 3 managers (Admin, Track et Nest).

o Gestion des modes de marche et des états (Admin).

o Mode dégradé par sélection des Tracks et Nests.

o Séquenceur synchrone et asynchrone (Prog).

o Part-ID and Shift-Register data monitoring.

o Gestion de recettes multiples (Admin).

o Management de batch (Admin).

o Erreurs consécutives.

o etc...

4 actionneurs élémentaires avec les caractéristiques suivantes:

o La commande manuelle sans aucune programmation additionnelle.

o La quittance d'alarme simple ou double (HMI et/ou Enclosure).

o La safety et l'auto-recovery après quittance opérateur.

o L'OEE temps réel dans les 4 actuateurs.

o L'émulation de la réponse temporelle.

o Le mode sans échec par émulation.

o Le mirroring (en mode sonde).

o etc...

En sus

La génération automatique de "tests cases" et la modélisation du "Contrôle d'activité" (HMI, SCADA, Recipe, Batch, etc...) sont en cours de définition; le fichier de configuration définissant les séquenceurs et les données d'une machine et de ses stations dispose d'une macro qui génère les mnémoniques et les lignes d'instructions directement dans un PLC Rockwell; c'est d'ailleurs ce même fichier qui contient les informations nécessaires au volet spécifique d'une SDS machine. Pour conclure en adjoignant le rapport d'analyse des coûts software sur les plateformes actuelles, Komax pourrait envisager une réduction des coûts de développement software de 30 à 40% tout en étant réellement "médical".

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