SESAM September 28, 2010, Humlebaek, Denmark

Transcription

1 SESAM September 28, 2010, Humlebaek, Denmark Charlotta Johnsson Inst. för Reglerteknik, LTH Lunds Universitet, Sverige Humlebaek, Sept 28, 2010 Copyright 2010 Charlotta Johnsson 1 Name: Charlotta Johnsson Resident: Lund, Sweden Employments: Dept. of Automatic, LTH Associate Professor (education and research) Independent consultant, 2004 Siemens, Genova Italy, System Architect, Product Manager PhD studies, Dept. of Automatic LTH, A Graphical Language for Batch Voting member in ISA SP88 & SP95 committees. Chairman European Operations of WBF WBF the Forum for Manufacturing and Automation Professionals Member of, and Swedish national expert in, IEC/ISO JWG Copyright 2010 Charlotta Johnsson 1

2 Overblik over Make2Pack standarderne PackAL, PackML og PackTags. Relationen til ISA Hvad er fokusområdet for de enkelte dele i Make2Pack standarderne. Hvorledes anvendes de enkelte standarder. 3 Copyright 2010 Charlotta Johnsson What is OMAC? ISA? And Make2Pack? Short introduction to the documents PackAL, PackML and PackTags. Present the ISA Standard and Technical Report Where is this work being used to day? 4 Copyright 2010 Charlotta Johnsson 2

3 The OMAC Users Group was formed in OMAC = Organization for Machine Automation and (Open, Modular Architecture ) OMAC is the global organization for automation and manufacturing professionals that is dedicated to supporting the machine automation and operational needs of manufacturing. OMAC has about 500 members from end-user companies, OEM's, and technology providers and integrator companies. There are three Working Groups: Packaging Machinery, Manufacturing Infrastructure, Machine Tool. Copyright 2010 Charlotta Johnsson 5 There are five Packaging machinery sub-groups: PackSoft- developing guidelines for machinery programming languages to ease learning, support transportability of software across platforms, and allow continuing innovation PackConnect- defining the control architecture platforms and connectivity requirements for packaging automation systems PackAdvantage - Identify and communicate to the packaging industry the Benefits/Results of using connect & pack guidelines for packaging automation systems PackML naming convention guidelines for communications between production machinery within the packaging industry. PackLearn - promotes awareness of Group initiatives by defining, and developing programs to meet, the educational and training needs of the industry Copyright 2010 Charlotta Johnsson 6 3

4 The PackSoft sub-group has developed the document: PackAL v1.0 - Packaging Application Function Block Library, Guidelines for programming common functional elements in Packaging. Functional Blocks Structured text Ladder Logic Sequential Function Charts Etc PS_Wind_csv AXIS_REF Axis Axis AXIS_REF SRadius_REF PS_Direction BOOL Execute InVelocity BOOL REAL Velocity Error BOOL REAL SpoolRadius ErrorID WORD REAL SRadius Direction Min_S_Radius REAL REAL REAL REAL Max_S_Radius Acceleration Deceleration Jerk Copyright 2010 Charlotta Johnsson 7 The PackML sub-group has the objectives to collect, from users and suppliers Line types definitions in common use, Machine state names and definitions, Tag names and definitions/data sets. The work has resulted in the following documents: PackML v3.0 Defines State Models PS_Wind_csv PackTags v3.0 Defines Tags AXIS_REF Axis Axis AXIS_REF BOOL Execute InVelocity BOOL REAL Velocity Error BOOL REAL SpoolRadius ErrorID WORD SRadius_REF PS_Direction REAL REAL REAL REAL REAL SRadius Direction Min_S_Radius Max_S_Radius Acceleration Deceleration Jerk Copyright 2010 Charlotta Johnsson 8 4

5 ISA = International Society of Automation ISA is an international society that develops and publishes standards, provides training, publishes books, organized conferences and fairs etc ISA publishes standards for ANSI ANSI = American National Standards Institute ISA has appr members worldwide Copyright 2010 Charlotta Johnsson 9 ANSI/ISA 88: Batch ISA 88 is a standard that focuses on control of batch processes. ISA88, part 1: Models and Terminology ISA88, part 2: Data Structure and Guidelines for Languages ISA88, part3: General and Site Recipes ISA88, part 4; Batch Production Records Draft-ISA 88, part 5: Implementation Models & Terminology for Modular Equipment ISA TR : Machine and Unit States: An implementation Example of ISA88 Copyright 2010 Charlotta Johnsson 10 5

6 The Make2Pack project started in 2003/2004. People from WBF (World Batch Forum) and people from OMAC-Packaging Machines met and saw potentials in comparing, synchronizing and develop common models for discrete and batch control. Copyright 2010 Charlotta Johnsson 11 Make2Pack Copyright 2010 Charlotta Johnsson 12 6

7 Level 4 Level 3 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Reliability Assurance, Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels. Months, weeks, days 3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process. Days, Shifts, hours, minutes, seconds Level 2 Level 1 Batch & Converting & Packaging 2 - Monitoring, supervisory control and automated control of the production process 1 - Sensing the production process, manipulating the production process Level The actual production process Copyright 2010 Charlotta Johnsson 13 Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc 4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels. Months, weeks, days Level 3 Level 2 Level 1 Level 0 Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Reliability Assurance,... ISA 88 Batch & Converting & Packaging 3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process. Days, Shifts, hours, minutes, seconds 2 - Monitoring, supervisory control and automated control of the production process 1 - Sensing the production process, manipulating the production process 0 - The actual production process Copyright 2010 Charlotta Johnsson 14 7

8 Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc 4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels. Months, weeks, days Level 3 Level 2 Level 1 Level 0 Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Reliability Assurance,... ISA 88 OMAC Batch & Converting 3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process. Days, Shifts, hours, minutes, seconds 2 - Monitoring, supervisory control and automated control of the production process & Packaging 1 - Sensing the production process, manipulating the production process 0 - The actual production process Copyright 2010 Charlotta Johnsson 15 Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc 4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels. Months, weeks, days Level 3 Level 2 Level 1 Level 0 Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Reliability Assurance,... Batch ISA 95 ISA 88 OMAC & Converting 3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process. Days, Shifts, hours, minutes, seconds 2 - Monitoring, supervisory control and automated control of the production process & Packaging 1 - Sensing the production process, manipulating the production process 0 - The actual production process Copyright 2010 Charlotta Johnsson 16 8

9 Level 5 Level 4 Business Management Facility planning (buy, sell), cash management, asset management, product management Business Planning & Logistics Plant Production Scheduling, Operational Management, etc 5 - Develop business plan, resource plan, cash management plan, financials, Product Business Planning - ERP management, Long-term data management, Pay Roll, Human Recourses Years, Quarters, Months, Weeks 4 - Establishing the basic plant schedule - Business Execution - ERP production, material use, delivery, and shipping. Determining inventory levels. Months, weeks, days Level 3 Level 2 Level 1 Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Reliability Assurance,... Level 0 ISA 95 ISA Batch & 88 ISA Converting 88 Part 5 OMAC 3 - Work flow / recipe control to produce the ` desired Manufacturing end products. Execution Maintaining - records MES and optimizing the production process. Days, Shifts, hours, minutes, seconds Factory Floor Automation 2 - Monitoring, supervisory control and automated control of the production process & Actuators and Instruments Packaging 1 - Sensing seconds, the milliseconds production process, microseconds manipulating the production process 0 - The actual production process Copyright 2010 Charlotta Johnsson 17 ENTERPRISE SITE ISA88 AREA PRODUCTION LINE PRODUCTION UNIT PROCESS CELL STORAGE ZONE WORK CELL UNIT UNIT STORAGE UNIT Lower level equipment used in repetitive or discrete operations Lower level equipment used in continuous operations Equipment Module Module Lower level equipment used in inventory operations Copyright 2010 Charlotta Johnsson 18 9

10 Batch Process Unit 2 Batch Process Batch Process Batch Process Unit 1 Bagger Packing Process Batch Process Storage Cartoner Case Packer Packing Process Palletizer Packing Line(s) E.g.. Primary, secondary, tertiary Unit 2 Machine e.g. Bagger, Filler, Capper, Labeler Station of a Filler (Station, Section, Unit Function) e.g. Forming station, material injection Actuator, sensor or positioner e.g. stepping motor, servo motor and drive, torque sensor, rejection mechanism Copyright 2010 Charlotta Johnsson 19 Part 3 Parts 1 & 2 Part 5 Enterprise Site Process Cell Unit Unit Equipment Module Module General and Site Recipes Master and Recipes Recipe Coordination and Recipe Procedural TR 02 and other future work Recipe/ Equipment Interface Equipment Equipment Coordination Equipment Procedural Equipment Basic Part 4 Batch Production Records Copyright 2010 Charlotta Johnsson 20 10

11 ISA88 concepts Copyright 2010 Charlotta Johnsson 21 ISA 88 Batch 1. Defines structures and models for organizing control systems for flexibility and modularity 2. Defines a recipe/equipment model for batch functions 22 Copyright 2010 Charlotta Johnsson 11

12 PLC PLC What Information is Central to Batch? The Schedule We need to make a batch of QR6 Execution QR6 The Batch Equipment & Other Resources The Recipe The Report 23 Copyright 2010 Charlotta Johnsson Recipes reference basic equipment capabilities, independent of how the capabilities are actually implemented Manual & Automated Operations handled the same way 1. xxx 2. xxx 1. xxx 2. xxx 1. xxx 2. xxx 1. xxxx 2. xxxx Copyright Dennis Brandl 24 Copyright 2010 Charlotta Johnsson 12

13 Equipment entities and procedural elements may have modes Automatic Semi-automatic Manual 25 Copyright 2010 Charlotta Johnsson Equipment entities and procedural elements may have states. An example of procedural states: 26 Copyright 2010 Charlotta Johnsson 13

14 PLC PLC ISA88 Part 5 Copyright 2010 Charlotta Johnsson 27 Part 5: Implementation Models & Terminology for Modular Equipment ISA88 Part 5 provides detailed guidance on how to create the actual automation that delivers the Equipment concept as defined in Part xxx 2. xxx 1. xxx 2. xxx 1. xxxx 2. xxxx 1. xxx 2. xxx Copyright 2010 Charlotta Johnsson 28 14

15 Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Level 3 Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Reliability Assurance,... ENTERPRISE SITE Level 2 AREA Level 1 Level 0 ISA Batch & & Converting Packaging 88 ISA 88 Part 5 PRODUCTION LINE WORK CELL Equipment Module PRODUCTION UNIT UNIT Equipment Module PROCESS CELL UNIT ISA 88 Equipment Module STORAGE ZONE STORAGE UNIT Module Module ISA 88 Part 5 Module Copyright 2010 Charlotta Johnsson 29 Working Draft 6 out (July 2010) During the last years the work has been lessened with all the changes in the ISA88-Part 1 update WEB Ex and Face-To-Face meetings scheduled regularly. The work is led by Dave Chappell (chappell.da@gmail.com) Copyright 2010 Charlotta Johnsson 30 15

16 ISA88 Part 5 Technical Report Copyright 2010 Charlotta Johnsson 31 Official name: ISA-TR Machine and Unit States: An Implementation Example of ISA-88 Approved: August 1, 2008 The ISA88 committee has defined a set of standards that provides terminology and a consistent set of concepts and models for batch manufacturing plants and batch control. These standards, however, were not defined in the context of packaging machines or machines that perform discrete operations. This technical report is an example of the application of the ISA 88 standards for packaging machines and other types of discrete operation machines that perform a single dedicated operational function. Copyright 2010 Charlotta Johnsson 32 16

17 PLC PLC The purpose of the technical report is to a) Explain functional state programming for automated machines; b) Identify definitions for common terminology; c) Explain to practitioners how to use state programming for automated machines; d) Provide actual implementation examples and templates from automation control vendors; e) Identify a common tag structure for automated machines in order to: Provide for Connect & Pack functionality; Provide functional interoperability and a consistent look and feel across the plant floor; Provide consistent tag structure for connection to plant MES and enterprise systems. Copyright 2010 Charlotta Johnsson 33 The TR defines a common model for communication between machines (represented as Units in the ISA 88 model) and a recipe execution system using OPC tags. The terms and definitions are harmonized, as much as possible, with ISA xxx 2. xxx 1. xxx 2. xxx 1. xxxx 2. xxxx 1. xxx 2. xxx Copyright 2010 Charlotta Johnsson 34 17

18 The models used in this document are extensions to the procedural and equipment state and mode models presented in ISA88.01 and describe how they could be applied to the similar, yet somewhat differing machine functionality. Copyright 2010 Charlotta Johnsson 35 Copyright 2010 Charlotta Johnsson 36 18

19 Producing Mode Maintenance Mode Manual Mode Copyright 2010 Charlotta Johnsson 37 The TR identifies a common communication tag structure for automated machines in order to: Provide consistent tag structure for connection to plant supervisory, MES and enterprise systems. Provide functional interoperability and a consistent look and feel across the plant floor. Provide for Connect & Pack functionality defined by OMAC. PackTags are broken out into three groups Command Tags Status Tags Administration Tags Copyright 2010 Charlotta Johnsson 38 19

20 Conclusions Copyright 2010 Charlotta Johnsson 39 Tack för er uppmärksamhet! Charlotta Johnsson Voting member ISA SP88 Voting member ISA SP95 National Expert IEC/ISO JWG 15 Humlebaek, Sept 28, 2010 Copyright 2010 Charlotta Johnsson 40 20