VISUALISATION OF COMPLEX PROCESSES OF CONTROL

Transcription

1 International Journal of Advanced Research in Engineering and Technology (IJARET) Volume 7, Issue 2, March-April 2016, pp , Article ID: IJARET_07_02_016 Available online at Journal Impact Factor (2016): (Calculated by GISI) ISSN Print: and ISSN Online: IAEME Publication VISUALISATION OF COMPLEX PROCESSES OF CONTROL Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska, Jacek Kozyra University of Technology and Humanities, Faculty of Transport and Electrical Engineering, ul. Malczewskiego Radom,Poland ABSTRACT Visualisation application based on Wonderware InTouch is presented in this article. This software is an engineering tool created for visualisation and control of industrial processes, meeting all guidelines of SCADA systems (Supervisory Control and Data Acquisition) and HMI (Human Machine Interface). It is also a part of Wonderware System Platform. This platform is a set of services and applications using ArchestrA technology. The authors showed the options of technical solutions in creating visualisation applications and supervision and control of large and complex control objects. Keywords: Process Visualization, Scada, Industrial Process Cite this Article: Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska and Jacek Kozyra Visualisation of complex processes of control. International Journal of Advanced Research in Engineering and Technology, 7(2), 2016, pp INTRODUCTION Visualisation is a dynamically developing field of technology, combining many issues related to control, exchange, archiving and processing of process data in the industry and scientific research.[1],[2] In general, visualisation is a method of creating, analysing and transmitting information using visual means, which are based on a real object, reflecting its state in real time.[20] Visualisation environments must provide not only predefined options of object programming, but also meet requirements of real time systems. Moreover, visualisation applications should provide interface for processing and acquisition of data, enabling support of database applications.[4],[5],[6] This solution enables reporting, diagnostics and statistical editor@iaeme.com

2 Visualisation of complex processes of control control, which would be difficult or impossible in the systems that not use visualisation means.[18],[19] Analysis of visualisation applications is based on Wonderware InTouch. This software is an engineering tool created for visualisation and control of industrial processes, meeting all guidelines of SCADA systems (Supervisory Control And Data Acquisition) and HMI (Human Machine Interface).[7],[8],[22] The main feature of InTouch is fast and intuitive use of predefined visual objects and their large library.[9] 1. APPLICATION TEMPLATE OF VISUALISATION PROJECT Creating a visualisation project starts from creating an application template, which allows to divide a model into smaller functional units and realizing functionality of these units in stages and then integrating them. A diagram illustrating the stages of creating a visualisation application is presented in the Fig. 1. This diagram shows that defining an application template and its content is one of the first and the most important activity that a designer must make. Typical template should have a window fulfilling a role of information bar, main window showing a model of visualisation and navigation window.[10] A diagram of hierarchy of windows in the application is presented in the Fig. 2, implementing a template in In Touch in the Fig. 3 Planning Creating a model Combining windows Determining which information should be displayed Determining the number of windows in the application Determining hierarchy of windows Drawing all objects in the windows w Creating navigation from an application template Combining objects and parts of model with tags Declaration of variables Creating combinations of animation objects Creating a Bindlist Data archiving Defining ODBC driver Creating reports Rys. 1 Diagram showing the stages of creating a project of visualisation application editor@iaeme.com

3 Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska and Jacek Kozyra Status bar Navigation Alarms Trends Reports Login Current History Main window Machine 1 Machine 2 Machine 3 Machine n Rys. 2 Diagram of hierarchy of windows Rys. 3. Control application of Tobacco Factory ( 1. menu information bar showing: name of a user, access level, date and hour; 2. main visualisation window; 3. menu bar with the references to all the most important windows and functions in the application.)[3] editor@iaeme.com

4 Visualisation of complex processes of control Visualisation application created for the purposes of this article is SCADA system responsible for control, supervision and acquisition of data of Tobacco Factory, the so-called primary department responsible for preparing and processing tobacco. In this part of the plant, forming, packing and production of cigarettes do not take place. Preparing tobacco for further use is made in stages. Subsequent stages of preparing tobacco are presented in the diagram below (Fig. 4). Tobacco production process is divided into two parts: initial conditioning and drying. (Fig. 3) Each zone is finished with silos for storing tobacco until decisions about further processing is made. This solution also allows to store product in case of failure of any of the belt conveyors, preventing from stoppage of production line. Two buffers regulating the amount of tobacco put into precision cutting machine and dryer were also installed in the second zone. Buffering machines, due to smaller capacity than silos, give better precision of control of tobacco put into the machines. Conditioning preliminary Drying zone and storage Buffer 1 Guillotine Slicing DCC Buffer 2 Refinement Storage silos Accessories Drying Scent Silos final Rys 4 General diagram of a process of tobacco production [3] 2. CURRENT AND HISTORICAL ALARMS InTouch is equipped with a system informing an operator about the state of process and control system.[10],[14] This system enables to display, print and keep the register of history of alarms and events occurring and registered in the system. Modules of tables and a set of variable fields are used for displaying and management of alarms. Alarms alert about some values of the process, whereas events contain information about the state of the system. A window of historical alarms is presented in the Fig. 5 It differs from a window of current alarms only in declaration Query Type: Historical and lack of buttons confirming acceptance of individual historical alarms. The remaining functionality is identical as in the window of current alarms editor@iaeme.com

5 Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska and Jacek Kozyra Rys. 5 A window of historical alarms [3] 3. STATISTICAL CONTROL OF SPC-PRO PROCESS SPCPro was created to fully integrate functions of SPC with In Touch. SPC is short for Statistical Process Control. In this method, data about the process are collected and analysed in order to solve quality problems. A term "statistical" means using of numerical calculations. A term "process" refers to a given production process and its ability to get an appropriate quality. A term "control" means monitoring the process and its regulation, whenever the need arises, in order to enable optimal realization of a process.[16],[17] To sum up, SPC control is a method of monitoring and control of a process, that is, collecting parameters characterizing output, analysing these data and drawing conclusions based on them.[12],[11] A window of control card of statistical control is presented in the Fig. 6 SPC module requires to use ODBC driver, the simplest solution is to use small databases in MS Access or to link module with a database server. Due to the fact that this module is a standard equipment of application, reported information are more important for an experienced statistician than operator.[15] Therefore, it is better to use a server with an option of making resources from TCP/IP protocol available, for example, MS SQL Server It allows to link application of production layer with business layer in a configuration server-server editor@iaeme.com

6 Visualisation of complex processes of control Fig. 6 Control card of SPC module [3] Components linked with a module of SPC-Pro software can be found in a library FactorySuite, among others, Control card (Fig. 6), SPC Histogram (Fig. 7) and Pareto chart (Fig. 8). Declaring SPC module in InTouch automatically creates a group of alarms related to the values monitored by this module. Rys. 7. Part of SPC-Pro module SPCHistogram [3] editor@iaeme.com

7 Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska and Jacek Kozyra Fig 8 Part of SPC-Pro module SPCPareto [3] 4. MOBILE TECHNOLOGIES IN AN ENTERPRISE Mobile technologies are more and more commonly applied in the production plants. A person having a smartphone or tablet can, in the city centre, keep an eye on the progress of production, potential stoppages, and even makes changes in a production line. In practice, it means that using, for example, a mobile phone, we may track not only columns and charts that show functioning of an enterprise, but also use many settings allowing to generate reports, change of parameters of devices and advanced functions connected with the whole production process (Fig. 9)[21]. In this case, technological bar is set very high. Any devices with the access to the Internet may become an important element of production process. Access to application is realized directly from the internet browser, therefore, installing additional software on a mobile device is not required. Technical requirements are not complicated, for example, for Wonderware InTouch Access Anywere, management of production is possible from the level of any device with the internet browser supporting HTML5. Figure 9 Visualisation of complex processes of control with the use of mobile technologies [21] Implementing mobile applications should be performed together with formulating new safety procedures in a company. We must also remember that new technologies bring also new threats.[21] editor@iaeme.com

8 Visualisation of complex processes of control 5. CONCLUSIONS Development of systems of industrial automation is mainly connected with development of computerization, communication, telemetry and planning. All these issues are integral part of large industrial plants and without computer support, its realization would be difficult or even impossible. Producers of software created for production more and more often enable cooperation of application with different layers of IT systems. It enables cooperation between control, planning and business layers. Wonderware InTouch is a software for visualisation of processes in SCADA and HMI systems. It is also a part of Wonderware System Platform. This platform is a set of services and applications using ArchestrA technology. This technology has now four main trends which enable: open communication between various systems, support for ERP systems (Enterprise Resource Planning) planning resources of an enterprise (e.g. cooperation with SAP system), use of such technologies as: OPC, SQL, XML, OLE DB/ADO in the applications supporting systems: MES (Manufacturing Execution Systems) systems of realization of production, HMI, DCS (Distributed Control System) distributed control systems, Historian or SCADA; communication with actuators and PLC drivers through development of technology: DI Objects, DA Server, I/O Server, OPC Server. REFERENCE [1] Kwicień Roman, Komputerowe systemy automatyki przemysłowej, Helion, Gliwice [2] Vieira Robert, SQL Server 2005 Programowanie, Helion, Gliwice [3] Opracowanie Zakładu Automatyzacji Procesów UTH Wizualizacja wybranego procesu przemysłowego_intouch Radom 2013 [4] Schneider Electric, 8 Chapter Human-machine interface, Singapur [5] Informator Techniczny Wonderware nr 10, ASTOR, Kraków [6] Kuśmińska-Fijałkowska, A., and Z. Łukasik. Efekty wynikające z wdrożenia Systemu Zarządzania Jakością, Logistyka (2014). [7] National Communications System, Technical Information Bulletin 04-1: Supervisory Control and Data Acquisition (SCADA) Systems, Arlington U.S.A [8] FactorySuite Menedżer receptur Podręcznik użytkownika, ASTOR, Kraków [9] Invensys Systems, Inc., FactorySuite Menedżer SQL Access Podręcznik użytkownika, Wonderware, Wersja A, Lake Forest U.S.A [10] Materiały szkoleniowe, InTouch Cz. II: Zagadnienia zaawansowane, ASTOR, Kraków [11] Łukasik, Zbigniew, Aldona Kuśmińska-Fijałkowska, and Waldemar Nowakowski. "Europe's energy efficiency requirements for household appliances." Przegląd Elektrotechniczny 91.3 (2015): [12] Invensys Systems, Inc., FactorySuite SPCPro Podręcznik użytkownika, Wonderware, Wersja A, Lake Forest U.S.A [13] editor@iaeme.com

9 Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska and Jacek Kozyra [14] Prof. Dr. Z. ŁUKASIK, Ph.D, DSc, Dr. Eng. Aldona Kuśmińska-Fijałkowska and Dr. Eng. Waldemar Nowakowski, Ecological Powder Coating Technology Based On Innovative Solutions. International Journal of Advanced Research in Engineering and Technology, 5(9), pp [15] Kuśmińska-Fijałkowska, A., and Z. Łukasik, Koordynowanie działań w organizacji w odniesieniu do systemu zarządzania jakością, Logistyka 3/2014. ISSN [16] Kozyra, J., and A. Kuśmińska-Fijałkowska, Elementy liniowej logistyki stosowane w zabezpieczaniu obiektów zagrożonych wybuchem, Logistyka 4/2014. ISSN [17] Czarny, Krzysztof, Andrzej Rozmarynowski, and Jerzy Wojciechowski. Tendencje zużycia energii elektrycznej wybranych obszarów zasilania." [18] Zakrzewski, B., and D. Zakrzewska, Rola zaopatrzenia i metodyka wyboru dostawcy w działalności przedsiębiorstw przemysłowych, Logistyka(2014). [19] Zakrzewski, B., and D. Zakrzewska, Przedsiębiorstwo produkcyjne i procesy realizowane w sferze produkcji, Logistyka(2014). [20] Olczykowski, Z., and J. Wojciechowski. Pomiary podstawowych parametrów jakości energii elektrycznej z wykorzystaniem mierników wirtualnych." Prace Naukowe Politechniki Radomskiej, Elektryka 2. [21] Arkadiusz Rodak Czy smartfon może być narzędziem do zarzadzania nie tylko biurem, ale i fabryką Biuletyn Automatyki nr 84 2/2015 ISSN [22] Jitendra Kumar Gupta and Dr. Anil Kumar Sharma, Programmable Logic Controller Based Implementation of Supervisory Control for Sugar Refinery.International Journal of Advanced Research in Engineering and Technology, 5(9), pp editor@iaeme.com