Inteface requirements and specifications for units, PackML for unit supplyer.

Inteface requirements and specifications for units, PackML for unit supplyer

PackML- Agenda

What is the problem to be solved?

Why standardize interface?

How is the solution? Organizational Technical

Demands to unit supplier Specification Test

Other devices SafePLC and E-Stop Scale and Printer

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What is the problem to be solved?

Unit suppliersSystem integratorDairy

Problem – Interfaces1) Vertically (Unit to supervisory control system)

2) Horisontal (unit to unit)

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Why standardize interface to units?

• Easier coupling units in a line• Easier deployment of job data• Easier detection of warnings and errors• Better supervisory control and data acquisition• Standardized measurements of OEE

• Define “best practice” • Easier ways to change control on units, supervisory control and MES.• Common data interface and I/O interface to all units

• Common commands, states, modes, eventID, warning & errors• Reduce system and interface complexity (technically and

organizationally)

Unit

Line Controller

MES

SAP

CAPEX: Reduces develoment time and costOPEX: Improve OEE and reduce maintenance cost

PackML

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How is the solution? - Technical

• One Interface State Model• Definition of a Unit• The control of a line an units• Digital I/O for synchronization of units• The Interface State Model• Control Commands• Unit Control modes• Data requirements for OEE calculation

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How is the solution? - Technical: One Interface State Model

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How is the solution? - Technical: Definition of a Unit

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How is the solution? - Technical: The control of a line an units

The data types are:• Job data (Recipe and Unit Parameter)

• Command• Unit State • Unit Mode• Warning & Errors• OEE data• Additional data

The physical I/Os:• Used for fast control and

synchronization of units in the line

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How is the solution? - Technical: Digital I/O for synchronization of units

Infeed Ready

Downstream Ready

Comments

1 1 The unit(N) is ready to produce - Execute.1 0 The unit(N) is ready to produce, but the downstream unit(N+1) is not

ready to receive products. The unit(N) is only able to produce until the internal buffers are full. Hereafter, the unit(N) will move to the SUSPENDED state.

0 1 The unit(N) is not ready to produce. The downstream unit(N+1) are ready to receive products. The reason for the non ready unit(N) can be that the unit isn’t started, the units is moved to HELD state, STOPPED state or COMPLETE state

0 0 Either the unit(N) or the downstream unit(N+1) aren’t ready to produce.

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How is the solution? - Technical: The Interface State Model

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Color DescriptionGreen Dual State - The Unit is in a stable acting state - Unit is producing. Blue Wait State – A stable state used to identify that a Unit has achieved a defined set of conditions.

In such a state the Unit is holding or maintaining a status until transitioning to an Acting state (White color). The unit is powered and stationary.

White Acting State – A state which represents some processing activity e.g. ramping up speed.It implies the single or repeated execution of processing steps in a logica order, for a finite time or until a specific condition has been reached, e.g. Starting is checking the quality af the received data, before raping up speed for execution.

Red Wait state – A state which represents an error state on the Unit. In this state the Unit is not producing, until the operator have managed to make a transition to the EXECUTING state. The state holds the unit operations while material blockage are cleared, or safe correction of an equipment fault before the production may be resumed.

Orange Wait State – A state which represents an error state on the line and the Unit is running at a relevant set point speed, but there is no product being produced while the unit is waiting for external process conditions to return to normal. The unit will also enter this state if the operator want to have a break.

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How is the solution? - Technical: Control Commands

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How is the solution? - Technical: PackML State model implementation

Unit Control Modes

Description PackML State Model implementation(Mandatory / Optional)

Undefined Initialization of Unit when power up.

No

Producing The Unit executes relevant logic in response to commands which are mainly coming from line controller, or entered directly by the operator.

Mandatory

Maintenance This mode allows authorized personnel to run the Unit independent of other Units in the production line. This mode would typically be used for faultfinding, machine trials, or testing operational improvements. Fx. Cleaning a print head is maintenance.

Optional

Manual This provides an operator to directly control of individual Unit modules. This feature will be used for the commissioning of the Unit for testing and synchronization of drivers, to set up Unit specific parameters.

Optional

Clean Clean the Unit. OptionalJog Step through a process. OptionalCIP Cleaning in Process (CIP). Optional….. ….. Optional

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How is the solution? - Technical: Data requirements for OEE calculation

• Unit only send OEE data to the line controller.• OEE calculation off KPI etc. is not a part of the unit.• OEE data to be send contains :

• EventID• Detailed error info• Product counters

Line Controller

OEE Data

OEE calculation

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OEE and product counters:The counters must be reset with a new recipe. The counter is reset in the resetting state. The reset proces is issued by a Reset command.

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Demands to unit supplier- Specifications

• Software Design Specification (SDS)• Communication topology• Standard communication data

• Handshake • Mode and State• Command

• Unit specific communication data• Job data• Warning and error• OEE data• Additional data

• SDS Template, and SDS examples

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Demands to unit supplier- Test

• Test requirements• PackML Factory Acceptance Test• PackML I/O test• PackML Site Acceptance Testing• PackML Take Over Certificate

• Test Suitcase for Factory Acceptance Test

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Demands to unit supplier- Specifications test: Communication topology

Unit specific Unit specific

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Demands to unit supplier- Specifications & test: Standard communication data

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Addr.

Description Data format

Value range

Unit Data length

0.0 Not used Byte 0-1 1 Byte1.0 Not used Byte 0-1 1 Byte2.0 Heart Beat Unit

Increment frequency 2 HzINT 0-100 2 Bytes

DB100 Unit write

Addr.


Value range

Unit Data length

0.0 Not used Byte 0-1 1 Byte1.0 Not used Byte 0-1 1 Byte2.0 Heart Beat Line Controller

Increment frequency 2 HzINT 0-100 2 Bytes

DB106 Line Controller write

Data Block “Heart Beat”

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Data Block “Mode” and “State”

DB101 Unit write

Addr. Description Data format

Value range

Unit Data length

0.0 Status Unit Byte 0-1 1 Byte1.0 Status Line Controller Byte 0-1 1 Byte2.0 Mode INT 1-32 2 Bytes4.0 State INT 1-17 2 Bytes

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DB107 Line Controller write

Data Block “Command”

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Demands to unit supplier- Specifications & test: Unit specific communication data

Data Block “Job data”(Recipe and Unit Parameter)

DB102 Unit write (download)/ DB108 Line controller write (upload)

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Data Block “Warning & ErrorDB 104 Unit write

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Data Block “Warning & ErrorWarning

Error

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Data Block “OEE data”

DB 103 Unit write

Addr.


Value range Unit Data length

0.0 Status Unit Byte 0-1 1 Byte1.0 Status Line Controller Byte 0-1 1 Byte2.0 EventID INT XXX 2 Bytes

4.0 Detail Error Info(First error)

INT XXX 2 Bytes

6.0 Good product counter DINT 1 – 99999999 pcs 4 Bytes

10.0 Rejected portions counter

DINT 1 – 99999999 pcs 4 Bytes

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Data Block “Additional data”(f.x. Unit to unit data)

DB105 Unit write DB109 Line controller write

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Demands to unit supplier- Specifications & test: PackML Factory Acceptance Test

PackML Factory Acceptance TestThe purpose of this test is to test the interface data blocks and the I/O signals are working correctly and the physical Unit response to the exchanged information and commands. Reference is made to the Agreement. The test will take place at the seller and buyer provides a test case available that can act Line Controller and test the unit communication, state model, eventIDs and data structures. The test is carried out in order to verify that the data blocks can be exchanged between the Unit and the Line Controller. Furthermore, the content of the data blocks needs to be tested. It is warnings, errors, job data, and OEE data. The test will also include the control of the Unit from the Line Controller and the response from the Unit when an error occurs. For example open a door, send information about Held state and the OEE EventID. All relevant seller personnel must be present during the test. The Software engineer and the architect of the Unit must be present during the test. A software engineer appointed by the Buyer might be part of the test.

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Demands to unit supplier- Specifications & test: PackML I/O test

PackML I/O testThe I/O test will take place at the Place of Installation, and the purpose is to control that the wiring is done correctly between the Unit and the Line Controller. It might include control signals, Infeed ready, and downstream ready. The E-stop Is to be tested separately. The buyer appoints a software engineer that will describe the results in a test report.

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Demands to unit supplier- Specifications & test: PackML Site Acceptance Testing

PackML Site Acceptance TestingThe Site Acceptance Test is to verify that the Unit can run according to the defined performance criteria - Reference is made to the Agreement. It includes a full test of interface, the mapping and PackML states and OEE EventIDs, the exchange of warning and error information. The calculation of OEE figures will be tested. For the seller, the software engineer must be present during the test.The buyer must appoint a software engineer for PLC applications and a software engineer for MES applications for the test. The appoint software engineer for PLC applications must prepare a test report. Such test reports must be approved by the Buyer.

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Demands to unit supplier- Specifications & test: Test suitcase for Factory Acceptance Test

Test Suitcase for Factory Acceptance TestAt the Factory Acceptance Test Arla Foods provides a test suitcase. The test suitcase act like a Line Controller. All communication data from the packML interface can be simulated from the test suitcase.

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Demands to unit supplier- Specifications & test: Test suitcase for Factory Acceptance Test

Test step, from Test suitcase :Start Unit from LC (Test State & Event ID)Suspend Unit Starvation (local Suspend test State & Event ID)Unsuspend Unit Starvation (local Suspend test State & Event ID)Suspend Unit Saturation (local Saturation test State & Event ID)Unsuspend Unit Saturation (local Saturation test State & Event ID)Suspend Unit from LC (LC Suspend test State & Event ID)Unuspend Unit from LC (LC Suspend test State & Event ID)Hold Unit (local Hold test State, Event ID & Detailed error info)UnHold Unit (local Hold test State, Event ID & Detailed error info)Complete Unit (Unit Complete test State & Event ID)Job data upload (test upload Job data according to spec.)Job data download (test download af job data)Reset Unit on unit itself (Test State & Event ID)Stop Unit from LC (Test State & Event ID). Check from different states

EXECUTE, HELD, SUSPENDED, IDLE and COMPLETE.Start Unit from LC (Invalid Job data test State, Event ID & Detailed error info)Abort Unit (Test State & Event ID)

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Other Devices- SafePLC and E-Stop

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Other Devices- Scale and Printer

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Questions

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Inteface requirements and specifications for units, PackML for unit supplyer.

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Transcript of Inteface requirements and specifications for units, PackML for unit supplyer.