wonderware ® factorysuite™ [inbatch getting started]

Wonderware FactorySuite

InBatch

Getting Started GuideRevision C

October, 2001

Wonderware Corporation

This document contains information for InBatch Premier edition. For information

regarding the Getting Started Guide and tutrorial for InBatch FlexFormula

edition, please visit the following URL:

http://www.wonderware.com/Products/mmi/inbatch.htm

All rights reserved. No part of this documentation shall be reproduced, stored in a

retrieval system, or transmitted by any means, electronic, mechanical,

photocopying, recording, or otherwise, without the prior written permission of the

Wonderware Corporation. No copyright or patent liability is assumed with respect

to the use of the information contained herein. Although every precaution has

been taken in the preparation of this documentation, the publisher and author

assume no responsibility for errors or omissions. Neither is any liability assumed

for damages resulting from the use of the information contained herein.

The information in this documentation is subject to change without notice and

does not represent a commitment on the part of Wonderware Corporation. The

software described in this documentation is furnished under a license or

nondisclosure agreement. This software may be used or copied only in accordance

with the terms of these agreements.

2001 Wonderware Corporation. All Rights Reserved.

100 Technology Drive

Irvine, CA 92618

U.S.A.

(949) 727-3200

http://www.wonderware.com

Trademarks

All terms mentioned in this book that are known to be trademarks or service

marks have been appropriately capitalized. Wonderware Corporation cannot attest

to the accuracy of this information. Use of a term in this book should not be

regarded as affecting the validity of any trademark or service mark.

Wonderware, InTouch and FactorySuite Web Server are registered trademarks of

Wonderware Corporation.

FactorySuite, Wonderware FactorySuite, WindowMaker, WindowViewer, SQL

Access Manager, Recipe Manager, SPCPro, DBDump, DBLoad, HDMerge,

HistData, Wonderware Logger, Alarm Logger, InControl, InTrack, InBatch,

IndustrialSQL, FactoryOffice, FactoryFocus, License Viewer, Scout, SuiteLink

and NetDDE are trademarks of Wonderware Corporation.

Contents

System Requirements ...............................................................................................1-6

Microsoft SQL Server........................................................................................1-6

InBatch Server ..................................................................................................1-6

Batch Runtime Client ........................................................................................1-6

Batch Development Client.................................................................................1-6

InBatch Program Menus...........................................................................................1-7

InBatch Server ..................................................................................................1-7

InBatch Batch Development Client....................................................................1-7

InBatch Batch Runtime Client...........................................................................1-8

Installing InBatch ....................................................................................................1-9

InBatch Server Installation ................................................................................1-9

InBatch Client Installation ................................................................................1-9

Overview of Capabilities ........................................................................................1-10

Flexible Recipes and Process Lines..................................................................1-10

Process Modeling ............................................................................................1-10

Materials Tracking Management .....................................................................1-12

Recipe Management ........................................................................................1-13

Batch Management..........................................................................................1-13

Batch History ..................................................................................................1-14

Batch Reports..................................................................................................1-14

Extensibility...........................................................................................................1-15

Managing InBatch Configurations .........................................................................1-15

InBatch Application Modules.................................................................................1-16

Configuration Modules....................................................................................1-16

Runtime Modules ............................................................................................1-17

Utility Modules................................................................................................1-18

InBatch Configuration Architecture .......................................................................1-19

The Breading Plant Process Area ...........................................................................2-22

Hardware Architecture ...........................................................................................2-22

Hardware Architecture ...........................................................................................2-23

Install the InBatch Software ...................................................................................2-23

Start InBatch Environment Display........................................................................2-24

Configuration Steps................................................................................................2-24

Model the Process ..................................................................................................2-25

Define Units ....................................................................................................2-26

Define Connections .........................................................................................2-27

Define Process Classes ....................................................................................2-28

Define Process Phases .....................................................................................2-29

Define Transfer Classes...................................................................................2-33

Define Transfer Phases....................................................................................2-34

Define Segments .............................................................................................2-35

Validate the Model ..........................................................................................2-37

Use the Tag Linker.................................................................................................2-38

Define Export Configuration ...........................................................................2-39

Perform a Simulation Export ...........................................................................2-40

Update the Runtime Databases ...............................................................................2-41

Define the Process Trains.......................................................................................2-42

Defining the Materials and Material Locations.......................................................2-43

Define Materials..............................................................................................2-44

Define Material Locations ...............................................................................2-45

Build a Recipe........................................................................................................2-46

Recipe Header .................................................................................................2-47

Define Equipment Requirements .....................................................................2-48

Define Formula Inputs.....................................................................................2-49

Construct the Recipe Procedure....................................................................... 2-51

Validate the Recipe......................................................................................... 2-54

Save the recipe................................................................................................ 2-54

Approve the Recipe for Production.................................................................. 2-55

Create an InBatch Runtime Client (InTouch) Application...................................... 2-56

Create an Operator Interface on InTouch using InBatch Wizards.................... 2-56

Define Windows ............................................................................................. 2-57

Modify Access Name ...................................................................................... 2-72

Set Initial Value for IB_TIM_ACCESS Tag ................................................... 2-73

Define Complimentary Scripts ........................................................................ 2-74

Start the InBatch Runtime System ......................................................................... 2-77

Schedule and Execute Batches ............................................................................... 2-78

From the InBatch Server ................................................................................. 2-79

From the InBatch Runtime Client (InTouch)................................................... 2-80

Execute an End-of-Batch Report............................................................................ 2-81

C H A P T E R 1

Welcome to InBatch

InBatch is a “Flexible Batch Management System” that is designed to be quickly

and easily configured once fundamental concepts are understood. It is extremely

important to read this section of the manual before attempting to use InBatch.

Once InBatch concepts are understood, you should be able to quickly build and

edit configurations without using this manual. As with most menu driven

systems, you will become more proficient by using the manual as a reference to

improve your understanding of InBatch and how to apply features that may not be

obvious.

This manual is written for the individuals who will be configuring and applying

the batch control system. Process and control engineers or experienced

technicians, who are very knowledgeable about control system programming and

process control, are the most obvious individuals.

The batch system does not require programming at the PC. However, control

system programming is required. Also, the batch system is a very complex, yet

configurable software product that requires a fundamental knowledge of Windows

NT 4.0 operating system, computer system networking, programmable logic

controllers (PLCs), and process control. Server and client licensing are not

discussed in this section.

ContentsSystem Requirements

InBatch Program Menus

Installing InBatch

Overview of Capabilities

Extensibility

Managing InBatch Configurations

InBatch Application Modules

InBatch Configuration Architecture

The Breading Plant Process Area

Hardware Architecture


Install the InBatch Software

Start InBatch Environment Display

Configuration Steps

Model the Process

Use the Tag Linker

Update the Runtime Databases

Define the Process Trains

Defining the Materials and Material Locations

Build a Recipe

Create an InBatch Runtime Client (InTouch) Application

Start the InBatch Runtime System

Schedule and Execute Batches

Execute an End-of-Batch Report

n

System RequirementsInBatch system requirements are the same as for InTouch with additional

requirements as described below.

Microsoft SQL ServerInBatch utilizes Microsoft SQL Server 7.0 on a separate Information Server

machine for database storage and retrieval.

• Allow at least 200-300 MB free hard disk space for your InBatch databases.

InBatch Server• InBatch Server (only) requires 40 MB free hard disk space.

• InBatch Server with a Batch Runtime Client requires 70 MB free hard disk

space.

• SVGA(1024X768) display and adapter w/2MB Video RAM.

Batch Runtime Client• Wonderware InTouch.

• Microsoft Windows 95, 98 or NT 4.0.

• Client requires 30 MB free hard disk space.

• SVGA Monitor, 2MB Video RAM.

Batch Development Client• Microsoft Windows NT 4.0.

• SVGA(1024X768) display and adapter w/2MB Video RAM.

InBatch Program MenusInBatch Server

When you install the InBatch Server, the Wonderware FactorySuite menu is

created which contains the InBatch Server submenu. The contents of the

InBatch Server sub-menu are summarized below.

Environment Display - starts the Environment Display and initializes the

background processes necessary to access InBatch configuration and runtime

applications.

History Admin. - starts the History Administration utility, and is used to define

the user account that will be used to access the historical database.

History Archive - starts the History Archive utility, and is used to set when

InBatch will create archival databases of completed batch information.

Release Notes - starts a Windows Help file that contains a summary of

enhancements, user documentation that was unable to be included in this User’s

Guide, and known problems with, and work-arounds for InBatch.

The UnInstall - allows you to remove the InBatch server. Use this only if you

want to remove InBatch from your computer.

InBatch Batch Development ClientWhen you install a Batch Development Client, the Wonderware FactorySuite

menu is created which contains the InBatch Development Client sub-menu and

the items described below.

Process Modeling Editor - starts the InBatch Process Modeling Editor on the

client.

Tag Linker - starts the InBatch Tag Linker on the client.

Train Editor - starts the InBatch Train Editor on the client.

Material Editor - starts InBatch Material Editor program on the client.

Recipe Editor - starts InBatch Recipe Editor program on the client.

Report Editor - starts the InBatch Report Editor on the client.

Security Editor - starts InBatch Security Editor program on the client.

Process Log Editor - starts InBatch Process Log Editor program on the client.

UnInstall - allows you to remove the Batch Development Client. Use this only if

you want to remove InBatch from your computer.

InBatch Batch Runtime ClientWhen you install a Batch Runtime Client, the Wonderware FactorySuite menu

is created which contains the InBatch Runtime Client sub-menu and the items

described below. InTouch 7.0 is required in order to install the Batch Runtime

Client.

Batch Display - starts InBatch Batch Display program on the client.

Batch Scheduler - starts InBatch Batch Schedule program on the client

Report Display - starts InBatch Report Display on the client.

UnInstall - allows you to completely remove the Batch Runtime Client. Use this

only if you want to remove InBatch from your computer.

In addition to these items, the following items are added to the InTouch

installation.

InBatch Wizards – loads batch wizards into InTouch.

ActiveX Objects – loads the Batch ActiveX object and the SFC ActiveX object

onto the client system.

Alarm/Event Interface – loads the wwextalm.dll and the ibhist.dll into InTouch.

Script Add-On Functions – loads several script add-on functions that can be

used with InBatch into InTouch.

? For more information on using InTouch, see your online InTouch User’s

Guide.

Installing InBatchInBatch is installed from the FactorySuite CD-ROM. The installation program

provides the capability to install various Batch Server and Batch Client

configurations. A summary of the server and client configuration options specific

to InBatch is provided below.

InBatch Server Installationn Configuration and runtime components

n Redundancy

InBatch Client Installationn Batch Development Client (InBatch configuration applications) for NT 4.0

only

n Batch Runtime Client (InBatch runtime applications, Batch Wizards,

ActiveX objects, etc.) for NT 4.0

n Batch Runtime Client (InBatch runtime applications, Batch Wizards,

ActiveX objects, etc.) for Windows 95

n Redundancy

Overview of CapabilitiesWonderware InBatch is flexible batch management software designed to automate

and provide a complete production history for batch processes. Consistent with

the Instrument Society of America (ISA) S88.01 standard, InBatch allows you to

quickly and easily create recipes and simulate their execution against a model of

the process – all before writing one line of control code. InBatch also provides

complete production history and materials genealogy. InBatch's powerful batch

engine, combined with its integration with FactorySuite, means that you can

reduce the cost and time to implement your batch-related processes by up to 40 to

60% over competitive solutions.

InBatch provides "Out of the box" batch management functionality that

eliminates the need for unsustainable custom code in the PLC or DCS and

dramatically reduces the life-cycle engineering effort. The sophisticated batch

engine is responsible for Unit-to-Unit Material Tracking, Short Term Scheduling,

Dynamic Batch and Equipment Management, and Batch History and Reporting.

The batch management system also supports redundancy for mission-critical

applications.

Flexible Recipes and Process LinesIn the batch control system, recipe procedures can be changed and new formula

and process lines can be easily re-configured, not re-engineered, for new product

introductions. The batch system is flexible because it lets you model your plant,

create new process lines, manage recipes, schedule and execute batches, and keep

a history of all batch processing activity.

Flexibility in a batch process will make a plant more competitive. Improvements

will result because of faster line changeovers, faster time-to-market for new

products, quick response to customer orders, accurate batch history, and

consistent product quality.

Process ModelingA batch processing plant is made up of units and connections. Units process

and/or hold materials while connections transfer materials between units.

A unit is defined as any vessel that can hold and/or process materials. Some units

have no processing capabilities, as is the case with bulk storage vessels, manual

add stations, and hold tanks. Other units have significant processing capabilities,

as is the case with most reactors, blenders, mixers, dryers, retorts, and washers.

Examples of processing capabilities are agitating, mixing, heating, cooling,

blending, and packaging. Other examples of units are storage tanks, silos, ovens,

fillers, washers, retorts, molders, bottlers, wrappers, cartoners, and palletizers.

Connections are defined as the equipment, i.e. pumps, valves, separators,

condensers and flow meters, that is necessary for transferring a product from one

unit to another. Many plants have units that are connected to more that one unit

and some plants have multiple connections between the same two units.

All units that have the same processing capabilities or perform the same function

are grouped into one process class. All the connections between the same two

process classes are grouped into one transfer class. Process Classes and Transfer

Classes define a family of units and connections, respectively. The ability to group

units and connections into classes is the essence of a true flexible batch system.

Processing and transferring capabilities are defined by Phases. Each phase is an

independent action that may contain a unique set of Parameters. Parameters

configure the phase based on a recipe’s requirements. Phases can be automatically

executed by the control system. The can also be manually executed by an

operator. The execution of automatic phases is performed by the control system

using Phase Logic.

Units, Process Classes (Processes), Connections, Transfer Classes (Transfers),

and Processing Capabilities are the five main components of the Process Model.

Defining the plant processing capability is called Process Modeling and involves

the steps listed below.

1. Identify each unit and its attributes.

2. Group units into process classes.

3. Identify all connections between units.

4. Define all equipment segments and assign to connections.

5. Group connections into transfer classes.

6. Define the processing capabilities of each process class (phases and

parameters).

7. Define the transferring capabilities of each transfer class (phases and

parameters).

8. Define equipment statuses.

9. Define trains.

10. Develop phase logic.

An integral part of Process Modeling involves defining specific data points, called

Tags, for Units, Processes, Connections, and Transfers. Tags allow data to move

between the batch system and the control system. Tags must be defined prior to

configuring any of the batch system application modules. The number of tags

allowed in the batch system is only limited by the amount of mass storage in the

system.

Materials Tracking ManagementMaterials Tracking Management includes the ability to define materials as

ingredients, intermediates, finished goods, by-products, and others. The ability to

define characteristics is provided for each material entered in the system.

The Materials Editor is used to track the location of materials that are stored in

units. This usually pertains to bulk ingredients and work in process materials.

The batch management system uses the ingredient location data to determine

where to get ingredients when a batch is to be produced. This capability allows

ingredient locations to be independent of recipes and control programs, and

permits ingredients to change locations with no effect on recipe execution.

The materials database is used by the Recipe Editor in the construction of recipes.

Only materials in the materials database can be used in recipes.

When new bulk ingredients are received, the unit location may be entered into the

materials database by plant personnel. A lot identification can also be assigned to

the material. Multiple lots of the same ingredient may be stored in the same

vessel. The batch management system updates the database when ingredients are

used and when intermediates or finished goods are produced. The database

provides for easy access to WIP information and can be used to update higher

level material management and material resource planning (MRP) systems with

ingredient usage information, WIP, and finished goods production. The Materials

Editor is not an inventory management system, but may be used to complement

existing systems.

Recipe ManagementThe batch control system manages and constructs recipes according to the

guidelines outlined in the Instrument Society of America (ISA) SP88 Flexible

Batch Specification.

The batch control system provides a recipe management system that enables

Master Recipes to be constructed and edited. Master recipes are not process line

specific, but rather are equipment independent. They can be assigned to any

process line (train) that has units belonging to the classes of process equipment

defined in the recipe. A master recipe becomes a Control Recipe as the units

defined in the train are dynamically allocated and used in producing a batch.

A master recipe is not size specific, but is scalable to the batch size defined by

production scheduling. All formula quantities for ingredients, intermediates, by-

products, and finished goods are entered as either actual quantities or can be

expressed as a percent of the total batch size. Quantities expressed in percentages

are scaled by the batch management system when the batch is executed.

The Recipe Editor provides several text and graphical editors to construct and

alter recipes. Recipes can be saved, retrieved, and printed. A revision control

system provides an accurate time stamped history of all changes and revisions

that have been made to the recipe.

Batch ManagementBatch Management consists of scheduling batches, initializing batches,

coordinating the execution of batches with the control system, interfacing with

operators, and storing all batch activity. This functionality is achieved through the

Batch Manager, Batch Scheduler, and Batch Display programs. The final result is

a flexible, reliable, and intuitive approach to the management of a batch process.

Scheduling: The Batch Manager’s scheduling capability is that of dispatching

batches that are ready to run to plant floor operators. Scheduling involves the

manual entry of the batch identification, master recipe, batch size, and Train

(Process Line) into the Batch Scheduler. Once entered, the batch can be

initialized.

Initialization: Each batch must be initialized before it is executed. The

initialization process involves validation of the recipe, checking if the Train

exists, checking if the bulk materials defined in the recipe are available in the

Train, ensuring that the recipe’s equipment requirements are satisfied by the

Train, and verifying that the Process Model database is compatible with the

recipe.

Batch and Unit Management: Batch Manager directs and supervises the

execution of each batch. The Batch Manager interprets recipes and enables the

control system. Based on the recipe’s procedure, blocks of control software,

referred as phase blocks, are signalled to execute by the Batch Manager. Phase

block control logic, located in the control system, is responsible for controlling

the process. Prior to enabling each phase block, the Batch Manager verifies that

the phase block is ready to be executed. If so, phase parameter values are

downloaded to the block, then the block is started.

Batch Manager also interfaces with Batch Display programs. The Batch Display

programs provide operators with information on all batches initialized and/or

executing in the system. Through these displays, operators can put a batch or

phase in hold, as well as restart and abort batches or phases. In addition,

operators can change phase parameter values, acknowledge the execution of

phases, review phase interlock statuses, and enter comments while the batch is

executing.

The Batch Manager coordinates the usage of process units for each batch. The

Batch Manager is capable of running a large number of batches simultaneously.

Each batch is a separate entity and contends along with other batches to possess

the process units it needs. Batch Manager allocates ownership of units to batches

as units become available, and releases units when the batch no longer requires

the unit.

Flexible batch systems using controllers must take the approach in which the

supervisory workstation becomes an active participant in executing a batch. The

reason for this is that unit management is very sophisticated in a flexible batch

system. Most controllers do not have the ability to program a unit manager

capable of interpreting and executing the recipe procedures that can be

constructed in the batch control system.

A Master Recipe uses classes of process units, not specific units. This means

phases pertain to a class of units not a specific unit. When the Batch Manager

executes a Master Recipe, each phase encountered is converted into a unit specific

phase. This process is called Master Recipe to Partial Control Recipe conversion.

The Train assigned to produce the batch specifies all the units that can be used.

The Batch Manager automatically converts the Master Recipe to a Control Recipe

based on the units found in the Train.

History: Batch Manager captures and stores all processing and operator activity

during the execution of a batch.

Batch HistoryInBatch uses Microsoft SQL Server as its historical repository to provide open

and easy access to all batch history data

The Batch Management System is responsible for writing all information related

to the production of a batch to the history database. This includes events, process

data, production information, material usage, operator comments, operator

actions, and equipment used.

Batch ReportsInBatch uses Seagate Crystal Reports Professional for report development. This

provides a flexible and open platform so that the user can easily build custom

reports. Retrieval of historical data in the form of reports is provided by the

runtime Reporting System. Reports can be automatically triggered during the

execution of a batch or at the end of a batch. InBatch is supplied with a set of

predefined reports.

ExtensibilityInBatch offers a rich set of ActiveX objects and API functions for integrating

external applications such as ERP or scheduling systems and allowing exchange

of formulas/recipes, materials and production results. InBatch also uses Microsoft

SQL Server as its historical repository to provide open and easy access to all batch

history data. These interfaces make it easy to integrate with ERP and Advanced

Planning Systems, allowing InBatch to be a key link in a successful supply chain

management initiative.

Managing InBatch ConfigurationsWhen the InBatch Server is installed, the following folder structure is created.

The folders and files shown must never be modified, except for one notable

exception, the configuration folder.

The InBatch configuration that you create is stored in the

“…/FactorySuite/InBatch/cfg/config_A” folder. The InBatch system looks for

your configuration and must find it in config_A. If you want to work on a

different configuration, you can create a different folder. For example, create a

folder named “AnotherConfig,” and then move the configuration files from

“config_A” into it. An empty set of default database files can be copied from the

dflt_cfg folder to “config_A.”

InBatch Application ModulesThe following section is a summary of the applications that are available within

the Environment Editor.

Configuration Modules

Environment Editor (EnvEdit)(Required) The Environment Editor is used to define the batch configuration and

runtime applications that are to be executed.

Process Modeling Editor (ModelEdit)(Required) Provides the capability for a user to create a process model database.

Only one Process Modeling Editor can run in a system at a time.

Tag Linker Editor (TagLinker)(Required) The Tag Linker Editor associates InBatch tags with a control system.

It is also capable of associating InBatch tags with InTouch tags. Tag Linker also

exports InBatch tags to a comma separated variable file that will ultimately

populate the InTouch tag dictionary with memory and IO tags.

Train Editor (TrainEdit)(Required) The Train Editor is used to create production lines on which batches

are scheduled.

Materials Editor (MaterialEdit)(Required) Provides the capability for a user to create and edit a materials

database both on and off-line. Multiple Materials Editors can run in a system

enabling multiple users to edit the same database simultaneously.

Recipe Editor (RecipeEdit)(Required) Provides the capability for a user to create and edit a recipe database

both on and off-line. Multiple Recipe Editors can run in a system enabling

multiple users to edit the same database simultaneously.

Report Editor (ReportEdit)(Optional) The Report Editor is used to create, edit, and print report

configurations.

Process Log Editor (LogEdit)(Optional) The Process Log Editor is used to create, edit, and print batch-related

data logging configurations.

Security Editor (SecEdit)(Optional) Provides the capability for a user to define the users of the system,

security levels for each user, appropriate workstation access for each user,

appropriate recipe access for each user, and enable/disable applications and

functions requiring security.

Runtime Modules

Environment Manager (EnvMngr)(Required) The Environment Manager manages the execution of the batch

runtime applications defined with the Environment Editor.

Environment Display (EnvDspl)(Required) The Environment Display is a client of the Environment Manager and

provides a single interface for starting and stopping all batch system GUI

applications.

Unilink Manager (UnilinkMngr)(Required) Manages inter-process communications between all of the batch

system applications.

InBatch Client (IBCli)(Required for Runtime) Runtime client application which allows InBatch to

access tag data from SuiteLink and DDE Servers.

Memory Tag Manager (MemTagMngr)(Required) The Memory Tag Manager is responsible for generating all of the tags

configured as InBatch Memory Tags in the Tag Linker application.

Simulation Manager (SimMngr)(Required for Simulation) The Simulation Manager replaces the communication

drivers for a batch system and allows the system to be executed without control

system hardware present.

Information Manager (InfoMngr)(Required) Provides general batch server information to client applications.

InBatch Server (IBServ)(Required) Runtime server application, which allows SuiteLink and DDE client

applications (e.g. InTouch), to use InBatch TIM tags and Control System tags.

InBatch Function Server (IBFServ)(Required if you are using Batch Function Tags) Runtime server application,

which allows SuiteLink and DDE client applications (e.g. InTouch), to use

InBatch Batch Function Tags.

Batch Manager (BatchMngr)(Required) Interfaces with the process model, recipe, and materials databases.

The Batch Manager works in conjunction with the Batch Scheduler and Batch

Display programs. The Batch Manager executes all recipes, manages unit

allocation, moves batch information to the History Manager, and triggers reports.

Batch Scheduler (BatchSched)(Optional) Interfaces with the Batch Manager and is used to construct a schedule

of batches to be executed. Multiple Batch Schedulers can run in a system.

Batch Display (BatchDspl)(Optional) The Batch Display is a client of the Batch Manager, and provides all

of the runtime information concerning the execution of a single batch. Multiple

Batch Displays can run in a system.

Report Manager (ReportMngr)(Optional) The Report Manager interfaces with the Batch Manager for report

triggers. In addition, the Report Manager will retrieve historical data from the

Historical Database. Only one Report Manager can be run in a system.

Process Logger Manager (LogMngr)(Optional) The Process Logger Manager controls the data logging of any tag in

the system according to the logging configuration.

Security Manager (SecMngr)(Optional) Security Manager is used in batch and external applications to evaluate

and respond to requests for security clearance.

Tag Interface Management (TIM) System BatchProcess (TIMBatch)(Optional) The TIM System Batch Process manages the runtime tag interface

between the batch management system and the computers and/or controllers

defined in the system.

Tag Interface Management (TIM) System Function Library Process (TIMFunc)(Optional) The TIM System Function Library Process manages the runtime tag

interface between the batch functions and the computers and/or controllers

defined in the system.

Tag Interface Management (TIM) System Security Process (TIMSec)(Optional) The TIM System Security Process manages the runtime tag interface

between the security system and the computers and/or controllers defined in the

system.

Utility Modules

Phase Logic Testing Tool (PhaseLogic)(Optional) The Phase Logic module permits individual phase execution

independent of any batch operation.

Change Password (ChgPwd)(Optional) The Change Password application permits the user to interact with the

security system from the command line in order to change a user’s password. The

Change Password utility is part of the security system.

Tag View (TagView)(Optional) The Tag View application permits monitoring and changing any of the

InBatch equipment or TIM tags.

InBatch Configuration Architecture

RecipeEditModelEdit MaterialEdit ReportEdit

SecEditEnvEditTagLinker

MaterialDB

LogDB

ReportDB

CfgTIMDB SecurityDBEnvDBDBLoad Files

LogEdit

CfgLinkDB

LinkDB Imp/Exp

CfgModelDB RecipeDB

TrainEdit

InBatch Runtime Architecture

IBHist

SQLServer

InSQL

RecipeDB

LogDB

LinkDB

ModelDB

TIMBatch

TIMSec

TIMFunc

TIMDB

MaterialDB

BatchDspl

(OCXBatch,

SFCOCX)

BatchSched

(OCXBatch)

BatchMngr

TrainEdit

SysTagMngr

UnilinkMngr

RecipeEdit

IBCli

LogMngr

IBServ

SimMngr

MaterialEdit

EnvDB

EnvMngr

Lock Manager

(lm_tcp)

IO Server InControl

BatchDB .BatchWR

InfoMngr

WindowMaker/Viewer

InBatch Wizards

and Script

Functions

SFC

ActiveX

Object

Batch

ActiveX

Object

Alarm/Event

Interface (.dlls)

InBatch Tag

Browser

Server

C H A P T E R 2

Discovering InBatch - A Tutorial

This chapter guides you through the process of developing actual InBatch Server

and Client applications using a generic Breading Plant process as a reference.

The purpose of the tutorial is to show you the ease with which you can configure

InBatch and the power that InBatch provides as a design, engineering and

simulation tool. Additionally, it familiarizes you with all other InBatch

capabilities associated with configuration and control system logic, material

management, recipe management, history, reporting, and operator interface. As

you work through this tutorial, you will develop a complete understanding of what

InBatch is and how it is configured.

This tutorial assumes that the user has a properly configured, operational

hardware system and strong working knowledge of InTouch.

ContentsThe Breading Plant Process Area



Install the InBatch Software

Start InBatch Environment Display

Configuration Steps

Model the Process

Use the Tag Linker

Update the Runtime Databases

Define the Process Trains


Build a Recipe


Start the InBatch Runtime System

Schedule and Execute Batches

Execute an End-of-Batch Report

The Breading Plant Process Area

Mix Time_Min, Speed_%

ManAdd Qty_Kgs (Input)

Instruct

Bulk1

(Flour)

Mixer1

Hold1

Blk1_Dis Blk2_DisCommon

Mix1_Chg Mix2_Chg

Bulk2

(Salt)

Mixer2

Hold2

BulkTks Process Phases

None

Bulk_Mix Transfer Phases/Parameters

BulkAdd Qty_Kgs (Input)

Mixers Process Phases/Parameters

Mix_Hold Transfer Phases/Parameters

Discharg Qty_Kgs (Output)

HoldTks Process Phases

None

Hardware ArchitectureOur example architecture is shown below. MERCURY is the name of the InBatch

Server. MIXER1 is the name of the InBatch Development Client and MIXER2 is

the name of the InBatch Runtime Client.

Install the InBatch Softwarel Install the InBatch Server software on MERCURY.

l Install and Configure Microsoft SQL Server on MERCURY. This can be

done by installing IndustrialSQL Server.

l Install the InBatch Development Client software on MIXER1.

l Install the InBatch Runtime Client software on MIXER2.

Note The MIXER1 node is used for illustration purposes only. This node is

portrayed as an InBatch Development Client. All configuration information

presented can be performed from the InBatch Server or the InBatch Development

Client. This example refers to the server.

InBatch

Development Client

"MIXER1"

Windows NT 4.0

InBatch

Runtime Client

"MIXER2"

Windows NT or 95

InBatch Server

"MERCURY"

Windows NT 4.0

Start InBatch Environment DisplaySelect the Environment Display option from the Start/Programs/Wonderware

FactorySuite/InBatch Server folder. The InBatch Environment Display will be

displayed. This application is used to start the InBatch configuration and runtime

applications.

Configuration Steps1. Model the Process

2. Use the Tag Linker

3. Update the Runtime Databases

4. Define the Process Trains

5. Defining the Materials and Material Locations

6. Build a Recipe

7. Create an InBatch Runtime Client (InTouch) Application

8. Start the InBatch Runtime System

9. Schedule and Execute Batches

10. Execute an End-of-Batch Report

Model the ProcessDouble-click the ModelEdit icon on the Environment Display window. The

Process Modeling Editor main window is displayed.

Define UnitsUnits are equipment entities that hold, process and/or package materials.

Select the Units tab to display the Units editor. Use the Units editor to enter the

units as shown below.

Define ConnectionsConnections are defined by a source and a destination unit. If materials can move

between two units, then the connection must be defined. The way in which

materials move is not important at this time.

Select the Connections tab to display the Connections editor. Use the

Connections editor to enter the connections as shown below.

Define Process ClassesA Process Class is a group of one or more units that perform the same functions.

Select the Processes tab to display the Processes editor. Use the Processes editor

to enter the process classes and assign all of the units as shown below.

Process Class Name Assigned Units

BulkTks Bulk1, Bulk2

Mixers Mixer1, Mixer2

HoldTks Hold1, Hold2

Define Process PhasesOnly define process phases for the classes of equipment that actually process

material. In our example, only the Mixers process material. The BulkTks and

HoldTks classes do not.

Select the Mixers process class and then click the Phases… button from the

Processes tab dialog. This displays the Edit Phases dialog. Enter the process

phases shown below.

Phase Name Phase Type

Mix Automatic

ManAdd Manual

Instruct Manual

In the Save History pane, select the Control/Status Activity and Parameter

Status check boxes for each phase in the Mixers class. If you do not set these

check boxes, then phase events and parameters will not be stored in the history

database.

Note You must select the Change button following any phase modifications.

Create Phase Control/Status TagsAll Automatic phases must have Phase Control and Status tags. These are the

tags that would ultimately be linked to the control system memory/register

addresses.

There is only one automatic phase in the Mixes class. Select the Mix phase from

the Phases list and then click Phase Control/Status... The Edit Phase

Control/Status dialog is displayed. Click Select All and then click Create Tags.

All tags needed to control and monitor the status of the Mix phase will be

automatically created.

Define Formula ParametersFormula parameters are used to provide phases with information they need to do

their job. Parameter values are defined in the recipe and written to the control

system when the phase is executed. The recipe procedure determines when each

phase is executed.

Select the appropriate phase from the Phases list, then click the Formula

Parameters… button. The Edit Formula Parameters dialog will be displayed.

Enter the following parameters for each of the defined process phases.

Phase Parameter Parameter Type

Mix Speed_% Process Variable

Time_Min Process Variable

ManAdd Qty_Kgs Input

Configure both Mix formula parameters as follows:

1. Create tags for the Target and Actual elements by enabling the check box for

each and selecting the Create Tags button.

2. Set the Edit Allowed check box for the Target element.

3. Set the Enable Display check box for the Actual element.

Configure the ManAdd formula parameter as follows:

1. Set the Enable Display check box for the Target and Material ID elements.

2. Set the Edit Required check box for the Actual and Lot Code elements.

Note You do not have to create tags for the ManAdd phase.

Define Transfer ClassesA Transfer Class is a group of one or more connections that perform the same

functions. Within a Transfer Class, all of the source units are in the same process

class and all of the destination units are in the same process class. The source and

destination process classes can be the same.

Select the Transfers tab to display the Transfers editor. Use the Transfers editor

to enter the transfer classes and assign all of the connections as shown below.

Transfer Class Name Source Process Destination Process

Bulk_Mix BulkTks Mixer

Mix_Hold Mixer HoldTks

Transfer Class Name Assigned Connections

Bulk_Mix Blk1Mix1, Blk1Mix2, Blk2Mix1, Blk2Mix2

Mix_Hold Mix1Hld1, Mix2Hld2

Define Transfer PhasesEach transfer class should have at least one transfer phase defined. The phase is

responsible for moving material from a source unit to a destination unit.

Select a transfer class and then click the Phases… button from the Transfers tab

dialog. This displays the Edit Phases dialog. Enter the transfer phases shown

below.

Transfer Class Name Phase Name Phase Type

Bulk_Mix BulkAdd Automatic

Mix_Hold Transfer Automatic

In the Save History pane, select the Control/Status Activity and Parameter

Status check boxes for each phase. If you do not set these check boxes, then phase

events and parameters will not be stored in the history database.

Note You must select the Change button following any phase modifications.

Create Phase Control/Status TagsAs previously discussed for process phases, all Automatic phases require control

and status tags. These are the tags that would ultimately be linked to the control

system memory/register addresses.

Select the appropriate transfer class. Select the automatic phase defined for the

class from the Phases list and then click Phase Control/Status... button. The

Edit Phase Control/Status dialog is displayed. Click Select All and then click

Create Tags. All tags needed to control and monitor the status of the Mix phase

will be automatically created.

Define Formula ParametersSelect the appropriate phase from the Phases list, then click the Formula

Parameters… button. The Edit Formula Parameters dialog will be displayed.

Enter the following parameters for each of the defined transfer phases.

Transfer Class Name Phase Parameter Type

Bulk_Mix BulkAdd Qty_Kgs Input

Mix_Hold Transfer Qty_Kgs Output

Configure each of the formula parameters as follows:

1. Create tags for the Target and Actual elements by enabling the check box for

each and selecting the Create Tags button.

2. Set the Edit Allowed check box for the Target element.

3. Set the Enable Display check box for the Actual element.

4. Set the Enable Display check box for the Material ID element.

Define SegmentsA segment is a subsection, that is, part of a connection. Segments are the lowest

equipment entities that are managed by InBatch. The segments that make up a

connection are allocated to a batch when a transfer is executed. This prevents

other transfers from using the same segments associated with their connection.

This permits the batch engine to provide some automatic process interlocking.

Select the Segments tab to display the Segments editor. Use the Segments editor

to enter the segments as shown below.

Assign Segments to ConnectionsSelect the Connections tab to display the Connections editor. At the bottom of the

Connections tab dialog assign the required segments to appropriate connections.

Select the connection and then click the Assign Segments… button to display the

Assign Segments to Connection dialog. Select the required segments from the

Segments list and Apply to the connection as shown below.

Connection Name Segments

Blk1Mix1 Blk1_Dis, Common, Mix1_Chg




Define Equipment Status

Equipment statuses apply to all units and segments in the system. The status of a

unit or segment is evaluated before it is allocated to a batch. The status must be

Available before it is allocated.

Select the Equipment Status tab to display the Equipment Status editor. Use the

Equipment Status editor to enter the segments as shown below.

Validate the ModelSelect the File/Validate… menu option from the Process Modeling Editor main

window to check for modeling errors. Correct any discrepancies.

Use the Tag LinkerDouble-click the TagLinker icon on the Environment Display window. The Tag

Linker main window is displayed. The Tag Linker is used to configure tags to

point to the control system and to export tags to a .csv file for use in InTouch.

Define Export ConfigurationSelect the Edit/Export… menu option. This displays the Export Editor dialog.

Configure this dialog as shown below.

Perform a Simulation ExportSelect the File/Simulation Export… menu option. An Export Results dialog will

be displayed telling you what is being exported and when it is complete. The

Simulation Export performs two primary functions. First, it creates a .csv file for

the client type. Secondly, the InBatch Server creates a set of Tag Interface

Management (TIM) System tags using the Client Type name and the declared

Number of Clients, and creates a unique topic name for MIXER2.

Update the Runtime DatabasesThe InBatch Environment system provides the user with the ability to make off-

line changes to the process model and link databases. The Environment Display

Update/Runtime menu option copies the contents of the process model, link, and

TIM configuration databases to the corresponding runtime databases. This option

must be performed before the runtime system will recognize the latest changes.

Note This option is not permitted in a running system.

Define the Process TrainsDouble-click the TrainEdit icon on the Environment Display window. The Train

Editor main window is displayed.

Enter train names and assign units to the trains as shown below.

Train Name Assigned Units

Mixer 1 Train Bulk1, Bulk2, Mixer1, Hold1

Mixer 2 Train Bulk1, Bulk2, Mixer2, Hold2


Double-click the MtlEdit icon on the Environment Display window. The

Materials Status main window is displayed.

IMPORTANT You MUST select the Update/Runtime from the Environment

Display as described at the end of the previous section before continuing.

Define MaterialsSelect the Edit/Materials Editor… menu option on the Material Status main

window. The Materials Editor dialog is displayed.

Define the following ingredients.

Material ID Material Name UOM Hi Dev Low Dev

Flour 100 Pure White Flour LBS 1.0 1.0

Salt 200 Pure Salt LBS 1.0 1.0

CS102 Chicken Spice LBS 1.0 1.0

PS102 Pork Spice LBS 1.0 1.0

Define the following finished goods.

Material ID Material Name UOM Hi Dev Low Dev

CB1000 Chicken Breading LBS 1.0 1.0

PB1000 Pork Breading LBS 1.0 1.0

Define Material LocationsSelect the Edit/Material Locations… menu option on the Material Status main

window. The Material Location Assignment Editor dialog is displayed.

Assign the bulk materials to the appropriate bulk tanks and define Lot Tracking

Information as shown below.

Material ID Material Name Unit Lot

Quantit

y

Flour 100 Pure White Flour Bulk1 Flour Vendor 1 50,000

Salt 200 Pure Salt Bulk2 Salt Vendor 3 30,000

Build a RecipeDouble-click the RecipeEdit icon on the Environment Display window. The

Recipe Editor main window is displayed. This editor is used to define a recipe.

Recipe HeaderSelect the Edit/Recipe Header… menu option on the Recipe Editor main window.

The Recipe Header dialog is displayed. Enter the Header information for the

Chicken Breading recipe as shown below.

Define Equipment RequirementsSelect the Edit/Equipment Requirements… menu option on the Recipe Editor

main window. The Equipment Requirements Editor dialog is displayed. Select

the Add Processes… button and add the process classes as shown below.

Define Formula InputsSelect the Edit/Formula Inputs… menu option on the Recipe Editor main

window. The Formula Inputs Editor dialog is displayed. Select the Add

Inputs… button and add the ingredients as shown below.

Define Formula Outputs

Select the Edit/Formula Outputs… menu option on the Recipe Editor main

window. The Formula Outputs Editor dialog is displayed. Select the Add

Outputs… button and add the finished goods as shown below.

Construct the Recipe ProcedureConstruct the recipe procedure for the Chicken Breading product as shown on the

following pages.

Add Materials Operation

WaitSec(35)

Material: Flour 100

Qty_Kgs: 40%

Material: Salt 200

Qty_Kgs: 15%Speed_%: 40

Time_Min: 8

Material: CS102

Qty_Kgs: 5%

Mix Materials Operation

Speed_%: 10

Time_Min: 4Material: Flour 100

Qty_Kgs: 40%

Instruction: “Take Sample for

QA Test. Wait for Results.”

Enable “Ack On Entry”

Instruction: “Enter Speed and

Time, then Acknowledge.”

Ask(“Test OK?”)

Ask(“Mix Again?”)

Speed_%: 10

Time_Min: 4

Discharge Operation

Material: CB1000

Qty_Kgs: 100%

Validate the RecipeSelect the File/Validate… menu option from the Recipe Editor main window to

check for configuration errors. Correct any discrepancies.

Note The recipe must be valid in order to schedule and execute.

Save the recipeSelect the File/Save… menu option from the Recipe Editor main window to save

the recipe. Enter the information shown below.

Approve the Recipe for Production.Select the File/Approvals… menu option from the Recipe Editor main window to

approve the recipe. Enable the Approved for Production check box as shown

below.


This section will describe the steps required to create the batch client application

using InTouch. Several windows will be created that use wizards, ActiveX

objects, and InBatch tags to represent the batch activity.

Note There are two alternatives to making batch tags available within the

InTouch application. The first involves importing the .csv file that was created by

selecting the File/Simulation Export… menu option in the Tag Linker into

InTouch using the DBLOAD utility. The second makes use of the tag browsing

and remote referencing capabilities on InTouch. The latter option will be used in

this example.

Create an Operator Interface on InTouch using InBatch Wizards

Use the InTouch – Application Manager program to create a new InTouch

application named IB_Client. After the application has been created, select the

new application and start WindowMaker.

Note This example assumes that a screen resolution of 800x600 is used for the

InBatch Runtime Client application.

Define WindowsCreate a new Popup window named Questions as illustrated below.

Insert the Batch Questions (w/Close) wizard in the center of this window with

the font settings of Courier New, 8pt, Bold.

Save the Questions window.

The Questions window should look similar to the one shown below.

Create a new Popup window named Equipment as illustrated below.

Insert the Equipment Allocation wizard in the center of this window with the

font settings of Courier New, 8pt, Bold.

Save the Equipment window.

The Equipment window should look similar to the one shown below.

Create a new Popup window named Errors as illustrated below.

Insert the Errors wizard in the center of this window with the font settings of

Courier New, 8pt, Bold.

Save the Errors window.

The Errors window should look similar to the one shown below.

Create a new full-screen, Replace window named Schedule as illustrated below.

Insert the Batch Scheduler/Dispatcher wizard at the top of this window with the

font settings of Courier New, 8pt, Bold.

Double-click the schedule wizard and change the List Size to 4.

Below the schedule wizard, insert the Active Batch List wizard with the font

settings of Courier New, 8pt, Bold.

Double-click the batch list wizard and change the List Size to 4.

To the right of the Active Batch List wizard, add a column of four

Batch/Phase/Misc Button wizards with font settings of Courier New, 8pt, Bold.

Double-click each of the buttons and configure each to have the following name

and action assignments.

Label Button Action

Batch Start Batch Start

Batch Hold Batch Hold

Batch Restart Batch Restart

Batch Abort Batch Abort

Below the schedule wizard, insert the Batch Comments wizard with the font


To the right of the Batch Comments wizard, add two button wizards using the

directions provided earlier with font settings of Courier New, 8pt, Bold.

Double-click each of the buttons and configure each to have the following label


Label Button Action WindowName

Batch Display Window Show: Show ‘Window Name’; Batch

Display

Equipment Window Show: Show ‘Window Name’; Equipment

Note The Batch Display window will be defined later. This step will have to be

completed after the Batch Display window is defined.

Save the Schedule window.

The Schedule window should look similar to the one shown below.

Create a new full-screen, Replace window named Batch Display as illustrated

below.

Insert the Active Phase List wizard at the top of this window with the font



Insert the Phase Parameter List wizard below the Active Phase List wizard with



Insert the Phase Instructions wizard below the Phase Parameter List wizard with



Insert the Phase Message Display wizard to the right of the Phase Instructions

wizard with the font settings of Courier New, 8pt, Bold.

To the right of the phase wizards, add a column of six Batch/Phase/Misc Button

wizards with font settings of Courier New, 8pt, Bold.



Label Button Action

Phase Start Phase Start

Phase Hold Phase Hold

Phase Restart Phase Restart

Phase Abort Phase Abort

Ack On Entry Phase: Ack On Entry

Ack On Exit Phase: Ack On Exit

Add another Batch/Phase/Misc Button wizard with font settings of Courier New,

8pt, Bold.



Label Button Action WindowName

Schedule Window Show: Show ‘Window Name’; Schedule

Add the InBatch SFC Control to the bottom of the window and position

accordingly.

Save the Batch Display window.

The Batch Display window should look similar to the one shown below.

Modify Access NameA default Access Name is created when an InBatch wizard is used in an

application. This access must be modified to point the InTouch batch client

application to the InBatch Server for runtime wizard data. Select the

Special/Access Names… menu option to display the Access Names dialog.

Modify the IB_TIM_TAGS access as shown below.

Set Initial Value for IB_TIM_ACCESS TagThere are several tags created in the InTouch Tagname Dictionary when an

InBatch wizard is used in an application. One tag in particular must be modified

to point the InTouch batch client application to the InBatch Server for runtime

wizard data. Select the Special/Tagname Dictionary… menu option to display the

Tagname Dictionary. Modify the initial value of the IB_TIM_ACCESS_TAG

tag as shown below.

Define Complimentary ScriptsIn order to complete the batch client application, several scripts are required.

These scripts will use several of the InBatch tags. These tags will be remotely

referenced from the InTouch tag browser.

Define Tag SourcesIn order to use the InBatch tags within the scripts defined on the next few pages,

an InTouch tag source must be defined that points to the InBatch Tag Interface

Management (TIM) System tags. These are the wizard tags that provide access to

the runtime batch information from InTouch. Create the tag source shown below

from any script entry dialog. The Location will correspond to the configuration

directory (config_A) on the InBatch Server (MERCURY) node.

Questions Condition ScriptCondition: IB_TIM_TAGS:BTRQ-QUES-NUMITEMS > 0

Condition Type: On True

Script: Show “Questions”;

Condition Type: While True (Every 5000 Msec)

Script: Show “Questions”;

Errors Data Change ScriptTagname: IB_TIM_TAGS:BTEE-MSG-NUMITEMS

Script:

Window ScriptWindow: Batch Display

Condition Type: On Show

Script: #InBatchSFCCtrl1.Host = "mercury";

Condition Type: On Hide

Script: #InBatchSFCCtrl1.Term();

InBatch SFC ActiveX Control Event ScriptDouble-click the InBatch SFC ActiveX control object to display the

InBatchSFC1 Properties dialog. Select the Events tab. Select the

SystemShuttingDown event and define the following script.

Script Name: TermControl

Script: #InBatchSFCCtrl1.Term();

Batch Focus Data Change Script

Tagname: IB_TIM_TAGS:BTB-SEL-SCHFOCUSOK

Script:

Start the InBatch Runtime SystemClick the Runtime… button on the Environment Display window. The Runtime

Application Display dialog is displayed.

Select the Start All button in this dialog to start all of the runtime applications.

After the Server Applications are started, start the InTouch WindowViewer.

Schedule and Execute BatchesDouble-click the BatchSched icon on the Environment Display window. The

Batch Scheduler main window is displayed.

Schedule the following batches.

Select the Initialize/All menu option from the Batch Scheduler main window to

change the status of all of the batches from Open to Ready.

From the InBatch ServerDouble-click the BatchDspl icon on the Environment Display window. The Batch

Display main window is displayed.

Select the Windows/Schedule… menu option from the Batch Display main

window. This displays a list of available batches. Select a batch from the list. Start

the batch by clicking the Batch Start button.

Monitor the execution of the batch, answering any question, entering data for

manual phases and acknowledging phases when necessary.

From the InBatch Runtime Client (InTouch)Make sure the InTouch WindowViewer application is running and displaying the

Schedule window.

Enter the information shown below and then click Add.

Campaign: C001

Lot: L002

Batch: 1

Recipe: CB1000

Quantity: 5000

Train: Mixer 1 Train

Click the Init Batch button to initialize the new batch. The batch status will

change from Open to Ready.

Select a batch from the list at the bottom of the Schedule window and click the

Batch Start button. After the batch status changes to Run, click the Batch

Display button to activate the Batch Display window.

Monitor the execution of the batch, answering any question, entering data for

manual phases and acknowledging phases when necessary until the batch is done.

Execute an End-of-Batch ReportDouble-click the ReportDspl icon on the Environment Display window. The

Report Display main window is displayed.

Select the File/Open… menu option from the Report Display main window. This

displays a list of available reports. Select the B_Journal.rpt file.

Upon opening, the search criteria dialog will be displayed. Enter the information

shown below to generate a report for the batch executed.

After defining the search criteria, the report will be displayed containing all batch

information.

wonderware ® factorysuite™ [inbatch getting started]

Documents