PRODUCTS

PLCbatch – Functions & features

Functions:

  • Recipe creation and management
  • Automatic execution of recipes
  • Creation of batches and control of their execution
  • Recipe vs. Physical model consistency check on batch creation
  • Automatic unit allocation
  • Failures and start conditions summary

Features:

  • Simultaneous execution of more recipes
  • Supports parallel and selective branches
  • Execution of the state-transition algorithm of individual phases, extended by the notion of superstates to improve the abstraction level
  • The programmer can define his/her own model of phase behavior by selecting a particular subset of the predefined states and superstates

Hydraulic Controller

Universal Hydraulic Positioning System with module SPAC20-PA4

  • Motion control in open-loop or closed-loop
  • Up to 16 channels available to drive servo/proportional valves
  • Hydraulic motion control with high accuracy and repeatability
  • Simple calibration of the complete hydraulic system (including valve, cylinder and linear position sensor)

Parison Controller

Parison Thickness Controller for Blow Molding Extruder Machines 

  • Wall thickness control using profiles with up to 128 points.
  • Smooth interpolation between points.
  • Control loop update in 80µs/160µs.
  • For continuous extrusion and for accumulator-based machines.
  • Using the touch screen technology the design of profiles is simple and very efficient

PLCbatch – Hot topic

Safety, speed & ease of use

Through 20 years of field experience our engineers have repeatedly come across same issues. Most of established batch products on the market are highly complexed & priced products that are suitable for larger production processes.  Because of the history, and because not everyone is happy with PC-based solutions, many home-made solutions exist.

One of the main disadvantages of batch products is also the fact that they are executed on PC server. As PCs and communication links are widely known as a weak point in the automation industry, their failure often results in procedure termination. This often leads to high unexpected cost.  PLCbatch relocates the execution of recipes from the inherently unreliable PC platform to the considerably more reliable PLC platform. The simplification of recipe-based batch process control systems does not reduce the expressive power and the abstraction level significantly.

What our colleagues are saying about PLCbatch:

I think that there is a considerable need for this type product for smaller and highly reliable batch control applications.
Asish Ghosh
Vice President
ARC Advisory Group

It is to my knowledge unique in offering recipe execution at the PLC level…
Randy Dwiggins, P.E.
Principal Engineer
Maverick Technologies

Because of the history, and because not everyone is happy with PC based solutions, many home-made solutions exist.
Jean Vieille
Manufacturing IT Consulting
Psynapses

PLCbatch – FAQ

Which commercial PLC platforms is it compatible with?

It is compatible with Mitsubishi, Siemens, (Allen Bradley in future).

Does it actually include a PLC executable that interprets PLC-based recipes or does it just assemble/download PLC code from the recipes?

The system consists of a PLC executable (i.e. interpreter) that interprets PLC-based tabular recipes.

How does it interface and with which PC-based recipe execution systems to manage equipment allocation, batch parameters/records, and the downloading of partial recipes (e.g., unit recipes or operations)?

The system does not include any PC-based recipe execution system.

PC part of the system covers the following functions:

  • equipment editor,
  • recipe editor,
  • batch management, including batch creation, batch downloading, batch state tracking and batch archiving.

PLC part of the system covers the following functions:

  • executing batches (executing, i.e. interpreting recipe tables),
  • managing equipment allocation,
  • controlling individual phases.
  • Does it support other state-transition models besides S88’s example, such as Pack ML (unit level) or user-defined?

PLCBatch defines its own state-transition model, which is an extension of the S88 model, similar to the Statecharts model (superstates and substates, entry, loop and exit actions of the states, actions of the transitions). The model is on a higher abstraction level than the S88 model and consequently more powerful. It is important to note that the model is tailorable, meaning that the programmer can choose his/her own state-transition model, based on any subset of the PLCBatch state model (hence also the pure S88 model is possible). The programmer has only to fill the sequences of the model he defined and the phase logic interface (which is a part of the interpreter) takes over the execution of the model.

Are the “procedure tables” graphically represented using SFC format in the recipe editor and batch view?

The procedure tables are in a tabular form. The main idea is to have an overview of the process also via HMI panels, therefore the tabular presentation is used. The future development could include graphical SFC presentation of recipes, based on sufficient interest.

How much (%) of PLC memory and CPU time does the batch server generally require?  Including client activity?  Will users have to buy more PLCs to support the extra loading?

The required size of the memory and CPU time depends of the process size. Typically, the PLCBatch uses about 50% resources for procedural control and other 50% for basic process control. Most of the applications could run batch and basic control algorithms on the same PLC. Only when pretension functions are required (complex batch process or high speed basic control) two separate PLCs will be suggested for batch and basic control. In this case, two different brand PLCs could also be used (if using one open communication protocol).

The Batch clients (PCs) will not require any special performance and would be able to run on average computer. This computer could be used also for other tasks, like remote process control, normal office work, etc.

LET'S WORK TOGETHER!

There is no universal solution in computer control of the energy sector and industry that would suit all the companies! Because our client is our partner and we work with many different industries, we understand your needs and are able to provide you with customized solution.

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