FAQ about SIMATIC BATCH€¦ · Task/motivation . The SIMATIC BATCH scaling functionality allows the user to formulate unit-independent recipes for a standard quantity – thus completely

FAQ about SIMATIC BATCH

How do I Configure Scaled Recipe Parameters?

FAQ


ID Number: 26686386

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Table of Contents

Table of Contents ......................................................................................................... 2

1 General Information ...................................................................................... 3

1.1 Task/motivation ............................................................................................. 3

1.2 Definitions...................................................................................................... 3

2 Configuring Scaled Recipe Parameters in practical Operation ................ 4

2.1 Practical example 1 ....................................................................................... 4

2.2 Practical example 2 ....................................................................................... 8

3 Interpretation of the Messages .................................................................. 10

3.1 Interpretation of the messages when releasing the recipe ..................... 10 3.1.1 “High limit violated” message.......................................................................... 11 3.1.2 “Maximum quantity too large” message.......................................................... 12

3.2 Behavior when creating and releasing a batch ........................................ 13

4 History .......................................................................................................... 15

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Question

How do I configure scaled recipe parameters?

Answer

The information, instructions and notes listed in this document provide a detailed answer to this question.

http://support.automation.siemens.com/WW/view/en/%3cIDNumber%3e


ID Number: 26686386

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1 General Information

1.1 Task/motivation

The SIMATIC BATCH scaling functionality allows the user to formulate unit-independent recipes for a standard quantity – thus completely independent of the quantities actually to be produced.

It is only when a batch is released that the setpoints are adjusted accordingly and only those units are offered in which the production can be realized with the adjusted selections.

This document uses two examples to describe how the system provides optimum support in creating recipes and in using scaled recipe parameters.

1.2 Definitions

Reference quantity “Reference quantity for quantity scaling” characterizes the reference quantity to which all values to be scaled refer.

“Reference quantity” is frequently used synonymously with “standard quantity”. This can be handled accordingly on a plant-specific basis. However, these things are completely independent of the system and a “standard quantity” is not defined for SIMATIC BATCH.

Recipe limits The reference quantity is completely independent of the recipe limits “Minimum quantity of a batch” or “Maximum quantity of a batch”. These are the limits that have to be defined for a recipe in the “Product” tab.

Quantity The quantity is neither checked for the recipe limits when creating nor when releasing a batch. To the operator it serves as an orientation or is considered when using the “Create batches automatically” option.

Consequently, batches whose quantity is outside the recipe limit can be created, released and started.

Scaled setpoints When using scaled setpoints, a check whether the scaled setpoints are within the limits defined by the object (RPH, ROP) is performed when a batch is released. Candidates that are no longer permissible are removed from the candidate list. It may also occur that a valid candidate for the batch no longer exists.

The system supports the planner already in the work in the Recipe Editor and shows possible conflicts for the specified quantities.


ID Number: 26686386

2 Configuring Scaled Recipe Parameters in practical Operation

The following sections use the example of two practical examples to show the configuration of scaled recipe parameters.

2.1 Practical example 1

The selections of this example are listed in the following table: Table 2-1

Designation Value

Reference quantity Reference quantity for quantity scaling REFRecipe 120kg Minimum quantity Minimum quantity of a batch LLRecipe 80kg Maximum quantity Maximum quantity of a batch HLRecipe 150kg

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Figure 1 Recipe parameters

The setpoint of the phase considered here has the following unit-specific setpoint limits:


ID Number: 26686386

Table 2-2

Unit Setpoint low limit Setpoint high limit

LLSP HLSP Unit_A 30 70 Unit_B 0 100 Lowest / highest value 0 100

If several candidates (units) are possible for the Recipe Unit Procedure (RUP) (for example, for “Operator selection”, “Process parameters” or “The longest out of use”), the lowest low limit (0, 30 => 0) or the highest high limit (100, 70 => 100) of all candidates is indicated for the setpoint to be scaled. To illustrate this, the setpoints are shown in green. (See also Figure 2-2).

sf SP SPscal ∗=

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When modifying the batch quantity between minimum and maximum quantity, the following scaled setpoints (SPscal_xx) would ensue for the phase (SP = setpoint in the master recipe).

• Quantity = minimum quantity

3.33666.050sf SP SP scal_LLscal_LL =∗=∗=

• Quantity = maximum quantity

5.62250.150sf SP SP scal_HLscal_HL =∗=∗=

sfscal_xx being the scaling factor for quantity = minimum quantity or maximum quantity.

For linear scaling • Quantity = minimum quantity

666.0kg120kg80

REFLL

sfRecipe

Recipescal_LL ===


25.1kg120kg150

REFHL

sfRecipe

Recipescal_HL ===


ID Number: 26686386 For quadratic scaling

• Quantity = minimum quantity

444.0666.0kg120kg80

REFLL

sf 222

Recipe

Recipescal_LL ==⎥

⎦

⎤⎢⎣

⎡=

⎥⎥⎦

⎤

⎢⎢⎣

⎡=


563.125.1kg120kg150

REFHL

sf 222

Recipe

Recipescal_HL ==⎥

⎦

⎤⎢⎣

⎡=

⎥⎥⎦

⎤

⎢⎢⎣

⎡=

The scaled values are checked when releasing the recipes or batch and messages are generated or candidates are removed.

Calculated setpoint limits as tooltip text

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To facilitate recipe design for the recipe writer, the limits within which the sepoint may be without violating the setpoint limits for quantities between minimum and maximum quantity are displayed as tooltip text. They are calculated from the conversion of the above-listed formula as follows:

scal_LL

SPSP_Tooltip sf

LL LL = scal_HL

SPSP_Tooltip sf

HL HL =

Figure 2-2, Display of the setpoint limits for several candidates, here Unit_A or Unit_B (in green and associated tooltip text)

0 666 , 0 0

sf LL

LL skal_LL

SP SP_Tooltip = = = 80

25 , 1 100

sf HL

HLskal_HL

SP SP_Tooltip = = =0

666 , 0 0

sf LL

LL scal_LL


25 , 1 100

sf HL

HLscal_HL

SP SP_Tooltip = = =


ID Number: 26686386 Figure 2-3, Display of the setpoint limits for one candidate, here Unit_A (in black and associated tooltip

text)

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45 666 , 0 30

sf LL

LL skal_LL


25 , 1 70

sf HL

HLskal_HL


666 , 0 30

sf LL

LL scal_LL


25 , 1 70

sf HL

HLscal_HL

SP SP_Tooltip = = =

The ratios are again to be shown in a chart. Unit_A and Unit_B have the “real” setpoint limits.

Figure 2-4

Unit_A

Unit_B

0 10 20 30 40 50 60 70 80 90 100 110

If the quantity was at the permissible high limit HLRecipe, the allowed setpoint range Unit_x_scal_HL would ensue for the corresponding unit or, analogously, Unit_x_scal_LL for the low limit LLRecipe.

This is combined in the Unit_x_range bar. When selecting setpoints from the green section, each quantity between LLRecipe and HLRecipe can be selected, whereas the selection of setpoints in the yellow section is limited.


ID Number: 26686386 Figure 2-5

Unit_A_scal_L

Unit_A_scal_H

Unit_B_scal_L

Unit_B_scal_H

Unit_B_range

Unit_A_range

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

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If the setpoint is outside the limits calculated in the tooltip text, this causes a warning when releasing the recipe (see also chapter 3.1 Interpretation of the messages when releasing the recipe), although it is within the setpoint limits, e.g.

HLSP_Tooltip (= 56) < SP (= 60) < HLSP (= 70)

2.2 Practical example 2

The same parameters as in the first example are used. Merely the reference quantity has been reduced from 120kg to 1kg.

Table 2-3

Designation Value

Reference quantity Reference quantity for quantity scaling REFRecipe 1kg Minimum quantity Minimum quantity of a batch LLRecipe 80kg Maximum quantity Maximum quantity of a batch HLRecipe 150kg

In this example, the reference quantity is even outside the recipe limits and thus certainly not identical to a standard quantity. This enables the user to standardize recipes to, for instance, 1kg of final product, the real production volumes deviating considerably from this value.

80kg1kg80

REFLL

sfRecipe

Recipescal_LL === 150

kg1kg150

REFHL

sfRecipe

Recipescal_HL ===

The tooltip text then displays the following recommended setpoint limits for several candidates (e.g., operator selection) or one candidate:


ID Number: 26686386 Figure 6 Display of the setpoint limits for several candidates, here Unit_A or Unit_B, in green and tooltip

text

0 80 0

sf LL

LLskal_LL

SP SP_Tooltip = = = 666 , 0

150 100

sf HL

HLskal_HL


80 0

sf LL

LLscal_LL


150 100

sf HL

HLscal_HL

SP SP_Tooltip = = =

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Figure 7 Display of the setpoint limits for one candidate, here only Unit_A, in black and tooltip text

375, 0 80 30

sf LL

LL skal_LL


150 70

sf HL

HLskal_HL

SP SP_Tooltip = = =375, 0

80 30

sf LL

LL scal_LL


150 70

sf HL

HLscal_HL

SP SP_Tooltip = = =


ID Number: 26686386

3 Interpretation of the Messages

3.1 Interpretation of the messages when releasing the recipe

If the Recipe Editor detects possible conflicts, it displays corresponding warnings. In our example, two different warnings are generated that examine different views:

The same recipe as before is used; setpoint SP = 60; several candidates (Unit_A, Unit_B)

Figure 8 Setpoint parameters for which the messages shown below are generated.

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ID Number: 26686386

3.1.1 “High limit violated” message

Figure 9 Details on the “High limit violated” message

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SPHL HLRecipe REFRecipe SP SPskal_HLSPHLSPHL HLRecipeHLRecipe REFRecipeREFRecipe SP SP SPskal_HLSPscal_HL

The setpoint for the indicated unit (here Unit_A) SPHL= 70 triggers the warning.

For a recipe limit HLRecipe = 150 and reference quantity REFRecipe = 120kg the scaled setpoint would result from the unscaled setpoint SP = 60;

75kg120kg15060

REFHL

SP sf SP SPRecipe

Recipescal_HLscal_HL =∗=∗=∗=

this scaled setpoint exceeeds the upper setpoint limit. The recipe is still released!


ID Number: 26686386

3.1.2 “Maximum quantity too large” message

Figure 10 Details on the “Maximum quantity too large” message

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In this case, the upper recipe limit HLRecipe = 150 triggers the warning. If the setpoints SP (and their limits LLSP or HLSP) are assumed as given or valid, the upper recipe limit HLRecipe must not exceed the value

140kg60kg70*120

SPHLREF HL SP

RecipeRecipe_max ==∗=

to ensure that there are no restrictions when releasing the batch.


ID Number: 26686386

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3.2 Behavior when creating and releasing a batch

In the master recipe, several units (here Unit_A, Unit_B) are to be possible as, for instance, for the “Operator selection” strategy.

A batch with a quantity of 145 is to be created.

Figure 11 Details of the created batch


ID Number: 26686386

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When releasing the batch, the following message is displayed: Figure 12 Dialog box to inform you that candidates have been deactivated

Select “Display Results” to obtain more details:

Figure 13 Details on the deactivation of candidates

Unit_A cannot be used since the upper setpoint limit HLSP is violated by the scaled setpoint

5.72kg120kg14560

REFQuantitySP SP

Recipescal =∗=∗=


ID Number: 26686386

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4 History Table 4-1 History

Version Date Modification

V1.0 10/10/07 First edition

Documents

FAQ about SIMATIC BATCH€¦ · Task/motivation . The SIMATIC BATCH scaling functionality allows the user to formulate unit-independent recipes for a standard quantity – thus completely