JP2517674B2 - Sequence control method for batch process - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention provides a sequence table control method in a batch process having a single or a plurality of facilities for producing a variety of chemicals, paints, fine chemicals, foods, etc. The present invention relates to a sequence control method capable of flexibly coping with a change in brand when a plurality of brands are manufactured by using the brand.

[Conventional technology]

The control method based on the sequence table defines a time chart table that represents the operation of the device depending on the transition destination between the output device and the step, a transition condition table that describes the transition conditions, and parameters described in the time chart table. By using a sequence table composed of a parameter table and the like, and defining the number of another sequence table as an output device in each of them, another sequence table is activated from a certain sequence table to realize sequence processing. This is a well-known technique (if necessary, for example, "Fuji Jikki" VOL.60 (1987), No.8, P.558 to 561 "Personal supervisory control system FPEC", or Japanese Patent Application No. 62-127966. Please refer to No.).

[Problems to be Solved by the Invention]

By the way, the process is generally composed of a plurality of equipment. Therefore, equipment A, equipment B, as shown in Fig. 10 (a),
When considering a process consisting of equipment C and equipment D, and controlling such a process in a single sequence, there is no problem if the number of brands is small. However, if a large number of brands are to be manufactured by such a process as shown in FIG. 2B, a sequence corresponding to the number of brands is required.
As a result, many sequences must be prepared for each brand in the controller, but there is a problem that the data storage unit for this purpose becomes large-scale and expensive.

Also, in the batch process, not only are there many raw material types and product types, but due to market trends
The control method must be changed each time, and the sequence is often modified accordingly.

Furthermore, if there is a branch route as shown in Fig. 11,
In the conventional control method, the route is not selected by the controller alone, but the route is selected by the operator's judgment or the host system (for example, the overall process monitoring computer system) at the time of branching. In other words, in order to determine whether a certain equipment is being used, check the operating statuses of all the sequences used by that equipment, and confirm that all the sequences are stopped and in the "empty state". There is a need. However, the sequence for this confirmation is complicated and there are many types of sequences. That is, there is also a problem that the sequence becomes more and more complicated as the number of types of stocks increases.

Therefore, an object of the present invention is to make it possible to flexibly deal with a change in a brand when a plurality of brands are manufactured using a sequence table in a batch process in which single or multiple facilities exist, and Depending on the brand sequence that manufactures the equipment, the equipment state is judged from the operating state of the equipment sequence that is in charge of the equipment so that the brand sequence can select its own brand manufacturing route or wait until the equipment becomes available. Yes, there is.

[Means for solving the problem]

In controlling the batch process using the sequence table, the batch process is divided into a plurality of equipments, and a plurality of grandchild sequence tables for processing each small step of each equipment and this grandchild sequence table are combined into one. Providing a plurality of child (equipment) sequence tables for processing equipment and a plurality of parent (brand) sequence tables for determining which equipment to use by combining a plurality of child sequence tables for each brand Select and control each hierarchical sequence table consisting of parent, child, and grandchild according to the brand to be used. In addition, the parent sequence determines whether the corresponding equipment is available from the state of the child sequence to be used, transfers the brand to the next equipment when it is available, and waits when it is not available. To

[Action]

A sequence or sequence table is assembled into a hierarchical structure such as parent, child, and grandchild as shown in FIG. 1, and the necessary sequence is prepared for each issue in the hierarchical sequence.
By specifying the sequence to be used in each layer, it is possible to deal with different issues. In this way, each sequence can specify the lower sequence (child sequence or grandchild sequence) to be used by itself, and can flexibly deal with the change of the sequence.

That is, rather than controlling one process in a single sequence, it is desirable to control the process by dividing it in a plurality of sequences. Therefore, in the present invention, a sequence is prepared for each facility.

Considering this in the example of FIG. 2 similar to that of FIG. 10, sequence A, sequence B, sequence C and sequence D corresponding to four facilities of facility A, facility B, facility C, facility D Prepare and prepare one process by dividing and controlling one process with these four sequences. For example, when manufacturing 1000 kinds of brands, consider each of these four sequences with 10
The sequence according to 00 kinds of stocks is required,
I can't think of it first. In other words, among different brands, when viewed by equipment, some brands may use the same sequence. In other words, the subdivision of the sequence is further subdivided, and small steps (for example, charging, paying,
If the sequence is divided into (for example, temperature rising), the probability that different brands use the same small-step sequence increases. Therefore, it can be said that a brand can be manufactured by combining small process sequences that are required by multiple types of brands to be manufactured, and in this way, it is possible to use fewer sequences than the type of brand to be manufactured. Become.

The equipment sequence is a virtual sequence and actually refers to a sequence using a certain equipment. If one or more sequences are being executed in a piece of equipment, the state of the equipment sequence is a combination of the states of the plurality of sequences. In FIG. 2 the shaded equipment is in use and the shaded child, grandchild or equipment sequence is in operation.

By virtually providing such an equipment sequence, it is possible to easily determine the usage status of a certain equipment. The sequence for manufacturing each brand judges the vacant state of the facility from the operating status of this facility sequence and transfers the brand to the next facility or waits for it. Alternatively, when the route is branched, the sequence for manufacturing each brand can independently transfer the brand to an empty facility. This is clearly shown in FIG.

This is to judge the operating status of the equipment by the tables T1 and T2 and the OR gates 4A and 4B, and transfer the brand to the next equipment when the equipment is in an empty state.

Further, in the example of FIG. 2, when the series of sequences of the equipment B is completed and the brand a is transferred to the next equipment C, the operation status of the equipment sequence C (SEQ-C) is judged to judge the equipment C.
Transfer to.

〔Example〕

 FIG. 4 shows an example of a typical batch process.

The figure shows two weighing tanks 11A and 11B, two reaction vessels 12A and 12B,
This is an example including two intermediate tanks 13A, 13B, discharge valves 14A, 14B, 14G, 14H and charging valves 14C, 14D, 14E, 14F, 14I, 14J, 14K, 14L.

"Facilities" are defined for such processes.
In the process of FIG. 4, for example, the measuring tank 11A and the dispensing valve 14A, the measuring tank 11B and the dispensing valve 14B, the charging valves 14C and 14D, and the reaction vessel.
12A and dispensing valve 14G, charging valves 14E and 14F, reaction kettle 12B and dispensing valve 14
H, charging valves 14I, 14J and intermediate tank 13A, charging valves 14K, 14L and intermediate tank 13B are defined as "equipment". First, pay attention to the weighing tank 11A (SEQ No. 10, equipment UNiT001), and for example, construct the equipment sequence as shown in FIG. TR in the figure
M003 indicates the timer set time, and the payout valve in steps 2 and 3
It is shown to drive 14A. This SEQ No. 10 is an equipment (child) sequence corresponding to the weighing tank 11A, and this is an example when the grandchild sequence is an immediate child sequence (equipment sequence). Similarly, weigh tank 11B (SEQ
No.20, equipment UNiT002), reaction kettle 12A (SEQ No.30,31, equipment UNiT003), reaction kettle 12B (SEG No.40,41, equipment UNiT00)
4) Establish each equipment sequence of the intermediate tank 13A (SEQ No.50, equipment UNiT005) and the intermediate tank 13B (SEQ No.60, equipment UNiT006).

Here, it is assumed that the equipment sequence of the reaction kettle 12A is composed of the steps of charging->heating-> discharging, and that there is a unit operation (grandchild) sequence as shown in Figs. ,
The equipment (child) sequence of the reaction kettle 12A is as shown in FIG. That is, the equipment (child) sequence of the reaction kettle 12A shown in FIG. 7 is the sequence SEQ100 of the valves 14C and 14D, the sequence SEQ101 of the reaction kettle 12A and the sequence SEQ102 of the valve 14G.
It consists of three grandchild sequences. As described above, when the equipment sequence is composed of a plurality of grandchild sequences, the output signal name in the sequence table is described by the grandchild sequence number.

Next, regarding the brand sequence, how to move the above equipment sequence is described with a time chart.
An example thereof is shown in FIG. FIG. 3 is used at this time. UNiT003.RDY and UNiT004.RDY in the figure indicate that the reaction kettles 12A and 12B are not used, and in STEP 1, monitor the usage status of the reaction kettles 12A and 12B and jump to the step that uses the one not used. , Run the time chart and go. In FIG. 8, where a plurality of destination process numbers (two) are described for one process, it indicates that selection is performed according to the result of the above-mentioned monitoring.

A man-machine interface is generally used in process control, and the monitoring screen in this case is as shown in FIG. 9, for example. By displaying such a screen, it is possible to easily monitor the entire facility.

Further, in the above, various sequence tables having a hierarchical structure are used, but these can be appropriately rewritten except for those in operation.

〔The invention's effect〕

According to the present invention, a variety of brands can be manufactured even with a personal computer or controller having a relatively small storage capacity, and the scale of the control system can be reduced. Further, in the case of manufacturing a plurality of brands within the manufacturing process, the sequence for managing the brands can judge the vacant state of the equipment by itself and transfer the brands one after another to automatically manufacture the brands. Furthermore, even if there is a branch in the manufacturing route inside the process, the sequence for managing the brand itself can automatically select the route depending on the availability of the equipment for the next process.

As a result, once the brand management sequence starts operation, the brand can be manufactured only by the controller that executes the sequence. Even if the man-machine interface or the host computer system goes down during this time, the brand can be manufactured only by the controller and transferred to the final equipment.

In addition, by adopting the equipment sequence, it is possible to easily realize the progress status of the brand and the usage status of the equipment at the higher-level man-machine interface or the higher-order computer system, which can greatly contribute to the monitoring of the brand. .

[Brief description of drawings]

FIG. 1 is a block diagram for explaining the concept of the present invention,
FIG. 2 is a block diagram for explaining the equipment sequence,
FIG. 3 is an explanatory view for explaining a method of judging the usage status of equipment, FIG. 4 is a block diagram for explaining an example of a batch process, and FIG. 5 is an explanation for an equipment sequence example of a weighing tank. , FIG. 6 is an explanatory view for explaining a unit operation sequence of the reaction kettle, FIG. 7 is an explanatory view for explaining an equipment sequence example of the reaction kettle, and FIG. 8 is a brand sequence of FIG. FIG. 9 is an explanatory diagram for explaining an example, FIG. 9 is an explanatory diagram for explaining a monitor screen, FIG. 10 is a block diagram showing an example of a conventional sequence control method, and FIG. 11 is an example when a process has a branch. It is a block diagram showing. Description of symbols 1 ... Parent sequence, 2 ... Child sequence, 3 ... Grandchild sequence, 4A, 4B ... OR gate, 11A, 11B ... Measuring tank,
12A, 12B ... Reactor, 13A, 13B ... Intermediate tank, 14A-14L
……valve.

Front Page Continuation (72) Inventor Nobutaka Tanaka 1-14-1 Minami Sanrokusho, Yokohama City, Kanagawa JGC Corporation (72) Inventor Masakazu Ikoma 1-1, Tanabe Shinden, Kawasaki-ku, Kanagawa Prefecture Fuji Electric Machinery Co., Ltd. (72) Inventor Hideaki Takishita 1-1 Tanabe Nitta, Kawasaki-ku, Kawasaki-shi, Kanagawa Fuji Electric Co., Ltd. (56) Reference JP-A-1-91207 (JP, A)

Claims (2)

(57) [Claims] 1. When controlling a batch process using a sequence table, the batch process is divided into a plurality of equipments, and a plurality of grandchild sequence tables for processing each small step of each equipment, and the grandchild sequence table. A plurality of child sequence tables (equipment sequence tables) for processing one piece of equipment and a plurality of parent sequence tables for determining which piece of equipment to use by combining a plurality of sequence tables for each brand. A sequence control method for a batch process, which is characterized in that a hierarchical sequence table including a parent, a child, and a grandchild is selected and controlled according to the brand to be manufactured. 2. The parent sequence determines from the state of the child sequence to be used whether or not the corresponding equipment is available, transfers the brand to the next equipment when it is available, and when it is unavailable. The sequence control method of the batch process according to claim 1), wherein the method is waiting.