JPH08211912A - Batch plant controller - Google Patents

Abstract

PURPOSE: To easily deal with a complicated batch plant by deciding an actual device to be used by reserving its operation based on a production plan, and preparing execution prescription data from basic prescription data defined for each product brand. CONSTITUTION: At a monitoring device ICS, a reservation managing means 4 registers the contents of a producing instruction for each system and reserves the operation based on the production plan. An execution prescription data arithmetic means 5 decides the actual device to be actually used by processing the reservation and prepares the execution prescription data from the basic prescription data defined for each product brand. An operation prescription managing means 6 down loads the execution prescription data to the side of a controller FC and instructs series of batch operations by tracking the execution prescription data under operation to the designated process or device corresponding to the progress of process. A communicating means 7 communicates data with the side of each controller FC through a communication line BS according to fixed communication regulations and transfers required data or commands from the monitoring device side to the controller side with the batch operation.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a batch plant control apparatus for controlling and operating a batch plant by inputting signals from sensors and actuators installed in a process and other various electric devices, and more specifically, The present invention relates to a batch plant control device that allows an operator to dynamically change an operation prescription even when equipment (for example, a reaction kettle) forming a batch plant is complicatedly combined.

[0002]

2. Description of the Related Art Conventionally, there is a plant control / monitoring device called a distributed control system for controlling and operating a plant by using a CRT display device. Such a plant control device displays various information necessary for controlling and operating the plant on the CRT screen of the display device, and when an abnormality occurs in the plant, an alarm is displayed to notify the operator. However, the operator is configured to be able to give appropriate instructions and processing for the abnormality.

In such a system, a batch plant for high-mix low-volume production has features such as complicated process rearrangement and product type switching, and the execution of the batch sequence requires a large number of plant facilities (for example, reaction). It is carried out sequentially via the shuttle. FIG. 9 is a structural conceptual diagram showing an example of a batch plant when a certain one product is produced.

In this example, the raw material A is first charged into the measuring kettle K1 and then into the reaction kettle K2, where a semi-finished product B is produced. After that, the semi-finished product B obtained in the reaction kettle K2
Is charged into the reaction kettle K3, and a predetermined process is performed therein to discharge the product C. Therefore, until the product C is completed, it goes through a plurality of facilities (measurement kettle, reaction kettle, etc.).

In the conventional apparatus of this type, it is assumed that a plurality of facilities are connected in series in principle, and a complicated batch process (for example, a process in which a plurality of reaction vessels are arranged in parallel relationship) ) Could not be easily dealt with.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a batch plant control device capable of easily dealing with a complicated batch plant. .

[0007]

The present invention which achieves such an object manages a control device for controlling a batch plant and various information handled by the control device which is connected to the control device through a communication line. A batch plant control device having a monitoring device having a management function, wherein the monitoring device,
The contents of the production instruction are registered for each system, and the reservation management means for making an operation reservation based on the production plan and the actual device to be actually used are determined by the reservation processing performed by the reservation management means,
Execution prescription data calculation means that creates execution prescription data from basic prescription data defined for each product brand, a function to download the execution prescription data created by the execution prescription data calculation means to the control device side, and according to the progress of the process A batch plant control device having a function of tracking the execution prescription data during operation to the next process, and an operation prescription management means for instructing a series of batch operations.

[0008]

The reservation management means registers data, such as which prescription and how much to produce, on the basis of a production plan and the like for each system using a screen. The execution prescription data calculation means creates execution prescription data from basic prescription data defined for each product brand, and constants and the like used by each calculation function can be registered and changed using a screen.

The operation prescription management means is capable of issuing a series of batch operation instructions and displaying the actual data collected for each process (which can be arbitrarily designated) on the screen during the operation of the batch. You can monitor the driving situation.

[0010]

Embodiments of the present invention will now be described in detail with reference to the drawings. FIG. 1 is a configuration block diagram showing an embodiment of the present invention. In the figure, ICS is a monitoring device (operator station), which is a display device 1 such as a CRT having a man-machine interface function, an operation keyboard 2 for operating / operating a batch plant and inputting data, and a pointing device such as a mouse. Is equipped with. FC is a plurality of distributed control devices (control stations), which are connected to a monitoring device ICS via a communication line BS.

In the monitoring device ICS, 3 is a display means 1.
The display control unit for controlling the display of (1) displays various screens or windows necessary for controlling or monitoring the batch plant on the CRT screen and controls the display. Reference numeral 4 denotes a reservation management means, which has a function of registering the contents of the production instruction for each system and making an operation reservation based on the production plan. Generally, an operator who operates a batch process performs a production activity and work based on a production instruction. The reservation management means 4 has a function of systematically registering the content of this production instruction (which prescription and how much is produced), and which equipment is operated according to what process according to the production plan of the registered content. It has a function to decide and make a reservation.
In addition, among the registration functions, an additional reservation function that allows you to make additions and insertion reservations after you register once, insertion reservation function,
A copy reservation function for making a reservation by copying the same reservation as already registered, a reservation cancellation function for canceling a reservation, and the like may be prepared.

Reference numeral 5 denotes an execution prescription data calculation means, which determines the actual device (series) to be actually used by the reservation processing performed by the reservation management means 4, and defines the basic prescription data defined for each product brand (product group). It has a function to create execution prescription data from. If it is necessary to process the prescription data by the actual device or system that operates, the data is also processed here. For example, in the basic process data, the raw material preparation amount for producing a fixed amount of product is registered, the production amount is given at the time of reservation, and the operation prescription data is recalculated based on the production amount.

Reference numeral 6 denotes a driving prescription management means, which controls the execution prescription data created by the execution prescription data calculating means 5 into a control device F.
It has a function to download to the C side, a function to track the execution prescription data during operation according to the progress of the process to the specified process or device, a batch operation start and end function, etc. Is configured to do.

That is, the processing here is subdivided and constructed as a module so as to be compatible with all batch processes, and each module is converted into a command and one event (sequence message reception)
It is possible to freely combine the processes to be started. FIG. 2 is a diagram showing an example of commands for designating each function provided in the driving prescription management means 6, and shows types of commands and processing contents corresponding thereto.

The following commands are prepared as the types of commands for executing the tracking function. (A) Reservation transfer ... Reservation prescription is transferred as an operation prescription for process 1. (b) Transfer process to n process ... Reservation transfer process specifying transfer destination process (c) Tracking process ... Prescription data during operation Tracking to a process (d) Process jump process ... Tracking process specifying a tracking destination process Also, the following commands are prepared as the types of commands for executing the download function.

(E) Batch download ... Sets prescription data to the control device in batch (f) Individual download ... Sets to control device in units of prescription data (g) Doug setting download process ... Designates specified group of prescription data 3 is a diagram showing a concept of a characteristic function in each of these functions provided in the driving prescription management means 6. (A)
Indicates a batch operation start function. Here, this batch operation start function is divided into a data tracking function, a download function, and a start function so that they can be treated as independent functions.

As a result of subdividing the batch operation start function in this way and making it independent, for example, the data tracking function and the download function are simultaneously specified in step 1, but the start function is specified at a different timing. It will be possible. (B) shows the operation start device specifying function, and the device to be tracked (for example, step 2) can be specified in the data tracking function at the start of operation.

With such a function, it becomes possible to start the batch operation from an intermediate process or apparatus.
(C) shows the interlace function of the device, and the device of the tracking destination can be designated for the data tracking function from the device. This feature allows you to distribute data to multiple devices in parallel,
The data can be tracked to a plurality of devices.

Returning to FIG. 1, 7 is a communication means, which is a communication line B.
Data is exchanged with each control device FC side via S according to a certain communication protocol. The monitoring device ICS collects and monitors various data handled by each control device FC side in charge of itself. It is possible to transfer necessary data and commands from the device ICS side to the control device side in accordance with the batch operation.

In the control device FC, 8 is a communication means,
Monitoring device ICS and each control device FC via communication line BS
Data is transmitted and received between and according to a certain communication protocol. 9 is a functional block, which is a batch plant PL
Input signals from various sensors SN installed in T,
It has a function of sequence-controlling actuators ACT such as valves and pumps. Examples of each of these functional blocks are an SFC block described by SFC, an SEBOL block described by a sequence language SEBOL suitable for detailed description of process step sequence control, a patterned monitoring sequence and a process step. Shape table sequence blocks suitable for the sequence, logic chart blocks that describe the relationship between input signals and output signals using logic elements, etc. are prepared, and batch sequence control can be executed efficiently by appropriately combining these functional blocks. It is like this.

The operation of the apparatus thus configured will be described below. The distributed control devices FC perform predetermined sequence control calculations using signals from various sensors SN, operate each actuator ACT, and control the batch plant PLT. Various control information handled by each control device FC is sent to the monitoring device I via the communication line BS.
It is sent to the CS side, and the monitoring device ICS displays process control information, monitoring results, etc. on its display screen. Further, the monitoring device ICS transmits control information for operating / operating the plant to the control device FC via the communication line BS. Such an operation is an operation of a general distributed control device.

In such an operation, the monitoring device ICS
Based on the display command of the batch sequence control state (such an instruction is output by the operator's instruction from the keyboard 2, the touch screen, etc.), the reservation management means 4 executes the screen required for the operation and monitoring of the batch operation. Display means 1 in cooperation with prescription data calculation means 5, driving prescription management means 6, etc.
To be displayed.

FIG. 4 is a diagram showing an example of an operation screen for the batch operation / monitoring function. An operation screen for this batch operation / monitoring function exists for each series, and various operation commands and prescription state monitoring are all performed using this screen. Operation commands other than reservation operation and operation start command are
It is an unnecessary function because it is usually operated in an automatic sequence, but an operation command is used during manual operation, which is used during a test operation of a new brand, and when restarting after an abnormality is detected.

All the various operation commands are assigned to the buttons at the bottom of the screen. In the state shown in the figure, the reservation-related function is assigned to each button, but when the leftmost button B1 is pressed, the function of each button is changed, and the button to which another operation command is assigned is displayed. When button B2 (start operation) is pressed, operation start is instructed, and button B3 (TRACKING)
Press to activate the tracking function. Also, button B4
Alternatively, when B5 is pressed, a window W1 for selecting a prescription name is displayed.

As a prescription state monitoring function, production reservation information is displayed on the left half of the screen. Here, a list of currently reserved brands is displayed together with the production amount (unit: Kg). In the right half of the screen, the operating status is displayed as a list of brands operating in each device. Also, although it is not understood in the figure, the state of the brand being driven is colored (for example, waiting for setting is white, waiting for start of operation is green, cyan during operation is magenta, end of operation is magenta, forced end is red, etc. It is displayed so that it can be recognized by ().

FIGS. 5 to 7 are views showing the states of the respective screens developed by the button operation in the operation screen shown in FIG. FIG. 5 is an execution prescription data correction screen, which is displayed by operating the button B6 that specifies the device name / process name of the operating condition (right half side) and specifies the execution prescription in FIG. Using this screen, it is possible to set and correct data (including reservations) such as execution prescription data item names and production quantities. In this screen, the prescription data group selection window W2 is displayed by operating the button B7 designating the group, and the screen of the desired prescription data group No can be directly designated.

Similarly, in FIG. 4, the prescription name / U code 1 of the production reservation information (on the right half side) is designated, and the reserved prescription data correction screen is displayed by operating the button B6 designating the prescription screen. You can FIG. 6 is a calculation constant correction screen in which each constant used by the calculation function executed at the time of reservation can be changed using this screen.

FIG. 7 is a performance collection data monitoring screen, in which the performance data collected for each process (which can be arbitrarily designated) is displayed during the operation of the batch so that the operation status can be monitored.
Note that each of these screens may be displayed in full size on the CRT screen, but if necessary, for example, the operation screen for the batch operation / monitoring function shown in FIG.
It is also possible to reduce the size of each screen and display it, and reduce each of the screens developed on the other part based on the button operation to 1/4 and display it as a multi-screen.

[0029]

As described in detail above, according to the present invention, it is possible to perform tracking management of data of a batch plant in which complicated apparatus combinations and complicated movements are performed.
As a result, the operator can easily dynamically change the driving method.

The apparatus of the present invention can easily cope with a complicated batch process as shown in FIG. That is, in the process shown in FIG. 8, (a) has a plurality of devices at the start of operation. In addition, the device cannot be specified until just before the start of operation. In (b), data tracking is performed by a plurality of devices. In (c), data tracking cannot be specified until immediately before. (D) uses the same device many times. However, these problems can be solved by using the designation function of the operation starting device, the jump function of the device, and the like.

[Brief description of drawings]

FIG. 1 is a configuration block diagram showing an embodiment of the present invention.

FIG. 2 is a diagram showing an example of a command for causing each function provided in a driving prescription management means 6.

FIG. 3 is a diagram showing a concept of each function provided in a driving prescription management means 6.

FIG. 4 is a diagram showing an example of an operation screen for a batch operation / monitoring function.

5 is a diagram showing an execution prescription data correction screen which is developed by a button operation on the operation screen shown in FIG.

FIG. 6 is a diagram showing a calculation constant correction screen developed by operating a button on the operation screen shown in FIG. 4;

FIG. 7 is a diagram showing a performance collection data monitoring screen developed by button operation on the operation screen shown in FIG. 4;

FIG. 8 is a diagram showing an example of a complicated batch process.

FIG. 9 is a structural conceptual diagram showing an example of a batch plant when a certain product is produced.

[Explanation of Codes] ICS monitoring device (operator station) FC control device (control station) BS communication line PLT batch plant SN sensor AC actuator 1 display means 2 keyboard 3 display control section 4 reservation management means 5 execution prescription data calculation means 6 operation Prescription management means 7, 8 Communication means 9 Functional blocks

Claims (2)

[Claims] 1. A batch plant control device comprising a control device for controlling a batch plant, and a monitoring device connected to the control device via a communication line and having a management function for managing various information handled by the control device. In the monitoring device, the contents of the production instruction are registered for each system, and a reservation management unit for making an operation reservation based on the production plan, and an actual device actually used by the reservation process performed by the reservation management unit And the function to download the execution prescription data created by the execution prescription data calculation means to the control device side, and the process for creating the execution prescription data from the basic prescription data defined for each product brand. The operation prescription management means for tracking the execution prescription data during operation to the next process according to the progress of Batch plant control device. 2. The batch plant control device according to claim 1, wherein the operation prescription management means has a process jump tracking function that specifies a tracking destination process.