JP6418996B2 - Program design apparatus, batch plant control system, and program design support method - Google Patents

Description

  The present invention relates to a batch plant control system, and more particularly, to a technology for supporting creation of a product manufacturing program executed by the control system.

  When constructing a control system in a batch plant, in general, a manufacturing process and a production facility are modeled. In S88, which is a collective term for international standards related to batch plants, process models, physical models, and procedural control models are handled as important models for constructing a control system.

  The process model is a hierarchical model viewed from the process side such as a chemical reaction or a physical reaction. For example, the manufacturing process is expressed by chemical and physical changes that do not have the concept of equipment such as “preparation”, “cooling”, and “addition”.

  The physical model is a hierarchical model from the viewpoint of hardware. For example, as shown in FIG. 10, the relationship between production facilities is expressed by connecting devices (referred to as “units”) that are a collection of devices such as “tank”, “mixing pot”, “pump”, “flow meter”, and “valve”. Is done.

  The procedural control model is a hierarchical model from the viewpoint of software. For example, detailed procedures (referred to as “sub-processes”) are hierarchically expressed for each “preparation”, “addition”, “transfer”, etc. (referred to as “medium process”) in the unit.

  When mounting on a control system, a product manufacturing program is created for each product manufacturing method based on a procedural control model. And a product manufacture in a batch plant is performed by running a product manufacture program with the batch plant control apparatus which controls the field apparatus arrange | positioned at each unit.

  By the way, in a batch plant, a product is manufactured for each manufacturing unit called a lot. However, in many cases, a production efficiency is increased by simultaneously manufacturing a plurality of lots. Here, if different products, naturally, it is a different lot, and even if the same product is manufactured at the same time, if the manufacturing unit is different, it is a different lot.

  When a unit performs a middle process for a lot, another unit can perform a middle process for another lot. For example, as shown in FIG. 11, a batch composed of four units. If it is a plant, a maximum of 4 lots can be manufactured simultaneously. In this case, different intermediate processes are performed for each lot even in the same unit.

JP 2011-243128 A

  In a control system in a batch plant that manufactures multiple lots simultaneously, it is not sufficient to simply control the middle process or small process of each product for each unit. For example, the following functions are further required. The

  First, it is necessary to manage the execution order between units. For example, as shown in FIG. 12, after a request is made simultaneously from unit A to unit B and unit C, the transfer from unit C to unit A is performed prior to the transfer from unit B to unit A. This is a management function when there is an indispensable restriction.

  Also, in the cooperative operation between the units, for example, as shown in FIG. 13A, a synchronous cooperation in which a request is made from the unit A to the unit B and a transfer is performed after the response from the unit B is received. As shown in FIG. 13 (b), there is an asynchronous linkage that is completed by making a request from unit A to unit B, and a function to distinguish and manage these is required.

  Furthermore, a management function that complies with the lot manufacturing order for each unit is required. Generally, when a middle process is sequentially performed on different lots in a certain unit, processing must be performed from a lot with a smaller lot number. This is because it is premised on manufacturing in order of lot numbers for equipment cleaning and contamination prevention measures.

  For example, as shown in FIG. 14, when the unit D is used for both the production of the product X with the lot number N and the production of the product Y with the lot number N + 1, even if the lot number N + 1 precedes in the unit D, The lot number N must be processed before the lot number N + 1.

  Conventionally, each of these functions is realized by an individual program, and the implementation method and management method depend on a programmer who creates each program. For this reason, it is difficult to grasp the overall image of the cooperation of the respective functions, and it takes time to construct the control system, and it is extremely difficult to cope with the change of the batch plant.

  In view of the above, an object of the present invention is to make it possible to easily create a manufactured product program to be operated by a control system of a batch plant.

In order to solve the above problems, a program design apparatus according to a first aspect of the present invention is a batch plant in which product manufacturing facilities are divided into units, and manufacturing procedures in each unit are hierarchized into middle and small processes. A program design device that supports creation of a product manufacturing program to be executed by a control system, a template storage unit for storing a template in which a procedure of a small process constituting a middle process is defined for each middle process, and a unit for each manufacturing method The middle process flow definition part that accepts the definition of the middle process flow that shows the procedure of each middle process, and the designation of the coordinated operation of the middle process unit, and the coordinated operation of the small process unit based on the coordinated operation of the middle process unit The intermediate definition flow is expanded into a small process flow with reference to the template and the linkage definition unit that accepts the designation of the small process flow and the designation Characterized in that it and a product manufacturing program creation unit that creates a product manufacturing program based on cooperative operation of the small steps units.
Here, the cooperation definition unit can accept the designation of the cooperation operation in units of middle processes, distinguishing between synchronous cooperation and asynchronous cooperation.
In addition, the cooperation definition unit can accept a specification including information on the order of cooperation for the cooperation operation in the middle process unit.
In addition, when the definition of the intermediate process flow is received, the intermediate process flow definition unit can display the process symbols indicating the respective intermediate processes on the editing screen, and can accept the designation of the arrangement of the process symbols.
In order to solve the above-mentioned problems, a batch plant control system according to a second aspect of the present invention includes the above-described program design device, and a batch plant control device that executes the product manufacturing program to control product manufacturing in units of lots. It is characterized by providing.
Here, the batch plant control device accepts a manufacturing instruction including an instruction of a product to be manufactured and an instruction of the order of manufacturing the product, and the intermediate process in the unit is performed according to the specified manufacturing order according to the product manufacturing program. It is possible to provide a lot management unit for controlling product production in units of lots.
In order to solve the above-described problem, a program design support method according to a third aspect of the present invention is a batch plant in which product manufacturing facilities are divided into units, and the manufacturing procedure in each unit is hierarchized into a middle process and a small process. Is a program design support method for supporting creation of a product manufacturing program to be executed by the control system of the present invention, the step of accepting the definition of the intermediate process flow indicating the procedure of the intermediate process for each unit for each manufacturing method, and the cooperative operation of the intermediate process unit A step of accepting the designation of the intermediate process, a step of developing the intermediate process flow into the small process flow with reference to a template in which the procedure of the small process constituting the intermediate process is defined for each intermediate process, and a linked operation in units of the intermediate process A step of accepting designation of a coordinated operation in units of small processes based on, and a product manufacturing program based on the coordinated operations of the small process flow and small steps And having a step of creating a beam, a.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacture product program operated with the control system of a batch plant can be created easily.

It is a block diagram which shows the structure of the batch plant control system which concerns on this embodiment. 4 is a flowchart for explaining a product manufacturing program creation support operation of the program design apparatus 100. It is a figure explaining the definition process of a middle process. It is a figure explaining the connection process of the middle process to cooperate. It is a figure explaining the name setting process of a cooperation flag. It is a figure which shows the example of a display screen when finishing to the name setting process of a cooperation flag. It is a figure explaining a small process flow. It is a flowchart explaining the product manufacture control operation | movement of a batch plant control apparatus. It is a figure which shows the image of the product manufacture for every lot. It is a figure explaining a physical model. It is a figure explaining simultaneous manufacture of a plurality of lots. It is a figure explaining the function which manages the execution order between units. It is a figure explaining the synchronous cooperation and asynchronous cooperation between units. It is a figure explaining the management function which observes the manufacturing order of a lot for every unit.

  Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a block diagram showing a configuration of a batch plant control system 10 according to the present embodiment. As shown in the figure, the batch plant control system 10 includes a program design device 100, a batch plant control device 200, and a field device 300.

  The field device 300 is a valve, a measuring device, a converter, or the like, and a plurality of types and a plurality of units are arranged for each unit included in the batch plant.

  The program design apparatus 100 is an apparatus that supports creation of a product manufacturing program, and includes a template storage unit 110, a middle process flow definition unit 120, a linkage definition unit 130, and a product manufacturing program creation unit 140. The program design apparatus 100 can be configured using a general-purpose information processing apparatus such as a PC.

  The template storage unit 110 is an area for storing templates prepared in advance for various intermediate processes such as “preparation”, “addition”, and “transfer” in the unit.

  A template is created for each intermediate process, and a procedure for small processes constituting the intermediate process is defined. For example, in the template of the intermediate process “preparation”, small processes are defined by procedures such as “liquid feeding request”, “single material acceptance”, “matebara check”. In addition, there are small processes that require cooperation with small processes included in other medium processes, such as synchronous cooperation requests, asynchronous cooperation receptions, etc., and for such small processes, there are nodes for connection. Is defined.

  The middle process flow definition unit 120 receives a definition of the middle process flow from the user in units of units for each manufacturing method. In defining the middle process flow, the middle process template stored in the template storage unit 110 may be used, and a symbol mark indicating the middle process may be arranged on the editing screen in accordance with the procedure of the middle process.

  The cooperation definition unit 130 first accepts designation of cooperation in units of middle processes from the user, and then accepts designation of cooperation in units of small processes included in the linked middle processes. The designation of linkage in the middle process unit may be performed by connecting the symbol marks of the linked middle processes with a line and setting the name. When specifying the linkage, the synchronous linkage and the asynchronous linkage are distinguished, and the execution order of the linkage is also defined.

  The designation of cooperation in units of small processes is performed in order to indicate the cooperation between designated intermediate processes as a specific cooperation between small processes. When linking small process units, it is only necessary to connect the target nodes for connection from the small processes included in the linked intermediate processes.

  The product manufacturing program creation unit 140 develops the intermediate process flow defined by the user into small process flows according to the template. And the designation | designated of the cooperation of small processes is received based on the cooperation designated between middle processes, and the product manufacturing program which shows the manufacturing procedure for every manufacturing method is created. In the product manufacturing program, the procedure and linkage of the small process are defined for each unit in the middle process unit.

  The batch plant control device 200 is a device that executes a product manufacturing program to control the production of a lot unit of a product designated by a user, and includes a lot management unit 210, a unit control unit 220, and a field control unit 230. . The batch plant control apparatus 200 can be configured using a computer system, for example.

  The lot management unit 210 includes a product manufacturing program receiving unit 211, a manufacturing order receiving unit 212, and an execution control unit 213.

  The product manufacturing program receiving unit 211 receives an input of a product manufacturing program created by the program design device 100. The manufacturing order receiving unit 212 receives manufacturing instructions from the user. The production order includes designation of a product to be produced, an amount, and a production order (lot number). When there are a plurality of units having the same function, designation of the unit to be used may be included. The execution control unit 213 executes a product manufacturing program according to the manufacturing instructions. When the product manufacturing program is executed, an instruction is sent to the unit controller 220 so that the processing is performed in the order of the lot numbers.

  The unit control unit 220 controls the execution of small processes in the unit based on instructions from the lot management unit 210. For this reason, the unit control part 220 is provided with the unit control program 221 provided with the process execution program 222 for every small process corresponding to the unit contained in a batch plant. When executing the small process, an instruction is sent to the field control unit 230 according to the process execution program 222.

  The field control unit 230 controls the operation of the field device 300 based on an instruction from the unit control unit 220 and acquires information such as measurement values from the field device 300.

  Next, the product manufacturing program creation support operation of the program design apparatus 100 will be described with reference to the flowchart of FIG. First, the middle process flow definition unit 120 receives the setting of the definition target product from the user (S101). That is, the product for which the product manufacturing program is created is specified.

  Next, the middle process flow definition unit 120 accepts registration of a unit used for manufacturing a product (S102). The user registers units corresponding to the apparatus configuration of the batch plant, such as a mixing tank, a reaction tank, and a storage tank.

  Then, the intermediate process flow definition unit 120 receives the definition of the intermediate process flow for each unit (S103). As shown in FIG. 3, the middle process flow can be defined by arranging process symbols displaying the names of middle processes in the area corresponding to the registered unit on the display screen in the order of processes. Each process symbol is prepared in the template storage unit 110 in advance.

  When the definition of the middle process flow is finished, the linkage definition unit 130 accepts a linked middle process connection from the user (S104). As shown in FIG. 4, in the middle process, the process symbols of the middle processes to be linked are connected with a line. The connected line is called a linkage flag. The process symbol has a terminal for synchronous cooperation and a terminal for asynchronous cooperation. When the terminals for synchronous cooperation are connected, the cooperation flag is displayed with a solid line, and when the terminals for asynchronous cooperation are connected, the cooperation flag is a broken line. Is displayed. The linked middle process includes utility equipment that does not operate like a “raw material tank”.

  And the name of each cooperation flag is received from a user (S105). The operation of the cooperation flag is defined by its name. Specifically, the synchronous linkage flag indicating synchronous linkage such as raw material input and liquid transfer is given the name TXX, and the asynchronous linkage flag indicating asynchronous linkage such as activation of ancillary equipment, liquid request to utility equipment, etc. And the name RXX. As a result, a function for managing synchronous linkage and asynchronous linkage separately is realized.

  Here, XX indicates the execution order of cooperation, and a name that is younger is assigned to the cooperation performed earlier. As shown in FIG. 5, the user assigns the name “T01” to the synchronous cooperation flag if it is the first synchronous cooperation, and the name “R01” to the synchronous cooperation flag if it is the first asynchronous cooperation. Is attached. Thereby, the function of managing the execution order between units is realized. FIG. 6 shows an example of a display screen when the process up to the link flag name setting process is completed. This display screen can be diverted to, for example, a document indicating a product manufacturing procedure. Thereby, for example, maintenance of the batch plant becomes easy.

  When the name of each cooperation flag is received, the product manufacturing program creation unit 140 develops the middle process flow into the small process flow (S106). The development to the small process flow is performed based on the template stored in the template storage unit 110. Thereby, the procedure of a small process is defined about each unit.

  Next, designation of cooperation in units of small processes is received from the user (S107). When specifying the linkage of small process units, as shown in Fig. 7, the small process flow developed from the middle process flow is displayed, so the small process of the connection source and the small process of the connection destination are specified on the screen do it. At this time, in order to simplify the user's operation, a list of small processes that are candidates for connection destinations is displayed based on the cooperation flag set in units of medium processes.

  When cooperation is specified in units of small processes, the product manufacturing program creation unit 140 generates a product manufacturing program based on the small process flow and the small process unit cooperation flag (S108). The product manufacturing program is a program that can be executed by the batch plant control apparatus 200 that shows a product manufacturing procedure in a small process flow for each unit, and further shows synchronous cooperation and asynchronous cooperation of small processes.

  Next, the product manufacturing control operation in the batch plant control apparatus 200 will be described with reference to the flowchart of FIG.

  First, the product manufacturing program receiving unit 211 of the lot management unit 210 receives an input of the product manufacturing program created by the product manufacturing program creating unit 140 (S201). For example, the product manufacturing program accepts each manufacturing method of a product to be manufactured based on a user instruction.

  Next, the production order receiving unit 212 of the lot management unit 210. Accept manufacturing instructions from the user. The production order includes designation of a product to be produced, a lot amount, and a production order (lot number). When there are a plurality of units having the same function, designation of the unit to be used may be included.

  When the manufacturing instruction is received, the execution control unit 213 sends an instruction to the unit control unit 220 so that the processing is performed in the order of the lot number in each unit according to the product manufacturing program of the product to be manufactured and the lot order (S204). FIG. 9 is an image diagram showing a state in which a product manufacturing program in which a middle process flow is defined for each unit is executed in order of lot numbers. That is, when the product X is manufactured as the lot number N, the product Y is manufactured as the lot number N + 1, and the product Z is manufactured as the lot number N + 2, the middle process flow and the unit flow in each lot are arranged. Become.

  Since the execution control unit 213 of the lot management unit 210 can grasp the units used in each lot, the unit control unit 220 performs processing in the lot order for different lots in which the same unit is used. To give instructions. Thereby, the management function which observes the manufacturing order of a lot for every unit is implement | achieved.

DESCRIPTION OF SYMBOLS 10 ... Batch plant control system, 100 ... Program design apparatus, 110 ... Template storage part, 120 ... Middle process flow definition part, 130 ... Cooperation definition part, 140 ... Product manufacturing program creation part, 200 ... Batch plant control apparatus, 210 ... Lot management unit 211 ... Product manufacturing program reception unit 212 ... Production order reception unit 213 ... Execution control unit 220 ... Unit control unit 221 ... Unit control program 222 ... Process execution program 230 ... Field control unit 300 ... field equipment

Claims (7)

A product design apparatus that divides product manufacturing equipment into units and supports creation of a product manufacturing program to be executed by a control system of a batch plant in which manufacturing procedures in each unit are hierarchized into medium and small processes,
A template storage unit for storing a template in which the steps of the small process constituting the intermediate process are defined for each intermediate process;
A middle process flow definition unit that accepts a definition of a middle process flow indicating the procedure of the middle process for each unit for each manufacturing method;
A linkage definition unit that accepts designation of a coordinated operation in units of medium processes, and further, accepts designation of coordinated operations in units of small processes based on the coordinated operations in units of medium processes;
A product manufacturing program creating unit that develops the middle process flow into small process flows with reference to the template and creates a product manufacturing program based on the small process flow and the coordinated operation of the designated small process unit; ,
A program design apparatus comprising:   The program design apparatus according to claim 1, wherein the cooperation definition unit accepts a designation for a cooperation operation in a middle process unit, distinguishing between synchronous cooperation and asynchronous cooperation.   The program design apparatus according to claim 1, wherein the cooperation definition unit receives a specification including information on a cooperation order for a cooperative operation in a middle process unit.   2. The intermediate process flow definition unit, when receiving a definition of a middle process flow, displays a process symbol indicating each intermediate process on an editing screen and accepts designation of an arrangement of process symbols. The program design device according to any one of to 3.   A batch plant control comprising: the program design device according to any one of claims 1 to 4; and a batch plant control device that executes the product manufacturing program and controls product manufacturing in units of lots. system. The batch plant control device
Accepts production instructions that include instructions for the products to be manufactured and instructions for the order in which the products are to be manufactured;
6. The batch plant control system according to claim 5, further comprising: a lot management unit that controls product manufacturing in units of lots so that intermediate processes in the units are performed in accordance with a specified manufacturing order according to the product manufacturing program. . A program design support method for supporting the creation of a product manufacturing program to be executed by a batch plant control system in which product manufacturing facilities are divided into units and manufacturing procedures in each unit are hierarchized into medium and small processes,
Receiving a definition of a middle process flow showing a procedure of a middle process for each unit for each manufacturing method;
A step of accepting designation of a cooperative operation in a middle process unit;
A step of developing the intermediate process flow into a small process flow with reference to a template in which the procedure of the small process constituting the intermediate process is defined for each intermediate process;
Receiving a designation of a coordinated operation in units of small processes based on a linked operation in units of medium processes;
Creating a product manufacturing program based on the cooperative operation of the small process flow and small process units;
A program design support method characterized by comprising: