Considerations for Batch & Sequencing System Selection. Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

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1 Considerations for Batch & Sequencing System Selection Rev 5058-CO900D

2 Equipment Cost Requires HMI software Sequencer engine Requires a controller Operator electronic work instructions Material management Batch campaigning Formulation management Electronic journal Web-based reporting No controller required for manual processes No HMI required Low-cost or free sequencing engine HMI and controller application code Higher upfront investment due to the required purchase of batch software 2

3 Equipment Requirements Requires a controller Works with a variety of user Requires HMI software and interfaces operating system Does not require a controller for recipe manuals operating instructions Does not require a server operating system Multi-controller interface and coordination Requires a server operating system to run batch service 3

4 Robustness Recipe will continue to run Components detect loss of without HMI or network; no network or server and bring operation view if loss of recipe and phases to held safe sequencing network state Recipe will continue to run in the controller without an HMI or network Loss of power will cause loss of current or sequence state Upon system restore, the recipes reconstruct and recipes continue where they left off after an operator restart Requires the PC and the network in order to continue No built-in redundancy, relies on third party like virtualization 4

5 Reporting Capabilities Reporting available on certain Custom reporting required Comprehensive data collection Requires an operating system data types High cost of implementation performed by batch service Only some valued data is Ability to move data to multiple captured data bases Free predefined reports Interaction with historical datatracking software provides the ability to correlate batches with historical trend data 5

6 Equipment Definition & Specification All equipment model Limited parameters and report Extensive number of Addition of new equipment configuration performed via HMI values parameters and report values requires stopping and restarting Ability to add equipment phases Typically no strings or Each equipment definition can batch service, no online to definition without affecting enumeration parameters or be different for units, phases, equipment definition changes running recipes report values parameters and reports allowed Simple to understand and deploy Controller memory usage tool available Ability to add or remove units, phases, parameters and report values on-the-go Only requires HMI and controller know-how to maintain All equipment definitions require the same controller memory overhead to be reserved whether it is in use or not Maximum of 32 phases per unit Consumes controller processor memory (estimating tool available) Parameters and report data types: integer, real, strings, enumerations Unit attributes allow equipment to be automatically selected based on equipment conditions Phases have the ability to acquire shared resources Equipment allocation and arbitration is performed by batch server not in controller code Does not require controller to run if manual process Equipment phase logic can be distributed among multiple controllers or varying types Unit and phase class definition 6

7 Recipe Definition and Usability Intuitive user interface for operator and Single-unit recipes Multiple-unit recipe coordination formulators No class-based recipes, each one Recipe operations and unit procedures Ability to modify existing running needs to be maintained can be reused by other recipes recipes on the go individually Ease of creating, saving and replicating recipe Ability to save running recipe as One (S88) operation per recipe recipes master recipe No recipe structure reusability Class-based recipes allow one recipe to Simple to step forward or backward to Maximum of 32 steps per recipe run in multiple units as the same time, predefined pausing points Maximum of 32 recipes per unit simplifying recipe management & control All recipe definition is performed via All recipes reserve the same Number of recipes virtually unlimited, HMI amount of controller memory recipes may contain many steps All recipe definitions reside in the regardless of number of steps or Recipes do not reside in the controller and controller recipes per unit do not consume controller memory Recipe step transitions are solely Recipes are transportable (copy/paste) based on phase completion Recipe changes are audited No looping or branching in recipe; Phase parameters and reports can be always performs the same steps calculations that reference other of a sequence parameters and report values, unit tags, Risk of losing recipe intellectual property by exposing controller code to anyone working in the controller etc. Recipe step transitions can be configured to be the result of calculate values, unit conditions, recipe conditions, reported values, parameters, equipment states, etc., or simply phase complete Looping and branching can be performed Changes made to running recipe cannot be stored as the master Steps cannot be added or removed from running control recipes 7

8 Validation Recipes need to be validated Sequencing engine allows Network performance needs to for each product and for all class-based recipes to be be reliable equipment deployed on class-based equipment which only requires one time recipe validation Non-hard coded controllerbased solutions require less validation effort than hardcoded solutions Typically more functionality is designed into the phase logic of these systems, requiring additional effort 8

9 Considerations for Batch and Sequencing System Selection Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900D