Administrator Training. IDC TMWeb System. Control Room Technologies. IDC Corporation and. Presented for GM. April 2003 IDC Corporation

Transcription

1 IDC TMWeb System Administrator Training Presented for GM By IDC Corporation and Control Room Technologies April 2003 IDC Corporation

2 Topics of Discussion Introduction to the system Steps to setup the system Configuring tonnage monitors Setting up die recipes Viewing historical data Viewing live graphs View peak graphs April 2003 IDC Corporation

3 Introduction What is TM Web? Prerequisites for the system to function TM Hardware Server Hardware Server Software Client Software April 2003 IDC Corporation

4 Tonnage Monitor Hardware TM90 Series CPU Ethernet Interface (Modbus/TCP) + Ethernet connection 486-E processor or 386 Processor+Ethernet Optional PLC interfaces AB Remote I/O ControlNet April 2003 IDC Corporation

5 Server Hardware GM Standard Package 72 GB RAID 5 drive Array Redundant Power Supply Memory: 1 Gb Tape Backup CD-ROM Dual Ethernet ports Jet Drive OOPS! Not just an LED: Shutdown Button! April 2003 IDC Corporation

6 Server Software Windows 2000 Server IIS Internet Server Cold Fusion Server Dynamic Database-driven Web Page generation, user I/O Oracle Database Server Stores data collected by Press Interface Service Stores/Retrieves recipe data Press Interface Service Continuously polls TM90s -> Oracle Detects Die Recipe requests Downloads TM recipes from database Transmits user input/commands to TM Java Applets (sent to clients as needed) April 2003 IDC Corporation

7 Client Software Internet Explorer 5.5 or later Draws frames, tables, buttons, etc, from HTML pages Action buttons send requests to server via HTTP Java Runtime Environment Executes applets that draw signature graphs & peak charts on the client screen using data from database April 2003 IDC Corporation

8 Overview of Entire System April 2003 IDC Corporation

9 System Overview: Connection 1 This connection uses HTTP protocol to transfer data between the Internet Explorer web browser running on a client computer and Microsoft s Internet Information Services (IIS) running on the server. The browser posts a request to view a certain page IIS passes the request upstream (next slide) the page data is delivered (back to IIS), IIS sends new page data to the client browser in HTML language format. The browser generates its display from the HTML data. April 2003 IDC Corporation

10 System Overview: Connection 2 IIS recognizes a ColdFusion MX request from the file extension (.cfm) IIS passes the request to ColdFusion MX for processing, which may include: Storing something in the database Generating a fresh page from database information ColdFusion passes page data back to IIS April 2003 IDC Corporation

11 System Overview: Connection 3 An ODBC connection allows ColdFusion MX to exchange data with the Oracle Database, such as: Requests for tonnage monitor updates (writes) Response from the Press Interface service Requests for register retrieval requests (reads) Response from the Press Interface service Configuration data for a monitor Network configuration data User configuration data April 2003 IDC Corporation

12 System Overview: Connection 4 ODBC connection allows Press Interface service to exchange data with the Oracle Database, such as List of monitors to scan for cycle update status Cycle information (signature, status, etc) Queue of user information requests (read) Queue of user update requests (write) Die Recipe data April 2003 IDC Corporation

13 System Overview: Connection 5 Press Interface Service communicates with TM90s using Modbus/TCP (aka OpenModbus) protocol Continuously scans for changes in status New cycle signatures & status sent to database Automatic Die Recipe response Recognize update command via mailbox register Database lookup of recipe data via ODBC request Write recipe data to TM90 via Modbus/TCP Confirm written data via Modbus/TCP Update transaction history database via ODBC Processes database queue of user requests via ODBC & Modbus/TCP April 2003 IDC Corporation

14 System Overview: Pressline Interface TM90 Tonnage Monitor Die Setup data, including AutoTrak See Die Setup screens 3 TMWeb Server Die Recipe Database TM90 Die Recipe Mailbox (see usage spreadsheet) 1 5 Mailbox Word # RIO/CN Func50 Address Modbus/TCP register (Ethernet) System Function Line Control Die Code (from PLC) Download Request Flag (PLC -> 1) Server Response (OK = Die Code) 2 4 PLC Line Controller April 2003 IDC Corporation

15 System Overview: Presssline Interface The Press Control system initiates Die Change Requests by sending data to TM90 mailbox registers via one of: Remote I/O ControlNet Modbus/TCP (via customer s Modbus Bridge/other) Server system writes result to TM90 Mailbox via Modbus/TCP (OK/Error code) Line free to run when OK response received April 2003 IDC Corporation

16 Login Screen Enter Username & Password (Case Sensitive) Closes IE browser Opens Change Password dialog Verifies ID, if OK: Enables site access according to user permissions Creates login record April 2003 IDC Corporation

17 More Login Screen Functions Plant name configured on System tab Helpful information set up on System tab by Administrator (see System Tab) Administrator configures local URLs (web links) on System tab (e.g., download java, download IE, etc.) Users can click to use the links Displays current workstation name & IP address April 2003 IDC Corporation

18 Change Password Dialog This screen is accessed from the Main Login screen (section 1.1) and allows a user to change the password associated with their username. Once the entered information is verified the system will update the user s record within the database with the new password. April 2003 IDC Corporation

19 System Tab Functions Update information on login screen Update screen refresh time Update help tab links Update database maintenance settings April 2003 IDC Corporation

20 System Tab Layout Screen Label, database field Database field Set up ColdFusion Server: timeouts, database connection Text for Login screen: use to identify your administrator, show guest login ID/Password, etc. Set up useful web links like Download Java, Update IE, etc. Set up links to TM90 Manual, TMWeb documents, or any other documents Database maintenance schedule setup April 2003 IDC Corporation

21 Network Tab Functions Add / edit / delete TM monitors Add / edit / delete workstations Assign monitor access to workstations April 2003 IDC Corporation

22 Network Tab Takes user to New Monitor screen Takes user to Edit Existing monitor screen Takes user to New Workstation screen Scroll tables to handle many entries Takes user to Edit existing Workstation screen April 2003 IDC Corporation

23 Edit Monitor Screen IP address must be unique: assigned via keypad on monitor.(15chars) Ex Location up to 100 chars. Description up to 250 chars. Show on graphs, etc. If you choose to delete, all die settings and signature history will be lost. A second screen with a warning is displayed. If the active property is set to No the monitor will be accessible on the TM Configuration tab but will not be queried by the Press Interface service in order to check for signatures. This should be used to configure monitors before they have been placed online. Set to yes for on line operation. April 2003 IDC Corporation

24 New Monitor screen IP address must be unique: assigned via keypad on monitor.(15chars) Ex Location up to 100 chars. Description up to 250 chars. Show on graphs, etc. Saves the new monitor to the database. Returns the user to the Network Tab Listing screen If the active property is set to No the monitor will be accessible on the TM Configuration tab but will not be queried by the Press Interface service in order to check for signatures. This should be used to configure monitors before they have been placed online. April 2003 IDC Corporation

25 Delete Monitor This screen allows the user to delete a selected monitor and is accessed from the Monitor Edit screen. It prompts the user to be sure they wish to delete the selected monitor Yes Delete this monitor: Deletes the monitor information from the database. This also deletes all signatures that have been gathered for this monitor along with any die recipes that have been created for the selected monitor. Then returns the user to the Network Tab Listing screen April 2003 IDC Corporation

26 New Workstation Yes: Level 2/3 users can edit No: Level 2/3 users cannot edit from this site IP must be unique, 15 chars max (Ex ) Station location & description text Assign selected monitors to this station at level 2 Assign all monitors to this station at level 2 List of monitors in database: click to select individual monitors you wish to assign at each level Remove all monitors from this station at level 2 Remove selected monitors from this station at level 2 Same as above, but for level 3 users List of monitors presently assigned at each level Saves new workstation to database and returns to Network Tab Listing April 2003 IDC Corporation

27 Edit Workstation Unique IP address of workstation. Ex Yes: Level 2/3 Users can edit from this station No: Level 2/3 Users are Read-Only from this station > Move highlighted monitor to selected list >> Move all monitors to selected list << Remove all monitors from selected list < Remove highlighted monitor from selected list Click to access the Delete Workstation screen Verifies the entered information and updates the workstation April 2003 IDC Corporation

28 Delete Workstation Description of station about to be deleted Deletes the workstation information from the database and returns to the Network Tab Listing April 2003 IDC Corporation

29 Users Tab Functions Add / edit / delete users Assign access levels to users Assign individual Web and Monitor function to Nonadministrative personnel April 2003 IDC Corporation

30 Users Tab Provides screen for setting up a new user and assigning access privileges Takes the user to the Edit User screen to change user privileges Login History goes to a screen that lists the login history for the currently selected user: shows the IP of the workstation where the user logged in along with the login and logout dates and times. April 2003 IDC Corporation

31 New User Allows the current user to create a new user by assigning username and password combination for system login and defining edit priveleges. System Admin: full access to all monitors to edit Level 2 and 3: Restricted Editing only allows the user to edit monitor functions assigned for that user level to the workstation they are accessing the site from (see checkboxes). View Only: disables all editing and creation functions Verifies & saves entered information Shows privileges (by system tab) enabled for the chosen access level. Users can be assigned customized privileges by checking on/off these access functions April 2003 IDC Corporation

32 Edit User Allows the current user to change the user name and password combination of the user whose Edit button was clicked from the list on the main Users tab Save user data Go to Delete User screen System Admin: full access to all monitors to edit Level 2 and 3: Restricted Editing only allows the user to edit monitor functions assigned for that user level to the workstation they are accessing the site from (see checkboxes). View Only: disables all editing and creation functions Shows privileges (by system tab) enabled for the chosen access level. Users can be assigned customized privileges by checking on/off these access functions April 2003 IDC Corporation

33 Delete User screen Name of user about to be deleted This screen allows the current user to delete the user presently being edited, and is accessed from the User Edit screen. It prompts the user to be sure they wish to delete the selected user. April 2003 IDC Corporation

34 Login History This screen lists out the login history for the currently selected user, showing the IP of the workstation where the user logged in along with the login and logout times. List navigation functions detailed here are typical of most list screens Show last page of records (as sorted) Show Next/Prev page of records (as sorted) Show first page of records (as sorted) Sort Column, Direction (Ascending/Descending): Click Header of any column to re-sort by that column or change sort direction April 2003 IDC Corporation

35 TM Configuration Tab Functions Configure TM monitor calibration settings Download new settings to monitor and update database Calibration settings are usually not edited under normal use. Encoder calibration and configuration for press are only edited if physically altered; i.e. replacing or remounting encoder. April 2003 IDC Corporation

36 Monitor Listing This screen lists all monitors in the database. Clicking on the Configure button of a particular monitor takes you to the Monitor Configuration screen where that monitor s calibration data can be checked, edited, or downloaded to the monitor. This calibration data resides in the monitor, and is normally only edited as a maintenance function. The Configure screen can be used to download configuration data to restore a monitor s setup (e.g., after a board replacement) April 2003 IDC Corporation

37 TM Configuration Tab Saves edits (database column) to database, then downloads that setup data to monitor This data configures the monitor for the press it s on. For quick reference and description of prompts see Monitor Data Configuration 1 & 2 slides below. Allows changes previously made at monitor site (e.g., during press calibration) to be copied into the data base Encoder based (most monitors) Peak Picker Linear encoder Red flag highlights fields with some difference between monitor and database Mailbox titles allow user to customize titles and display of extra data variables on Live Graph screen. April 2003 IDC Corporation

38 Monitor Data Configuration 1 Specifies no. of channels usually 4. (Outer on dual action) Specifies no. of Cha for second slide or(inner) (0 for single slide) This field only used for certain types of monitors Sets direction: 0 or 2 for resolver (most transfers) 1 or 3 for encoder Software rotate to correctly time encoder position (0-255) Software rotate for display on monitor only 0 for all monitors except dual action shared sensors (120 typical) 0 or 2 to set count direction of encoder Sets count resolution for calibration Number added to current transducer reading to display shut height Usually 16 but can be lower for inverted transducers 0 or 2 to set count direction of encoder Sets count resolution for calibration Number added to current transducer reading to display shut height Usually 16 but can be lower for inverted transducers April 2003 IDC Corporation

39 Monitor Data Configuration 2 Motion table defines a relationship of crank degrees to inches. This calibrates the Inch graph on the live graph screen for signatures and the Die Limit curve. Once set usually not changed. One table for each slide supports dual action and eight channel dual slide transfers. Data is usually obtained from press manufacturer. Note: Degree data must be incremented by 2 or more for each successive position. Allows assignment of physical TM channels to screen quadrant (shown in diagram at right) to accommodate various part flow depictions Tonnage rating of press sets the digital range of operation in the monitor. Monitor will process 50% beyond rating. Typically each channel is 25% of total press rating. Single action presses slide 2 is not used and set to 0. April 2003 IDC Corporation

40 Die Setup Tab Functions Add / edit / delete dies Configure die recipes Configure AutoTrak settings Update database with new settings Export/Import files with recipe and AutoTrak settings View AutoTrak and tonnage comparison graphs April 2003 IDC Corporation

41 Die Setup Tab This screen lists out all available monitors found in the database. From this screen the user can edit the recipes for the selected monitor using the Die Setup screen. If no dies have been created it takes you to the Create New Die screen. April 2003 IDC Corporation

42 Go to the Save Die As screen Validates data, Saves changes to Database, prompts you to download Die Setup Select any die defined for this press: if not the currently running die, edits will be offline Takes you to the Create New Die screen Go to Edit AutoTrak screen Takes you to the Import/Export File screen Values that are specifically for this die. See Die Setup Prompt Descriptions Allows you to graphically view edited tonnage curve before saving and/or downloading to monitor. Target tonnage for graphical reference lines only. Manually entered. April 2003 IDC Corporation

43 Create New Die Die Code unique to the selected monitor; PLC requests this Die Code for download Die description up to 100 characters Part Description up to 64 characters Pulls down available monitors for die to be assigned to. If die is assigned to more than one press create a separate die for each press with the same die code description by selecting the additional presses. Verifies the entered information and saves it to database. This screen allows a user to create a die within the database for a selected monitor. Once a die record is created the recipe will be available to edit and to download to a monitor. This screen can be accessed from the Die Setup screen or from the Monitor Listing screen if no dies exist for the selected monitor. April 2003 IDC Corporation

44 Save Die AS Die code unique to the selected monitor limited to four digits (9999) Die description up to 100 characters Part Description up to 64 characters Pulls down available monitors for die to be assigned to. If die is assigned to more than one press create a new die with the same die code description selecting the additional presses. Verifies and saves to database including all original recipe and AutoTrak settings. This screen allows a user to create a die within the database for a selected monitor from an existing die. Once a die record is created the recipe will be available to edit and to download to a monitor. This screen can be accessed from the Die Setup screen or from the Monitor Listing screen if no dies exist for the selected monitor. April 2003 IDC Corporation

45 Die Setup Prompt 1 Upper AutoTrak limit to function as cycle stop (0), E stop (1), cycle stop after AutoTrak End setting Time in seconds for production hit to hit time to setup AutoTrak to automatically turn on (10 = 6 SPM) Number of press cycles the monitor will look in memory calculate AutoTrak (3-16) Time in seconds when press is idle to turn off the AutoTrak function (example 1800 = ½ hr) Consecutive empty cycles before initiating an AutoTrak Low alarm (1-16) Drops out CR2 relay when part count matches preset. Program 0 to disable. No/Yes Yes will disable alarm curve after bottom of press stroke. Used on extended dwell transfers and DA s Sets flat tonnage line maximum tonnage limit. Not used in AutoTrak monitors program to 0 Sets flat tonnage line minimum tonnage limit. Not used in AutoTrak monitors program to 0 Entered in tons expands AutoTrak upper limit by value divided by no of channels (typically 4) Entered in tons expands AutoTrak lower limit by value divided by no of channels (typically 4) Selects starting window of AutoTrak operation. Value is programmed in degrees. Selects ending window of AutoTrak operation. Value is programmed in degrees. Selects ending window of AutoTrak operation. Value is programmed in degrees. Display actual shut height value if monitor has shut-height transducers installed. April 2003 IDC Corporation

46 Die Setup Prompt 2 Tonnage limit curve that is associated with the E- stop alarm CR2. Table will set an upper limit for 13 points across the down stroke of the press. Value is divided by number of channels (typically 4 ). Values can be programmed in the database or in the monitor. Any difference will pop up a red flag. Tonnage curve may be viewed before being saved to monitor or database. This allows fine tuning of values before they are implemented. April 2003 IDC Corporation

47 Edit AutoTrak This message, when present, indicates that the settings currently found in the monitor do not match the current master settings Copies the current monitor values to the database and makes them the master record. This displays a graphical comparison between edited and master AutoTrak values. Copies currently displayed values to the database and makes them the master record. Edits the allowable deviation from the corresponding average value. Any channel, any point in the stroke can be edited. Edits the average value for each point of the stroke: limits are Average +/- Deviation +/- Margins. Any channel, any point in the stroke can be edited. April 2003 IDC Corporation

48 Download Tab Functions Download die recipe and AutoTrak settings to a selected monitor April 2003 IDC Corporation

49 Download Tab Monitor to which the download will occur Selects die to be downloaded to monitor (defaults to die code currently running) Initiates the download operation April 2003 IDC Corporation

50 History Tab Functions View communication history with monitors View signature and fault history of monitors Compare changes in die recipes Compare changes in AutoTrak settings View die download history April 2003 IDC Corporation

51 Live Graphs Tab Functions View live signature graphs for monitors View historical signatures View live and historical comparisons Catch die faults and add comments to signatures April 2003 IDC Corporation

52 Live Graphs Tab Graph color legend Active AutoTrak curve is Green, inactive AutoTrak curve is gray. Select from available Presses BDC = Bottom Dead Center S =AutoTrak start E = AutoTrak end Click on a graph quadrant to see it full screen. Click All Channels to restore all-graphs screen Hold right mouse button to drag a zoom window. Select reset Graphs to un-zoom and view default scaling. Zoom In/Out scales Tonnage axis on all graphs. Goto Stored Reference Curves screen, this die Sends request for load monitor to Calculate AutoTrak User mailbox variables (if titles are defined) Turns TM90 AutoTrak On or Off. Get signature of incomplete cycle Show other slide Get Current AutoTrak from Load monitor Show graphs in Inches off bottom April 2003 IDC Corporation

53 Stored Reference Curve Show this Stored Reference on Live Graph for comparison back to Live Graph screen Remove this Stored Reference signature from permanent table Save data as text file (on user s machine) for other use Use calendar and Time Filters to locate desired signatures. Rebuild list using filters above Show this signature as reference on Live Graph Copies signature to permanent Stored Signature data table above (not purged) April 2003 IDC Corporation

54 Recent Operating Curves List of curves now being shown on Live Graph screen as references to Live Graph screen Use calendar and Time Filters to locate desired signatures. Rebuild list using filters above List of signature curves meeting filter criteria April 2003 IDC Corporation

55 History Tab To Communication History screen for a monitor To Signature/Fault history selection screen: find historical signature by die, date, time, or fault condition and view or export it To Die History screen: select a particular die in this particular press and view its history Each line of main table above is a particular monitor: buttons go to history of that monitor To Die Download History screen: view download events filtered by any/all monitors, date/time, success Access signatures with faults for any/all monitors, allowing selection by date, time & press, and view or export selected records. April 2003 IDC Corporation

56 Communication History This screen lists out the communication history for a selected monitor. It displays when the monitor was seen as online and when it was seen as offline. Any error message displayed is that which was returned to the Press Interface service when a TCP connection to the monitor was attempted. The columns can be sorted by clicking on the corresponding column header for the desired column. Previous page, Next page Last page 1 April 2003 st page IDC Corporation

57 Signature/Fault History April 2003 IDC Corporation

58 Die Listing This screen lists out all die recipes found for a selected monitor. The user can choose to either view the die recipe history or the AutoTrak history for a particular die. April 2003 IDC Corporation

59 Die Change Listing This screen lists out the die recipe change history for a selected recipe/monitor combination along with the username of the user who saved each recipe revision. The user can either view a comparison page for the master (most recently saved) recipe and a historical recipe or can compare 2 historical recipes. This screen is accessed from the Die Listing screen. April 2003 IDC Corporation

60 Current Die Comparison This screen displays a comparison between the master die recipe and a historical recipe. The user can choose to make the historical recipe the new master record by clicking the Make Master Database Record button. This creates a copy of the historical recipe in the database which becomes flagged as the master recipe for this die and also stores the username of the current user. April 2003 IDC Corporation

61 Selected Two Die Comparison This screen displays a comparison between two historical recipes. The user can choose to make either of the historical recipes the new master record by clicking the Make Master Database Record button for the appropriate recipe based on date. This creates a copy of the historical recipe in the database which becomes flagged as the master and also stores the username of the currently user. April 2003 IDC Corporation

62 AutoTrak Change Listing This screen lists out the AutoTrak change history for a selected recipe/monitor combination along with the username of the user who saved each AutoTrak revision. The user can either view a comparison page for the master (most recently saved) AutoTrak and a historical AutoTrak record or can compare 2 historical AutoTrak records April 2003 IDC Corporation

63 Current AutoTrak Comparison This screen displays a comparison between the master AutoTrak record and a historical AutoTrak record. The user can choose to make the historical AutoTrak settings the new master record by clicking the Make Master Database Record button. This creates a copy of the historical AutoTrak record in the database which becomes flagged as the master AutoTrak record for this die and also stores the username of the current user. If a discrepancy exists between a value in the database and the value found in the monitor the record will be flagged with a! image. If the values match an equal sign will be displayed. April 2003 IDC Corporation

64 Selected Two AutoTrak Comparison This screen displays a comparison between two AutoTrak historical records. The user can choose to make one of the historical AutoTrak settings the new master record by clicking the Make Master Database Record button. This creates a copy of the historical AutoTrak record in the database which becomes flagged as the master AutoTrak record for this die and also stores the username of the current user. If a discrepancy exists between a value in the database and the value found in the monitor the record will be flagged with a! image. If the values match an equal sign will be displayed. April 2003 IDC Corporation

65 AutoTrak Comparison Graph This popup window allows a user to view comparison graphs between two different AutoTrak records. This screen is accessed from the Current AutoTrak Comparison screen or the Selected Two AutoTrak Comparison screen. This screen will update to show the most current signature for the selected monitor if the monitor is currently active. April 2003 IDC Corporation

66 All Monitors Fault History This screen lists out the fault history for all monitors or a selected monitor. Only signatures that contain a fault will be displayed. The signatures that are displayed can be filtered based on the parameters on the left, which include monitor and date range. The resulting signatures can be displayed by clicking the Display Signatures button. April 2003 IDC Corporation

67 Die Download History This screen lists out the die download history of all monitors or a selected monitor. The download history records that are displayed can be filtered based on the parameters on the top, which include monitor, if it was successful or not and date range. The resulting download records can be displayed by clicking the Filter button. All the filter parameters can be removed by clicking the List All button. April 2003 IDC Corporation

68 Peak Graphs Tab Functions View historical peak tonnage information about dies over date range April 2003 IDC Corporation

69 Peak Graphs: Monitor Listing Listing of All Monitors In plant Selects Graph Screen April 2003 IDC Corporation

70 Peak Graphs Tab Selects density of viewing graph Selects a date field of view Selects additional Press and Dies Scrolls time chart to desired date Selects Curser with arrows or slider: tonnage value at cursor is displayed in red for each channel. April 2003 IDC Corporation

71 Logout Tab Functions Clears out session specific user variables Helps increase security Logs time for user login history viewing Displays Login screen for next user April 2003 IDC Corporation