Tech Note 710 Wonderware MES Operations Capability Object: Configuring Rolling Counter Reset
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- Esmond Strickland
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1 Tech Note 710 Wonderware MES Operations Capability Object: Configuring Rolling Counter Reset All Tech Notes, Tech Alerts and KBCD documents and software are provided "as is" without warranty of any kind. See the Terms of Use for more information. Topic#: Created: June 2010 Introduction The release of Wonderware MES 4.0 introduced the Operations Capability Object (OCO). This ArchestrA object includes the ability to configure Production and Consumption Counters with enhanced functionality versus the Production Counters that are available in the Utilization Capability Object (UCO). This Tech Note explains one of these new features, the ability to reset a rolling counter to 0 on demand. Application Version Wonderware MES 4.0 Types of Counters and Considerations The Operations Capability Object (OCO) can be enabled for Production and Consumption counting. The following Counter Types are available: Absolute Counter: This counter consists of two parts, the counter value and a trigger. When triggered, the current value of the counter is recorded as production or consumption. Rolling Counter: This is a continuously incrementing counter. The difference between the current value and the last value is recorded as production or consumption when the value changes. This counter is also subject to the following restrictions on when the data is recorded: Deadband: This is the amount the counter must increment before the change is recorded. Update Interval: This the time period that must elapse before the data is recorded. Max Value: The counter obviously can t increment infinitely. This setting is must match the setting in the PLC of when the counter will roll-over, back to 0. It is important to remember that every time production is recorded, you are transacting against the MES database. The Deadband and Update Interval are critical to limiting the volume and frequency of transactions to keep database performance at its best. If Deadband and Update Interval are 0, you will record production on every scan of the engine, very likely overloading the system and creating a massive amount of MES database records. In some cases, waiting for the PLC to reach the auto-rollover count (Max Value) is not desirable. For example, the customer prefers to reset the counter to 0 before each job, shift, etc. because it shows on an operator screen or some other display or report. The OCO provides the capability of an on-demand rolling counter reset with options on how outstanding counts are recorded. This reset ability is not available in the UCO. Sample Configuration For this example, the customer requires that the Production Counter be reset for each job. When the counter is reset, they require that any outstanding production be recorded to the job that just ended. Object Deployment
2 We have a Bottling Area defined with a Filler machine and OCO (Figure 1 below). FIGurE 1: ArcHEStrA OBJEct DEPLoYMENt Push Production Counts on Reset Configuration Figure 2 (below) shows a typical OCO Rolling Production Counter configuration to record good production.
3
4 FIGurE 2: OPEratIoNS CaPaBILItY OBJEct RoLLING ProductIoN CouNtEr CoNfIGuratIoN Enable Rolling Counter is selected Input sources are extended to MyContainer attributes. A properly deployed OCO is contained by a User Defined Object which represents the MES Entity. Rolling Counter Data Deadband: The count must increment by at least 1 to be recorded Update Interval: Production is recorded every 1 minute (but only if the deadband is exceeded). Max Value: The PLC is configured to auto rollover when the count reaches Push Production Counts on Reset is enabled. When the counter is forced to reset to 0, any outstanding production will be recorded regardless of the Deadband and Update Interval settings. Entity Object Configuration The Filler object includes multiple scripts. The first is a PLC simulation script. When triggered, it will increment production by 15 every 10 seconds, automatically rolling over at (Figure 3 below).
5 FIGurE 3: PLC SIMuLatIoN ScrIPt This script is included below for copy/paste from this Tech Note: 'Add 15 produced items every period dim increment as float; dim rollover as float; increment = 15; rollover = 10000; 'if count will exceed rollover, reset and add difference if me.jobpos0.prod.good.addprodqtycounter + increment > rollover then me.jobpos0.prod.good.addprodqtycounter = increment - rollover + me.jobpos0.prod.good.addprodqtycounter; 'Otherwise add prod else me me.jobpos0.prod.good.addprodqtycounter = me.jobpos0.prod.good.addprodqtycounter + increment; endif; The second script, when triggered, will stop the PLC simulator script, reset the counter, and end the current job. The counter will then be ready at 0 for the next job (Figure 4 below).
6 FIGurE 4: SaMPLE ScrIPt to RESEt the RoLLING CouNtEr and ENd the JoB This script is included below for copy/paste from this Tech Note: 'This is a sample where the machine needs to have its counter reset after each job. 'Physical production has ended. Stopping Production Counter Simulation Script. me.jobpos0.prod.good.addprodqtycounter.go = 0; 'Reset Rolling Counter: 'Since OCO Counter option Push Production Counts Upon Reset is enabled, any outstanding production 'not recorded to the database will be written before the counter is reset to 0. me.jobpos0.prod.good.resetrollingcountercmd = 1; 'At this point the OCO is expecting the PLC/Operator to set teh counter back to 0. 'We will do this within the script. 'Set the machine counter back to 0 me.jobpos0.prod.good.addprodqtycounter = 0; 'End the job me.jobexec.endjobcmd = 1; 'Reset the trigger for this script me.jobexec.endjobtrig = 0;
7 Sample Operation To help make it clearer as to what attributes are updating and changing during operation, use Object Viewer to start the job, count production, and end the job (Figure 5 below). FIGurE 5: OBJEct AttrIButES IN OBJEct VIEWEr JobExec.JobPosN.Prod.<Counter Name>.AddProdQtyCounter: A counter value that automatically triggers production data to be added. This counter tag contains a running count value of the quantity produced. If this value has changed or exceeds the configured dead band, and if the update interval has been exceeded since the last flush, the production quantity that is being measured will be added automatically. JobExec.JobPosN.Prod.<Counter Name>.ResetRollingCounterCmd: Resets the selected production counter. JobExec.JobPosN.CurWoId: Identifies the work order that is currently running on this entity at this job position. (Read-only from MES Database) JobExec.JobPosN.CurOperId: Identifies the operation id of the job that is currently running on this entity at this job position. (Read-only from MES Database) JobExec.JobPosN.CurSeqNo: Identifies the job sequence number (normally 0, >1 in case of split jobs). (Read-only from MES Database) JobExec.JobPosN.ItemId: Identifies the item that is currently being produced by this job. JobExec.JobPosN.QtyProd: Identifies the number of quantities produced so far. JobExec.JobPosN.WorkOrder: Work Order that the counter is referring to when recording production (Counter will fail if this is not populated) JobExec.JobPosN.Operation: Operation that the counter is referring to when recording production (Counter will fail if this is not populated) JobExec.JobPosN.SequenceNumber: Sequence Number that the counter is referring to when recording production (Counter will fail if this is not populated) The job must be started in order to begin recording production against that job. How to create and start a job is outside the scope of this Tech Note. Work Order WO_1003 and Operation Oper_001 have been started (Figure 6 below). Jobexec.JobPos0.WorkOrder, Jobexec.JobPos0.Operation, Jobexec.JobPos0.SequenceNumber, and Jobexec.JobPos0.ItemId are populated. The counter will use these attributes to know which job to record production against and which item to produce.
8 FIGurE 6: JoB StartEd The PLC simulator is started by triggering Filler.JobPos0.Prod.Good.AddProdQtyCounter.Go. Production counting begins. In Figure 7 (below) note that we are between update intervals, so the counter is incrementing, but not updating the MES DB until the interval elapses. FIGurE 7: ProductIoN INcrEMENtING and REcordING Production has ended. We are still between update intervals, so the object thinks total production should have been 120, but only 105 has been recorded to the database (Figure 8 below).
9 FIGurE 8: ProductIoN HaS ENdEd But Not REcordEd The EndJob script is triggered. When the PLC simulator script ends The Filler_OCO.ResetRollingCounterCmd is triggered and records the remaining production count of 15 Filler_OCO.AddProdQtyCounter is reset to 0, and The current job ends. The counter is then ready at 0 for the next job. When you view the job in the Wonderware MES Operator client, you see the job has ended and a total production of 120 has been recorded (Figure 9 below).
10 FIGurE 9: CoMPLEtEd JoB D. Scott Tech Notes are published occasionally by Wonderware Technical Support. Publisher: Invensys Systems, Inc., Rancho Parkway South, Lake Forest, CA There is also technical information on our software products at Wonderware Technical Support. For technical support questions, send an to Back to top 2010 Invensys Systems, Inc. All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, broadcasting, or by anyinformation storage and retrieval system, without permission in writing from Invensys Systems, Inc. Terms of Use.
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