An approach in the implementation of control systems using 'batch engine' technique

Abstract

The batch engine, a flexible batch control implementation technique enabling the user to implement and configure real-time batch control applications without the need for system analysts and programmers, is discussed. The batch engine is entirely different from the conventional programmable logic controller (PLC) software. The supervisory and PLC software are integrated to allow new installations and modifications in the plant without making changes to the PLC software. A distributed architecture is used to implement the batch engine technique. In the functional architecture of the batch engine, PLCs are dedicated to real-time analog discrete input/output (I/O) control, fault detection, and activity block sequencing. The human-machine interface (HMI) stations are used for process graphics, variable trending, semiautomatic operation, manual-off-auto control, and analog discrete I/O monitoring. Higher-level functions like inventory management, batch monitoring/control, batch data reporting, recipe management, batch scheduling, and high-level facility interface are supported by the batch supervisor. The HMI workstations act as a backup supervisor in case of batch supervisor failure. The batch engine is well suited for applications that require the flexibility to expand the physical configuration with equipment of similar functionality. >