Kapitel 5
Freelance Batch Solution
Freelance Formulation 2016
capabilities and technical features
What is Freelance Formulation?
Freelance Formulation is an essential Recipe Management component
for single product or multi-grade product process cells, controlled by
Freelance DCS. The Control Recipes are executed on a single
Sequential Function Chart (SFC) and only one Control Recipe can run
on an SFC at any time.
Multiple Control Recipes may run on different SFCs at the same time.
The database used to store the recipes can be shared among several
Freelance Formulation workstations.
The Freelance Formulation database supports up to 50 SFCs with 30
Master Recipes for each and 30 Control Recipes per Master Recipe.
Each recipe can have up to 300 parameters and report items.
Unused master recipes can be achieved and restored in server station.
Once a Control Recipe has been executed, Freelance Formulation will
run a simple batch report based on MS Excel.
What is Freelance Formulation not?
Freelance Formulation is not a recipe package for multi-
product multi-path, sophisticated batch applications.
.
Freelance Formulation
Key items
New Freelance product
V1.0 released March/2014, V1.1 released in Oct/2015
Integrated in Freelance Operations
Same look and feel as Freelance Operations
Operation on the same screen as Freelance Operations
process graphic
Using ISA 88 terms to name the functionalities
No product specific vocabulary
Batch reporting
Operation logging
User administration
Freelance Formulation
Installation topologies
Freelance Formulation can be installed in different topologies
Call up Freelance Formulation
Icon on desktop
New Freelance-Icon for Formulation on Desktop
V1.0
V1.1
Call up Freelance Formulation
From Freelance Operations process graphic - I
Formulation can be called via right-click from the FPX-
faceplate in Freelance Operations
Getting automatically the assigned control recipe
parameter list with the current valid values and the
opportunity to change the current control recipe
parameter values (depends on the user rights)
Call up Freelance Formulation
From Freelance Operations process graphic - II
User-rights dependent access from parameter view to the recipe
configuration via FPX context menu
Freelance Formulation
Principle and example “Bakery“
Master Master Control
procedure recipe recipe
Masterrecipe
Master Procedure Master Recipe “Rye Control Recipes “Rye
“Bakery“ Bread“ Bread” with scalable
amounts
Formula for Rye Bread RyeBreadA1:
Rye Bread 50 kg:
RyeBreadA2 A2:
Rye Bread 30 kg:
Is used by
RyeBreadA3:
Rye Bread 90 kg:
Master Recipe “Wheat
Bread“
Formula for Wheat Bread
Master Procedure
Elements
The Master Procedure elements are configured and downloaded in the
Freelance controller
To be built up of
FPX-Module, controls the procedure state
SFC (Sequence Function Chart), carry out the procedure logic
(Structured- Freelance variables for parameter and report values
FPX (Phase X Control) SFC Structured variables
for report values
Structured variable for
parameter set
Control Recipes
Principle
When the Control Recipe is downloaded to the controller it becomes a Batch.
The Control Recipe procedure is the configured Master Procedure SFC in the
Freelance controller
Parameter values are downloaded before start
Visualisation and manual operation via FPX and SFC
Control Recipes
Contains the parameters and connect information
A Control Recipe in Freelance Formulation contains the parameter
values and the connect information
Downloads the parameter values and connect the assigned FPX
with the SFC
Easy and simple structure
Control Recipe “RyeBreadA1”
Parameter Is using the assigned Master
Procedure to control the process
in the controller
Control Recipe “RyeBreadA2”
Parameter
Control Recipe “WheatBreadB1”
Parameter
Freelance Formulation
Tree structure for managing the recipe levels
The formulation packet manages the
following recipe levels and presents
1
they in a tree structure for an easy
2
overview and navigation
3
Master Procedure (1)
Master Recipe (2)
Control Recipe (3)
Recipe Levels
Master Procedure
The Master Procedure level represents and manages the Master
Procedure elements in the Formulation.
Recipe Levels
Master Recipe
The Master Recipe level represents and manages the Master Recipes
in the Formulation.
Recipe Levels
Master Recipe parts - I
The Master Recipe has four main tabs to present the
information
MR Header
Parameter
Report Items
List of Control Recipes
Recipe Levels
Master Recipe parts - II
Parameter
Recipe Levels
Master Recipe parts - III
Report Items
List of Control Recipes
Recipe Levels
Master Recipe parts - IX
Achieve and Restore
Recipe Levels
Master Recipe parts - X
Copy parameters
Recipe Levels
Control Recipe
The Control Recipe level represents and manages the Control Recipes
in the Formulation.
Recipe Levels
Control Recipe parts - I
The Control Recipe has three main tabs to present the information
CR Header
Parameter
Report Items
Recipe Levels
Control Recipe parts - II
Parameter
Report Items
Recipe Levels
Control Recipe parts - III
List of running recipes
Recipe Levels
Control Recipe parts - IX
Reason for download button is disabled in the tooltip
Parameter Tab
Features
Displays the parameter with his attributes as list.
Input of Norm Value, Limits, Engineering Unit, Scalable (check-box), Scale-
Factor, Severity etc.
Freelance Formulation
Operate a Recipe Level
To operate a recipe level, right-click on the object in the navigation panel to
show the context menu.
Only the current possible menus are in black text color, the others are in grey,
depends on the mode and the user rights.
Freelance Formulation
Create one or more new Control Recipes as Campaign
Enter the intended amount to produce into the cell “Amount” or use the
slider.
By directly entering into the cell you are able to specify an amount
bigger than “Max. Capacity”. In that case Freelance Formulation will
create more than one Control Recipe so that the sum of all Control
Recipes created will match the specified amount.
A dialog will pop up to inform about the multiple creation.
Note: Freelance Formulation will detect that the Batch-ID of the
multiple instances would not be unique and will add an incremental
number for the second Control Recipe and higher.
Life Cycle for Recipe Levels
Production Planning
The implemented life cycle concept provides the opportunity, to decide at every
moment, if a Master Recipe is allowed to use for production (state “Effective”) or
not (state “Released”)
Can be operate for example by the shift leaders or senior operators
A Master Recipe has 5 life cycle states: Draft, Approved, Released, Effective
and Withdrawn
Life Cycle of a Control Recipe
Using ISA-88.01 states of the FPX-Module
Control Recipe
life cycle states
Freelance Formulation
Easy practice and clear indication
Formulations provide browsers
to choose necessary inputs
like:
FPX-Modules
Assigned parameters
Assigned report
parameters
Clear and comprehensible text
are used for fields, tabs,
checkboxes and menus
Formulation
Online help included
Online Help
Call up the User‘s
Manual via
Help-button
or Book-item
Freelance Formulation
Batch Reporting
At the end of the batch, or the batch is stopped or aborted, the configured
report items values will be read.
When the batch finishes (CR goes to Finished life cycle state) and the
Report Generation checkbox in the CR header was set, the configured
Freelance Formulation will create the batch report.
Freelance Formulation uses Microsoft Excel for reporting, so Excel can be
used to print the report.
Freelance Formulation
Batch Reporting template included
Freelance Formulation delivers a template for batch reports
Batch Report Template.xls
Operation Action Logging
Log file
The actions related to the recipe are
stored as FLOG-file, readable with Excel.
This log includes the life cycle changes,
the download and batch running
information.
Operation Action Logging
Configuration
© ABB Group
Month DD, Year | Slide 37
Batch-ID
Auto-ID Rule for generating the Batch-ID
Easy definition input window to build up the generation rule for the auto
generation of the Batch-ID
No programmer knowledge necessary
The Batch-ID can consist of up to 5 parts which can be configured individually.
The parts can be separated by configurable separators
Freelance Formulation
Can make use of Freelance Security Lock
Using Access Rights
Freelance Formulation uses the system permissions for
Configuration (CONF), Commissioning (COMM) and for
running Security Lock (Lock) given to user groups
configured in Security Lock and adds permissions for
viewing (only), operating and approving recipes
Freelance Formulation
Summary
The user has one tool to configure recipes, organise
parameters and schedule control recipes. It provides all the
information the operator needs to schedule batches in one
simple application, easily integrated into user graphics.
Little or no knowledge of a batch manager software
packets is required to use the Formulation-tool. Less time
learning a tool, more time to focus on the process.
Ideal for procedures where multiple formulations apply to
one Master Procedure (SFC).
Freelance Formulation
FAQs
How many Formulation stations can I use for one controller?
Each Formulation station (both server and client) will use one Uni-Gateway.
Total number of Formulation + OS + other gateways (OPC,Trend..) can not
exceed the controller limitation.
Formulation uses Access as center database, maximum connection number for
windows also limited the number of Formulation clients.
Freelance Formulation
FAQs
How to open Formulation in operation station?
Formulation can be used as external aspects in Freelance. If you do not have
access to your windows desktop, you can configure Formulation as an item in the
context menu in FPX faceplate or SFC display.
In addition, there are two modes: “configuration” and “operation” for Formulation.
Default view for Formulation will be different accordingly.
For detail, please refer to Freelance Formulation manual Chapter 5.1.4.
Freelance Formulation
FAQs
How to modify the master recipes not in “Draft” state
Once a master recipe is approved, user can not directly make changes on the
approved recipe.
New recipe in draft state will be created by copying all the informations from old
master recipes, all modifications need to be approved again before use. This is
mainly for security reason.
Freelance Formulation
FAQs
How to sync data between Engineering tool and Formulation
Uni-Gateway need to be downloaded each time after project is modified. Even if
the change is not related to Formulation, project version will be changed and may
affect the use of Formulation. There are several things needs to be checked before
download:
1. Corresponding Uni-Gateway for Formulation shall have “rw” access to all
variables and tags needed.
2. Formulation station keeps the data in folder C:\digimat\gwy\res?? (?? stand for
configured resource id) by default, if some files in this folder is damaged,
please delete all files under this folder and download Uni-Gateway again.
Freelance Formulation
FAQs
What will happened if I try to download parameters to
variables no longer existed in controller?
Formulation will check the data consistency between Formulation station and
controller before download.
If changes are downloaded for Uni-Gateway but not for controller, download
control recipe in Formulation will cause following error:
“One or more variables are invalid in controller. Please make sure both of the
controller and gateway are downloaded. ”
If changes are downloaded for controller but not for Uni-Gateway, download
control recipe in Formulation will cause following error:
“One or more variables are invalid in Formulation”
Freelance Formulation
FAQs
What if I accidently closed Formulation in use?
If Freelance Operations is running, close Formulation will only minimize the
Formulation window. Formulation is still running in the background and can be
called up by external aspect or desktop icon.
If Formulation process is ended while one or more batch is running, report will not
be generated. For detail, please refer to the first know problem in release note.
Freelance Formulation
FAQs
How to lookup batch reports and logs for deleted control
recipes
Delete finished control recipes will not delete corresponding batch reports and
logs.
Click Open report/Open log item in context menu of Formulation operation “Root”
node will open the default folder of all reports/logs.
Freelance Formulation
FAQs
Can I change the format of batch report?
Report template is provided for Formulation, use can only change the first sheet of
report template. The second sheet of batch report is password protected. Neither
the format nor the values can be changed manually.
Logs are generated by Formulation automatically as FLOG file. Logs are
encrypted and can not be edit by user.
Questions
Questions?
© 2011 ABB Automation GmbH
March 3, 2016 | Slide 49
