COMMON PLANT MODEL FOR MODELING PHYSICAL PLANT ITEMS OF A PRODUCTION PLANT

Abstract

The common plant model offers the possibility to create a mechanism that allows an easier linking of plant items from an engineering aspect being independent of the system, such as MES, SCADA, DCS, ERP, the engineer is working with. The common plant model includes: a node type model aggregating different aspects for the modeling of a single physical plant item; a number of nodes; a library model with a project library and a global library; and a wiring chart model defining the interaction between interface members of different facets. Each facet has at least one interface member and the logical link among the interface members is a virtual wire defining a connection used to propagate and align facet parameters linked to a specific node. The wiring chart is usable by different users. The SCADA and DCS systems have access to the distinct modeling of their individual needs.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority, under 35 U.S.C. §119, of European application EP 141 95 398.4, filed Nov. 28, 2014; the prior application is herewith incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a common plant model for modeling of physical plant items of a production plant within a manufacturing execution system having an engineering environment and a runtime environment.

As it is well known, a method for manufacturing processes planned by an Enterprise Resource Planning (ERP) and produced by a shop floor, provides a Manufacturing Executing System (MES) for modeling, planning, scheduling and implementing the manufacturing processes and controlling the corresponding production steps at plant floor level. In the automation pyramid consisting of Level 0 to Level 4, the ERP system resides on the highest level at Level 4 which represents the enterprise level taking care of a rough production planning and purchase order processing. The MES system is located at level 3 representing the plant control level comprising the detailed production modeling, planning, production execution, production data acquisition, KPI calculations, resource and quality management.

The process control level is located at level 2 and comprises SCADA systems (Supervisory Control and Data Acquisition) which are used for the controlling and observation of the production, the administration of production recipes and the archiving of the production data. At level 1 which represents the field level process signals and I/O modules as well as the fieldbus are located thereby offering the interface to the technical production process via I/O signals. At level 0 representing the actuator/sensing level fast data collection of predominantly binary signals is typically fulfilled. Of course, the borders of the diverse levels are floating according to the set-up and circumstance of the respective production facility (plant).

An Enterprise Resource Planning System—hereinafter referred to as ERP—is a system including hardware devices and corresponding software applications for planning the business resources of an enterprise, i.e. material provisions, human resource managements, purchasing, orders, profits, finance, inventory controls, customer managements, etc., while the term “shop floor” at level 0 and 1 has been used to indicate a system supporting the control of single machines performing production actions and being involved in the manufacturing processes, for example by measuring the number of pieces produced per hour by each machine or the functioning parameters thereof, the quality of the pieces produced and so on.

A Manufacturing Execution System—hereinafter referred to as MES—is an intermediate layer at level 3 providing computing machines and software tools between the ERP upper layer and the shop floor lower layer, including a software tool for production order management, which receives requests of production from the ERP, and a software tool for production modeling, which supports the phases of selecting and managing the resources to be involved in the manufacturing processes, i.e. employees, machines and materials, in order to realize a planned manufacturing process within required time constraints.

Therefore, manufacturing execution systems being regulated by the ANSI/ISA/95 standard require modeling plant equipment for both scheduling and controlling activities. Therefore, the productive process typically consists of production request which define a request for production for a single product. The predefined product is identified by a production rule, each of which is divided in many segment requirements that represent simple productive actions which are controlled by the MES.

Thus, a production request (could be also called operation request or work order) contains at least one segment requirement; even it spans all production of the product. A segment requirement contains at least on material produced requirement with the identification, the quantity and the units of measure of the product to be produced. Usually, in MES, the user would like to modify the quantity of the product to be produced due to various reasons, such as machine down time, shortage of material, absence of personnel.

Another critical problem for the MES is to react immediately to the operation schedules developed by the ERP. In this activity, the creation of work orders from the operation schedule is one of the most challenging tasks in the interaction of the MES and the ERP and should be therefore operated under the best performance circumstances possible. Typically, a work order is rather complex in terms of execution steps, resources and parameter that its creation from scratch is very time consuming and often not compatible with the mostly tight manufacturing schedules.

Considering only the very few demands on an appropriate software structure for an overall system being enable to exchange data between the diverse levels of the automation pyramid, today's software systems available cannot satisfy these demands. Currently, each system ERP, MES, SCADA and DCS (Distributed Control System) comprise their own modeling tools for modeling the physical equipment resources and the respective hierarchies which are therefore not done in a homogenous and permeable way.

Therefore, in engineering as well in runtime the integration between the products of these different levels is difficult and error prone due to the necessity of keeping different planning models aligned. So far it is a tremendous effort to link a new control function (i.e. temperature of an equipment) to a new target destination in the control environment. Usually, a separate script is required to get this new information transferred.

BRIEF SUMMARY OF THE INVENTION

It is accordingly an object of the invention to provide a common plant model for modeling physical plant items of a production plant which overcomes the above-mentioned and other disadvantages of the heretofore-known devices and methods of this general type and which provides a common plant model for the MES, SCADA and DCS systems of a production facility benefitting from an integration architecture which enables a stringent and persistent modeling of the physical resources of the production facility for all type of systems (MES, SCADA, DCS) that attach to the common plant model. In particular, the common plant model shall offer the possibility to create a mechanism that allows an easier linking of plant items from an engineering aspect being independent from the system (MES, SCADA, DCS, ERP) the engineer is working with.

With the foregoing and other objects in view there is provided, in accordance with the invention, a common plant model for modeling physical plant items of a production plant within a manufacturing execution system having an engineering environment and a runtime environment. The common plant model comprises:

a) a node type model aggregating different aspects for modeling a single physical plant item involving public interface parameters and automation parameters;

b) a plurality of nodes, each representing an instance of a node type;

c) a library model including a project library and a global library, said project and global libraries containing the node type model, a facet model, a rule model and a hierarchy model;

d) a graph model representing physical and/or logical connections between the nodes;

e) a wiring chart model defining an interaction between interface members of different facets within a common node and/or among different nodes; and

wherein each facet contains at least one interface member and a logical link among the interface members is a virtual wire defining a connection used to propagate and align facet parameters that are linked to a specific node.

This common plant model therefore provides a standardized architecture for the modeling of the physical plant items with respect to the logical connection within the same physical plant items or among different physical plant items. The wiring chart can be used by a plurality of different users that are in a business relation to the physical plant items. In particular, the SCADA system and the DCS system have now access to the distinct modeling of their individual needs in terms of the connections within the same physical plant item and/or among different physical plant items within the environment of the MES which is with respect to the execution and the control of the production of the plant the predominant system. The present invention creates a kind of a piping stereotype without the need to add any business logic into the logical link.

This wiring concept assumes that the facets of the nodes comprise a set of principal parameters as inputs and as outputs (e.g. for a functional facet the response or the results coming from its automation server). Nonetheless, in case of a wired pair of interface members, the parameters exchanged over this connection might require some kind of data manipulation. To achieve this objective as a preferred embodiment of the present invention, the wiring chart model comprises an insertion mechanism allowing to attach a rule defined according to the rule model to the logical link thereby enabling any kind of manipulation to a parameter which is exchanged among the two interface members associated with the logical link. Therefore, a dedicated environment is offered to the engineers of the diverse software systems (MES, SCADA, DCS) to specify the conversion logic for the parameter separately and without any need to program the conversion logic to the link. Preferably, the insertion mechanism allows to attach a series of rules to the logical link which offers the possibility to link an interface member outputting a parameter from a first rule to an interface member inputting this parameter to a second rule.

In order to allow the engineers from diverse systems to model the specific demands of their systems within the common plant model, it can be advantageously when each wiring chart is associated with a node type and comprises a list of rules and a list of connections. With other words, MES engineer, SCADA engineer and the DCS engineer are now enable to work simultaneously on the modeling of the same node. The MES engineer for example may focus on parameters which value are delivered from the automation layer (layer 0 and 1) of the physical plant items operated at shop floor which will involve the wiring with the automation facet of this node. Another parameter which value is set by operator input value or by any kind of external business logic more involves the SCADA or ERP layer and therefore the wiring of the structure facet is concerned. Further, a parameter which value is linked to a result provided by another functional facet might rather involve the wiring with the functional facet of a node.

In general the wiring process is therefore mainly used to propagate and align facet parameters which are linked to a specific node. This aspect decreases tremendously the engineering effort and allows the engineers of the diverse systems to re-use parameters and rules already in place. Therefore, a further preferred embodiment of the present invention provides the possibility to define different wiring charts for the same node and/or for the same group of nodes.

In order to support the compatibility of the rule and parameters and their respective wiring among the interface members of the various facets, each rule may comprise an interface member being identically defined as the interface member of a facet. This measure enables the rules to expose themselves by the same type of interface members as the various facets.

Other features which are considered as characteristic for the invention are set forth in the appended claims.

Although the invention is illustrated and described herein as embodied in a common plant model for the modeling of physical plant items of a production plant, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 schematically an overview on the library model applied in the Common Plant Model according to the invention;

FIG. 2 schematically an overview on the node type model applied in the Common Plant Model;

FIG. 3 schematically an overview on the facet model applied in the Common Plant Model;

FIG. 4 schematically an overview on the wiring chart model applied in the Common Plant Model;

FIG. 5 schematically a first example on a wiring chart developed according to the wiring chart model of FIG. 4;

FIG. 6 schematically a second example on a wiring chart developed according to the wiring chart model of FIG. 4;

FIG. 7 schematically an overview on the rule model applied in the Common Plant Model;

FIG. 8 schematically a third example on a wiring chart developed according to the wiring chart model of FIG. 4;

FIG. 9 schematically an overview on the node model applied in the Common Plant Model;

FIG. 10 schematically the structure of a central repository within the Common Plant Model;

FIG. 11 schematically an overview on the hierarchy model applied in the Common Plant Model;

FIG. 12 schematically an overview on the hierarchy models according to the existing ISA-95 and ISA-88 standards;

FIG. 13 schematically an example for a hierarchy according to the hierarchy model shown in FIG. 11;

FIG. 14 schematically a node template to be used for the creation of nodes according to the node model shown in FIG. 9;

FIG. 15 schematically an overview on the group model applied in the Common Plant Model;

FIG. 16 schematically an overview on the graph model applied in the Common Plant Model;

FIG. 17 schematically an overview on the management of movable equipment (plant items) within the Common Plant Model;

FIG. 18 schematically an overview on an integration model to integrate DCS and SCADA hierarchies into the MES hierarchy according to the hierarchy model shown in FIG. 11;

FIG. 19 schematically an overview on a collaboration model to integrate DCS and SCADA hierarchies into the MES hierarchy according to the hierarchy model shown in FIG. 11;

FIG. 20 schematically an example for a hierarchical distribution of nodes to different runtime servers;

FIG. 21 schematically an example for a hierarchical distribution applying a single node selection;

FIG. 22 schematically an example on a non-hierarchical distribution of nodes which typically represents an DCS use case;

FIG. 23 schematically an overview on the runtime architecture and the integration of the Common Plant Model into an over-all plant architecture; and

FIG. 24 schematically an overview on the common plant model and the applications using the common plant model.

DETAILED DESCRIPTION OF THE INVENTION

In the following the object model of the Common Plant Model—hereinafter referred to as CPM—is described from a realization independent perspective. The general idea for the creation and application of the CPM is to adopt a single software platform for the control and execution of a production process wherein MES, SCADA and DCS+ system are assigned to distinct tasks within the usually very complex realization of the software platform customized for a distinct manufacturing plant. The customized software platform is hereinafter also referred to as project.

The CPM aims to model and organize each relevant item in the physical manufacturing plant. A physical plant item could represent fixed equipment, movable equipment, tools, assets, etc. This specification uses the term “CPM Node” for physical plant items. The objective of a CPM Node is to aggregate different aspects for the modeling of single plant physical elements. The aggregation involves the public interface parameters, as well as the automation parameters. All CPM Nodes are characterized by a set of common parameters (unique identifier, name, display name for multilingual support, description, etc.) and by an additional set which is specific for each node type (level for tank, temperature for the oven, availability for a press-machine). CPM Node parameters can be consumed by external applications (e.g. UI, OEE.), used for data representation or for implementing business logic.

The following table 1 provides a brief description of the most frequent plant items:

Type                             Description
Plant structure                  Physical production equipment
Equipment modeled in an ISA-95   (fixed location in the equipment hierarchy)
compliant hierarchy.             Example: Mixers, reactors, assembly lines, etc.
                                 Premises/Work centers
                                 Areas/Cells where physical equipment and
                                 other types of equipment are located. They
                                 sometimes need to be cleaned (e.g. for Life
                                 Science Industry) and maintained under
                                 specific environmental conditions. They are
                                 always “locations” for other resources.
                                 Example: Receiving area, Weighing room, Quality
                                 control room, and Sterile manufacturing room.
                                 Storage equipment
                                 Equipment where materials are stored (e.g.
                                 warehouse locations, buffer locations, tanks,, etc.)
                                 Virtual lines
                                 Temporary organization of physical
                                 equipment for fulfilling a specific production.
Movable equipment                Containers
Equipment used to contain/transport Any type of container, used to keep or move
materials.                       material.
Containers can be moved between  Pallets
locations during manufacturing   A particular type of container
operations.                      Other movable equipment
Tools can be attached on such    Movable tanks, AGVs, Forklifts
equipment.
They can be attached to physical
equipment.
They can contain other movable
equipment
Auxiliary Tools                  Instruments
Instruments, devices and tools used for They are not used to apply transformations,
executing manufacturing operations. but they give measures and values on the
They can be attached to equipment (fixed product (e.g. balances and thermometers).
or movable).                     Tools
                                 They are used in operations to transform the
                                 product (e.g. filters, drills, mold for press
                                 machine and cutters).
                                 Workstation
                                 The workstation represents the computer
                                 station from which the operator accesses to
                                 the applications. The workstation name is not
                                 the computer name on the network but is a
                                 logical name.
                                 The physical ID (computer ID) must be linked
                                 to only one logical ID (workstation name)
                                 Printers
                                 E.g. label printers
                                 Additional devices
                                 Any additional device that must be modeled
                                 in the system, whose properties have to be
                                 configured and used during manufacturing
                                 operations.

FIG. 1 schematically shows a library model that is used in the CPM. A library according to this library model is an abstract object that has two concrete representations: a project library and a global library. A library generally comprises predefined objects that can be reused (i.e. types and templates and hierarchy definitions) as well as any objects serving as master copies. The CPM foresees two types of libraries as mentioned above:

A Global Library is a project-independent library which can be used by several projects. A user can loosely couple global libraries to a project by means of the “shows” association. All thereby related global libraries can be used when working on a project. In practical Global Library aims to release product/industry specific Type definitions as explained hereinafter in more detail in order to meet a set of cross-functionalities (e.g. equipment types for food and beverage micro vertical industry).

A Project Library is a unique part of a project. It contains all project master data. A Project aggregates one and only one Project Library.

The objects that are comprised in a library are:

• • Types, e.g. see CPM node type model explained later in FIG. 9;
  • Template, e.g. see facet model, rule model explained later in FIGS. 3 and 7 resp.
  • Hierarchy definitions

The global library is provided by different automation specific products, such as MES, SCADA, DCS+, and can be specialized for micro-verticals (e.g. Food and Beverage, Automotive, etc.). Each global library is versioned.

The objective of a project library is to manage/contain all types and templates and their proper set of functionalities relevant for a dedicated customer project. The project library is versioned, too.

A CPM Node Type as schematically shown in FIG. 2 and contained in a library, represents the main object type managed by the CPM and is used to model physical plant items. CPM Node Type comprises:

• • Header, providing the identity information of the CPM Node Type (unique identifier, name, description, versioning, etc.)
  • One Structure Facet for high level representation
  • Optionally one Automation Facet for automation representation
  • Optionally one or multiple Functional Facets for different functional aspects
  • Optionally one or multiple Wiring Charts defining the relationship between the Facets
  • Optionally one to multiple CPM Node Views providing a view to CPM Node data exposed by the Structure Facet, such as icon representation in plant displays, or so-called faceplates for detailed views.

As it can be seen here for the description of the CPM node type model the facet model plays an important role in the CPM object model and is therefore described later on with respect to FIG. 3. More information regarding the wiring chart model is given with reference to FIG. 4.

CPM Node Types can be defined for dedicated levels within defined hierarchies. Therefore, one or multiple Hierarchy Levels can be assigned to a CPM Node Type. This enables guidance in an engineering system to create CPM Nodes in a hierarchy at their intended level. CPM Node Type Templates support reuse of CPM Node Type template definitions for similar CPM Node Types inside a library. This increases ease of use in the CPM Node engineering workflow (e.g. creation and management of CPM nodes in the plant).

A CPM Node Type Header is defined as a set of information to uniquely identify a CPM Node Type. This information cannot be extended by users. The table below lists the relevant parameters:

TABLE 2
Attribute   Description
Identifier  Unique identifier for system-internal use only (not human
            readable)
Name        Canonical (mono-lingual) unique name used for name-
            based addressing
DisplayName Multilingual display name used for UI
Description Additional multilingual description
Version     Version information
IsMovable   Defines if the physical plant item (i.e. equipment) is
            movable
IsLocked    Protection flag in order to prevent node type modification

FIG. 3 schematically shows an overview on the facet model applied in the CPM. A Facet is designed to extend the CPM Node by exposing data and functionalities from different domains, related to the Facet scope, filtering and contextualizing them for the plant equipment. By means of a Facet, an external system is able to access to CPM Node information and enrich it by publishing proper business logic results (e.g. KPI calculation).

One of the most important facets is the Automation Facet which is a unique, but optional element intended as physical representation from the automation perspective. The Automation Facet relates to one or multiple Structure Tag Types in order to exchange data with the automation system. Thus, the Automation Facet in conjunction with a corresponding Structure Tag type acts like a wrapper to the automation system allowing to use the CPM Node Type for different automation system types.

At CPM Node instance level, the Automation Facet of the CPM Node relates to corresponding Structure Tag type instance inside the process image of the runtime system managing, controlling and executing the production process. Automation Facet Templates support reuse of Automation Facet template definitions for similar Automation Facets inside a library. This increases ease of use in the CPM Node engineering workflow.

The Structure Facet is a mandatory element representing the public interface of the CPM Node. Structure Facet defines the external CPM Node interface through the Interface Member that it exposes. External business logic or User Interface, through CPM Node structure facet, can:

• • Read and write parameters of a CPM Node
  • Define a subscription to a parameter of a CPM Node

The Structure Facet may optionally relate to a Structure Tag Type in order to exchange data with the process image for interface member value persistency. At CPM Node instance level, the Structure Facet of the CPM Node relates to corresponding Structure Tag instance inside the process image of the runtime system. Depending on the configuration of the Structure Tag, IOWA services may apply additional functionality such as alarm condition monitoring and/or data logging.

A Functional Facets optionally enrich the CPM Node with additional functional aspects. Examples for Functional Facets are:

• • OEE: providing CPM node availability represented by any equipment by means “OEE Facet”.
  • Batch Control: assigns batch information to a CPM node representing a Unit via a “Batch Facet”.
  • Maintenance: calculation of operation hours, maintenance intervals by means of “Maintenance Facet”.
  • Material management: assigns material information including quantity to a CPM Node representing a storage location via a “Material Facet”.

MES, SCADA and DCS products deliver their required Function Facets via their own libraries. The Functional Facet is a logical container providing data interfaces for exchange data coming from different products or system sources to the CPM. It allows loosely coupling between different existing systems that interact with the CPM, moreover allows systems working independently of each other in a way that if one of them is momentarily slow or unavailable it doesn't slow down or kill the entire system (loose coupling).

The facet objective is to cover certain functionality (e.g. Automation System, Overall Equipment Effectiveness, Quality, Diagnostic, etc.) by offering a subset of data and functions filtered and configured for the CPM Node Type that is using it. Functional Facet Templates support reuse of Functional Facet template definitions for similar same or similar Functional Facets inside a library, e.g. the definition of an OEE or Material Facet which applies to a set of CPM Node Types within a library.

A Facet is an Interface that provides a set of Interface Members. Hence, each Facet is able to expose Interface Members. The table below lists the general information for interface member parameter definition:

TABLE 3
Attribute   Description
Identifier  Interface member identifier (it must be unique)
Name        Interface member name
DisplayName Interface member multilingual name
Data type   Interface member data type
Direction   Interface member binding direction
            (input/output/input-output)
Read Only   It indicates if the interface member value cannot
            be modified by users during execution

The Interfaces should accessible with a simple namespace string, something like mixerA.OEEFacet.Status.

A Decorator is an annotation that can be added to interface members. The purpose of the decorator is to extend the interface member. The interface member can be extended according to user specific needs. The table below lists the general parameters for decorator definition.

TABLE 4
Attribute  Description
Identifier Decorator identifier (it must be unique)
Key        Decorator key
Data type  Boolean, Integer, String decorators supported.
Value      Decorator value

CPM releases system decorators as well as offers the possibility to create new ones. Examples of default system decorator are listed in the following table:

TABLE 5
Examples for default system decorators
Decorator    Description
HMIRelevant  Suggest that interface member is originally
             designed to be used for HMI system
NodeRelevant Suggest that interface member is originally designed
             to be published within the structure facet
PIM          Suggest that interface member is originally designed
             to mirror back to Process Image (available only
             interface members belonging to structure facet)
             Restriction: Structure Facet only

Parts of the Structure Facet are “mirrored” back to the process image to support alarming, logging, and other aspects of tags without the need to re-implement all these features in the CPM runtime.

Interface member decorator are available:

• • At engineering for easier interface member manipulation.
  • At runtime for detecting improper data manipulation or instance marshaling rules.

Example of decorator use can be:

• • Read-only: value cannot be modified during execution, example: tank's capacity, equipment's mobility;
  • Read-write: value can be modified during execution, example: quantity in the tank, sterilization status)

FIG. 4 schematically shows a Wire Chart Model applied within the CPM. A Wiring Chart defines the interaction between Interface Members of different Facets. A Wire is drawn from one Interface Member to another. The Wiring Chart Model supports Rules in order the adapt values for Interface-specific needs.

FIG. 5 shows a first example for a Wiring Chart. If the interface members of two different facets don't require any data manipulation, the wiring is direct (e.g. IMb.2→IMc.2). If the interface members, which belong to different facets, require data manipulation, the wiring is done by means of a mediator object called rule (e.g. IMa.1→rule→IMc.1). This approach allows always specifying 1:1 connection between two interface members. The decoupling in two separate objects (rule and connection) allows writing reusable code, independent from the interface members and connection. Interface members connected by a wire must be of the same type of Interface members.

The wiring process is mainly used to propagate and align Facet parameters which are linked to a specific CPM Node. This aspect decreases the engineering effort and allows the engineer to re-use parameters already in place. Another aspect is data adaptation. The wire bonding process carried out by various kind of parameter: in case of a wired pair parameters needs some kind of data manipulation, a dedicated environment is offered to the Engineer to specify the conversion logic. The wiring is able to connect objects that expose their public interface as a list of interface members. A pair of interface member defines a Connection. The wiring connections and rules are organized within the wiring charts according to the Wiring Chart Model. The CPM Wiring Model, including wiring charts with rules and connections, is an optional part of the CPM Node.

A wiring chart has a list of rules and a list of connections. The wiring model is partitioned in several wiring charts in order to:

a) separate different project responsibilities (e.g. SCADA team and MES team working on the same CPM Node Type)

b) separate different product implementation (e.g. SCADA, MES, DCS) on the same project

c) manage complexity.

Since rule interface member and facet interface member are defined in the same way, it is possible to connect two or more rules using the same mechanism described in the previous paragraph as this is shown for a second wiring chart example in FIG. 6. The connection from Facet A, IMb.1 goes via a first rule (upper box) and a second rule (lower box) to Facet C, IMc.2. Both rules can be engineered independently.

FIG. 7 schematically shows rule model used within the wiring chart model which both are applied in the CPM. The Wiring rule is necessary when:

a) the wire between interface members requires any kind of data adaptation or manipulation in terms of rule.

b) More than two interface member have to be connected.

Just as the facets also the rule exposes itself by means of interface members. The logic inside the rule is realized with a Script that can contain more than one Script Function. An authorized user can create a Script Function or use an existent one available in a Library. The script is meant to be stateless. In case of a state must be maintained between different of executions of the same rule a Local Variables must be defined. Because of rule is independent from connections and facet interface members, rules can be organized in libraries so that they can be reused as building blocks. FIG. 8 schematically shows a third example for a wiring chart involving the mechanism of variable and script. The example of FIG. 8 therefore can describe the following case:

• • The wiring chart involves the facets Facet A and Facet C through the mediator RULE
  • The variable within the rule contains the counter value
  • The script within the rule updates the current counter value with the value of the interface member rule.1 if the machine status is active (rule.2→1)
  • The Counter is reset when the machine status changes from 1 to 0 (Facet A.2 passes from 1 to 0)

FIG. 8 now schematically illustrates the design of a CPM Node which represents the instance of the CPM Node Type. The CPM Node comprises a CPM Node Header which provides its identity information (unique identifier, name, description, versioning, etc.). A CPM Repository controls the lifecycle of each single CPM Node. A CPM Node instance inherits all its structures (i.e. Structure Facet, Automation Facet, certain Functional Facets, and Wiring Charts) from the CPM Node Type. The reference to the CPM Node Type is valid throughout the entire lifecycle in order to apply type changes at runtime to the CPM Node instance. The configuration engineer may overwrite properties at CPM Node level in order to apply distinct behavior to the instance. Such properties are default values such as set-points, value ranges, and CPM Node Views (in case that multiple ones are defined for a CPM Node Type).

In order to reduce complexity, wiring charts and rules are not subject for changes at instance level. The CPM Node can be further extended with user defined parameters in order to meet customer needs. The CPM Node Header is defined as a list of information which objective is to uniquely identify a CPM Node. The table below lists the relevant parameters:

TABLE 5
CPM Node Header
Attribute           Description
Identifier          Identifier (it must be unique)
Name                Name
Display Name        Multilingual display name
Description         Additional description
Version             Version information
Hierarchy path list Node path according to selected hierarchies
Target system       System field for distribution specification
                    (e.g. CPMNode A1 will run on EV1)
Is Movable          It defines if the equipment is a movable equipment
Is Locked           Protection flag in order to forbid node type
                    modification

The CPM Runtime environment manages a flat node repository that contains all CPM nodes. The objective of the CPM Node repository is to manage the CPM Node life cycle. So that, each time a CPM Node/s is created or imported (bulk import), automatically its/their instance is managed independently from the possible hierarchies that the CPM node/s shall belong to. According to possible domain models (e.g. production, maintenance, energy), it is possible to organize nodes in different hierarchies as schematically shown in FIG. 10.

Another outstanding improvement of the CPM is realized by the Hierarchy model which is schematically shown in FIG. 11. The CPM supports hierarchical object structures in order to organize equipment in different way in order to meet project and business process needs at the same time. This means that equipment (physical plant items) can be organized as a part of a production area. Similarly, the same equipment can be organized in a location structure where the objects fit into the physical/geographical context (e.g. it would show exactly where in the plant the Mixer is installed). Additional views could be defined by the user in order to organize the equipment for electricians, maintenance engineers so that they can work with appropriate views.

Hence, the objective of hierarchy definition is to define several organizations (that can have different level of details) so that the user can organize its equipment according to functional/physical/logical aspects. In addition it is possible to specify constraints when defining hierarchies' structure (e.g. an Area cannot contain a Site).

The aim of hierarchy model is to support hierarchically organized structures. The CPM nodes, which belong to a unique repository, can be organized in different hierarchies. FIG. 12 shows an example of a combined view of ISA 95 and ISA 88 hierarchy models to describe the domain objects of the repository and the hierarchy. In this example Enterprise, site, area, work center, work unit are hierarchy levels.

Before a hierarchy can be built with CPM Nodes, it is necessary to specify a Hierarchy Definition. The engineering system can hide the need of Hierarchy Definitions by means of default hierarchies (e.g. ISA 88/95, Parent-Child with no constraints). The Hierarchy Definition comprises the Hierarchy Levels and the relationship to each other via parent-child link of the Hierarchy Level Constraints.

The tables below show an example of Hierarchy definition:

TABLE 6
Hierarchy entity definition - Hierarchy Definition
Hierarchy Definition Hierarchy Level
Equipment Hierarchy  Site
                     Building
                     Line
                     Machine

The above table 6 lists the Hierarchy Levels for single Hierarchy definition (Equipment Hierarchy).

TABLE 7
Hierarchy entity definition - Hierarchy Level
Hierarchy Level Parent Hierarchy Level
Site            —
Building        Site
Line            Building
Machine         Line

The above table 7 lists the Hierarchy Constraints among Hierarchy levels. The “concrete” hierarchy is built using the CPM Nodes available in CPM repository. This example is shown schematically in FIG. 13.

The CPM Node Template is created from instances and contains all information, including Automation and Functional Facet configuration, of these instances and hierarchy definition. From the practical point of view, the user is able to reuse a CPM Node Template to create multiple CPM Node instances. Depending on the template it could be a simple unit with few equipment modules or an entire Packaging Line. FIG. 14 schematically illustrates an example of a packaging line, usually present in a bottling plant.

A bottling packaging line template consists of a number of CPM Nodes, such as a:

• • Filler,
  • De-palletizer,
  • Pasteurizer,
  • Palletizer,Each CPM Node contains its structure facet and MES functional facets which are relevant for the Bottling process. In case of multiple facets contained in one CPM Node, the CPM Node contains wiring charts, too. The CPM Node instances, which are created from a CPM Node Template, still maintain the reference to their CPM Node Types.

The group model schematically shown in FIG. 15 allows a grouping of CPM nodes. This type of organization consists of grouping (statically or dynamically) a set of CPM Node both at engineering and at runtime phase. CPM Nodes can be manually added to a Group. A CPM Node can be assigned to multiple groups, as well.

Typical examples are:

• • group CPM Nodes that belong to the same ERP cost center;
  • group CPM Nodes according to maintenance teams.

TABLE 8
Group model
Attribute    Description
Identifier   Identifier (it must be unique)
Name         Name
Display Name Multilingual display name
Description  Additional description
Version      Version information

FIG. 16 shows schematically the graph model applied in the CPM. The graphs are used to model the physical/logical connections between CPM Nodes. Each connection can contain an attribute list (time, cost etc.). The system recognizes all possible graphs by analyzing and filtering the connections among graph nodes.

The Graph model comprises:

• • Graph: graph definition in terms of unique identifier, name and display name
  • GraphConnection: a couple of CPM Nodes are linked via Graph Connection link
  • GraphConnectionAttribute: each GraphConnection is further enrich with more than one attribute

As an example, a graph is used as a constraint for the routings definition (e.g. packaging line).

Movable equipment is an important and mandatory feature especially in process and pharmaceutical industry. Movable equipment is uniquely identified and has the same properties/features as a static CPM Node (Name, Description, Facets and proper Interface members, etc). In addition to that movable equipment is moved from one hierarchy position to another one.

As for all other CPM Nodes, Movable equipment's life cycle is in charge of CPM Node Repository. From a hierarchical organization point of view, the Movable Equipment is

• • assigned to a “Storage/Static location” (e.g. kitting area, Site etc.), see line for static location in FIG. 17
  • dynamically moved into new assigned location (in runtime move the equipment in the hierarchy), see line for dynamic location in FIG. 17.
  • “query-able” by path (hierarchical view) or by its general identity information by means of CPM Node Header
  • addressable via path in the hierarchy showing current location.

With this concept, movable equipments can be addressed by fixed IDs (they will not be changed when the equipment moves) like:

• • CPM-Path of the storage static location
  • Unique Identifier
  • And it can be addressed/shown by changing IDs:
  • CNS-path to the location.

In the following, integration and collaboration scenarios are explained in more detail. From the project implementation point of view, four different scenarios are foreseen:

A. Greenfield TOP Down, Implemented Using SIEMENS® Portfolio:

Top down from plant design perspective means a brand new CPM project where the CPM node composition can be enriched in any time with functionality coming from different automation system products.

This does not imply that the commissioning is done for all products at the same time (e.g. SCADA can be commissioned before MES)

B. Greenfield Bottom Up, Implemented Using SIEMENS® Portfolio:

A CPM project is already in place and, in a second time, additional functionality is added. (e.g. MES project not designed in the first project phase and SCADA/DCS already in operation. CPM Nodes can be enriched with MES functions.

It should be noted that in case of regulated industries where the existing project is validated (“sealed”), there could be the case where a new validation is required or a “proxy CPM Node” has to be engineered (see scenario C).

C. Brownfield Bottom Up, Implemented Using SIEMENS® Portfolio:

Different OEMs deliver part of the whole plant by means of independent CPM projects. In a second time, additional functionalities are requested on top of commissioned project. Example: MES on top of existing SCADA projects.

Unless there is an owner that takes the responsibility for changes the OEM system there is the need to create a new CPM project. The engineering effort could be mitigated if the source code of “sealed” project is available or “sealed” project structure can be only browsed for CPM project extension.

D. Brownfield, Bottom Up, 3rd Party Systems:

In this case none of the strategies can be applied because of third party systems that do not conform to CPM model at all. Only interface level approach can be applied (e.g. OPC). For the above mentioned scenarios, the following two models shall be applied.

First model is the Integration Model which is schematically shown in FIG. 18. The integrated model shall be applied in all not “sealed” systems. A “sealed” scenario is a system that cannot be modified from the engineering point of view. Typical example is a system released from OEMs which is a validated systems in regulated industries. In order to implement an integrated scenario, the systems must not be treated as “sealed” in order to extend CPM Nodes with Functional Facets coming from different automation system products.

As a specific feature of the integration model, the hierarchies of the SCADA and the DCS system are mounted to the hierarchy of the MES. Therefore, both SCADA and DCS comprise in its specific nodes the facets from the MES. A duplication of the diverse hierarchies is omitted which leads to a break on the seal of the SCADA and DCS system.

The second model is the collaboration model which is schematically illustrated in FIG. 19. The collaboration model is the preferred model for application on all kind of “sealed” systems. Because the system cannot be modified from the engineering point of view, in the collaboration model exists the need to create proxy CPM Node (CPM node with attribute “proxy off” referencing CPM Node counterpart) representation of relevant objects of the sealed system. The system will provide transparent access to remote CPM Nodes belonging to the “sealed” system, but in the separated hierarchy. Non merger of hierarchy is done.

The engineering system shall support:

• • Copying the hierarchy (selected parts) from the lower level systems to the upper level system
  • Copying the structure facets (selected parts) from the lower level systems to the upper level system

In this scenario, value to the present solution of Siemens® can be added by the propagation of later modifications on the Sealed System and possibly applying consistency rules in order to alert on conflicts.

Therefore, in the collaboration model, the SCADA and DCS hierarchies are imported and integrated into the MES hierarchy (e.g. hierarchy according to ISA-95 and ISA-88). MES facets are exclusively used in the MES only which is completely different from the integration model. Both the SCADA and the DCS systems remain sealed and the respective hierarchies are duplicated as it can be seen in FIG. 19 where the nodes of the SCADA and DCS systems are duplicated into the MES. In this regards, cross-node and cross-system wiring are required which means for example that MES facets have to be linked via the wiring to non-MES facets in the SCADA and/or DCS system.

In the present example, a single dedicated Engineering Instance is in charge of configuring hierarchies, groups and graphs and how CPM nodes belong to them. The full CPM Node configuration is then distributed, kept aligned and locally cached in all server stations by means of the CPM Runtime and the IOWA Name Service. This Engineering Instance (engineering system ES) is responsible to send each runtime server its proper configuration as this is shown in FIG. 20. If this runtime server is not accessible, the engineering system cannot download the new configuration to the target. A redundant configuration of the runtime server reduces the probability to not apply engineering changes as shown in FIG. 20

The distribution of the CPM Nodes to different runtime servers is supported and it can be performed according to one or both of the following strategies.

1. Selecting higher a level hierarchy node containing relevant CPM Nodes from one of the hierarchies:

• • In case of distribution driven by a selected hierarchy, all child nodes of the selected parent node are distributed to the same target server station until a subordinate node is distributed to another server.
  • Nodes not assigned to the distribution hierarchy may be highlighted to the user.
  • The central server can be a dedicated server station (as in the example) or even part of one of the “regular” server stations.
  • This approach enables easy engineering in terms of distributing the CPM.

2. Selecting single CPM Node from one of the Hierarchy

This example is schematically shown in FIG. 1. Even if the majority of CPM Nodes can be distributed according to the selection of a higher-level hierarchy node, certain, individual CPM Nodes may be distributed differently. Hence, the configuration engineer assigns single nodes to different systems (e.g. Line_22 to Server Station A). The configuration engineer configures one or multiple hierarchies, groups, and graphs and how CPM Nodes belong to them via a dedicated engineering system. The entire CPM Node configuration is then distributed to one or multiple runtime stations. This option enables high flexibility in terms of distributing the CPM.

Non-hierarchical distribution as schematically shown in FIG. 22 is a typical DCS+ use case. In contrary to the hierarchical distribution (see previous paragraphs) no dedicated runtime server station may exist as central server providing the common, higher-level hierarchy entity levels. A dedicated Engineering Station is in charge of configuring hierarchies, groups and graphs and how CPM nodes belong to them. The full CPM Node configuration is then distributed, kept aligned and locally cached in all server stations by mean of the CPM Runtime and the IOWA Name Service. This is necessary to provide a transparent view to the plant hierarchy to each client station, regardless to which server station a client station may be connected with. In this distribution mode, a dedicated runtime server exists as communication partner for the Engineering Station. If this runtime server fails, no parameterization is needed. FIG. 22 therefore describes how the previous example configuration is distributed to three peer runtime stations:

• • The Name Service of each runtime server represents the local process or work cell as well as “mounted” information concerning the process or work cells that have been distributed to the peer runtime stations. This is accomplished by means of so-called “mounted to” relations linking remote information to the local content.
  • System spanning information of the “Site” entity is therefore available at each server station.
  • A client station connected to any of the peer server stations is able to browse data of all peer server stations, hence the entire plant model, too.
  • Each name service is able to provide references to local and remote objects, so that a client is able to access objects in a distributed system.
  • This approach does not require a central server for a distributed CPM.

FIG. 23 schematically illustrates how the CPM is integrated into an Over-All Architecture of the bundle of software applications which execute and control the manufacturing process in the plant (Runtime Architecture). FIG. 23 therefore represents the relation between CPM and applications belonging to different products and the functional dependence of CPM from Scripting Framework (wiring chart execution engine), User Manager and Access Control component. Each single software system MES, SCADA and DCS+ now comprise both individual engineering and runtime systems which couple to the CPM. Therefore, none of these systems needs an individual system to model the production plan for its specific needs and demands. The engineering is therefore concentrated in the CPM which can be addressed from the engineering systems of the diverse software applications (here MES, SCADA and DCS+). Each individual engineering specialist therefore bases his particular engineering work on the models described above and can therefore model his individual needs within the scope of models for the nodes, the facets, the rules, the wiring, the hierarchy and so on. Therefore, engineering now becomes completely transparent and permeable to all system engineers regardless for which specific software application they are working for.

GLOSSARY/ABBREVIATIONS

Term              Definition
ADI               Simatic IT ® data access interface
AGV               Automatic Guided Vehicle: Vehicles designed to transport goods,
                  connecting different machines within the warehouse
Automation Facet  The automation facet is in charge of collecting all the structured tag
                  types that the CPM Node needs for connection to automation
                  system.
CPM               Common Plant Model as shown in FIG. 24
CPM Node          It represents the equipment instance.
CPM Node Type     It represents the main object type managed by the Common Plant
                  Model (e.g. Valve, Mixer, Conveyor etc.)
CPM Node Template It represents the template object that the user is able to reuse for
                  CPM Node instances. It could represent simple (containing one
                  CPM Node instance) as well as complex (containing hierarchically
                  structured CPM Node Instances) objects (valve or packaging line
                  template).
Functional Facet  Functional Facets enrich the CPM Node with functional aspects
                  such as maintenance information, efficiency etc.
IOWA Runtime      Comprehends the runtime platform of IOWA
IPC               Inter Process Communication
MES               Manufacturing Execution System
OEE               Overall equipment effectiveness: OEE quantifies how well a
                  manufacturing unit performs relative to its designed capacity and to
                  the material produced, during the periods when it is scheduled to
                  run. It is also referred as key performance indicator (KPI)
PIM               Process Image
RDF               Runtime Data Format used by IOWA to store the configuration data
                  needed at runtime
Structure Facet   The structure facet is in charge of publishing the CPM Node
                  interface and hiding the complexity of the CPM Node structure.
WCEE              Wiring Chart Execution Engine

Architectural Significant Requirements

The following table lists all architectural significant requirements.

TABLE
Title                     Description
Definition                The term “node” used to identify single object as well as
                          objects that contain other objects. In the engineering
                          system, it is possible to create user-defined properties to
                          the CPM node type.
                          A node has an Id (unique), a path (unique) and name (not
                          unique) which is part of the path.
Scope                     The common plant model includes information about all
                          static elements of the plant that need to be exchanged
                          between different components.
                          Remarks:
                          Static = lives longer than 1 day and is being defined by
                          using engineering methods.
                          The information is related to physical elements (Common
                          Equipment Hierarchy) as well as conceptual elements
                          (Common Master Data).
Hierarchy                 The plant model is organized in a hierarchical fashion. It is
                          possible to navigate through the hierarchy via browsing. It
                          is possible to reference nodes via their hierarchy name.
Hierarchy name freely     Components using the common plant model should not
defineable                introduce constraints on this hierarchy name that could be
                          in conflict with other components, node names itself don't
                          have to be unique when the path name is unique.
                          Example: For nodes Vessel1/Outlet and Vessel2/Outlet, the
                          node name is duplicated but the path name is unique. The
                          system shall support this situation.
Node types                In order to support reuse the CPM supports a type concept
                          for nodes.
IDs as unchanging         As the path name of a node can be changing when moving
primary identifiers       it, the system shall keep a (non human-readable) unique
                          object id that keeps the original reference especially with
                          respect to historical data.
Nested node instances     Node instances may contain other node instances. When a
                          node instance contains other node instance it can be
                          considered as a folder.
Number of CPM             There isn't a hard coded limit in the SW regarding number
elements                  of node type etc.
Engineering efficiency -  For engineering purpose a section of the hierarchical
Reuse of an hierarchical  structure is reusable as a template in order to create and
section                   maintain multiple instances of a CPM items which are
                          composed of several nodes spanning over several
                          hierarchical levels. It shall be possible to propagate
                          template changes to the already existing instances which
                          are based on the template.
                          Use case:
                          In a plant there are 10 equal fillers. A filler in the CPM is
                          composed by 5 CPM nodes. A configuration engineer
                          creates the nodes defining the filler only once save it as a
                          template and creates based on this template the 10 filler
                          instances in the plant model. Changes in the template like
                          e.g. adding a node (structural change) and changing a
                          node's content can be applied to the already exiting
                          instances which are based on the template.
Node data - Data types    The data of an node may contain members of
                          type:
                          Simple data type (Boolean, Integer, Real,
                          String, etc.)
                          Enumeration
                          Structure
                          Array
                          Reference to object
Node data - Nested data   Array elements and structure elements may be
types                     again from type ‘Simple data type’, ‘Structure’
                          or ‘Array’ (nested types).
Node data - Access path   Dynamic data of a node is managed in the process image.
                          The process image is considered to be an integral part of
                          the CPM. This means addressing of tags shall be possible
                          by using a nodes unique path + CPM leaf node name +
                          element path. (e.g. Plant/Section-1/Unit-1/Aggregate-
                          1/Pump-1.Response.Measuring_point.Speed)
                          It is possible to copy parts of the hierarchy without getting
                          uniqueness errors.
Runtime collaboration     To enable runtime collaboration between two or more CPM
                          servers, the data of a node may be retrieved from another
                          CPM server and vice versa.
Instance specific data    In a real plant there are often nodes that partly differ from
                          an already existing node types. E.g. a new unit has an
                          additional flap than the original “Flap” object type. To avoid
                          defining a completely new object type for this deviating kind
                          of unit, the node (representing this unit) shall have
                          optionally instance specific data and facets. Instance
                          specific data and facets only exist at the object instance
                          and not at the object
                          type. Nevertheless changes at the object type shall still be
                          propagated to the object instance even it this has object
                          specific data.
                          Instance specific data can optionally be taken over to the
                          object type.
Facets - general          In order to support cross-versioning, CPM shall act as a
                          repository and not include business logic. Facets of an
                          object represent the usage of the object's data (e.g.
                          alarming, archiving, audit, etc.) and can be attached or
                          integrated to nodes (e.g. by an product like SCADA 2015).
                          Facets can be used to expose the behavior of the node but
                          the implementation of the behavior is not part of the
                          Common Plant Model. Facets on a node are optional and
                          defined within the configuration of the type/node. Logic for
                          wiring of facets is not a problem and may be included with
                          CPM.
Single repository for     Engineering of a plant model is possible interchangeably by
engineering               any engineering system of SCADA, DCS or MES
                          independent whether the project starts as DCS, SCADA or
                          MES project. There is no necessity for entering data twice
                          or for synchronizing different repositories. This requirement
                          can be fulfilled best by using a single repository for
                          engineering data without forcing each product to adopt the
                          same language natively.
Single repository for     For a single (non-distributed system) there exists a single
runtime                   repository for the common plant model at runtime,
                          independent whether the project starts as DCS, SCADA or
                          MES project. The intention of this requirement is
                          a) to avoid duplication of data in different parts of the
                          runtime and subsequent potential inconsistencies, and
                          b) to avoid synchronization overhead that could result if
                          information (e.g. concerning the same node) is spread
                          across several repositories.
Client notification       It is possible for components to register for certain objects
                          in order to get notified of runtime changes of dynamic
                          properties or of engineering changes of static properties.
System Type protection    The system shall distinguish between system defined node
                          types (types that come with a system library or with a
                          component) and user defined node types.
                          It is possible to customize system defined node types by
                          adding user defined properties. It is also possible to add
                          user defined node types. It isn't possible to change system
                          defined object types (the only exceptions are the user
                          defined properties), to delete system defined object types
                          or to modify system defined properties.
General types protection  It is possible to add protection flag to node types in order to
                          forbid node type modification.
Runtime type support      The common plant model supports types at runtime. That
                          means that a configuration change on a single node type
                          only forces the engineering system to update one single
                          object (the type object) at the runtime system. The
                          subsequent updates of the node instances are executed on
                          the runtime system.
Properties with dynamic   Nodes can have dynamic properties where the values
values                    change at runtime such as e.g. process values, operator
                          input values or calculation results. Dynamic properties shall
                          have a timestamp (referring to time of last change) and a
                          quality code (quality code only for tags).
Properties with static    Nodes can have static properties with values defined during
values                    engineering/online delta download. When downloading
                          changed static properties of an object, dynamic attribute
                          values shall not get lost.
User and system defined   There are user defined node types which are created
node types                during configuration and predefined system maintained
                          node types (e.g. coming from global or project library).
System/user defined       In the engineering the system distinguishes between
properties                predefined and user defined properties. For this reason a
                          reference to the “base” system type must be kept inside the
                          modified node type.
Schema driven for         A schema based description of the common plant model
equipment description     shall allow equipment type descriptions (meta data). The
                          schema shall apply to types, type relations and type
                          properties. It is possible to retrieve information about a type
                          including its customization from the schema.
                          The schema is also used for description of export/import
                          file formats.
Schema driven             A schema based description of the common plant model
versioning                shall include a version information of the common plant
                          model (meta data). The schema version information
                          includes in the export/import file formats.
Upgradable                It is possible to upgrade the system maintained part of the
                          common plant model to a new version without affecting the
                          customized properties.
Transactional delta       In the scope of CPM it is possible to create, modify or
change                    delete a node at runtime. The modification must be
                          consistent inside one node. Processing (like e.g. execution
                          of calculations or component methods) for node that is
                          currently being changed is stopped in order to avoid
                          inconsistencies. Clients that have registered for
                          parameterization changes of this node are notified.
Hot standby redundancy    The common plant model supports a hot standby
                          redundancy scheme that supports engineering changes at
                          runtime (consistent online delta download) as well as delta
                          synchronization of dynamic properties. During a
                          redundancy failover, double processing of the same change
                          events for dynamic properties shall be prevented via
                          checking the timestamp of the last change. A calculation
                          shall not be executed again if the timestamp of the result
                          attribute indicates that it has already been done.
Transparent distribution  Within the context of one engineering system, it is possible
                          to distribute the common plant model across different
                          servers. For clients, this distribution is transparent. This
                          means that any client can access plant model data on any
                          server.
Cascading                 It is possible to cascade common plant models that have
                          been engineered independently. This means that individual
                          installations/plant models can be integrated into a larger
                          model. This can be done with remodeling (remapping) or
                          via simple replication of information.
                          Note: As the individual parts of the cascaded system
                          continue to work unchanged, cascading typically involves
                          duplication of information in the different engineering
                          context of the higher level system.
User rights & roles       The system controls user access to objects in the common
                          plant model. The access control is object granular. Runtime
                          access rights: read/write. Engineering access rights: read/
                          update/create/delete.
                          If there is a primary node hierarchy defined in engineering,
                          access rights can be inherited by lower level nodes from
                          higher level nodes.
Node related version ID   Each node instance in the common plant model
                          automatically gets a new system maintained version
                          number after any engineering change/download. This
                          version number links the runtime representation of the node
                          to the engineering data. It can be used to make a
                          consistency check whether current runtime and current
                          engineering version are really the same.
Version labels for        The user can define a version label for a selection of nodes.
multiple objects          This label can be used to retrieve the individual node
                          versions from the version repository in the engineering
                          system. This is implemented similar to version labels as
                          used in source code control systems.
Consistency check         In case of offline engineering, the system provides the
                          possibility to compare runtime node versions with
                          engineering node versions in order to ensure that they
                          match.
Customization             Step 1: Customization of plant model via customizing node
                          types.
                          A set of customized node types can be collected in a
                          library.
                          Step 2: Creation of plant hierarchy/instantiation of nodes
Engineering libraries     Libraries can be handled independent of project (export/
                          import). The engineering system can distinguish between a
                          global library and a project related library. A new system
                          release can come with a new global library - installation of
                          this release shall not affect the project related library
Additional plant          The system supports multiple hierarchies. That means a
hierarchies               single node can be related to multiple hierarchies with
                          different address path.
Mobile equipment          The system supports movable equipment that means an
                          equipment can be associated to different location in the
                          plant. A “Movable equipment” has the same
                          properties/features as a static node (e.g. Name,
                          Description, Attributes, Facets, etc.). In addition to “fixed
                          equipment properties” mobile equipment provides a unique
                          readable identifier that does not belong to the location
                          where the mobile equipment is located. Mobile equipment
                          is represented in the hierarchical view (like the static ones)
                          in the current location.
Changes regarding         Engineering changes in the hierarchy like
hierarchical structure    adding/deleting/modifying/moving nodes does not result in
                          any engineering effort regarding the subordinated
                          nodes/objects in the
                          hierarchy (e.g. no manually renaming of objects, alarm
                          sources etc.). E.g. when moving a node in a hierarchy, all
                          the sub-nodes are also moved. Any references between
                          nodes remain unaffected. Moving a node from a position to
                          another in a hierarchy will not affect the relation of the node
                          in other hierarchies.
Inconsistent changes      Inconsistencies resulting from object/node changes in the
                          engineering (e.g. deleting data used by other objects) are
                          checked and reported by
                          the engineering system. Note: Of course this applies only, if
                          the engineering system cannot avoid the inconsistency
                          early on.
Approval of changes       Applying of changes in types/instances needs to
                          be optionally approved by configuration engineer in the
                          engineering system.
Engineering - general     Engineering allows to define object types, add, alter and
                          remove object type properties, instantiate objects from
                          objects types, add, alter, remove instance specific object
                          properties, define a hierarchical plant model.
Engineering approach      There are different approaches to creating a plant model:
                          Top Down (typical in DCS): Plant Model is created
                          synchronously with the automation;
                          Bottom Up: Several independently engineered units are
                          combined to form the plant, but no extra modeling
                          involved (not a real MES case)
                          Bottom Up + Top down (typical in SCADA): Several
                          independently engineered units are integrated into a top
                          down engineered plant model.
Node data                 In the engineering system, it is possible to create user-
                          defined properties to the CPM node type. These properties
                          are optionally checked for uniqueness in engineering.
                          Properties marked for uniqueness cannot be changed at
                          runtime.
Node data constrains      These properties are optionally checked for constraints like
                          range checks. Details to be defined.
Decorator for equipment   It is possible to define a MES relevant-flag for SCADA parts
parameter                 of CPM to be able to filter the automation facets for MES-
                          relevant parts only.
Dynamic or static         CPM gives the possibility to set if a property value can be
parameters                modified or not during the execution.
                          Static properties: value cannot be modified during runtime,
                          example: tank's capacity, equipment's mobility;
                          Dynamic properties: value can be modified during
                          execution, example: quantity in the tank, sterilization
                          status)
Persistency equipment     CPM gives the possibility to define if a parameter value has
parameters value          not to be permanently stored in CPM storage
Objects assignment        CPM is able to contain DPs/tags as well as additional
                          objects such as screens.
Connection between        It is possible to use the Common Plant model as screen
CPM and screen hierarchy  topology.
Remote objects assignment CPM is able to access Objects of remote systems.
from distribution point   Independently if remote systems comprise CPM or not.
of view
CPM Distribution          CPM is distributed across several server nodes in a
                          hierarchical organization. A system on the bottom of the
                          hierarchy (for example a line) defines its own hierarchy. A
                          top level system must be able to combine the bottom
                          hierarchies into one, so there is a complete hierarchy
                          available in the top level system
CPM Online Engineering    Hierarchy and nodes of the CPM can be created and
                          changed during runtime.
Support of multiple       It is possible to create more than one hierarchy, e.g.
hierarchies               equipment
                          hierarchy, screen hierarchy, device hierarchy
Interoperability          It is possible to import and map equipment types and nodes
                          from third party system. E.g., The equipment is created
                          starting from a model coming from ERP or PLM and further
                          enhanced with SCADA/MES functions.
Access control            It is possible to define access rights for CPM by using user
                          roles definition, e.g.:
                          no change of “remote” parts of the CPM
                          Read-only
                          Rights per tree
                          Rights per node; lower nodes inherit from nodes above, if
                          they do not have their own permissions
Multi-language            Each node has a single-language name for identification,
                          and a multi-language display name
Interface/Wrapper         It is possible to define a wrapper between objects (e.g.
support                   valve) in the PLC and CPM, to be able to map different kind
                          of implementations of one object in different PLCs/different
                          projects) to one implementation model in the CPM to make
                          standardization possible.
Data Access               Each system integrated in CPM is able to access data
                          exposed by the other systems.
Equipment relationships   CPM provides the possibility to define and organize
                          different relationships among nodes. The capability of
                          organizing the equipment is not always based on a
                          hierarchical structure. Other types of relationship must be
                          taken into account.
                          Hierarchy
                          Graph
                          Group
Node graph relation       CPM provides functional properties so that each graph
specification             relationship among nodes can be further detailed, e.g. the
                          connection between equipment can be plain or specialized
                          with:
                          Capacity (e.g. a pipe flow specification etc.)
                          Behavior (e.g. FIFO, LIFO, FEFO, etc.)
                          Topology
Object definition         The user is able to specify additional system properties that
                          characterize the node from a behavioral point of view. The
                          CPM node can be defined as:
                          tool,
                          fixed equipment
                          movable equipment
                          shared equipment among more equipment
                          etc.
Nodes with and without    CPM gives the possibility to define nodes with and without
automation relation       automation relation
Versioning                CPM manages plant version to allow that all changes
                          applied to the equipment structure are stored. This allows a
                          better controlling the compatibility and upgrade of existing
                          applications where the equipment has already been used.
Revision management       CPM provides the possibility to assign a revision number to
                          one or more CPM nodes under editing to allow grouping
                          and uniquely identify all changes.
Undoing of changes        CPM provides the possibility to undo object changes with
                          reference to a specific revision number
Side by side deployment   CPM provides the possibility to apply type changes either to
of CPM node types         all instances or to a subset.
Process related           CPM gives the possibility to define more than one
constraints               constraint so that a runtime object cannot be modified or
                          deleted.
Audit trail               CPM supports audit trail for actions or changes on the
                          system.
Electronic logbook        CPM provides information on the equipment history.
                          Manual entry into the logbook should also be possible, e.g.
                          Production activities, maintenance activities, calibration
                          activities, status changes.
CPM project type          It is possible to define physical objects within CPM either on
agnostic                  green-field projects or brown-field projects., e.g.:
                          Greenfield Top Down with Siemens Portfolio (SCADA
                          and MES done in meantime)
                          Greenfield Bottom Up with Siemens Portfolio (first
                          SCADA then MES)
                          Brownfield Top Down with Siemens Portfolio (first
                          SCADA then MES)
                          Brownfield Top Down 3rd Party SCADA (first SCADA
                          then MES)
Interchangeable           Engineering of a plant model is possible interchangeable by
Engineering               any engineering system of SCADA, DCS or MES
                          independent whether the project starts with SCADA, DCS
                          or MES.
Hierarchy navigation      The CPM supports Hierarchy navigation starting from node
CPM supports SQL like     The user is able to query CPM data (nodes, hierarchies,
query                     groups, graphs) including the current values in a relational
                          way.
                          Note: Queries support CNS-part in FROM (like already
                          available in WinCC OA for dpGroups). This enables the
                          restriction of query results (for current alarms and original
                          values) to a part of the CNS-tree
Import automation         It is possible to import automation facets from TIA-portal,
facets                    from OPC-server, and from 3rd-party PLC engineering tools

Claims

1. A common plant model for modeling physical plant items of a production plant within a manufacturing execution system having an engineering environment and a runtime environment, the common plant model comprising: a) a node type model aggregating different aspects for modeling a single physical plant item involving public interface parameters and automation parameters;b) a plurality of nodes, each representing an instance of a node type;c) a library model including a project library and a global library, said project and global libraries containing the node type model, a facet model, a rule model and a hierarchy model;d) a graph model representing physical and/or logical connections between the nodes;e) a wiring chart model defining an interaction between interface members of different facets within a common node and/or among different nodes; andwherein each facet contains at least one interface member and a logical link among the interface members is a virtual wire defining a connection used to propagate and align facet parameters that are linked to a specific node.

2. The common plant model according to claim 1, wherein said wiring chart model comprises an insertion mechanism allowing to attach a rule defined according to said rule model to said logical link, thereby enabling any kind of manipulation to a parameter which is exchanged between two said interface members associated with said logical link.

3. The common plant model according to claim 2, wherein said insertion mechanism allows attaching a series of rules to the logical link.

4. The common plant model according to claim 1, wherein said wiring chart is associated with a node type and comprises a list of rules and a list of connections.

5. The common plant model according to claim 1, wherein different wiring charts are defined for the same node and/or for the same group of nodes.

6. The common plant model according to claim 1, wherein the rule comprises an interface member being identically defined as the interface member of a facet.