The present invention relates to a method and apparatus for displaying batch execution data of an industrial plant. It particularly relates to displaying batch execution data obtained during batch procedural control.
As defined in ANSI/ISA-88.01-1995, Batch Control, Part 1: Models and Terminology, a batch process is “a process that leads to the production of finite quantities of material by subjecting quantities of input materials to an ordered set of processing activities over a finite period of time using one or more pieces of equipment.” In batch manufacturing plants, each ordered set of processing activities is typically referred to as a batch execution. In most batch processes, no two batch executions are exactly alike. Each batch execution will have a set of unique characteristics include production quality, cost, and speed.
In procedural control for batch processes, as also defined in “ANSI/ISA-88.01-1995, Batch Control, Part 1: Models and Terminology,” there are typically four levels in a hierarchy 800 of levels of procedural elements 810, 820, 830, 840, as shown in
In a batch manufacturing plant, a number of batch executions are usually monitored at once. Some of the batch executions may be completed while others are uncompleted or reserved pending performance. Each of the batch executions is typically a first level element or procedure 810 under procedural control as described above. All the batch executions or first level elements 810 are normally displayed as a list of first level elements 810 in a first window on a display screen. If a user wishes to check on the unit procedures or second level elements 820 for a particular batch execution 810, the user clicks on that particular batch execution 810. This will open a second window on top of the first window, showing all the unit procedures 820 for that batch execution 810. To check on a few batch executions 810 at once, a corresponding number of new windows need to be opened on the screen. To go further down the levels to check on operations 830 and phases 840 for a number of batch executions 810, even more new windows need to be opened on top of each other on the same screen. The screen is quickly cluttered, earlier-opened windows become obscured, and it becomes confusing for users to know which window is showing which level element 820, 830, 840 for which batch execution 810.
Furthermore, it is common in batch manufacturing plants for trend data to be collected during performance of each batch execution so that a trend data set is collected from each completed batch execution. In this way, production characteristics of each completed batch execution of the industrial plant may be recorded for future use.
Users of a batch management function in a control system of a batch manufacturing plant often want to remember specific completed batch executions that had particularly good characteristics. This is important as the users can then try to replicate those specific completed batch executions when performing subsequent batch executions in order to achieve similar good characteristics. Currently, particularly good completed batch executions are recorded by manually writing down their batch execution reference numbers in a log book or on a white board in a control room. Remarks are frequently written down beside each reference number to describe the specific characteristics that made that particular batch execution worth noting. Besides good batch executions, users may also record poorly completed batch executions to serve as negative examples. Looking for a specific recorded completed batch execution is therefore a tedious process as users need to pore over all the recorded batch executions in order to find a specific one.
An uncompleted batch execution may be a batch execution that is reserved and pending performance, or may be a batch execution that is being performed but has not yet been completed. When an uncompleted batch execution is being performed, for a specific completed batch execution to serve as a reference for the uncompleted batch execution, trend data that has been collected from the completed batch execution should be shown as a reference trend together with current trend data of the uncompleted batch execution. In this way, a user can see how well the uncompleted batch execution is matching the completed batch execution or how far any deviations may be.
Currently, to display a reference trend while monitoring an uncompleted batch execution, a user opens a window in the batch management function to look for a specific completed batch execution reference number among a plurality of stored completed batch execution reference numbers. The user knows the specific reference number that is being sought by having previously looked it up in the log book or white board containing the list of manually recorded completed batch execution reference numbers. When the specific reference number is found, the user selects it and the trend data set corresponding to this specific completed batch execution is then displayed as a reference trend together with the display of the current trend data.
According to a first exemplary aspect, there is provided a method of displaying batch execution data of an industrial plant configured for performing a plurality of batch executions, each batch execution comprising a hierarchy of levels of elements, each level comprising at least one level element. The method comprises selecting a first level element in a first level window; and displaying in a second level window second level elements comprised by the selected first level element, the second level window being displayed within the first level window directly beneath the selected first level element without obscuring any other first level element in the first level window.
The method may further comprise selecting another first level element displayed in the first level window; and displaying in another second level window second level elements comprised by the another first level element, the another second level window being displayed within the first level window directly beneath the another first level element without obscuring any other first level element in the first level window.
The method may further comprise selecting a second level element in the second level window and displaying in a third level window third level elements comprised by the selected second level element, the third level window being displayed within the second level window directly beneath the selected second level element without obscuring any other second level element in the second level window.
The method may further comprise selecting another second level element in the second level window; and displaying in another third level window third level elements comprised by the another second level element, the another third level window being displayed within the second level window directly beneath the another second level element without obscuring any other second level element in the second level window.
The method may further comprise displaying the selected first level element in a topmost row of first level elements in the first level window when displaying the second level window.
The method may further comprise displaying a particular level element as a marked level element, the marked level element being a procedural element at which the batch execution is currently transitioning.
The method may further comprise flagging at least one completed batch execution among a plurality of completed batch executions. The flagging may comprise selecting a flag from a group of flags, each of the flags denoting a distinct batch execution characteristic.
The method may further comprise associating a reference trend with an uncompleted batch execution, the reference trend being a trend data set collected from a completed batch execution; and selectably displaying the reference trend together with displaying the current trend data of the uncompleted batch execution.
Associating the reference trend with the uncompleted batch execution may comprise selecting a particular flagged completed batch execution. The method may further comprise displaying a plurality of flagged completed batch executions for selection of the particular flagged completed batch execution therefrom.
The method may further comprise selecting a second trend data set as a second reference trend and displaying the second reference trend together with displaying the current trend data.
According to a second exemplary aspect, there is provided an apparatus for displaying batch execution data of an industrial plant configured for performing a plurality of batch executions, each batch execution comprising a hierarchy of levels of elements, each level comprising at least one level element. The apparatus comprises a window display module configured for displaying at least one second level window within a first level window such that upon selection of a first level element in the first level window, a corresponding second level window is displayed within the first level window directly beneath its corresponding first level element without obscuring any other first level element in the first level window, each second level window displaying second level elements comprised by its corresponding first level element.
The window display module may be further configured to display the selected first level element in a topmost row of first level elements in the first level window when the second level window is displayed.
The window display module may be further configured for displaying at least one third level window within a second level window, such that upon selection of second level element in the second level window, a corresponding third level window is displayed within the second level window directly beneath its corresponding second level element without obscuring any other second level element in the second level window, each third level window displaying third level elements comprised by its corresponding second level element
The window display module may further be configured to display a particular level element as a marked level element, the marked level element being a procedural element at which the batch execution is currently transitioning.
The apparatus may further comprise a flag module configured for flagging at least one completed batch execution among a plurality of completed batch executions by selecting a flag from a group of flags, each of the flags denoting a distinct batch execution characteristic.
The apparatus may further comprise an association module configured for associating a reference trend with an uncompleted batch execution, the reference trend being a trend data set collected from a completed batch execution; and a trend display module configured for displaying current trend data of the uncompleted batch execution and for selectably displaying the reference trend together with the current trend data.
The association module may be further configured for displaying a plurality of flagged completed batch executions for selection of a particular flagged completed batch execution therefrom for providing the reference trend.
The trend display module may be further configured for displaying a second reference trend together with the current trend data, the second reference trend being selected from a plurality of collected trend data sets.
For both aspects, the second level window may comprise a plurality of rows configured for single-row scrolling display using a scroll bar provided for the first level window. The second level window may be configured to display a predetermined maximum number of rows of second level elements at a time if the first level window is of limited size. The third level window may comprise a plurality of rows configured for single-row scrolling display using a scroll bar provided for the first level window. The third level window may be configured to display a predetermined maximum number of rows of third level elements at a time if the first level window is of limited size.
In order that the present invention may be fully understood and readily put into practical effect, an embodiment of the invention will now be described by way of non-limitative example, the description being with reference to the accompanying illustrative drawings, in which:
With reference to
In a batch manufacturing plant, it is often desirable to monitor a number of batch executions 161 at once, as shown in the exemplary screen shot of
In the method 900, to check on a particular batch execution or first level element 811 that is shown in a first level window 801, as depicted in the exemplary screen shot of
Similarly, the method 900 and apparatus 1000 allow a user to select a second level element 821 in the second level window 802 for expansion by clicking on its provided icon 829. Upon doing so, third level elements 830 comprised by the selected second level element 821 are displayed in a subsequent or third level window 803. The third level window 803 is displayed within the second level window 802, directly beneath the selected second level element 821, as shown in the exemplary screen shot in
Fourth level elements 840 may similarly be displayed in a subsequent fourth level window 804, as shown in the exemplary screen shot in
The method 900 and apparatus 1000 thus permit each subsequently opened level window 802, 803 or 804 to be displayed within its preceding level window, without obscuring other level elements in the preceding level window. This results in a progressive nest of windows being displayed whenever a user wishes to view each batch execution 811 in more detail by expanding subsequent level elements 811, 821, 831, for example as shown by the nest of level windows 801, 802, 803, 804 displayed in
The method 900 and apparatus 1000 are also configured to allow more than one level element for a same level to be displayed at any one time. For example, as shown in the exemplary screen shot of
To facilitate ease of viewing for users, a scroll bar 880 may be provided for the first level window 801 in order to view all contents that are further down within the first level window 801, as shown in
Within subsequent level windows 802, 803, 804, preferably no scroll bar 880 is provided because this would undesirably reduce the display area of each subsequent level window 802, 803, 804 opened. Instead, scroll buttons 881 to 886 are preferably provided to still allow scrolling within each subsequent level window 802, 803, 804. Preferably, the scroll buttons 881 to 886 are configured to “jump to top” 881, “jump to bottom” 886, move a page up 882, move a page down 885, move one row up 883 and move one row down 884. By providing the scroll bar 880 only for the first level window 801 and scroll buttons 881 to 886 for the subsequent level windows 802, 803, 804, a user-friendly and intuitive interface that also maximizes display area is provided to users.
To further simplify the display of batch execution data, each subsequent level window 802, 803, or 804 that is currently active (for example the third level window 803 in
To further improve clarity for users, any currently selected first level element 811 in a first level window, as shown in
In addition to displaying the level windows in a progressively nested manner, the method 900 and apparatus 1000 may further be configured to display a particular level element as a marked level element. The marked level element is a procedural element at which the batch execution is currently transitioning. For example, as shown in the exemplary screen shot of
As shown in
The apparatus 1000 may also comprise an association module 120 configured for associating a reference trend 142 with an uncompleted batch execution 302, in additional method steps 300 shown in
A trend display module 140 is provided to display the current trend data 144 so that a user may monitor how the uncompleted batch execution is performing. The trend display module 140 is also configured for selectably displaying the reference trend 142 together with displaying the current trend data 144. This may be done by superimposing the reference trend 142 on the current trend data 144, as shown in the exemplary screen shot 141 in
By displaying the reference trend 142 together with the current trend data 144, a user can attempt to match current trend data 144 to the reference trend 142 by adjusting appropriate production parameters of the uncompleted batch execution while it is being performed. In this way, the uncompleted batch execution that is being performed may achieve similar characteristics as the completed batch execution from which the reference trend 142 was obtained.
Where a flag module 160 is provided, a particular flagged completed batch execution 162 may be selected by a user for providing the reference trend 142 for association with an uncompleted batch execution 164. Accordingly, the association module 120 may be further configured to display a plurality of flagged completed batch executions 168 as shown in
In addition to selectably displaying the reference trend 142 together with the current trend data 144, 304, the trend display module 140 may also be configured to display a second reference trend 146 together with the current trend data 144. Unlike the reference trend 142 which has already been associated with the uncompleted batch execution, the second reference trend 146 is a second trend data set collected from a second completed batch execution 176 which has not been associated with the uncompleted batch execution. This configuration of the trend display module 140 is to allow users to call up ad-hoc reference trends for comparison with the current trend data 144 if need be. To do so, as shown in
Whilst there has been described in the foregoing description preferred embodiments of the present invention, it will be understood by those skilled in the technology concerned that many variations or modifications in details of design or construction may be made without departing from the present invention.