1、DESIGN PATTERNSFOR FLEXIBLE MANUFACTURINGBrandl_finalpages.book Page I Tuesday, October 31, 2006 3:54 PMBrandl_finalpages.book Page II Tuesday, October 31, 2006 3:54 PMDESIGN PATTERNSFOR FLEXIBLE MANUFACTURINGbyDennis BrandlBrandl_finalpages.book Page III Tuesday, October 31, 2006 3:54 PMCopyright 2
2、007 by ISAInstrumentation, Systems, and Automation Society67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All rights reserved.Printed in the United States of America.10 9 8 7 6 5 4 3 2ISBN-13: 978-1-55617-998-3ISBN-10: 1-55617-998-7No part of this work may be reproduced, stored in a
3、retrieval system, or transmitted in anyform or by any means, electronic, mechanical, photocopying, recording or otherwise,without the prior written permission of the publisher.NoticeThe information presented in this publication is for the general education of the reader.Because neither the author no
4、r the publisher has any control over the use of theinformation by the reader, both the author and the publisher disclaim any and all liabilityof any kind arising out of such use. The reader is expected to exercise sound professionaljudgment in using any of the information presented in a particular a
5、pplication.Additionally, neither the author nor the publisher have investigated or considered theaffect of any patents on the ability of the reader to use any of the information in aparticular application. The reader is responsible for reviewing any possible patents thatmay effect any particular use
6、 of the information presented.Any references to commercial products in the work are cited as examples only. Neither theauthor nor the publisher endorses any referenced commercial product. Any trademarks ortradenames referenced belong to the respective owner of the mark or name. Neither theauthor nor
7、 the publisher makes any representation regarding the availability of anyreferenced commercial product at any time. The manufacturers instructions on use of anycommercial product must be followed at all times, even if in conflict with the information inthis publication.Library of Congress Cataloging
8、-in-Publication Data in processBrandl, Dennis.Design patterns for flexible manufacturing / by Dennis Brandl.p. cm.ISBN 978-1-55617-998-3 (pbk.)1. Flexible manufacturing systems. 2. ProductioncontrolStandardsUnited States. I. Title. TS155.65.B73 2006658.51dc222006035821Brandl_finalpages.book Page IV
9、Tuesday, October 31, 2006 3:54 PMTo Diane for all of her support and understanding. Brandl_finalpages.book Page V Tuesday, October 31, 2006 3:54 PMBrandl_finalpages.book Page VI Tuesday, October 31, 2006 3:54 PMVIICONTENTSList of Figures . XIIIList of TablesXVIIPrefaceXIXAcknowledgmentsXXIIIAbout th
10、e Author XXV1 Manufacturing Control 11.1 Production Processes 21.1.1 Batch Manufacturing 31.1.2 Continuous Manufacturing 31.1.3 Discrete Manufacturing 41.2 ISA 88 Productivity Increases 41.3 S88 and NS88 Design Patterns 51.4 Reading This Book 62 Design Patterns 112.1 Class Diagrams 122.2 State Diagr
11、ams 142.3 Sequence Diagrams 153 Recipe/Equipment Separation .173.1 Control Types 183.2 Recipes 203.2.1 Recipe Elements 213.2.2 Recipe Types 223.2.3 Recipe/Equipment Sequence 263.2.4 Nonproduct Recipes 26Brandl_finalpages.book Page VII Tuesday, October 31, 2006 3:54 PMVIII CONTENTS3.3 Equipment 283.3
12、.1 Enterprise 293.3.2 Site 293.3.3 Area 293.3.4 Production Line 293.3.5 Production Unit 303.3.6 Storage Zone 303.3.7 Work Center 303.3.8 Equipment Structure for Recipe Control 313.3.9 Process Cell 313.3.10 Units 343.3.11 Equipment Phases 353.3.12 Equipment Tags 363.4 Campaigns 383.5 Trains 393.6 Sum
13、mary 404 Master and Control Recipe Procedures414.1 Recipe Procedure Hierarchy 424.1.1 Unit Procedures 424.1.2 Unit Recipes 434.1.3 Operations 444.1.4 Recipe Phases 444.1.5 Recipe Procedure Collapsing and Expansion 464.2 Recipe Procedure Diagrams 484.2.1 PFC Diagrams 484.2.2 Equipment Allocation Cont
14、rol 504.2.3 Unit-to-Unit Material Transfers and Synchronization 524.3 Control Recipes 534.4 How Much in the Recipe, How Much in the Equipment 544.5 Modes, States, and Commands 574.5.1 States 574.5.2 Commands 584.5.3 Modes 604.6 Just a Calculation Phase 644.7 Summary 655 S88 Pattern for Automated Equ
15、ipment.675.1 Process Cells 715.1.1 Process Cell Coordination Control 725.1.2 Recipe Procedural Control 745.1.3 Process Cell Data Collection 765.1.4 Design Pattern Rules for S88 Process Cells 77Brandl_finalpages.book Page VIII Tuesday, October 31, 2006 3:54 PMCONTENTS IX5.2 Units 785.2.1 Unit Boundar
16、y Example 805.2.2 Unit Coordination Control 815.2.3 Unit Recipe Procedural Control 875.2.4 Unit Data Collection and Manual Interface 895.2.5 Unit Classes 905.2.6 Design Pattern Rules for S88 Units 915.3 Equipment Modules 915.3.1 Equipment Phase Modes and States 935.3.2 Equipment Module States and Mo
17、des 965.3.3 Equipment Module Control 975.3.4 Equipment Module Example 1025.3.5 Phases for Calculations and Communications 1025.3.6 Bumpless Control Using Phases 1045.3.7 Design Pattern Rules for S88 Equipment Modules 1075.4 Control Modules 1075.4.1 Control Module Modes and States 1105.4.2 Common Con
18、trol Module Logic 1125.4.3 Complex Control Modules 1155.4.4 Control Module Libraries 1155.5 Why Equipment Modules and Control Modules? 1165.6 Material Transfers 1195.6.1 Simple Transfer Pattern 1205.6.2 Header Transfer Pattern 1205.7 Summary 1256 Patterns for Manual Operations.1296.1 Recipe-Equipmen
19、t Separation 1296.2 SOPs in Manual 1306.3 Equipment Phase to MPP Mapping 1336.4 Map MPPs to Equipment 1336.5 Unit with No Fixed Equipment 1346.6 Dont Put SOP Text into Recipes 1356.7 MPP Instructions 1356.8 Equipment Phases 1366.9 Procedure Automation and Manual Operations 1376.10 Incremental Automa
20、tion 1406.10.1 Control Step Incremental Automation 1416.10.2 Equipment Phase Incremental Automation 1426.10.3 Unit Incremental Automation 1426.11 Summary 142Brandl_finalpages.book Page IX Tuesday, October 31, 2006 3:54 PMX CONTENTS7 Nonstop Production .1457.1 Nonstop Production Examples 1477.2 Nonst
21、op Production Lines 1477.3 NS88 Unit Pattern 1507.4 NS88 Phase State Model 1547.5 General-Purpose Equipment State and Model 1547.6 NS88 Filling Unit Example 1557.7 Applying the NS88 Design Pattern 1567.7.1 Nonstop Product Switchover 1587.7.2 Batch B1 Finishing Fill 1607.7.3 Batch B2 Starting Fill 16
22、17.7.4 Batch B2 Finishing Coating 1627.7.5 Finished Product Switchover 1627.8 Generating the Right NS88 Batch Record 1647.9 Special Situations 1657.9.1 High Speed Material Flow 1657.9.2 Cannot Detect the End of Batch 1667.9.3 Cleaning Lines 1677.9.4 Line Startup and Shutdown 1687.9.5 Clearing Units
23、1697.9.6 Sizing the Units 1707.9.7 When You Just Have to Stop 1707.10 Switching Conveyor Lines and Valve Arrays 1727.10.1 One-to-Many and Many-to-One Paths 1757.10.2 Many-to-Many Material Switches 1777.10.3 Multiple Switching Paths 1777.10.4 Switching Units 1797.11 Summary 1808 Continuous Production
24、 Processes 1838.1 Continuous Production Example 1848.2 Continuous Production Design Pattern 1848.3 Continuous Unit Partitioning and Recipes 1858.4 NS88 Continuous Production Product Switchover 1878.5 Continuous Startup and Shutdown 1908.6 Continuous Production Valve Arrays 1908.7 NS88 Continuous Pro
25、duction Summary 191Brandl_finalpages.book Page X Tuesday, October 31, 2006 3:54 PMCONTENTS XI9 Splitting and Merging Batches.1939.1 Splitting and Merging Design Pattern 1959.2 Recipes for Splitting and Merging Batches 1969.2.1 Merge Batches 1969.2.2 Splitting Batches 1969.3 Transferring Materials 19
26、710 Summary.199Index.203Brandl_finalpages.book Page XI Tuesday, October 31, 2006 3:54 PMBrandl_finalpages.book Page XII Tuesday, October 31, 2006 3:54 PMXIIILIST OF FIGURES31 The recipe/equipment separation process. 1832 The three types of control in S88 Design Patterns. . 1933 Implementations of co
27、ntrol types. 2034 Elements of a recipe. 2335 A hierarchy of recipe types. 2336 Recipe/equipment separation of functions 2637 Recipe/equipment information exchange. 2738 ISA 95 equipment hierarchy. . 2839 Equipment hierarchy as seen by a recipe. 32310 The process cell. . 32311 Typical area-level prod
28、uction routing. 33312 A process-cell hierarchy. 34313 Recipe to equipment linkage. 36314 Multiple recipes using the same equipment 37315 Equipment phases and equipment tags. 38316 Three trains within a process cell. 4041 Master and control recipes. 4242 Recipe elements and procedural hierarchy 4343
29、Unit procedure, operation, and recipe phase example 4544 Expanded recipe procedure examples 4745 Different ways to collapse the recipe procedure 4746 Procedure function chart elements 4947 Explicit transaction. . 4948 Recipe operation with a loop. 5049 Multiple recipes requiring the same units. 5141
30、0 Example of allocation and deallocation use 51411 Example of transfer synchronization. 53412 Configuring a control recipe for a batch. 54413 All product-related procedures in the recipe. 55414 Operations in the equipment. . 55415 The unfortunate reality of laying S88 onto an existing system. 56416
31、Sample procedural control state model. 57Brandl_finalpages.book Page XIII Tuesday, October 31, 2006 3:54 PMXIV LIST OF FIGURES417 Propagation of a recipe hold. . 58417 Propagation of a recipe hold. . 60419 Propagation of an equipment-initiated stop 61420 Stop sequence 61421 Procedural element modes.
32、 62422 Semiautomatic operator control. . 63423 Procedural element states and modes. . 6451 Types of control in automated systems. 6852 Some interactions of types of control. . 7053 Automated control design pattern. 7054 Objects for automated control. 7155 Process cell structure. 7356 Design pattern
33、elements of a unit 7957 A three-unit process cell. 8058 Unit boundaries 8259 Shared equipment modules and control modules. 83510 One-to-one unit to equipment module phase mapping. 84511 Equipment modules with multiple phases. . 84512 General-purpose charge phase. 85513 Unit recipe procedural control
34、. 88514 Unit class example 90515 Equipment module structure. 93516 Typical equipment modules. 94517 Sample equipment module hierarchy 94518 Sample equipment phase state and mode model. . 95519 Equipment module pattern 96520 Sample equipment state. 97521 Complex equipment module states. 97522 Equipme
35、nt module procedure control functions. . 98523 Equipment module with multiple phases 99524 SFC procedure diagram. 100525 Equipment module EM53-E. 103526 Calculations performed in a shared equipment module. 103527 Sequence diagram for communication phases. . 105528 Environmental phases crossing opera
36、tion boundaries. . 105529 Environment control using persistent actions. 106530 Control modules within Unit U53. 110531 All low-level control modules within a process cell. . 111532 Sample control module state models. 111533 Sample states for a valve. 113Brandl_finalpages.book Page XIV Tuesday, Octob
37、er 31, 2006 3:54 PMLIST OF FIGURES XV534 Control modules, the lowest-level of the equipment hierarchy113535 Sample valve control module representation 113536 The equipment and control module pattern. 118537 Simple material transfer paths. 119538 Transfer phases in units. 121539 Single-use and multip
38、le-use header transfers. . 121540 Sample complex switching equipment module. . 123541 Control hierarchy and equipment hierarchy. . 12761 Recipe and equipment phases 13162 Manual execution of equipment phases 13163 Objects in manual operations 13364 Mapping SOPs to units. 13465 MPP instructions. . 13
39、666 Basic pattern for manual interactions 13967 Control action automation 14168 A unit with manual and automated phases. 14371 Electronic board assembly 14672 Nonstop continuous production. 14873 Production runs in continuous production. 14874 NS88 rules. 15075 The NS88 Design Pattern. 15176 End-of-
40、batch detection and propagation. 15377 Example phase state model 15478 General-purpose NS88 equipment state model. 15679 NS88 pattern for a filling unit 159710 Sample nonstop work center. 159711 Sample recipe for a nonstop process cell. 160712 Time T1 with one batch running. 160713 Time T2 with new
41、batch approaching. 161714 Time T3 product switchover in FILL #1. 162715 Time T4 product switchover in COAT #1 163716 Time T5 product switchover complete. . 163717 Using reporting units to report on a batch 165718 Early detection of EOB. 167719 Sequence diagram for EOB detection and calculation. . 16
42、7720 Using a cleaning recipe between products. . 168721 Sample startup recipe. 169722 Example of a buffering unit. 171723 Buffering in a discrete process 171724 HOLD sequence diagram for units with buffers. . 172Brandl_finalpages.book Page XV Tuesday, October 31, 2006 3:54 PMXVI LIST OF FIGURES725 S
43、witching path using a multi-use unit. 173726 Switching path using a NS88 equipment module. 173727 NS88 switching path pattern 173728 One-to-four switching path conveyor system. 176729 Sequence diagram for the one-to-four switch 176730 Many-to-many switching conveyor system. 178731 A four-batch examp
44、le. 178732 Unit diagram with NS88 switching units. 17981 A sample of a continuous process. . 18582 Sample parameter changes for a switchover 18583 NS88 pattern for nonstop continuous production. . 18684 Units within a production unit 18685 Typical NS88 continuous recipe. 18786 A typical NS88 product
45、 switchover recipe. 18887 Recipes before product switchover. 18988 Switching products. 18989 Units F1 and C1 switched. . 189810 Switching to the new batch. 19191 Typical batch-merging situation. . 19492 Typical batch-splitting situation. . 19493 Pattern for merging and splitting batches. 19694 Scope
46、 of upstream and downstream batches. 198Brandl_finalpages.book Page XVI Tuesday, October 31, 2006 3:54 PMXVIILIST OF TABLES31 Equipment Hierarchy Equivalent Levels 3141 Recipe Procedural Element States 5942 Recipe Procedural Element Commands. 6243 Sample Procedural Control Modes 6351 Design Pattern
47、Rules for S88 Process Cells. 7752 Design Pattern Rules for S88 Units 9153 SFC Action Qualifiers . 10154 Design Pattern Rules for S88 Equipment Modules 10855 Examples of Control Module Classes. 11756 Design Pattern Rules for S88 Control Modules 11871 Sample Equipment Phase States. 15572 General-Purpo
48、se NS88 Equipment State Definitions. 15773 General-Purpose NS88 Equipment Mode Definitions . 158Brandl_finalpages.book Page XVII Tuesday, October 31, 2006 3:54 PMBrandl_finalpages.book Page XVIII Tuesday, October 31, 2006 3:54 PMXIXPREFACEI have been fortunate to be able to participate in the develo
49、pment ofmultiple control projects, the architecture and design of multiple batchsystems, and most importantly, the development of the ISA 88 BatchControl standards. The ISA 88 standards were a milestone in automationand control-system design because they provided, for the first time, a wellthought-out approach to flexible manufacturing that was accepted byautomation, control, and process engineers. The standards provided aconsistent model f
