calidad

1. Industrial IT Quality Control 4.0
powered by 800xA extended automation
Theory of Operation Guide
System Version 4.0
3BUS208222 R4001
i

2. NOTICE
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that may
appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB be liable
for incidental or consequential damages arising from use of any software or hardware
described in this document.
This document and parts thereof must not be reproduced or copied without written permission
from ABB, and the contents thereof must not be imparted to a third party nor used for any
unauthorized purpose.
The software or hardware described in this document is furnished under a license and may be
used, copied, or disclosed only in accordance with the terms of such license.
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low
Voltage Directive 72/23/EEC.
Copyright © 2005 ABB
All rights reserved.
Release: January 2005
Document Number:
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3BUS208222 R4001
3BUS208222 R4001

3. TRADEMARKS
Registrations and trademarks used in this document include:
•
Windows is a registered trademark of Microsoft Corporation.
•
Acrobat Reader is a registered trademark of Adobe Systems Inc.
•
IndustrialIT is a trademark of ABB.
3BUS208222 R4001
iii

4. About This Book
General
This book describes the theory of operation and troubleshooting tools and procedures for
Industrial IT Quality Control 4.0. The targeted audience includes ABB Project and Service
engineers. The user of this guide is expected to have experience with ABB IndustrialIT
products and the Industrial IT Quality Control 4.0 and to have attended the appropriate
training courses.
Intended User
Use of Warning, Caution, Information, and Tip Icons
This publication includes Warning, Caution, and Information where appropriate to point out
safety related or other important information. It also includes Tip to point out useful hints to
the reader. The corresponding symbols should be interpreted as follows:
Electrical warning icon indicates the presence of a hazard, which could result in electrical
shock.
Warning icon indicates the presence of a hazard, which could result in personal injury.
Caution icon indicates important information or warning related to the concept discussed in
the text. It might indicate the presence of a hazard, which could result incorruption of
software or damage to equipment/property.
Information icon alerts the reader to pertinent facts and conditions.
Tip icon indicates advice on, for example, how to design your project or how to use a certain
function.
Although Warning hazards are related to personal injury, and Caution hazards are associated
with equipment or property damage, it should be understood that operation of damaged
equipment could, under certain operational conditions, result in degraded process
performance leading to personal injury or death. Therefore, comply fully with all Warning
and Caution notices.
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5. Document Conventions
The following conventions are used for the presentation of material:
1. The words in names of screen elements (for example, the title in the title bar of a window, the
label for a field of a dialog box) are initially capitalized.
2. Capital letters are used for the name of a keyboard key if it is labeled on the keyboard. For
example, press the “ENTER” key.
3. Lowercase letters are used for the name of a keyboard key that is not labeled on the keyboard. For
example, the “space bar”, “comma” key, and so on.
4. Press “CTRL+C” indicates that you must hold down the “CTRL” key while pressing the “C” key.
In this case, “CTRL+C” copies the selected object.
5. Press “ESC E C” indicates that you press and release each key in sequence. In this case, “ESC E
C” copies the selected object.
6. The names of push and toggle buttons are boldfaced. For example, click “OK”.
7. The names of menus and menu items are boldfaced. For example, the “File Menu”.
8. The following convention is used for menu operations: “MenuName > MenuItem >
CascadedMenuItem”. For example: select “File > New > Type”.
9. The “Start menu” name always refers to the “Start” menu on the Windows Task Bar.
10. System prompts or messages are shown in the Courier font. For example, if the user enters a value
out of range, the system might reply with the following message:
Entered value is not valid. The value must be 0 to 30.
11. User responses or inputs are shown in the boldfaced Courier font. For example, a user may be
required to enter the string “TIC132” in a field. The string is shown as follows in the procedure:
TIC132
12. Variables are shown using lowercase letters.
sequence name
3BUS208222 R4001
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6. Terminology
The following is a list of terms associated with the Theory of Operation Guide that you
should be familiar with. The list contains terms and abbreviations that are unique to ABB or
have a usage or definition that is different from standard industry usage.
Term
Description
ActiveX
Microsoft standard for integration of user interface components, based on
definition of software interfaces.
Aspect
An aspect is a description of some properties of a real world entity. The
properties described could be mechanical layout, how the object is
controlled, a live video image, name of the object etc. In the Aspect
Integrator Platform is an aspect residing in an Aspect Object. Some
examples are circuit diagram, process display, and control logic.
Aspect Objects
A computer representation of a real world entity like a pump, a valve, an
order or a virtual object like a service. This computer representation is
implemented by the Aspect Integrator Platform. An Aspect Object works like
an information container for its aspects.
Aspect Server
PC server that hosts the various QCS Object/Aspects and serves as the
primary gateway to external aspects systems.
Connectivity
Server
PC server that hosts MeasureIT and ControlIT applications and serves as
the primary “connection” between the QCS LAN and the outside world.
IndustrialIT
IndustrialIT is ABB’s solution, that creates a business enterprise where your
plant automation, asset optimization, and collaborative business systems
are seamlessly linked in real time.
Industrial IT
Quality Control 4.0
ABB’s Quality Control Solution consisting of MeasureIT Scanners/Sensors,
ControlIT controllers (AC450, AC800M, and/or PC), ProfileIT actuators,
OperateIT Process Portal consoles, and MeasureIT /ControlIT software
applications. Integrated with Pulp and Paper Making Suite 3.0.
Node
A computer communicating an a network e.g. the Internet, Plant, Control or
IO network. Each node typically has a unique node address with a format
depending on the network it is connected to.
OPC
An application programming interface defined by the OPC Foundation. The
standard defines how to access large amounts of real-time data between
applications. The OPC standard interface is used between
automation/control applications, field system/devices and business/office
applications.
OperateIT
The name for the collection of products for daily operation and supervision
of an automated process.
Plant Explorer
An application that is used to create, delete and organize Aspect Objects
and Aspects within the Aspect Integrator Platform. The plant explorer
organizes the Aspect Objects in structures of the plant.
Process Portal A
Product containing functionality for efficient control and supervision of an
automated process. Key functions are presentation of process graphics,
process dialogs and presentation of alarms and trends.
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7. Term
Description
Property
A data field on an aspect on Aspect Object that can be accessed through
OPC using the standard Aspect Object reference syntax. A data field on an
ActiveX control accessible from the Visual Basic editor.
Structure
A hierarchical tree organization of Aspect Objects. Each structure is used to
define a certain kind of relation between Aspect Objects. The functional
structure for example, defines how a function can be divided into sub
functions, the location structure defines how different objects are executed
by tasks, controllers etc. An Aspect Object can be located in several
structures, for example both in a functional structure and in a location
structure.
View
An Aspect can have several ways to be presented depending on the task
performed, like viewing or configuration. Each presentation form is called a
view.
3BUS208222 R4001
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8. Abbreviations
Term
Description
CD
Compact Disk
CPU
Central Processing Unit
DHCP
Dynamic Host Configuration Protocol
DNS
Domain Name Server
DPI
Dots per inch
GB
GB Gigabyte
IP address
Internet Protocol address
MB
Megabyte
Mbps
Megabits per second
MHz
Megahertz
NetBIOS
Network Basic Input Output System
NTFS
NT File System
OEM
Original Equipment Manufacturing
OPC
OLE for Process Control
OLE
Object Linking and Embedding
OS
Operating System
PC
Personal Computer
RAM
Random Access Memory
SCSI
Small Computer System Interface
SVGA
Super Video Graphics Adapter
TCP/IP
Transmission Control Protocol/Internet Protocol
WINS
Windows Internet Name Services
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3BUS208222 R4001

9. Related Documentation
Category
Title
800xA System
Installation
Industrial IT, 800xA System
Version 4.0, Automated
Installation
3BSE034679R4001
Industrial IT, 800xA System
Version 4.0, Installation
3BSE034678R4001
Industrial IT, 800xA System
Version 4.0, Upgrade and
Installation
3BSE036342R4001
Industrial IT, 800xA System
Version 4.0, Post
Installation Setup
3BUA000156R4001
800xA System
Administration
Industrial IT, 800xA
System, Administration and
Security
3BSE037410R4001
800xA
Software
Industrial IT, 800xA
System, Automation
System Network Design
and Configuration
3BSE034463R4001
Industrial IT, 800xA
System, System Guide
3BSE038018R4001
Industrial IT, 800xA
System, Release Notes
3BSE038357R4001
Industrial IT Quality Control
4.0, Installation Guide
3BUS208220R4001 -This book describes how
you install the Industrial IT Quality Control 4.0
Industrial IT Quality Control
4.0, Upgrade Guide
3BUS208226R4001 -This book describes how
you upgrade from Industrial IT Quality Control
3.0 to Industrial IT Quality Control 4.0
Industrial IT Quality Control
4.0, Administrator’s Guide
3BUS208217R4001 - This book describes how
you configure the Industrial IT Quality Control
4.0 application and how you then perform
maintenance.
Industrial IT Quality Control
4.0, Operations User Guide
3BUS208221R4001 - This book describes how
an operator can control and operate Industrial
IT Quality Control 4.0.
Industrial IT Quality Control
4.0, Engineering Methods
Reference Manual
3BUS208218R4001 - This book is a guide for
plant engineering functions related to Industrial
IT Quality Control 4.0.
Industrial IT Quality Control
4.0, Theory of Operation
Guide
3BUS208222R4001 - This book describes the
theory of operation for Industrial IT Quality
Control 4.0 and provides troubleshooting
guidance.
Industrial IT
Quality Control
4.0 Installation
3BUS208222 R4001
Description
ix

10. Category
Description
Industrial IT
Quality Control
4.0 Features
Industrial IT Quality Control
4.0, CD Tuning Guide
3BUS208224R4001 - This book describes how
to setup and tune the Industrial IT Quality
Control 4.0 CD Control feature.
Industrial IT Quality Control
4.0, MD Tuning Guide
3BUS208223R4001 - This book describes how
to setup and tune the Industrial IT Quality
Control 4.0 MD Control features.
Industrial IT Quality Control
4.0, Service Workstation
Getting Started Manual
3BUS208230R4001 - This book describes how
to install and configure the Industrial IT Quality
Control 4.0 Smart Platform Service Workstation
Industrial IT Quality Control
4.0, Coat Weight &
Computed Sensors Manual
3BUS208229R4001 - This book describes how
to configure and verify coat weight, calculated
measurements and synchronized scanning.
Industrial IT Quality Control
4.0, Color Control Guide
3BUS208227R4001 - This book describes how
to configure, verify and tune Color Controls.
Industrial IT Quality Control
4.0, Multi-Ply Controls
Tuning Guide
3BUS208228R4001 - This book describes how
to configure, verify and tune Multi-Ply Controls.
Industrial IT Quality Control
4.0, Color Measurement
Operations Use Guide
x
Title
3BUS208232R4001 - This book describes how
to operate Color Measurement.
3BUS208222 R4001

11. Table of Contents
CHAPTER 1 THEORY OF OPERATION ................................................................... 23
1.1
Overview .............................................................................................................................23
1.2
Physical Architecture.........................................................................................................23
1.2.1
Devices...................................................................................................................23
1.3
Software Package Deployment..........................................................................................24
1.4
Application Architecture ...................................................................................................25
1.4.1
Startup and Shutdown ............................................................................................25
Client Connectivity ................................................................................................26
1.4.2
Quality Control PC Applications...........................................................................27
1.4.3
Scanners, Sensors and Advanced Scanning...........................................................27
Operation ...............................................................................................................28
Configuration and Startup......................................................................................32
1.4.4
Production Accumulation ......................................................................................32
1.4.5
Reporting ...............................................................................................................33
1.5
Networking..........................................................................................................................33
1.6
Job Order Configuration...................................................................................................33
1.6.1
Overview................................................................................................................33
1.6.2
Database.................................................................................................................33
1.6.3
Configuration File Generation ...............................................................................34
Overview................................................................................................................34
XSLT Transforms ..................................................................................................34
Main.xslt ................................................................................................................34
DirectStruct.xslt .....................................................................................................35
1.6.4
Configuration File Deployment .............................................................................39
Overview................................................................................................................39
Graphical User Interface ........................................................................................40
Directory structure at configuration Tool PC ........................................................40
Destination Directory Structure .............................................................................42
Actions ...................................................................................................................44
1.6.5
Troubleshooting .....................................................................................................44
General...................................................................................................................44
Configuration File Deployment .............................................................................44
1.7
OPC Server .........................................................................................................................45
1.7.1
Overview................................................................................................................45
1.7.2
Role of OPC...........................................................................................................45
1.7.3
Data Dictionary......................................................................................................45
1.7.4
Publishing ..............................................................................................................45
1.8
OPC Transporter ...............................................................................................................47
1.9
OPC Direct IT ......................................................................................................................47
1.9.1
Overview................................................................................................................47
1.10 Tag Lookup .........................................................................................................................47
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12. 1.10.1
1.10.2
1.10.3
1.10.4
Overview................................................................................................................47
Usage......................................................................................................................50
Configuration .........................................................................................................50
Startup.xml.............................................................................................................50
HSI server XML file ..............................................................................................52
HSI tags XML file .................................................................................................53
Revision ID (RevID)..............................................................................................54
Troubleshooting .....................................................................................................54
Task Manager ........................................................................................................55
Debug Message Viewer (ABB Debug Client).......................................................55
Windows Event Viewer .........................................................................................55
OPC Direct IT View................................................................................................55
OPC Inspector........................................................................................................55
TagLookUp Viewer ...............................................................................................55
1.11 Startup Engine....................................................................................................................57
1.11.1 Overview................................................................................................................57
1.11.2 Usage......................................................................................................................57
1.11.3 Configuration .........................................................................................................57
1.12 System Status Reporting....................................................................................................57
1.12.1 Overview................................................................................................................57
1.12.2 Configuration .........................................................................................................57
1.13 DCOM .................................................................................................................................58
1.13.1 Overview................................................................................................................58
1.13.2 Usage......................................................................................................................58
1.13.3 Configuration .........................................................................................................58
CHAPTER 2 ASPECTS AND OBJECTS ................................................................... 60
2.1
Overview .............................................................................................................................60
2.2
Object Type Structure .......................................................................................................60
2.3
Aspect categories and Filtering.........................................................................................60
2.4
Quality control aspect functionality .................................................................................61
2.5
Process Graphics ................................................................................................................62
2.5.1
Overview................................................................................................................62
2.5.2
Tag Lookup............................................................................................................62
2.6
Grade Code Handling ........................................................................................................62
2.6.1
Overview................................................................................................................62
2.6.2
Usage......................................................................................................................62
2.6.3
Configuration .........................................................................................................62
2.7
Coldstart File Handling .....................................................................................................62
2.7.1
Overview................................................................................................................62
2.7.2
Usage......................................................................................................................62
2.7.3
Configuration .........................................................................................................62
2.8
MD Control .........................................................................................................................62
2.8.1
Overview................................................................................................................62
2.8.2
Configuration .........................................................................................................63
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13. 2.8.3
2.8.4
2.9
AC800M Control Project.......................................................................................63
AC800M Control Libraries....................................................................................63
Operator Interface Configuration...........................................................................63
Default Tuning and Configuration Data ................................................................64
OPC Transporter Configuration.............................................................................64
Project Configuration File .....................................................................................64
Configuration Verification.....................................................................................65
Operation Verification ...........................................................................................67
CD Control..........................................................................................................................69
2.9.1
Overview................................................................................................................69
2.9.2
Application Framework Dependencies..................................................................70
ABB QCS Service..................................................................................................70
OPC Publishing......................................................................................................70
OPC Transporter Service .......................................................................................71
TagsLookup ...........................................................................................................71
ABB Health Watch ................................................................................................73
2.9.3
Configuration .........................................................................................................74
Required Job Order Information............................................................................74
Deployment Directory Structure............................................................................75
XML Documents ...................................................................................................76
2.9.4
Interface to Dependent Application.......................................................................77
Frame and Sensor Transporters .............................................................................77
Actuator Transporters ............................................................................................78
Grade Data Transporter .........................................................................................78
2.9.5
Verify Configuration and Operation......................................................................79
QC Server Node.....................................................................................................79
Process Portal Functional Structure.......................................................................80
Error/Event Log File..............................................................................................81
2.10 CD Control Coater Operation ..........................................................................................82
2.10.1 Overview................................................................................................................82
2.10.2 Application Framework Dependencies..................................................................82
ABB QCS Service..................................................................................................82
OPC Publishing......................................................................................................83
OPC Transporter Service .......................................................................................83
TagsLookup ...........................................................................................................84
ABB HealthWatch .................................................................................................84
2.10.3 Configuration .........................................................................................................85
Required Job Order Information............................................................................85
Deployment Directory Structure............................................................................86
XML Documents ...................................................................................................86
2.10.4 Interface to Dependent Application.......................................................................87
CD Control.............................................................................................................87
Grade Data .............................................................................................................87
2.10.5 Verify Configuration and Operation......................................................................88
QC Server Node.....................................................................................................88
Process Portal Functional Structure.......................................................................89
Error/Event Log File..............................................................................................90
2.11 Local Variability (LV) Control .........................................................................................91
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14. 2.11.1
2.11.2
2.11.3
2.11.4
2.11.5
Overview................................................................................................................91
Application Framework Dependencies..................................................................91
ABB QCS Service..................................................................................................91
OPC Publishing......................................................................................................92
OPC Transporter Service .......................................................................................92
TagsLookup ...........................................................................................................92
ABB HealthWatch .................................................................................................94
Configuration .........................................................................................................94
Required Job Order Information............................................................................94
Deployment Directory Structure............................................................................95
XML Documents ...................................................................................................95
Interface to Dependent Application.......................................................................96
Verify Configuration and Operation......................................................................96
QC Server Node.....................................................................................................96
Process Portal Functional Structure.......................................................................98
Error/Event Log File..............................................................................................98
2.12 CD Actuator Agent.............................................................................................................99
2.12.1 Overview................................................................................................................99
2.12.2 Application Framework Dependencies..................................................................99
ABB QCS Service..................................................................................................99
OPC Publishing....................................................................................................100
OPC Transporter Service .....................................................................................100
TagsLookup .........................................................................................................101
2.12.3 Configuration .......................................................................................................101
Required Job Order Information..........................................................................101
Deployment Directory Structure..........................................................................103
XML Documents .................................................................................................104
2.12.4 Interface to Dependent Application.....................................................................105
2.12.5 Verify Configuration and Operation....................................................................105
QC Server Node...................................................................................................105
Process Portal Functional Structure.....................................................................107
Error/Event Log File............................................................................................108
CHAPTER 3 TROUBLESHOOTING ........................................................................ 110
3.1
Quality Control Diagnostics Aspect................................................................................110
3.1.1
Configuration .......................................................................................................110
3.2
Debug Message Viewer ....................................................................................................111
Key.......................................................................................................................111
3.2.2
Application Menu ................................................................................................112
Mode ....................................................................................................................112
Activity ................................................................................................................113
3.3
Windows Event Viewer....................................................................................................114
3.4
System Status Viewers .....................................................................................................114
3.4.1
Quality Control Status Viewer.............................................................................114
3.4.2
Nodes Status Viewer............................................................................................115
3.4.3
AC800M Controller Status Viewer .....................................................................115
3.5
License Viewer..................................................................................................................115
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15. 3.6
Task Manager...................................................................................................................116
3.7
OPC Inspector ..................................................................................................................117
3.8
OPC Direct IT Viewer.......................................................................................................117
3.8.1
Top Window - Active OPC Server Monitors ......................................................118
3.8.2
Bottom Window – Active Data Points.................................................................119
3.9
Control Builder.................................................................................................................121
3.10 Measurement Spreadsheets.............................................................................................121
3.11 Service Workstation.........................................................................................................121
3.12 Performance Monitor ......................................................................................................121
3.13 Collecting Information for Technical Support..............................................................121
3.13.1 Information to Collect..........................................................................................121
3.13.2 How To ................................................................................................................122
Screen Captures ...................................................................................................122
Debug Message Viewer Contents........................................................................122
Event Log Contents .............................................................................................122
3.14 Trouble Shooting Flowcharts..........................................................................................123
APPENDIX A. OPC TRANSPORTER ........................................................................ 128
A.1 Introduction ......................................................................................................................128
A.1.1Purpose ......................................................................................................................128
A.1.2Overview ...................................................................................................................128
A.1.3Limitations, Restrictions, Caveats.............................................................................128
A.1.4XML Basics...............................................................................................................128
A.2 Transporter File ...............................................................................................................129
A.2.1File Content ...............................................................................................................129
A.2.2Element Definitions...................................................................................................130
<transporter>........................................................................................................130
<sourceOPC> & <targetOPC> ............................................................................131
<group>................................................................................................................131
<branch> ..............................................................................................................132
<input> & <output>.............................................................................................133
<assign> ...............................................................................................................133
<quality >.............................................................................................................134
<timestamp> ........................................................................................................134
<transport >..........................................................................................................135
<breakArray>.......................................................................................................136
<makeArray> .......................................................................................................137
<breakFlag> .........................................................................................................138
<makeFlag> .........................................................................................................139
<trigger> & <triggeredBy>..................................................................................140
<watchdog> & <heartbeat> .................................................................................141
<sub> ...................................................................................................................142
<global> ...............................................................................................................144
A.2.3Data References.........................................................................................................145
Variable Name .....................................................................................................145
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16. Data Type.............................................................................................................146
Arrays...................................................................................................................146
A.2.4Transporter Programming Language.........................................................................146
Comments ............................................................................................................146
Declarations .........................................................................................................146
Arithmetic Expressions........................................................................................147
Assignment Statement .........................................................................................148
If Statement..........................................................................................................148
Select Statement...................................................................................................148
Example <sub> Element......................................................................................149
A.3 Operation ..........................................................................................................................149
A.3.1Invocation..................................................................................................................149
A.3.2Error recording ..........................................................................................................150
Event Log.............................................................................................................150
Debug modes .......................................................................................................150
A.3.3Error recovery............................................................................................................151
A.4 Document Type Definition...............................................................................................152
A.5 TPL Formal Definition ....................................................................................................154
A.5.1<program> ::= <declarations> <statements> ............................................................154
APPENDIX B. ACTIVEX CONTROLS LIST ............................................................... 156
B.1 Introduction ......................................................................................................................156
B.2 ActiveX Controls ..............................................................................................................156
APPENDIX C. TAGLOOKUP ACTIVEX CONTROLS ................................................ 163
C.1 Introduction ......................................................................................................................163
C.2 ABB Auto Grid .................................................................................................................163
C.2.1Introduction ...............................................................................................................163
C.2.2Functionality..............................................................................................................163
Supported Data Types..........................................................................................163
Visual Appearance ...............................................................................................163
Scalar AttriIDs only .............................................................................................163
Array AttriIDs only..............................................................................................164
Mixed scalar and array AttriIDs ..........................................................................164
Mixed AttriIDs within a TagID ...........................................................................164
User Interface.......................................................................................................165
Show OPC Tag ....................................................................................................166
Set Decimal Places...............................................................................................166
Export to Excel ....................................................................................................166
Copy Data to Clipboard .......................................................................................166
OperateIT context extension................................................................................166
C.2.3XML Configuration ...................................................................................................167
XML Keywords ...................................................................................................167
Example Configuration........................................................................................168
C.2.4Dependencies.............................................................................................................169
C.3 ABB Auto Plot ..................................................................................................................169
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17. C.3.1Introduction ...............................................................................................................169
C.3.2Functionality..............................................................................................................170
Supported Plot Types and Data Requirements ....................................................170
User Interface.......................................................................................................178
Display Options Dialog .......................................................................................180
Rulers ...................................................................................................................182
Zooming and Scrolling ........................................................................................182
Stacking and Merging Plots.................................................................................183
Rearranging Plots.................................................................................................184
C.3.3XML Configuration ...................................................................................................184
XML Keywords ...................................................................................................184
Example XML Configuration ..............................................................................188
C.3.4Dependencies.............................................................................................................189
C.4 ABB Command Button ....................................................................................................190
C.4.1Introduction ...............................................................................................................190
C.4.2Functionality..............................................................................................................190
Basic XML Structure ...........................................................................................190
Properties .............................................................................................................190
C.4.3DisplayType...............................................................................................................190
C.4.4NumberOfButtons......................................................................................................191
XML Key Word...................................................................................................191
C.4.5RevID.........................................................................................................................191
C.4.6HelpID .......................................................................................................................191
C.4.7Resource ....................................................................................................................192
C.4.8Request ......................................................................................................................192
C.4.9State ...........................................................................................................................192
C.4.10Confirm, ConfirmRes ..............................................................................................192
C.4.11Writable, NotWritable .............................................................................................193
Right Click Menu.................................................................................................193
C.4.12Show OPC Tag ........................................................................................................193
C.4.13XML Keywords .......................................................................................................195
C.4.14Example of XML File..............................................................................................196
C.5 ABB Indicator Control ....................................................................................................196
C.5.1Introduction ...............................................................................................................196
C.5.2Functionality..............................................................................................................197
Basic XML Structure ...........................................................................................197
C.5.3XML Key Word.........................................................................................................197
C.5.4RevID.........................................................................................................................197
C.5.5HelpID .......................................................................................................................197
C.5.6Resource ....................................................................................................................198
C.5.7Value..........................................................................................................................198
C.5.8IndBackColor, IndForeColor.....................................................................................198
C.5.9ReverseFlag ...............................................................................................................198
Right Click Menu.................................................................................................199
C.5.10Show OPC Tag ........................................................................................................199
C.5.11Example of XML File..............................................................................................199
C.6 ABB CD Mapping Control ..............................................................................................200
C.6.1Introduction ...............................................................................................................200
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18. C.6.2Functionality..............................................................................................................200
C.6.3RevID.........................................................................................................................200
C.6.4HelpID .......................................................................................................................201
C.6.5Resource ....................................................................................................................201
C.6.6Confirm, ConfirmRes ................................................................................................201
C.6.7Writable, NotWritable ...............................................................................................201
Right Click Menu.................................................................................................202
C.6.8Show OPC Tag ..........................................................................................................202
C.6.9XML Keywords .........................................................................................................202
C.6.10Example of XML File..............................................................................................203
C.7 ABB Enhanced Auto Grid Control.................................................................................204
C.7.1Introduction ...............................................................................................................204
C.7.2Tags XML..................................................................................................................205
Basic Structure .....................................................................................................205
Attribute Key Words............................................................................................206
3.14.2 Event KeyWords..................................................................................................214
C.8 ABB Tag Lookup Selector Control.................................................................................216
C.8.1Introduction ...............................................................................................................216
C.8.2Tags XML..................................................................................................................216
Basic Structure .....................................................................................................216
Attribute Key Words............................................................................................217
C.8.3Example .....................................................................................................................218
XML.....................................................................................................................219
C.9 ABB AC800 Auto Grade Change Button.......................................................................221
C.9.1Introduction ...............................................................................................................221
C.9.2Functionality..............................................................................................................221
C.9.3XML Key Word.........................................................................................................221
C.9.4Example Of XML File...............................................................................................222
C.10 ABB AC800 Auto Grade Change Current Info ............................................................222
C.10.1Introduction .............................................................................................................222
C.10.2Functionality............................................................................................................222
C.10.3XML Key Word.......................................................................................................222
C.10.4Example Of XML File.............................................................................................223
C.11 ABB AC800 Auto Grade Change Previous....................................................................224
C.11.1Introduction .............................................................................................................224
C.11.2Functionality............................................................................................................224
C.11.3XML Key Word.......................................................................................................224
C.11.4Example Of XML File.............................................................................................224
C.12 ABB OPC Tag AGC Level 1 Control .............................................................................225
C.12.1Introduction .............................................................................................................225
C.12.2Functionality............................................................................................................225
C.12.3XML Key Word.......................................................................................................225
C.12.4Example Of XML File.............................................................................................227
C.13 ABB OPC Tag AGC Level2 Control ..............................................................................228
C.13.1Introduction .............................................................................................................228
C.13.2Functionality............................................................................................................229
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19. C.13.3XML Key Word.......................................................................................................229
C.13.4Example Of XML File.............................................................................................231
C.14 ABB OPC Tag Level 1 singleline ....................................................................................232
C.14.1Introduction .............................................................................................................232
C.14.2Functionality............................................................................................................233
C.14.3XML Key Word.......................................................................................................233
C.14.4Example Of XML File.............................................................................................235
C.15 ABB OPC Tag Level 1 grid .............................................................................................235
C.15.1Introduction .............................................................................................................235
C.15.2Functionality............................................................................................................236
C.15.3XML Key Word.......................................................................................................236
C.15.4Example Of XML File.............................................................................................238
C.16 ABB OPC Tag Level 1 Vertical ......................................................................................239
C.16.1Introduction .............................................................................................................239
C.16.2Functionality............................................................................................................240
C.16.3XML Key Word.......................................................................................................240
C.16.4Example Of XML File.............................................................................................242
C.17 ABB OPC Tag Level 2 singleline ....................................................................................242
C.17.1Introduction .............................................................................................................242
C.17.2Functionality............................................................................................................243
C.17.3XML Key Word.......................................................................................................243
C.17.4Example Of XML File.............................................................................................246
C.18 ABB OPC Tag Level 2 grid .............................................................................................246
C.18.1Introduction .............................................................................................................246
C.18.2Functionality............................................................................................................246
C.18.3XML Key Word.......................................................................................................246
C.18.4Example Of XML File.............................................................................................249
C.19 ABB OPC Tag Speed Control .........................................................................................250
C.19.1Introduction .............................................................................................................250
C.19.2Functionality............................................................................................................250
C.19.3XML Key Word.......................................................................................................250
C.19.4Example Of XML File.............................................................................................253
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20. List of Figures
Figure ‎1-1 Example system architecture ............................................................................................ 24
Figure ‎1-2 Software component architecture with example installation components ........................ 25
Figure ‎1-3 Quality Control Application Architecture Overview............................................................ 26
Figure ‎1-4 Main.xslt flow chart ............................................................................................................ 35
Figure ‎1-5 Batch file location for Job Order configuration .................................................................. 40
Figure ‎1-6 After configuring system chose Deploy Job button ........................................................... 40
Figure ‎1-7 Directory structure on configuration tool PC ..................................................................... 40
Figure ‎1-8 - Quality Control Object Server Overview ......................................................................... 46
Figure ‎1-9 Tag Lookup flowchart on server ........................................................................................ 49
Figure ‎1-10 Tag Lookup on client ....................................................................................................... 50
Figure ‎1-11 Tags XML Information Pop-up contains tag look-up information for the system ............ 56
Figure ‎1-12 Scanner Object Setup ..................................................................................................... 58
Figure ‎2-1 Object Type Structure example......................................................................................... 60
Figure ‎2-2: Example of MD Project Create Tool Message for Variable Name Discrepancy.............. 65
Figure ‎2-3: Example of Status Viewer ................................................................................................ 66
Figure ‎2-4: Example of MD Objects in Functional Structure .............................................................. 66
Figure ‎2-5: Example of MD Objects in Control Structure ................................................................... 67
Figure ‎2-6: Simulation Configuration .................................................................................................. 68
Figure ‎2-7: Example Faceplate........................................................................................................... 68
Figure ‎2-8: Example Right Click Menu ............................................................................................... 69
Figure ‎2-9: CD control job order configuration tab ............................................................................ 75
Figure ‎2-10: ABB Debug Client for startup of CD control .................................................................. 80
Figure ‎2-11: Status viewer example for CD control ........................................................................... 81
Figure ‎2-12: Functional structure example for CD Control ................................................................ 81
Figure ‎2-13: CD control job order configuration tab with “CD Coat Weight” as an option for the “CD
Type” ............................................................................................................................................ 85
Figure ‎2-14: ABB Debug Client for startup of CDCTW...................................................................... 89
Figure ‎2-15: Status viewer example for CDCTW............................................................................... 90
Figure ‎2-16: CD control job order configuration tab with LVC checkbox........................................... 94
Figure ‎2-17: ABB Debug Client for startup of LVC ............................................................................ 98
Figure ‎2-18: Status viewer example for LVC ..................................................................................... 98
Figure ‎2-19: CD actuator agent job order configuration tab ............................................................. 103
Figure ‎2-20: ABB Debug Client for startup of CD actuator agent.................................................... 107
Figure ‎2-21: Status viewer example for CD actuator agent............................................................. 108
Figure ‎2-22: Functional structure example for CD actuator agents................................................. 108
Figure ‎3-1 Quality Control Diagnostics Aspect in the Functional Structure...................................... 110
Figure ‎3-2 Quality Control Diagnostics Example Display ................................................................. 110
Figure ‎3-3 Debug Message Viewer Tool example ........................................................................... 111
Figure ‎3-4 Toolbar icons functionality ............................................................................................... 112
Figure ‎3-5 Available Application Debug Mode Selection for Scanner.............................................. 112
Figure ‎3-6 Available Application Debug Mode Selection for OPC Transporter................................ 113
Figure ‎3-7 Application Activity status properties for Measurement Basis Weight ............................ 113
Figure ‎3-8 Application Activity status properties for OPC Transporter ............................................. 113
Figure ‎3-9 Windows application log on Event Viewer ...................................................................... 114
Figure ‎3-10 Quality Control Status Viewer example......................................................................... 115
Figure ‎3-11 License Manager Utility ................................................................................................. 116
Figure ‎3-12 Windows Task Manager aids in troubleshooting .......................................................... 117
Figure ‎3-13 OPC Direct IT Viewer .................................................................................................... 118
Figure ‎3-14 OPC Direct IT Viewer Top Area .................................................................................... 118
Figure ‎3-15 OPC Direct IT Viewer Bottom Area ............................................................................... 119
Figure ‎3-16 OPC Direct IT buttons ................................................................................................... 120
Figure ‎3-17 OPC Direct IT Configuration........................................................................................... 121
Figure ‎3-18 Windows message with OPC Server and tag information ............................................ 166
Figure ‎3-19 Set decimal places using Windows pop-up................................................................... 166
Figure ‎3-20 Target dialog pop-up ..................................................................................................... 173
Figure ‎3-21 Actuator profile modes and setpoints pop-up................................................................ 175
Figure ‎3-22 Reflected Plot example.................................................................................................. 176
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21. Figure ‎3-23 Reflected Target Plot example ...................................................................................... 177
Figure ‎3-24 Reflected Target Plot pop-up for individual points ........................................................ 177
Figure ‎3-25 X-Y plot example ........................................................................................................... 178
Figure ‎3-26 User Interface OPC Tag information message box ...................................................... 179
Figure ‎3-27 Right click in plot area to get pop-up menu options ...................................................... 179
Figure ‎3-28 Measurement plot display options................................................................................. 180
Figure ‎3-29 Target Plot Display Options........................................................................................... 180
Figure ‎3-30 Actuator Array Plot Display Options .............................................................................. 181
Figure ‎3-31 Reflected Plot Display Options...................................................................................... 181
Figure ‎3-32 Reflected Target Plot Display Options .......................................................................... 181
Figure ‎3-33 X-Y Plot Display Options ............................................................................................... 182
Figure ‎3-34 Vertically stacked plots .................................................................................................. 183
Figure ‎3-35 Merging Plots................................................................................................................. 184
Figure ‎3-36 Keywords for all plot types ............................................................................................ 184
Figure ‎3-37 ABB Auto Plot example ................................................................................................. 189
Figure ‎3-38 Display Type.................................................................................................................. 190
Figure ‎3-39 DisplayType=“1 – ndtVerical” ........................................................................................ 190
Figure ‎3-40 DisplayType=”2 – ndtHorizontal”................................................................................... 190
Figure ‎3-41 Buttons resulting from XML file implementation............................................................ 191
Figure ‎3-42 Button state On.............................................................................................................. 192
Figure ‎3-43 Button state Off.............................................................................................................. 192
Figure ‎3-44 Using reserved resource string ..................................................................................... 193
Figure ‎3-45 Button not writeable....................................................................................................... 193
Figure ‎3-46 Button writeable............................................................................................................. 193
Figure ‎3-47 Show OPC tag gives server names and tags associated with button .......................... 194
Figure ‎3-48 CD Overview Indicator messages ................................................................................. 197
Figure ‎3-49 CD Mapping ActiveX control ......................................................................................... 200
Figure ‎3-50 Using reserved resource string ..................................................................................... 201
Figure ‎3-51 Show OPC tag gives server and tag names ................................................................. 202
Figure ‎3-52 Heirarchy Levels............................................................................................................ 218
Figure ‎3-53 Automatic Grade Change button................................................................................... 221
Figure ‎3-54 Automatic Grade Change Current Information Example .............................................. 222
Figure ‎3-55 Automatic Grade Change Previous Pop-up Example ................................................... 224
Figure ‎3-56 Automatic Grade Change Level 1 Control Pop-up Example......................................... 225
Figure ‎3-57 Automatic Grade Change Level 2 Control Pop-up Example......................................... 229
Figure ‎3-58 OPC Tag Level 1 SingleLine example .......................................................................... 233
Figure ‎3-59 Level 1 Control Grid Example ....................................................................................... 236
Figure ‎3-60 OPC Tag Level 1 Vertical Example............................................................................... 240
Figure ‎3-61 OPC Tag Level 2 SingleLine Example .......................................................................... 243
Figure ‎3-62 OPC Tag Level 2 Grid Example .................................................................................... 246
Figure ‎3-63 OPC Tag Speed Control Example ................................................................................ 250
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22. List of Tables
Table ‎1-1Industrial IT Quality Control 4.0 PC nodes and software .................................................... 23
Table ‎1-2 System Status Reporter S_Status property meanings....................................................... 57
Table ‎1-3 Aspects used to support Quality Control System Status Viewer Aspect............................ 57
Table ‎2-1: OPC Transporter Groups for MD Control.......................................................................... 64
Table ‎2-2: CD control TagsLookup ControlID.................................................................................... 72
Table ‎2-3: CD control job order information....................................................................................... 74
Table ‎2-4: CD control XML documents.............................................................................................. 76
Table ‎2-5: CDCTW TagsLookup ControlID ....................................................................................... 84
Table ‎2-6: CDCTW XML documents ................................................................................................. 86
Table ‎2-7: LVC TagsLookup ControlID.............................................................................................. 93
Table ‎2-8: LVC XML documents........................................................................................................ 95
Table ‎2-9: CD actuator agent TagsLookup ControlID ..................................................................... 101
Table ‎2-10: CD actuator agent job order information ...................................................................... 101
Table ‎2-11: CD actuator agent XML documents .............................................................................. 104
Table ‎3-1 Active X Control names, file name, and interface definitions ........................................... 156
Table ‎3-2 Array value and ratio table................................................................................................ 164
Table ‎3-3 Mixed scalar and array AttriIDs ........................................................................................ 164
Table ‎3-4 Mixed AttriIDs within a TagID ........................................................................................... 165
Table ‎3-5 XML keywords supported by ABB Auto Grid................................................................... 167
Table ‎3-6 Display information ........................................................................................................... 169
Table ‎3-7 Measurement Plot inputs .................................................................................................. 170
Table ‎3-8 Actuator Array Plot inputs ................................................................................................. 173
Table ‎3-9 Reflected Plot input........................................................................................................... 176
Table ‎3-10 Reflected Target Plot input ............................................................................................. 176
Table ‎3-11 X-Y Plot inputs ................................................................................................................ 177
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23. Chapter 1 Theory of Operation
1.1 Overview
Industrial IT Quality Control 4.0 is an application providing measurement and control
solutions for the paper manufacturing process. The primary features are:
1. Scanning and measurement
2. Machine direction control of scanning measurement parameters (weight, moisture, ash,
…)
3. Advanced controls (speed change, automatic grade change, headbox, …)
4. Cross direction (profile) control of scanning measurement parameters
5. Reporting
1.2 Physical Architecture
1.2.1 Devices
The normal Industrial IT Quality Control 4.0 consists of the following PC nodes and
software.
Table 1-1Industrial IT Quality Control 4.0 PC nodes and software
Node Type
Function
Quality Control
Connectivity
Server & AC800M
Connectivity
Server
Provides Quality
Control measurement
and control
functionality and
access to AC800M
controller.
Process Portal
Standard Process
Portal Aspect Server
Functionality
Process Portal
Process Portal
Aspect Server
Software Required
OPC Server for AC800M/C
Control Builder M Professional
Industrial IT Quality Control 4.0
AC800M Connect
Industrial IT Quality Control 4.0
Process Portal
Client
Standard Process
Portal Client
Functionality
Process Portal
AC800M Connect
Industrial IT Quality Control 4.0
AC800M Controller
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Control
Latest AC800M Firmware
23

24. The normal Industrial IT Quality Control 4.0 will consist of one System 800xA Process Portal
Aspect Server, one System 800xA Process Portal Connectivity Server (Quality Control and
AC800M) and some number of System 800xA Process Portal Clients.
Figure 1-1 Example system architecture
1.3 Software Package Deployment
The diagram below illustrates, at a high level, the software components that for each type of
application PC node and the installation options for installing those components.
24
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25. Figure 1-2 Software component architecture with example installation components
1.4 Application Architecture
The Industrial IT Quality Control 4.0 PC based applications provide access to all of the
system features except for machine direction and level 1 control, which are implemented in
the AC800M Controller. The Quality Control applications are COM EXE type applications
and are referred to as “components” here.
1.4.1 Startup and Shutdown
Refer to Figure 1-3 Quality Control Application Architecture Overview. The QCS Service is
normally configured for automatic startup. It will run when the computer is started, even if
no user logs on to the Quality Control Connectivity server machine. The QCS Service’s main
function is to launch the ABBQCSApplication component. This component is the top level
Quality Control application. It launches and coordinates all of the other Quality Control
applications.
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26. Figure 1-3 Quality Control Application Architecture Overview
The ABBQCSApplication component uses a Startup Engine component to launch the other
Quality Control application components and utility applications. The Startup Engine
component starts the applications configured in the startup.xml file. This file is created and
deployed to the ../System/config directory by the job order configuration tool. The contents
of startup.xml depend upon the number and type of Quality Control devices and application
features configured. Typically there will be a separate component for each system feature or
subsystem. Refer to the Startup Engine section later in this document for more details.
Each Quality Control application component implements COM interfaces that allow the
ABBQCSApplication component to coordinate their activities. The ABBQCSApplication
uses these interfaces to tell the Quality Control Application components when to connect to
their OPC server, when to publish their OPC tags, when to shutdown, etc.
When the ABB QCS Service is stopped, it tells the ABBQCSApplication to shutdown. The
ABBQCSApplication then uses the standard COM interfaces of each Quality Control
application component to tell the application components to shutdown.
Client Connectivity
Refer to Figure 1-3 Quality Control Application Architecture Overview, above. Quality
Control process graphic displays do not normally use the normal OperateIT graphic elements.
Most Quality Control process graphic displays are based upon special process graphic aspect
categories that contain logic for connecting to the Quality Control connectivity server. See
the Aspects and Objects section later in this document for more details on these special
process graphic Aspect Categories.
Many of the Quality Control process graphic Aspects contain ActiveX controls that display /
modify OPC tags. These ActiveX controls use a tag lookup server to locate the OPC tags that
they use. See the OPC Direct IT section below.
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27. 1.4.2 Quality Control PC Applications
The Quality Control applications are COM EXE type applications and are referred to in this
description as “application components” or just “components”.
While application components each tend to implement only one subsystem or feature of the
entire system, they frequently have a need to communicate with each other. To this end there
are two methods used to interface from application component-to-component and to the
outside world. These are 1) via COM interfaces and 2) via OPC tags. The majority of
communication between components is through the COM interfaces which are common
method or subroutine calls. A description of the data or command sequencing for several
features will be found in the detailed descriptions below, and they make frequent reference to
these COM interface methods.
Due to the object-oriented nature of the application component implementation the interaction
between components can be quite complex with several back-and-forth transactions required
to accomplish a relatively simple task. The advantage of this approach is that the software is
modular and feature independent, allowing easy addition or removal of features and isolating
functional responsibility for ease of diagnosis.
The primary Industrial IT Quality Control 4.0 application components are:
1. Scanner and Sensor
2. Color Measurement
3. Reporting Accumulation
4. Reporting
5. Reporting History
6. Roll Set
7. Speed Input
8. Grade and Shade File Handling
9. High Frequency Trending
1.4.3 Scanners, Sensors and Advanced Scanning
The application COM component ABBSmartPlatform.exe is responsible for all interaction
with the scanner and its complement of sensors. At startup, a separate ABBSmartPlatform
object is created for each scanner in the system. Once in operation, the ABBSmartPlatform
object coordinates the activities of a group of ABBSmartMeasurement objects, one started for
each measurement configured on that scanner. The scanner object acts as the ‘owner’ of the
measurements and insures that all its measurements understand the current operating
conditions, such as the desired measurement mode, the position of the head package, etc. The
scanner object insures that all the sensor results are tabulated and reported in a coordinated
fashion and that the measurement results align with each other in time. In general, operator
communication with the scanner and measurement objects flows through the COM interfaces
associated with each object.
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28. Between the objects and the real-world physical devices reside the QC Object Server (QCOS)
and its OPC tag-set. The Job Order Configuration Tool is used to define the physical
complement of scanners and sensors that will be available to talk to. Each scanner and
measurement object subscribes to the full set of OPC tags available from that device.
The scanner keeps a list of its measurement objects that can be accessed through the scanner
COM interface. Some of the measurement specific operator commands (e.g., sample check
mode, compensation values, etc.) use this list to directly access specific measurement objects
on a specific scanner. In this case, once they have identified the desired measurement object,
they use the measurement COM interface to talk directly to that measurement object.
Operation
Positioning
Operationally, the scanner’s ‘command’ OPC tag is the direct connection from the scanner
object to the physical scanner through the OPC interface. Once an operator command has
been received by the scanner object via the COM interface, it flows through this OPC tag.
The commands are general in nature, asking the scanner to assume a particular state (e.g.
offsheet, scanning, etc.) and waiting for the response in the ‘mode’ OPC tag. No direct head
package control is performed by the scanner component. The ‘CurrentHeadPosition’ OPC tag
returns the current physical position of the head package to the scanner object.
Advanced Scanning
Advanced Scanning is an optional, licensed, value-added feature that allows multiple scanners
to ‘see’ the same part of the process. In a moving sheet process with several scanners
distributed along the length, it is useful to insure that each discrete measurement window
measures the same material, especially when there are mathematical relationships between the
measurements on different scanners. For example, a weight difference that subtracts one
weight from another on two different scanners is obviously more precise when both
measurements are from the same location on the process. The difficulty with this is that the
measurements occur at different times by virtue of their separation on the process.
The mechanism for accomplishing this is to insure that different scanners start their scans at
the same ‘command point’ on the process which is tracked between the scanners based upon
their relative separation and the line speed of the process. This feature is referred to as
“Synchronized Scanning”.
A global component ABBGlobalScanner is responsible for recognizing and coordinating
individual scanner components, ABBSmartPlatform. It makes decisions about which scanner
is most upstream and insures that scanner is aware that it is the ‘leader’. The leader is
responsible for starting new ‘command points’ that will be followed by downstream scanners
– followers. The software components of the Connectivity Server are entirely responsible for
operation of this feature. When activated, this feature causes each ABBSmartPlatform
component to override normal independent scanning operation of its connected Smart
Platform by changing the Smart Platform’s mode from “scan-at-will” to “scan-on-command”.
Downstream follower scanners accept new ‘command points’ from the leader and track them
from the leader to themselves by monitoring the process line speed. Each individual scanner
is assigned a relative position on the process at startup which is used to decide when the
‘command point’ has reached them and should be obeyed. The synchronization mechanism
for the downstream scanners is designed in such a way that the origin (leader) of a ‘command
point’ is irrelevant and simply has to match the position of the specific downstream scanner.
The lead scanner may change at any time by virtue of its availability (local, out-of-operation,
maintenance, etc.). The change of leadership is one of the commands that is synchronized
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29. between scanners so that intervening commands (and potentially measurements) are not lost
to downstream scanners.
Missing Scans
By virtue of the fact that downstream scanners are dependent on synchronization for their
start-scan command, it is possible for downstream scanners to miss scans. In these cases the
next best possibility for measurement is to wait for the next ‘command point’ on this side of
the process sheet to arrive; in other words to quit scanning until a complete bi-directional scan
is tracked to this scanner. Some of the scenarios for missed scans and the mechanisms
implemented to reduce their occurance are:
Change of line speed
Since the line speed determines when a ‘command point’ will reach a downstream scanner, a
change in line speed will obviously have an impact. In general a decrease in line speed is
benign in the sense that the start-scan command will eventually reach the scanner, it’s just
delayed for a while. There is a ‘delayed scan’ feature built into the tracking that will allow a
downstream scanner to proceed with a scan (and measurement) only if it can be in position to
receive the next ‘command point’ in the tracking queue based on the current line speed. In
other words, if the scanner can successfully reach the other side of the process sheet and
return to the current position before the next start-scan command will arrive, then scanning is
allowed to proceed. There are special considerations to handle or discard mis-aligned
measurements in this case – see Inter-scanner Measurement, below.
An increase in scan speed is a potential problem in that ‘command points’ may flow by the
downstream scanner before it is in a position to accept them i.e., the scanner is still moving
for the previous scan. This is physically an unsolvable dilemma that is somewhat alleviated
by the fact that due to the higher line speed subsequent scan points on this side of the process
sheet will arrive sooner than originally scheduled. Start-scan ‘command points’ that are
missed are discarded, however some commands are honored regardless – for example, a
change of tracking leadership or a standardize request will be honored immediately.
Scanner activities
Activities of downstream scanners may affect their ability to start scanning when a ‘command
point’ becomes available. For example, a substantially slower scan time may insure that a
downstream scanner misses the ‘command point’ scan request and subsequently loses the
opportunity to measure for a complete forward and reverse scan. This sort of scenario will
result in periodic ‘skipping’ of scans on a downstream scanner. The mechanism described
above (Change of line speed) will insure that a scan will eventually occur, however,
subsequent scans will fall further behind until they are discarded and a catch-up is required.
This could be severe enough that only alternate scans are honored.
A second activity that impacts’ scanning is standardize duration. A downstream scanner may
have a substantially longer standardize duration than the lead scanner, since this is sensor
dependent. A self-tuning feature has been implemented that considers the relative duration of
standardizes between scanners and causes the lead scanner to delay its scan until it is sure that
all scanners will have sufficient time to ‘catch’ its first start-scan ‘command point’ after a
global standardize. In effect the lead scanner takes on the standardize duration of the longest
downstream scanner duration. This is controlled by the ABBGlobalScanner component. An
initial value for this duration is provided in a coldstart value.
Some additional comments about standardize – requests for standardize are classified as either
individual or global, depending upon whether the request is issued via a specific scanner’s
interface or the global scanner’s interface. The difference between these two is that tracking is
considered only for the global type, not for the individual. An individual standardize request,
whether via button or timer causes that scanner to become ‘unavailable for synchronization’.
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30. The effect for downstream scanners is to step out of synchronization temporarily, but to return
as soon as standardize is complete – note that when they return they may be totally out of
alignment with respect to the leader and may have to wait a full bi-directional scan to get
properly aligned. The effect for the lead scanner is similar, except that leadership is
reassigned to the next most downstream scanner. In this case when returning from standardize
it will reclaim leadership, which may result in downstream scanners waiting for scans.
A feature to force measurement quickly after a standardize causes downstream scanners to
perform an immediate scan after returning on-sheet after standardize regardless of
synchronization. The concept allows quick measurement and simply defers the wait for
‘command point’ to the far sheet edge.
Operator intervention
Requests from the operator to disable a scanner or to cause it to operate in a different mode
will impact synchronization. As mentioned above, standardize requests may affect scanning
of both the lead scanner and downstream followers. Also, any operator intervention to take
the scanner out of computer control will obviously affect synchronization. If the lead scanner
is put out-of-service, a new lead scanner will be selected by ABBGlobalScanner component.
When scanners are returned to operation, they will resume synchronized scanning. If they are
the most upstream, they will be assigned as the lead scanner.
Independent Operation Mode
A independent mode is provided via operator request that completely disassociates the
scanner from the ABBGlobalScanner component and all synchronization. Once placed in
independent mode, the scanner will operate totally independently from other scanners,
including scanning. When in independent mode, the scanner will not participate in
synchronization and cannot become the lead scanner.
Measurement
All measurement processing is performed exclusively on 5-second data by the scanner
component and its measurement objects. The measurement objects and their subordinate
objects are responsible for building profiles from this 5-second data. The profiles and their
related statistical data are published as OPC tags at every edge-of-sheet.
The scanner monitors the OPC tag ‘TBM5SecDataReadyTrigger’. This tag is sent from the
Smart Platform to indicate that all measurements for this 5-second time slice (TBM) have
been completed. When this trigger is seen, the data box and head position arrays are read
from the Smart Platform. The scanner component uses the collection of measurements
configured on this scanner to iteratively ask all measurement arrays to be read and processed
and on-going profile construction to be performed. When an edge-of-sheet is detected in the
scanner’s data box array the profile processing is completed, the profile result is published
and the profile is initialized in preparation for the next scan.
The scanner expects a returned result from each measurement as a data object of class
CABBDataObject which contains the processed TBM array, the TBM average, the scan
average, and a status among other things.
Calculated Measurement
Measurements that calculate their result by reference to some other measurement are known
as ‘calculated measurements’. A calculated measurement is an object instance of a (new)
CABBCalcMeas class which supports the same COM interface (IABBMeasurementIF) as
‘real’ measurements. The concept of the calculated measurement is tightly coupled to the
entire ABBSmartPlatform component design and impacts the functionality of all
measurement features and as such is implicit and not optional.
30
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31. Calculated measurements are made aware of their measurement dependencies at startup via a
‘contributors’ list. The relationship between the calculated measurement and its contributors
is determined by an algorithm which is defined in the “std_algorithms.xml” file and is also
established at startup. In general, any local (this scanner) or upstream (different scanner)
measurement is fair-game as a contributing measurement; even other contributing
measurements may contribute. Conversely, downstream measurements are inaccessible as
contributors (although their grade information is available).
Processing of calculated measurements follows the same initial sequence as ‘real’
measurements. After seeing the scanner’s data ready trigger, the scanner object asks each
calculated measurement to read and process its measurement arrays. The scanner object is
unaware of the different measurement types and only expects the returned result to be
consistent (a CABBDataObject instance).
When a calculated measurement receives its processing request from the scanner object it asks
each of its contributing measurements for their TBM array and forwards this data to the
algorithm processor. The accessing of TBM array data from the contributing measurements
differs depending upon whether they are local measurements (this scanner) or whether they
reside on a different (upstream) scanner (see Measurement Tracking, below). The finished
TBM array, its average and status are all returned in the CABBDataObject.
Measurement Tracking
Measurement tracking is the proprietary mechanism that allows the measurements from
multiple scanners to be properly aligned in both the machine and cross-machine directions.
Measurement tracking, or tracking as it is referred to herein, is tightly coupled to the entire
ABBSmartPlatform component design and impacts the functionality of all measurement
features and as such is implicit and not optional.
The implementation of tracking rests on the two object classes CABBVirtualScanner and
CABBVirtualMeasurement. [Software detail: These classes act as agents for a calculated
measurement and represent an upstream scanner or upstream measurement respectively to the
local scanner or ‘owner-scanner’. When a calculated measurement object is first started, it’s
contributors list is examined for residence of each measurement. A new virtual scanner object
is created for every unique scanner identified from this list. This virtual scanner retains COM
interface ties to its target (upstream) scanner which will be used during subsequent
measurement processing. A new virtual measurement object is created for each measurement
that is identified from the contributors list that resides on that scanner and likewise retains
COM interface ties to its target (upstream) measurement. The virtual scanner keeps a
collection of these virtual measurements in a similar fashion to how the scanner component
keeps its collection of ‘real’ measurements.]
The virtual scanner object (CABBVirtualScanner) is primarily responsible for recognizing
when a tracked measurement has reached the owner-scanner and for distributing the tracked
data to the virtual measurements that it contains. An incidental (but very important)
responsibility is to track scanning commands for the Synchronized Scanning feature.
The virtual measurement object (CABBVirtualMeasurement) has two primary
responsibilities. First is to populate a “living” profile with tracked measurement from its
target upstream measurement. When notified by the virtual scanner that new tracked
measurement is available, the new data is overlaid onto a permanent profile array. Second,
when requested, examine this “living” profile for a prescribed set of boxes and create an
artificial TBM array for this contributing measurement. This is the TBM array that will
eventually be used in the calculated measurement’s algorithm as described above.
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