Methods and apparatus to modify a recipe process flow associated with a process control system during recipe execution

• US 8,150,541 B2
• Filed: 11/13/2007
• Issued: 04/03/2012
• Est. Priority Date: 11/13/2007
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Pettus, Nathan William, Irwin, William George, Nanda, Tusar, Moore, James Henry Jr.
• Primary Examiner(s): Decady, Albert
• Assistant Examiner(s): Rapp, Chad
• Application Number:
  US11/939,304
• Publication Number:
  US 20090125126A1
• Time in Patent Office: 1,603 Days
• Field of Search: 700/19, 700/20, 700/31, 700/103, 717/136, 717/151, 717/168, 718/105
• US Class Current: 700/103
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32077 Batch control system
• CPC Class Codes: G05B 2219/32095 Text, menu driven editor for batch programming, phase sequence, parameters
• CPC Class Codes: G05B 2219/32096 Batch, recipe configuration for flexible batch control
• CPC Class Codes: G05B 2219/32128 Gui graphical user interface
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Example methods and apparatus to modify a recipe process flow during recipe execution are disclosed. A disclosed example method involves executing a recipe, and before completion of execution of the recipe, receiving process flow change information indicative of a modification to a process flow of the recipe. Process flow rules are then retrieved from a process flow rules data structure. The recipe process flow is modified based on the process flow change information in response to determining that at least one requested change indicated by the process flow change information does not violate one of the process flow rules.

Claims

1. A method to modify a recipe process flow during recipe execution, the method comprising:

executing a recipe using a plurality of manufacturing equipment resources; and

before completion of execution of the recipe;

receiving process flow change information indicative of a modification to a process flow of the recipe;

determining, via a processor, whether a process step being executed by one of the manufacturing equipment resources can be stopped prematurely; and

stopping the executing process step prematurely and modifying a process flow of the recipe based on the process flow change information in response to determining that the executing process step can be stopped prematurely.

2. A method as defined in claim 1, further comprising receiving a process flow change request to modify the process flow based on the process flow change information and modifying the process flow in response to receiving the process flow change request.

3. A method as defined in claim 1, further comprising configuring the execution of the recipe to not execute a subsequent process step prior to modifying the process flow.

4. A method as defined in claim 1, further comprising identifying at least one active process step to be deactivated and at least one target process step to be activated based on the process flow change information.

5. A method as defined in claim 1, further comprising when the executing process step cannot be stopped prematurely, waiting for the executing process step to finish execution prior to modifying the recipe process flow in response to determining that the executing process step cannot be stopped prematurely.

6. A method as defined in claim 1, further comprising determining whether the executing process step can be stopped prematurely based on rules stored in at least one of the process flow change information or a process flow rules data structure.

7. A method as defined in claim 6, wherein the process flow rules data structure is to store at least one of manufacturer-defined process flow rules or industry-defined process flow rules, and wherein the process flow rules are applicable to any other recipe executed by a process control system used to execute the recipe.

8. A method as defined in claim 1, wherein the process flow of the recipe is modified based on the process flow change information in response to a user performing only the procedures of selecting a process step to be activated and selecting a step change user interface button.

9. A method as defined in claim 1, wherein the process flow of the recipe is modified based on the process flow change information in response to a user selecting only a step change user interface button.

10. A method as defined in claim 1, wherein determining whether the process step being executed by one of the manufacturing equipment resources can be stopped prematurely comprises determining whether the process step being executed by one of the manufacturing equipment resources can be stopped prematurely based on maintaining a safe operating condition or based on maintaining a particular quality for a product being produced by the manufacturing equipment resources.

11. An apparatus to modify a recipe process flow during recipe execution, the apparatus comprising:

a user input interface to receive process flow change information indicative of a modification to a process flow of a recipe before completion of execution of the recipe, the execution of the recipe being carried out using a plurality of manufacturing equipment resources;

a process step terminator to stop an executing process step prematurely in response to determining, via a processor, that the executing process step can be stopped prematurely, the executing process step being executed by one of the manufacturing equipment resources; and

a process step activator to modify the process flow based on the process flow change information.

12. An apparatus as defined in claim 11, wherein the user interface is further to receive a process flow change request to modify the process flow based on the process flow change information.

13. An apparatus as defined in claim 11, further comprising a process step deactivator to identify at least one active process step to be deactivated based on the process flow change information, and wherein the process step activator is to identify at least one target process step to be activated based on the process flow change information.

14. An apparatus as defined in claim 11, wherein the process step terminator is further to determine whether a wait period is required to wait for the executing process step to finish execution prior to modifying the recipe process flow.

15. An apparatus as defined in claim 11, wherein the process step terminator is to determine whether the executing process step can be stopped prematurely based on rules stored in at least one of the process flow change information or a process flow rules data structure.

16. An apparatus as defined in claim 15, wherein the process flow rules data structure is to store at least one of manufacturer-defined process flow rules or industry-defined process flow rules, and wherein the process flow rules are applicable to any other recipe executed by a process control system used to execute the recipe.

17. A non-transitory machine accessible medium having instructions stored thereon that, when executed, cause a machine to at least:

execute a recipe using a plurality of manufacturing equipment resources; and

before completion of execution of the recipe;

receive process flow change information indicative of a modification to a process flow of the recipe;

determine whether a process step being executed by one of the manufacturing equipment resources can be stopped prematurely; and

stop the executing process step prematurely and modify a process flow of the recipe based on the process flow change information in response to determining that the executing process step can be stopped prematurely.

18. A machine accessible medium as defined in claim 17 having instructions stored thereon that, when executed, cause the machine to receive a process flow change request to modify the process flow based on the process flow change information and modify the process flow in response to receiving the process flow change request.

19. A machine accessible medium as defined in claim 17 having instructions stored thereon that, when executed, cause the machine to configure the execution of the recipe to not execute a subsequent process step prior to modifying the process flow.

20. A machine accessible medium as defined in claim 17 having instructions stored thereon that, when executed, cause the machine to identify at least one active process step to be deactivated and at least one target process step to be activated based on the process flow change information.

21. A machine accessible medium as defined in claim 17 having instructions stored thereon that, when executed, cause the machine to, when the executing process step cannot be stopped prematurely, wait for the executing process step to finish execution prior to modifying the process flow.

22. A machine accessible medium as defined in claim 17 having instructions stored thereon that, when executed, cause the machine to determine whether the executing process step can be stopped prematurely based on rules stored in at least one of the process flow change information or a process flow rules data structure.

23. A machine accessible medium as defined in claim 22, wherein the process flow rules data structure is to store at least one of manufacturer-defined process flow rules or industry-defined process flow rules, and wherein the process flow rules are applicable to any other recipe executed by a process control system used to execute the recipe.

24. A machine accessible medium as defined in claim 17 having instructions stored thereon that, when executed, cause the machine to modify the process flow of the recipe based on the process flow change information in response to a user performing only the procedures of selecting a process step to be activated and selecting a step change user interface button.

25. A machine accessible medium as defined in claim 17 having instructions stored thereon that, when executed, cause the machine to modify the process flow of the recipe based on the process flow change information in response to a user selecting only a step change user interface button.