Campaign management for batch processes

• US 7,020,876 B1
• Filed: 06/30/2000
• Issued: 03/28/2006
• Est. Priority Date: 06/30/2000
• Status: Expired due to Term

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Pettus, Nathan W., Deitz, David L., Wilson, Grant, Lenich, Robert M., Benavides, Diego M.
• Primary Examiner(s): An, Meng-Al T.
• Assistant Examiner(s): Ali, Syed J
• Application Number:
  US09/609,091
• Time in Patent Office: 2,097 Days
• Field of Search: 700/1, 700 9- 12, 709100-102, 718/100, 718/102
• US Class Current: 718/100
• 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 2219/32128 Gui graphical user interface
• CPC Class Codes: G05B 2219/33148 CLS client server architecture, client consumes, server provides services
• CPC Class Codes: G05B 2219/35488 Graphical user interface, labview
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A campaign management technique for batch processes enables a process control system user to flexibly create, edit and execute batch process campaigns. The campaign management technique uses a campaign management function that sends messages requesting batch information to a batch executive function. The batch executive function extracts the requested batch information from a database and sends responsive messages containing the requested batch information to the campaign management function. The campaign management function displays the requested batch information to a user via a graphical display and enables the user to select batch information to be included within a batch process campaign. The user can create a campaign having multiple types of batches, which can include special startup and cleanup batches. The campaign management function releases batches of a campaign for execution by the batch executive function according to a user-specified batch execution mode, which may queue a ready batch in the batch executive function prior to the completion of a currently executing batch. A user can add batches to a campaign and/or can modify or delete unreleased batches of a currently executing campaign. Additionally, the campaign management function is tightly integrated with a data historian function and a security function and automatically sends campaign execution messages to the data historian and uses the security function to control user access to the campaign management function.

Claims

1. A method of creating a batch process campaign including a plurality of batches for use in a process control system having a batch executive and a graphical user interface, the method comprising the steps of:

sending a first message requesting batch information to the batch executive, the batch executive configured to send instructions to a process controller for directing a set of field devices to carry out process steps associated with a batch being executed by the batch executive, the batch executive having a database containing batch information;

receiving from the batch executive a second message containing a set of batch information in response to the first message requesting batch information, the set of batch information including recipe information, the set of batch information retrieved from the database of the batch executive;

displaying the set of batch information using the graphical user interface;

prompting a user to enter a first input identifying a subset of the set of batch information from the displayed set of batch information to be included within at least one batch from the plurality of batches;

prompting the user to enter a second input specifying campaign information to be included within the batch process campaign;

using the first and second inputs to create the batch process campaign; and

executing the batch process campaign by releasing batch process instructions to the batch executive.

2. The method of claim 1, wherein the step of requesting the recipe information includes the step of requesting recipe information associated with a setup batch.

3. The method of claim 1, wherein the step of requesting the recipe information includes the step of requesting recipe information associated with a cleanup batch.

4. The method of claim 1, wherein the step of prompting the user to enter the second input specifying campaign information to be included within the batch process campaign includes the step of prompting the user to specify a batch execution mode.

5. The method of claim 1, wherein the step of prompting the user to enter the second input specifying campaign information to be included within the batch process campaign includes the step of prompting the user to specify a maximum number of active batches.

6. The method of claim 1, wherein the step of prompting the user to enter the second input specifying campaign information to be included within the batch process campaign includes the step of prompting the user to specify a number of batches within the batch process campaign.

7. The method of claim 1, wherein the step of prompting the user to enter the second input specifying campaign information to be included within the batch process campaign includes the step of prompting the user to specify a parameter value associated with a process step.

8. The method of claim 1, wherein the step of prompting the user to enter the second input specifying campaign information to be included within the batch process campaign includes the step of prompting the user to specify batch identification information.

9. A system that creates a batch process campaign including a plurality of batches for use in a process control system having a batch executive, a graphical user interface and a processor, the system comprising:

a computer readable medium;

a plurality of routines stored on the computer readable medium and adapted to be executed by the processor, wherein the plurality of routines comprises;

a first routine adapted to send a first message requesting batch information to the batch executive, the batch executive configured to send instructions to a process controller for directing a set of field devices to carry out process steps associated with a batch being executed by the batch executive, the batch executive having a database containing batch information;

a second routine adapted to receive a second message from the batch executive containing a set of batch information in response to the first message requesting batch information, the set of batch information including recipe information, the set of batch information retrieved from the database of the batch executive;

a third routine adapted to display the set of batch information using the graphical user interface;

a fourth routine adapted to prompt a user to enter a first input identifying a subset of the set of batch information from the displayed set of batch information to be included within at least one batch from the plurality of batches;

a fifth routine adapted to prompt the user to enter a second input specifying campaign information to be included within the batch process campaign; and

a sixth routine adapted to use the first and second inputs to create the batch process campaign; and

a seventh routine adapted to release batch process instructions to the batch executive, the batch process instructions configured to cause the batch process campaign to be executed.

10. The system of claim 9, wherein the first routine is further adapted to request recipe information associated with a setup batch.

11. The system of claim 9, wherein the first routine is further adapted to request recipe information associated with a cleanup batch.

12. The system of claim 9, wherein the fifth routine is further adapted to prompt the user for a batch execution mode.

13. The system of claim 9, wherein the fifth routine is further adapted to prompt the user for a number of batches within the batch process campaign.

14. The system of claim 9, wherein the fifth routine is further adapted to prompt the user for a maximum number of active batches.

15. The system of claim 9, wherein the fifth routine is further adapted to prompt the user for a parameter value associated with a process step.

16. The system of claim 9, wherein the fifth routine is further adapted to prompt the user for batch identification information.

17. A method of executing a batch process campaign including a plurality of batches for use in a process control system having a batch executive, the method comprising the steps of:

sending a first message requesting batch information to the batch executive, the batch executive configured to send instructions to a process controller for directing a set of field devices to carry out process steps associated with a batch being executed by the batch executive, the batch executive having a database containing batch information;

receiving from the batch executive a second message containing a set of batch information in response to the first message requesting batch information, the set of batch information retrieved from the database of the batch executive;

creating the batch process campaign using at least a portion of the set of batch information retrieved from the database of the batch executive;

determining a batch execution mode associated with the batch process campaign;

releasing one or more batches from the plurality of batches to the batch executive based on the batch execution mode; and

sending messages to the batch executive to cause the batch executive to execute one or more of the released batches.

18. The method of claim 17, wherein the step of releasing the one or more batches from the plurality of batches to the batch executive based on the batch execution mode includes the step of releasing a ready batch prior to the complete execution of a currently executing batch.

19. The method of claim 17, wherein the step of sending the messages to the batch executive to cause the batch executive to execute the one or more of the released batches includes the step of sending a message to cause the batch executive to execute the one or more released batches according to the batch execution mode.

20. The method of claim 17, wherein the step of sending the messages to the batch executive to cause the batch executive to execute the one or more of the released batches includes the step of sending a message specifying a parameter value associated with a process step associated with the one or more of the released batches.

21. The method of claim 17, wherein the step of sending the messages to the batch executive to cause the batch executive to execute the one or more of the released batches includes the step of sending a message specifying a recipe associated with the one or more of the released batches.

22. The method of claim 17, wherein the step of releasing the one or more batches from the plurality of batches to the batch executive based on the batch execution mode includes the step of releasing the one or more batches from the plurality of batches according to a user specified maximum number of active batches.

23. A system that executes a batch process campaign including a plurality of batches for use in a process control system having a processor and a batch executive, the system comprising:

a computer readable medium; and

a plurality of routines stored on the computer readable medium and adapted to be executed by the processor, wherein the plurality of routines comprises;

a first routine adapted to send a first message requesting batch information to the batch executive, the batch executive configured to send instructions to a process controller for directing a set of field devices to carry out process steps associated with a batch being executed by the batch executive, the batch executive having a database containing batch information;

a second routine adapted to receive from the batch executive a second message containing a set of batch information in response to the first message requesting batch information, the set of batch information retrieved from the database of the batch executive;

a third routine adapted to create the batch process campaign using at least a portion of the set of batch information retrieved from the database of the batch executive;

a fourth routine adapted to determine a batch execution mode associated with the batch process campaign;

a fifth routine adapted to release one or more batches from the plurality of batches to the batch executive based on the batch execution mode; and

a sixth routine adapted to send messages to the batch executive to cause the batch executive to execute one or more of the released batches.

24. The system of claim 23, wherein the fifth routine is further adapted to release a ready batch prior to the complete execution of a currently executing batch.

25. The system of claim 23, wherein the sixth routine is further adapted to send a message to cause the batch execution function to execute the one or more released batches according to the batch execution mode.

26. The system of claim 23, wherein the sixth routine is further adapted to send a message specifying a parameter value associated with a process step associated with the one or more of the released batches.

27. The system of claim 23, wherein the sixth routine is further adapted to send a message specifying a recipe associated with the one or more of the released batches.

28. The system of claim 23, wherein the fifth routine is further adapted to release the one or more batches from the plurality of batches according to a user specified maximum number of active batches.

29. A method of editing a batch process campaign including a plurality of batches for use in a process control system having a graphical user interface and a data store, the method comprising the steps of:

sending a first message requesting batch information to a batch executive, the batch executive configured to send instructions to a process controller for directing a set of field devices to carry out process steps associated with a batch being executed by the batch executive, the batch executive having a database containing batch information;

receiving from the batch executive a second message containing a set of batch information in response to the first message requesting batch information, the set of batch information retrieved from the database of the batch executive;

creating the batch process campaign using at least a portion of the set of batch information retrieved from the database of the batch executive;

prompting a user to enter a first input via the graphical user interface identifying one or more unreleased batches from the batch process campaign;

prompting the user to enter a second input via the graphical user interface specifying a change to batch information associated with the identified one or more unreleased batches, including prompting the user to enter an input specifying a recipe change to the batch information; and

storing the change to the batch information together with the batch process campaign in the data store before sending a batch of the batch process campaign to the batch executive.

30. The method of claim 29, wherein the step of prompting the user to enter the second input via the graphical user interface specifying the change to batch information associated with the identified one or more unreleased batches includes the step of prompting the user to enter the second input while the batch process campaign is executing.

31. The method of claim 29, wherein the step of prompting the user to enter the first input via the graphical user interface specifying the change to the batch information associated with the identified one or more unreleased batches includes the step of prompting the user to enter an input specifying a parameter value change.

32. The method of claim 29, wherein the step of prompting the user to enter the second input via the graphical user interface specifying the change to the batch information associated with the identified one or more unreleased batches includes the step of prompting the user to enter an input specifying an additional batch to be added to the batch process campaign.

33. A system that edits a batch process campaign for use in a process control system having a processor, a graphical user interface and a data store, the system comprising:

a computer readable medium; and

a plurality of routines stored on the computer readable medium and adapted to be executed by the processor, wherein the plurality of routines comprise;

a first routine adapted to send a first message requesting batch information to a batch executive, the batch executive configured to send instructions to a process controller for directing a set of field devices to carry out process steps associated with a batch being executed by the batch executive, the batch executive having a database containing batch information;

a second routine adapted to receive from the batch executive a second message containing a set of batch information in response to the first message requesting batch information, the set of batch information retrieved from the database of the batch executive;

a third routine adapted to create the batch process campaign using at least a portion of the set of batch information retrieved from the database of the batch executive;

a fourth routine adapted to prompt a user to enter a first input via the graphical user interface identifying one or more unreleased batches from the batch process campaign;

a fifth routine adapted to prompt the user to enter a second input via the graphical user interface specifying a change to batch information associated with the identified one or more unreleased batches, the second routine adapted to prompt the user to enter an input specifying a recipe change to the batch information; and

a sixth routine adapted to store the change to the batch information together with the batch process campaign in the data store.

34. The system of claim 33, wherein the second routine is further adapted to prompt the user to enter the second input while the batch process campaign is executing.

35. The system of claim 33, wherein the fifth routine is further adapted to prompt the user to enter an input specifying a parameter value change.

36. The system of claim 33, wherein the fifth routine is further adapted to prompt the user to enter an input specifying an additional batch to be added to the batch process campaign.

37. A batch process campaign management system for use in a process control system, comprising:

a batch executive including a batch information database and a batch execution engine, the batch executive configured to send instructions to a process controller for directing a set of field devices to carry out process steps associated with a batch being executed by the batch executive; and

a campaign manager communicatively coupled to the batch executive that exchanges messages with the batch executive, wherein the messages contain batch-related information from the batch information database and campaign-related information generated by the campaign manager in response to a user input, the campaign manager configured to create a batch process campaign using batch-related information from the batch information database of the batch executive and user inputs identifying a set of the batch information to be included within a batch process campaign.

38. The system of claim 37, wherein the batch executive further includes a batch definition/instantiation function.

39. The system of claim 37, further comprising a graphical user interface that is communicatively coupled to the campaign manager, and wherein the campaign manager includes a campaign creation function, a campaign execution function and a campaign editing function.

40. The system of claim 39, wherein the campaign creation function displays batch information using the graphical user interface and the batch-related information from the batch information database.

41. The system of claim 40, wherein the batch process campaign includes multiple types of batches.

42. The system of claim 37, wherein the batch-related information includes recipe information.

43. The system of claim 37, wherein the batch-related information includes parameters associated with process steps.

44. The system of claim 37, wherein the campaign-related information includes a batch execution mode.

45. The system of claim 37, wherein the campaign manager automatically sends messages to a batch historian that maintains historical campaign information and a security system that controls user access.