Process controller avoids making mistakes

Edited by the Engineeringtalk editorial team Jun 9, 2006

A controller specifically developed to "mistake proof" process activities is set to have a massive impact on general industry.

A controller specifically developed to "mistake proof" process activities is set to have a massive impact on general industry - especially after the glowing feedback it has already received from early adopters in the automotive industry.

The SmartBox from PivotWare is a complete hardware and software solution that can cater for the varying needs of many different process activities.

Thanks to its intelligent design, each SmartBox component is portable and easily replaced.

Multiple contingencies are covered by both mobile backup systems and a built-in resilient network fail over - in combination these can help guarantee that there is no disruption to the manufacturing process.

Indeed, the system is designed in such a way that should any of the individual SmartBoxes or the central server fail the system will continue to operate - a feature not commonly available from other PC- and PLC-based process control architectures.

At the heart of the SmartBox is extremely powerful Process Manager software that allows nontechnical people to build and change complex processes without having to call on internal IT staff or expensive external resources.

Process Manager links to the Process Engine that, in turn, distributes the correct process to the appropriate SmartBox.

Processes can be modified, tested and stored for release when the change in production needs to happen.

Continuous development activities mean that PivotWare is constantly developing new objects/devices to be supported and all objects, as they are released, become standard components of the software product, fully supported by a technical team that operates 24/7.

David Studd, Director at PivotWare explains: "Mistake proofing - defined as the prevention of errors rather than the detection and subsequent action - is the concept that underpins the development and operation of the SmartBox".

Within a process environment, users are presented with clear, easy-to-follow instructions as to the next step within the process procedures.

No matter what happens, when it happens or who does it, the SmartBox will record every detail and then relay this information to the central server.

Using this approach mistakes are far less prone to happen and should an issue arise, it is quick and easy to discover what and why - to provide an immediate remedy.

Traceability is also becoming more vital in a great many industries, with this in mind there is an Intranet facility that allows report queries to be built and run as and when required.

This feature can allow management to find a specific production log regarding a production cycle, or, indeed, enquire on the performance of teams or individuals.

The SmartBox, based on an industrial PC architecture that uses industry-standard components, is available in a variety of models; with I/O counts up to 64.

Units with varying I/Os can be mixed and matched to suit the needs of different process stages without causing any system overheads, as the core components used are consistent across all models.

HMIs are also available and connectivity can be achieved using a variety of different methods and protocols - including Ethernet, RS232 and USB - depending on the sophistication and amount of data being passed between devices.

Each SmartBox has embedded CE or XP, according to the application, while the central server uses SQL Server, IIS and standard Microsoft development tools.

Each SmartBox can operate autonomously and be offline from the server for up to five days without data being lost.

As soon as the server is live again, the data are synchronised automatically and the firmware in the SmartBox can also be updated if necessary.

Studd concludes: "The Beauty of the SmartBox is that it does not pretend to be anything else - it is a dedicated process controller that does exactly what it has been designed to do".

"It has no delusions of grandeur and none of the complexities of many proprietary PLC-based systems".