1. Kevin Miller, SYD Darryl Jacobs, Rockwell Automation
Power Programming V2.1
Kevin Miller, SYD
Darryl Jacobs, Rockwell Automation
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

2. What is Power Programming?
Clear and consistent structure
Easy to follow program example.
Application note to guide you through a program example.
State Model programming
Pack ML State Model as “Behavioral Model for machine”
Standardized Tags
Pack Tags are used to provide raw efficiency data.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

3. What can Power Programming do for you?
Save time
Save money
Allow you to reuse modules in future projects
Make troubleshooting easier in all machines in which you use modular code -- no matter the customer or application
Provide a quicker return on investment
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

4. So many standards, so little time!
ERP
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc
Level 4
ISA 95
Level 3
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
MES
Automation
Levels
2,1,0
ISA 88
IEC 61512
OPC
PackML*
Batch
Control
Continuous
Control
Discrete
Control
Motion
Control
Many standards, guidelines, and best practices exist in the Factory Automation world. In addition, each piece of your machine may need to meet different specifications. The OEM needs to supply a machine that works seamlessly within a larger system.
RA understands how difficult it is for both OEMs and end users to get their arms around all of these needs and make them work together.
Many companies are running much leaner and can no longer afford to have experts in all areas. Because of our extensive expertise and breath of offering, Rockwell Automation can help you to sort it all out. You have enough to do trying to make your customer’s machine the best it can be. Let us be the experts when it comes to standards.
IEC 61131
Fieldbus
Equipment Control
Intelligent Devices
Adapted from: ISA
* PackML Model is in development
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

5. Rockwell Automation has assembled the right tools for the job
The application engineer’s toolbox:
Functional specifications
Program structure examples
State models
Machine control templates
Axis routine module templates
Before you begin to write your application program, you need to assemble the right tools for the job. RA has assembled what you need into Power Programming.
We call it:
Power Programming
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

6. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Power Programming is:
Integrated
Provides interoperability with plant-wide systems through Logix
Provides standard animated diagram showing the various machine states arranged in a flow diagram
From shop floor to top floor, you and your applications down the line, will know exactly what is going on with each of your applications, no matter where you are in the plant or which application you’re looking at -- only one play book required
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RA Power Programming
Notice the consistent structure, between the Machine program and the Line Program. The Machine Logic is the routine that the Hardware I/O is connected to, E-Stops and permissive. This structure was reused for line connections to individual machines.
Machine Program
Line Program
Machine Logic
State Logic
This is showing the reusability of the RAPP structure.
The basic structure of the machine Conditions logic is always the same, you may have different I/O or e stop connections for different machines, but the basics are the same.
The Auto_State Logic defines the behavior of the machine, if for instance we command the machine to the Starting State, this will command each individual axis on the machine to do whatever it has to do to initialize, as seen in the example HMI code, this could include Fault reset, Homing, and Camming or Gearing, it can be different things for each axis, but once all axes are initialized, the machine transitions into the ready state.
Now take that thought one step further and move this to a overall line controller, and you could consider different machines being Sub elements to the line controller. In this case the commanded state of the line is Starting, (which would translate to Initialize all of your machines) each machine (if in Remote Mode) will receive the commanded state and would command its axes to initialize.
This structure can be applied throughout your application, and your plant, and have similar look and feel and predicted behavior.
Axis Programs
Machine Programs
The Same State Logic was used, there are NO differences between these routine (Except one is written in ladder and the other is a SFC for illustration of different programming techniques.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

8. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
RA Power Programming
Upstream
Equipment
Downstream
Your
Machine
This is to further expound on the thought that your machine could be a “black box” to other machines on the line. Your machine gets upstream and downstream signals through the User Defined Data Types UDTs (e.g., speed, produce conditions, package size, etc.). Your machine takes that information, produces based on that info, and sends that info along to the next machine.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

9. How PhaseManager fits into ISA-88 (S88) batch control model
RSBizWare Batch provides Batch Management for this part for complex batches OR an SFC routine in the controller can be the entire Procedure for a simple batch.
All the instructions to make a product. (For example, Tomato Soup Recipe)
Recipe
Defines product-specific recipe values. (Use 200 gallons water)
Procedure
Formula Values
SFC(s) defining the order in which the phases run. Can be collapsed to just a Procedure.
Consists of
Unit Procedures
Consist of
Operations
Consist of
PhaseManager in the controller provides the state logic framework for phases and enforces the state model.
ANSI/ISA S88.01 Defines Batch Terminology, Recipe and Procedure Models, and a Design Methodology for design of applications related to Batch Production and Control
Lowest level of recipe control. (Add Water)
Phases
Support ISA-88 Phase State Model.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

10. Controller Organizer View
Phases are created and scheduled at the task level (similar to Programs)
Phase state routines are created within a phase
Can be written in any language
Equipment Phases added in Task View
Phase Scoped Tags Folder and Control Tags are automatically generated.
Not all States need to be implemented – only those implemented are shown
Phases can be unscheduled
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

11. Programs compared to Phases
Batch Sequencer
RSBizWare Batch
Application Code
1 Main Routine per program
Main is called each time task executes
Main calls other subroutines based on user Logic
Monitor code within routine to determine what is executing
“- ing” routines act like main routines
Aborting, Holding, Resetting, Restarting, Running, and Stopping
Execution determined by phase sequencer (RSBizWare Batch or application code)
Phase monitor tool to see which routine is executing
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

12. Equipment Phase Backing Tag
A controller-scoped equipment phase backing tag is created by RSLogix automatically
Tag’s name matches equipment phase name
Makes code easier to read
Allows users to debug and monitor equipment phase’s execution
Tag is accessible via HMI screens
Additionally, it provides self-documenting code by leveraging the description pass-through functionality
Equipment Phase
Backing tag
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

13. Create Phase State Routine
Select equipment phase state
Phase State routines are just like “Normal” routines except:
Have a fixed name
Are executed according to the state machine rules
State names chosen from a list of valid states:
Restarting
Running
Holding
Resetting
Stopping
Aborting
Just like “Normal” routines, state routines can be implemented in any available language
Ladder Diagram
Sequential Function Chart
Function Block Diagram
Structured Text
Select equipment phase state language
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

14. Vertical Form Seal Machine
Physical Model
Process Cell
Unit
Equipment Module
Control Module
Vertical Form Seal Machine
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15. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
OEM benefits
Design efficiencies
Reusability
Standardized, modular code development improves time to market
Improves design quality
Reduces errors
Uses best practices
Training costs can be focused
Scalability
Uses the same straightforward terminology no matter the size of your machine
allows you to easily match what customer is already using because of standardized code
common interface minimizes customer resistance to a different brand of machine (e.g., Siemens can be migrated to A-B easily)
Simplified maintenance
Standardized code allows allows for simplified troubleshooting
Less training required if all of the machines behave the same way
Following a design discipline provides the methodology and framework that drives out efficiencies in development, production, and down into services. Design efficiencies are key. They save time, improve design quality, and reduce errors.
Power Programming’s modular program approach uses reusable code sections that can be cut and pasted into a program for homing gearing camming etc. This allows rapid program development and copying of entire control programs, for reuse in other similar machines.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

16. The right tools for the job
The application engineer’s toolbox:
State models
Functional specifications
Modular code use examples
Machine program structure examples
We call it:
Power Programming
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

17. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Let’s take a lesson
Observe what has taken place in batch with regard to defined standards and powerful tools to model, create, and monitor systems.
Motion Control and Packaging is undergoing some of the same development.
Generally the end customer needs are well defined;
Access to efficiency information.
Maintainable code or a great support contract.
Highest performance possible from the machine.
Low cost of integration of machine into facility.
A clean intuitive HMI.
We are aware that our goal is to re-invent the wheel, let’s learn from the pain Batch has seen.
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Times are Changing
The packaging world has gone from (Line shaft) to (some servos) and (Integrated servo motion) machines. increased complexity of the control system required to run these machines compel technology providers to provide a more structured approach to integrating these control systems. In the end we would like to have a method available to integrate our systems with consistent tags, and data.
Cam
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

19. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
What RA is doing to help
Rockwell Automation is continually pursuing and incorporating what you need to be successful
active on industry committees to keep abreast of emerging practices and technology
incorporating new industry technology and trends to provide the right tools
Batch
Control
Levels
2,1,0
Equipment Control
Intelligent Devices
Automation
* PackML Model is in development
Continuous
Discrete
Motion
ISA 88
IEC 61512
OPC
*PackML
IEC 61131
Fieldbus
Adapted from: ISA
creating integrated, modular programming to provide:
A modular format
A consistent structure
State models
Consistent terminology
Rockwell Automation actively participates on appropriate industry committees, which allows us to lead the way with solutions that meet all of your needs.
Power Programming works on the discrete machine level of control, down in the 0,1,2 layers of automation. We provide hooks to the MES ERP Levels, by embracing some of the programming standards available today, such as efficiencies and downtime reporting through our Unique User Defined Data Types (UDTs).
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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PackML
Covers
Auto Mode State Model (S88 derived)
Data Definitions (Pack Tags)
Assists
Derive efficiency information through Pack Tags
Maintenance & Trouble Shooting through common approach in Machine Sequence
Consistent data format makes integration go smoother, adoption of a OEM machine is easier.
Pack ML and Pack tags benefits. The end user needs this information and you can provide this easily with Power Programming.
Pack tags are a useful method of collecting and organizing data.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

21. How Power Programming Helps You
Allows you to view HMI using a machine state model
The functional specification allows you to create a useful HMI that gives the operator the opportunity to view the states of the machine. Because of this, the end user to know how the machine should behave and operators, technicians, and engineers can all speak the same language.
When you touch any one of the states, the explanation of actions for that state pop up in a window. The color of the states change based on which state the system is in.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

22. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
OEM benefits
Design efficiencies
Reusability
Modular code development improves time to market
Improves design quality, and reduces errors
Uses best practices
Scalability
allows you to easily match what customer is already using because of standardized code
Uses the same straightforward terminology no matter the size of your machine
Common interface minimizes customer resistance to a different brand of machine (e.g., Siemens can be migrated to A-B easily)
Simplified maintenance
Standardized code allows allows for simplified troubleshooting
Less training required
Following a design discipline provides the methodology and framework that drives out efficiencies in development, production, and down into services. Design efficiencies are key. They save time, improve design quality, and reduce errors.
Power Programming’s modular program approach uses reusable code sections that can be cut and pasted into a program for homing gearing camming etc. This allows rapid program development and copying of entire control programs, for reuse in other similar machines.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

23. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
End user benefits
Simplified maintenance
Easier machine integration.
Quicker upgrades and on-site changes
Less downtime
Standardization means easier troubleshooting
Lower training costs
Reduced changeover time
Production
Greater machine interoperability
Higher efficiencies
Standardized efficiency reporting
Lower operator training costs
The top reasons for PackML: OEE, machine acquisition costs (standardized programming and operation).
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

24. Rapid Application Development
When you reuse code multiple times in one program:
C Programmers = Instances
Automation Desktop = Subsystems
ISA S88 = Equipment Modules
Machine builders = Sections
Reusable code is sometimes referred to as:
C Programmers = Classes
Automation Desktop = Templates
ISA S88 = Equipment Modules
Machine builders = Sections
This shows how you would reuse code segments and create new instances of the program and it will reuse the same logic, but be different instances.
Develop quickly Control Applications by reusing libraries of standard Logix program objects that contain all the data and code required to control every device in the plant floor
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

25. Visio Version of state model
It is important to understand the benefit of laying out the behavioral model for a machine, this allows the states and conditions to be considered beforehand. This keeps everyone on the same page, from design to implementation of the application, through operators running the machine. Consistency throughout.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

26. States and Transitions
This is a states and transitions matirx showing what the legal transitions from state to state are, and how you would make them happen.
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Program Flow Diagram
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28. Pseudo Code to Program View
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29. How to integrate using base code
This screenshot shows the Main Program PackTags, and where the customer would put their own code, and pack tags.
Upstream
Equipment
Downstream
Your
Machine
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30. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
How to qualify its use
Clear Structure
Local tags in main program
Sub routines
MachineConditions
AutoStateCommands, AutoState, SectionConditions
State Model
Built in data structure
UDT Pack Tags
One could say that someone has implemented Power Programming on an application if they have PackML state model, Pack Tags, and Main program with Machine Conditions, PackTags,State Transitions and auto state, routines.
How to know if someone is using Power Programming? If you have these three elements from our program sample you are using it.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

31. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Steps
Stepping up in technology and structure.
Take a look at where we are today and where we are heading…
State Models introduced, use of structure
Power Programming
PML State Model
Clear Structure
Best Practices
Pack Tags 2.0
Advanced Code
Cam Builder
Higher Performance
Appnotes/Sample Code
Hand build one of a kind code.
Artistic code
Generally fast executing
Often difficult to follow
always requires further integrations work
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

32. A walk through Initialization
This is a brief look at the program structure, it is not intended to be completely understood by one look, the application note goes into more detail. From this you can see there is a sequence of operations that must take place, and we show you how. Remember, you will have mapped out what has to happen to make this work with your functional description.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

33. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
From a customer
Q The PACKML automatic mode state model provides an excellent framework or structure for organizing and developing machine control applications.
A Consider Power Programming with Pack ML a behavioral model for a machine, or discrete process, ie. Starting= Initialize= do whatever you have to do to get ready.
Q I am curious to know if you are aware of any OEMs or users who have adopted the PACKML automatic mode state model in there automation specifications.
A I am aware of many of our OEM's that we have had this discussion with, and sometimes it breaks down when we get to adoption, I am working on specifying what "using Power Programming" means. I have pretty much boiled it down to 3 elements, PackML state model, State Transitions routine, Pack Tags Beyond those basics the "artistry" of the OEM come back into play. We provide the basic structure, Model, Structure, consistent Data.
Q Also, in your opinion, do you feel or have you seen that the PACKML automatic mode state model & PowerProgramming have lead to significant re-use of code?
A I can speak for many of the Rockwell Applications Engineers when I tell you we use it as our "starter code". From and OEM-centric point of view, it would be wise to reuse good structure and proven code for their machines also. I have been evangelizing the benefits of code reuse for some time now, and believe the message is coming across loud and clear.
Q Do you find that the PACKML automatic mode state model useful for rapid development of machine functional requirements?
A Sure, we have used is as the foundation of the behavior model. See the Visio file attached to the examples available at ab.com/powerprogramming.
Q Please let us know what your experience or knowledge is with respect to adoption of the PACKML automatic mode state model in company standards, practices or specifications.
A Many of our customers are attempting to specify Pack ML, and we are presenting a more integrated solution with Power Programming as the 3 elements I discussed earlier, and some example code to get them going. This goes far beyond the PackML state model, and goes more into program structure.
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Resources
Power Programming Website
PackML OMAC Website
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

35. Thanks for your attention
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.