SW_Platform

SOFTWARE PLATFORM SPECIFICATION
Document #: SW_Platform.doc
Equipment: Machines based on Rockwell or Siemens systems. Project #: 100xxx Customer: EEDpt
File: ...SW_Platform.doc Révision: 1.13 Page: 1 / 104
SOFTWARE
PLATFORM SPECIFICATION
Supplier
Komax Medtech
Allée du Quartz, 12
2301 La Chaux de Fonds
Switzerland
Equipment
Machines based on Rockwell or Siemens systems.

Table of Contents
1. Introduction .....................................................................................................................................................9
1.1. Account of modifications .........................................................................................................................................9
1.2. Signatures ...............................................................................................................................................................10
1.3. Reference documents .............................................................................................................................................11
1.3.1. Standards & References ........................................................................................................................................................ 11
1.3.2. Working Documents.............................................................................................................................................................. 11
2. Executive Summary.......................................................................................................................................12
2.1. Preliminary.............................................................................................................................................................12
2.2. Objective.................................................................................................................................................................12
2.2.1. One Goal ............................................................................................................................................................................... 12
2.2.2. Three Needs .......................................................................................................................................................................... 12
2.2.2.1. Standard & References (State of the Art) .............................................................................................................................................12
2.2.2.2. Good Automation Practices..................................................................................................................................................................12
2.2.2.3. Rapid Application Development ..........................................................................................................................................................12
2.2.3. Five E2
ASY Paths ................................................................................................................................................................. 12
2.2.3.1. Emulation for early de-risking + Fail Safe for auto-recovery...............................................................................................................12
2.2.3.2. Effectiveness for ahead diagnostics......................................................................................................................................................12
2.2.3.3. Agility for last minute changes.............................................................................................................................................................12
2.2.3.4. Simplicity always in mind....................................................................................................................................................................12
2.2.3.5. Yes we comply.....................................................................................................................................................................................12
2.2.4. Key points Summary............................................................................................................................................................. 13
2.2.4.1. Three major needs................................................................................................................................................................................13
2.2.4.2. 5 outstanding features...........................................................................................................................................................................13
2.2.4.3. 4 elementary managers manage the following features ........................................................................................................................13
2.2.4.4. 4 elementary actuators incorporate the following features ...................................................................................................................13
2.2.4.5. In addition............................................................................................................................................................................................13
2.3. Document Summary ..............................................................................................................................................14
2.3.1. Gamp Guide Lines ................................................................................................................................................................ 14
2.3.2. Design Guide Lines............................................................................................................................................................... 14
2.3.3. Hardware Interfaces .............................................................................................................................................................. 14
2.3.4. Admin Details ....................................................................................................................................................................... 14
2.3.5. Machine Details..................................................................................................................................................................... 14
2.3.6. Asynchronous Stations Details.............................................................................................................................................. 14
2.3.7. Synchronous Stations Details................................................................................................................................................ 14
2.3.8. Actuators Details................................................................................................................................................................... 14
3. Gamp Guide Lines.........................................................................................................................................15
3.1. V Life Cycle ............................................................................................................................................................15
3.2. Tests Overview .......................................................................................................................................................16
3.2.1. Objectives.............................................................................................................................................................................. 16
3.2.2. Modules................................................................................................................................................................................. 16
3.2.3. Box........................................................................................................................................................................................ 16
3.2.3.1. Black....................................................................................................................................................................................................16
3.2.3.2. White....................................................................................................................................................................................................16
3.2.4. Komax Rules......................................................................................................................................................................... 17
3.2.5. Software Architecture............................................................................................................................................................ 17
3.2.6. Architecture & Scope ............................................................................................................................................................ 17
3.2.6.1. "Out of scope"......................................................................................................................................................................................17
3.2.6.2. "In the scope".......................................................................................................................................................................................17
3.2.6.3. Risky Station........................................................................................................................................................................................17
3.2.6.4. Black Box Scope..................................................................................................................................................................................17
3.2.6.5. White Box Scope..................................................................................................................................................................................17
3.3. Tests Procedures ....................................................................................................................................................18
3.3.1. Black Tests............................................................................................................................................................................ 18
3.3.1.1. "State transition" ..................................................................................................................................................................................18
3.3.1.2. Imperative vs Sequencing Logic ..........................................................................................................................................................18
3.3.2. White Tests............................................................................................................................................................................ 19
3.3.2.1. "Data Flow"..........................................................................................................................................................................................19
3.3.2.2. "Branch/Decision"................................................................................................................................................................................19
3.3.2.3. Standard Model....................................................................................................................................................................................19
3.4. Software Plan .........................................................................................................................................................20
3.4.1. Design ................................................................................................................................................................................... 20
3.4.2. Code ...................................................................................................................................................................................... 20
3.4.3. Setup...................................................................................................................................................................................... 20
3.4.4. Debug.................................................................................................................................................................................... 20
3.4.5. Test-Up.................................................................................................................................................................................. 20
3.5. Categories ...............................................................................................................................................................21

3.5.1. Operational system................................................................................................................................................................ 21
3.5.2. Firmware ............................................................................................................................................................................... 21
3.5.3. Standard software package.................................................................................................................................................... 21
3.5.4. Configurable software package ............................................................................................................................................. 21
3.5.5. Fitted software....................................................................................................................................................................... 21
3.6. Changes Control.....................................................................................................................................................21
3.6.1. Revisions Numbering............................................................................................................................................................ 21
3.6.2. Revisions Traceability........................................................................................................................................................... 21
3.6.3. Program Header Update ........................................................................................................................................................ 21
3.7. Check lists...............................................................................................................................................................22
3.7.1. Software ................................................................................................................................................................................ 22
3.7.2. Hardware............................................................................................................................................................................... 22
4. Design Guide Lines........................................................................................................................................23
4.1. ISA-IEC's Models ..................................................................................................................................................23
4.1.1. S88 / 61512 ........................................................................................................................................................................... 23
4.1.2. TR88 / PackML..................................................................................................................................................................... 23
4.1.2.1. Line......................................................................................................................................................................................................24
4.1.2.2. Machine ...............................................................................................................................................................................................24
4.1.2.3. Station..................................................................................................................................................................................................24
4.1.2.4. Actuator ...............................................................................................................................................................................................24
4.1.3. Physics .................................................................................................................................................................................. 25
4.1.4. Configuration ........................................................................................................................................................................ 25
4.1.5. Programs ............................................................................................................................................................................... 25
4.1.6. Machine Modes..................................................................................................................................................................... 26
4.1.6.1. Producing.............................................................................................................................................................................................26
4.1.6.2. Maintenance.........................................................................................................................................................................................26
4.1.6.3. Manual-Emulation................................................................................................................................................................................26
4.1.6.4. Purge....................................................................................................................................................................................................26
4.1.6.5. Dry Cycle.............................................................................................................................................................................................26
4.1.6.6. Single Cycle.........................................................................................................................................................................................26
4.1.6.7. Limp Track...........................................................................................................................................................................................26
4.1.6.8. Limp Nest.............................................................................................................................................................................................26
4.1.7. Machine States ...................................................................................................................................................................... 27
4.1.7.1. Aborting...............................................................................................................................................................................................27
4.1.7.2. Aborted ................................................................................................................................................................................................27
4.1.7.3. Stopping-Clearing ................................................................................................................................................................................27
4.1.7.4. Stopped ................................................................................................................................................................................................28
4.1.7.5. Resetting ..............................................................................................................................................................................................28
4.1.7.6. Idle.......................................................................................................................................................................................................28
4.1.7.7. Starting.................................................................................................................................................................................................28
4.1.7.8. Execute.................................................................................................................................................................................................28
4.1.7.9. Holding ................................................................................................................................................................................................28
4.1.7.10. Held......................................................................................................................................................................................................28
4.1.7.11. Suspending...........................................................................................................................................................................................28
4.1.7.12. Suspended ............................................................................................................................................................................................28
4.1.8. Station States......................................................................................................................................................................... 29
4.1.8.1. Aborting...............................................................................................................................................................................................29
4.1.8.2. Resetting ..............................................................................................................................................................................................29
4.1.8.3. Idle.......................................................................................................................................................................................................29
4.1.8.4. Execute.................................................................................................................................................................................................29
4.1.9. Actuator States ...................................................................................................................................................................... 29
4.1.9.1. Cmd:=1 ................................................................................................................................................................................................29
4.1.9.2. Alm1=1................................................................................................................................................................................................29
4.1.9.3. Sts=1 ....................................................................................................................................................................................................29
4.1.9.4. Cmd:=0 ................................................................................................................................................................................................29
4.1.9.5. Alm0=1................................................................................................................................................................................................29
4.1.9.6. Sts=0 ....................................................................................................................................................................................................29
4.2. UML's Models ........................................................................................................................................................30
4.2.1. Object Oriented ..................................................................................................................................................................... 30
4.2.2. UML's Quatuor...................................................................................................................................................................... 30
4.2.3. Objects Diagram.................................................................................................................................................................... 31
4.2.4. States Diagram ...................................................................................................................................................................... 31
4.2.5. Sequential Diagram............................................................................................................................................................... 31
4.2.6. Class Diagram ....................................................................................................................................................................... 32
4.2.6.1. Hierarchy .............................................................................................................................................................................................32
4.2.6.2. Specialization.......................................................................................................................................................................................32
4.2.6.3. Main Class ...........................................................................................................................................................................................32
4.2.6.4. Interfaces..............................................................................................................................................................................................32
4.2.7. Class & Interfaces ................................................................................................................................................................. 33
4.2.7.1. Mgr_Adm.............................................................................................................................................................................................33
4.2.7.2. Mgr_Prog.............................................................................................................................................................................................34
4.2.7.3. Mgr_Track ...........................................................................................................................................................................................35
4.2.7.4. Mgr_Nest .............................................................................................................................................................................................36

4.2.7.5. Act_Bin................................................................................................................................................................................................37
4.2.7.6. Act_Cam..............................................................................................................................................................................................38
4.2.7.7. Act_Num..............................................................................................................................................................................................39
4.2.7.8. Act_Pls.................................................................................................................................................................................................40
4.2.7.9. Typ_Batch............................................................................................................................................................................................41
4.2.7.10. Typ_Recipe..........................................................................................................................................................................................41
4.2.7.11. Typ_Nest..............................................................................................................................................................................................42
4.3. Embedded Features ...............................................................................................................................................43
4.3.1. Real Time OEE for Ahead Diagnosis.................................................................................................................................... 43
4.3.1.1. TR88 Theory........................................................................................................................................................................................43
4.3.1.2. Mgr_Adm.............................................................................................................................................................................................45
4.3.1.3. Mgr_Track ...........................................................................................................................................................................................45
4.3.1.4. Mgr_Nest .............................................................................................................................................................................................45
4.3.1.5. Act_??? ................................................................................................................................................................................................45
4.3.1.6. OEEs Supervision ................................................................................................................................................................................45
4.3.2. Emulation for Early De-risking + Fail-Safe for Auto-recovery............................................................................................. 46
4.3.2.1. Response Time.....................................................................................................................................................................................46
4.3.2.2. Principle...............................................................................................................................................................................................46
4.3.2.3. Binary...................................................................................................................................................................................................46
4.3.2.4. Came....................................................................................................................................................................................................46
4.3.2.5. Numeric ...............................................................................................................................................................................................46
4.3.2.6. Pulse.....................................................................................................................................................................................................46
4.3.3. Agility for Last Minute Changes........................................................................................................................................... 47
4.3.3.1. Double solenoid cylinder......................................................................................................................................................................47
4.3.3.2. Linear axis with limit switches.............................................................................................................................................................47
4.3.3.3. Rotary table..........................................................................................................................................................................................47
4.4. Configuration Conventions ...................................................................................................................................48
4.4.1. Keys Codes Meanings........................................................................................................................................................... 48
4.4.1.1. Ack.......................................................................................................................................................................................................48
4.4.1.2. Act_......................................................................................................................................................................................................48
4.4.1.3. Adm, Admin ........................................................................................................................................................................................48
4.4.1.4. Alm ......................................................................................................................................................................................................48
4.4.1.5. Bin........................................................................................................................................................................................................48
4.4.1.6. Cam......................................................................................................................................................................................................48
4.4.1.7. Cfg .......................................................................................................................................................................................................48
4.4.1.8. Clr ........................................................................................................................................................................................................48
4.4.1.9. Cmd......................................................................................................................................................................................................48
4.4.1.10. Ctl ........................................................................................................................................................................................................48
4.4.1.11. Ctr........................................................................................................................................................................................................48
4.4.1.12. ...ID ......................................................................................................................................................................................................48
4.4.1.13. Inp........................................................................................................................................................................................................48
4.4.1.14. Log.......................................................................................................................................................................................................48
4.4.1.15. Man......................................................................................................................................................................................................48
4.4.1.16. Mode....................................................................................................................................................................................................49
4.4.1.17. Nak.......................................................................................................................................................................................................49
4.4.1.18. Nest......................................................................................................................................................................................................49
4.4.1.19. NestInt...................................................................................................................................................Error! Bookmark not defined.
4.4.1.20. Num .....................................................................................................................................................................................................49
4.4.1.21. Out .......................................................................................................................................................................................................49
4.4.1.22. Par........................................................................................................................................................................................................49
4.4.1.23. Pls ........................................................................................................................................................................................................49
4.4.1.24. Prog......................................................................................................................................................................................................49
4.4.1.25. Rep.......................................................................................................................................................................................................49
4.4.1.26. ...s.........................................................................................................................................................................................................49
4.4.1.27. Safe ......................................................................................................................................................................................................49
4.4.1.28. State .....................................................................................................................................................................................................49
4.4.1.29. Sts ........................................................................................................................................................................................................49
4.4.1.30. Tmr ......................................................................................................................................................................................................49
4.4.1.31. Track....................................................................................................................................................................................................49
4.4.1.32. Typ.......................................................................................................................................................................................................49
4.4.2. Tags Configuration................................................................................................................................................................ 49
4.4.2.1. Description...........................................................................................................................................................................................49
4.4.2.2. Name....................................................................................................................................................................................................49
4.4.2.3. Domain.................................................................................................................................................................................................49
4.4.2.4. DataType..............................................................................................................................................................................................49
4.4.2.5. TagType...............................................................................................................................................................................................49
4.4.2.6. TagReference .......................................................................................................................................................................................49
4.4.3. Programs Names ................................................................................................................................................................... 50
4.4.3.1. Machine ...............................................................................................................................................................................................50
4.4.3.2. Station..................................................................................................................................................................................................50
4.4.3.3. Actuator ...............................................................................................................................................................................................50
4.4.4. Controller Tags...................................................................................................................................................................... 50
4.4.4.1. Admin ..................................................................................................................................................................................................50
4.4.4.2. Programs ..............................................................................................................................................................................................51
4.4.4.3. Machine ...............................................................................................................................................................................................51
4.4.4.4. Station..................................................................................................................................................................................................51
4.4.4.5. Actuator ...............................................................................................................................................................................................51

4.4.5. Programs Tags....................................................................................................................................................................... 51
4.4.5.1. Machine ...............................................................................................................................................................................................51
4.4.5.2. Station..................................................................................................................................................................................................52
4.4.5.3. Actuator ...............................................................................................................................................................................................52
4.5. Design Process ........................................................................................................................................................53
4.5.1. Machine................................................................................................................................................................................. 53
4.5.1.1. Machine Overview...............................................................................................................................................................................53
4.5.1.2. Machine Configuration ........................................................................................................................................................................53
4.5.1.3. Machine Data.......................................................................................................................................................................................53
4.5.1.4. Stations Configuration..........................................................................................................................................................................53
4.5.1.5. Admin Configuration ...........................................................................................................................................................................54
4.5.1.6. Admin Data..........................................................................................................................................................................................54
4.5.2. Asynchronous Station............................................................................................................................................................ 55
4.5.2.1. Sample, Pick & Place...........................................................................................................................................................................55
4.5.2.2. Horizontal Time Diagram Reference....................................................................................................................................................55
4.5.2.3. Vertical Time Diagram with Transients Choices..................................................................................................................................55
4.5.2.4. Transients to Matrix .............................................................................................................................................................................56
4.5.2.5. Station Configuration...........................................................................................................................................................................56
4.5.2.6. Station Sequencer.................................................................................................................................................................................57
4.5.2.7. Sequences Details.................................................................................................................................................................................57
4.5.2.8. Tags List ..............................................................................................................................................................................................57
4.5.3. Synchronous Station.............................................................................................................................................................. 58
4.5.3.1. Sample, Build & Check Time Diagram Reference...............................................................................................................................58
4.5.3.2. Vertical Time Diagram with Transients ...............................................................................................................................................58
4.5.3.3. Transients to Matrix .............................................................................................................................................................................58
4.5.3.4. Station Configuration...........................................................................................................................................................................59
4.5.3.5. Station Sequencer.................................................................................................................................................................................59
4.5.3.6. Sequences Details.................................................................................................................................................................................59
4.5.3.7. Tag List................................................................................................................................................................................................59
4.5.4. Actuator................................................................................................................................................................................. 60
4.5.4.1. Configuration .......................................................................................................................................................................................60
4.5.4.2. Actuators List.......................................................................................................................................................................................60
4.5.4.3. Programming........................................................................................................................................................................................61
4.5.5. Design Workflow.................................................................................................................................................................. 61
5. Hardware Interfaces......................................................................................................................................62
5.1. Topology..................................................................................................................................................................62
5.1.1. Physical Interface .................................................................................................................................................................. 62
5.1.2. Human Interface.................................................................................................................................................................... 62
5.2. Components............................................................................................................................................................63
5.3. Operator Panel.......................................................................................................................................................64
5.3.1. E-Stop.................................................................................................................................................................................... 64
5.3.2. Stop ....................................................................................................................................................................................... 64
5.3.3. Start....................................................................................................................................................................................... 64
5.3.4. Jog -....................................................................................................................................................................................... 64
5.3.5. Jog +...................................................................................................................................................................................... 64
5.4. Lights.......................................................................................................................................................................64
5.4.1. Red Light Flashing................................................................................................................................................................ 64
5.4.2. Red Light Steady................................................................................................................................................................... 64
5.4.3. Amber Light Flashing ........................................................................................................................................................... 64
5.4.4. Amber Light Steady .............................................................................................................................................................. 64
5.4.5. Green Light Flashing............................................................................................................................................................. 64
5.4.6. Green Light Steady................................................................................................................................................................ 64
5.4.7. White Light Flashing............................................................................................................................................................. 64
5.4.8. White Light Steady................................................................................................................................................................ 64
5.4.9. Buzzer 2 sec .......................................................................................................................................................................... 64
5.4.10. Stop Button Flashing............................................................................................................................................................. 64
5.4.11. Stop Button Steady................................................................................................................................................................ 64
5.4.12. Start Button Flashing............................................................................................................................................................. 64
5.4.13. Start Button Steady................................................................................................................................................................ 64
5.5. H M I.......................................................................................................................................................................65
5.5.1. Screens Map.......................................................................................................................................................................... 65
5.5.2. Screens Header...................................................................................................................................................................... 65
5.5.2.1. Recipe ..................................................................................................................................................................................................65
5.5.2.2. Batch....................................................................................................................................................................................................65
5.5.2.3. Modes...................................................................................................................................................................................................65
5.5.2.4. States....................................................................................................................................................................................................65
5.5.2.5. Date & Time ........................................................................................................................................................................................65
5.5.3. Screenshots............................................................................................................................................................................ 66
5.5.3.1. Machine Overview...............................................................................................................................................................................66
5.5.3.2. Machine Recipe & Batch .....................................................................................................................................................................66
5.5.3.3. Machine Modes....................................................................................................................................................................................67
5.5.3.4. Machine States.....................................................................................................................................................................................67

5.5.3.5. Machine Stops Reasons........................................................................................................................................................................68
5.5.3.6. Machine Stations..................................................................................................................................................................................68
5.5.3.7. Stations States ......................................................................................................................................................................................69
5.5.3.8. Station Overview..................................................................................................................................................................................69
5.5.3.9. Actuator States.....................................................................................................................................................................................70
5.5.3.10. Actuator Overview...............................................................................................................................................................................70
5.5.3.11. Touch Screen Cleaning ........................................................................................................................................................................70
5.5.3.12. On line Users Guides............................................................................................................................................................................70
5.5.3.13. On Line Design References..................................................................................................................................................................70
5.5.4. Alarms Severities Levels....................................................................................................................................................... 71
5.5.4.1. vs Colors ..............................................................................................................................................................................................71
5.5.4.2. vs Stations............................................................................................................................................................................................71
5.5.4.3. Single Acknowledgement.....................................................................................................................................................................71
5.5.4.4. Double Acknowledgement...................................................................................................................................................................71
5.5.5. User Access........................................................................................................................................................................... 72
5.5.5.1. User Login ...........................................................................................................................................................................................72
5.5.5.2. Access Matrix ......................................................................................................................................................................................72
6. Admin Details.................................................................................................................................................73
6.1. Header.....................................................................................................................................................................73
6.1.1. MainType.............................................................................................................................................................................. 73
6.1.2. Main_ID................................................................................................................................................................................ 73
6.1.3. SubType ................................................................................................................................................................................ 73
6.2. States & Modes.......................................................................................................................................................73
6.2.1. E-Stop.................................................................................................................................................................................... 73
6.2.2. Stop ....................................................................................................................................................................................... 73
6.2.3. Start....................................................................................................................................................................................... 73
6.3. Public Data .............................................................................................................................................................74
6.3.1. Current State.......................................................................................................................................................................... 74
6.3.2. Command State ..................................................................................................................................................................... 74
6.3.3. Current Mode ........................................................................................................................................................................ 74
6.3.4. Command Mode.................................................................................................................................................................... 74
6.3.5. Login Identifier ..................................................................................................................................................................... 74
6.3.6. Safety Identifier..................................................................................................................................................................... 74
6.3.7. Acknowledge Identifier......................................................................................................................................................... 74
6.3.8. Alarms Identifier ................................................................................................................................................................... 74
6.3.8.1. Alarm to Abort.....................................................................................................................................................................................74
6.3.8.2. Alarm to Stop.......................................................................................................................................................................................74
6.3.8.3. Alarm to Idle........................................................................................................................................................................................74
6.3.8.4. Alarm to Suspend.................................................................................................................................................................................74
6.3.8.5. Alarm to Hold ......................................................................................................................................................................................74
6.3.8.6. Alarm to Warn .....................................................................................................................................................................................74
6.3.8.7. Alarm to Help.......................................................................................................................................................................................74
6.3.9. Clear Identifier ...................................................................................................................................................................... 74
6.3.9.1. Oper's Stats Clear.................................................................................................................................................................................74
6.3.9.2. Shift's Stats Clear .................................................................................................................................................................................74
6.3.9.3. Batch's Stats Clear................................................................................................................................................................................74
6.3.10. Admin Array ......................................................................................................................................................................... 74
6.3.10.1. Admin Operator ...................................................................................................................................................................................74
6.3.10.2. Admin Shift..........................................................................................................................................................................................74
6.3.10.3. Admin Batch ........................................................................................................................................................................................74
6.3.11. Alarms Array......................................................................................................................................................................... 74
6.3.12. Camshafts Array.................................................................................................................................................................... 74
6.3.13. Parameters Array................................................................................................................................................................... 74
6.3.14. Parameters Length................................................................................................................................................................. 74
6.3.15. Reports Array........................................................................................................................................................................ 74
6.3.16. Tracks Manager..................................................................................................................................................................... 74
6.3.17. Nests Manager....................................................................................................................................................................... 74
6.3.18. Nests Empty .......................................................................................................................................................................... 74
6.3.19. Nest Identifier........................................................................................................................................................................ 75
6.3.20. Part Identifier ........................................................................................................................................................................ 75
6.3.21. Pulse per Second ................................................................................................................................................................... 75
6.3.22. Batch Interface ...................................................................................................................................................................... 75
6.3.23. Recipes Array........................................................................................................................................................................ 75
6.3.24. Recipe Name ......................................................................................................................................................................... 75
6.3.25. Recipe ID .............................................................................................................................................................................. 75
6.4. Diagram ..................................................................................................................................................................75
6.5. Interfaces Configuration .......................................................................................................................................76
6.5.1. Admin Statistics .................................................................................................................................................................... 76
6.5.2. Alarms vs Stations & Severities ............................................................................................................................................ 76
6.5.3. Parameters / Cams vs Stations............................................................................................................................................... 76
6.5.4. Reports vs Stations................................................................................................................................................................ 76
6.5.5. Tracks vs Station's Sides ....................................................................................................................................................... 76

6.5.6. Nests Managers vs Fixture's Sides......................................................................................................................................... 76
6.6. PLC Files.................................................................................................................................................................77
6.6.1. Programs Tags....................................................................................................................................................................... 77
6.6.2. Program_Logic...................................................................................................................................................................... 77
6.6.3. Actuators_Sub....................................................................................................................................................................... 77
6.6.4. AlmScan_Sub........................................................................................................................................................................ 77
6.7. HMI Screen.............................................................................................................................................................77
7. Machine Details.............................................................................................................................................78
7.1. Header.....................................................................................................................................................................78
7.1.1. MainType.............................................................................................................................................................................. 78
7.1.2. Main_ID................................................................................................................................................................................ 78
7.1.3. MainName............................................................................................................................................................................. 78
7.1.4. MaindT.................................................................................................................................................................................. 78
7.1.5. SubType ................................................................................................................................................................................ 78
7.1.6. Sub_ID .................................................................................................................................................................................. 78
7.1.7. SubName............................................................................................................................................................................... 78
7.1.8. SubdT####............................................................................................................................................................................ 78
7.1.9. _Adm..................................................................................................................................................................................... 78
7.2. States .......................................................................................................................................................................78
7.2.1. Abort ..................................................................................................................................................................................... 78
7.2.2. Reset...................................................................................................................................................................................... 78
7.2.3. Exec....................................................................................................................................................................................... 78
7.3. Diagram ..................................................................................................................................................................79
7.4. Public Data .............................................................................................................................................................79
7.4.1. Program Manager.................................................................................................................................................................. 79
7.4.2. Program Track....................................................................................................................................................................... 79
7.4.3. Motions Group ...................................................................................................................................................................... 79
7.4.4. Motions Array ....................................................................................................................................................................... 79
7.4.5. Outputs Array........................................................................................................................................................................ 79
7.4.6. Inputs Array .......................................................................................................................................................................... 79
7.5. Interfaces Configuration .......................................................................................................................................80
7.5.1. Motions Interfaces vs Stations............................................................................................................................................... 80
7.5.2. Outputs- & Inputs vs Stations................................................................................................................................................ 80
7.6. PLC Files.................................................................................................................................................................80
7.6.1. Programs Tags....................................................................................................................................................................... 80
7.6.2. Program_Logic...................................................................................................................................................................... 80
7.6.3. Actuators_Sub....................................................................................................................................................................... 80
7.7. HMI Screen.............................................................................................................................................................80
8. Asynchronous Stations Details......................................................................................................................81
8.1. Header.....................................................................................................................................................................81
8.1.1. MainType.............................................................................................................................................................................. 81
8.1.2. Main_ID................................................................................................................................................................................ 81
8.1.3. MainName............................................................................................................................................................................. 81
8.1.4. MaindT.................................................................................................................................................................................. 81
8.1.5. SubType ................................................................................................................................................................................ 81
8.1.6. Sub_ID .................................................................................................................................................................................. 81
8.1.7. SubName............................................................................................................................................................................... 81
8.1.8. SubdT####............................................................................................................................................................................ 81
8.1.9. Sub Details ............................................................................................................................................................................ 81
8.2. States .......................................................................................................................................................................81
8.2.1. Abort ..................................................................................................................................................................................... 81
8.2.2. Reset...................................................................................................................................................................................... 81
8.2.3. Exec....................................................................................................................................................................................... 81
8.3. Diagram ..................................................................................................................................................................82
8.4. Public Data .............................................................................................................................................................82
8.4.1. Prog....................................................................................................................................................................................... 82
8.4.2. Track0 ................................................................................................................................................................................... 82
8.4.3. Track1 ................................................................................................................................................................................... 82
8.4.4. Nest0 ..................................................................................................................................................................................... 82
8.4.5. Nest1 ..................................................................................................................................................................................... 82
8.5. PLC Files.................................................................................................................................................................83
8.5.1. Programs Tags....................................................................................................................................................................... 83
8.5.2. Program_Logic...................................................................................................................................................................... 83
8.5.3. Actuators_Sub....................................................................................................................................................................... 84
8.5.4. Motion_Sub........................................................................................................................................................................... 84
8.6. HMI Screen.............................................................................................................................................................84
9. Synchronous Stations Details........................................................................................................................85

9.1. Header.....................................................................................................................................................................85
9.2. States .......................................................................................................................................................................85
9.3. Diagram ..................................................................................................................................................................85
9.4. Public Data .............................................................................................................................................................85
9.5. PLC Files.................................................................................................................................................................85
9.5.1. Programs Tags....................................................................................................................................................................... 85
9.5.2. Program_Logic...................................................................................................................................................................... 86
9.5.3. Actuators_Sub....................................................................................................................................................................... 86
9.5.4. Motion_Sub........................................................................................................................................................................... 86
9.6. HMI Screen.............................................................................................................................................................86
10. Actuators Details............................................................................................................................................87
10.1. Overview.................................................................................................................................................................87
10.1.1. Principle ................................................................................................................................................................................ 87
10.1.2. Behaviour.............................................................................................................................................................................. 87
10.1.3. Programming Style................................................................................................................................................................ 87
10.2. Binary......................................................................................................................................................................88
10.2.1. Single Solenoid - Single Sensor ............................................................................................................................................ 88
10.2.2. Single Solenoid - Double Sensors ......................................................................................................................................... 88
10.2.3. Double Solenoids - Double Sensors ...................................................................................................................................... 88
10.2.4. Operator Button with Lamp................................................................................................................................................... 88
10.2.5. Emergency Stop .................................................................................................................................................................... 88
10.2.6. Light / Lamp.......................................................................................................................................................................... 89
10.2.7. Recipe Confirm ..................................................................................................................................................................... 89
10.2.8. Batch Confirm....................................................................................................................................................................... 89
10.3. Camodulo................................................................................................................................................................90
10.3.1. Rotary Indexer....................................................................................................................................................................... 90
10.3.2. Came Follower ...................................................................................................................................................................... 90
10.3.3. Master Came ......................................................................................................................................................................... 91
10.4. Numeric...................................................................................................................................................................91
10.4.1. Probe ..................................................................................................................................................................................... 91
10.4.2. Axis....................................................................................................................................................................................... 91
10.5. Pulse ........................................................................................................................................................................92
10.5.1. Flip-Flop................................................................................................................................................................................ 92
10.5.2. Feeder Level.......................................................................................................................................................................... 92
A. Appendices .....................................................................................................................................................93
A.1. Overall Model.........................................................................................................................................................93
A.2. Structured Text ......................................................................................................................................................94
A.3. Glossary ..................................................................................................................................................................97
A.4. French Summary..................................................................................................................................................103

1. Introduction
The purpose of this document is to describe and specify the machine software platform.
1.1. Account of modifications
Version Date Modified by Description of modification
0.01 28 August 2011 JC Pourchet Creation of the document
0.02 29 August 2011 JC Pourchet §3. Gamp Guide Lines
§4. Design Guide Lines
§7. Machine Details
0.03 30 August 2011 JC Pourchet §4. Design Guide Lines
§5. Hardware Interfaces
§8. Stations Details
0.04 11 Sept. 2011 JC Pourchet §3. Gamp Guide Lines
§4. Design Guide Lines
§6. Admin Details
§10. Actuators Details
0.05 1st Oct. 2011 JC Pourchet §4. Design Guide Lines
§5. Hardware Interfaces
§A.1. Overall Model
0.06 8th Dec. 2011 JC Pourchet §5.1. Hardware Topology
§5.2. Hardware Components
§5.5. Screens Map
0.07 19th Dec. 2011 JC Pourchet §A.2. Structured Text
§A.3. Glossary
0.08 24th Feb 2012 JC Pourchet §8. Asynchronous Station Details
§9. Synchronous Station Details
0.09 04th April 2012 JC Pourchet §4.2.6. Class Diagram
§4.2.7. Class & Interfaces
§5.5.2. Screens Header (Recipe, Batch, Mode, ...)
§5.5.3.1. Machine Overview Screenshot
§5.5.3.6. Stations View Screenshot
§6.4. Public Data (Recipe and Batch information)
1.00 17th July 2012 JC Pourchet §4.2.6. Class Diagram
§4.2.7.4. Mgr_Nest
§4.2.7.11 Typ_Nest (not used anymore)
§10.1. Actuators Detail, Overview
1.01 1st Dec. 2012 JC Pourchet §4.1.7. Machine States witch Hold & Suspend)
§4.3.1.2. Mgr_Adm
§4.5.1.5. Admin Configuration
§5.4. Lights
§5.5.4. Screens Header
§6.4. Admin Diagram
1.11 30th Jan. 2013 JC Pourchet §3.7. Check Lists
§4.4. Configuration Conventions
1.12 06th Feb. 2013 JC Pourchet §5.5.4. Alarms Severities Levels
§6.5.2. Alarms vs Stations & Severities
1.13 02th Dec. 2014 JC Pourchet §3.7. Checklist

1.2. Signatures
KOMAX MEDTECH
Role1
Name Function Date Signature
Preparer JC Pourchet Electrical Engineering Lead
Reviewer T. Perret D&D Software Engineer
Reviewer T. Sordel Validation Engineer
Approver
1
ROLES DESCRIPTION
Preparer: Your signature indicates that you prepared this document.
Reviewer: Your signature indicates that, as a subject matter expert, you have reviewed the content of this document and agree its contents
are accurate.
Approver: Your signature indicates that this document respects regulation requirements of Good Manufacturing Practices and Good
Documentation Practices. You agree with its structure and its relations with others validation documents

1.3. Reference documents
1.3.1. Standards & References
 Component Testing Standard for Software Component Testing
 Fisher-Pillai S88 Batch Control - Applying the S88.01 / IEC 61512-1 by G. Fisher.
 IEC-61131-3 Normalisation des langages de programmations.
 IEEE-1008;1987 Standard for Software Unit Testing
 ISA-S88-01 (IEC-61512-1) Batch Control, Models and Terminology.
 ISA-S88-02 (IEC-61512-2) Batch Control, Data Structure & Guideline for Languages.
 ISA-S88-05 (IEC-61512-5) Batch Control, Automated Equipment Control Models.
 ISA-S88, Commissioning Models and Commissioning / Qualification Mapping.
 ISA-TR88.00.03 Machine and Unit States: ISA-S88 Implementation Example.
 ISO 13849-1 Safety of machinery – Part 1. General principles for design.
 ISPE-Gamp 5 Risk Based Approach to Comply GxP Computerized Systems.
 Matrice Asynchrone Logique séquentielle asynchrone, Uni-Marseille - J. Guizol.
 Matrice d'Huffman Synthèse des systèmes séquentiels.
 Rockwell IA-RM001C-EN-P Integrated Architecture: Modular Programming Foundations.
 Siemens S88, 2007 La norme S88 selon Siemens, Bernard E. Cubizolles.
 SoftwareTesting Canergie Mellon University
 UML II Unified Modelling Language.

1.3.2. Working Documents
 SW_Checklist.xls Software Tasks check lists sample.
 SW_Platform.L5K PLC's project sample (RSLogix).
 SW_Platform.ppt Slides show with all attached figures.
 SW_Platform.xls Machine-Stations-Actuators configuration sample.
 SW_Platform_ActBinCheck.xls Tests Protocols for each Binary Actuator.
 SW_Platform_ActCamCheck.xls Tests Protocols for each Camshaft Actuator.
 SW_Platform_ActNumCheck.xls Tests Protocols for each Numeric Actuator.
 SW_Platform_ActPlsCheck.xls Tests Protocols for each Pulse Actuator.
 SW_Platform_IQCheck.xls Check-list for IQ (I/O, Parameters, Alarms, Reports, etc...).
 SW_PlatformDDETest.xls Tracks and Nests data tracking through DDE link.


Rapid
Application
Development
Standards
&
References
Good
Automation
Practices
2. Executive Summary
2.1. Preliminary
Automated machine programming is typically done
by software engineers, machine designers, and
system integrators. The form and style of the
machine software ranges from modular, to
monolithic in nature. The objective of this project is
to specify the application of a common software
methodology that is consistent with the modular
programming of automated machinery as described
in the ISA-88 standard. This project enables a
consistent method of machine interconnection and
operability.
2.2. Objective
In pharmaceutical industry the most required systems are Rockwell or Siemens.
2.2.1. One Goal
The SW_Platform defines 1 design guide lines for
2 PLC so only one HMI should comply with anyone.
2.2.2. Three Needs
Beside the unique HMI goal, there are 3 targets to keep in mind:
2.2.2.1. Standard & References (State of the Art)
versus ISA-S88, ISA-TR88.02 and ISO-13849
2.2.2.2. Good Automation Practices
with specifications, tests and validation
2.2.2.3. Rapid Application Development
"Time is money", "Ready early", ...
2.2.3. Five E2
ASY Paths
After few technical performance tests, activity based costing analysis and normative references studies,
the 5 following matters appear to be the right paths to achieve the 3 main targets.
2.2.3.1. Emulation for early de-risking + Fail Safe for auto-recovery
To pre-test and failure-compensate process sequences
2.2.3.2. Effectiveness for ahead diagnostics
Detailed real-time OEE at every level for ahead
diagnosis and to identify predictable failures
2.2.3.3. Agility for last minute changes
Through combination of specialization ability
and flexible aggregation, "lego mindstorm"
2.2.3.4. Simplicity always in mind
To make programs running earlier and faster
with less files, data, code, bugs, pain, money...
2.2.3.5. Yes we comply
With standards & references so we reuse
supplier's codes without reinventing wheel.
Only One
HMI-SCADA
For Two
Hardwares
Effectiveness
ahead diagnosis
with O.E.E.
Emulation
for de-risking
& Fail Safe
Simplicity
always
in mind
Yes
we comply
to standards
Agility
for "last minute"
changes

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