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We have been using the zenon HMI software from Copa-Data in various divisions since 2013. CTE has been a partner of manufacturer Copa-Data since the beginning and was also involved in the development of the Batch Control module. Last year, we were promoted to Qualified Partner in their three-stage partner programme. This award shows that we, at CTE, have the necessary expertise to realise the maximum customer benefit in our projects.
As early as possible in the projects, the functional units of the plants are identified based on the R&I and divided into equipment modules (basic functions). This is a prerequisite for the use of zenon Batch Control and for the project to proceed successfully. For the interaction between zenon Batch and the PLCWhat is a PLC?A PLC (programmable logic controller) is a system used for process control. It collects sensor data via inputs, processes it, and controls actuators such as motors or valves via outputs. We use the “Basic Function Header” library module, which we developed and validated ourselves.
This GFC head handles all communication and interactions between the HMI Batch Control, the operator, and the PLC program. Seamless switching between automatic and manual modes, and vice versa, Run/Stop (ISA88What is ISA-88?ISA-88 is an international standard for batch processes and continuous plants. It enables modular, scalable, and reusable automation.) Handling and comfort HMIWhat is HMI?HMI (Human Machine Interface) is the interface between humans and machines. Typically implemented as a dashboard, it is used to control and display operating data and status information. Status messages are just a few of the features that make our GFC Head so valuable to our customers. With many other validated PLC modules in our library for the most common Siemens controllers—such as CFC for the S7-300/S7-400 series or the S7-1200/1500 in the TIA Portal—we are well-equipped to meet all requirements.
We also rely on standard functions for the HMI. Everything is configured in zenon out of the box, which keeps the effort for qualification in the projects low. The standard report configured by us in the projects does not require any additional high-level languages, scripts or programs in the background.
Thanks to the many projects we have already completed using various system architectures, CTE has built up extensive expertise with zenon. We have had very positive experiences with our zenon Multi Client and Multi Server solutions, as well as with standalone projects. In this setup, all individual production lines are equipped with zenon Batch Control and can operate autonomously (usually with control panels located in cleanrooms or EX ZonesWhat are EX zones?Areas with explosive atmospheres. These areas are classified based on the risk and duration of the hazard in order to specify appropriate protective measures and permitted equipment.). To make it easier to create Batch Control RecipesWhat is a batch control recipe?A batch control recipe describes the commands, ingredients, and process parameters that a batch control system needs to produce a fully automated and reproducible batch of product. In addition to remote control, a so-called prescription station is used, which accesses the zenon server of the respective system. This structure offers many advantages but also presents certain challenges, which we can overcome thanks to our extensive experience.
Remote access is another topic that comes up time and again. More and more customers want to be able to check the status of their systems even when they are away from the office. For this use case, we successfully retrofitted the zenon HTML5 web server into an existing application for a pharmaceutical customer. In this process, the Web clientWhat is a web client?A web client is a program that accesses server services through a browser. This allows users to access data flexibly from any device without having to install local software. not directly to the system, but only to specific, approved images of the system that are hosted on a separate web server. Using encrypted communication, only the current values and status are requested from the web server and provided to the system. Whether the customer wishes to simply monitor or also operate the system can be easily defined via the zenon licensing. All of these features comply with current IT security requirements.