VISUALISATION OF COMPLEX PROCESSES OF CONTROL

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International Journal of Advanced Research in Engineering and Technology
(IJARET)
Volume 7, Issue 2, March-April 2016, pp. 168–176, Article ID: IJARET_07_02_016
Available online at
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Journal Impact Factor (2016): 8.8297 (Calculated by GISI) www.jifactor.com
ISSN Print: 0976-6480 and ISSN Online: 0976-6499
© IAEME Publication
___________________________________________________________________________
VISUALISATION OF COMPLEX
PROCESSES OF CONTROL
Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska, Jacek Kozyra
University of Technology and Humanities,
Faculty of Transport and Electrical Engineering,
ul. Malczewskiego 29
26-600 Radom,Poland
ABSTRACT
Visualisation application based on Wonderware InTouch is presented in
this article. This software is an engineering tool created for visualisation and
control of industrial processes, meeting all guidelines of SCADA systems
(Supervisory Control and Data Acquisition) and HMI (Human Machine
Interface). It is also a part of Wonderware System Platform. This platform is a
set of services and applications using ArchestrA technology. The authors
showed the options of technical solutions in creating visualisation
applications and supervision and control of large and complex control
objects.
Keywords: Process Visualization, Scada, Industrial Process
Cite this Article: Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska and
Jacek Kozyra Visualisation of complex processes of control. International
Journal of Advanced Research in Engineering and Technology, 7(2), 2016, pp.
168–176.
http://www.iaeme.com/IJARET/issues.asp?JType=IJARET&VType=7&IType=2
INTRODUCTION
Visualisation is a dynamically developing field of technology, combining many issues
related to control, exchange, archiving and processing of process data in the industry
and scientific research.[1],[2] In general, visualisation is a method of creating,
analysing and transmitting information using visual means, which are based on a real
object, reflecting its state in real time.[20] Visualisation environments must provide
not only predefined options of object programming, but also meet requirements of
real time systems. Moreover, visualisation applications should provide interface for
processing and acquisition of data, enabling support of database
applications.[4],[5],[6] This solution enables reporting, diagnostics and statistical

Visualisation of complex processes of control
control, which would be difficult or impossible in the systems that not use
visualisation means.[18],[19]
Analysis of visualisation applications is based on Wonderware InTouch. This
software is an engineering tool created for visualisation and control of industrial
processes, meeting all guidelines of SCADA systems (Supervisory Control And Data
Acquisition) and HMI (Human Machine Interface).[7],[8],[22] The main feature of
InTouch is fast and intuitive use of predefined visual objects and their large library.[9]
1. APPLICATION TEMPLATE OF VISUALISATION PROJECT
Creating a visualisation project starts from creating an application template, which
allows to divide a model into smaller functional units and realizing functionality of
these units in stages and then integrating them. A diagram illustrating the stages of
creating a visualisation application is presented in the Fig. 1. This diagram shows that
defining an application template and its content is one of the first and the most
important activity that a designer must make. Typical template should have a window
fulfilling a role of information bar, main window showing a model of visualisation
and navigation window.[10] A diagram of hierarchy of windows in the application is
presented in the Fig. 2, implementing a template in In Touch in the Fig. 3
Rys. 1 Diagram showing the stages of creating a project of visualisation application
Planning
Creating a model
Combining windows
Combining objects and
parts of model with tags
Determining which information
should be displayed
Determining the number of
windows in the application
Determining hierarchy of windows
Drawing all objects in the
windows
w
Creating navigation from an
application template
Declaration of variables
Creating combinations of
animation objects
Data archiving
Creating a Bindlist
Defining ODBC driver
Creating reports

Zbigniew Łukasik, Aldona Kuśmińska-Fijałkowska and Jacek Kozyra
Rys. 2 Diagram of hierarchy of windows
Rys. 3. Control application of Tobacco Factory ( 1. menu information bar showing: name of a
user, access level, date and hour; 2. main visualisation window; 3. menu bar with the
references to all the most important windows and functions in the application.)[3]
NavigationStatus bar
Alarms Trends Reports Login
Current History
Main
window
Machine 1 Machine nMachine 2 Machine 3

Visualisation application created for the purposes of this article is SCADA system
responsible for control, supervision and acquisition of data of Tobacco Factory, the
so-called primary department responsible for preparing and processing tobacco. In
this part of the plant, forming, packing and production of cigarettes do not take place.
Preparing tobacco for further use is made in stages. Subsequent stages of preparing
tobacco are presented in the diagram below (Fig. 4).
Tobacco production process is divided into two parts: initial conditioning and
drying. (Fig. 3) Each zone is finished with silos for storing tobacco until decisions
about further processing is made. This solution also allows to store product in case of
failure of any of the belt conveyors, preventing from stoppage of production line. Two
buffers regulating the amount of tobacco put into precision cutting machine and dryer
were also installed in the second zone. Buffering machines, due to smaller capacity
than silos, give better precision of control of tobacco put into the machines.
Rys 4 General diagram of a process of tobacco production [3]
2. CURRENT AND HISTORICAL ALARMS
InTouch is equipped with a system informing an operator about the state of process
and control system.[10],[14] This system enables to display, print and keep the
register of history of alarms and events occurring and registered in the system.
Modules of tables and a set of variable fields are used for displaying and management
of alarms. Alarms alert about some values of the process, whereas events contain
information about the state of the system.
A window of historical alarms is presented in the Fig. 5 It differs from a window
of current alarms only in declaration Query Type: Historical and lack of buttons
confirming acceptance of individual historical alarms. The remaining functionality is
identical as in the window of current alarms.
Buffer 1
Buffer 2
Slicing
Drying
Scent
Silos final
Accessories
Guillotine
DCC
Refinement
Storage silos
Conditioning
preliminary
Drying zone
and storage

Rys. 5 A window of historical alarms [3]
3. STATISTICAL CONTROL OF SPC-PRO PROCESS
SPCPro was created to fully integrate functions of SPC with In Touch. SPC is short
for Statistical Process Control. In this method, data about the process are collected
and analysed in order to solve quality problems. A term "statistical" means using of
numerical calculations. A term "process" refers to a given production process and its
ability to get an appropriate quality. A term "control" means monitoring the process
and its regulation, whenever the need arises, in order to enable optimal realization of a
process.[16],[17] To sum up, SPC control is a method of monitoring and control of a
process, that is, collecting parameters characterizing output, analysing these data and
drawing conclusions based on them.[12],[11]
A window of control card of statistical control is presented in the Fig. 6 SPC
module requires to use ODBC driver, the simplest solution is to use small databases in
MS Access or to link module with a database server. Due to the fact that this module
is a standard equipment of application, reported information are more important for an
experienced statistician than operator.[15] Therefore, it is better to use a server with
an option of making resources from TCP/IP protocol available, for example, MS SQL
Server 2005. It allows to link application of production layer with business layer in a
configuration server-server.

Fig. 6 Control card of SPC module [3]
Components linked with a module of SPC-Pro software can be found in a library
FactorySuite, among others, Control card (Fig. 6), SPC Histogram (Fig. 7) and Pareto
chart (Fig. 8). Declaring SPC module in InTouch automatically creates a group of
alarms related to the values monitored by this module.
Rys. 7. Part of SPC-Pro module – SPCHistogram [3]

Fig 8 Part of SPC-Pro module – SPCPareto [3]
4. MOBILE TECHNOLOGIES IN AN ENTERPRISE
Mobile technologies are more and more commonly applied in the production plants.
A person having a smartphone or tablet can, in the city centre, keep an eye on the
progress of production, potential stoppages, and even makes changes in a production
line. In practice, it means that using, for example, a mobile phone, we may track not
only columns and charts that show functioning of an enterprise, but also use many
settings allowing to generate reports, change of parameters of devices and advanced
functions connected with the whole production process (Fig. 9)[21].
In this case, technological bar is set very high. Any devices with the access to the
Internet may become an important element of production process. Access to
application is realized directly from the internet browser, therefore, installing
additional software on a mobile device is not required. Technical requirements are not
complicated, for example, for Wonderware InTouch Access Anywere, management of
production is possible from the level of any device with the internet browser
supporting HTML5.
Figure 9 Visualisation of complex processes of control with the use of mobile technologies
[21]
Implementing mobile applications should be performed together with formulating
new safety procedures in a company. We must also remember that new technologies
bring also new threats.[21]

5. CONCLUSIONS
Development of systems of industrial automation is mainly connected with
development of computerization, communication, telemetry and planning. All these
issues are integral part of large industrial plants and without computer support, its
realization would be difficult or even impossible.
Producers of software created for production more and more often enable
cooperation of application with different layers of IT systems. It enables cooperation
between control, planning and business layers. Wonderware InTouch is a software for
visualisation of processes in SCADA and HMI systems. It is also a part of
Wonderware System Platform. This platform is a set of services and applications
using ArchestrA technology. This technology has now four main trends which enable:
 open communication between various systems,
 support for ERP systems (Enterprise Resource Planning) – planning resources of an
enterprise (e.g. cooperation with SAP system),
 use of such technologies as: OPC, SQL, XML, OLE DB/ADO in the applications
supporting systems: MES (Manufacturing Execution Systems) – systems of
realization of production, HMI, DCS (Distributed Control System) – distributed
control systems, Historian or SCADA;
 communication with actuators and PLC drivers through development of technology:
DI Objects, DA Server, I/O Server, OPC Server.
REFERENCE
[1] Kwicień Roman, Komputerowe systemy automatyki przemysłowej, Helion,
Gliwice 2013.
[2] Vieira Robert, SQL Server 2005 Programowanie, Helion, Gliwice 2007.
[3] Opracowanie Zakładu Automatyzacji Procesów UTH Wizualizacja
wybranego procesu przemysłowego_InTouch Radom 2013
[4] Schneider Electric, 8 Chapter Human-machine interface,
http://www.schneider-electric.com/, Singapur 2009.
[5] Informator Techniczny Wonderware nr 10, ASTOR, Kraków 1998.
[6] Kuśmińska-Fijałkowska, A., and Z. Łukasik. Efekty wynikające z wdrożenia
Systemu Zarządzania Jakością, Logistyka (2014).
[7] National Communications System, Technical Information Bulletin 04-1:
Supervisory Control and Data Acquisition (SCADA) Systems, Arlington
U.S.A. 2004.
[8] FactorySuite™ Menedżer receptur Podręcznik użytkownika, ASTOR,
Kraków 2002.
[9] Invensys Systems, Inc., FactorySuite™ Menedżer SQL Access Podręcznik
użytkownika, Wonderware®, Wersja A, Lake Forest U.S.A. 2002.
[10] Materiały szkoleniowe, InTouch Cz. II: Zagadnienia zaawansowane,
ASTOR, Kraków 2003.
[11] Łukasik, Zbigniew, Aldona Kuśmińska-Fijałkowska, and Waldemar
Nowakowski. "Europe's energy efficiency requirements for household
appliances." Przegląd Elektrotechniczny 91.3 (2015): 194-196.
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[13] http://www.astor.com.pl

[14] Prof. Dr. Z. ŁUKASIK, Ph.D, DSc, Dr. Eng. Aldona Kuśmińska-Fijałkowska
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Advanced Research in Engineering and Technology, 5(9), pp. 26–30.
[15] Kuśmińska-Fijałkowska, A., and Z. Łukasik, Koordynowanie działań w
organizacji w odniesieniu do systemu zarządzania jakością, Logistyka 3/2014.
ISSN 1231-5478
[16] Kozyra, J., and A. Kuśmińska-Fijałkowska, Elementy liniowej logistyki
stosowane w zabezpieczaniu obiektów zagrożonych wybuchem, Logistyka
4/2014. ISSN 1231-5478
[17] Czarny, Krzysztof, Andrzej Rozmarynowski, and Jerzy Wojciechowski.
Tendencje zużycia energii elektrycznej wybranych obszarów zasilania."
[18] Zakrzewski, B., and D. Zakrzewska, Rola zaopatrzenia i metodyka wyboru
dostawcy w działalności przedsiębiorstw przemysłowych, Logistyka(2014).
[19] Zakrzewski, B., and D. Zakrzewska, Przedsiębiorstwo produkcyjne i procesy
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[22] Jitendra Kumar Gupta and Dr. Anil Kumar Sharma, 2014. Programmable
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