Review FlexLink Administrators Manual Production logistics software YOUTILIZE ADMINISTRATORS MANUAL Providing production efficiency
Providing production efficiency Version History Version 0.1 0.2 1.0 1.1 Modifications Initial Creation Update to the Drive Motor Servicing Screenshot for build 7.7.7.
Providing production efficiency Contents Version History.............................................................................................................................................. 2 Contents........................................................................................................................................................ 3 Introduction ......................................................................................................................................
Providing production efficiency System Uninstall.......................................................................................................................................... 41 iMonitor Express Uninstall...................................................................................................................... 41 Additional Uninstall Steps.......................................................................................................................
Providing production efficiency Units Per Hour Gauge and Indicator ....................................................................................................... 88 Average Cycle Time Gauge and Indicator ............................................................................................... 88 Completed Units Gauge and Label.......................................................................................................... 89 Cycle Count Numeric Indicator .............................
Providing production efficiency Database Cleanup ................................................................................................................................. 109 Database Maintenance Plan ................................................................................................................. 109 TC/IP Ports Necessary for System Funcionality .................................................................................... 109 Appendix B .......................................
Providing production efficiency Introduction What is Youtilize Youtilize is a software product designed to accompany a conveyor system at many levels. At the Service Monitoring level, Youtilize can deliver benefits relating to the maintenance of the conveyor system, providing timely information indicating the time to next service for the chain and the guide rails. In addition information on the state of each motor is provided, current consumption, etc. Information is gathered and displayed in real time.
Providing production efficiency iMonitor Designer Youtilize Solution iMontor Viewer Flexlink Conveyor with PLC controller Figure 1 System Requirements Hardware As with any software system, specific hardware requirements may vary depending on the scale and complexity of the situation. In the case of Youtilize, both the size and production rate of the line play a critical role in determining the hardware requirements.
Providing production efficiency Calculating Tracking Transactions per minute Each time the location of a unit moving down the production line is tracked by the Youtilize system, a tracking transaction is recorded in the Youtilize database. Tracking transactions are typically generated by the workstations specified in your line definition. However, X45, X46, and other functions may also be optionally configured to generate tracking transactions, so these must be accounted for as well in your calculations.
Providing production efficiency 3 Workstations * 15 units per minute = 45 Transactions per minute Standard Youtilize Hardware Requirements All Youtilize components and 3rd party dependencies are installed on one PC, which is referred to as the Youtilize server. This includes SQL Server Express 2008 R2, Matrikon OPC Server, iMonitor Express, and xLink. If Youtilize dashboard visibility is desired on the line, one or more additional PC’s may also be deployed for purpose of displaying dashboards only.
Providing production efficiency System Recovery None Warranty & Service 3 Year Basic Hardware Service with 3 Year NBD Onsite Service after Remote Diagnosis Accidental Damage Service None Keyboard Dell KB212-B USB 104 Quiet Key Keyboard,English Security Software None OptiPlex 9010 SFF OptiPlex 9010 Small Form Factor w/ Standard PSU Energy Efficiency Options No ESTAR Settings MISC. Cables & Display Accessories None Second Hard Drive Options 500GB 2.
Providing production efficiency Figure 2 In Figure 2 you see that Microsoft .NET Framework 4 is installed. This satisfies the .NET Framework requires since this is a more recent install. Microsoft C++ Redistributable 2008 SP1 Microsoft C++ Redistributable 2008 SP1 is used for running C++ applications on a system that does not have Microsoft Visual C++ installed. • • NOT Included in the iMonitor Express Installation package.
Providing production efficiency • • NOT Included in the iMonitor Express Installation package. . http://www.matrikonopc.com/opc-drivers/plcs.aspx (product information) Sentinel Protection Drivers The Sentinel Protection Drivers are necessary to interface with the Hardware Dongle used to license control the Youtilize Solution. • • NOT included in the iMonitor Express Installation Package. http://c3.safenet-inc.com/downloads/8/0/804F8C5F-F88F-4443-88712AD993DC33DB/Sentinel%20Protection%20Installer%207.6.5.
Providing production efficiency After selecting ‘Run as administrator’ you will be presented with a dialog asking to confirm that you have allowed the installation program to make changes to your system. Figure 4 For more information regarding User Access Control (UAC) please see ‘Working with Microsoft User Access Control (UAC)’ in the Appendix. After Double Clicking the Microsoft .
Providing production efficiency Figure 6 Click ‘Finish’ to finalize the installation of Microsoft .NET Framework 4. Microsoft C++ Redistributable 2008 SP1 The following details the installation of Microsoft C++ Redistributable 2008 SP1.
Providing production efficiency Figure 8 For more information regarding User Access Control (UAC) please see ‘Working with Microsoft User Access Control (UAC)’ in the Appendix. After Double Clicking the Microsoft C++ Redistributable 2008 SP1 installation package you will be presented with the following dialog (please complete steps necessary to allow installation with UAC enabled): Figure 9 Click ‘Next’ to advance to the next screen.
Providing production efficiency Figure 10 Check ‘I have read and accept the license terms’, and Click ‘Install’ to start the installation. Figure 11 Click ‘Finish’ to finalize the installation of Microsoft C++ Redistributable 2008 SP1. Sentinel Protection Drivers The following details the installation of the Sentinel Protection Drivers.
Providing production efficiency After selecting ‘Run as administrator’ you will be presented with a dialog asking to confirm that you have allowed the installation program to make changes to your system. For more information regarding User Access Control (UAC) please see ‘Working with Microsoft User Access Control (UAC)’ in the Appendix.
Providing production efficiency NOTE: If UAC (User Access Control) is enabled it is a good idea to install using the ‘Run as Administrator’ Option accessible by right clicking on the installation program and selecting ‘Run as administrator’ as shown below: Figure 12 After selecting ‘Run as administrator’ you will be presented with a dialog asking to confirm that you have allowed the installation program to make changes to your system.
Providing production efficiency Figure 14 Click ‘Next’ to advance to the next screen. Figure 15 Select ‘I accept the terms in the license agreement’, and click ‘Next’ to advance to the next screen.
Providing production efficiency Figure 16 Select ‘Custom’ and click ‘Next’ to advance to the next screen. Figure 17 For each of the options indicated with a red ‘X’ in Figure 17 click on the icon and set to ‘This feature will not be available’. Each option that will not be installed will have an Click ‘Next’ to advance to the next screen. icon next to it.
Providing production efficiency Figure 18 Click ‘Install’ to start the installation. Figure 19 Click ‘Finish’ to finalize the installation of the Sentinel Protection Drivers. At this point you can now plug in the USB hardware key. Once you plug in the key the drivers will automatically install. You can use Windows Device Manager to verify that the USB hardware key has been installed and is working properly. In Figure 20 note the presences of ‘SafeNet USB SuperPro/UltraPro’.
Providing production efficiency Figure 20 Figure 21 Matrikon OPC Server Matrikon sells its products with service contracts. For specific details regarding the Matrikon software and service contract details you should contact Matrikon directly using the following options: Software Acquisition • http://www.matrikonopc.com/opc-drivers/plcs.aspx NOTE: There are a number of options listed under MatrikonOPC PLC Servers.
Providing production efficiency GE Fanuc PLC OPC Server No Honeywell HC900 OPC Server No Mitsubishi OPC Server No Modbus (Modicon) OPC Server No OMRON OPC Server No Siemens S7 PLC OPC Server Yes Siemens SIMATIC TI505 OPC Server Matrikon OPC Genie Yes No http://www.matrikonopc.com/opcdrivers/opc-ge-plc-fanuc/base-driverdetails.aspx http://www.matrikonopc.com/opcdrivers/opc-hc900/base-driver-details.aspx http://www.matrikonopc.com/opcdrivers/opc-mitsubishi/base-driverdetails.aspx http://www.
Providing production efficiency Figure 23 For more information regarding User Access Control (UAC) please see ‘Working with Microsoft User Access Control (UAC)’ in the Appendix. After Double Clicking the Matrikon OPC Server installation package you will be presented with the following dialog (please complete steps necessary to allow installation with UAC enabled): Figure 24 Select ‘I accept the license agreement’ and click ‘Next’ to advance to the next screen.
Providing production efficiency Figure 25 Select “Complete Setup’ and click ‘Next’ to advance to the next screen. Figure 26 Click ‘Next’ to accept the destination folder and advance to the next screen.
Providing production efficiency Figure 27 Click ‘Next’ to accept the default Start Menu Group and advance to the next screen. Figure 28 Enter a password of ‘fusion220*’ and confirm the password. Click ‘Next’ to advance to the next screen.
Providing production efficiency Figure 29 Select the appropriate option based on the current state of your license. The software can be upgraded from a 30 Day Evaluation to a full license at a later date. Click ‘Next’ to advance to the next screen. Figure 30 Click ‘Next’ to start the installation.
Providing production efficiency Figure 31 Deselect ‘Launch configuration panel’ and click ‘Finish’ to finalize the installation of the Matrikon OPC Server. Matrikon Support • Email: support@MatrikonOPC.
Providing production efficiency SQL Server (If Applicable) If you are deploying the system using Option ‘B’ (distributed) or are not using the iMonitor Express Installation Wizard. You may also be deploying a new SQL Server or using an existing one. As with Microsoft Operating System Patches/Updates it is best to install all Service Packs and updates that are available.
Providing production efficiency Second is a manual deployment which includes manually installing/configuration the SQL Server, manually installing/configuring the Youtilize Solution. This is considered an advanced approach to the deployment of the Youtilize solution and considered outside the scope of this document. iMonitor Express Wizard Install Procedure The following details the installation of the of iMonitor Express using the wizard install procedure..
Providing production efficiency Figure 34 Click ‘Install’ to confirm the installation of Microsoft SQL Server 2008 R2 Express. Figure 35 Click ‘Next’ to advance to the next screen.
Providing production efficiency Figure 36 Select ‘I accept the terms of the license agreement’ and click ‘Next’ to advance to the next screen. Figure 37 Click ‘Next’ to accept the destination folder and advance to the next screen.
Providing production efficiency Figure 38 Click ‘Install’ to start the installation. Figure 39 Click ‘Finish’ to finalize the installation of iMonitor Express. Following the installation iMonitor Express will launch into a Configuration Wizard. The following steps will walk you through the configuration process.
Providing production efficiency Figure 40 Click ‘Next’ to advance to the next screen. Figure 41 Select ‘Add new line’ and ‘FlexLink Conveyor System’ and click ‘Next’ to advance to the next screen.
Providing production efficiency Figure 42 Next to ‘Select a FlexLink configuration file’ and ‘Select the OPC server controlling this line’ there is button. For ‘Select a FlexLink configuration file’ you will select the ellipsis button and an ellipsis select the *.flx file created for the line you are setting up. Next, for ‘Select the OPC server controlling this line’ you will select the ellipsis button and select the OPC Server applicable to the type of PLCs used for controlling the line.
Providing production efficiency Figure 44 If the Windows Firewall is enabled you may be presented with the above dialog (Figure 44). Select the following options and click ‘Allow access’.
Providing production efficiency Figure 46 Now that the installation and configuration have been completed you will be launched into the iMonitor Express –Home Menu. iMonitor Express - Add or Modify an Existing line. 1. Modify or create a new .flx file. 2. In Fusion Server Manager remove the xLink adapter under the machine data source see: FlexLink xLink Adapter – Fusion Server Manager section of the manual. 3. Start iMonitor express and enter the Machine Setup. 4.
Providing production efficiency The following procedure goes over the process of installing the iMonitor Express Viewer. In order to install the iViewer you need to have network access to the host computer where iMonitor Express is installed. Select the host computer from the network explorer. Browse to the ‘C:\Program Files (x86)\Aegis\iMonitor Express‘ folder (might only be named ‘iMonitor Express’). NOTE: this folder needs to be shared on the host computer in order to be visible and selectable.
Providing production efficiency Figure 49 If the Windows Firewall is enabled you may be presented with the above dialog (Figure 49). Select the following options and click ‘Allow access’.
Providing production efficiency System Uninstall This section covers uninstall of the Aegis product. There may be specific cases where you need to uninstall the software. This should not be used if you are upgrading the software as upgrade code is included in the installation package.
Providing production efficiency Figure 53 When the Uninstall completes click ‘Finish’ Additional Uninstall Steps The following steps include modifying the registry. Make sure you are caution when modifying the registry. Delete the iMonitor Express Database In order to delete the iMonitor Express Database you need to have Microsoft SQL Management Studio Express. Microsoft SQL Management Studio Express can be downloaded from Microsoft using the following link: http://www.microsoft.com/download/en/details.
Providing production efficiency Figure 54 Logon to the system using either Windows Authentication or SQL Authentication as applicable NOTE: for SQL Authentication the username is ‘sa’ and the password is ‘Sapassword1’. This information should not be shared with the customer. If this information changes we may no longer have access to the database should the information be lost by the customer and a full system reinstall will be necessary.
Providing production efficiency Figure 55 Expand Databases and right click on the database ‘IMONITOREXPRESS’ and select properties.
Providing production efficiency Figure 56 In the ‘Database Properties’ dialog on the left hand side select ‘Files’ Page 45 of 125
Providing production efficiency Figure 57 On the right hand side make note of the path where the database files which represent the ‘IMONITOREXPRESS’ database exist. You can copy this path by selecting one of the paths and pressing ‘ctrl’ + ‘C’.
Providing production efficiency Figure 59 In the Delete Object dialog make sure to check ‘Close existing connections’ and click ‘OK’.
Providing production efficiency Figure 60 Page 48 of 125
Providing production efficiency Figure 61 The database IMONITOREXPRESS has now been deleted from the system. Clear the HKEY_LOCAL_MACHINE and HKEY_CURRENT_USER Registry Keys Please exercise caution when working in the registry. Working within the registry could cause damage to the system which cannot be undone and may require the system to be reloaded. Only make the changes specified below. HKEY_LOCAL_MACHINE Click Start Æ and in ‘Search programs and files’ text box type ‘regedit’ and press ‘Enter’.
Providing production efficiency Figure 62 Expand ‘HKEY_LOCAL_MACHINE Æ SOFTWARE Æ Wow6432Node. NOTE: If you have installed iMonitor Express on a 32 bit system you will not see the ‘Wow6432Node and will be working directly in the SOFTWARE key.
Providing production efficiency Figure 63 Right click on ‘Aegis Industrial Software Corporation’ and select ‘Delete’. Figure 64 Click ‘Yes’ to delete the registry Key. HKEY_CURRENT_USER Collapse the HKEY_LOCAL_MACHINE key and expand HKEY_CURRENT_USER Æ Software key.
Providing production efficiency Figure 65 Right click on ‘Aegis Industrial Software Corporation’ and select ‘Delete’. Figure 66 Click ‘Yes’ to delete the registry Key. This concludes the steps necessary for preparing the system to have iMonitor Express reinstalled. You can now proceed with the install of iMonitor Express.
Providing production efficiency communication between iMonitor Express and a Line PLC, SQL Database used for data storage and only applicable if not using the database installed with the iMonitor Express Wizard, and the Youtilize Solution made up of iMonitor Express and iMonitor Express Viewer as well as several underlining services (xLink and Real-Time, Alarms, Report Scheduler Services). In the following section I will be going over the configuration of each of these components.
Providing production efficiency Figure 67 FlexLink xLink Adapter – Fusion Server Manager The FlexLink Configuration Tool included in the Fusion Server Manager Snap-in is primarily designed to make changes to the *.flx file associated to the adapter. If you are starting a deployment and have not been provided with the *.flx file you can also create a new one.
Providing production efficiency Figure 68 Information pertaining to the *.flx file are located on the line ‘FlexLink System Configuration File’. First is the path/filename of the *.flx file currently associated to the adapter. If this field is empty (Create New) button. This button is used to create a you will only have access to the new FlexLink Configuration file. If the file is currently associated to the FlexLink adapter both and (settings) will be enabled. The make changes to an existing *.flx file.
Providing production efficiency Figure 69 To start the process of creating a FlexLink Configuration you go to File Æ New.
Providing production efficiency Figure 71 Enter information as described below: • • • • • • • OPC Branch Name (OPC): Name of the FlexLink line. Name: Name of the OPC PLC Server (Copied from the Matrikon Configuration, note setting in Figure 71 above. Description: Any information that can be used to describe the FlexLink line. Enabled: Checked by default and should remain checked. IP Address: IP Address of the PLC Controller Controller Type: Type of PLC used to control the FlexLink line.
Providing production efficiency Figure 72 Notice the ‘Current Controller’ setting which is important when configuration a line that contains more than one controller. You can see that you have two tabs at the top of the ‘FlexLink System Configuration Tool’ dialog, Devices and Layout. Devices The Devices tab presents the options for adding and configuration various devices that are being controlled by the ‘Current Controller’ (PLC). In this tab you can add Motors, Functions, and/or Analog Sensors.
Providing production efficiency Figure 73 Click ‘Add’ and select ‘Motor’. Figure 74 Under ‘Properties’ enter information as described below: • • • • • • • PLC Item Index: This is also known as the Tag in the PLC. FlexLink Identifier: Identifying name FlexLink uses to describe the motor. Name: Name used to identify the item in the iMonitor Express GUI. Description: Field for entering a description for the device. Enabled: Checked by default and should remain checked.
Providing production efficiency New Function Make sure you have the correct ‘Current Controller’ selected. Figure 75 Click ‘Add’ and select ‘Function’ Figure 76 Under ‘Properties’ enter information as described below: • • • • • PLC Item Index: This is also known as the Tag in the PLC. FlexLink Identifier: Identifying name FlexLink uses to describe the motor. Name: Name used to identify the item in the iMonitor Express GUI. Description: Field for entering a description for the device.
Providing production efficiency • • • • • Controller: Populated with information relative to the ‘Current Controller’ setting. Collect Performance Metrics: Check if performance metrics will be provided by this function. Function Type: Select the type of function connected to the PLC. Lane 1: Not required for Youtilize leave as is. Factory Model required with routing information. Lane 2: Not required for Youtilize leave as is. Factory Model required with routing information.
Providing production efficiency Under ‘Properties’ enter information as described below: • • • • • • PLC Item Index: This is also known as the Tag in the PLC. FlexLink Identifier: Identifying name FlexLink uses to describe the Analog Sensor. Name: Name used to identify the item in the iMonitor Express GUI. Description: Field for entering a description for the device. Enabled: Checked by default and should remain checked. Controller: Populated with information relative to the ‘Current Controller’ setting.
Providing production efficiency Figure 80 Under ‘Properties’ enter information as described below: • • • • • • • PLC Item Index: This is also known as the Tag in the PLC. Route Index: Not required for Youtilize leave as is. Factory model required with routing information. FlexLink Identifier: Identifying name FlexLink uses to describe the Work Station. Name: Name used to identify the item in the iMonitor Express GUI. Description: Field for entering a description for the device.
Providing production efficiency • • • • • • • PLC Item Index: This is also known as the Tag in the PLC. Route Index: Not required for iMonitor express leave as is. Factory model required with routing information. FlexLink Identifier: Identifying name FlexLink uses to describe the Work Station. Name: Name used to identify the item in the iMonitor Express GUI. Description: Field for entering a description for the device. Enabled: Checked by default and should remain checked.
Providing production efficiency A new node will now appear under ‘Server Nodes Configuration’ in the left side tree structure. On the right side the Ethernet/IP configuration will be presented. Enter a name for the Configuration (Description is optional). Select the ‘IP Address’ radio button in ‘Device Settings’ section. Enter the IP address of the PLC you want to connect to. Then click the ‘Apply’ button in the bottom right corner. Right click on the created node in the left side tree structure.
Providing production efficiency On the right side the PLC Configuration will be presented. Enter a name for the PLC configuration. NOTE: This name will later be used in the FlexLink Configuration Tool (see section ‘FlexLink Configuration Tool’). Check the ‘Re-Read Configuration from PLC’ in the ‘Automatic Configuration’ section. Then click the ‘Create’ button in the bottom right corner.
Providing production efficiency The configuration is now done for one PLC connection. Repeat the steps if you want more PLC connections. When all configurations are completed then right click on the ‘MatrikonOPC Server’ node in the tree structure Æ persistence Æ and select ‘Save Configuration…’ and specify the save location. Then also make this configuration to automatically load at startup by right click on the ‘MatrikonOPC Server’ node in the tree structure Æ persistence Æ and select ‘Make Default…’.
Providing production efficiency Figure 82 Click okay and you will then be presented with the ‘Realtime Server Settings’ dialog. Figure 83 For Server Name enter the name or IP address of the system you installed the iMonitor Express or where you know the Realtime service is running. iMonitor Express Viewer will then open.
Providing production efficiency Dashboard Workspace The Dashboard Workspace is where you design dashboards. In this section you will get an overview of the various components that make up the workspace. When you first open the Dashboard Designer you will see the following view: Figure 85 The following is a description of the various sections seen in the above screenshot. • • • • Toolbox: The toolbox contains all of the items that can be used in a dashboard.
Providing production efficiency • • • • • • • Current Time Clock: Displays the current time in a Dashboard. Useful when in full screen mode which hides the Windows taskbar. Circle: Used to draw a circle. Tray: Used to create groups of gadgets. Picture Box: Used to insert a picture. Rectangle: Used to draw a rectangle. Smart Text Label: Used to display text based on the item the Smart Text Label is linked with. Text Label: Used to display text.
Providing production efficiency are the same between the selected gadget and/or gauge will show up. Below is a list of some of the common properties. • • • • • • (Name): Displays the name Back Color: Color to be used for the background. Border Color: Color to be used for boards if they have been enabled. Border Width: Width of the border. Border Style: Style of the border. Dashboard Link: Ability to link gadgets and/or Gauges to other Dashboards.
Providing production efficiency Figure 87 Gadgets Here you are able to see the gauges based on the data source type and name that they are associated to. Please keep in mind that they are grouped based on both the type and name property and if a process point does not have an associated model point in the system it will show the same name. But if you select model point one time and then process point the next they will be grouped separately.
Providing production efficiency Figure 88 To change the Data Source Properties right click on an individual gauge to change just a single gauge or select a group by the associated point to change the entire group of gauges from one point to another.
Providing production efficiency Working with Gauges Types of Gauges iMonitor consist of many types of gauges. Each gauge has properties that control the amount of data to be displayed, look and feel of the gauge, graphic limits for indicating acceptable values. For the most part the properties are self-explanatory and therefore will not be covered. This includes setting fonts and turning on certain true/false options.
Providing production efficiency • Information Grid • Count Down/Count Up Timer • Label • Area Chart Youtilize Supported Gauges The iMonitor solution contains a large number of gauges. The following is a list of those that are supported by the Youtilize Solution: • • • Time to Next Service (gauge type: Count Down Timer) – Displays the time to next service for a single Drive Motor. Time Since Last Service (gauge type: Count Up Timer) – Display the time the last time service was performed on a motor.
Providing production efficiency • • • • • • • • • • • • • speed, or motor, runtime. Additionally a maximum, minimum, and average or median value can be set. Equipment Measurement History Chart (gauge type: Rolling Line Chart) – Displays the specified drive motor measurement value. The measured values can be configured to for motor power, motor speed, or motor runtime. Utilization (gauge type: Area or Pie Chart) – Displays how much time the Functions and Motor points have spent at any given state. i.
Providing production efficiency Dashboard Designer To view dashboards in the Dashboard Designer, accessible from iMonitor Express) you first need to make sure the Real Time service settings are present. Figure 90 After opening iMonitor Express select ‘iMonitor Designer’. Figure 91 After opening the Dashboard Designer go to ‘Options’ and select ‘Real Time Server Settings’.
Providing production efficiency Figure 92 Verify that the ‘Server Name’ and ‘Server Port’ settings are correct and click ‘OK’. Figure 93 With the Dashboard you want to view selected (visible in the designer) click View and select ‘Run Dashboard’.
Providing production efficiency Figure 94 The ‘Dashboard Viewer’ window will open. The viewer will connect to the Real Time Service and display production data in the dashboard. iMonitor Viewer Like the Dashboard Designer the iMonitor Viewer is accessible form within iMonitor Express. However you can go directly into the viewer. You will also have the ability to open more than one Dashboard at a time and setup slide shows.
Providing production efficiency Figure 95 After opening iMonitor Express select ‘iMonitor Viewer Figure 96 Page 80 of 125
Providing production efficiency Opening Dashboards Figure 97 To open a Dashboard you will click the Blue button. Figure 98 Select the Dashboard you would like to open and click ‘Open’. NOTE: After you click ‘Open’ the ‘Dashboard Selection’ dialog does not close. This gives you the opportunity to open additional dashboards. Once you have opened all the dashboards you would like to view click ‘Close’.
Providing production efficiency Figure 99 Slide Shows A slide show is a collection of dashboards that have a slide display time property in seconds that can be saved as a template and later opened under Dashboard Slide Shows. The process of Opening a slide show is very similar to opening a Dashboard however you can only open on slide show at a time. If you would like to view additional dashboards you can open them individual from the ‘Live Dashboards’ tab.
Providing production efficiency Figure 101 Select the ‘Dashboard Slid Shows’ tab and a slide then click ‘Open’. Figure 102 Once all of the slides show dashboards are open you can adjust the ‘Slide display time’ as well as add additional dashboards.
Providing production efficiency NOTE: Any changes made to a slide show in iMonitor Express Viewer cannot be saved. To make changes for future use you will need to use iMonitor Express – iMonitor Viewer. Closing Dashboards At any point you may want to close dashboards that are no longer needed or that were opened to get additional information. To close a dashboard make sure that that it is currently in the active view.
Providing production efficiency Drive motor servicing In iMonitor Settings there is a tab for Drive Motor Servicing. This tab is used for entering data about the service monitoring on each conveyor. For each service activity the Item Serviced must be filled in. Only process points of the type Motor is possible to choose. The Service Type describes which kind of activity that is to be executed. There are two types of components, Chain or Slide rail.
Providing production efficiency Gauge Calculations The following calculations are meant to be used as references for how each gauge is returns the results that are presented. As with any calculation the data presented is key to determining whether the presented results match the expected results.
Providing production efficiency Equipment Measurement History Gauge Filters Supported – Process Point The Equipment Measurement Gauge does not use any calculations. The gauge only displays data provided by the equipment it is connected too. Equipment Measurement History Chart Filters Supported – Process Point The Equipment Measurement History Chart does not use any calculations. This gauge only displays historical data based on measurements provided by the equipment.
Providing production efficiency The State gauge displays the state as provided by the attached point. There is no calculation used to provide this data. Pass Yield Gauge, Pass Yield Numeric Indicator Filters Supported – Model Point / Process Point Configured to use first pass or second pass yield. Pass yield is calculated using pass unit failures. First pass failures are units that have ever failed and second pass failures are units that have ever been failed more than once.
Providing production efficiency Cycle Time (2) to (3) = 80 seconds Average Cycle Time = (80 + 90) / 2 = 85 seconds Completed Units Gauge and Label Filter Supported – Factory Line/Process Point Subtract the number of units that have failed, from the number of units processed through the point, to derive at the number of completed units. If the number of completed units is greater than the job quantity, the completed quantity is reduced to the job quantity.
Providing production efficiency time. The designation of a machine state as operating time or not is achieved in the OEE Configuration tab within the iMonitor Settings of iMonitor Express. If no machine state information is recorded within the planned production time window the last known machine state value shall be used. If no machine state information has ever been recorded for the process point then the operating time shall equal the planned production time window.
Providing production efficiency If Ideal Cycle Time for a given machine is 60 seconds and the Operating Time is 1 hour then at 100% performance we would have to process the following number of items: Performance = Ideal Cycle Time / (Operating Time / Total Pieces) 1 =1 / ( 60 / Total Pieces) Total Pieces = 60 If we had processed 48 items the performance would be: Performance = Ideal Cycle Time / (Operating Time / Total Pieces) =1 / ( 60 / 48 ) = 0.
Providing production efficiency 1. Availability 2. Performance 3. Quality Availability is the percentage of the planned time that a machine is available. It is a measurement of uptime that is designed to remove the effects of scheduled downtime, quality and performance. Performance is the percentage of the designed speed at which the machine is running. It is a measurement of speed that is designed to remove the effects of availability and quality.
Providing production efficiency Figure 103 Opening Dashboards Figure 104 To open a Dashboard you will click the Blue button.
Providing production efficiency Figure 105 Select the Dashboard you would like to open and click ‘Open’. NOTE: After you click ‘Open’ the ‘Dashboard Selection’ dialog does not close. This gives you the opportunity to open additional dashboards. Once you have opened all the dashboards you would like to view click ‘Close’.
Providing production efficiency Figure 106 Slide Shows A slide show is a collection of dashboards that have a slide display time property in seconds that can be saved as a template and later opened under Dashboard Slide Shows. The process of Opening a slide show is very similar to opening a Dashboard however you can only open on slide show at a time. If you would like to view additional dashboards you can open them individual from the ‘Live Dashboards’ tab.
Providing production efficiency Figure 108 Select the ‘Dashboard Slid Shows’ tab and a slide then click ‘Open’. Figure 109 Once all of the slides shows dashboards are open you can adjust the ‘Slide display time’ as well as add additional dashboards.
Providing production efficiency NOTE: Any changes made to a slide show in iMonitor Express Viewer cannot be saved. To make changes for future use you will need to use iMonitor Express – iMonitor Viewer. Closing Dashboards At any point you may want to close dashboards that are no longer needed or that were opened to get additional information. To close a dashboard make sure that that it is currently in the active view.
Providing production efficiency Troubleshooting SQL Server Unable to Connect to the Database When the software throws this error, it indicates that there was some kind of problem when attempting to connect to the SQL Server Express database. When the software starts up, it attempts to connect to the database. If the database does not respond, it simply returns this error. The system has no ability to diagnose why. This error is kind of like the "Service Engine" light on your vehicle.
Providing production efficiency Is the Database Service Running If the service is running, it is an indication that SQL Server has installed correctly and the database is available for use by the toolset. You can check to see if the Database Service is running by navigating to your the Services application. Depending on your operating system, the path may be a bit different, but it should be along the lines of Start>>Control Panel>>Administrative Tools>>Services(alternately type "services.
Providing production efficiency IMONITOREXPRESS_log.ldf and IMONITOREXPRESS.mdf If these files exist, it indicates that the SQL Server was installed. If they are not present, you may need to perform a restore (assuming the presence of a backup). If the files exist, continue on to the next step of the troubleshooter. If the files do not exist, then the database was not installed. You can either re-run the complete installer, or install the database manually.
Providing production efficiency Sample SQL Statements In Fusion Server Manager enable SQL logging to determine problems with generated SQL statements. 1. Fusion Server Manager – Diagnostics – System Logging: Select SQL add the required service: 2. AegisRealTimeAnalysisServer.exe, xLinkTransmitter.exe or iMonitorExpress.exe 3. Check all Output Levels 4. Set a log File directory and other applicable miscellaneous settings. 5. Select the formatting tab 6.
Providing production efficiency Expand the ‘Local host’ node in the tree structure to view the OPC servers running on the computer. Typically you will found two OPC Server items, one PLC specific server item and one simulation server item. Right click on the PLC specific server item Æ and select ‘Connect’. Now right click the node item again Æ and select ‘Add group’.
Providing production efficiency The ‘Add Group’ dialog will appear. Press ‘Ok’. The tag browser will appear. In the upper tree structure, you will find your Ethernet/IP configuration made previously with the MatrikonOPC Server (The Alias node can be ignored). Expand the configuration and then you should see another node which is the PLC configuration. Expand that node. Now the available tags are shown.
Providing production efficiency corner. Now the selected variables can be viewed in the explorer. Look in ‘Quality’ column. A ‘Good’ value indicates that the variable is properly read from the PLC. A ‘Bad’ value indicates that PLC cannot be read properly.
Providing production efficiency Licensing Sentinel Protection Troubleshooting 1. Ensure the key driver only is installed. 2. Reboot the Computer. 3. Try the USB key in a different port. Uninstall the key driver and re-install. Verify Aegis services are running 4. 5. Verify Connection to Aegis License Server Assuming a cleanly executed install of the Sentinel software, the file “aislicen.htm” can help you check the installed license.
Providing production efficiency Add License Server to Systems Internet Options – Trusted Sites To add the License server to trusted sites the server name needs to added in internet options.
Providing production efficiency To add input server name and click the button Diagnostic Logging In Fusion Server Manager enable Application and SQL logging to determine problems with generated. 1. Fusion Server Manager – Diagnostics – System Logging: Select Application , SQL and/or Service 2. a. AegisRealTimeAnalysisServer.exe and xLinkTransmitter.exe logs can be produced for Application , SQL and/or Service. b. iMonitorExpress.exe logs can be produced for Application and/or SQL 3.
Providing production efficiency FlexLink xLink Adapter not processing data from Matrikon OPC server 1. Confirm the OPC service is installed and the service is running Dashboards Dashboards are not displaying any data 1. 2. 3. 4. 5. Confirm all Aegis services are running. Viewer is marked as connected. Turn on system logging. Confirm xLink configuration. Confirm Alan Bradley software is installed and configured.
Providing production efficiency Appendix A Working with Microsoft User Access Control (UAC) Beginning with Windows Vista, Microsoft added a new layer of protection to prevent unwanted applications from executing on systems without first being authorized by the user. Configuration settings for UAC are available under Control Panel Æ User Accounts.
Providing production efficiency iMonitor Settings OEE Availability = Operating Time / Planned Production Time Planned Production Line settings If no schedule is set the default scheduled time will be 24/7. Once a schedule has been set up a schedule will always be required. Operating Time The operating time calculation can be configured by selecting a machine state. - Will include in the OEE Operating Time calculation. - Will excluded in the OEE Operating Time calculation.
Providing production efficiency Startup Procedure Users who would like the system to start the iMonitorViewer on startup. Locate the iMonitorViewer.exe on the local drive right click Send to Æ Desktop (create shortcut) Copy the iMonitor Express icon into the windows startup application.
Providing production efficiency Limit the number of dashboards that can be opened Select the Start Æ Type ‘regedit’ in the search screen and press Enter Æ Navigate in the left pane: HKEY_LOCAL_MACINE\Software\Aegis Industrial Software Corporation\WebOptions In the right hand pane double click on“MaximumDashboards" Page 112 of 125
Providing production efficiency After adding double click on the MaximumDashboards amend to the required value .
Providing production efficiency Appendix B Service Monitoring The following describes what needs to be done for every conveyor in the system. Initial measuring data Gap, chain-beam, top (Gap_top) The initial (nominal) value must be measured by a service engineer at start up or change of the component. • Measure_NominalGap_top Thickness of chain top (Chain_top) The initial (nominal) value must be measured by a service engineer at start up or change of the component.
Providing production efficiency The initial (nominal) value must be measured by a service engineer at start up or change of the component. • Measure_NominalChain_tab Initial input data The limit values for all component wear values must be filled in at start up.
Providing production efficiency Inspection measuring data The measurements points mentioned above are to be measured all over again at the inspection occasion. Gap, chain-beam, top • Measure_InspectionGap_top The inspection value is decreasing due to wear of the components. This wear distance is the sum of the wear of the slide rail (top) and the chain (top). Wear (1.
Providing production efficiency Wear (1.2) Inspection measure Nominal measure Reference point Picture 2: Measure, Thickness of chain top Formatted: Danish Gap, chain-side plate, idler end (Gap_idler) • Measure_InspectionGap_idler The inspection value is increasing due to wear of the components. This wear distance is the sum of the wear of the slide rail (idler) and the chain (tab). Wear (1.
Providing production efficiency Wear (1.4) Inspection measure Nominal measure Reference point Picture 4: Measure, Thickness of tab Wear calculations The wear of the components can then be calculated. The chain wear can be different on the two measuring points: • Wearchain_top = Measure_NominalChain_top – Measure_InspectionChain_top • Wearchain_tab = Measure_NominalChain_tab – Measure_InspectionChain_tab The slide rail wear can be different on the two measuring points.
Providing production efficiency • IMotor Continuous task Every sample occasion, there is a new current value from the motor. Then a number of calculations have to be updated. Accumulated Service Index, SInew (Ah) The estimation is that the motor current has been fixed to this value the whole period since the last sample. This SI value must be calculated unique for every component on the conveyor.
Providing production efficiency These values must be possible to reset when a new component is installed. Estimated remaining Runtime, Runtimeto limit The next calculation is to estimated remaining lifetime in Runtime. • Runtimeto limit_chain • Runtimeto limit slide_rail Generic formula: Runtime to limit Runtime new = * (SI Lim − SI new ) SI new For the chain and the slide rail there are two SI values each. The lowest of these decides when the limit is reached.
Providing production efficiency SI(Ah) Wear (mm) Starting point, [Y0;X0] Inspection point, [Y1;X1] Estimated lifetime (SI), [YLim;XLim] Picture 5: Graph SI(Ah) vs wear(mm) The starting point is called [Y0;X0]. This is the time when a new component is installed. Both the Service Index (Y0) and the wear (X0) is zero because the conveyor has not been run at all yet. When an inspection is done we have an actual wear value of the component, X1. The corresponding accumulated SI value is called Y1.
Providing production efficiency • SIlimit_slide rail idler SI Lim = YLim = f(X Lim ) = Y1 * X Lim X1 The next inspection point is over writing all these values with (hopefully) even more accurate values. Database Requirements Time to next service uses data from two tables in the database – ServiceLogs (max size approximately 200 bytes per motor) and EquipmentMeasurements (max size approximately 150 bytes per motor per measurement).
Providing production efficiency Appendix C Upgrade Installation: It is usually possible to install a newer version of iMonitor Express on top of an existing one. Here are the steps required: • Stop all AEGIS services. o Windows Start Button->Run->services.msc o Stop all five Aegis services by right-clicking on the service, and the select ‘stop’ from the menu: • Run the new installer until complete.
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Publication 5117028 EN 2012-10 Providing production efficiency Page 125 of 125
