June 12, 2018 – COPA-DATA presents versions of its automation and reporting software with zenon 8.00 and zenon Analyzer 3.20. The updates include extensive functionality for smart factories and energy distribution, as well as new predictive analytics calculations.
As well as module and industry-specific extensions, the focus of this year’s release is fundamental adaptations to product infrastructure. In future, zenon customers can take advantage of improved performance in the areas of data distribution, grids and redundancy, as well as cycling archiving. For example, through optimized data distribution between driver and Runtime, zenon 8.00 processes more than 10,000 variable changes per second in one screen. In stress tests, cycling archiving performance of 250,000 variables written per second has been demonstrated.
Equipment Modeling in zenon organizes a physically existing system into any number of hierarchically structured groups and units. Variables, recipes, functions and archives, and other meta-information can be assigned to these equipment groups over several projects. This allows for data modeling in the development environment, as well as the user environment. This way, the module offers an optimal overview of the status of equipment used. In zenon 8.00, the Industrial Maintenance Manager module is now coupled with Equipment Modeling. Machine and maintenance data can, therefore, be managed. Service intervals can be planned and represented.
zenon Batch Control is a solution for batch-based production in a variety of industries. With zenon 8.00, master recipes can now be automatically released. In addition, a recipe can be created in an external program, then automatically imported and released for production. This allows for a consistently automated workflow.
zenon 8.00 also brings features for shift management. Process data in the Alarm Message List, the Chronological Event List, and in Trends and Reports can now be filtered based on shifts. As a result, informative production analysis with consideration of shift data is an option.
zenon Process Recorder offers the possibility to analyze errors and problems after the event. It supplements existing zenon tools for error analysis. With zenon 8.00, the evolution of a project can now be illustrated. Any deviations from the current state are highlighted in the replay mode tables. That way, several project development stages can be consistently analyzed using one tool.
For energy automation, COPA-DATA has developed additional functionality with regard to a comprehensive Distribution Management System. Two new modules, Load Flow Calculation and State Estimator enable grid calculations in the context of energy distribution. The State Estimator plays a role in larger energy grids in which complete measurements do not take place. Furthermore, calculations can now be made to optimize grid operation, such as topologic interlocking from the grid calculation or the (n-1) calculation to assess faults in subcomponents of the grid.
If invalid data is sent from a Remote Terminal Unit (RTU), this can lead to widespread loss of function at the operator site. The newly developed Alternative Data Points (ADP) driver helps avoid this issue and provides improved data consistency and operation safeguarding through data flow. The alternative data points jump in during an RTU fault and maintain the data flow either with redundantly collected data from other RTUs or through programmable simulation data. Moreover, the ADP driver is also useful for control systems in other industries.
To measure and ensure production quality, the Statistical Process Control – SPC is frequently used. The most common SPC reports can be created and analyzed in the new version of the COPA-DATA reporting software, zenon Analyzer 3.20. These include process capability analysis to assess quality stability in pilot production, control charts for quality checks in series production and a histogram to render the distribution of measured values around the average value. Additional statistical reports such as box plot, trend with limits, or the XY trend, supplement the already extensive analysis offered to optimize production quality.
In addition, zenon Analyzer 3.20 offers smart analysis tools through Predictive Analytics Reports. zenon Analyzer offers two types of predictions. Time-based predictions provide an outlook of how a variable will develop in the future. Value-based predictions show how a value will develop if another value is changed, for example, to assess energy consumption following a fictitious change in production volume.
In the future, the project engineer will configure the prediction model in the Prediction Model Manager. This newly introduced tool is a part of the zenon Analyzer Management Studio. It includes helpful wizards for step-by-step creation of prediction models.