International Journal of Advanced Research in Engineering and Technology

(IJARET)
Volume 7, Issue 2, March-April 2016, pp. 168176, Article ID: IJARET_07_02_016
Available online at
http://www.iaeme.com/IJARET/issues.asp?JType=IJARET&VType=7&IType=2
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 ukasik, Aldona Kumiska-Fijakowska, 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 ukasik, Aldona Kumiska-Fijakowska and
Jacek Kozyra Visualisation of complex processes of control. International
Journal of Advanced Research in Engineering and Technology, 7(2), 2016, pp.
168176.
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

http://www.iaeme.com/IJARET/index.asp

168

editor@iaeme.com

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
Determining which information
should be displayed

Planning

Determining the number of

windows in the application
Determining hierarchy of windows

Creating a model

Combining windows

Drawing all objects in the

windows
w
Creating navigation from an
application template
Declaration of variables

Combining objects and

parts of model with tags

Creating combinations of
animation objects
Creating a Bindlist

Data archiving

Defining ODBC driver

Creating reports

Rys. 1 Diagram showing the stages of creating a project of visualisation application

http://www.iaeme.com/IJARET/index.asp

169

editor@iaeme.com

Zbigniew ukasik, Aldona Kumiska-Fijakowska and Jacek Kozyra

Status bar

Alarms

Current

Navigation

Trends

Reports

Login

History

Main
window

Machine 1

Machine 2

Machine 3

Machine n

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]

http://www.iaeme.com/IJARET/index.asp

170

editor@iaeme.com

Visualisation of complex processes of control

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.

Conditioning
preliminary

Drying zone
and storage

Buffer 1

Guillotine

Slicing

DCC

Buffer 2

Refinement

Drying
Accessories
Scent

Storage silos

Silos final

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.

http://www.iaeme.com/IJARET/index.asp

171

editor@iaeme.com

Zbigniew ukasik, Aldona Kumiska-Fijakowska and Jacek Kozyra

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.

http://www.iaeme.com/IJARET/index.asp

172

editor@iaeme.com

Visualisation of complex processes of control

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]

http://www.iaeme.com/IJARET/index.asp

173

editor@iaeme.com

Zbigniew ukasik, Aldona Kumiska-Fijakowska and Jacek Kozyra

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]

http://www.iaeme.com/IJARET/index.asp

174

editor@iaeme.com

Visualisation of complex processes of control

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]
[2]
[3]
[4]
[5]
[6]
[7]

[8]
[9]
[10]
[11]

[12]
[13]

Kwicie Roman, Komputerowe systemy automatyki przemysowej, Helion,

Gliwice 2013.
Vieira Robert, SQL Server 2005 Programowanie, Helion, Gliwice 2007.
Opracowanie Zakadu Automatyzacji Procesw
UTH Wizualizacja
wybranego procesu przemysowego_InTouch Radom 2013
Schneider
Electric,
8
Chapter
Human-machine
interface,
http://www.schneider-electric.com/, Singapur 2009.
Informator Techniczny Wonderware nr 10, ASTOR, Krakw 1998.
Kumiska-Fijakowska, A., and Z. ukasik. Efekty wynikajce z wdroenia
Systemu Zarzdzania Jakoci, Logistyka (2014).
National Communications System, Technical Information Bulletin 04-1:
Supervisory Control and Data Acquisition (SCADA) Systems, Arlington
U.S.A. 2004.
FactorySuite Meneder receptur Podrcznik uytkownika, ASTOR,
Krakw 2002.
Invensys Systems, Inc., FactorySuite Meneder SQL Access Podrcznik
uytkownika, Wonderware, Wersja A, Lake Forest U.S.A. 2002.
Materiay szkoleniowe, InTouch Cz. II: Zagadnienia zaawansowane,
ASTOR, Krakw 2003.
ukasik, Zbigniew, Aldona Kumiska-Fijakowska, and Waldemar
Nowakowski. "Europe's energy efficiency requirements for household
appliances." Przegld Elektrotechniczny 91.3 (2015): 194-196.
Invensys Systems, Inc., FactorySuite SPCPro Podrcznik uytkownika,
Wonderware, Wersja A, Lake Forest U.S.A. 2002.
http://www.astor.com.pl

http://www.iaeme.com/IJARET/index.asp

175

editor@iaeme.com

Zbigniew ukasik, Aldona Kumiska-Fijakowska and Jacek Kozyra

[14]

[15]

[16]

[17]
[18]
[19]
[20]

[21]

[22]

Prof. Dr. Z. UKASIK, Ph.D, DSc, Dr. Eng. Aldona Kumiska-Fijakowska

and Dr. Eng. Waldemar Nowakowski, 2014. Ecological Powder Coating
Technology Based On Innovative Solutions. International Journal of
Advanced Research in Engineering and Technology, 5(9), pp. 2630.
Kumiska-Fijakowska, A., and Z. ukasik, Koordynowanie dziaa w
organizacji w odniesieniu do systemu zarzdzania jakoci, Logistyka 3/2014.
ISSN 1231-5478
Kozyra, J., and A. Kumiska-Fijakowska, Elementy liniowej logistyki
stosowane w zabezpieczaniu obiektw zagroonych wybuchem, Logistyka
4/2014. ISSN 1231-5478
Czarny, Krzysztof, Andrzej Rozmarynowski, and Jerzy Wojciechowski.
Tendencje zuycia energii elektrycznej wybranych obszarw zasilania."
Zakrzewski, B., and D. Zakrzewska, Rola zaopatrzenia i metodyka wyboru
dostawcy w dziaalnoci przedsibiorstw przemysowych, Logistyka(2014).
Zakrzewski, B., and D. Zakrzewska, Przedsibiorstwo produkcyjne i procesy
realizowane w sferze produkcji, Logistyka(2014).
Olczykowski, Z., and J. Wojciechowski. Pomiary podstawowych parametrw
jakoci
energii
elektrycznej
z
wykorzystaniem
miernikw
wirtualnych." Prace Naukowe Politechniki Radomskiej, Elektryka 2.
Arkadiusz Rodak Czy smartfon moe by narzdziem do zarzadzania nie
tylko biurem, ale i fabryk Biuletyn Automatyki nr 84 2/2015 ISSN 15073890
Jitendra Kumar Gupta and Dr. Anil Kumar Sharma, 2014. Programmable
Logic Controller Based Implementation of Supervisory Control for Sugar
Refinery .International Journal of Advanced Research in Engineering and
Technology, 5(9), pp. 19.

http://www.iaeme.com/IJARET/index.asp

176

editor@iaeme.com