7.8 KiB
7.8 KiB
Estates
@startuml BlenderOperationalStates
skinparam state {
BackgroundColor<<Production>> LightGreen
BackgroundColor<<CIP>> LightBlue
BackgroundColor<<Rinse>> LightYellow
BackgroundColor<<Startup>> LightPink
}
[*] --> Idle
state Idle
state "Production Mode" as Production <<Production>> {
state "First Production" as FirstProd
state "Normal Production" as NormalProd
state "Production Runout" as RunOut
FirstProd --> NormalProd : First production\ncompleted
NormalProd --> RunOut : End production\nrequested
RunOut --> FirstProd : New recipe
}
state "CIP Mode" as CIP <<CIP>> {
state "Tank Cleaning" as TankCIP
state "Line Cleaning" as LineCIP
TankCIP --> LineCIP
}
state "Rinse Mode" as Rinse <<Rinse>> {
state "Cold Rinse" as ColdRinse
state "Hot Rinse" as HotRinse
ColdRinse --> HotRinse
}
state "Startup Sequence" as Startup <<Startup>> {
state "Deaerator Startup" as DeaerStartup
state "Syrup Startup" as SyrupStartup
state "Blend/Fill Startup" as BlendStartup
DeaerStartup --> SyrupStartup
SyrupStartup --> BlendStartup
}
Idle --> Startup : Start system
Startup --> FirstProd : Startup complete
Production --> Rinse : Production complete
Rinse --> CIP : Rinse complete
CIP --> Idle : CIP complete
Production --> CIP : Emergency CIP
Rinse --> Idle : Emergency stop
@enduml
Calculations
@startuml BlenderPIDCalculationFlow
skinparam activity {
BackgroundColor<<Recipe>> PaleGreen
BackgroundColor<<Calculation>> LightBlue
BackgroundColor<<Decision>> LightYellow
BackgroundColor<<Output>> Pink
BorderColor Black
}
start
:Initialize variables;
partition "Recipe Parameters" {
:Determine beverage type;
if (Sugar beverage?) then (yes)
:Calculate syrup percentage based on Brix;
note right: gActualSyrupPerc = (ProductBrix + ProdBrixOffset) / gActualSyrupBrix
else (no)
:Calculate syrup percentage based on ratio;
note right: gActualSyrupPerc = 1 / (Ratio + 1)
endif
:Calculate water percentage;
note right: gActualWaterPerc = 1 - gActualSyrupPerc
:Calculate mixing ratio;
note right: gActualRatioM = gActualWaterPerc / gActualSyrupPerc
}
partition "Flow Setpoint Calculations" {
if (Production mode?) then (yes)
:Calculate CO2 equilibrium pressure;
:Set tank pressure setpoint based on mode;
:Calculate target production rate;
:Apply slew rate limiting;
:Calculate water flow setpoint;
note right: gSP_H2O = gActual_Prod_SP / (gActualSP_RatioVol + 1.0) * gActualSP_RatioVol
:Check for critical blending conditions;
:Calculate syrup flow setpoint;
note right: gSP_SYR = (gSyrSPRef + gSyrSPTemp) * gActualSyrupDens
:Calculate CO2 setpoint;
if (Second gas injection enabled?) then (yes)
:Calculate second gas setpoint;
else (no)
:Set second gas setpoint to zero;
endif
else (no)
:Set all flow setpoints to zero;
endif
}
partition "Tank Level Controls" {
:Calculate syrup tank level setpoint;
:Calculate deaeration tank level setpoint;
:Calculate storage tank level setpoint;
}
partition "Temperature Controls" {
:Calculate water and product temperature setpoints;
}
stop
@enduml
Components
@startuml BlenderSystemComponents
skinparam component {
BackgroundColor LightCyan
BorderColor Black
}
package "Blender System" {
[Syrup Flow Control] as SyrupControl
[Water Flow Control] as WaterControl
[CO2 Injection] as CO2Control
[Second Gas Injection] as Gas2Control
[Deaeration System] as DeaerSystem
[Temperature Control] as TempControl
[Tank Level Control] as LevelControl
[Pressure Control] as PressControl
}
package "BlenderPID_PIDSPCalc" as PIDCalc {
[Ratio Calculator] as RatioCalc
[Water SP Calculator] as WaterSPCalc
[Syrup SP Calculator] as SyrupSPCalc
[CO2 SP Calculator] as CO2SPCalc
[Level SP Calculator] as LevelSPCalc
[Temperature SP Calculator] as TempSPCalc
[Critical Condition Detection] as CritDetect
}
package "Input Parameters" {
[Recipe Parameters] as Recipe
[Production Settings] as ProdSettings
[System Constants] as Constants
}
package "PID Controllers" {
[RMM301 PID] as WaterPID
[RMP302 PID] as SyrupPID
[RVM301 PID] as PressurePID
[RVN304 PID] as DeaerPID
}
Recipe --> RatioCalc
ProdSettings --> WaterSPCalc
Constants --> RatioCalc
RatioCalc --> WaterSPCalc
RatioCalc --> SyrupSPCalc
RatioCalc --> CO2SPCalc
WaterSPCalc --> WaterPID
SyrupSPCalc --> SyrupPID
CO2SPCalc --> CO2Control
LevelSPCalc --> LevelControl
TempSPCalc --> TempControl
WaterPID --> WaterControl
SyrupPID --> SyrupControl
PressurePID --> PressControl
DeaerPID --> DeaerSystem
WaterControl --> CritDetect
SyrupControl --> CritDetect
CritDetect --> SyrupSPCalc : Correction feedback
@enduml
Sequence
@startuml BlenderSequence
skinparam sequence {
LifeLineBackgroundColor LightYellow
ParticipantBackgroundColor LightCyan
}
participant "BlenderPID_PIDSPCalc" as Calc
participant "Water Flow Controller" as Water
participant "Syrup Flow Controller" as Syrup
participant "CO2 Controller" as CO2
participant "Tank Level Controller" as Level
participant "Temperature Controller" as Temp
activate Calc
== Startup Phase ==
Calc -> Level : Set deaerator tank level setpoint
activate Level
Level -> Calc : Level feedback
deactivate Level
Calc -> Temp : Set target water temperature
activate Temp
Temp -> Calc : Temperature feedback
deactivate Temp
== First Production Phase ==
Calc -> Water : Set initial water flow
activate Water
Water -> Calc : Flow measurement
deactivate Water
Calc -> Syrup : Set initial syrup flow (with extra syrup)
activate Syrup
Syrup -> Calc : Flow measurement
deactivate Syrup
Calc -> CO2 : Set CO2 injection (with extra CO2)
activate CO2
CO2 -> Calc : CO2 measurement
deactivate CO2
== Normal Production Phase ==
loop While in production mode
Calc -> Water : Adjust water flow setpoint
activate Water
Water -> Calc : Flow measurement
deactivate Water
Calc -> Syrup : Adjust syrup flow setpoint
activate Syrup
Syrup -> Calc : Flow measurement
alt Critical blending detected
Calc -> Syrup : Apply correction factor
end
deactivate Syrup
Calc -> CO2 : Adjust CO2 setpoint
activate CO2
CO2 -> Calc : CO2 measurement
deactivate CO2
Calc -> Level : Monitor and maintain target levels
activate Level
Level -> Calc : Level feedback
deactivate Level
end
== Runout Phase ==
Calc -> Water : Ramp down water flow
Calc -> Syrup : Ramp down syrup flow
Calc -> CO2 : Reduce CO2 injection
Calc -> Level : Adjust tank levels for end of production
deactivate Calc
@enduml
Clases
@startuml BlenderClassDiagram
skinparam class {
BackgroundColor LightCyan
BorderColor Black
}
class BlenderPID_PIDSPCalc {
+Execute()
}
class RecipeParameters {
+ProductBrix: REAL
+ProdBrixOffset: REAL
+SyrupBrix: REAL
+Ratio: REAL
+CO2Vols: REAL
+CO2Fact: REAL
+GAS2Vols: REAL
+SP_ProdTemp: REAL
+ProdTankPress: REAL
}
class SystemVariables {
+gActualSyrupPerc: REAL
+gActualWaterPerc: REAL
+gActual_RatioM: REAL
+gActual_Prod_SP: REAL
+gActual_Prod_Flow: REAL
+gSP_H2O: REAL
+gSP_SYR: REAL
+gSP_CO2: REAL
+gSP_GAS2: REAL
+gCriticalBlending: BOOL
}
class PIDControllers {
+RMM301: PID
+RMP302: PID
+RVM301: PID
+RVN304: PID
}
class OperationModes {
+gBlenderProdMode: BOOL
+gBlenderRinseMode: BOOL
+gBlenderCIPMode: BOOL
+gBlenderStableFlow: BOOL
+First_Production: BOOL
}
class TankSetpoints {
+gSP_SYR_Level: REAL
+gSP_DEAIR_Level: REAL
+gSP_STORAGE_Level: REAL
+gSP_H2O_Temperature: REAL
+gSP_Prod_Temperature: REAL
}
BlenderPID_PIDSPCalc -- RecipeParameters
BlenderPID_PIDSPCalc -- SystemVariables
BlenderPID_PIDSPCalc -- PIDControllers
BlenderPID_PIDSPCalc -- OperationModes
BlenderPID_PIDSPCalc -- TankSetpoints
@enduml