Software features

Security features

Software includes a configurable security system capable of the following:

  • Flextime has the ability to create multiple user accounts for each operator, supervisor, engineer, or maintenance person.
  • Each account can be assigned permissions for specific Flextime tasks.
  • Flextime has the ability to permit or restrict any software function from any specific user or group of users.
  • Ability to track user login and logout operations, including time stamping.
  • Ability to program an auto-logout after a specific period of operator inactivity.
  • Ability to program an auto-logout at specific times during the day (i.e. shift changes)
 

Visualization

  • Animation of hoist/crane movements, including different image for loaded or unloaded hoists.
  • Visual indication of bar in tank, deactivated tanks, and alarms.
  • Fully integrated mobile system with rotating, lockable casters.
  • Shuttle animations.
  • Large buttons for mouse-click access.

    • Screen Customization

    Customized screens are provided for monitoring and control of the equipment.
  • Screens are easily modified by the user using the built-in screen designer tool (with proper security credentials).

    • Main screen display

  • Shows tank and hoist status.
  • Shows animation of hoists, including up and down indications.
  • Shows animations of shuttles, tank doors, and other items.
  • Shows grid-view of loads.
  • Shows grid-view of tanks, time in tank, and time settings.

    • Process recipe generation

    FLEXTIME offers an intuitive and easy-to-use management screen for recipe creation, deletion, and editing.
  • Easy grid-based programming design
  • Drag-n-drop station to add or delete
  • Time entries as well as variable names to match
  • Part Database field Batch tank identification
  • Shuttle identification Min, Max, and Nominal times for dynamic scheduling constraints Identified by-name or by-number.
  • To add a station, operator clicks on right-hand station and drags and drops onto recipe.
  • To remove a station, operator clicks on recipe row and drag and drop to right-hand station list.
  • Security levels apply to recipe
  • Customization of stations, including ability to instruct system to leave the crane at the station during process time (ie. critical tanks).

    • Dynamic scheduling

    FLEXTIME has the most flexible and powerful dynamic scheduling engine available for multiple hoist control in tanklines. Flextime is the only software that provides a real-time visual indication of schedules – as they run. Both tank and crane utilization is shown in a time-based chart format. The graphic screen also provides the ability to identify crane utilization, tank utilization, and other resource allocation.
  • Powerful genetic algorithm for optimization of primary recipes.
  • Flexible dynamic fit algorithm for fast, auto-fit of concurrent recipes, including configurable fit algorithms to maximize cycle times and fit density.
  • Automatically compensates for crane times, pre-move times, post-moves, and different acceleration and velocities.
  • Automatic crane collision avoidance, including auto-clear capability to move cranes out of conflict zone prior to movement.

    • Fixed-timeway scheduling

    FLEXTIME can also be used a flexible fixed-timeway solution. With an integrated graphical timeway design tool, writing and maintaining fixed timeways has never been easier. Flextime is the only software that provides a real-time visual indication of schedules – as they run. Both tank and crane utilization is shown in a time-based chart format. The graphic screen also provides the ability to identify crane utilization, tank utilization, and other resource allocation.
  • The best alternative to PLC-based fixed timeways.
  • Create and edit timeways in easy graphical environment.
  • Unlimited timeways can be created and stored for operation.
  • Click, drag, and drop crane movements on the timeway generator screen.
  • Auto crane conflict identification.
  • Capable of generating oscillation and other non-standard movements of crane.
  • Change crane allocation of each move instantly via mouse click.

    • Hoist and shuttle positioning

    FLEXTIME automatically controls the position of cranes and shuttles. By utilizing distributed positioning systems such as ICS-5000 and Stahltronic, FLEXTIME becomes a powerful controller
  • Automatic operations
  • In automatic mode, the movement of the cranes and shuttles are timed to coincide with the current part load, recipes selected, and time-in-tank requirements. FLEXTIME takes into account each cranes velocity and acceleration when determining the exact move initiation time.
  • Semi-automatic operations
    • A simple drop-down form interface is provided to allow semi-auto moves of cranes from station to station. The crane can be moved by pressing the specific button.
  • Positioning hardware options:
    • SICK laser distance meter with Flextime’s “SmoothHoist” control algorithm.
    • P&F (Stahltronic) distance meter with Flextime’s “SmoothHoist” control algorithm.
    • Use existing PLC and/or positioning units on line.

    • Temperature control and monitoring

    FLEXTIME automatically controls and monitors tank temperatures, including time/date scheduling of production versus weekend setpoints, hi/low alarming, trend displays, and other features.
  • Easy to visualize HMI screens
  • High and low temperature alarms
  • Powerful and accurate PID algorithm, including time-proportioning of heating and cooling valves
  • Automatic and manual setpoint entry
  • Discreet control of “enable” circuitry
  • Group settings to “normal”, “standby” or “shutdown” temperatures.
  • Global temperature settings
    • With “mode” settings, you can instruct the system to automatically set all temperatures based on pre-programmed settings. The time that settings are applied can be immediate (via button) or can be timed to coincide with a specific date/time or a specific time on pre-defined days (ie. Friday @ 4:00am).
  • Screen trending of tank temperatures

    • Rectifier and dosing control and monitoring

    FLEXTIME automatically controls and monitors rectifiers, including alarming, automatic activation, ramping, and trickle settings. Automatic chemical dosing is also supported.
  • Rectifier monitoring and control features
    • Easy to visualize MMI screen.
    • On/Off control of rectifier.
    • Auto or Manual rectifier setpoint.
    • Controlled ramping of rectification (Amp/sec) for better plating.
    • Selectable open-loop or closed-loop control of voltage and/or current.
    • Alarming on high, low, or deviation.
    • Totalize amp-hrs of rectification for each tank.
    • Trickle-mode activation during excess time-in-tank in order to control excessive and/or reverse plating.
  • Automatic chemical metering/dosing control
    • Automatic control of metering pump for exact dose amount.
    • Interval control setting.
    • Configurable for exact implementation.

    • Pump, ventilation, agitation, and misc. controls

    FLEXTIME can be configured to control all elements of your tankline, including pumps, fans, ventilation, agitation, ultrasonics, and any other discrete or analog component.
  • Typical control elements
    • Pumps
    • Fans
    • Valves
    • Motors
  • Discrete control features
    • Configurable auto or manual control.
    • Elements can be turned on or off based on “lift” or “drop” commands.
    • Capable of pre-enabling items prior to use.
  • Discrete control features
    • Timed operation of specific control elements (see below 

    • Alarm and Event log

    FLEXTIME maintains an alarm and event log that can be configured to provide detailed accounts of specific alarms and override conditions.
  • Color coded entries.
  • New alarm log every day, week, or month (configurable).
  • Customized groupings by-crane, by-station, or by-part for post-run query and alarm analysis.
  • Time and date stamping.
  • Query and monitoring screen for easy selection and search of specific alarm results.
  • MS Access format.

    • Database operations

    FLEXTIME can utilize a part database for recipe selection and by-part settings for rectifiers, temperatures, and other elements.
  • Database creation and entry.
  • Customer-configured fields.
  • Bar-code enabled selection of parts, including auto-lookup.
  • Part fields can be pre-configured for use in Recipes as MinTime, MaxTime, Nominal, and Drip times.
  • Part fields can be used to indicate agitation, oscillation, or other discrete controls during the parts process cycle.
  • Fields can be used to generate production database at completion of each cycle.
  • MS Access, MS SQL Server, and any ODBC-compliant database.

    • Production database operations

    FLEXTIME can utilize an MS Access, SQL, or customer database in order to store production and cycle information for long-term or short-term verification of process.
  • Database creation and entry.
  • Customer-configured fields.
  • Global record entry at end of recipe, or during process.
  • Time and date stamping.
  • Query and monitoring screen for easy selection and search of specific production variables.
  • Automatic database file creation at predefined times (ie. new database every day).
  • MS Access, MS SQL Server, and any ODBC-compliant database.

    • Object-oriented configuration

    FLEXTIME utilizes ASC’s CPC object-oriented engine as the base foundation for the package. Object-orientation provides maximum flexibility with minimal software overhead.
  • Object
    • An object is an independent software component that has a preset functionality and maintains all of its configurations within the object structure. In the case of FLEXTIME objects, each object can contain properties (variables), methods (actions), and events (quick-scripts). New objects are created from a specific class (ie. Crane) and often have a parent-child relationship.
  • Types of predefined objects
    • FLEXTIME incorporates many pre-designed and pre-tested object classes. The following list includes some of the related classes:
    • Crane, Shuttle, CraneAxis, ICS5000, Station, Tank, Rectifier, DosingPump, Input, Output, Alarm, Scheduler, ScheduleRunner, ScheduleBuilder, and many others.
    • FLEXTIME and CPC include more than 400 different classes of objects designed and tested to meet hundreds of different equipment and application requirements.
  • Ease of troubleshooting
    • As you can see above, the object structure in FLEXTIME affords an easy interface for troubleshooting. For example, you will notice that the all elements relating to a Crane are positioned as “children” of the crane object. Here is a example object hierarchy:
      • Cranes—> Crane1 —> Horizontal —> ICS5000
    • This example shows how you can “drill” down in the object editor to identify a specific object element – in this case the ICS5000 positioning system object. When you click on a specific object, the object editor will show the current properties for that object. Within the object editor you can modify practically any attribute and/or control function for the system.

    • Scripting language for customization

    The FLEXTIME software incorporates VB-like scripting for all of the “logic” configurations of a system. This capability allows for easy, “on the fly” changes to system configurations and operations.
  • CPC scripting engine
    • FLEXTIME incorporates ASC’s CPC scripting engine, which offers the capability to provide custom logic and custom functionality without leaving the FLEXTIME environment.
    • The scripting language is similar to Microsoft’s VB Script language, and provides parallel processing capabilities which allow hundreds of concurrent scripts to be running within the FLEXTIME environment.
  • Changes “on the fly”
    • With CPC’s scripting engine, trouble-shooting and development changes can be made on-the-fly, without ever leaving the FLEXTIME environment. This provide unequalled troubleshooting and maintenance flexibility.
  • All logic in software
    • Because of the scripting capabilities, the FLEXTIME package is usually configured to include all custom logic required to operate your process line. In most implementations, only minimal logic is processed within the attached PLC or I/O hardware.

    • Equipment Control

  • Incorporates internal logic programming that allows it to control real-world devices with or without additional PLC or setpoint controllers.
  • Incorporates a high-level logic or script language allowing future modifications to equipment operations, including valve operation, interlocks, heater operation, and other related operations.
  • Monitors all analog sensors (i.e. thermocouples, transducers, etc.) as well as all digital input devices (limit switches, pressure switches, etc.) for use in logic, program flow, and display.
  • Is capable of independently controlling all discreet devices, including pumps, motors, valves, and indicators.
  • Provides closed-loop PID control of equipment temperature, rectifier, dosing, and other elements.
  • Continuously reads and monitors all sensors and inputs when in a run or when dormant. This is required for remote viewing and screen logging.

    • Maintenance

  • Calibration
    • Ability to calibrate all analog readings
    • Ability to utilize high and low external standards for calibration.
      • Software to automatically calibrate reading based on comparison between technician entered Hi and Low values (i.e. 0 and 100) and actual technician driven high and low values at the sensor.
    • Ability to calibrate any selected group of sensors at one time.
    • Ability to view and compare old and new calibration prior to accepting the new results.

    • Troubleshooting

    The following troubleshooting features are included.
  • Ability to force any individual I/O point
    • Security locked to Maintenance only.

    • Maintenance database

    Includes an optional database to track and record maintenance operations.
  • Tracks operator entered problems and bugs.
  • Tracks maintenance operations.
  • Ability to query maintenance records based on person, item (i.e. Inlet Valve), and problems.
  • Minimum fields
    • Date/Time
    • Name
    • Item
    • Problem
    • Solution