With increasing requirements to lower the emissions and growing demands for cars, one of the
world leading catalyst manufacturers decided to increase and modernize its production plant.
In the extension and modernization of the production of catalytic converter described above the
task of the INEA company was to write the code to manage batch process with a programmable
logic controller (PLC), model of the batch process and write test recipes in the InBatch software
and application for supervisory control and data acquisition. My job in this project was to write
part of the software code for control of devices, some phase sequences, testing the written
program with the simulation software and also commissioning and testing on the real system.
The second chapter of the thesis presents the scope of a batch system (used devices and link
between them), short description of the production line and requirements of the company for
the production of catalytic converter. In the third chapter the Studio 5000 Logix Designer
software for programming programmable logic controllers it’s described as well as
Wonderware Inbatch software for making batch process models and test recipes, Wonderware
InTouch application for supervisory control and data acquisition, used Allen Bradley 1756-
L73S GuardLogix programmable logic controller, AS-i bus and AS-I master and Allen Bradley
PowerFlex 753 frequency converter.
The following chapters describe some of the used function blocks, phase state transitions, phase
interface and one of the transfer phases is described. After finishing the programming and
testing with the simulation system (Factory acceptance test - FAT), the program was transferred
to the PLC of the real system and then carried out commissioning and testing of the real
equipment in the factory (Site acceptance test - SAT).
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