Infact and Winfact Process Control Systems
These process control systems were custom designed for a worldwide household products
manufacturer for use in their factories. Systems were installed in the U.S.A.,
Mexico, England, France, Brazil, Columbia, Thailand, China and elsewhere.
The systems run on PC hardware using standard PLC hardware from GE, Allen Bradley,
Siemens and others for interface to the factory hardware. The Infact system is IBM OS/2
based; the Winfact system runs from a Windows Server and can handle up to about 200 (or more, depending on server hardware)
remote nodes on Windows NT, Vista or Windows 7 platform, as well as all Apple and Samsung tablet systems with reduced
Major components of the Infact/Winfact system:
Systems in the factory consist of one or more master nodes, (nodes that are
connected directly to a PLC), and as many slave nodes as desired. The major current implementaton of this system in a liquid soap factory consists of 55 OS/2 master nodes, 75 OS/2 slave
nodes, and a Winfact server which typically handles about 80 nodes.
- Graphics Display program - Interfaces the operator to the factory.
Displays custom screens depicting the process with real-time animation and
variable display. It also provides real-time control of valves, motors, etc.
- Graphics Editor program - Used by engineers and developers to
create the custom screens used by the Graphics Display programs.
- Trend program - Provides comprehensive trending of process variables
over time. Display of real-time or stored trends is available.
- Alarm program - Displays alarms which happen throughout system. Filters
can be set to display different areas, priorities, alarm types, etc. For
example a node in a maintenance area could be set to display only alarms that
pertain to machinery failures.
- Schedule program - Scheduler that can run programs, change process
variables, etc., based on elapsed time, time of day or change in process variable
- Math program - Simple spreadsheet program that does math on process
variables in real time.
- Interface software - provides the "glue" that ties all the programs
together, including a RAM based real time database, interprocess communications
software, and internode software (via TCP/IP).
- Security program - A program to bring up the system in the desired
configuration, provide menu access to auxiliary
programs and, with the Infact (OS/2) version, provide protection of the
operating system and files from the operator.
- Driver programs - Programs that interface with the PLC's which control
factory hardware. Drivers are available for the GE series 6,
GE 90/70, Allen Bradley, Siemens and others. There are actually 14 different drivers now available for various hardware.
- Configuration and information programs - Various programs to
configure the system, show current status of progams and communications links,
This system is extremely robust. Development started in 1992, and has been continuously debugged and improved since then,
with new features to numerous to mention. I still maintain and improve this system on a part-time basis.