DDAS Equipment Performance Library Manual

About this documentation

This documentation provides essential information for working with components of the DDAS software ecosystem. It is intended for software developers and machine manufacturers who integrate, validate, and operate DDAS function blocks within CODESYS‑based applications.

Note!

Before installing or configuring any software, ensure that you have read and understood the operating instructions of all relevant hardware devices!

Tip!

Further information can be found at: https://www.ddas.digital

This manual is part of the DDAS library collection, which includes documentation for license management, date and time handling, scheduling, equipment performance, and other functional modules:

Document history

General

Library

This library provides a comprehensive solution for real-time monitoring and historical tracking of equipment performance. It enables the calculation and analysis of key performance indicators (KPIs) such as production counts, overall equipment effectiveness (OEE), performance rates, and loss metrics across different operational contexts, including batches, shifts, or product runs.

In addition to real-time evaluation, the library supports the structured capture and storage of performance data over time. This allows for detailed trend analysis, traceability, and long-term performance assessment.

The solution includes capabilities for identifying and analysing production losses and operational states, helping to improve transparency and support continuous optimization of manufacturing processes.

The library includes the following user function blocks:

• EquipmentPerformance

• EP_History

EquipmentPerformance

This Function block calculating and tracking key equipment performance indicators (KPIs), including production counts,

OEE, performance rates, and loss analysis, for an active batch, shift, or product run.

EP_History

This Function block stores equipment performance data into historical arrays, capturing snapshots of performance, production, loss, and top-state metrics from the EquipmentPerformance function block.

Detailed descriptions of the function blocks and their relevant dependencies are provided in the following chapters.

Licensing Concept

All libraries require a valid license. Each license is based on three mandatory keys:

• SiteCode
  Provided by the user (e.g. ‘DDAS-Site-License’)

• LibraryGuid
  Delivered with the library (e.g. ‘{LIB-DDAS-D5BA612E}’)

• LibraryActivationKey
  Issued by DDAS (e.g. ‘EDB86DA0’)

License Activation Mechanism

To activate a library license, one instance of the function block Get_Lib_License must be called for each licensed library.
This function block is part of the DDAS_LicenseManager_Lib library.

Licensing Process

The following steps are required to license and use a library:

1. The user selects the required libraries.

2. The user integrates the selected libraries into a test project or uses the provided demo program and evaluates them using the time‑limited demo license.

3. If the user intends to use the library function blocks in a machine application, the library is ordered and the selected SiteCode is sent to DDAS.

4. DDAS provides the corresponding LibraryActivationKey.

5. In the machine application, the user instantiates the function block Get_Lib_License once for each library and assigns all required license keys to activate the library license.

6. After successful activation, all function blocks of the licensed library can be implemented and executed.

Note: Detailed information on how to use the function block Get_Lib_License is provided in the software manual of the library DDAS_LicenseManager_Lib.

Note: The function Get_sError is available in every library and provides access to the error description and enumeration corresponding to a function block’s error code, when required.

FB EquipmentPerformance

General Information

This chapter describes the function block EquipmentPerformance.

Function Block Name: EquipmentPerformance

Library: DDAS_ EquipmentPerformance_Lib

Dependent Coveys libraries: Nonel

CODESYS Version Compatibility: CODESYS V3.5 and higher

License / Usage Restrictions: Requires valid full or demo library license

Purpose & Scope

This Function block calculating and tracking key equipment performance indicators (KPIs), including production counts, OEE, performance rates, and loss analysis, for an active batch, shift, or product run.

It processes production data, schedules, and state information to generate detailed KPIs, production insights, and loss analytics, supporting performance optimization, OEE tracking, and reporting at batch, shift, or product level.

Typical Use Cases

This function block is used in industrial automation systems to monitor and analyse machine performance in real time.

Functional Overview

When enabled, the Equipment Performance function block provides real-time calculation and tracking of key equipment performance indicators (KPIs) for an active production context, such as a batch, shift, or product run.

It continuously processes operational inputs including production counts, product cycle time, machine performance targets, equipment states, and time information to generate a comprehensive view of machine efficiency and productivity.

The function block evaluates production output by distinguishing between good (OK) and defective (NOK) units and compares actual performance against planned production rates. Based on this data, it calculates key metrics such as performance rates and overall equipment effectiveness (OEE), enabling transparent assessment of production efficiency.

In addition to production metrics, the function block monitors equipment states to identify and categorize production losses. It analyzes downtime, scheduled breaks, and operational conditions to provide detailed loss information and supports prioritization through top-state analysis, highlighting the most significant contributors to reduced performance.

The solution manages lifecycle events of production schedules, including activation and completion, ensuring that KPI tracking is aligned with the current operational context. It also handles transitions between production runs by resetting and reinitializing relevant data at the end of each schedule.

All calculated KPIs and analytical results are made available through structured data outputs, enabling further processing, visualization, or storage in higher-level systems. Built-in status and diagnostic signals provide transparency regarding execution state, licensing, and potential errors, ensuring reliable integration into industrial automation environments.

Note: Multiple instances can be used in parallel. For example, one instance can monitor batch or shift OEE KPIs, while another instance can be used to track product-specific OEE KPIs.

Interface Description

Function block Inputs and Outputs

Execution & Timing Behaviour

The function block is intended to be executed cyclically in a task context.

Timing precision depends on the configured task cycle time and target platform

Error Handling & Diagnostics

If an internal error, a library issue, or a licensing problem occurs, xError is set to TRUE and iErrorID provides the corresponding error code. Detailed descriptions of the error codes are defined in the enumeration eError.

Assumptions & Limitations

Accuracy depends on the system clock. Hardware‑dependent behavior may vary across different CODESYS platforms.

The function block KPI calculation is restricted to a 49-day window. If the required build time extends beyond this period, the function block cannot provide a valid result.

Before ordering this library, please verify the correct functionality of the library function block in your target system.

Example Implementation

Declaration and Call of the Function Block EquipmentPerformance:

GVL_MIF:

VAR_GLOBAL

END_VAR

GVL_Par_EP:

VAR_GLOBAL

END_VAR

GVL_Par_EP_History:

VAR_GLOBAL

END_VAR

VAR

fb_EP : DDAS_EP.EquipmentPerformance;

END_VAR

FB call in structure text:

fb_ EP(

xEnabled := TRUE,

xActivated := GVL_MIF.xActiveSchedule,

xActiveScheduledBreak := GVL_MIF.xActiveBreak,

diScheduleID := GVL_MIF.diJobID,

sScheduleDescription := GVL_MIF.sActiveScheduleDesc,

diProductID := GVL_MIF.diProductID,

sProductDescription := GVL_MIF.sProductDescription,

rProductsPerMin := GVL_MIF.rProductsPerMin,

lrProductCountOK := GVL_MIF.lrActualBuildOK,

lrProductCountNOK := GVL_MIF.lrActualBuildNOK,

rOEEpercent := GVL_MIF.rOEEpercent,

dtLocalDateTime := GVL_MIF.dtLocalDateTime,

eProdState := GVL_Par_EP.eProdState,

scPar := GVL_Par_EP.scPar,

scEP := GVL_EP_History.scEP,

scPD := GVL_EP_History.scPD,

scPL := GVL_EP_History.scPL,

scTS := GVL_EP_History.scTS

);

FB call in continuous function chart diagram:

Function block sample input and output parameter:

Screenshot example in Online / Monitor mode

Demo Visualisation

FB EP_History

General Information

This chapter describes the function block EP_History.

Function Block Name: EP_History

Library: DDAS_EquipmentPerformance_Lib

Dependent Codesys libraries: None

CODESYS Version Compatibility: CODESYS V3.5 and higher

License / Usage Restrictions: Requires valid full or demo library license

Purpose & Scope

his Function block stores equipment performance data into historical arrays, capturing snapshots of performance, production, loss, and top-state metrics from the EquipmentPerformance function block.

This function block is used to maintain a rolling history of equipment performance data for analysis, visualization, and reporting.

It enables controlled storage and clearing of historical KPI datasets, preserving time-based snapshots in reverse chronological order.

Typical Use Cases

Typical applications include trend analysis, dashboard visualization, batch/shift comparison, and short-term buffering of performance data for higher-level systems such as SCADA, MES, or cloud analytics.

Functional Overview

When enabled, the Equipment Performance History function block provides structured storage and management of time-based equipment performance data. It captures snapshots of key performance datasets, including performance metrics, production details, loss information, and top-state analysis, and organizes them into historical records for further use.

The function block enables selective recording of different data categories, allowing flexible control over which information is stored. Data is captured on demand and inserted into history buffers in reverse chronological order, ensuring that the most recent dataset is always immediately accessible while maintaining a defined history depth.

In addition to data storage, the function block supports controlled clearing of historical records, enabling reset operations when required, such as at the start of new production phases or for memory management purposes.

The stored historical data can be used for trend analysis, visualization, and reporting in higher-level systems. This supports use cases such as performance monitoring over time, comparison of batches or shifts, and short-term buffering of KPIs before transfer to SCADA, MES, or cloud-based analytics platforms.

Status signals indicate the successful execution of storage and clearing operations, while integrated diagnostic outputs provide transparency regarding licensing status and potential errors. This ensures reliable and traceable operation within industrial automation environments.

Note: Multiple instances can be used in parallel. For example, one instance can store history data of batch or shift OEE KPIs, while another instance can be used to store history data of product-specific OEE KPIs.

Interface Description

Function block Inputs and Outputs

Execution & Timing Behaviour

The function block is intended to be executed cyclically in a task context.

Timing precision depends on the configured task cycle time and target platform

Error Handling & Diagnostics

If an internal error, a library issue, or a licensing problem occurs, xError is set to TRUE and iErrorID provides the corresponding error code. Detailed descriptions of the error codes are defined in the enumeration eError.

Assumptions & Limitations

Accuracy depends on the system clock. Hardware‑dependent behavior may vary across different CODESYS platforms.

Before ordering this library, please verify the correct functionality of the library function block in your target system.

Example Implementation

Declaration and Call of the Function Block EP_History:

GVL_Par_EP:

VAR_GLOBAL

END_VAR

GVL_Par_EP_History:

VAR_GLOBAL

END_VAR

VAR

fb_EP_History : DDAS_EP.EP_History;

END_VAR

FB call in structure text:

fb_EP_History(

xEnabled := TRUE,

xStoreHistoryEP := TRUE,

xStoreHistoryPD := TRUE,

xStoreHistoryPL := TRUE,

xStoreHistoryTS := TRUE,

xStoreHistoryData := GVL_Par_EP.xScheduleEnd,

xClearHistoryData := GVL_Par_EP.xClearHistoryData,

scEP := GVL_EP_History.scEP,

scPD := GVL_EP_History.scPD,

scPL := GVL_EP_History.scPL,

scTS := GVL_EP_History.scTS,

ascEP := GVL_EP_History.ascEP,

ascPD := GVL_EP_History.ascPD,

ascPL := GVL_EP_History.ascPL,

ascTS := GVL_EP_History.ascTS

);

FB call in continuous function chart diagram:

Function block sample input and output parameter:

Screenshot example in Online / Monitor mode

Global

Structures

scPar

This structure provides input user‑configuration.

scPerformanceDetails

This structure provides Equipment performance KPI’s about the active scheduled batch, shift, or product run.

scProductionDetails

This structure provides detailed information about the active scheduled batch, shift, or product run.

scProductionLossDetails

This structure provides detailed information about the losses of the active scheduled batch, shift, or product run.

scTopState

This structure provides top-state analysis of the duration and occurrences of losses in the active scheduled batch, shift, or product run.

scTopStateDuration

This structure provides the duration of losses in the active scheduled batch, shift, or product run.

scTopStateOccurances

This structure provides occurrences of losses in the active scheduled batch, shift, or product run.

Enumerations

eProductionState

Defined input production states as enumeration.

eTopState

Defined provided production loss states as enumeration.

eEP_ProductionState

Defined output production states as enumeration.

eError

Library Possible Error Codes and Descriptions as enumeration.

Global Variable

GVL_Constant_EP

Library constants.

GVL_LibGuide

This Global Variable List provides the library license GUID. Relevant input parameter for the function block DDAS_LM.Get_Lib_License, required to activate the library license in conjunction with the activation key and side code.

Example Implementation

The following screenshots illustrate a complete implementation of the library function blocks, including the license function block.

The current local date, time, and day of the week can be obtained using the DDAS function block DDAS_DT.GetDateTimeInfo from the DDAS_DateTime_lib library.

Your Feedback Matters

These instructions have been prepared to the best of our knowledge and belief to provide you with the highest possible level of support when working with our product.

Despite our best efforts, we may not always fully achieve this objective. If you identify any issues or have suggestions for improvement, we would greatly appreciate your feedback.

Please send your comments or criticism in a short e‑mail to:

support@ddas.digital

Thank you for your support.

Your DDAS Application Software Team