Production Control Apparatus

U.S. Pat. No. 3,825,208 shows an article to be advantageously processed by apparatus and methods of the present invention.

U.S. Pat. No. 3,833,280 shows a random access article storage and retrieval apparatus employable as the article random access storage apparatus for practicing the present invention.

U.S. Pat. No. 3,584,284 shows an article transport control apparatus usable with the U.S. Pat. No. 3,833,280 illustrated apparatus.

U.S. Pat. No. 3,854,605 shows an article autoloader and associated recorder usable in connection with the U.S. Pat. No. 3,833,280 illustrated apparatus.

U.S. Pat. No. 3,854,604 shows an article transporter usable with the U.S. Pat. No. 3,833,280 illustrated apparatus.

The present invention relates to production apparatus particularly, to computerized control of such apparatus.

The production and quality control of large numbers of product or articles incurs substantial cost in labor and capital equipment. For controlling such cost, it is imperative that a certain amount of automation be employed. Depending upon the manufacturing process, as well as the product being produced, such automation can be achieved with various degrees of success. As an example, the assemblage of two diverse parts having close tolerance requirements can result in very expensive production costs. A prior solution to such a problem was to measure each of the parts and separately store same in two different random access article storage units. Storage would be in accordance with the measurements made such that all parts having like tolerances are stored together. Then, under computer control, parts having matching tolerances would be supplied from the random access storage unit to an automatic assembler, wherein the parts would be mated based upon their tolerance measurements.

In other automatic production equipment such as in semi-conductor manufacturer, classification of components produced in accordance with predetermined electrical test criteria, was a major portion of a production process. The produced electrical components were categorized in accordance with a plurality of tests and sorted, all under computer control. The testing operations were such that all of the components could be tested in seriatim, i.e., the test procedures for one component required the same amount of time as for any other component. Accordingly, with such simplified test procedures, a seriatim approach to the automation of testing for the satisfactory solution. However, not all components are subject to such easy and predictable test times. As an example, magnetic tape cartridges have a plurality of characteristics, all of which can be tested. The degrees of magnetic recording and high-quality control considerations require that various parameters be tested. Such parameters may interact such that retesting or more extensive testing may be called for. For example, if a particular area of a magnetic medium was scanned by a test transducer, lack of a successful test may be due to debris disposed intermediate the test transducer and the medium. Accordingly, a retest is called for ensuring that the appropriate yield of the magnetic material is achieved. Such retesting results in variable test times for tape containing cartridges being automatically produced. Accordingly, seriatim testing is not a viable production solution.

In an attempt to solve variable production and test rates, production lines have placed slow operating machines in parallel such that a single-flow production line may have a plurality of parallel paths through the slow machines, and a single serial path through a high production machine. Such solutions appear to be expensive and exhibit a limited degree of flexibility. A better solution for high-speed production of articles, particularly magnetic tape and related articles, is desired.

It is an object of the invention to provide a highly flexible, fully computerized production apparatus having a maximal degree of production rate flexibility, while enhancing monitoring capabilities.

An apparatus incorporating the present invention is characterized by a random access article storage and retrieval unit with various diverse production units including test units, disposed about the periphery of such random access storage unit. A programmed computer controls the transfer of articles within the storage apparatus and between the diverse manufacturing apparatus in a manner that quality control is facilitated while maintaining each of the diverse manufacturing and test apparatus, utilization to a maximal extent. Queues for the various diverse manufacturing and test apparatus consists of article storage cell locations within the storage apparatus, each article having but one storage cell location for facilitating article tracing.

In another aspect of the invention, the computerized control of such apparatus, includes a simple program driver loop for selectively invoking one of a plurality of control computer programs which not only control and monitor operation of the central random access article storage and retrieval unit, but also the diverse manufacturing and test apparatus, as well as generating a trace record for each article being processed through the manufacturing apparatus. Quality control of the diverse apparatus is also provided by computer program control.

The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.

FIG. 1 is a block diagram of an article production facility employing the present invention.

FIG. 2 is a flow diagram illustrating operation of the FIG. 1 illustrated apparatus.

FIG. 3 is a flow diagram of the computer control program driver aspects for automatically operating the FIG. 1 illustrated apparatus.

Referring now more particularly to the attended drawings, like numerals indicate like parts and structural features in the various views and diagrams. FIG. 1 illustrates a typical apparatus incorporating the present invention. It includes a centrally controlled and located random access article storage and retrieval apparatus 10 surrounded by a plurality of manufacturing and test apparatus. The present apparatus is designed to produce an article as shown in U.S. Pat. No. 3,825,208, which shows the physical construction of the article and as shown in U.S. Pat. No. 3,932,894, which shows the format on the magnetic medium in the article of U.S. Pat. No. 3,825,208, which is advantageously produced and tested by the FIG. 1 illustrated apparatus. A first of the peripheral manufacturing apparatus is a hot stamp unit 11 which receives under program control, articles to be produced. After hot stamping which will be later described, the article may be placed in a queue within apparatus 10 for transfer to servo writer degausser 12. Servo writer degausser 12 adds a format to the magnetic media in the article of U.S. Pat. No. 3,825,208, as shown in U.S. Pat. No. 3,932,894. Subsequently thereto, the article is transferred from the writer degausser 12 to apparatus 10, or to one of the many test units (TU) for verifying that the appropriate format has been recorded on the magnetic medium. If the test is unsuccessful, the article is supplied to reject port 14 for further analysis beyond the scope of the present invention. If the test was successful, the article is returned to apparatus 10 awaiting transfer via conveyor 15 as a finished article to be shipped. All of the above described apparatus is sequenced, operated and monitored by control processor 16 which contains microcode as will be described, for effectuating the manufacture of the articles. Control processor 16 is connected to a supervisory processor, such as an IBM 370 Model 155 or 168, (manufactured and sold by International Business Machines Corporation, Armonk, N.Y.), which serves as a factory control computer. The supervisory processor 17 is connected to other apparatus (not shown) for manufacturing diverse products.

The description assumes that the magnetic medium in the form of an elongated tape and the various portions of the article, have been assembled by apparatus (not shown) and supplied to a suitable conveyor line 20 for transfer to apparatus 10. Upon the completion of the initial assembly of the physical parts, the article is delivered to conveyor 20 and a serial number is assigned to each of the articles. This is achieved in the illustrated apparatus via a punched card or unit record reader represented by symbol 21. The serial number is internally recorded by the control processor which, at that time, assigns a storage location within apparatus 10, to the article to be processed. In FIG. 2, the flow-chart showing the flow of articles through the FIG. 1 illustrated apparatus, shows the assignment of serial number at 21A, whereupon the article is placed on conveyor 20 at 20A, and the serial number recorded by the control processor 16. The control processor 16 then determines whether or not hot stamp unit 11 is available. If it is not available, the article is received by apparatus 10 and transferred to the assigned storage location, as represented by the spaced lines at 22. Such stored articles are a queue of work to be performed by hot stamp unit 11. If the queue is empty, the article is immediately transferred to the hot stamp unit 11. Normally, the queue is not empty, requiring the article to reside in apparatus 10 for a short time.

The cartridge is hot stamped to visually record the assigned serial number at the free end of the tape as shown in U.S. Pat. No. 3,932,894. Hot stamping is achieved by a heated die pressed against the polyester based magnetic medium. Such an operation is well known and not described for that reason. Transfer of the article from the storage apparatus to the hot stamp unit 11, is as shown in the referenced patents, for apparatus 10.

Subsequently, servo writer 12 receives the article. Servo writer 12 consists of a multiple head magnetic tape recorder for recording signals along the length of the medium. The article is received with the signals recorded thereon using known magnetic recording techniques. It is preferred that the tape may be degaussed prior to the recording. This is achieved by passing the article physically through a magnetic field such as that provided by a permanent magnet or AC magnetic field. Subsequent to the writer 12 operation as at 12A, the cartridge is returned to apparatus 10 for enqueuing to a test unit (TU). Upon entry into a test unit (TU) the test operation at 23 is performed. Such test operation verifies the continuity of the magnetic coding of the magnetic medium of the data cartridge. Also, the ability of the magnetic medium to be unspooled and spooled is vertified. In the event a certain percentage of the coating is unsatisfactory for magnetic recording purposes, particularly of the data processing type, the article is rejected and sent to reject port 14. Control processor 16 tallies the number of articles being rejected for input to quality control (QC). Following the test operation 23, the article is returned to storage, awaiting transfer to a packing machine (not shown) via conveyor 15. Upon accumulation of a predetermined number of articles within apparatus 10, all of the articles to be packaged are transferred over conveyor 15 at step 15A, and packaged for shipment at 24. The packaging apparatus is not shown.

To assist in quality control, manual entry station 14A receives articles to enable analyzing random samples of articles received by apparatus 10 at various stages of the above described manufacturing operation. As shown in FIG. 2, raw received articles can be analyzed, as well as articles at any stage of the operation.

Control processor 16 is responsive to an input sensing switch 30 for verifying that an article has been received, in accordance with the serial number assigned at 21, for transfer to the assigned storage location within apparatus 10. The addressing and identification of such storage locations can be as shown in the referenced patents and as indicated later in the microcode listings.

Further, reject port 14 is adapted to receive articles after reject analysis as at 25. In such a situation, control processor 16 maintains a serial number from 21, and assigned storage location, until a console (not shown) entry orders control processor 16 to erase the serial number from the manufacturing operation. In this manner, integrity of the entire manufacturing operation is maintained through diverse forms of tests and functions. It is to be understood that additional diverse testing and control may be achieved by adding additional units to the FIG. 1 illustrated apparatus. Further, in a practical embodiment, control processor 16 monitors operations of the parts assembly apparatus (not shown) as indicated by lines 31. Such apparatus takes all of the parts of the cartridge and assembles them together. Additionally, magnetic medium is slit to the appropriate width and automatically wound on a spool of the cartridge by a winder (not shown) before being transferred to input conveyor 20.

Before going into the details of the program control, control processor 16 is described. The architecture of the processor is as shown in FIG. 3 of U.S. Pat. No. 3,654,617 but using the instruction words and as defined and mnemonics as listed hereinafter, rather than the limited instruction repertoire used in the referenced U.S. Pat. No. 3,654,617. The A and B bus of U.S. Pat. No. 3,654,617 is the X and Y bus of the control processor 16. As described herein, the machine instruction level description, is based upon an assembler language for assemblying the actual numeric instructions (binary 1's and 0's) such that any machine architecture can be employed using the later described microcode elements.

Each instruction word in source language form includes:

Label: Identify machine instructions, etc. (data access). The label is useful when an assembler converts the source statements into machine coding. The label field includes only symbols, defined below:

Storage areas, instructions, and other elements may be given symbolic names for the purpose of referring to them in a program. All symbols must conform to the following rules:

1. The symbol must not consist of more than six characters. The first character must be alphameric. The other characters may be combinations of alphameric and numeric digits.

2. No special characters may be included in a symbol.

3. No blanks are allowed in a symbol.

4. A symbol may be defined only once in an assembly.

5. A symbol used as a name entry in an equate statement is assigned the value designated in the operand field. If the label field is left blank, it is ignored by the assembler. If column 1 contains an asterisk (*), the entire statement is treated as a comment and appears only in a program listing and is not used as a machine instruction.

Each machine instruction has a unique mnemonic operation code associated with it. The mnemonics are indicated below with the various instructions.

Each machine ALU function has been assigned a unique mnemonic. An ALU function may be specified with all instruction mnemonics except BRANCH and BRANCH AND LINK. If an operation mnemonic is coded and no ALU functin mnemonic is coded, the assembler defaults to the PASS X (PX) ALU function. All extended mnemonics have an implied ALU function associated with them, as later described.

The operand field is used to specify subfields in instructions and constants. Operand fields are discussed in Section 6.2.

The comment field appears to the right of the operand field and must be separated from it by at least one blank.

Some symbolic operands are written as a single field, others as a single field with subfields, and still others as multiple fields. Fields and subfields in a symbolic operand may be represented either by symbolic names or by decimal or hexadecimal self-defining terms. Operand fields are separated by a comma. Up to three fields may be coded for some UTS machine operations. Operand subfields must be enclosed in parentheses. Operand fields enclosed in parentheses indicate that indirect addressing is to be used.

When indirect addressing is specified for a register field, it means that the address of the register to be operated on is contained in the register R1.

When a Control Store or Main Store operand field is addressed indirectly, the CS or MS effective address is contained in the register specified in the A1 field.

In this document, operand fields will be numbered left to right, from 1 to 3. An alphabetic character is also used to indicate what type of operand is being specified. The following characters are used:

R = Register Field (in LSR)

I = Immediate Data Field (contained in instruction word)

A = A control Store or Main Store Address Field

X = An Index Register used as an Address Field or as a Subfield

S = A Shift Control Field

N = A decimal or hexadecimal self-defining term

The source language to assembler constraints are set forth herein for achieving one machine instruction for each symbolic language instruction.

Relative addressing is the technique of addressing instructions or data areas by designating their respective locations in relation to the Control Store Address Register CSAR or to some symbolic location (label). Relative addressing can be effected using the current value of the CSAR by specifying an asterisk as the first character of the operand fields. Data areas can be referred to by their symbolic name + or - some value.

Source language instructions and comments are written using the following characters:

Alphameric: A through Z, and $, #,

Numeric: 0 through 9

Special Characters: + - , * () ' blank

In addition, any of the 256 punch combinations may be used anywhere that characters may appear between paired apostrophes and in comments.

Instructions in the source language activate the programmable machine to execute one machine instruction. There are three program controlling type instructions:

The ALU functions to be named in an instruction word are as follows:

BRANCH and BRANCH AND LINK instructions are very similar. The only difference between the two is that when a BRANCH AND LINK is specified, the Control Store Address Register CSAR contents are stored in the X register. The instructions operate as follows:

If the BRANCH or BRANCH AND LINK is unconditional or if the condition code implied by the instruction mnemonic matches the condition code of the ALU output at the start of instruction execution, a branch is taken to the effective control store address (EA). If the condition code of the instruction does not match that of the ALU output, the next sequential instruction is executed.

The list below shows the eight BRANCH mnemonics and the eight BRANCH AND LINK mnemonics

BRANCH and BRANCK AND LINH instructions control store effective addresses (EA) are generated depending on the operand format used.

The following examples illustrate effective address generation for these instructions.

Example 1 above shows a "direct" branch to the control store address represented by the value A1. Example 2 is an "indexed" branch. The EA is generated by adding the control storage address A1 to the contents of index register X1. Example 3 is an "indirect" branch to the control store address contained in X1. Examples 3, 4, and 5 are all "displacement" branches. The EA is generated by adding the displacement of +N, -N, or A1 to the current setting of the Control Store Address Register CSAR.

The format of these instructions is:

TEST and BRANCH instructions place either the high order byte or the low order byte of the specified 2- byte (16 bit) register (R1) into the X register and the 8 bits of immediate data (I2) into the Y register. The specfied ALU function is performed and the resulting condition code is compared to the condition code of the instruction. The signal contents of registers X and Y are not changed. If the condition codes match, the branch (to A3) it taken. If there is not a match, the next sequential instruction is executed. The displacement of A3 must not be greater than +127 or -128. The TEST and BRANCH mnemonics are:

The format of the READ and WRITE REGISTER MASKED instructions is:

Both the READ REGISTER MASKED and the WRITE REGISTER MASKED instructions read the contents of the specified register (R1) into either the X or the Y register as indicated by the operation mnemonic. The immediate data (I2) is read into the opposite register (X or Y). The specified ALU function is performed and in the case of the READ REGISTER MASKED instruction, this completes the operation. The WRITE REGISTER MASKED instruction rewrites the specified register (R1) with the output of the ALU completing the operation. If the R1 field of the operand is enclosed in parentheses, it indicates indirect register addressing.

The following operation mnemonics have been defined for the READ and WRITE REGISTER MASKED instructions:

The MOVE/MODIFY REGISTER instructions have several variations. The basic form of the MOVE/MODIFY instructions will be explained first. All other forms of the instruction will be explained later. The format of the basic MOVE/MODIFY instructions is

These instructions move the contents of the "from" register (R2) into either X or Y register as implied by the operation mnemonic. The specified ALU function is performed and then the specified shift function is done on the output of the ALU. The output of the ALU is then stored in the "To" register (R1). This is the only instruction that has a shift function. A shift, left or right, logical or rotate, from 1 to 4 bit positions may be done. The S3 field of the operand defines the type of the shift to be done. The list below shows the valid forms of the operand shift field.

RLL.eta. = Rotate left logical

RRL.eta. = Rotate right logical

SLL.eta. = Shift left logical

SRL.eta. = Shift right logical

Note: .eta. is a decimal number from 1 to 4.

Indirect addressing is permitted on either the "From" register or the "To" register but not both. If any register is addressed indirectly, no shift function is allowed.

If only the R1 field of the operand is coded, the R1 field becomes both the "From" and the "To" register. The following chart shows all of the valid operand formats for the MDX/MDY instructions.

Another form of the MOVE/MODIFY instructions is a MOVE/MODIFY with SWAP. The format of this instruction is:

These MOVE/MODIFY instructions operate the same as the MDX/MDY operations. Then, after the ALU function is performed, bits 0-7 bits 8-15 of the ALU output are swapped. The examples above show all valid operand formats for the MDXS and MDYS instructions. When a shift operand is specified, the shift is done first, then the swap.

The last MOVE/MODIFY instructions are the MOVE/MODIFY DOUBLE and the MOVE/MODIFY DOUBLE with SWAP. Formats for these instructions are:

The double forms of the MOVE/MODIFY instructions move the contents of the "From" register (R2) into either the X or Y register as implied by the operation mnemonic. The contents of the "To" register are moved into the opposite register (X or Y). The specified ALU function is performed and in the case of the "Load Double" (LDXD/LDYD) instruction, this completes the operation. If a MOVE DOUBLE SWAP or a LOAD DOUBLE SWAP is coded, bits 0-7 and bits 8-15 of the ALU output are swapped. The MOVE DOUBLE and MOVE DOUBLE SWAP instructions rewrite the resulting ALU output back into the "To" register. Either the "from" or the "To" register may be addressed indirectly, but not both. No shifting is permitted with the MOVE/MODIFY DOUBLE instructions.

Write main store instructions use any one of three different sources of data. They are:

1. The previous contents of the X and Y registers.

2. Immediate data.

3. An LSR or external register.

The format of the WRITE MAIN STORE instructions that use the previous contents of the X and Y registers is:

In all of the examples above the specified ALU function is performed and the resulting ALU output is stored in the main store effective address EA. The main store EA is generated depending on the format of the operand used. If the operand coded is like the first example above, the main store EA is the main store address represented by A1. In the second example, the EA is the value of A1 plus the contents of the index register X1. If the third example is used, the main store EA is contained in the register S1.

If the WRITE STORAGE and INCREMENT (WSI) or the WRITE STORAGE and DECREMENT (WSD) mnemonic is used, the third operand type (X1) must be used and the contents of the register are incremented or decremented by one after the instruction is executed.

WRITE MAIN STORE MASKED (immediate data) instructions have the following format:

These three instructions place the immediate data (I2) into the Y register. The specified ALU function is performed and the ALU output is stored in the main store EA. In all cases, the main store EA is contained in the register X1. If the WSMI or the WSMD mnemonic is used, the contents of the register R1 will be incremented or decremented after the main store EA is generated.

The third type of write main store instruction uses signals stored in LSR. The formats are:

These instructions load the contents of the specified register (R1) into the Y register. The specified ALU function is performed and the ALU output is stored in the main store EA. The LDS instruction can have a direct main store EA (A1) or an indirect main store EA (contained in X1). The LDSI and LDSD instructions can only have an indirect EA. As with the WSMI and WSMD instructions, the LDSI and LDSD instructions increment or decrement the contents of the register X1 at the end of the instruction.

READ MAIN STORE instructions read the contents of the main store effective address into the Y register or through the Y register directly to a LSR. The "Read Storage" instructions shown below have the same effective address generation as their corresponding "Write Storage" instructions.

The format of the READ MAIN STORE to ALU instructions is:

The format of the READ MAIN STORE TO REGISTER instructions is:

The LEVEL EXIT instruction is used to exit from an interrupt level. All that is required is an operation mnemonic of LEX.

Extended mnemonics make the hardward register (X, Y, and ALU) transparent to the user.

The EXTENDED MNEMONICS fall into three classes. They are:

1. RR -- Register to Register Operations.

RI -- Register/Immediate Operations.

3. RS -- Register/Storage Operations.

The format for all extended mnemonics is:

Because of the format indicated above, only the operation and basic operand fields are shown. The class of instruction (RR, RI, or RS) will be shown as well as the equivalent unextended instruction. All indirect addressing rules that are applicable to the basic operand formats are valid for the extended codes.

The LOAD INSTRUCTIONS place the contents of the second operand in the first operand location. The second operand is not changed. The Load and Increment Instruction (LIN) increments the contents of "X2" after the load is performed.

The STORE INSTRUCTIONS place the contents of the first operand in the second operand main store location. The first operand is not changed. The Store and Increment Instruction (STIN) increments the contents of "X2" after the store is performed.

The first operand is compared with the second operand and the result determines the setting of the condition code.

The second operand is AND'ed with the first operand and the result is placed in the first operand location. The second operand is unchanged.

The second operand is OR'ed with the first operand and the result is placed in the first operand location. The second operand is unchanged.

The second operand is exclusive OR'ed with the first operand, and the result is placed in the first operand location. The second operand is unchanged.

The second operand is added to the first operand, and the sum is placed in the first operand location. The sign and magnitude of the sum determine the condition code. The second operand is not changed.

The second operand is subtracted from the first operand, and the difference is placed in the first operand location. The sign and magnitude of the difference determine the condition code. The second operand is not changed.

The contents of the second operand are incremented by +1 and the result is placed in the first operand location. The second operand is not changed.

The contents of the second operand are decremented by +1 and the result is placed in the first operand location. The second operand is not changed.

*Note: If only the R1 field is coded; that register will be incremented or decremented.

The contents of the first operand (R1) are shifted or rotated left or right the number of bits specified by the I2 operand. The I2 operand must be a decimal number from 1 to 4.

These three instructions are provided to allow the programmer to manipulate interrupt levels. In all cases, the I1 field is a decimal number 0 to 3 representing interrupt levels 0 to 3.

SPI = Set Programmed Interrupt

DIL = Disable Interrupt Level

EIL = Enable Interrupt Level

Source code is included only for the important operating routines which perform functions not readily apparent or known from the brief description and the present state of related arts. Driver Loop, DR, scans active flags and gives control to later described service routines as needed.

The driver loop is a closed set of microcode instructions which checks various indicators and gives control to service and functional microcode routines as described below.

Service or function steps performed are:

1. Sets channel interrupt mask

2. Detects micro checks

3. Detects operator request

4. Operator display

5. Test routine service

6. General Service

7. Printer Service

8. Cartridge Tester Service

9. A4 Input Port Service

10. Hot Stamp Service

11. Servo Writer Service

12. XY Carriage Service

13. Host Service

14. 370 Channel Poll Service

15. TU Channel Service

16. Winder Service

17. Packaging Service

18. Reject Port Service

19. Queue Limit Service

20. Manual Entry Station Service

21. Device Time Out Service

22. Trace Reader Service

23. Quality On Line Tester Service

24. Special Channel Service

25. A4 Output Port Service (output from unit 10)

26. Timer Service

Steps 8 through 26 are executed only if the driver loop is running. START and STOP commands with no operands are used to control the driver loop. For most of the service routines, a check is made of the active flag and if on, control is passed to the requested routine. If the active flag is off, the service is skipped. Each service routine returns control to instruction following the branch to the routine. The active flags are controlled by the START and STOP commands with appropriate operands. The last instruction in the driver loop is an unconditional branch to the top, thus closing the loop.

Items 1, 2, 3, 5, 16, 22, 23, and 24 are not further mentioned because explanation would not further the understanding of the present invention.

FIG. 2 is a flow chart showing the operations of the Driver Loop, DR. The machine instruction level source microcode is shown in the tables below. The remarks in the table ties the flow chart into the table. ##SPC1##

Input Port Service, A4I, processes cartridges from input conveyor 20 into apparatus 10.

Control is received from the driver loop DR if the driver loop DR and input port are active (START and START A). Control is returned to the driver DR if no move queue elements are available. If the input conveyor 20 is not on-line, then the service is made inactive, a message is posted and control returned to driver DR. If no, then a cartridge is at the input port, control is returned to the driver DR. For a cartridge present at the port, the following is done:

1. Input port pause is checked and if set, control is returned to the driver DR.

2. Moves pending to cell or hot stamp will cause return to the driver.

3. A cartridge is dequeued from the conveyor queue.

4. A move is requested to a cell or to the hot stamp if immediately available.

5. For an even system number, cartridge is placed in the testing queue. For odd system number, cartridge is placed in the hot stamp queue.

The above functions are illustrated in source microcode in the tables below. ##SPC2##

Hot stamp service, HS, processes cartridges into and out of the hot stamp unit 11.

Control is received from the driver DR if the driver loop DR and hot stamp unit 11 are active (START and START H). The hot stamp unit 11 is made inactive, a message issued and control returned to the driver if on-line is not present. If manual intervention required is present, a message is issued to CRT display or the printer, the hot stamp unit 11 made inactive. Control is returned to the driver DR. The cartridge move queue (later described) is checked and if no elements are available, control is returned to the driver. The remaining service is unique for the input pot and the output port.

For the input port of hot stamp unit 11:

1. If no cartridges are waiting to be hot stamped or the hot stamp unit 11 is paused, control is given to the output port service (later described).

2. If a cartridge is present at the hot stamp input port (not shown), control is given to the output service.

3. If no XY carriage (not shown) moves are pending, a cartridge is dequeued and a move requested to the input port of hot stamp unit 11.

4. The assigned serial number is checked and if the next number will be an even million, the hot stamp unit 11 is paused and a message requesting manual indexing is issued.

5. If more move queue elements are available, then control is given to the output service; if not, control is returned to the driver DR.

For the output port of hot stamp unit 11:

1. If no cartridge is at the output port, the timer is allowed and control is returned to the driver DR.

2. If a cartridge is present at the output port, the following is done:

A. the timer is held.

B. if the cartridge is a calibration cartridge, it is moved to the manual exit station, MES (not shown).

C. if no I/O queue elements for supervisory processor 17 are available, control is returned to driver DR.

D. if cartridge is a reject, it is moved to the reject port 14 or reject queue if XY carriage (not shown) move is not pending.

E. for a good cartridge, checks are made of any XY carriage moves pending, if so, control is returned to driver DR.

F. good and bad cartridges are reported to the yield/throughput routine which sends the information to supervisory processor 17.

G. if a visual check command, a good cartridge will be sent to the manual exit station, MES (not shown).

H. good cartridges will be moved to a apparatus 10 storage cell or to servo writer 12, if immediately available.

3. After a move is posted, control is returned to the driver DR.

The above functions are detailed at the machine introduction source microcode level below. ##SPC3##

Since hot stamp is a first function in the manufacturing operation, it provides a convenient point to count the inputted cartridges. Included with this operation is a subroutine of the hot stamp service that checks for the millionth cartridge. That subroutine is illustrated below in the machine instruction level source code chart. ##SPC4##

SERVO WRITER SERVICE, SW, processes cartridges into and out of the servo writer 12.

Control is received from the driver DR if the driver and the servo writer 12 are both active (START and START S). The servo writer 12 is handled in the same manner as the hot stamp unit 11 with the following exceptions:

1. When intervention required is detected, the next cartridge to be processed out of the servo writer 12 is removed. A message is sent to the operator (console) requesting that the offending cartridge be removed.

2. Only three cartridges are permitted in the servo writer 12 at a given time.

3. The reject code is encoded for processor 17. A message is issued for ID/SERVO LOW LEVEL REJECT.

4. Cartridges are not processed directly into the next device TU.

The machine instruction level source code is listed below. ##SPC5##

Cartridge tester service, CT, processes cartridges into the out of the cartridge tester, TU's.

Control is received from driver loop DR if the driver loop DR and the testers are active. (START and START C). Checks are made first for the input ports then for the output ports. For the input ports:

1. Move queue elements available; if none are available, return to driver.

2. Cartridges waiting to test; if not, try output ports.

3. All testers paused (PAUS C), try output ports.

4. All tester input ports are checked for availability.

5. The pause and active indicator is checked for all testers.

6. All testers are checked for a move pending to the input port.

7. A check is made for cartridge present at input.

8. If steps 4 through 7 are satisfied for tester, it is marked available.

9. A cartridge is dequeued and the cell address is taken from the queue for the nearest available tester.

10. Considering only the X value, the nearest available tester is found.

11. A move is requested from the cell to the tester input port and posted pending.

12. If more move queue elements are available, control is passed to the output port service, otherwise control is returned to the driver loop DR.

For the output ports:

1. The output port sensor register is tested and if no cartridges are present, all tester timers are started and control is returned to the driver loop DR.

2. Each output port is tested for a cartridge. If none, the tester is skipped.

3. If a cartridge is present, the following is done:

A. timer is held

B. move pending tests are made, if any pending, tester is skipped.

C. if tester is not active, it is skipped.

D. if calibration cartridge, then it is sent to manual exit station (MES) (not shown).

E. if cartridge is a reject, then retest is performed by placing cartridge back in servo writer 12 queue if eligible for retest.

F. if cartridge is good and a visual check is pending, then cartridge is sent to the manual exit station.

G. good and bad cartridges are reported to the yield/throughput collection routine.

H. good cartridges go to packaging queue if not visual checked. Bad cartridges go to reject port or reject queue if not retested.

4. After a move is requested, a check is made for more available move queue elements. If none are available, the next tester is considered. Control is returned to the driver loop when all testers have been tried. If no move queue elements are available, then control is returned to the driver DR.

The above listed functions are described in machine instruction level source microcode in the tables below. ##SPC6##

Retest, RTST, CT, CHS, provides retest functions for the cartridge testers, TU's.

Control is received from the console service for the RETEST command. The command allows the operator to enable/disable retest, specify retest count, specify reject codes, and control reservo writing. The command processor builds a table of reject codes and sets indicators and retest count. When the 3830 Channel Service (CHS) reads the summary data, if retest is active, the reject code is tested for retest. If eligible, the high order bit is set in the serial number. The cartridge testers service (CT) tests the retest bit and if set, increments the retest count which is carried in the next three bits of the serial number. If more retests are required, then the cartridge is moved to a storage cell in unit 10 and placed in the servo writer 12 queue or tester TU queue according to the reservo indicator.

Packaging service, PK, processes cartridges from unit 10 via conveyor 15 to the packaging system (not shown).

Control is received from the driver loop DR after packaging is started (START P). The on-line indicator (not shown) is checked, and if not present, a message is issued and the packaging system stopped. When operating in a normal mode (START P), even counts of 10 are processed. Checks are made of the output port sensors (not shown), if neither is available, control is returned to the driver DR. If a port is available, then a cartridge is dequeued from the packaging queue. The X address is checked and a move is posted to the nearest port available. The cartridge queue element is returned to the free queue.

The machine instruction level source microcode is shown below. ##SPC7##

Manual entry service, MES, processes requests from the unit 10 manual entry station 14A (MES).

MES 14A enables removal and reinsertion of cartridges at various manufacturing levels. This feature enables visual checking and off-line listing and evaluation of partially completed cartridges.

Control is received from the driver loop DR. If no device end has been received from the manual entry station 14A, control is returned to the driver loop DR. When a device end is outstanding, if a move is pending, then the request is neglected. If no move is pending, then a move is posted back to a cell if a cartridge is out of the system, or to the manual exit station. An error message is issued in the second case.

Reject service, RJ, processes cartridges to the reject port 14.

Control is received from the driver loop DR if reject is active (START R). If cartridges are in the reject queue and no moves are pending, a move is requested from a cell to the reject port. Control is returned to the driver loop DR. Cartridges are counted and if the count exceeds the capacity of the reject port, a message is issued and the reject service is stopped.

The reject service is detailed at the machine instruction level in the two charts below. ##SPC8##

The microcode routines now described have to do primarily with operation of unit 10, processor 16 and processor 17.

Console service, CON and KB, provides connection to the operators station "console and keyboard".

When the driver loop DR detects that the `Function Select` key (not shown) on the keyboard has been hit, control is given to the console service routine. The operator action, pending indicator, is cleared for the display service, the alarm is turned off, and the alarm timers are stopped. The bottom line of the CRT is cleared, then the keyboard input routine is called. When the required operator input is complete, control is returned. The first four characters are considered a command and are compared against a valid list. If the command is not in the list, it is posted as illegal and control is given to the general service (SRV) for printing. If the command is valid, two operands are decoded and stored. Operands are separated from the command and other operands by one or more blanks. A command may have none, one or two operands. Control is passed to the routine requested by the command. Control is returned from the command processor to either a normal path or an error path which will cause the command to be marked invalid. Control then goes into the general service routine (SRV) which places the operator input on the printer. Control is then returned to the driver loop DR.

Since microcode and programming for connecting such devices to a programmed control processor 16 is well known, further description is dispensed with.

Display service, CRT, displays messages on the operators station CRT display.

The driver loop DR determines if any messages are in the CRT queue and gives control to the display service CRT. A check is made to determine if operator action is pending due to a previous full screen condition. If so, control is returned to driver loop DR. The next line position is tested for end of display. If the next message will overflow, then the audible alarm is sounded (2 seconds every 30 seconds), operator action pending is set, and control is returned to the driver loop DR. If the previous conditions are correct, a message queue element is removed from the CRT queue (dequeued). If the line printer is active, the queue element is placed on the printer queue (enqueued) to be printed later by the printer service. If the printer is not active, the queue element is marked not pending. The message word count is checked and limited to 20 (one line on display), if necessary. The current line pointer is incremented and the message is placed on the screen by calling the CRT routine. The next line is blanked out, if it is not the bottom line on the display.

Such microcode is well known and is not further described.

General service, SRV, performs general support service.

A branch is taken to the general service routine from the driver loop DR. For each of the services performed, a check is made to see if action is required, the service is provided if required, then the next service is tried. After all services are done, control is returned to the driver loop DR. Services provided are:

1. Print results of YIELD command.

2. Print message for low yield for devices.

3. Print results of CHI SQUARE command.

4. Print results of THROUGHPUT command.

5. Print hex data.

6. Print intervention required messages for cartridge testers TU's.

7. Print message for bad mode word for testers TU.

8. Process device end for manual exit station.

9. Place operator input on printer.

10. Process and print time message.

11. Print TU load or patch error message.

12. Print calibration cartridge data from testers.

13. Print TU sense data.

14. Process trace card reader data.

15. Print online quality test failed.

16. Print results of LAST command.

17. Print trace data and enqueue for SBCA (Host 17).

18. Print mode words from MODE command.

19. Provide bypass service as requested by BYPASS command.

20. Print message for unexpected interrupt.

21. Print tester reject codes as requested by the PRINT command.

22. Process good and bad messages for the AUTO CALIBRATION command.

23. Print serial numbers of cartridges going to packaging.

24. Print reject codes for servo writer as requested by the PRINT command.

25. Print special channel error messages.

26. Print queue empty messages.

27. Print Delta X messages for XY Carriage.

Because of the general nature of this microcode and its peripheral relationship to the present invention, further description is dispensed with. Some items listed above are not explained since they do not pertain to the present invention.

Printer service, PRS, prints messages on a line printer (not shown).

Control is received from the driver loop DR. If the printer is not active (START and STOP control active), a return to the driver loop DR is taken. The printer busy flag (signal) is checked and if still busy, control is returned to the driver DR. If not busy, a timer is cancelled. If there is an outstanding queue element, it is marked no longer pending. If there are no more queue elements in the printer queue, control is returned to the driver loop. An element is dequeued and requested to be printed if present. The system number is copied into the message before printing. A timer is started, then control is returned to the driver loop DR. If the timer expires before the line is printed, control is received in a timer exit routine from the timer service. An error message is written on the bottom line of the operator display, the alarm turned on, and the timer restarted. Control is then returned to the timer service. All of the above represent typical printer control microcode not requiring further explanation.

370 channel, CH, provides 370 channel protocol for communication between processor 16 and 17.

Control is received from areas requesting data transfer over the 370 channel. The channel protocol of the IBM OEM document A22-6974 is followed. This document is available from IBM at Mechanicsburg, Pa., 17055. All sequences are timed.

Visual check, VISU, verifies the visual (hot stamped) serial number against the magnetic serial number (servo writer 12 written).

Control is received from the console service for the VISUAL command. The visual command allows the operator to specify the check frequency, force a check, and verify a cartridge being checked. Frequence is the number of cartridges for the hot stamp 11 and servo writer 12 and minutes of test for the testers TU. The visual check is done by the device routines. The output service detects that a visual check is due and sends the next good cartridge to the manual exit station. The operator must type in the visual number which is compared to the expected number. If a cartridge is out of the system at check time, the next cartridge will not be sent. The hot stamp or servo writer will be stopped and messages issued. The tester will wait for the cartridge to be entered. A message will be issued.

Time out monitor, TOM, starts timers for devices.

Control is received from the driver loop DR if started. As a cartridge enters the hot stamp 11, servo writer 12 or testers TU, a timer is started. When the cartridge comes out of the device, the timer is stopped. If a cartridge does not come out, due to an error condition in the device, the timer times out and a message is posted. The time out monitor checks to see if the device is active and has a cartridge, then starts a timer. The timers are stopped by the respective device service routine.

Timer service, TC and TCI, provide software timers.

Control is received from the driver loop DR. If no requests are on the timer queue, control is returned to the driver. Each request on the quque is removed and processed. The time/hold/cancel indicator is checked and the proper action taken. For cancel, the element is left off the queue. Hold causes the element to be returned to the queue without timing. For time, the remaining time is decremented by the quantity kept by the interrupt routine. If the remaining time is positive, the element is returned to the queue. If the time period has expired, then the timer exit routine is given control.

During initialization, the timer/counter hardware (not shown) is started for 100 milliseconds. When the 100 milliseconds has elapsed, an interrupt is issued. The interrupt routine increments the time counter and restarts the timer counter.

Host Service, SB, sends data to host or supervisory processor 17.

Control is received from the driver loop DR if the SBCA connection to processor 17 is started (START B). If a request is active, the SBCA status is checked. If still busy, control is returned to the driver DR. If a bad status was returned, ten retries are attempted, then SBCA is stopped. For good status, if the last operation was fetching the date and time, the date and time is copied into the data to be transmitted to processor 17 and the data is sent. Good status following sending data causes the operation to be marked complete and the queue element to be returned to the proper queue. A 10 second timer is started for each operation. The timer exit routine is activated if the 10 seconds expire before the operation is complete. The status is set to x'FFFF', the SBCA is reset and normal handling done.

SBCA (Sensor Based Communication Adaptor) connects processor 16 to processor 17. SBCA is an adapter sold by International Business Machines Corporation (IBM) for connecting a System 7 computer or processor to a host processor, such as a 370/168-3 computer, also sold by IBM.

3830 channel service, CHS, processes host 370 (processor 17) channel supplied data signals to and from the cartridge testers, TU. Each TU includes a 3830 director unit manufactured and sold by IBM which also controls a DRC unit (not shown) used to test the cartridges being manufactured.

Control is received from the driver loop, DR, only if the TU channel is active (START 3). Two basic sections process data from the TU's. The first section checks to see if a TU is through testing a cartridge and has polled in a device end signal. If ending status signals has been presented, then a read command is issued to TU to receive the summary test data. For unit check (error) indicated in the ending status signals, a sense command is issued by processor 16 to TU, a message is built indicating the abort code and any intervention required if present. The read command is then sent to TU (3830). The cartridge serial number sent to the TU is compared to the cartridge serial number returned in the summary data. If the two do not compare, a message is issued and the TU channel and testers are stopped. The summary data is posted to be sent to the host 17 or printed for calibration data. In this regard, at this stage of manufacture, servo writer 12 should have magnetically recorded the cartridge serial number assigned at 21 and imprinted by hot stamp unit 11, onto the magnetic medium of cartridge. All three numbers must match.

The second section finds TU's with cartridges waiting to be tested. The serial number of a successfully tested cartridge is removed from the CT queue element, converted to EBCDIC coding, and sent, along with the modeword, to TU. Unit check (error) conditions are handled for bad modeword or 3830 hardware failure.

370 channel poll, CH, tests for Request In for pending request from devices, as TU's, Hot stamp 11, writer 12, port 14, etc. This routine begins communication between processor 16 and any of the controlled devices.

Control is received from the driver loop DR. The Request In Line is tested and if not active, control is returned to the driver loop DR. If the line is active, the address of the requesting device is taken and compared to an expected list. If the device address is not in the list, an error message is posted and control is returned to driver DR. For legal addresses, control is given to the normal 370 Channel routine where the request is processed.

Yield, YLD, YIEL, REYI, FIYI, gathers, monitors and displays cartridge yield information.

Control is received from any device (hot stamp, etc.) routines for the yield gathering and monitoring functions. The console service gives control to the yield display functions. As a cartridge comes out, each device reports the good/bad status to the yield gathering routine. Tables are maintained of the total cartridges and good cartridges for the long term (since system start) and short term (last ten cartridges) for each device.

The short term yield is monitored and if it drops to 50% or below, a message is issued. For cartridge testers, the serial numbers of good cartridges are saved for the LAST command. For the winder, hot stamp, and servo writer, the reject code is reported to the host. From the information in the tables, the YIEL, REYI, FIYI commands compute and display the total yield, retest yield and first pass yield, respectively.

Throughput, THRU, TRU, maintains cartridge throughput rates for display purposes.

Control is received from the console service for the THRU command from the timer service. A 15 minute timer is started the first time the driver loop DR is started. Each 15 minute time out, control is given to the monitor routine. Using the yield tables, a long term (since last system start) and a short term (last 15 minute) cartridge throughput rate is computed. When the THRU command is issued, the rates are posted on the CRT and printer.

The routine is detailed at the machine instruction level in the source code below. ##SPC9##

Queueing, QU, provides queue chaining (queue manage).

Control is received from any microcode area requiring queue service. Two functions are performed. The enqueue routine places elements on a queue chain and the dequeue routine removes elements.

The machine instruction level source code in the charts below show the controlling microcode (two charts), the XY carriage move enqueue (one chart), the cartridge move request words (two charts), cartridge queue areas (CARTQS -- seven charts), the queue limit source (description plus three charts) and an example of free cell identifications (eight charts). The latter identifies where a cartridge received by unit 10 from conveyor 20 can be stored (empty cell). Once a cartridge is assigned to a cell, it is always returned to that same cell in any all queuing during the manufacturing process. ##SPC10##

Queue Limit Service, QL, controls the size of cartridge queues.

Control is received from the driver loop DR if active. Cartridge counts are tested for the queues before hot stamp 11, servo writer 12, cartridge testers TU and packaging (not shown). Default limits are set as desired.

Any set limits may be modified by the ALTER command from the keyboard. If a queue is over the limit, the device processing into the queue is paused (no move cartridges to be sent to the paused device). For example, if the queue before the cartridge testers has 1901 cartridges, the servo writer 12 will be paused and a message issued. When the count drops to 20 below the limit, a message is issued. The operator can then start the paused device (send more cartridges to it). ##SPC11##

XY carriage service, XY, processes requested carriage moves to the carriage control hardware (not shown) of article storage and retrieval unit 10, and performs error recovery with respect thereto.

The microcode removes a move request from the move queue (infra) and sends the move request to the control circuits (not shown) of unit 10, then wait for ending status signals to be returned from unit 10. The ending status signals are analyzed and if good, the move request is posted as completed.

The routine is divided into two basic sections. The first section sends the moves to the library and the second section analyzes ending status.

The first section removes all move queue elements if any are present. A sort is performed to determine the nearest "from" X (horizontal address or location) address in the outstanding move requests to the last `To` "X" address. The resultant optimum move is then sent to unit 10. The initial status of unit 10 is checked for channel end only. Any initial errors are handled here.

The second section waits for the device (unit 10) end signal indicating the successful end of a move. If no errors occured, the move is marked complete and the cartridge is posted to the destination queue. Unit check (error) conditions are handled here. ##SPC12## ##SPC13##

In addition to the above described microcode, a practical embodiment would include additional microcode usually associated with programmable systems, such as program loading diagnostics, retries, start-up and initializations from emergency power-off and normal shut downs, additional routines for monitoring and controlling auxilliary apparatus (not shown) not necessary for practicing the present invention, calibration of TU's and the like, mapping cartridge locations in unit 10 (audit and verification of program controls) and intercommunication with parallel production lines. All of the above are omitted for clarity and brevity.

The chart below lists pertinent labels used in the illustrated machine instructions source code listings. The term "command" indicates operater input at the keyboard, KB.

A better understanding of the manufacturing functions can be gleaned from the following exemplary commands entered into the FIG. 1 illustrated apparatus via the keyboard KB by an operator.

While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the arts that various changes in form and details may be made therein without departing from the spirit and scope of the invention.