Obsidean_VM/04-InLavoro/HENKEL/93040 - HENKEL - BowlingGreen/Description/HENKEL - ALPLA - AUTEFA - Batch Data/HENKEL - ALPLA - AUTEFA - Data & Batch Management System.md

## Plant Overview

The system operates in a manufacturing plant where:
- **ALPLA**: Bottle manufacturing (blow molding)
- **HENKEL**: Bottle filling operations
- **AUTEFA**: Empty bottle storage logistics
- **Vetromeccanica**: Bottle conveyor system and inter-system communications hub

## System Architecture

```mermaid
graph TD
    subgraph "Line N"
        Q1[Q1 PLC] --> Q2[Q2 PLC]
        Q1 --> Q3[Q3 PLC]
        Q1 --> Q4[Q4 PLC]
        Q1 <--> H[Henkel]
    end
    
    subgraph "Supervisor PLC"
        S[Supervisor]
    end
    
    Q1 <--> S
    S <--> AU[AUTEFA]
    S <--> AL[ALPLA]
```

### PLC Distribution
- **Q1 PLCs**: Main line controller, interfaces with Henkel and other line PLCs
- **Q2-Q4 PLCs**: Secondary line controllers for conveyor sections
- **Supervisor PLC**: Central system managing communications with ALPLA and AUTEFA

## Batch Identification System

### ID Types and Formats
1. **HENKEL System**
   - PO_NUMBER: 12-char Production Order number
   - IDH_BTL: 12-char Article Number (bottle specifications)
   - IDH_CON: Container specifications

2. **ALPLA System**
   - CustomArticleNum: 12-char identifier
   - Article Variant (AV): Numeric ID
   - Product Family: Numeric ID for recipe selection

3. **AUTEFA System**
   - Uses ALPLA's Article Variant (AV) ID

### ID Conversion Process

```mermaid
graph LR
    A[Henkel IDH_BTL] -->|Q1 Processing| B[CustomArticleNum]
    B -->|Supervisor Search| C[ALPLA SKU]
    C -->|Extract| D[Article Variant ID]
    D -->|TG10 Telegram| E[AUTEFA]
```

## Data Flow Details

### 1. Q1 PLC (Client) Functions
- Receives data from Henkel in Data_From_EbConvey[0-49] array
- Performs byte-swapping based on data type:
  ```pascal
  CASE index OF
      0, 10, 20, 35..40, 44..49:  // Control words & IDs
          // 4-byte swap
      ELSE:
          // 2-byte word swap
  END_CASE;
  ```

### 2. Supervisor PLC (Server) Functions
- Manages SKU database (AlplaSkuList)
- Performs ID conversions and validations
- Handles AUTEFA telegram communications
- Provides OPC-UA interface for ALPLA

## Batch Management

### Data Location in HENKEL Array
```
Current Batch (AB):
- PO_NUMBER: di[44-46]
- IDH_BTL: di[35-37]

Next Batch (NB):
- PO_NUMBER: di[47-49]
- IDH_BTL: di[38-40]

Next+1 Batch:
- PO_NUMBER: di[1-3]
- IDH_BTL: di[7-9]
- IDH_CON: di[4-6]
```


### Identifier Explanations
| Prefix | Meaning            | Usage                                    |
| ------ | ------------------ | ---------------------------------------- |
| AB     | Actual Batch       | Current production batch being processed |
| NB     | Next Batch         | Next scheduled production batch          |
| IDH    | Internal Henkel ID | Unique identifier used by HENKEL         |
| BTL    | Bottle             | Relates to bottle specifications         |
| CON    | Container          | Relates to container specifications      |
| PO     | Production Order   | Order number for batch tracking          |

PO_NUMBER : Batch IDH_CON  ( 12 char )
IDH_BTL : Article Number ( 12 char )

|           |                      | ACTUAL | NEXT  | NEXT + 1 |     |     |
| --------- | -------------------- | ------ | ----- | -------- | --- | --- |
| PO_NUMBER | Batch IDH_CON        | 44-46  | 47-49 | 1-3      |     |     |
| IDH_BTL   | Batch Article Number | 35-37  | 38-40 | 7-9      |     |     |
| IDH_CON   |                      |        |       | 4-6      |     |     |

### AUTEFA Telegram System

4. **TG10 - Production Info**
   - Sends current and next batch information
   - Includes Article Variant IDs and batch targets

5. **TG20/21 - Line Change Request**
   - Used for tray loader assignment changes
   - Includes validation of product compatibility

6. **TG40 - Speed Updates**
   - Line speed synchronization
   - Values from 0-100 in steps of 10


Each telegram type (TG10, TG20, etc.) has three associated control bits:

1. **Trigger_TGxx**
    - Purpose: Initiates sending of new telegram
    - Usage: Set when new data needs to be transmitted
    - Example: `Trigger_TG10` set when batch information changes
2. **TT_TGxx** (Test Trigger)
    - Purpose: Manual testing of telegram transmission
    - Usage: Can be set from HMI for testing communications
    - Example: `TT_TG10` for testing production info transmission
3. **KT_TGxx** (Kill Trigger)
    - Purpose: Cancels pending telegram transmission
    - Usage: Set to stop telegram from being sent
    - Example: `KT_TG10` to cancel production info update

### SKU Search Process

```pascal
// In Supervisor PLC
FOR #i := 0 TO 249 DO
    IF LineN[line].ReqActualCustomProdNum = 
       AlplaSkuList[#i].CustomArticleNum THEN
        // Store complete SKU info
        LineN[line].SkuActualReq := AlplaSkuList[#i];
        // Mark search complete
        LineN[line].SearchActualSku := FALSE;
        EXIT;
    END_IF;
END_FOR;
```

## Line Indexing System

The system uses a consistent line indexing system across all communications:

| Index | Configuration | Line Reference |
|-------|--------------|----------------|
| 0 | Fill_TL21_L23 | Line 23 |
| 1 | Fill_TL22_L25 | Line 25 |
| 2 | Fill_TL23_L43 | Line 43 |
| 3 | Fill_TL25_L41 | Line 41 |
| 4 | Fill_TL26_L42 | Line 42 |
| 5 | Fill_TL27_L40 | Line 40 |

## Change Management Process

4. **Batch Change Initiation**
   - HENKEL sends "CalculatedBottlesRemainingToFill" = 0
   - Line clearance verification process starts

5. **Change Execution**
   - Q1 initiates emptying sequence
   - Supervisor coordinates with AUTEFA
   - New batch parameters loaded after confirmation

6. **Production Resume**
   - System waits for all confirmations
   - New batch counters initialized
   - Production flow resumes

## Error Handling

7. **Communication Timeouts**
   - 60-second threshold for Q1-Henkel communication
   - Automatic reconnection attempts

8. **SKU Validation**
   - Not found conditions trigger warnings
   - Invalid format handling
   - Automatic zero-padding for string fields

9. **Batch Change Safety**
   - Multiple confirmation requirements
   - Line status verification
   - Product compatibility checks


## NEXT2 Batch Information (New Implementation)

| Position From Henkel | Data Type | Processing      | Description                                                     |
| -------------------- | --------- | --------------- | --------------------------------------------------------------- |
| di[1]-di[3]          | SINT      | Direct transfer | Production Order Number for second next batch (PO_NUMBER_NEXT2) |
| di[4]-di[6]          | SINT      | Direct transfer | Container ID for second next batch (IDH_CON_NEXT2)              |
| di[7]-di[9]          | SINT      | Direct transfer | Bottle ID for second next batch (IDH_BTL_NEXT2)                 |