445 lines
21 KiB
Markdown
445 lines
21 KiB
Markdown
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| HENKEL | Alpla | Vetromeccanica | AUTEFA | |
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| ---------------------- | ------------------------------------------------------------------------------------------------------------ | ---------------------------------------------------------------------------------------------------- | ---------------------------------------------------------------- | ---------------------------------------------------------------------------------------- |
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| Before Changeover | Sends IDH_BTL_NEXT number to be validated | | | |
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| _Data_To_EbConvey[38]_ | | | | |
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| | Validates IDH_BTL_NEXT is valid number and send acknowledge | | | |
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| | _Data_From_EbConvey[0].2_ | | | |
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| Step 1 | Operator manually selects "Line Clearance" (?) and send signal "0" on "CalculatedBottlesRemainingToFill". | | | |
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| | _Data_To_EbConvey[23]_ | | | |
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| Step 2 | | Stops taking bottles out of trays and sends what is already on the tables and conveyors. | Emptying Merger and Line | Stops taking bottles out of trays and sends what is already on the tables and conveyors. |
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| | | _N/A_ | _TG10 Send 0 in Bottles for Actual Batch_ | |
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| Step 3 | Operator verifies line is empty and sends "changeover request" signal after last bottle goes thorugh filler. | | | |
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| | _Data_To_EbConvey[0].0_ | | | |
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| Step 4 | | Operator verifies line is empty and sends "line is busy with changeover", confirming on Popup screen | | |
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| | | _Data_From_EbConvey[0].0_ | | |
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| Step 5 | | | Starts changeover | Starts changeover |
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| | | | _Data_From_EbConvey[0].0_ | _Data_From_EbConvey[0].0_ |
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| Step 6 | | | Ends changeover. Sends signal "Changeover is finished and ready. | Ends changeover. Sends signal "Changeover is finished and ready. |
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| | | | _Data_From_EbConvey[0].1_ | _Data_From_EbConvey[0].1_ |
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| Step 7 | Send Reset counters signal | | Reset Counters | |
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| | _Data_To_EbConvey[0].1_ | | | |
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| Step 8 | Send new value on "CalculatedBottlesRemainingToFill". | | | |
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| | _Data_To_EbConvey[23]_ | | | |
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| Step 9 | Send Changeover Complete. To be considered "Production Ready" | Starts conveying bottles. | Finish Chanover Cycle | |
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| | _Data_To_EbConvey[0].2_ | | | |
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# Batch Lifecycle Process Documentation
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## Overview
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This document details the step-by-step process of a batch changeover in the production line, including all interactions between HENKEL, ALPLA, Vetromeccanica, and AUTEFA systems.
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## System Roles
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- **HENKEL**: Controls filling process and initiates batch changes
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- **ALPLA**: Manages bottle production and validates batch data
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- **Vetromeccanica**: Coordinates conveyor systems and inter-system communications
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- **AUTEFA**: Handles empty bottle logistics and tray loading
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## Pre-Changeover Phase
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### Batch Validation
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1. **HENKEL → ALPLA**
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- Sends next batch bottle ID (IDH_BTL_NEXT)
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- Location: `Data_To_EbConvey[38]`
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2. **ALPLA Response**
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- Validates IDH_BTL_NEXT number
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- Sends acknowledgment
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- Signal: `Data_From_EbConvey[0].2`
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## Changeover Process
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### Step 1: Line Clearance Initiation
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- **HENKEL Action**:
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- Operator selects "Line Clearance"
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- Sets "CalculatedBottlesRemainingToFill" to 0
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- Location: `Data_To_EbConvey[23]`
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### Step 2: Production Stop
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- **Vetromeccanica Actions**:
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- Stops bottle unloading from trays
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- Continues processing bottles already on conveyors
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- **AUTEFA Actions**:
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- Initiates merger and line emptying
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- Updates TG10 telegram with 0 in Bottles for Actual Batch
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### Step 3: Line Verification
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- **HENKEL Action**:
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- Operator verifies empty line
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- Sends changeover request after last bottle passes filler
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- Signal: `Data_To_EbConvey[0].0`
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### Step 4: Changeover Confirmation
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- **Vetromeccanica Action**:
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- Operator verifies empty line
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- Confirms "line busy with changeover" via popup
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- Signal: `Data_From_EbConvey[0].0`
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### Step 5: Changeover Execution
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- **AUTEFA & Vetromeccanica**:
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- Start changeover process
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- Signal: `Data_From_EbConvey[0].0`
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### Step 6: Completion Confirmation
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- **AUTEFA & Vetromeccanica**:
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- Send "Changeover finished and ready" signal
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- Signal: `Data_From_EbConvey[0].1`
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## Post-Changeover Phase
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### Step 7: Counter Reset
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- **HENKEL Action**:
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- Sends reset counters signal
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- Signal: `Data_To_EbConvey[0].1`
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- **AUTEFA Action**:
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- Resets internal counters
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### Step 8: Production Parameters
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- **HENKEL Action**:
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- Updates "CalculatedBottlesRemainingToFill" with new value
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- Location: `Data_To_EbConvey[23]`
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### Step 9: Production Resume
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- **HENKEL Action**:
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- Sends "Changeover Complete" signal
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- Signal: `Data_To_EbConvey[0].2`
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- **Vetromeccanica Action**:
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- Starts conveying bottles
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- **AUTEFA Action**:
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- Completes changeover cycle
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## Communication Flow Diagram
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```mermaid
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sequenceDiagram
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participant H as HENKEL
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participant A as ALPLA
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participant V as Vetromeccanica
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participant AU as AUTEFA
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H->>A: Send IDH_BTL_NEXT
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A->>H: Validate & Acknowledge
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H->>V: Set CalculatedBottlesRemainingToFill = 0
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V->>AU: Stop Unloading
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H->>V: Send Changeover Request
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V->>V: Confirm Empty Line
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V->>AU: Start Changeover
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AU->>V: Confirm Changeover Complete
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H->>V: Reset Counters
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H->>V: New Bottle Count
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H->>V: Production Ready
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```
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## Signal Reference Table
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| Step | Signal | Location | Description |
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|------|---------|-----------|-------------|
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| Pre-Change | IDH_BTL_NEXT | Data_To_EbConvey[38] | Next batch bottle ID |
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| Validation | Acknowledge | Data_From_EbConvey[0].2 | Batch validation |
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| Initiation | Zero Count | Data_To_EbConvey[23] | Remaining bottles count |
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| Request | Changeover | Data_To_EbConvey[0].0 | Start changeover |
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| Confirmation | Line Busy | Data_From_EbConvey[0].0 | Line status |
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| Completion | Ready | Data_From_EbConvey[0].1 | Line ready |
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| Reset | Counters | Data_To_EbConvey[0].1 | Reset counters |
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| Resume | Complete | Data_To_EbConvey[0].2 | Production ready |
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## Error Handling
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### Validation Errors
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- Invalid batch number detection
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- Communication timeout handling
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- Line status verification failures
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### Process Safeguards
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- Multiple operator confirmations required
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- Line emptiness verification
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- Status signal validation
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### Recovery Procedures
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1. Counter synchronization check
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2. Line status verification
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3. Communication reset if needed
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4. Manual intervention protocols
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***
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# Vetromeccanica Software Implementation Guide
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## Software Architecture
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### PLC Distribution
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1. **Q1 PLCs (Client Side)**
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- Main communication interface with Henkel
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- Manages line controllers Q2-Q4
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- Handles real-time batch data processing
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2. **Supervisor PLC (Server Side)**
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- Central communication hub
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- Manages AUTEFA telegrams
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- Provides ALPLA OPC-UA interface
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- Handles SKU database and searches
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## Data Structures
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### Client Side Structures
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```pascal
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// FromHenkel Communication Structure
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TYPE "FromHenkelv2_U"
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STRUCT
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di : Array[0..49] of DINT; // Raw data from Henkel
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STW : "Bool32_U"; // Status word bits
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LineStatus : Struct
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di0 : "Bool32_U"; // Line status bits
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END_STRUCT;
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SignalExchange : Struct // Line signals
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Filler : Struct
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CalculatedBottlesRemainingToFill : DINT;
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END_STRUCT;
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END_STRUCT;
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AB_IDH_BTL : Array[0..11] of CHAR; // Current batch ID
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NB_IDH_BTL : Array[0..11] of CHAR; // Next batch ID
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PO_NUMBER : Array[0..11] of CHAR; // Current order
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PO_NUMBER_NEXT : Array[0..11] of CHAR; // Next order
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ABBottlesNumber : DINT; // Current batch count
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NBBottlesNumber : DINT; // Next batch count
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END_STRUCT;
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END_TYPE
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```
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### Server Side Structures
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```pascal
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// SKU Information Structure
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TYPE "StSku_U"
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STRUCT
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Av : DInt; // Article Variant ID
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AvDesc : String[36]; // Description
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ProdFamily : DInt; // Product Family
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CustomArticleNum : String[12]; // Customer Article Number
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END_STRUCT;
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END_TYPE
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// AUTEFA Message Header
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TYPE "AUTEFA_message_header"
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STRUCT
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message_length : Int;
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endian_format : Word := 16#4321;
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telegram_number : Int;
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task : Int := 1;
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error_number : DInt;
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send_client_ID : "Client_ID";
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timestamp : "TX_Time";
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END_STRUCT;
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END_TYPE
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```
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## Key Functions Implementation
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### 1. Byte Processing (Q1)
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```pascal
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// Process incoming Henkel data
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FOR #i := 0 TO 49 DO
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#atFromHenkel[#i] := "FromHenkel".di[#i];
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CASE #i OF
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0, 10, 20, 35..40, 44..49: // Control words and IDs
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#diAppo.%B3 := #atFromHenkel[#i].%B2;
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#diAppo.%B2 := #atFromHenkel[#i].%B3;
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#diAppo.%B1 := #atFromHenkel[#i].%B0;
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#diAppo.%B0 := #atFromHenkel[#i].%B1;
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ELSE // Process data
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#diAppo.%W0 := #atFromHenkel[#i].%W1;
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#diAppo.%W1 := #atFromHenkel[#i].%W0;
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END_CASE;
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#atFromHenkel[#i] := #diAppo;
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END_FOR;
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```
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### 2. SKU Search (Supervisor)
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```pascal
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// Search SKU in ALPLA database
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IF NOT "LineN[#i].SearchEnd" THEN
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IF "LineN[#i].i" >= 249 THEN
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"LineN[#i].SkuActualNotFound" := TRUE;
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"LineN[#i].SkuActualReq.Av" := 0;
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"LineN[#i].SkuActualReq.ProdFamily" := 0;
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"LineN[#i].SearchActualSku" := FALSE;
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ELSIF "LineN[#i].ReqActualCustomProdNum" =
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"AlplaSkuList[LineN[#i].i].CustomArticleNum" THEN
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"LineN[#i].SkuActualReq" := "AlplaSkuList[LineN[#i].i]";
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"LineN[#i].SearchActualSku" := FALSE;
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ELSE
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"LineN[#i].i" += 1;
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END_IF;
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END_IF;
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```
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### 3. AUTEFA Telegram Preparation (Supervisor)
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```pascal
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// Prepare TG10 Production Info
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"TG10_send.DATA.Filling_Line" := #LineNumber;
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// Actual batch data
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Strg_TO_Chars(
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Strg := "BatchActual.BatchNumber",
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pChars := 0,
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Cnt => #uiCnt,
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Chars := "TG10_send.DATA.Batch_ID"
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);
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"TG10_send.DATA.Active_Batch_Target_1000" :=
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DINT_TO_INT("ToAutefa.TG10_ProductionInfo" / 1000);
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"TG10_send.DATA.Active_Batch_Target_Units" :=
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DINT_TO_INT("ToAutefa.TG10_ProductionInfo" MOD 1000);
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"TG10_send.DATA.Active_Batch_Article_Variant_ID" :=
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"WriteData_D.ToQ1.FromAlpla.ActualSku.Av";
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```
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## Data Flow Processing
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### 1. Q1 Processing Sequence
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```mermaid
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graph TD
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A[Receive Henkel Data] --> B[Byte Swap Processing]
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B --> C[Update Local Variables]
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C --> D[Send to Line PLCs]
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C --> E[Send to Supervisor]
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```
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### 2. Supervisor Processing Sequence
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```mermaid
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graph TD
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A[Receive Q1 Data] --> B[SKU Search]
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B --> C[Format Data]
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C --> D[Prepare AUTEFA Telegram]
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C --> E[Update OPC-UA Data]
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```
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## Error Handling Implementation
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### 1. Communication Monitoring
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```pascal
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// Monitor Q1-Henkel communication
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"T_LostComHenkel".TON(
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IN := NOT "TR_LostComHenkel".Q AND
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NOT "ToSV.STW.QE1.LostComQ1",
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PT := T#60s
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);
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"ToSV.STW.QE1.LostComHenkel" := "T_LostComHenkel".Q;
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```
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### 2. SKU Validation
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```pascal
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// Validate SKU data
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IF "LineN[#i].SearchActualSku" AND "LineN[#i].i" >= 249 THEN
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// SKU not found handling
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"LineN[#i].SkuActualNotFound" := TRUE;
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"LineN[#i].SkuActualReq.Av" := 0;
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"LineN[#i].SkuActualReq.ProdFamily" := 0;
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"LineN[#i].SkuActualReq.CustomArticleNum" := '';
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"LineN[#i].SkuActualReq.AvDesc" := '';
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END_IF;
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```
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## Line Index Configuration
|
||
|
|
|
||
|
|
Each line's data is managed through a consistent index system:
|
||
|
|
|
||
|
|
```pascal
|
||
|
|
CASE LineIndex OF
|
||
|
|
0: // Fill_TL21_L23
|
||
|
|
#locChar := "TL21_ReadData_D".FromQ1.FromHenkel.AB_IDH_BTL;
|
||
|
|
1: // Fill_TL22_L25
|
||
|
|
#locChar := "TL22_ReadData_D".FromQ1.FromHenkel.AB_IDH_BTL;
|
||
|
|
2: // Fill_TL23_L43
|
||
|
|
#locChar := "TL23_ReadData_D".FromQ1.FromHenkel.AB_IDH_BTL;
|
||
|
|
3: // Fill_TL25_L41
|
||
|
|
#locChar := "TL25_ReadData_D".FromQ1.FromHenkel.AB_IDH_BTL;
|
||
|
|
4: // Fill_TL26_L42
|
||
|
|
#locChar := "TL26_ReadData_D".FromQ1.FromHenkel.AB_IDH_BTL;
|
||
|
|
5: // Fill_TL27_L40
|
||
|
|
#locChar := "TL27_ReadData_D".FromQ1.FromHenkel.AB_IDH_BTL;
|
||
|
|
END_CASE;
|
||
|
|
```
|
||
|
|
|
||
|
|
## Important Memory Mappings
|
||
|
|
|
||
|
|
### Henkel Data Array Map
|
||
|
|
```
|
||
|
|
di[0-49] Layout:
|
||
|
|
- Current Batch Data:
|
||
|
|
- PO_NUMBER: di[44-46]
|
||
|
|
- IDH_BTL: di[35-37]
|
||
|
|
- Next Batch Data:
|
||
|
|
- PO_NUMBER: di[47-49]
|
||
|
|
- IDH_BTL: di[38-40]
|
||
|
|
- Next+1 Batch Data:
|
||
|
|
- PO_NUMBER: di[1-3]
|
||
|
|
- IDH_BTL: di[7-9]
|
||
|
|
- IDH_CON: di[4-6]
|
||
|
|
```
|
||
|
|
|
||
|
|
### Critical Status Bits
|
||
|
|
```
|
||
|
|
STW Bits:
|
||
|
|
- [0]: Changeover Request
|
||
|
|
- [1]: Counter Reset
|
||
|
|
- [2]: Production Ready
|
||
|
|
- [31]: Life Bit
|
||
|
|
|
||
|
|
Line Status:
|
||
|
|
- [0]: Line Empty
|
||
|
|
- [1]: Changeover Active
|
||
|
|
- [2]: Line Ready
|
||
|
|
```
|
||
|
|
|
||
|
|
## Debug Tips
|
||
|
|
|
||
|
|
1. **Communication Issues**
|
||
|
|
- Check life bit timing (bit 31)
|
||
|
|
- Verify byte swap patterns
|
||
|
|
- Monitor communication counters
|
||
|
|
|
||
|
|
2. **SKU Search Problems**
|
||
|
|
- Enable search debugging flags
|
||
|
|
- Log CustomArticleNum comparisons
|
||
|
|
- Verify AlplaSkuList content
|
||
|
|
|
||
|
|
3. **Telegram Failures**
|
||
|
|
- Validate header structure
|
||
|
|
- Check message length calculations
|
||
|
|
- Monitor acknowledgment timing
|
||
|
|
|
||
|
|
## Common Implementation Pitfalls
|
||
|
|
|
||
|
|
4. **Byte Ordering**
|
||
|
|
- Always use correct swap pattern based on data type
|
||
|
|
- Verify endianness in telegram headers
|
||
|
|
- Test with known data patterns
|
||
|
|
|
||
|
|
5. **String Handling**
|
||
|
|
- Zero-pad incomplete strings
|
||
|
|
- Handle empty/null characters
|
||
|
|
- Verify string length limits
|
||
|
|
|
||
|
|
6. **Counter Management**
|
||
|
|
- Synchronize counters after resets
|
||
|
|
- Handle rollover conditions
|
||
|
|
- Validate counter arithmetic
|