Obsidean_VM/HENKEL - ALPLA - AUTEFA - Data & Batch Management System.md at main - Obsidean_VM

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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

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

HENKEL System
- PO_NUMBER: 12-char Production Order number
- IDH_BTL: 12-char Article Number (bottle specifications)
- IDH_CON: Container specifications
ALPLA System
- CustomArticleNum: 12-char identifier
- Article Variant (AV): Numeric ID
- Product Family: Numeric ID for recipe selection
AUTEFA System
- Uses ALPLA's Article Variant (AV) ID

ID Conversion Process

graph LR
    A[Henkel IDH_BTL] -->|Q1 Processing- Ask Supervisor| B[CustomArticleNum/FamilyNumber - Vetro Recipe Number]
    B -->|Supervisor Search on ALPLA OPC Table| 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:

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

TG10 - Production Info
- Sends current and next batch information
- Includes Article Variant IDs and batch targets
TG20/21 - Line Change Request
- Used for tray loader assignment changes
- Includes validation of product compatibility
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:

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
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
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

// 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

Batch Change Initiation
- HENKEL sends "CalculatedBottlesRemainingToFill" = 0
- Line clearance verification process starts
Change Execution
- Q1 initiates emptying sequence
- Supervisor coordinates with AUTEFA
- New batch parameters loaded after confirmation
Production Resume
- System waits for all confirmations
- New batch counters initialized
- Production flow resumes

Error Handling

Communication Timeouts
- 60-second threshold for Q1-Henkel communication
- Automatic reconnection attempts
SKU Validation
- Not found conditions trigger warnings
- Invalid format handling
- Automatic zero-padding for string fields
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)

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