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HENKEL	Alpla	Vetromeccanica	AUTEFA
Before Changeover	Sends IDH_BTL_NEXT number to be validated
Data_To_EbConvey[38]
	Validates IDH_BTL_NEXT is valid number and send acknowledge
	Data_From_EbConvey[0].2
Step 1	Operator manually selects "Line Clearance" (?) and send signal "0" on "CalculatedBottlesRemainingToFill".
	Data_To_EbConvey[23]
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.
		N/A	TG10 Send 0 in Bottles for Actual Batch
Step 3	Operator verifies line is empty and sends "changeover request" signal after last bottle goes thorugh filler.
	Data_To_EbConvey[0].0
Step 4		Operator verifies line is empty and sends "line is busy with changeover", confirming on Popup screen
		Data_From_EbConvey[0].0
Step 5			Starts changeover	Starts changeover
			Data_From_EbConvey[0].0	Data_From_EbConvey[0].0
Step 6			Ends changeover. Sends signal "Changeover is finished and ready.	Ends changeover. Sends signal "Changeover is finished and ready.
			Data_From_EbConvey[0].1	Data_From_EbConvey[0].1


Step 7	Send Reset counters signal		Reset Counters
	Data_To_EbConvey[0].1
Step 8	Send new value on "CalculatedBottlesRemainingToFill".
	Data_To_EbConvey[23]
Step 9	Send Changeover Complete. To be considered "Production Ready"	Starts conveying bottles.	Finish Chanover Cycle
	Data_To_EbConvey[0].2

Batch Lifecycle Process Documentation

Overview

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.

System Roles

HENKEL: Controls filling process and initiates batch changes
ALPLA: Manages bottle production and validates batch data
Vetromeccanica: Coordinates conveyor systems and inter-system communications
AUTEFA: Handles empty bottle logistics and tray loading

Pre-Changeover Phase

Batch Validation

HENKEL → ALPLA
- Sends next batch bottle ID (IDH_BTL_NEXT)
- Location: Data_To_EbConvey[38]
ALPLA Response
- Validates IDH_BTL_NEXT number
- Sends acknowledgment
- Signal: Data_From_EbConvey[0].2

Changeover Process

Step 1: Line Clearance Initiation

HENKEL Action:
- Operator selects "Line Clearance"
- Sets "CalculatedBottlesRemainingToFill" to 0
- Location: Data_To_EbConvey[23]

Step 2: Production Stop

Vetromeccanica Actions:
- Stops bottle unloading from trays
- Continues processing bottles already on conveyors
AUTEFA Actions:
- Initiates merger and line emptying
- Updates TG10 telegram with 0 in Bottles for Actual Batch

Step 3: Line Verification

HENKEL Action:
- Operator verifies empty line
- Sends changeover request after last bottle passes filler
- Signal: Data_To_EbConvey[0].0

Step 4: Changeover Confirmation

Vetromeccanica Action:
- Operator verifies empty line
- Confirms "line busy with changeover" via popup
- Signal: Data_From_EbConvey[0].0

Step 5: Changeover Execution

AUTEFA & Vetromeccanica:
- Start changeover process
- Signal: Data_From_EbConvey[0].0

Step 6: Completion Confirmation

AUTEFA & Vetromeccanica:
- Send "Changeover finished and ready" signal
- Signal: Data_From_EbConvey[0].1

Post-Changeover Phase

Step 7: Counter Reset

HENKEL Action:
- Sends reset counters signal
- Signal: Data_To_EbConvey[0].1
AUTEFA Action:
- Resets internal counters

Step 8: Production Parameters

HENKEL Action:
- Updates "CalculatedBottlesRemainingToFill" with new value
- Location: Data_To_EbConvey[23]

Step 9: Production Resume

HENKEL Action:
- Sends "Changeover Complete" signal
- Signal: Data_To_EbConvey[0].2
Vetromeccanica Action:
- Starts conveying bottles
AUTEFA Action:
- Completes changeover cycle

Communication Flow Diagram

sequenceDiagram
    participant H as HENKEL
    participant A as ALPLA
    participant V as Vetromeccanica
    participant AU as AUTEFA

    H->>A: Send IDH_BTL_NEXT
    A->>H: Validate & Acknowledge
    H->>V: Set CalculatedBottlesRemainingToFill = 0
    V->>AU: Stop Unloading
    H->>V: Send Changeover Request
    V->>V: Confirm Empty Line
    V->>AU: Start Changeover
    AU->>V: Confirm Changeover Complete
    H->>V: Reset Counters
    H->>V: New Bottle Count
    H->>V: Production Ready

Signal Reference Table

Step	Signal	Location	Description
Pre-Change	IDH_BTL_NEXT	Data_To_EbConvey[38]	Next batch bottle ID
Validation	Acknowledge	Data_From_EbConvey[0].2	Batch validation
Initiation	Zero Count	Data_To_EbConvey[23]	Remaining bottles count
Request	Changeover	Data_To_EbConvey[0].0	Start changeover
Confirmation	Line Busy	Data_From_EbConvey[0].0	Line status
Completion	Ready	Data_From_EbConvey[0].1	Line ready
Reset	Counters	Data_To_EbConvey[0].1	Reset counters
Resume	Complete	Data_To_EbConvey[0].2	Production ready

Error Handling

Validation Errors

Invalid batch number detection
Communication timeout handling
Line status verification failures

Process Safeguards

Multiple operator confirmations required
Line emptiness verification
Status signal validation

Recovery Procedures

Counter synchronization check
Line status verification
Communication reset if needed
Manual intervention protocols

Vetromeccanica Software Implementation Guide

Software Architecture

PLC Distribution

Q1 PLCs (Client Side)
- Main communication interface with Henkel
- Manages line controllers Q2-Q4
- Handles real-time batch data processing
Supervisor PLC (Server Side)
- Central communication hub
- Manages AUTEFA telegrams
- Provides ALPLA OPC-UA interface
- Handles SKU database and searches

Data Structures

Client Side Structures

// FromHenkel Communication Structure
TYPE "FromHenkelv2_U"
    STRUCT
        di : Array[0..49] of DINT;    // Raw data from Henkel
        STW : "Bool32_U";             // Status word bits
        LineStatus : Struct
            di0 : "Bool32_U";         // Line status bits
        END_STRUCT;
        SignalExchange : Struct       // Line signals
            Filler : Struct
                CalculatedBottlesRemainingToFill : DINT;
            END_STRUCT;
        END_STRUCT;
        AB_IDH_BTL : Array[0..11] of CHAR;    // Current batch ID
        NB_IDH_BTL : Array[0..11] of CHAR;    // Next batch ID
        PO_NUMBER : Array[0..11] of CHAR;     // Current order
        PO_NUMBER_NEXT : Array[0..11] of CHAR; // Next order
        ABBottlesNumber : DINT;               // Current batch count
        NBBottlesNumber : DINT;               // Next batch count
    END_STRUCT;
END_TYPE

Server Side Structures

// SKU Information Structure
TYPE "StSku_U"
    STRUCT
        Av : DInt;                    // Article Variant ID
        AvDesc : String[36];          // Description
        ProdFamily : DInt;            // Product Family
        CustomArticleNum : String[12]; // Customer Article Number
    END_STRUCT;
END_TYPE

// AUTEFA Message Header
TYPE "AUTEFA_message_header"
    STRUCT
        message_length : Int;
        endian_format : Word := 16#4321;
        telegram_number : Int;
        task : Int := 1;
        error_number : DInt;
        send_client_ID : "Client_ID";
        timestamp : "TX_Time";
    END_STRUCT;
END_TYPE

Key Functions Implementation

1. Byte Processing (Q1)

// Process incoming Henkel data
FOR #i := 0 TO 49 DO
    #atFromHenkel[#i] := "FromHenkel".di[#i];
    CASE #i OF
        0, 10, 20, 35..40, 44..49:  // Control words and IDs
            #diAppo.%B3 := #atFromHenkel[#i].%B2;
            #diAppo.%B2 := #atFromHenkel[#i].%B3;
            #diAppo.%B1 := #atFromHenkel[#i].%B0;
            #diAppo.%B0 := #atFromHenkel[#i].%B1;
        ELSE  // Process data
            #diAppo.%W0 := #atFromHenkel[#i].%W1;
            #diAppo.%W1 := #atFromHenkel[#i].%W0;
    END_CASE;
    #atFromHenkel[#i] := #diAppo;
END_FOR;

2. SKU Search (Supervisor)

// Search SKU in ALPLA database
IF NOT "LineN[#i].SearchEnd" THEN
    IF "LineN[#i].i" >= 249 THEN
        "LineN[#i].SkuActualNotFound" := TRUE;
        "LineN[#i].SkuActualReq.Av" := 0;
        "LineN[#i].SkuActualReq.ProdFamily" := 0;
        "LineN[#i].SearchActualSku" := FALSE;
    ELSIF "LineN[#i].ReqActualCustomProdNum" = 
          "AlplaSkuList[LineN[#i].i].CustomArticleNum" THEN
        "LineN[#i].SkuActualReq" := "AlplaSkuList[LineN[#i].i]";
        "LineN[#i].SearchActualSku" := FALSE;
    ELSE
        "LineN[#i].i" += 1;
    END_IF;
END_IF;

3. AUTEFA Telegram Preparation (Supervisor)

// Prepare TG10 Production Info
"TG10_send.DATA.Filling_Line" := #LineNumber;

// Actual batch data
Strg_TO_Chars(
    Strg := "BatchActual.BatchNumber",
    pChars := 0,
    Cnt => #uiCnt,
    Chars := "TG10_send.DATA.Batch_ID"
);

"TG10_send.DATA.Active_Batch_Target_1000" :=
    DINT_TO_INT("ToAutefa.TG10_ProductionInfo" / 1000);

"TG10_send.DATA.Active_Batch_Target_Units" :=
    DINT_TO_INT("ToAutefa.TG10_ProductionInfo" MOD 1000);

"TG10_send.DATA.Active_Batch_Article_Variant_ID" :=
    "WriteData_D.ToQ1.FromAlpla.ActualSku.Av";

Data Flow Processing

1. Q1 Processing Sequence

graph TD
    A[Receive Henkel Data] --> B[Byte Swap Processing]
    B --> C[Update Local Variables]
    C --> D[Send to Line PLCs]
    C --> E[Send to Supervisor]

2. Supervisor Processing Sequence

graph TD
    A[Receive Q1 Data] --> B[SKU Search]
    B --> C[Format Data]
    C --> D[Prepare AUTEFA Telegram]
    C --> E[Update OPC-UA Data]

Error Handling Implementation

1. Communication Monitoring

// Monitor Q1-Henkel communication
"T_LostComHenkel".TON(
    IN := NOT "TR_LostComHenkel".Q AND 
          NOT "ToSV.STW.QE1.LostComQ1",
    PT := T#60s
);
"ToSV.STW.QE1.LostComHenkel" := "T_LostComHenkel".Q;

2. SKU Validation

// Validate SKU data
IF "LineN[#i].SearchActualSku" AND "LineN[#i].i" >= 249 THEN
    // SKU not found handling
    "LineN[#i].SkuActualNotFound" := TRUE;
    "LineN[#i].SkuActualReq.Av" := 0;
    "LineN[#i].SkuActualReq.ProdFamily" := 0;
    "LineN[#i].SkuActualReq.CustomArticleNum" := '';
    "LineN[#i].SkuActualReq.AvDesc" := '';
END_IF;

Line Index Configuration

Each line's data is managed through a consistent index system:

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

Communication Issues
- Check life bit timing (bit 31)
- Verify byte swap patterns
- Monitor communication counters
SKU Search Problems
- Enable search debugging flags
- Log CustomArticleNum comparisons
- Verify AlplaSkuList content
Telegram Failures
- Validate header structure
- Check message length calculations
- Monitor acknowledgment timing

Common Implementation Pitfalls

Byte Ordering
- Always use correct swap pattern based on data type
- Verify endianness in telegram headers
- Test with known data patterns
String Handling
- Zero-pad incomplete strings
- Handle empty/null characters
- Verify string length limits
Counter Management
- Synchronize counters after resets
- Handle rollover conditions
- Validate counter arithmetic

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