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Related to the NEXT2 addition that was asked by Lenin last week, the scope of the work is this?

Receive from Malisko the NEXT2 data on the Spare : Data_From_EbConvey[0-9]. We need to check if this area is free for all the lines.
Tunnel this dato to the Supervisor OPC and retransform to String as it is done actually on the BatchNext.BatchNumber e BatchActual.BatchNumber
The test will be made first on the 40,41 & 42 (TL25/TL26/TL27) and then on the other lines?

L41 4 days

TL25--------L41

L43/42 counters

Line index:

0	Fill_TL21_L23
1	Fill_TL22_L25
2	Fill_TL23_L43
3	Fill_TL25_L41
4	Fill_TL26_L42
5	Fill_TL27_L40

DINT diAppo

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


"ComSV".TL25_WriteToSv.FromHenkel := #FromHenkel;

Already in use:

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

Process to obtain the ActualSku from AB_IDH_BTL:

"FromHenkel".di -> AB_IDH_BTL -> ReqActualCustomProdNum -> Search( AlplaSkuList ) -> ActualSku -> ProdFamily -> PLC Recipe

HENKEL Communication Data Analysis

Data Array Structure (di[0] to di[49])

Control Words and Status (di[0] - di[1])

Position	Data Type	Description	Processing
di[0]	DWORD	Status Word (STW)	4-byte swap required
di[1]	DWORD	Control Word (CTW)	2-byte word swap

Batch Information Fields

Field	Array Positions	Description	Processing Type
PO_NUMBER	di[33]-di[44]	Current Production Order Number	Character conversion, zero-padding
AB_IDH_BTL	Direct mapping	Actual Batch Bottle ID	Space/null replaced with '0'
AB_IDH_CON	Not directly visible	Actual Batch Container ID	Space/null replaced with '0'
PO_NUMBER_NEXT	Mapped after PO_NUMBER	Next Production Order	Character conversion, zero-padding
NB_IDH_BTL	Direct mapping	Next Batch Bottle ID	Space/null replaced with '0'
NB_IDH_CON	Not directly visible	Next Batch Container ID	Space/null replaced with '0'
PO_NUMBER_NEXT2	di[1]-di[3]	Second Next Production Order	Direct transfer, no processing
IDH_BTL_NEXT2	di[7]-di[9]	Second Next Batch Bottle ID	Direct transfer, no processing
IDH_CON_NEXT2	di[4]-di[6]	Second Next Batch Container ID	Direct transfer, no processing

Data Processing Requirements

Data Type	Processing Steps	Purpose
Status Words	4-byte swap for positions 0,10,20,35-40,44-49	Align byte order for system compatibility
Word Data	2-byte swap for other positions	Standardize data format
Character Data	Replace spaces/nulls with '0'	Ensure consistent string handling
Numeric Data	Conversion to appropriate format	Enable mathematical operations

NEXT2 Implementation Considerations

The addition of NEXT2 fields will utilize previously spare array positions:

New Data Fields and Positions
- PO_NUMBER_NEXT2: di[1]-di[3]
- IDH_BTL_NEXT2: di[7]-di[9]
- IDH_CON_NEXT2: di[4]-di[6]

CustomProdNum:

Client Side (From HENKEL to Server):

In "Client - FC COM Data - QE1 from to Henkel.txt": The process begins with data reception from HENKEL through an array of 50 positions (0 to 49). The script implements specific byte-swapping operations based on array positions:

For positions 0, 10, 20, 35-40, and 44-49, it performs a four-byte swap where:

In "Client - FormatManagementQE1_G.txt":

The script manages the format change cycle and processes the data through several states:

Monitors the calculated bottles remaining
Tracks format change status
Manages batch transitions
Handles communication with Henkel regarding line status

Server Side (Processing and SKU Management):

In "Server - 10.01_SkuManage_G.txt": The server implements an indexing system for managing SKU requests:

Maintains a cycling index (0 to 5) for line management
Processes both actual and next batch requests simultaneously
Implements search functionality through the AlplaSkuList database

The search process includes:

Comparing requested CustomProdNum against stored values
Updating search flags for tracking purposes
Managing both current and next SKU searches independently

In "Server - TL25_ComAlpa_G.txt": This script handles the communication interface between systems:

Processes status words and counters
Manages batch information transmission
Handles character conversion for batch numbers
Implements communication monitoring with timeout detection

The server references the "10_FromAlplaSkuList_D" database which contains:

Article Version (Av)
Article Description (AvDesc)
Product Family ID (ProdFamily)
CustomArticleNum (12-character identifier)

Return Data Flow: When a match is found in the AlplaSkuList, the server:

Returns the complete SKU information
Provides the corresponding product family number
Updates the line status accordingly
Sets appropriate flags for format change management

The system maintains data integrity through:

Regular communication checks
Status word verification
Error flag management
Timeout monitoring

This software architecture ensures reliable data translation between HENKEL's batch information and ALPLA's product family system, with proper error handling and status tracking throughout the process.

Data_To_EbConvey Array Structure Documentation

Machine Status Words

Position	Data Type	Processing	Description
di[0]	DINT	4-byte swap	Main Status Word (STW) - Contains Life Bit (bit 31) and overall machine status
di[10]	DINT	4-byte swap	Labeler Status Word - Machine status and running conditions
di[20]	DINT	4-byte swap	Filler Status Word - Contains filler machine ready and running conditions

Machine Operating Parameters

Position	Data Type	Processing	Description
di[11]	DINT	2-byte word swap	Labeler Infeed Speed
di[12]	DINT	2-byte word swap	Labeler Machine Speed
di[13]	DINT	2-byte word swap	Master Filler Speed Command to Merge Slave
di[14]-di[15]	DINT	2-byte word swap	Duplicate Labeler Speed Values
di[16]	DINT	2-byte word swap	Spare
di[21]	DINT	2-byte word swap	Filler Infeed Belt Speed
di[22]	DINT	2-byte word swap	Processed Quantity
di[23]	DINT	2-byte word swap	Calculated Bottles Remaining to Fill

Current and Next Batch Information

Position	Data Type	Processing	Description
di[33]-di[38]	CHAR	Character conversion	Current Batch Production Order Number (PO_NUMBER)
di[39]-di[44]	CHAR	Character conversion	Next Batch Production Order Number (PO_NUMBER_NEXT)
di[17]-di[19]	SINT	2-byte word swap	SAP/SKU Data for Current IDH_CUP
di[24]-di[26]	SINT	2-byte word swap	SAP/SKU Data for Current IDH_SPOUT
di[27]-di[32]	SINT	2-byte word swap	SAP/SKU Data for Current IDH_CUP

NEXT2 Batch Information (New Implementation)

Position	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)

System Control and Reserved Fields

Position	Data Type	Processing	Description
di[45]-di[49]	DINT	4-byte swap	Reserved for system control words

With AUTEFA there is communication with the Next + 1

!Pasted image 20250204094751.png

DB2019 / FB 2014

!Pasted image 20250204095414.png


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

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