Crash

TRAINING

Speaker
Date
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 Agenda

1 Recovery guide crash

2 Container scrolling detection crash

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 Agenda

1 Recovery guide crash

2 Container scrolling detection crash

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 General description
The purpose of the bloc is to detect a jam or an ascending accumulation on back guide in combiners outlet. The detection is done with the
top sensor (photocell) used for the blow rejection and a crash sensor located just after the guide recovery.

The most important rules for the sensors location are:

- The crash sensor must be placed at a height lower than the smaller container diameter or ideally at the containers point of contact
(equivalent to a Recentring sensor).

- The sensor must be placed after the guide recovery at approximately 20cm.

Flow
Blower rejections Crash sensor
Rejection
top sensor
Blower
Guide

Back guide
Tray
Reflector

Reflector

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 General description
The functional purpose is to affirm that the containers that pass in front of blow top sensor must also pass in
front of the crash sensor. The two sensors detect the same containers in normal case but with a shift
depending to the distance between these sensors. We use a shift register that contain the state of the blow
top sensor. This register is shifting at the conveyor speed. We extract the value of the register at the position of
the crash sensor and we compare it with the state of this sensor. A crash is detected if there is bottles
memorised and they dont pass in front of the crash sensor with a distance set.

Remark: We dont use the blow bottom sensor in order to dont care about fallen container that are rejected by
the blow.

We detect also the jam on the single lane. A crash is detected if we dont detect hole between containers
during a distance set because we always have space between containers in normal case.

A sensor must be placed just before beginning of the back guide if the blow rejection is not install (sensor + blow).

Important remark: a dysfunction of these sensors (fouling of bad setting), or a bad calibration of speed on the
conveyor where the sensor are located, create immediately a dysfunction by detection of untimely crash
apparition.

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 Crash before back guide principle
It is based on a shift register. The register of the guides crash advance at the conveyor speed with a step of 5cm per bit. The first value of
the register is primed by the state of the blow crash sensor.

Value = 0 if presence of container / Value = 1 if no container

The distance set in the inputs of the bloc (Dist_eject_crash_sens_mm) permit to define when the container or the hole will arrive in front of
the crash sensor.

We launch a distance counter if the extracted bit is at 0. There is a crash if no containers are detected during a distance set
(Dist_crash_bef_guide).

We extract the value of the register at the crash sensor position and we compare it to the state of this sensor. A distance counter is
incremented if there is bottles memorised in the register (=0) and that they dont pass in front of crash sensor (=1). There is a crash if
the distance set is reached.

The counter is incremented only when the extracted bit is at 0. The counter is reset is the crash sensor detect a container.

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 Crash after back guide principle
It is based on a travelled distance for the chain.

There is a crash if the crash sensor stays at 0 during a distance set.

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 Siemens automation application

Input reading
L PEB216
T EB216

Crash Guide
function

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 Function bloc inputs
NAME DESCRIPTION
Par_DB Function parameter Database

Index Parameters index (container type code)

Used to select the parameters associated to container type code.

Top_sensor Upper sensor status (0= container presence)

Bottom_sensor Lower sensor status (0= container presence)

Reset Fault reset (=1)

Usually it is the combiner reset button.

Distance in mm between the two sensors

Dist_eject_crash_sens_mm
Max value 3200 mm (equivalent to 64 step of 50mm)

Scan_time Last block scan time (ms)

The cycle time must be fast and accurate: usually a fast task at 10ms is used. The real value is
available in the block system data OB35_EXC_FREQ

Spd_Mot_mmin Speed of the conveyor located under the blower in meters/minute

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 Function bloc Outputs

NAME DESCRIPTION
Crash_before_guide Crash on combiner outlet before the back guide (1=crash)

Crash_after_guide Crash on combiner outlet after the back guide (1=crash)

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 Function bloc parameter

NAME DESCRIPTION
Dist_crash_bef_guide Distance of crash detection if there is a jam at the recovery guide (in mm)
This parameter set the detection reactivity of a crash on the recovery guide.
There is a crash if the containers detected by the first sensor are not detected by the crash
sensor during the set distance. The counter is incremented only when there is a container in
front of crash sensor.
Typically: 3 container diameter.

Dist_crash_after_guide Distance of crash detection if there is a build-back on the single lane conveyor.
This parameter set the detection reactivity of a crash in case of a build-back in front on the
crash sensor.
There is a crash if the crash sensor doesnt detect any gap between containers during the set
distance.
Attention: It is possible that a lot of containers are in contact in this area after a crash. The
detection distance must be larger as the distance between the beginning of the back guide and
the crash sensor.
Value higher as 1000 mm to avoid wrong crash detection

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 Agenda

1 Recovery guide crash

2 Container scrolling detection crash

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 General description
The role of this block is to control the containers flow at one precise position.

Implantation:

We use 2 sensors:
Top sensor, counting sensor of the combiner
Bottom sensor
At bottle diameter maximum from the top sensor on horizontal plan
At one high lower than the bottle diameter on vertical plan

The block sends 2 signals by taking account of the state of the 2 sensors and the speed of the conveyor. These
signals must be treated by the other function:
Crash: bottle flow blocked by ascending accumulation.
Slippage: the chain go faster than the containers, it is an abnormal situation in outlet combiner area.
Remark: a dysfunction of these sensors (by fouling or bad setting) creates one fault see above immediately.

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 Slippage functional diagram
This diagram represents the curve of the trend line of the value that activates the output slippage .

The first part of the diagram show that in case of slipping of the container (conveyor faster the container flow) the
value increase until a high limit hysteresis slippage. The output slippage is activated when the value
excess the dimension of the container diameter.

The second part of the diagram shows that in case of not slipping container (space between containers) the value
decrease until a low limit corresponding of the hysteresis slippage. The output slippage is reset when this
value is lower than the dimension of the container diameter.

More the value of slipping i slow, more the system will react faster.

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 Siemens automation application

Input reading
L PEB216
T EB216

Scrolling crash
function

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 Function bloc inputs
NAME DESCRIPTION
Par_DB Function parameter Database

Index Parameters index (container type code)

Used to select the parameters associated to container type code.

Adr_C1 Address PEW of the counter C1

Address of the SIEMENS counting card.
We take also the state of the sensor. A bridge between the pin 5 and 8 must be install.

Bottom_sensor Lower sensor status (0= container presence)

Reset Fault reset (=1)

Usually it is the combiner reset button.

Scan_time Last block scan time (ms)

The cycle time must be fast and accurate: usually a fast task at 10ms is used. The real value is
available in the block system data OB35_EXC_FREQ

Spd_Mot_mmin Speed of the conveyor located under the blower in meters/minute

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 Function bloc Outputs

NAME DESCRIPTION
Crash =1 : containers jam under the 2 sensors
Signal to use in the equation of the concerned conveyors.
Reset by input Reset

Slippage =1 : container slipping under the 2 sensors

This signal can be use to modify the speed of the concerned conveyor

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 Function bloc parameter

NAME DESCRIPTION
Container_Length_mm Container diameter in mm

Crash_length_mm Distance that can be travelled by the chain without creating a fault when a container
pass. In mm.
Typical value: between 1,5 and 3 container diameter. A value higher than the bottle high can be
set in order to avoid the detection of fallen containers.

Slippage_crash_length_mm Distance that can be travelled by the chain without creating a fault when the containers
are slipping on the conveyor. (in mm)
It depends on the guide length between the tray and the two sensors or on the desired
sensibility.
Typical value between 500mm and 5000mm.

Slippage_hysteresis In number of containers. It defines the work hysteresis between beginning and end of
slipping.
Typically between 1 and 3 containers.

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 Instance value description

NAME DESCRIPTION
Info_totalizer _crash Number of crash detected.
Value to reset by an external action

Info_container_length Container length calculated with the bottom sensor and the conveyor speed. In mm
The calculation is done every 100 containers.
This information can be used to control the motor calibration.
This value should be more or less 5% the same as the real length of the container.

Info_gap_length Gap size between containers at the bottom sensor

The calculation is done every 100 containers.
This information gives the average space between the containers. The minimum gap should be
20mm. The right gap is depending on the container stability and on the containers accumulation
build-back point.

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Thank you!

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This presentation is solely intended for Gebo Cermex

personnel.
No part of it may be circulated, quoted, or reproduced for
distribution outside the organization without its prior approval.