ICTS-Hardwire Test Analysis part1

Yesterday we did the actual packaging room condition test for the hardwires circuit using the control system below. Here are the result and the analysis of the test.

1- Three conveyors (Cv-B, Cv-C, Cv-D) are required to feed the mooncake into packaging machine conveyor (Cv-A). Cv-B is the main one where most control are placed there such as sensors and pneumatic valve. Its speed must be faster than the Cv-A to avoid packaging of empty pack, and to ensure continuos supply to pusher area while waiting for cutter signal. Cv-C is the feeder to Cv-B where its main function is to create permissible gap for mooncake once it connects with Cv-B. This conveyor would run at medium speed. The last conveyor, Cv-D would run at slowest speed to allow the feeder operator to place the mooncake side by side. Once this Cv-D connect to the Cv-C, a small gap would be created to ensure no unnecessary pushing at the L-junction of the Cv-C and Cv-B. This would eliminate the misrotation of the mooncake once it fall from the L-junction slider.


2- The positioning of the sensor 1 and sensor 2 must be modified. The reasons are to avoid collision in case of the 2 consecutive mooncakes at S1 and S2 where S1 is not properly pushed out due to cutter signal mistiming. The sensors must be 130mm higher than the moving conveyors as the best working condition for E3Z-D62 is from 100mm to 2000mm distance. Next, while shorten the gap between S1 and S2 will ensure no collision as the conveyor Cv-B would stop if it detects both S1and S2 presence simultaneoulsy (1.5 tray gap), it also ensures continuos supply of mooncake at S1 on time prior to cutter signal.
3- The pneumatic pusher stopping arm needs modification. It seems that if there is mistiming between S1 and cutter signal, the mooncakes would keep on pushing the pusher arm as the Cv-B keeps on running filling the empty space on Cv-B. This indirectly built up unnecessary pressure that might damage or bend the pneumatic rod in a long run. To avoid this from happening, the arm would be dismantle leaving the L-shape pusher only. A new wall stopper would be designed to replace it that act as a guide as well.
4- Pneumatic pusher stroke of 50mm will be replaced be 75mm. This is simply because the mooncake base is about 100mm. Since the snowy mooncake require soft push to avoid damage, so longer stretch or or soft push is needed to feed the moving Cv-A so that the quality of the mooncakece can be preserved.
5- Feeder side guide installation is required to ensure the mooncake reached S1 area in right orientation. Right orientation will ensure smooth delivery to the Cv-A moving conveyor. Next it also will avoid unnecessary accident at S1 area or the mooncake tumble out of the slider that might hamper the packaging proceess.
6- Installation of the S3 and S4 sensors to the existed hardwires so that a more complete test can be done. These two sensors would act as a safety and control device. They would stop Cv-C if the Cv-B is full. This would avoid accident for oversupply of the mooncakes at the L-junction there.

7- Cutter signal automation design. As for the time being we are still using a manual cutting signal to avoid wastage of the Oxygen Absorber. Since the actual cutter signal would be in sequence with the packaging machine Cv-A that runs about 45 unit per minute (1.33s gap), so a pacemaker signal seems adequate as a replacement signal.
Those are the issues that we have to deal with until end of next week.

PLC Set
We also received the items required as control system yesterday as well. They are :
1-CPMA0056D - Omron CPM1A-30CDR-A-V1 CPU Unit (18/12)
2- CPM10018A - Omron CPM1A-CIF01 RS232 Adapter
3- CX010080B - Omron CXONE-AL01C-EV2-UPSP Software
4- S8J1649R - Omron S82J-02512D AC100/240 12V(2.1A)
5- S8JX0062F - Omron S8JX-05024C AC240 24V(2.1A)
6- E39 217G - Omron E39-L104 Bracket
7- RS232 - Omron RS232 PC-PLC/NT 3M (9F-25M-9PIN)

There is one more items not delivered which is another photosensor for S5 location that would only be available by end of this month.