Contents
Basic Operations 2-1 Operator Interface 2-1 Security Level Access 2-1 Machine Status 2-2 Machine Start/Stop 2-3 Change Pattern 2-4 Purge Partial Pallet 2-4 Production Data 2-5 Configuration 3-1 Timer Adjustment 3-1 Infeed Adjustment 3-1 System Backup 3-2
Troubleshooting 5-1 Alarms 5-1 Information Bulletins 5-1 Fault Conditions 5-2 Zone Status 5-3 Adjust Count 5-3 Sequence Monitor 5-4 Manual Control 5-4 System Restore 5-5
Overview
Overview EasyStack. palletizer controls architecture provides unmatched ease of use. EasyStack offers intuitive pallet build programming and operation interface, with no PLC code experience required. The control system integrates Allen Bradley components, including a color touchscreen HMI. EasyStack is capable of building virtually any pallet pattern, and patterns are named alphanumerically for easy identification during changeover.
TopTier makes the extra effort to simplify the operation of your palletizer:
n Fully automatic operation
n Instant pattern changeover
n Easy pattern programming
n Built-in troubleshooting
n Security level access
n Complete CF card backup
TopTier palletizers are built to suit your product and shipping requirements. Palletizer patterns are developed by TopTier engineers to each customer's specifications. Each machine is tested at the TopTier factory with your product and certified prior to delivery.
The standard EasyStack system contains up to 50 pallet build patterns, with additional capacity available. Following the initial installation, additional pallet build patterns can be created from scratch or by making modifications to existing patterns. A new pattern generated from an existing pattern inherits all the original unique build instructions. Only those modifications made necessary by changes in application, such as number of layers, are required.
New pallet build patterns and pattern changes are created using the EasyStack spreadsheet. The spreadsheet generates values for entry into the controller through the touchscreen HMI. As an additional feature, new patterns can be created and existing patterns modified directly through the HMI. Parameters for all palletizer features such as labelsout, tie sheets, and stretch wrapping are generated by following the simple guided steps.
Palletizer operation is fully automatic. Once a pattern is loaded and the palletizer is started, no additional operator intervention is required. Machine status and production data are enunciated on the HMI, and operational adjustments are performed through intuitive HMI screens. To change patterns, the operator can optionally purge an incomplete pallet and then select any pattern from the library.
EasyStack provides comprehensive error messaging with guided recovery. The graphical error enunciation feature includes images of the source to expedite recovery and accommodate operators with limited English language proficiency.
Basic Operations
Operator The color touchscreen graphical human machine interface (HMI) provides
Interface comprehensive information about palletizer operations and provides operators with real-time machine control. The HMI screens use the following conventions:
n Buttonized elements are interactive, and provide navigation or data entry n Non-buttonized elements are passive, and provide
system data n White text represents a label n Black text represents a value
ADJUST COUNT CURRENT PATTERN 12-PACK CASE PALLET LAYERS HEAD EMPTY LAYER BUILD BOXES ROW BUILD BOXES TURN AREA BOXES 4 4 7 1
SYSTEM RUNNING
PURGE PART PALLET SHOW ALARMS MANUAL SELECT SCREEN SELECT
Security Level Access to palletizer operational data and functions through the touchscreen
Access HMI is restricted by multiple levels of permissions. Security is implemented by passwords assigned to each level. A request for access to any HMI screen will generate a password prompt. Passwords and security levels may be modified by pressing Security on the Configuration screen.
Palletizer Status The condition of the palletizer is displayed on the HOME screen. Touching the PRODUCTION DATA screen, which is displayed by default during normal operations, activates the HOME screen. The HOME screen displays the following information:
COMPLETED LAYERS
CURRENT PATTERN
BOX COUNTS
FAULT CONDITION
STATUS
The following palletizer functions are accessed directly from the HOME screen:
CHANGE PATTERN ADJUST LAYER COUNTS
PURGE PARTIAL PALLET
OPEN MENU SCREEN
Palletizer
Start/Stop
All palletizer functions are available from the MENU screen. ˇ
ADJUST COUNT CURRENT PATTERN 12-PACK CASE PALLET LAYERS HEAD EMPTY LAYER BUILD BOXES ROW BUILD BOXES TURN AREA BOXES 4 4 7 1
SYSTEM STOPPED
PURGE PART PALLET SHOW ALARMS MANUAL SELECT SCREEN SELECT SCREEN SELECT
Pressing the green Start pushbutton on the main panel starts the palletizer. Wen first powering the system, the operator must press the Power On pushbutton before pressing Start. The palletizer controller retains all status data when stopped and will resume palletizing operations when restarted. Status data is retained during all stop conditions, including an E-Stop, a jam condition, a breach of the safety enclosure, and when power is recycled. Pressing the Stop pushbutton on the main panel brings the palletizer to an orderly halt.
Change Pattern
Purge Partial Pallet
To change to an alternative pattern, stop the palletizer by pressing the Stop pushbutton on the main panel. Purge the palletizer of product if necessary by pressing Purge Partial Pallet on the HOME screen. Navigate to the library of patterns by selecting Pattern Select on the MENU screen. Scroll to the desired pattern and press the Enter button to load the desired pattern. Verification that the alternative pattern is successfully loaded is announced on the PATTERN SELECT screen. Pressing the green Start pushbutton on the main panel starts the palletizer with the newly selected pattern.
Pressing Purge Partial Pallet on the Home screen clears product from all zones of the palletizer. A partial pallet is constructed. If so equipped, the partial pallet is stretch wrapped and exits the palletizer.
Production Data The following real-time production data is displayed on the PRODUCTION DATA screen:
Current Production: Total throughput for current run Boxes per Minute: Throughput rate for current run Lifetime Total: Total throughput for life of the palletizer
The PRODUCTION DATA screen is the default display screen and appears automatically following a set period of touchscreen HMI inactivity. The PRODUCTION DATA screen can also be accessed from the MENU screen.
Configuration
Timer Adjustment
The default palletizer component timers, counters, and integer values are typically appropriate for achieving smooth and efficient palletizer operations. These values are available for adjustment when required for unique applications. Selecting Timer/Counter Adjust from the MENU screen provides access to these variables. These variables are universal and apply to all pattern build activity.
Infeed Adjustment
Adjustment of the timers controlling the functions of the infeed components are sometimes required to resolve issues with separation or box rotation. These timers are specific to each pattern. Infeed Adjustment is a special utility provided for fine tuning the infeed functions of a pattern and adjustment of the timers modifies the pattern data. Pressing Infeed Adjustment on the MENU screen initiates a simple guided seven-step process of timer adjustment. The appropriate pattern must be loaded prior to adjusting timers.
System Backup The EasyStack control system provides a backup of all machine and pattern configuration data on compact flash media. Data is automatically recorded to the CF card daily. Press Save to CF Card on the Configuration screen to write all current machine data to the card.
Patterns
Creating Patterns TopTier palletizers stack cases, cartons, trays, buckets, bundles, and bags in almost any pallet pattern. Fifty patterns can be stored in standard control systems and are instantly accessible when production requirements change. Expanded memory options allow nearly unlimited patterns to be stored. All pattern menus are stored with customer-selected alphanumeric names that can match SKU or trade names.
Pattern Design
Designing new patterns using EasyStack does not require any experience with PLC code or a background in engineering. In a matter of minutes, operators are able to build complex patterns with gaps, interlocking layers, tie-sheets slipsheets and pallet liners, labels-out, and concurrent stretch wrapping.
EasyStack includes a specialized spreadsheet tool that allows the user to create patterns at a computer workstation. When the pattern is completed, the spreadsheet tool generates code values to be entered into the EasyStack touchscreen HMI.
Product is transferred from the infeed to the layer head in a series of push operations until the layer is complete. Each transfer constitutes a row. In designing the layer, the following determination is made for each box:
n Orientation
n Gap or stop
n Last in row
n Last in layer
Product always enters the palletizer with the narrow side leading.
Pattern design begins by placing an "x" in the appropriate cell for each box in the "A" Layer Pattern Build spreadsheet table. The "B" Layer Pattern Build table is used to create an optional interlock pattern on the same pallet. When the pattern is complete, EasyStack automatically generates corresponding code values for each box in the Pattern Data table. These values are entered directly into the touchscreen HMI from a print copy of the sheet.
Example The example pattern "12-Pack Case" consists of seven boxes in three
"12-Pack Case" rows. Layers A and B are alternately interlocked, with a total of eight layers on the finished pallet and tie sheets at layers 3 and 6. The pallet is concurrently stretch wrapped.
Finished Layer A Finished Layer B
The following properties are entered into the corresponding spreadsheet cells:
Layer A Layer B
Box 1: Turn 90° Box 1: No Action
Box 2: Turn 90° Box 2: Last in Row
Box 3: Turn 90° / Last in Row Box 3: No Action
Box 4: No Action Box 4: Last in Row
Box 5: Last in Row Box 5: Turn 90°
Box 6: No Action Box 6: Turn 90°
Box 7: Last in Layer Box 7: Turn 90° / Last in Layer
Installing the Pattern
With "x" entered in the appropriate cells in the spreadsheet, EasyStack generates the following codes for boxes 1-7. The codes contain the pallet build recipe data necessary for building both layers A and B.
Box 1: 1
Box 2: 513
Box 3: 3
Box 4: 512
Box 5: 258
Box 6: 256
Box 7: 1284
Installation of a new pattern begins by selecting Pattern Select on the MENU screen of the touchscreen HMI. To install a new pattern based on standard defaults, scroll down and select the first unnamed line and press Edit Pattern. EasyStack then guides the operator through the appropriate recipe screens.
Select the pattern name button across the top of the screen to name the new pattern. The data entry keyboard tool automatically appears for entering values. Patterns may be named in any combination of alphanumeric characters.
Select Features to configure the pattern for row stops, label-out, pallet orientation, slip-sheet, top cap, stretch wrap, and build-on-pallet options. The blue toggle state indicates "on" and a beige toggle state indicates "off". When complete, the appropriate Features code appears. The code value may be entered directly when know.
Patterns
Select Interlocking Value to configure interlocking options.
Select Tie Sheet Insert to configure tie sheet options.
Select Pallet Size to configure pallet dimension.
Select the number of layers on the pallet, and modify any other timer values as appropriate.
Enter the values from the EasyStack spreadsheet for each box. Press
Save Edits to close the edit screens and return to the HOME screen.
Alternatively, each box may be configured on the touchscreen HMI without using the spreadsheet. Create the recipe for each box by toggling the appropriate properties. Once complete, the appropriate box code value is generated for each box. Press Save Edits to finish the installation.
Pattern Copy The Pattern Copy function is used to create a new pattern based on the recipe of an existing pattern. All timers and machine configuration settings are inherited. The new pattern can optionally inherit the box data from the original pattern.
Pattern Adjust Changes are made to the pattern recipes by selecting Pattern Select on the MENU screen. Select and load the designated pattern and select Edit Pattern. To adjust control values not associated with a specific pattern, select Timer/Counter Adjust or Infeed Adjustment from the MENU screen.
Troubleshooting
Alarms Using timers to anticipate expected conditions as well as real-time feedback from motors and sensors, the control system continuously monitors hundreds of variables for indication of malfunction. An alarm is reported as either an information bulletin or as an error condition. A yellow zone marker on the HOME screen announces an alarm condition.
Information Bulletins Information bulletins are automatically displayed in yellow on the touchscreen HMI and report common conditions that prevent the system
from running, such as E-stop Engaged or Access Door Open. Press
Show Me to display a photographic image of the source of the error. The
message is cleared by either resolving the condition or by pressing Close.
Information bulletins are not recorded in the error log.
Fault Conditions Fault conditions are automatically displayed in red on the HMI and report an unanticipated condition that may cause a component of the palletizer
to stop functioning. Alarms indicate possible malfunctions such as Product
Jam, VFD Malfunction, and Stretch Wrap Roll Empty. When appropriate,
the ALARM screen displays a photographic image of the source of the
error. The message is cleared by either resolving the condition or by
pressing Close.
Fault events are recorded in the error log. Pressing Show Alarms on the HOME Screen displays the error log, and pressing Clear All deletes all log entries.
Zone Status
The status of each zone of the palletizer is displayed on the ZONE STATUS screen. The number of zones is a function of the various options configured on the palletizer. There are four potential status conditions: Empty, Full, Transferring, and Error. The ZONE STATUS screen provides a convenient means of resetting a component and avoids having to recycling all machine processes. Selecting the appropriate zone toggles the Full/Empty condition.
Adjust Count The palletizer relies on indexing product to build layers. In the event that product must be added or removed downstream of the palletizer infeed, the product count must be adjusted in order for the layer to be built in the correct pattern. Adjust Count provides a convenient tool for correcting product count without having to recycle the system and reload the pallet.
To correct a discrepancy, stop the palletizer and press Adjust Count on
the Menu screen. After entering revised values of the ADJUST COUNT
screen, the correct pattern will be built when the palletizer is restarted.
Sequence Monitor
The Sequence Monitor provides a convenient tool for resetting a component of the palletizer following a fault condition and continuing in automatic operation. Select Sequence Monitor from the MENU screen to view a real-time snapshot of the current status of each component. Press the corresponding component to display an explanation of the current status and suggested troubleshooting tips. When a sequence is reset, the system will automatically attempt to determine the correct sequence step of the component. Sequence Monitor allows the operator to reset all sequences or each component independently as required.
Manual Control The control system allows all palletizer functions to be manually operated. Manual operation may be required to clear palletizer of product, to check a component for possible malfunction, or for performing scheduled maintenance.
To operate the palletizer in manual mode, stop the palletizer and press Manual Select on the HOME screen. The Manual Select screen provides access to each of the palletizer component systems. Each Component MANUAL SELECT screen displays the current state of a function as a beige button element. Press the corresponding blue button for each function of the component to toggle or move the device. Explanations are enunciated when operation of a device is not possible due to an interlock condition.
System Restore In the event of failure of the main programmable logic controller (PLC), all system configuration data is automatically restored from the compact flash media. To restore the machine to a known good configuration, select Load From CF Card on the CONFIGURATION screen; this will restore all system data.