Control & Integration

01 / CONTROL OWNERSHIP

One coordinated line. Clear command ownership.

02 / PLC STATE FLOW

Station 10 movement, from arrival to release

Reusable command handshake

1. RequestSender latches Req + SeqID + payload.
2. AcknowledgeReceiver validates freshness and latches Ack + SeqID.
3. CompleteReceiver holds Done / ResultValid with the same SeqID.
4. Consume / clearSender commits once, sends DoneAck; both clear flags before a new request.

A duplicate request returns the stored response, without repeating motion. Unexpected SeqID, stale result or watchdog expiry enters the agreed hold path. Motion, focus, vision and transfer timeouts are individually measured and approved.

03 / VISION SOFTWARE

Acquisition jobs by physical location

on ScanStart(batch, recipe, scanSeq):
  validate recipe hash, dock, grip, focus and stability
  clear previous frame queues; enable all 32 light bars
  parallel for slot in 1..8:
    rotate(slot) within recipe limits (maximum search: 185°)
    if valid QR candidate detected:
      stop axis(slot); wait StopAck + image stability
      frame1 = acquire_fresh(slot, scanSeq, captureNo=1)
      frame2 = acquire_fresh(slot, scanSeq, captureNo=2)
      require distinct FrameIDs and ordered timestamps
      require both frames belong to this batch / slot / scanSeq
      if both reads valid and payloads match approved rule:
        latch VERIFIED; switch OFF this slot's 4 light bars
      else: latch NG_READ_MISMATCH / NG_INVALID_READ
    else if angle limit or search deadline reached:
      latch NG_UNABLE_TO_CHECK
  wait for 8 terminal results; switch remaining lighting OFF
  commit all results; publish ResultValid + matching scanSeq
  keep each final angle; return to original holder positions

The two opposed heads per bottle provide alternative views. Detailed design must define whether both heads must agree, how a usable head is selected and how conflicting decodes are rejected. Two matching captures must be two fresh images; replaying one buffer does not count. Timing depends on exposure, readout, processing, stop latency and settling trials.

Result envelope for every camera job

04 / INTERFACE REGISTER

Logical I/O and exchanged data

Directions below are relative to the named sender / receiver. A fieldbus bit or structured message is not automatically a physical wired I/O point. Final terminal counts, safety I/O, expansion reserve and cabinet hardware follow the agreed device list.

Candidate communication interfaces

No protocol is declared to be the customer's installed protocol. Confirm actual controller compatibility before assigning tags, update rates or trigger timing.

05 / END-TO-END LOGIC

Keep bottle identity through packaging and sorting

Startup / fault recovery

Load the durable ledger and freeze affected zones. Reconcile occupied holders and cartons against sensors and readable IDs. Quarantine uncertain items through the approved recovery procedure. A reset clears an alarm only after its cause is resolved; it does not clear identity records or automatically restart a robot.

STATION 12 / HORIZONTAL CARTON HANDOVER

Two methods for downstream carton identity

Station 11 loads bottles into cartons and binds their QR records. Station 12 closes the loaded cartons and places them horizontally on the conveyor, with the QR face against the belt. This changes the downstream inspection method.

Station 11 / 12 travel-unit sequence

1. Confirm both independent S11 module IDs, positive dock locks, recipe and eight reserved slots.
2. Read carton QRs at S11. Transfer eight bottles and verify insertion with overhead AI. Keep the carton association through all later moves.
3. Release the empty bottle module into its downward / lower return. Move the loaded upright carton module to S12 after robot clearance.
4. Check eight carton positions from above at S12. A missing carton inhibits group pickup and requires reconciliation.
5. Pick eight cartons, pass through the closing station and lay the closed group horizontally on the first ordinary belt conveyor.
6. Release the empty carton module into its own downward / lower return after robot clearance.

Placement-to-exit control sequence

on S12.HorizontalPlaceDone(closeSeq, cartonSlots, encoderCount):
  require matching CloseCycleID and known S11 carton records
  bind each CartonID to position, sequence and placement timestamp
  wait RobotClear and downstream permission before conveyor release

while carton is on horizontal conveyor:
  predict position from encoder displacement
  reconcile AI / zone observations against the same physical carton
  if missing, extra, swapped or unexplained position: HOLD + reconcile
  if optional re-read enabled:
    isolate carton; hold follower; confirm clamp
    stand up; require UprightOK, stability and FocusReady
    acquire fresh QR for this ReadSeq
    if unexpected identity: HOLD + reconcile
    if no-read with known isolated carton: latch NG
    lay flat; require FlatHome and Clear before release
  carry the original record to the selected reject mechanism
  close record only after the expected physical exit is confirmed

Encoder motion alone does not prove carton motion. Agree slip limits, sensor spacing, AI observation coverage, anti-reorder guides and manual-removal handling. Restart requires reconciliation of every occupied zone. QR re-reading strengthens identity evidence but does not remove downstream tracking or exit-confirmation requirements.

Commercial and OEM boundary

The optional conveyor modification follows the customer's requested higher-verification approach. It is an additional option, with no new price or contractual inclusion asserted here. Confirm the final QR face, carton dimensions / mass, allowed handling, actual Station 12 cycle, conveyor modification permissions and FAT criteria with the OEM.

R14 / ALTERNATIVE REJECT MECHANISM

Option 2 · Indexed side transfer

Configure the PLC for either the Option 1 Y gate or Option 2 side pusher. The mechanical selection is a commissioning setting; the Web App buttons are for concept comparison.

Proposed inputs: PusherHome, PusherExtended, CartonAtStop, FollowerHeld, CellStopped, RejectTransferPresent, RejectSpace, RejectExit, GoodExit. Outputs: PusherTarget, FrontStop, FollowerHold, CellRun, RejectBeltRun, UpstreamHold. Signal polarity, safe state and timeouts require OEM agreement.

06 / JOINT DESIGN-REVIEW BOARD

Confirm before detailed design is frozen

Use this register in the OEM / customer workshop. All items start as To confirm; checking a box here records a local review note, not engineering approval.

Proposed acceptance scenarios