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INTRODUCTION

~~rodomas video kaip naturoje atrodo aparatas ir programa~~

Program was developed to help in managing multiple juice production workshops in different locations that are intensively operated during apple harvesting season, up to 5000 Litters per 8 hour shift of pressed, pasteurized and filled fresh juice.
r~~odomas video spaudyklos~~

HOW THIS PROGRAM WILL HELP

Help employes with little training to work efficiantly, maximum automated calculation prevent human factor mistakes, so the emplayed can get the job done with minimum supervision.

All current filling calculations in cash and volumes as well as histotic statistics and consumed inventory computed automatically without human error.

Managers can remotelly monitor and control production also can diagnose and quide emplyees on site in case they need technical or training assitance.

The aquire up to date and accurate stock of consumables in production.

Ensures that data about filled products quantities can not be altered unintentionally or for malicious purposes

The operation of the filling machine has also been improved. The turn off of the pump can be set some milliseconds earlier then valve closing time to prevent hydraulic shock to increase service life of the pneuamtic valve cilinder and other expensive parts.

WORK SCREEN

PCS

Displays current filled bag count
Displays total declined bag count since last reset
DEC press down to move 1 piece from filled to declined

FEE

Displays current fill fee
Displays total addons count since last reset
ADDONS press down to add mark up to the current fee

SUM

Displays total sum of current fill
Total amount since the last reset rounded to the hundreds
Total number of customers since last reset
KEEP SUM press down to carry over the total sum to the next fill count*

* If you serve a customer who ordered their juice to be fill in 2 or more different types of bags, once you finish filling first type, press down on SUM button before selecting another bag type. That carrys over the total sum to the next sesion, therefore once you compleate the fill for a single customer you will have total combined sum of different types of bags on the screen. Furthermore in statistics register customer count will carry the same number.

FAULT / STATES

Flow timed out. Specified volume has not been attained in specified time interval**
Stop button actuated**
Cleaning on
Cleaning timed out.

** When flow timed out happens or stop button is triggered, fill count is increased by 1 piece automaticaly. If the actual filled bag is rejected by operator, the filled / declined bags register can be adjusted by operator manually. To move pieces from filled to declined register, press down on PCS button.

When machine is in faut state mode filling is suspended. To reset FAULT STATE back to filling mode press down on Fault state button.

TEST MODE

Test mode is actuated on index screen pressing Test mode button. It can be used to simulate filling for testing, teaching or demonstration purposes. In this mode the program’s filling counter gets pulse signal from timer therefore there is no need to move actual liquids in order to test the program’s functions. If during actual work there is a need to test if program or some other machine components are at fault you can actuate the test mode in the middle of actual work precess and after testing is compleated go back to actual work where you left of. All filling data simulated during test mode will be marked in statistics logs with digit 1 in test column therefore you will be able to fillted out the test data from actual work filling data.

~~show video with test colunm~~

START / STOP

Start and stop buttons are actuated on index screen pressing start button. You can use them to control the machine over the internet or in can wired buttons are faulty.

MS & PLS

PLS field shows flow counters actual pulse counts for current fill
MS field shows the elapsed time since pulse counting started im miliseconds
Presing down on MS or PLS fields takes you to index screen where all the other screens of the program are listed.

EXTR

Number of times the extra cash was registered since the last reset
the amount of last extra cash entered***

*** If you need to register some cash that is collected from something else then stardard filling operations, you can enter it throught EXTR field. The amoun entered will be added to total sum.

CLEAN

Press down for 2 seconds will start filling without fill volume limit untill there is flow increase counter for a duration of 5 seconds or stop button is presssed. No data is registed to statistics. Usually used for cleaning the system.

VAC

Press dow to start manual vacumm pull.

BAG TYPE AND VOLUME

6 different bag types and volumes can be set in total.

Statistics screen

RESET COUNT

[0] Top left corner. Each time the statistics are reset, the count increases by 1. Lest say you take statistics each evening. Since you know reset count number of last time, you can control that the statistics has not beet reset between last and current reset. Press down the reset count button for 3 sec to set count number to zero.

LAST RESET TOTAL SUM

[0.0] Next field from left to right. The total sum of the last reset.

DATE OF THE LAST RESET

[0.02.2025] The date of the alst reset

TIME OF THE LAST RESET

[18:29:56] The time of the last reset

BAG TYPE & VOLUME

Type of the bag and its volume

FILLED

The number of bags that have been successfully filled since the last reset.

DECLINED

The number of bags that have been rejected since the last reset.

OPEN_BOX

The number of bags remaining in the open box that is curently used for filling. Can be adjusted by pressing done on the open xox field and entering a required number. Otherwise when the number gets counted down to 0, the full box is increased to a set of full bow number and gets counted down again.

FULL_BOX

The number of full boxes stored of this partical bag type. Can be adjusted by pressing down on the full box field and entering a number as required. One the open box is counted to zero, the full box number is decreased by 1.

HOME

Go back to work screen

TOTAL

[0.0] Forward balance (Will be explained later).
[47.8] Total sum in eur of filled bags and Extra’s

VOLUME

[5] Total number of clients since the last reset.
[21.5] Total volume of fills since the last reset.

ADDONS

[1] Total number of addons since the last reset.
[0.4] Total sum of addons since the last reset.

EXTRA

[2] Total number of extra’s since the last reset.
[27.0] Total sum of extras’s since the last reset.

LOCATION INDICATOR

[AKME] If you have more then one location you can enter different names to help you to separate one location fron another when assesing remotelly or working with data files.

FILLING PARAMETER SCREEN

BAG TYPE

Press to enter name of the bag

VACUUM

Vacuum time: 10=1second.

VALVE

Counter pulse count to close the filling valve

PUMP

Counter pulse count to switch the pump off. It is very import that the value for pump is less of equil to the value of the value as pulp has to witch of earlier to about hidrolic hammer efect in the filling system.

OFF

The max time duration during which the filling has to comleate. When this time elapses the „flow timed out” fault is triggered.

HOME

Go back to work screen

LOAD DEFAULT VALUES

Press for 3 seconds to populate twith default values. Those values are for start up reference only. Each value has to be calibrated individually to to match local set up. Which depend on the piping diameter, length and it’s configuration, pump capasity etc.

STATISTICS PAPAMETER SCREEN

FEE

The fee charged for the bag type.

ADD ON

The surchage on the fee. E.g. you to take extra charge if juice are made from carrots instead of apples etc.

BAG_VOL

The value that is added to the total volume for different types of bags

BOX QTY

The number of bags in the box for each type of bags.

LOAD DEFAULT VALUES

Press for 3 seconds to populate with default values and chage them according to your specification.

FILLING LOG SCREEN [Fill_LG]

NO

The number of fills since the last stats reset

Date

The date of fill

Time

The time of fill

Bag

BAG type and volume

PCS

Pieces in the fill

FEE

The fee of the fill

SUM

The sum of fill

ADDON

The sum of addon in that fill

DEC

The numbe of declined pieces in that fill

EXTR

Record of extra´s entered on work screen

CUST_NO

The cusmer number. Please not that when keep sum button is pressed the next fill gets assined the same number as current fill. This way customers who requested their juice to be filled in different types of bags gets counted only once.

TEST

If filling had been performed while test mode was actuated in the midle of regular filling process the fill gets marker [1] in the test collumn. This way you can exclude test fills from actual operational data.

RESET

Each time the statistics are reset, this action is indicated in reset column by marker [1]. You need this information in case statistics was reset, but filling log data was not deleted from the machine.

LOCAT

Machine location infication

OPR

You can assing each individual operator to a specific number in order to identify, who was operating this machine. Operator number can be ented on home screen and it stays the same for all future fillings untill this number is altered.

Inventory change instances log screen [Bag_LG]

NO

The count of inventory change instances since the last stats reset

Date

The date of inventory change instance

Time

The time of inventory change instance

OPR

Operator identity number

Bag

The total number of filled bags at the time when inventory change accured

DEC

The total number of Declined bags at the time when inventory change accured

OPN_B

Remaining number of bags in open box BEFORE inventory change accured

OPN_A

Remaining number of bags in open box AFTER inventory change accured

Full_B

The number of full boxes in stock BEFORE inventory change accured

Full_A

The number of full boxes in stock AFTER inventory change accured

Wiring diagrams

PLC input & output

Flow meter wiring

Burkert flowmeter 8030