Predoser function

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This presentation is solely intended for Gebo Cermex

personnel.
No part of it may be circulated, quoted, or reproduced for
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distribution outside the organization without its prior approval.
 Predoser function
This block is used to feed a conveyor at a 100% priming rate (inliner dosing, divider, machine infeed,
etc.). It may also control 3 transfer motors located before this

Vocabulary :
Length (L): length of the container.
Row: number of container lanes on the conveyor.
In the example below, Row = 3
Tune: Fine tune offset. To use if all other parameters are not fine enough.

An offset (K) is calculated in the function as follow:

Row Package
K 1000
(Length Gap) Tune Slip

Conveyor final speed:

Speed cpm
Conveyor speed m/mn
K

cpm : unit speed display in containers / min

cpm/s : unit increase/decrease display in containers / min / sec
mmin : unit motor speed display in meter / min
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 Predoser function

Usual terms:

Package: Number of basic containers in a batch (tray, pack or crate) (enabled to use the function on pack conveyors).
In the example below, Package will be 1, due to single lane conveyor.

Length (L): length or diameter of the container.

Gap (G): gap length between 2 containers (mm).

Row: number of basic container lanes on the conveyor.

In the example below, Row will be 3

Slip: Slip offset between chain and product, only used if recovery speed is needed on a full conveyor. Not used in the
example below (conveyor not full), still set to 1.

Tune: Fine tune offset. To use if all other parameters not fine enough.

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 Predoser function automation bloc

Conveying
function block
(Sidel_predoser)

Motor Block
(1Motor
per motor,
Block
up to 4)

Drive Block
(1Drive
per motor,
Block
up to 4)

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 Constituent parts and terminology

The predosing chains are four in number and are driven by motor 102M1

Dosing less sensor Sensor_1

Dosing more sensor Sensor_2

Security sensor
for table
not used in this
Sensor 2 Sensor 1 function

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 Operating principles 1/6
General

"Predosing" controls the start/stop and the speeds of one to four motors: a predosing conveyor and in some cases the 3 preceding transfer
motors.

Priming

Ideally, the occupation on the predosing conveyor must be approx. 80% between the beginning of the predosing conveyor and the dosing
more sensor, then 100% (see diagram below). To start production in good conditions, the predoser must prime at fixed speed. We
must find the best setting between cadency and stability. Generally, this parameter can be set at 20% of upstream machine max
speed.

Priming can only start on the condition that there are enough containers available upstream (Bott_pres) and that the downstream conveyor
is stopped (DS_speed = 0). When the input Priming is activated, the priming stop after the delay Tpro_priming or after Tpro_pres
delay when the bottles lack at upstream (Bott_pres).

The output signal Bpres_out then goes to active status (as long as the input signal Bott_pres coming from upstream is still active) when
the priming is finish; the latter must be transmitted to the equipment downstream if necessary (inliner, machine, etc.).

Diagram: priming ratio and situation at end of priming.

100% Sensor 2 80%

Sensor 1

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 Operating principles 2/6

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 Operating principles 3/6
Production

Once priming is done, the predosing conveyor can start. It follows the speed of the downstream equipment. The setpoint is reduced or
increased according to the status of Sensor_1, Sensor_2.
Diagram 1: the supply of containers is insufficient because Sensor_2 is clear, the speed is increased.

Sensor 2 Sensor 1

Diagram 2: the supply of containers is sufficient, the speed is followed without dosing.

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 Operating principles 4/6
Diagram3: the supply of containers is excessive because Sensor_1 is accumulated, the speed is reduced.

The overspeed for dosing more on the predosing conveyor is approx. 20%. The system is correctly adjusted when the zone with a 100%
occupancy ratio is situated between Sensor_1 and Sensor_2 and remains stable as long as possible between these two sensors. If
stability cannot be obtained (variable upstream ratio, ex. accumulation table), it is necessary to change dosing +/- so that:

The upstream table never stops on its security sensor;

The containers do not fall over.

If Sensor_2 is release during a too long time (after delay seated in Tdel_S2_Pres_acc), the output bottle presence is switch off
(B_pres_out). It means that the predoser dont receive enough bottle from upstream. The delay Tdel_S2_Pres_acc must be longer
than the delay Tdel_S2_acc.

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 Operating principles 5/6

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 Operating principles 6/6
Emptying

At the end of production, the input signal Empty must be switched on active status to empty the whole system at the speed Ds_speed plus
over speed coefficient C_dos_plus_emptying. The sensors Sensor_1 and Sensor_2 must be release.

Important remark: the predoser will always start if the downstream equipement start. It doesnt depend of the status of Bott_pres.

Transfer conveyor
Depending on the mechanical layout, it may be that one or more conveyors are necessary between the table and the predosing. These
have a priming rate of approx. 80%. They will not have a control sensor. These discharge conveyors simply provide transit with the
downstream speed as their reference. These are not accumulation conveyors. They start and stop at the same time as the downstream
conveyor (predosing). The block can control four of them at most.

Remark: These transfer conveyors may be controlled indifferently by the predosing or table block. For reasons of FC and DB numbering,
it is more interesting to put them in the table block.

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 Function bloc inputs
NAME DESCRIPTION

Par_DB Data block containing the motor parameters

(Parameter DB)

Index Index of the set of parameters to be used (bottle code)

(Index) Used to apply different parameters to several container formats.

Start Authorisation to start predoser conveyor

(Start) This includes: line running, no emergency stop, no motor fault.

C_pres_in Container presence signal

(Container presence in) Must be on 1 to be able to carry out priming.

Empty Emptying request

(Empty out) By pass the input signal C_pres_in to empty the predoser. Active if the status is true.

Priming Priming request

(Priming) By pass the input signal C_pres_in to prime the predoser. Active if the status is true.

Sensor_min Sensor minus feeding

(Dosing - sensor) Connect the signal that must reduce the speed.

Sensor_plus Sensor plus feeding

(Dosing + sensor) Connect the signal that must increase the speed.

DS_speed Downstream conveyor speed in container per minutes

(Downstream speed)

DB_Mot1 to DB_Mot4 Data base of the motors 1 to 4

(Motor 1 to 4 DB) Let it free if not used.
It gives motor name and his max speed.

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 Function bloc outputs

NAME DESCRIPTION

Start_out Drives(s) unlock

(Start out conveyor)

C_pres_out Bottle presence for downstream equipment

(Container presence out) It is active when the upstream bottle presence is true and the predoser is not in priming
mode.

Pred_cpm Global predoser speed setpoint in container per minute

(Predoser setpoint) This is the downstream speed reference for an accumulation table for example.

Mot1_mmin to Mot4_mmin Outfeed setpoint for the motors 1 to 4 in m/min

(Motors setpoint m/min)

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 Function bloc parameter 1/3
NAME DESCRIPTION

T_accu_dos_min Sensor 1 accumulation delay (S1)

(Dosing minus sensor accumulation delay) Delay of internal signal sensor 1 in accumulation in 1/10 seconds.
Setting range: approx. 0 to 30

T_free_dos_min Sensor 1 free delay (S1)

(Dosing minus sensor free delay) Delay of internal signal sensor 1 free in 1/10 seconds.
Setting range: approx. 0 to 30

T_accu_dos_plus Sensor 2 accumulation delay (S2)

(Dosing plus sensor accumulation delay) Delay of internal signal sensor 2 in accumulation in 1/10 seconds.
Setting range: approx. 0 to 30

T_free_dos_plus Sensor 2 free delay (S2)

(Dosing plus sensor free delay) Delay of internal signal sensor 2 free in 1/10 seconds.
Setting range: approx. 0 to 30

T_accu_dos_plus_pres Sensor 2 presence accumulation delay for presence calculation

(Dosing plus sensor accumulation delay for Delay of internal signal sensor 2 in accumulation in 1/10 seconds.
presence) Setting range: approx. 0 to 50

T_free_dos_plus_pres Sensor 2 Presence free delay for presence calculation

(Dosing plus sensor free delay for presence) Delay of internal signal sensor 2 free in 1/10 seconds.
Setting range: approx. 0 to 30

T_pres_ext Product presence off delay timer

(Timer container presence extension) It permit to prime the downstream inliner when machine stop for lacking of bottle (in 1/10
seconds).
Setting range: approx.100

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 Function bloc parameter 2/3
NAME DESCRIPTION

Tpro_priming Priming prolongation delay

(Priming off delay timer) It permits to increase quality of priming before to start the machine.
Setting range: approx. 0 to 50

Priming_speed Priming speed in container per minute

(Priming speed) Substitute speed when priming.

Coeff_dos_plus Feeding plus coefficient

(Dosage + coefficient) Over speed dosing in case of under level priming in %.
Setting range: approx. 1 to 50

Coeff_dos_min Feeding less coefficient

(Dosage - coefficient) Over speed dosing in case of over level priming in %.
Setting range: approx. 1 to 50

Coeff_dos_plus_empty Feeding plus coefficient when emptying

(Dosage + empty out coefficient) Over speed dosing in case of emptying in %.
Setting range: approx. 1 50

Ramp Motor normal ramp

(Acceleration / decelerationl ramp) Smoothes the motor speed variations.
Setting range: approx. 50

Motor_pre1_no_dos No regulation for motor 1 in the predoser.

(Dosage inactive for the motor 1) Permits to disable regulation of the 1st motor.

Motor_pre2_no_dos No regulation for motor 2 in the predoser.

(Dosage inactive for the motor 2) Permits to disable regulation of the 2nd motor.

Motor_pre3_no_dos No regulation for motor 3 in the predoser.

(Dosage inactive for the motor 3) Permits to disable regulation of the 3rd motor.

Motor_pre4_no_dos No regulation for motor 4 in the predoser.

(Dosage inactive for the motor 4) Permits to disable regulation of the 4th motor.

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 Function bloc parameter 3/3
NAME DESCRIPTION

Motor_param.Length Bottle diameter in mm

(Bottle length)

Motor_param.Motor_pre1.Row Number of bottle in front.

For the 1st motor
(Number of front container)

Motor_param.Motor_pre1.Tune Offset coefficient

(Adaptation parameter) Adaptation parameter to adjust general speed for the 1st motor

Motor_param.Motor_pre2.Row Number of bottle in front.

For the 2nd motor
(Number of front container)

Motor_param.Motor_pre2.Tune Offset coefficient

(Adaptation parameter) Adaptation parameter to adjust general speed for the 2nd motor

Motor_param.Motor_pre3.Row Number of bottle in front.

For the 3rd motor
(Number of front container)

Motor_param.Motor_pre3.Tune Offset coefficient

(Adaptation parameter) Adaptation parameter to adjust general speed for the 3rd motor

Motor_param.Motor_pre4.Row Number of bottle in front.

For the 4th motor
(Number of front container)

Motor_param.Motor_pre4.Tune Offset coefficient

(Adaptation parameter) Adaptation parameter to adjust general speed for the 4th motor

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Thank you!

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www.gebocermex.com

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.