Tech Doc – Bulk Filling Sensor Version 1.

2 3 March 2004 Page 1 of 7

TechDoc – Automatic Bulk Filling Sensor

Written By: Technicians Date: 3 March 2004
Department: Service Version: 1.2
Valid From: October 30, 2003

1. Automatic Bulk Filling Overview

1.1. Feature Description

Semi-automatic bulk pack fillers can be used on Compac sorting machines.
These fillers use the standard Compac software to allocate the correct quantity of
produce to a pack. An output is then activated to "Step" the pack away from the
outlet and position the next pack in place. A SAM reading is used to exactly
position the new pack for the next load of produce. An additional sensor is used to
move the pack on as it fills, so that the pack fills evenly.

2. Automatic Bulk Filling Sensors

There are two options for configuring sensors to sense that packs are correctly
positioned to start filling: Basic, for systems with flight bars, and Advanced for
systems with continuous belts. Both of these are described below.

2.1. Basic Sensor Configuration with Flight Bars

Separating Packs
If the packs have guaranteed gaps between them, a single photo cell can sense
the leading edge of the pack to start filling it. This is the case when a flight bar
system is used to index the packs for filling. This system does not require
changes to the sensor position based on the pack length. Note that the pack
boundary gap for sensors is guaranteed by the flight bar separators.

Item Description Function

1 Photo Cell Check that a box is present for filling and that it senses the
leading edge of the box, to position an empty box for filling.

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M1 Belt Motor Drives the belt carrying the boxes.

2.2. Advanced Sensor Configuration with Packs on a

Continuous Belt
In a continuous belt setup, the boundaries between packs must be sensed on the
rear edge of the pack. In addition, a sensor (S1) must be used to ensure that it is
the trailing edge of a pack rather than the leading edge that is detected. The
disadvantage of this system is that different length packs require that the positions
of L1 and S1 are moved. Additional sensors (S2, S3) can be added to ensure that
the filling level is even. In the configuration below, we see that the rear/trailing
edge of the box is sensed by L1.

Item Description Function

1 Photo Cell Check that a box is present for filling.
2 Photo Cell When pack fills, the sensor detects the fruit level and turns on
M1 until the sensor is clear.
3 Photo Cell Senses the END of the box. Stops sensor 2 from causing the
NEXT box to fill. This sensor could be under the lip of the top
belt.
L1 Limit Switch Senses the edge of the box to position the Empty box, ready
to start filling.
M1 Belt Motor Drives the belt carrying the boxes.

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3. Automatic Bulk Filling Sensor Installation

and Configuration
Proceed in the order noted below.

3.1.1. Standard Wiring

The user is provided with a manual override push button to turn on Motor 1. All
other control is provided by a SAM 4000 or SAM 4020.

3.1.2. Positioning the Basic Filling Sensors

1. Position the pack in the Start Filling Position.

2. Move the S1 until it is just activated, while it is looking at the leading edge of
the box.

3.2. Advanced Configuration: Wiring at Soleil d'oc –

France
There is a special installation of this system at this site with wiring as follows

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3.2.1. Positioning the Advanced Filling Sensors

1. Position the box in the Start Filling Position.

2. Move the L1 until it is just activated.

3. Make sure that S1 detects the box to be filled.

Note: For larger boxes, L1 will be further back under the top belt.

4. Now set up the box for the Finished Filling Position. This is so that NO produce
fall into the next box by mistake. Move Sensor 3 so that it is just blocked by the
edge of a box.

5. Move Sensor 3 so that it is just blocked by the edge of a box.

Note: In the set-up shown advantage is taken of the fact that the boxes have lowers
sides than their ends. If this is not true, another limit switch may be needed.

6. Adjust Sensor 2 so that it only sees produce when the box is full.

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3.2.2. SAM Settings

SAM set-up in SCP is as follows:
Basic Setup
EMPTY IN INPUT: INPUT Sensor IOL TB INV AC IO NTT NL NT IOL4 IOL IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF3 OFF2 OFF1 OFF0
POSITION LINKED – A SET Linked to 3
CONTROL bit is 4 ON2 ON0 DLY OFF2 OFF1 OFF0 DO
cleared when ON
Input goes Active. 1
Linked IO's
1 1 1
CONTROL Bit
follows.
S2 SCP LAST STEP 0C

BELT OUTPUT: IOL TB INV AC IO NTT NL NT IOL4 IOL IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF3 OFF2 OFF1 OFF0
MOTOR Immediate ON/ 3
Immediate OFF- ON2 ON0 DLY OFF2 OFF1 OFF0 DO
Drives Takeout ON
Belt Motor WHILE 1
BELT_RUN_TIME
1 1
R is ON

SAMOUT2 SCP STEP 22

Advanced Setup
Name Description Links Mode Index
Flags

FRUIT INPUT: ON Delay To IOL TB INV AC IO NTT NL NT IOL4 IOL IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF3 OFF2 OFF1 OFF0
LEVEL – From S2 to say Output 2 3
HIGH Fruit present, Box ON2 ON0 DLY OFF2 OFF1 OFF0 DO
full. Delay to ON
ignore falling fruit. 1

1 1 1

S2 09 05

MOVE OUTPUT: IOL TB INV AC IO NTT NL NT IOL4 IOL IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF3 OFF2 OFF1 OFF0
BOX Immediate ON/ 3
Immediate OFF ON2 ON0 DLY OFF2 OFF1 OFF0 DO
Drives the PACK ON
1

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FEED Belt 1

SAMOUT 00 00
1

EMPTY IN INPUT: INPUT Sensor IOL TB INV AC IO NTT NL NT IOL4 IOL IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF3 OFF2 OFF1 OFF0
POSITION LINKED – A SET Linked to 3
CONTROL bit is 4 ON2 ON0 DLY OFF2 OFF1 OFF0 DO
cleared when ON
Input goes Active. 1
Linked IO's
1 1 1 1
CONTROL Bit
follows.
S2 SCP LAST STEP 1C

BELT OUTPUT: IOL TB INV AC IO NTT NL NT IOL4 IOL IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF3 OFF2 OFF1 OFF0
MOTOR Immediate ON/ 3
Immediate OFF- ON2 ON0 DLY OFF2 OFF1 OFF0 DO
Drives Takeout ON
Belt Motor WHILE 1
BELT_RUN_TIME 1
R is ON
SAMOUT2 SCP STEP 22

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