Tech Doc – Rotary Bin Fullness Sensor Version 1.

1 10/30/2003 2:24 PM Page 1 of 6

TechDoc – Rotary Bin Fullness Sensor

Written By: Technicians Date: 30 October 2003
Department: Service Version: 1.1
Valid From: October 30, 2003

1. Rotary Bin Fullness Sensor Overview

1.1. Feature Description

Rotary Bin Fullness sensors are used to identify how much produce is in a rotary
bin on a sorting machine, and to communicate this information to the Sizer
software. You can install and configure Bin Fullness sensors on a Compac sorting
machine that is equipped with rotary table bins at outlets.

The current Rotary Bin Fullness sensor part is the Sick sensor, BAAN part
number SDF300N30Ds.

Sensors used in the past have included Sunx, Idec, and Keyance PZ2-41. All
these sensors are diffuse-reflective. They have two lights to indicate the state of
the sensor (normally a red light) and one to indicate if the output value is stable
(normally a green light.)

The Bin Fullness sensor shows the % utilization or fullness for an outlet against its
maximum capacity. The fullness of each rotary table bin is continually monitored
and fruit delivery automatically stopped to any outlets where their level exceeds a
preprogrammed threshold. Produce is delivered to the outlet again when the bin
level has fallen below another user programmed threshold.

A colored % bar graph display for each outlet is overlaid on the packout
distribution screen on the SSP. If the measured % fullness is below an ON
threshold then the bar is green. If it is above the ON threshold but below an OFF
threshold it is yellow. Finally if the % is above the OFF threshold then the Display
is red and the outlet will not receive anymore fruit until the bar goes green.

If no other outlets are available to take the produce from the disabled outlet(s)
then the sorting machine can be set to shut down.

1.2. Functional Operation

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Each rotary bin at each outlet has one or Bin Fullness photo-sensors that monitor
the presence of produce in the bin. The % of time each sensor is blocked versus
the time it is clear is used by the sensor to measure bin fullness. The sensors are
connected to inputs on SAM 4000 units. These periodically send their fullness
counts back to the SCP software, which then combines the appropriate sensor
counts for each outlet and calculates the fullness of a bin.
Rotary Bin Fullness Sensor User Controls
ƒ Active - Turns the feature on and off
ƒ ON Threshold - The % fullness at which the sorter will automatically re-enable a
outlet to receive fruit. Below this value the display will show a green bar color.
ƒ OFF Threshold -The % fullness at which the sorter will automatically disable a
outlet from receive fruit. Above this value the display will show a red bar.
Between the ON and OFF thresholds the display will have a yellow bar.
Limitations
Because the sensors are looking at a fixed spot on the bin, there is a certain
latency that occurs; the bins take about 15 -20 seconds to complete a revolution
and it takes the sensors that long to see the whole bin. This lag can be avoided
by using more than one sensor on a bin.

Different produce types have different surface reflectance levels. Reflective

produce may not always be seen by the sensors.

There is no allowance for different speed rotary bins.

There is no allowance for a different threshold for each outlet; there is only one
global setting.

"Sort table counting" and "Bin fullness" are mutually exclusive. Only one may be
in use on a machine at the same time.

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2. Rotary Bin Fullness Sensor Installation and

Configuration
2.1.1. Physical Installation
Although any diffuse reflective photo sensor with approximately 150 mm range
and adjustable sensitivity can be used, the best one to use is the Erwin Sick
sensor.

Each rotary bin requires at least 1 photo sensor that detects the presence or
absence of produce in the bin.

The sensor should be mounted at an angle so that it is less likely to see between
pieces of produce.

It is preferable that all the sensors are connected to as few SAMs as possible,
because they always send 24 inputs regardless of how many are actually
connected.

The sensors should be mounted so that they are "downstream" of the packer but
"upstream" of the incoming fruit. This is based on the direction of rotation of the
rotary bin.

A 24 volt supply is required to power the Sensors.

2.1.1.1. Mounting Rotary Bin Fullness Sensors

To function correctly, Rotary Bin Fullness sensors must be mounted in the correct
position on the Rotary Bin.

The following are recommendations for mounting Rotary Bin Fullness sensors:
ƒ Sensors must be at a slight angle to the rotary bin surface (i.e., 70o to 80o), NOT
pointing straight down (90o).
ƒ Sensors should be mounted on the side away from the person packing the
produce in the bin. This means that the sensor will only count the produce left in
the rotary bin after the packer is done.

2.1.2. Configuration and Setup

2.1.2.1. SAM IO Configuration

Each SAM IO point that is used for fullness sensing should be set to mode 05 all
other values should be 0 (No flags need to be set.)
IOL TB INV AC IO A3 A2 A1 CS CON MODE INDEX

0 0 0 0 0 0 0 0 0 0 05 00

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In the Tab-Tab-Tab screen the IOSCAN_TIME notes how long the SAM waits
before checking the sensor for fruit in 50 ms intervals. This should be set to about
giving approximately 200ms between scans, or 5 scans per second.

2.1.2.2. Bin Fullness Settings in the SCP

ƒ Active - Set to YES to enable bin fullness function
ƒ Comms channel - Sets the channel for which the SCP looks for the messages.
This should be set to 0 (making it zero based, so setting to zero means look on
channel one).
ƒ Off threshold - Sets the fullness level at which a drops is inhibited and so doesn't
receive any more fruit (recommended 80%)
ƒ On threshold - Sets the fullness level at which a drop is re-enabled to get more
fruit. (recommended 60%)
ƒ SCAN time - This is how often the SCP asks the SAM's for their bin fullness
counts. This should be between 4 and 8 seconds and is dependant on the speed
of the rotary bins. This number effectively sets the time interval on which the ON
and OFF thresholds are checked.
It seems to give good performance where scanning period is set to between ¼
and a ½ a rotation of the bin.

2.2. The STC Counting Address in the SCP

The STC Counting Address screen is accessed in SCP by pressing F,Y,R. (File,
system setting, sort table counting)

In this screen, you must enter the address of the SAMs that are used for bin
fullness (i.e., where they are addressed in the Edit Sam IDs screen). The type
refers to the number of counters available on the SAM. This should always be 24.

The counter offset is a function of the number of counters available on the SAM.
The second SAM should have an offset of 24. The third 48 etc. These IO points
are then used in the COMPAC.INI [CounterMap] to map the inputs to the outlets.

2.3. The STC (Bin Fullness) IO Mapping in the

COMPAC.INI file
This is the process of mapping SAM inputs to outlets. It is possible to map
multiple sensors to the same outlet. In our constant effort for economy we only
use 1 sensor on the latest rotary bins

The [CounterMap] section in the Compac.ini is used to map SAM IO points to

outlets for t bin fullness.

You should put entries of the format:-

Ix = d1,d2,d3
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Where Ix refers to the index of the first IO point in the Array of numbers
d1,d2,d3…. Which are the drop numbers on the machine (-ve for SizerA, +ve for
SizerB)

Ix can be from 1 to 192. (8 SAM's with 24 counters).

Each position in the array thereafter is the next adjacent IO point on the SAM.

Hence:

49= -15, +15, -15, 0, -16, 16, …

means that outlet 15 on sizer A uses IO point 49 or the first IO point on the Third
SAM in the STC counter address map as its bin fullness sensor. +15 is the 50th IO
point etc.

Notes on the above INI entry:

ƒ The 51st IO point is also mapped to drop 15 so this drop has two sensors.
ƒ The 52nd IO point is not used.
ƒ The + sign is optional . If no sign is entered it will assume sizer B
ƒ For sizer A use a – in front of every number

2.4. Bin Fullness Settings in SSP

This enables the display in Windows but does not control the operation. The ON
threshold only controls the % at which the colour of the display bar turns yellow
and the OFF threshold controls the % at which the bar turns red.

2.4.1. Counter Diagnostic Display

This is available in the Alt-O screen 7 in the SCP. It simply shows the last fullness
% received for each drop. If the SCAN time is set short this screen should update
quickly. If you block a sensor completely for two scan periods then it will display
100 % in the appropriate column. (Unless there is more then one sensor)

2.5. Adjusting Rotary Bin Fullness Sensors

To adjust a sensor, follow the steps below.
1. Mount the sensor on the rotary bin.
2. If the bin does not have a white background, place a sheet of white paper
under the sensor.
3. Adjust the sensitivity screw so that the sensor sees the paper (the red LED
turns ON).
4. Now adjust the sensitivity screw until the red LED turns OFF and the green
LED turns ON (if present).

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5. Now place your hand flat (palm down) on the surface of the rotary table under
the sensor. The LED should now turn ON. If it does not turn the sensitivity up
slightly until it does and the Green LED comes back ON)
6. Remove your hand and check that the LED turns OFF again. Repeat step 4
and 5 until the sensor is adjusted to correctly identify the presence or absence
of an object.
7. When all the sensors have been adjusted run the rotary bins EMPTY for about
10 minutes and keep an eye on the bin fullness displays. Make sure that the
sensors are working correctly.
Note: If the sensor has a green stability LED then this should be ON in both blocked
and unblocked states.

2.6. Related Features

2.6.1. Outlet Displays

When outlets are used for bulk filling, it is possible to use the Bin fullness displays
to show the level of utilization of the bulk pack outlets.

2.6.2. ALARMS and Shutdown

When all the available outlets for a given size/grade combination are inhibited by
the bin fullness processing then fruit cannot be delivered. At this point an outlet
error is generated and an alarm can be used to signal that produce is being
recycled. The sorting machine can be shut down until at least one rotary bin is
ready for more produce.

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