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Industrial Automation



Defining the Palletiser Patterns

The palletiser patterns are stored in the individual palletiser PLCs and also in the “Movement Controller”. They are edited within the “Movement Controller”, and then downloaded to the PLCs.

The palletiser patterns are known through the industry by standard names such as 8S1, 9D1, and 6U1. If you need to define patterns differently for different machines, you may wish to append further information to this name, otherwise these names serve as our pattern names.

Below is shown the first table used to define a pattern, in this case the classic 8S1 (from the MS-DOS version of the “Movement Controller”):

Screen dump from DOS version of
Movement Controller, showing a table
used to define the most basic data pertaining to a pattern, converted to a 
“gif” file, thereby losing some of the colour definition

There are 12 fields to be filled in, to provide the overall information. In some instances, several fields share the same line; in these cases the prompt will change as the cursor is moved to these fields.

The next step is to provide the information for the rows of the odd and even layers. The table below corresponds to the first row of the odd layer (from the MS-DOS version of the “Movement Controller”):

Screen dump from DOS version of
Movement Controller, showing a table
used to define the data pertaining to a row in the odd layer of a pattern,
converted to a “gif” file, thereby losing some of the colour 
definition

The three blocks at the lower left of the screen represent the three rows of the pattern. Moving from block to block will present the table for each row in turn.

The first piece of information needed is the turn peg pattern, which consists of a number, indicating the number of cartons in the row, followed by a series of 'T's and '_'s to indicate whether the cartons are to be turned or not.

Following this is the carton counts to the various gates. Gates with counts equal to or greater than the number of cartons in the row will not operate.

Once all this information has been entered, the resulting pattern may be viewed. To view a pattern, first a machine must be chosen (as all machines have different dimensions a pattern will turn out differently on different machines), and then a product must be chosen (since the carton size will affect the pattern as well).

The results will be presented as shown below (from the MS-DOS version of the “Movement Controller”):

Screen dump from DOS version of
Movement Controller, showing the 
results of the pattern definition for a given carton on a given palletiser, 
converted to a “gif” file, thereby losing some of the colour 
definition

This shows the results for each layer, first in the row form area, then after the row sweep, then after the side compression and finally after both side and end compression and with respect to the pallet.

The yellow outline can be moved to any of the four windows, which can then be zoomed into. The display will then appear as shown below (from the MS-DOS version of the “Movement Controller”):

Screen dump from DOS version of
Movement Controller, showing the 
results of the pattern definition for a given carton on a given palletiser
for a given layer and in a given part of the machine, converted to a 
“gif” file, thereby losing some of the colour definition

Using the ‘Left’ and ‘Right’ cursor keys, the subsequent images can be seen, simulating the row sweep, enabling you to anticipate the pinch points.

For more information on defining patterns for palletisers and other palletiser properties, please refer to the Operator's Manual sections Enter or Modify Products for Pallets, Enter or Modify Palletiser Alarms, Enter or Modify Palletiser Patterns, Enter or Modify Palletiser Product Data, Enter or Modify the Palletisers, and Palletiser Commands.