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ConveyMerge Guide

Publication ERSC-1020 Rev 1.1 – April 2020

The following table identifies and defines these typical components.

Component

Description

Merging Zone

Powered conveyor section that accepts an item from any one of the 3 possible
upstream sources

Main Line

Term to describe the 3 in-line conveyor sections -

Center Line

Merging Zone

and

Discharge Zone

Center Line

Part of

Main Line

that is one of three possible sources of items that can flow into the

Merging Zone

. This term is used in the configuration screen of

EasyRoll

to designate

the network that serves as the trunk line that contains the

Merging Zone

Discharge Zone

Part of the

Main Line

that is downstream of the

Merging Zone

. This conveyor section

accepts the item from the

Merging Zone

Left Line

One of the three possible conveyor sections that can discharge items into the

Merging Zone

Right Line

One of the three possible conveyor sections that can discharge items into the

Merging Zone

ONVEY

ERGE

REREQUISITES AND

EQUIEMENTS

The following items are the prerequisites and constraints required to provide a fully functioning automatic conveyor
merge:



EasyRoll

version 4.3 or greater



ConveyLinx

Firmware version 4.25 or greater



Only (1) one

Merging Zone

is allowed for any given single ERSC module



Merging Zone

cannot have any Extension (slaved) zone



All ERSC modules controlling

Merging Zone

, Left Line Discharge, Right Line Discharge, and Center Line

discharge must be in ZPA mode



Left, Right, and Center Lines discharges cannot also be included in another instance of

ConveyMerge

Please refer to Insight Automation publication

ConveyLinx User’s Guide

for

ConveyLinx

ERSC

module hardware details and basic function. The remaining sections of this

document assumes reader if familiar with

ConveyLinx

ERSC

module and

EasyRoll

software operation.

Содержание CONVEYLINX ConveyMerge

Страница 1: ...Version 1 1 April 2020 Publication ERSC 1020 ConveyLinx module firmware and functionality is protected by U S and international patents For complete patent information visit www pulseroller com patents ...

Страница 2: ......

Страница 3: ...hat special attention should be paid in order to ensure correct use as well as to avoid danger incorrect application of product or potential for unexpected results This symbol indicates important directions notes or other useful information for the proper use of the products and software described herein ...

Страница 4: ...rounded object to discharge potential static Wear an approved grounding wrist strap Do not touch connectors or pins on component boards Do not touch circuit components inside the equipment Use a static safe workstation if available Store the equipment in appropriate static safe packaging when not in use Because of the variety of uses for the products described in this publication those responsible...

Страница 5: ... Since there are many variables and requirements associated with any particular installation Insight Automation Inc does not assume responsibility or liability to include intellectual property liability for actual use based on the examples shown in this publication Reproduction of the contents of this manual in whole or in part without written permission of Insight Automation Inc is prohibited ...

Страница 6: ...Publication ERSC 1020 Rev 1 1 April 2020 ...

Страница 7: ...il 2020 SUMMARY OF CHANGES The following table summarizes the changes and updates made to this document since the last revision Revision Date Change Update 1 0 April 2016 Initial Release 1 1 April 2020 Updated Publication Number GLOBAL CONTACT INFORMATION ...

Страница 8: ...Placement 12 Standard Merge Sensor Placement 12 90 Merge Sensor Placement 13 Module Logical Connections for Main Line 13 Merging Zone on Upstream Zone 13 Merging Zone on Downstream Zone 14 Single Zone ERSC 14 Merging Lines 15 Merging Functionality 17 Merge Types 17 Merge Priority 17 90 Merge Setting T Merge 18 Accept Timeout 18 Send Timeout 19 Configuring Dynamic Priority Merge Line Full 20 Dynami...

Страница 9: ...pstream zones connecting to it where ZPA logic only supports a single upstream zone ConveyMerge also has a simple priority schemes for the multiple upstream zones as well as the ability to dynamically change those priorities on the fly by utilizing the Merge Line Full option It also takes care of passing tracking information properly and has Jam condition detection CONVEYMERGE COMPONENTS ConveyMer...

Страница 10: ...ections that can discharge items into the Merging Zone Right Line One of the three possible conveyor sections that can discharge items into the Merging Zone CONVEYMERGE PREREQUISITES AND REQUIEMENTS The following items are the prerequisites and constraints required to provide a fully functioning automatic conveyor merge EasyRoll version 4 3 or greater ConveyLinx Firmware version 4 25 or greater On...

Страница 11: ...to communicate with each other as long as the third octets of their IP addresses are in the same range either 0 127 or 128 254 FIGURE 2 TYPICAL SUBNET ARRANGEMENT For example using the default mask of 255 255 128 0 you may setup the Main Line to be in the 192 168 1 XXX subnet the Left Line in the 192 168 2 XXX subnet and the Right Line in the 192 168 3 XXX subnet ARCHITECTURE SUMMARY The Main Line...

Страница 12: ...sically discharge on to the Merging Zone All three subnets must be connected to a common Ethernet switch only after each subnet has been Auto Configured SENSOR PLACEMENT It is very important for the internal ConveyMerge logic that the product is seen by only one photo eye at a time STANDARD MERGE SENSOR PLACEMENT Figure 3 shows a suggested sensor arrangement for Standard Left Line and Right Line a...

Страница 13: ...a Right Line merge to the Merging Zone FIGURE 4 90 MERGE SENSOR PLACEMENT MODULE LOGICAL CONNECTIONS FOR MAIN LINE Depending on the physical arrangement of actual zones on the Main Line the Merging Zone can be assigned to either the Upstream or Downstream zone of its particular ERSC This section illustrates some examples MERGING ZONE ON UPSTREAM ZONE FIGURE 5 MERGE ZONE ON UPSTREAM ZONE OF LOCAL E...

Страница 14: ...as been Auto Configured as a single zone regardless of whether the single zone is connected to the right side or left side of the ERSC the logical designation for the zone on the ERSC is always the Upstream Zone Figure 7 and Figure 8 each show an example of a single zone ERSC using the left and right sides of the module respectively FIGURE 7 SINGLE ZONE ERSC ON LEFT SIDE OF MODULE ...

Страница 15: ...form each other and different from the Main Line Regardless of whether these merging lines are an Standard arrangement or a 90 arrangement the conveyor zone that discharges product onto the Merging Zone must be the most downstream zone if its particular subnet Figure 9 and Figure 10 illustrate this for an Standard Left Line and a 90 Left Line respectively The same would apply if these were Right L...

Страница 16: ...16 ConveyMerge Guide Publication ERSC 1020 Rev 1 1 April 2020 FIGURE 10 90 LEFT MERGE LINE DOWNSTREAM MODULE ...

Страница 17: ...l be allowed to convey into the Merge Zone When the Merge Zone is clear the next line that has had a product arrive will be allowed to convey into the Merge Zone Center Line Priority The Center Line will be allowed to release as long as product arrives at the center line zone sensor prior to the previously released product having not cleared the Merge Zone When the Merging Zone is clear and if the...

Страница 18: ... the discharging conveyor is arranged perpendicular to the Merge Zone and this discharging conveyor needs to throw the product across the Merge Zone s rollers In order to mitigate carton alignment issues the logic controls need to make sure that it keeps the Merge Zone s rollers stopped until the discharging conveyor has completely finished throwing the product ontp the Merge Zone In order to acco...

Страница 19: ...s timer specifies how much time the discharging zone has to wait after the Merge Zone sensor is clear before it is allowed to release the next product into the Merge Zone This timer helps ensure that the Merge Zone is clear when sensor placement cannot guarantee that the zone is clear FIGURE 12 SEND TIMEOUT EXAMPLE ...

Страница 20: ...yRoll configured setting If multiple lines are configured for Dynamic Priority and each of their respective Block Timers have expired ConveyMerge logic will revert to the First Come First Serve release mode until one or more of the releasing lines Clear Timer has expired DYNAMIC PRIORITY EXAMPLE Please refer to Figure 13 for this example In EasyRoll Node 2 upstream zone of the Central Line has bee...

Страница 21: ...21 Merging Functionality Publication ERSC 1020 Rev 1 1 April 2020 FIGURE 13 MERGE LINE FULL PRIORITY EXAMPLE BLOCK TIMER FIGURE 14 MERGE LINE FULL PRIORITY EXAMPLE CLEAR TIMER ...

Страница 22: ...Rev 1 1 April 2020 USING EASYROLL WITH CONVEYMERGE Open EasyRoll Connect to the ERSC that will control the Merge Zone See indicated area in Figure 15 Press CTRL SHIFT M to open the ConveyMerge Configuration Screen FIGURE 15 EASYROLL MAIN SCREEN ...

Страница 23: ...EN FIGURE 16 CONVEYMERGE CONFIGURATION SCREEN Item Description 1 Browse Nodes 2 Drop down selector for Merge Type from Left Right or Both 3 Drop down selector for Merge Priority 4 Display of IP Address for the ERSC selected for the Merge Zone 5 User button to click to apply changes made during configuration ...

Страница 24: ...ne for the Merge Line Full function 10 Radio buttons to select whether the upstream or downstream zone of the ERSC identified in Item 9 will be used as the Monitor Zone 11 IP Address of Right Line s most downstream ERSC 12 User checkbox to select T Merge type 13 Graphical representation of the merge Please note this will update and change as settings and configuration is modified 14 Merge Line Ful...

Страница 25: ...with a single merge line on the left In the example we wish to set the Merge Priority to First Come First Served FIGURE 17 STANDARD MERGE EXAMPLE The Merge Zone is the upstream zone of the module at 192 168 25 28 and the most downstream ERSC for the Left Line is at 192 168 24 31 Figure 18 shows the ConveyMerge Configuration screen with these values entered ...

Страница 26: ...ERGE EXAMPLE The last step for configuration is to click the Apply button Please note that after clicking the Apply button if the configuration has changed the affected modules will reboot It will take a few seconds for the reboot to finish and some of all of the affected zones may briefly run their motors ...

Страница 27: ...n the right In the example we wish to set the Merge Priority to First Come First Served FIGURE 19 T MERGE EXAMPLE The Merge Zone is the upstream zone of the module at 192 168 24 28 and the most downstream ERSC for the Right Line is at 192 168 26 58 Figure 20 shows the ConveyMerge Configuration screen with these values entered ...

Страница 28: ...Publication ERSC 1020 Rev 1 1 April 2020 FIGURE 20 CONVEYMERGE SCREEN FOR T MERGE EXAMPLE ...

Страница 29: ...wnstream node is 192 168 24 31 and we want this line to have the Merge Line Full function enabled On the merge line Left Line we would like for the upstream zone of ERSC 192 168 24 25 to be the Merge Line Full function s Monitor Zone We would also like that once the Monitor Zone has been accumulated or blocked for 5 seconds we want the Left Line to release for 5 seconds and then return the priorit...

Страница 30: ...Publication ERSC 1020 Rev 1 1 April 2020 FIGURE 22 CONVEYMERGE CONFIGURATION SCREEN FOR MERGE LINE FULL EXAMPLE ...

Страница 31: ...31 Notes Publication ERSC 1020 Rev 1 1 April 2020 NOTES ...

Страница 32: ...Publication ERSC 1020 Rev 1 1 April 2020 ...

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