Integrated machinery lines · Reference
Interfaces and signals between the stations
Look up what crosses a station boundary on RL-1: which machine sends a signal, which one reads it, and what the line does with it. Use this page when you read a line diagnosis, plan a change at an interface or write instructions that refer to a signal.
Page context
- Line
- Reference line RL-1: end-of-line packaging (RL-1)
- Stations
- Infeed and accumulation conveyor → Filler and capper → Labeler → Inspection and reject → Case packer → Palletizer and stretch wrapper
- Lifecycle phase
- Engineering and integration
- For
- System integrators, Maintenance technicians, Technical writers
- Page type
- Reference — Lets you look up facts: signals, states, values
Z1 · Filling
- Infeed and accumulation conveyorSystem integrator
- Filler and capperSupplier A
Z2 · Labeling and inspection
- LabelerSupplier B
- Inspection and rejectSupplier B
Z3 · Case packing
- Case packerSupplier C
Z4 · Palletizing
- Palletizer and stretch wrapperSupplier D
| State | Meaning on RL-1 | What the line controller does |
|---|---|---|
| Idle | Machine is ready and waits for the start command | Starts the machines from the end of the line toward the filler |
| Execute | Machine is producing | Paces the line from the filler’s speed |
| Suspended | Machine waits for material or space (starved or blocked) | Keeps the neighbors running while buffers last; shows the cause on the line HMI |
| Held | Machine is paused because of an internal condition, e.g. label reel change | Holds upstream machines once the buffer ahead is full |
| Stopped | Machine was stopped by a command or a zone stop | Stops the zone; the other zones go to Suspended when their buffers run out |
| Aborted | Machine stopped because of a fault or an emergency stop | Reports the machine and the fault; restart needs reset and acknowledgment |
| Signal | From → to | Meaning | Missing signal means |
|---|---|---|---|
| Ready to receive | Downstream → upstream | The downstream machine can take product | Upstream machine goes to Suspended (blocked) |
| Product available | Upstream → downstream | Product is waiting at the transfer point | Downstream machine goes to Suspended (starved) |
| Buffer full / buffer low | Conveyor → line controller | Fill level of the accumulation conveyor between two machines | Line controller adapts the speed or holds the upstream machine |
| Reject confirmed | Inspection → line controller | A faulty bottle was removed | After three missing confirmations in a row the line stops Z2 |
| Batch code | Line controller → labeler | Batch and best-before date for the label print | Labeler goes to Held; no unlabeled product leaves Z2 |
| Signal | Scope | Triggered by | Reaction |
|---|---|---|---|
| Emergency stop | Whole line | Any emergency stop device on RL-1 | All zones stop (stop category 1); restart needs reset at the device and at the line HMI |
| Zone stop Z1 … Z4 | One zone | Opening an interlocked guard door of the zone | The zone stops (stop category 1); neighbors go to Suspended |
| Guard locking released | One zone | Request at the zone’s access panel after standstill | Door can be opened; zone stays in Stopped |
| Zone reset | One zone | Reset button outside the zone, all doors closed | Zone is ready for the restart command from the line HMI |
| Safe speed Z4 | Palletizer zone | Setup mode selected with the key switch | Palletizer moves only at reduced speed with the enabling device |
Notes
Signal names follow the line’s signal list. Machine-internal signals are documented in the supplier manuals and are not repeated here.
PackML states are named as in the line HMI; the underlying state model may name some states differently per supplier.
Safety signals are listed for orientation only. The safety functions, their required performance level and their validation are defined in the line’s safety concept.