Automated Food Filling System Programming

Food product filling control system Unitronics Samba SM43-J-R20 · VisiLogic · Programming specification 1. Overview The system controls two pneumatic filling valves on a food product filling machine. The machine starts with one active valve but the program must support two-valve operation from the outset. The controller is the Unitronics Samba SM43-J-R20 — an integrated HMI touch 4.3" + PLC in a single unit, programmed in VisiLogic. Valve logic: Valves are normally open (spring return). Output OFF = valve open = product flows. Output ON = valve closed = flow stops. Any failure or emergency forces outputs OFF and valves open automatically — fail-safe. 2. Hardware I/O Terminal Name Description I 0 Emergency Safety permissive — NC. I0=FALSE = emergency active. I 1 Foot pedal Manual mode only. Pressed = valve(s) close. O 0 Valve 1 Close valve 1. ON = closed. OFF = open (spring return). O 1 Valve 2 Close valve 2. ON = closed. OFF = open (spring return). O 2 Buzzer Warning / buzzer output — optional. O 3 Spare Reserved for future use. 3. Operating modes 3.1 Manual mode Controlled by the physical foot pedal (I1). Operator selects active valves on HMI (Valve 1, Valve 2, or both). Emergency always overrides and forces all outputs OFF. Pedal state Output Valve state Pressed ON Closed — product stops Released OFF Open — product flows 3.2 Automatic mode Runs according to the selected product recipe. Operator selects recipe and active valves, then presses START. Step Name Action 1 Select Select mode, recipe and active valve(s) on HMI. 2 Start Press START. System validates timing before starting cycle. 3 Fill / open Output OFF — valves open — product flows for the opening/filling time. 4 Wait / close Output ON — valves close — waiting for the closing/wait time. 5 Repeat Returns to step 3 until STOP, emergency, or invalid condition. Two active valves operate simultaneously. Alternated operation to be considered if practical. 4. Product recipes Up to 10 recipes stored in the HMI, retained after power-off. All fields editable from the HMI Recipe screen. Each recipe contains: recipe number, product name, volume per unit (ml), reference speed (units/min), opening time, closing time, enabled/disabled. 4.1 Initial product table # Product name Volume / unit Ref. speed Status 1 Cup 150 ml 32 units/min Active 2 Tub 2 500 ml 10 units/min Active 3 Tub 1 550 ml 9.5 units/min Active 4 Tub 3 1,000 ml 5.5 units/min Active 5 Tub 4 1,500 ml 3.5 units/min Active 6 Free product TBD TBD Free 7 Free product TBD TBD Free 8 Free product TBD TBD Free 9 Free product TBD TBD Free 10 Free product TBD TBD Free Max product flow: 500 litres/minute. Opening and closing times defined per product during commissioning. 5. Speed and timing logic Reference speed is loaded from the recipe and adjustable by the operator. The system calculates cycle time automatically: Cycle time = 60 / speed (seconds) Opening time + Closing time ≤ Cycle time If validation fails, automatic start is blocked and the message is shown: "Times incompatible with selected speed. Adjust opening time, closing time or speed." 6. Counters Counter Reset Partial unit counter Operator (HMI) Total unit counter Password protected Partial processed volume Operator (HMI) Total processed volume Password protected Each valve has its own counter. One active valve: +1/cycle. Two active valves: +2/cycle. Volume = units × ml per unit. Example: 100 units × 150 ml = 15,000 ml = 15 litres. 7. HMI screens Main screen Mode, recipe name and number Valve 1 and 2 active / inactive Valve state LED (open / closed) Start / Stop buttons Speed, opening time, closing time Partial units and volume Active warnings Recipe screen Recipe selection (1–10) Edit name, volume, speed Edit opening and closing times Enable / disable recipe Save / load recipe Maintenance screen Emergency input status (I0) Foot pedal status (I1) Manual output test V1 and V2 Buzzer test Partial counter reset Total counter reset (password) 8. Warnings and safety All warnings displayed on the main screen. No separate alarm screen required. Warning message Condition Emergency active I0 = FALSE — highest priority No active valve selected No valve selected before START Invalid recipe Recipe disabled or incomplete Timing incompatible with speed Opening + closing time > cycle time Automatic start blocked Any blocking condition active When emergency is active: all outputs OFF · valves open by spring return · cycle stops · manual mode inhibited · warning on main screen · operator must reset before restarting. 9. Deliverables required from programmer Complete VisiLogic .vlp source file (mandatory) HMI screens — 3 screens as specified 10 recipes pre-loaded (5 initial + 5 free) Counter logic — 4 counters as specified All warning messages implemented I/O list and operand register list Tested in VisiLogic simulation Short operating instructions Food product filling control · Unitronics SM43-J-R20 · VisiLogic · v1.0

Project ID: 40496316