|
 When a leading manufacturer of frozen food products approached DataScan with a bar code reading application in their packaging warehouse, they had some very specific requirements.
The project required automated data capture at several key points throughout the plant and the despatch process. An automated system integrated with the current IT infrastructure would enable complete product traceability as well as saving time, which was a fundamental requirement of the system.
As part of a detailed on-site survey several key areas were identified within the plant where scanning systems would be required. The most important of these were the main dock doors, where pallets are loaded on to delivery trucks. The process requires the use of hand driven pallet trucks to load the wagons, with standard euro pallets. The dock doors area standard 3 metre width, and there are 4 in total.
At the entrance to the warehouse, outer cases are transported via a roller conveyer system in to the storage area, and sent to a shrink-wrapping machine. At this point, a completed pallet is then delivered to either the cold store, or to the despatch area for loading.
The customer wanted to standardise hardware components as possible to assist with maintenance and complexity of spares. With this in mind DataScan opted for Datalogic DS6400 unattended scanning system.
Due to the margin of error that always arises from hand applied bar code labels, scanners with oscillating mirrors were utilised to ensure an accurate read rate. The oscillating mirror is totally adjustable using the Genius software platform that is included with the fixed position scanner, offering complete control of how the scanner functions.
 The DS6400 range of fixed position scanners have a new “FLASH™” dynamic focus system, with a reading range of up to 2.5 metres, ideal when the target area can be anywhere across a 3 metre wide door. Equipped with an advance code reconstruction feature to assist with poorly printed codes, and when labels are hand applied, often not in the ideal orientation. The in built Ethernet communication option allows transmission of data over large distances, with the ability to integrate easily in to IT systems.
The Modularity and flexibility of the DS6400 is based on an innovative mechanical design with the scanner separated in two parts: the reading head and decoder base. As a result, it is possible to always install the scanner in the ideal position, by simply rotating the Head / Base position.
A purpose built framework was constructed around each dock door, and access point in and out of the warehouse area to house the scanners and the associated custom designed control panels that were custom designed. An array of photocells are positioned so that it is possible to determine the direction of travel of the pallet, either in or out of the doors, and to differentiate between a full or empty pallet. A simple PLC is used to control this logic, and situated in the control panel on the framework. This resulted in the pallets being tracked out of the dock doors and back in and out of the cold store area automatically.
As there was no way of controlling which way round the pallets would be facing as they passed through the doors, DataScan utilised the master/slave communication ability of the DS6400 fixed position scanners. This meant that by linking scanners mounted on either side of the door, a result would always be achieved, without a no-read situation occurring.
The customer asked for a back-up device in case of either a scanner failure or an event when the bar code was positioned too far out of specification or damaged in any way.
.jpg)
DataScan utilised the new cordless Dragon hand held scanner from Datalogic for this purpose. It is an extremely robust design, ideal for factory production areas, as it is drop tested from 2 meters.
With any hand held scanner, the operator usually relies on the tell-tale ‘beep’ from the unit to let him know that a code has been scanned and read. In noisy environments, this can be a problem, so Datalogic use their patented ‘green spot’ system to give a visual signal that the code has been read. There are also green lights on both the top and bottom of the scanner, allowing the device to be operated in any orientation.
The RF base unit was mounted on the side of the panel, allowing the hand scanner to be operated anywhere within approx 50 metres of the system. Each hand scanner was coded to a particular base unit, allowing the system to recognise where in the process the pallet was.
To cover all eventualities, the customer purchased a Scan-Care+ maintenance contract from DataScan. This means that in the unlikely event of a scanner failure, they can send the unit for repair with minimum disruption, and a guaranteed turn around time. Simply by requesting an RPA number online, the products are returned and the repair.
The end result is a fully integrated scanning system, purpose built for the customer’s needs, with very few spare hardware components required and no worries or headaches about lost production due to failures. The company is currently expanding in to a further factory unit, and is looking to add additional systems to their plant.
To learn more about custom scanner applications, please contact a member of our dedicated Automation team at our Bromsgrove office on 01527 839010
|
