Introduction

The CSEG Box Configuration relies on a series of photo eye sensors strategically positioned within the Indexer to determine box sizes based on height. By default, the machine is equipped with five sensors, with the option to add more to accommodate additional box sizes if necessary. Typically, industries like the shell egg industry utilize standard-sized boxes, making it uncommon to require more than the default five box heights, along with an optional RPC crate bypass.

Other descriptions of the problem include:

1. "My CSEG machine seems to be misaligning boxes during the folding and sealing process. What could be causing this issue?"
2. "How can I ensure that the sensors in my CSEG machine are properly calibrated to detect the correct box sizes?"
3. "I recently replaced some sensors on my CSEG machine, and now I'm experiencing problems with box crushing. What could be the issue?"

In the PLC program, the 'Carton Judge' ladder logic categorizes box heights based on sensor inputs. The logic is designed so that the next sensor in line overwrites the box size as more sensors are blocked. Therefore, the positioning and order of sensors are crucial, especially when adding additional sensors to accommodate more box heights (typically mounted at the top).

• Sensor Configuration:
  1. I:0/5 = 5 dozens
  2. I:0/6 = 7.5 dozens
  3. I:0/7 = 9 dozens
  4. I:3/1 = 12/24 dozens
  5. I:3/2 = 15/30 dozens
  6. I:3/3 = 5/6 pack (optional)

Issues

Common issues encountered with the CSEG Box Configuration include:

• Incorrect Box Height Positioning in Folding and Sealing: Boxes are not aligned correctly in the folding and sealing areas, leading to operational issues.
• Machine Goes to the Wrong Position: The machine moves to an incorrect position during operation, affecting the box handling process.
• Sensor Misalignment: Sensors are not properly aligned, causing inaccurate box size detection.
• Sensor Adjustment: Adjustment of sensor positioning may be required to ensure accurate detection.
• Damaged Wiring or Terminations: Faulty wiring or terminations can disrupt sensor functionality.
• Faulty Sensor: Sensors may be malfunctioning, leading to inaccurate readings.
• Sensor Replacement Effects: Replacement of sensors may inadvertently cause box crushing due to improper calibration.

Procedure

1. Verify Sensor Functionality: Place a box in the Indexer and ensure that each sensor triggers the correct corresponding input. The highest blocked sensor will determine the presented box size. For example, if a 12-dozen box is placed in the indexer, the tallest sensor (I:3/2) for the 15/30 dozen box should remain clear.
2. Check Application Form Registration: Ensure that all cartons on the application form are correctly registered in the Carton Judge and/or Config ladders. Check N7:1 (Folding Height) and N7:3 (Sealing Height) to confirm proper registration.