Dynamic Indication for Packaging-Line Flow
Challenge
On a high-speed packaging line, conventional three- to five-segment tower lights alert operators to disruptions but provide little help locating the source. Basic Run, Warning, or Fault states do not show whether material is failing to arrive from upstream, accumulating locally, or blocked by a downstream jam. The time spent locating the source can turn small disruptions into line stoppages.
Solution
Configured in Run Mode, 20-cell CTL50 Continuous Tower Lights positioned along the line use their full displays to show a distinct color and animation for each flow condition. Steady green indicates normal flow, a downward blue animation indicates upstream starvation, an upward yellow animation indicates local accumulation, and flashing red indicates a downstream jam. Modbus states from the PLC select the appropriate indication.
Operators can immediately see whether to investigate upstream, locally, or downstream, shortening the time needed to locate the source and helping prevent small disruptions from becoming line stoppages.
