Category Archives: Sorter Automation

iPhone, iPad Remote Control for Grape Sorter

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Application specifications

  • Allow Stop, Start of conveyor belt.
  • Adjustment of conveyor belt speed.
  • Display of speed
  • Display of cupfill and 5hr cupfill history
  • Information on weight sorted, total punnets and total cartons.

Architecture Overview

Development:  Sybu Data
Hardware device: Vizier Grape Sizer
Communication architecture:  2 Tier Client-Server with custom message protocol
Communication protocol: TCP sockets
Distribution: Ad-hoc

This is only available for specific purposes to selective users of the Grape Sorter. An ad-hoc iPhone, iPad  installation will be made available on request.

 

Grape Sorter

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The Grape Sorter Management System configures, controls and manages the process of sorting (grading and sizing) of grapes into cartons or punnets in a packhouse.

The system groups bunches of grapes together, that meet a specified sort (size, colour and weight) criteria, and will allocate to a carton or punnet to optimal weight within a set tolerance.

System Features are:

  • Grape sorting to target carton weight, including colour and diameter grading.
  • Interfaces with Vizier Systems sizer hardware.
  • Support 4 grades per lane and 20 unique size and colour combinations.-Automatic or manual control on production belt speed for optimal performance
  • Visually intuitive graphical planning interface – fast setup of sort program
  • Real-time statistical data during sort process.
  • Comprehensive reporting and printing.
  • Support for mobile devices (allows for PDA devices to connect wirelessly and receive real-time statistical data)
  • Support for punnets (this includes setting the maximum number pf small pieces, also allows for punnets of mixed colour, each with a set minimum percentage)
  • Support for combined packing of punnets and cartons

The sort modes are:

  • Sort on bunch weight to specified carton target weight.
  • Sort on bunch weight and colour grading to specified carton target weight.
  • Sort on bunch weight and average berry diameter size to specified carton target weight.
  • Combined carton and punnet sorting
  • Punnet sorting with options to pack 2 colours, each with minimum percentage.

More Information:

  • Various statistics available during sorting (Cartons per Drop, Count per Drop, Counts per Kilogram, Counts per Number of Fruit, Cupfill, Carton Rate, Bunch Rate, Cupfull Errors Detected, Cups Missed, Weight Histogram, Carton Statistics)
  • Full configuration of hardware and sort setups
  • All sort data is stored to database, this allows for any production run data to be retrieved.
  • Resumes previous state in case of power-failure.
  • Information from various hardware inputs shown while sorting.
  • Network connections and activity monitor included in server application Automatic sorting mode lets sorted adjust its settings dynamically.
  • Easy calibration of various hardware devices from client.
  • Integration with Packhouse Production System, Barcode Scanning System, Reporting Engine and Cutter Monitoring System
  • Cutter monitoring module allows :
    • detecting number of bunches cut by a specific cutter
    • number of bunches of particular cutter inspected by quality control
    • cutter peformance reporting
    • intake and scrap weight for each cutter
  • Remote monitoring, administration and support via GSM cellular network using GPRS / 3G services.
  • Systems are installed on 3 continents in countries South Africa, Egypt, Chile and Mexico.
Bunches on the conveyor prior to weighing and classification. Grape sorting in progress.Bunches being weighed and classified to colour and size.
Intake being scanned. Intake being processed by cutters.
500g punnets after sorting.This example shows 2 grades per punnet with a minimum percentage required per grade. Cutters processing intake.Rejected berries are cut from bunch.QA personnel adding bunches to sorter after inspection.
Management application – displays real-time statistics and allow for sorer control.

Graoe Sorter Remote Mobile grape sorter client application.

Allows for wireless monitoring and remote control of sorter with an iPhone

 

grape sorter program

Grape sorter client showing a typical sort program.

 Grape sorter stats Statistics provided during sorting.

Fruit Sorter

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The Fruit Sorter Management System configures, automates and controls the sorting (sizing, grading and classification) of fruit such as apples, pears, plums, citrus, etc in packhouses and farms.

Fruit Sorter main screen

Product Features:

The system features are:

  • The Fruit Sorting System consists of an Fruit Automation Server and a Fruit Sorting Client Software.
  • Support up to 8 lanes, each with 64 drops and demand feed product belt
  • Classification and sorting by weight, colour, diameter, ratio and their various combinations
  • Support for 4 grades (classes) per run.
  • Support of a cuprate of 10+ cups/sec
  • Highly intuitive user interface to configure and setup new sort programs.
  • Fast and intuitive colour and diameter calibration.
  • Real-time statistical data.
  • Real-time built-in 1kHz oscilloscope for quick diagnostics.
  • Alarm subsystem for monitoring error conditions
  • Comprehensive reporting and printing
  • Software interfaces to Packhouse Production System to unify production information.
  • Hardware interfaces to Vizier Systems Cup and Roller sizers
  • The automation server of v4 and newer has been completely re-developed using Windows Embedded OS
  • The client software of v4 and newer has been completely re-developed for the Windows .NET framework and supports Windows Vista and Windows 7

Total number of fruit sorter installations nationally and internationally: 70+

Pears on conveyor Pears being washed. Pears on conveyor Pears on conveyor
Damaged pears removed Quality control at intake Classified pears at packing point Classified pears at packpoint
Final product Final packed product

On Microsoft Solution Finder

https://solutionfinder.microsoft.com/Solutions/SolutionDetailsView.aspx?solutionid=a2e30a5b395a4e58815f88b75f39d92f

Hybrid Sorter

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The Hybrid Sorter configures, automates and controls the sorting (sizing, grading and classification) of fruit such using a conveyor designed for grape sorting.

Product Features:

  • The Hybrid Sorting System consists of an Automation Server and Client Software.
  • Support of 1 lane, with a maximum of 20 drops
  • Classification and sorting by weight, colour, diameter
  • Support for 4 grades (classes) per run.
  • Highly intuitive user interface to configure and setup new sort programs.
  • Inverter, speed control from the Client User interface.
  • Fast and intuitive colour and diameter calibration.
  • Real-time statistical data.
  • Real-time built-in 1kHz oscilloscope for quick diagnostics.
  • Alarm subsystem for monitoring error conditions
  • Software interfaces to Packhouse Production System to unify production information.
  • Hardware interfaces to Vizier Systems Grape Sorter Hardware

Packhouse Production System

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Software to input all codes, lists, prices, costs, and associations for fruit production and packing for packhouse or farm. Network based. Multiple users.

Product Features:

Codes

  • Fruit Types, Variety, Brands, Target Markets, Classes/Grades, Counts and Sizes, Inner Packing, Fruit Definitions, Pallets, Packers, Growers, Bins, Bin Activities, Shift Information.

Costs, Prices and Fees

  • Price and Cost Periods, Salary Groups, Bin Fees, Bin Activity Fees, Re-bin Market Prices, Projected Market Prices, Pallet Costs, Carton Handling Costs (including Cold Chain, Storage, Bagging, PPECB, Marketing, Palletizing, Packhouse Handling), Bin Packing Costs, Bin Handling Costs, Inner Packing Costs, Carton Costs, Carton Packing Costs, Packer Packing Bonus.

Production Run Information

  • The following data can be acquired from manual input or from carton and barcode scanning: Bins Tipped, Re-bin, Cartons Produced. Additional data for UCC traceability standards can be edited and may be printed on produced cartons.

Barcode Scanning

  • Cartons produced from various packlines can be scanned for content and for packer information. This data will then be accumulated for production run reports. Label printers can print carton information in real-time in compliant format for export to EU.

Reporting

  • The system can generate the following reports: Packer Pay Report, Packer Performance Report, Fruit Specification Report, Batch/Production Run Report, Cumulative Reports, Difference Reports and Repack Reports.
  • An extensive production run report may contain the following information: Analysis of Production, Weight Reconciliation, Summary of Cost and Estimated Income, Variable Labour Costs, Carton Produced Data, Re-bin Information.
  • Cumulative Reports produces a summarized report from several production runs for either the packhouse or a producer.
  • If a fruit or grape sorter system is installed, reports for sorting can be generated.

Carton Pack Programs

  • Different pack programs can be configured for the layout of the packhouse and the pack requirements for a particular day.

Network Environment

  • The system supports multiple users in a network environment.

Multi-user Security

  • User roles and rights can be extensively configures for all aspects of the system. The system also supports fingerprint authentication.

Database Administration

  • Database administration tools allows for automated backup and scheduling policies.