Remote Demand and Surge Control Features

The Remote Demand and Surge Control are two features that regulate machine production. To better understand each feature, it’s important to understand the differences between them.

The Remote Demand feature includes a sensor that is placed 3 to 5 case lengths downstream from the machine. The sensor lets the machine know when the outfeed conveyor is full.

At the start of case production, the machine runs at a faster production rate than the nominal line speed. When the machine detects the activation of the remote demand sensor, it halts case production. Once the sensor detects that the outfeed conveyor is clear of cases, the machine resumes case production at its previous speed.

The Surge Control feature is only available on the WF30 machines. The Surge Control feature includes the remote demand sensor (which operates in the same way) plus an additional sensor placed further downstream (the surge sensor). The machine is set up to run two speeds and is able to switch between speeds “on the fly”. One speed is the actual production, or “nominal,” speed. The other is the surge speed—cases are formed as fast as the machine reliably can.

As long as the surge sensor detects a case backup, the machine will run at nominal production speed. At this speed, the machine will perform just fast enough to keep up with production needs. If for some reason the surge control sensor does not detect a case backup, the machine will switch to surge speed and try to fill the line quickly and efficiently.

One of the benefits of the surge control feature is that it speeds up the machine only when the production line requires it. Otherwise, the machine is kept at the nominal speed. Running a machine at a low speed for as much as possible increases its life and reliability.

The Surge Control and Remote Demand sensors need to be placed downstream from the discharge area of the machine. They are usually mounted alongside the outfeed conveyor. Follow the diagram for correct placement of these two sensors.

For the Surge Control to work, the entire length of the conveyor needs to be a minimum of 10 case lengths between the WF30 and the next machine in the line. Place the Remote Demand sensor 3 cases from the WF30. Place the Surge Control sensor 3 cases away from the Remote Demand sensor.

To use Surge Control, you’ll need to know the speed that the outfeed conveyor runs at in feet per minute. You’ll also need to make sure that the speed of the outfeed conveyor meets the minimum speed requirement for the surge control feature. The minimum speed requirement can be determined by using the formula below.

Once you know the speed of the conveyor and that it meets the minimum speed requirement, follow the steps below to activate Surge Control.

1. On the HMI, touch Setup > Parameters > Outfeed Conveyor Settings.
2. Enter the outfeed conveyor speed (in feet per minute).
3. Touch Main Control.
4. Touch the Surge Control button.

The Surge Control function is now active.