Problem & answerN-01
Incorrect Count
Also covers: Over- or under-count
Likely causes
- Vibrator speed too high (product overlapping) or uneven
- Counting sensors dusty or dirty
- Area limits (min/max) not set for the product
- Product broken, chipped or stuck together
- Bottle not positioned under the chute
- Discharge horn misaligned
How to fix it
- 1Stop the machine.
- 2Clean the counting head and sensors (dry, lint-free cloth or soft brush).
- 3Adjust vibrator speeds so product moves in a single, separated line.
- 4Check area limits, minimum interval and filter time against the product settings.
- 5Check product quality; remove broken or doubled pieces.
- 6Adjust bottle position and align the discharge horn/chute.
- 7Run in Manual/Jog mode, count 10 bottles manually and confirm accuracy.
Technical note
Electronic counters detect each piece as it falls past a photoelectric sensor. Min/max area filters reject fragments and doubles; minimum interval separates pieces falling close together. Overlapping product is the most common cause of miscounts.It is fixed when
10 consecutive bottles hand-counted correct; in-process counts correct.
Stop it coming back
- Clean sensors at start-up and when the dust alarm sounds.
- Hand-count check every 30 minutes.
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