All washers, dryers, and no-dry stations will have an assigned shuttle position that is programmed into each machine setups. When a washer is finished processing its load, depending on the type of unloading sequence that is programmed, it will send out an invitation to the C2 (BED A) shuttle that it is ready to be unloaded.

The shuttle will travel to its desired position, retract to the inviting washer, and wait for the washer to unload. The washer will open its door, tilt into the shuttle, and begin to unload. When the photo eye on the dryer end of the shuttle bed is broken, the shuttle is told that the washer is unloaded. While all of this is taking place the washer is transferring the information that it received from the BLMI or the Softrol PulseNet database on what was processed and how to dry the load.

When the washer reaches its loading position depending on its loading system, the shuttle will start looking for an available dryer to dry the load. If the washer is a shuttle-loaded system, the C1 (BED B) shuttle will position itself, load the washer, and then start looking for an available dryer to dry the load. If no dryer is available, the shuttle will go to its programmed home position and wait for the first available dryer that can accept the programmed item code.

If a dryer is available, (available meaning tilted into the load position asking to receive a load) the shuttle will move to the dryer position, extend towards the dryer, the belt will start transferring the load and the dryer basket will start rotating to receive the load. During this time, the dry information and destination data is transferred. After the load is transferred into the dryer the belt will continue to transfer until the programmed time in the shuttle setups for declares belt emptied has been timed out.

The shuttle will then return to it’s at travel position and start looking for another washer to unload and will restart this sequence. The dryer will return to the run position, close the door and run the desired dry formula that corresponds with the programmed item code. For No-dry/bypass conveyors, a dryer classification from 60 to 69 will allow all shuttles to respond. Dryer classifications 70 to 79 will allow only negative end shuttles to respond. Dryer classifications 80 to 89 will allow only positive shuttles to respond.

Node ID #
This is the Softrol AutoPulse ID that is unique to every machine connected to the network and must be a number from 1 - 255. The machine ID assignments should follow the following convention:

Machine Type Acceptable Node ID Numbers
Wet Process 1-100
Dryers 101-200
Shuttles 201-210
Conveyors 211-249
Chemicals 211-249
PC’s 250-255

There is an exception for a weighing conveyor in that this ID can also be set to zero (0), which is an indication to the conveyor control that it is not connected to a Softrol PulseNet network. This will allow the conveyor to be operated manually to load a shuttle. However, the Loading Conveyor was designed to be a part of the Softrol AutoPulse System and to operate as part of an automated system. There is no form of automatic operation at all without the Softrol PulseNet network and a valid Node ID of 1-255. If set to manual operation with a Node ID of zero (0), in the Stand By mode the conveyor will display “[YES] = Unload”. When the [YES] key is pressed the conveyor will unload the first loaded pocket after the motion alarm has been sounded regardless of whether the shuttle is in place to receive it or not.

Washers
The washer extractors in a Softrol AutoPulse system are always equipped with the necessary options for automatic machine movement. The hardware/software is embodied in the two-way tilt and automatic door options. For Bag loaded systems, automatic chutes should be installed on the machines. Automatic chemical injection is usually considered for full automatic operation.

Washer AutoPulse Setups
To include a machine into an AutoPulse system all that is required is to install the ArcNet card, connect it to the Softrol PulseNet Network, and then answer the AutoPulse setups on the machine. These AutoPulse setups contain the important operation information necessary for proper operation of the AutoPulse. Each setup is detailed in the following:

ArcNet Node
To include a machine into an AutoPulse system answer YES. To exclude a machine from the AutoPulse system, answer NO. Sometimes it is necessary to exclude machines from the network to perform manual operations or maintenance on a machine.
LAN Member ID #
This is the ID number for the machine. This ID number must be unique for the Softrol PulseNet system that the machine is being attached to. Valid ID numbers are 1 to 254. ID number #255 is reserved for Softrol Plant Monitor Database (PPMM).

Loading Position
This is the position for a shuttle to load the washer extractor. Positions are numbered in a system from 0 to 32. Position 0 is always to the far left of the wash aisle facing the wash aisle from the washer’s aspect. The rightmost position is determined for each system and is the last needed position to the far right of the wash aisle facing the wash aisle from the washer’s aspect. For bag-loaded machines, the loading position is determined by the machine’s position in the bag-loading queue. For instance, if three machines were to be accessed by one rail queue, then the loading positions would be 1, 2 and 3 respectively.

Unloading Positions
This is the position for a shuttle to unload the washer extractor. The unloading position setup follows the same rules as the loading position for shuttle loaded machines.

Machine Class Type
This is the class type of the machine. The valid range is 0 to 94. Certain machines may be equipped differently than other machines.

In addition, certain processes may be preferred in particular machines. This is accomplished through using the Class Type. When items to be processed are entered into the Softrol AutoPulse system, they are assigned a Class Type Number for the Wash Classification.

The corresponding items will be processed in a machine with a matching Class Number. Assigning a Machine Class Type 99 will prevent the machine from automatic operation and is useful when maintenance or testing is performed on a machine. On bag-loaded systems, the Machine Class Type corresponds to the Queue number of the rail system that will load the machine. In this case, if there are four different rail queues loading machines, then the machines will have either a Machine Class Type 1, 2, 3, or 4 respectively. All machines serviced by a rail queue must be capable of processing the same items.

On systems that do not have a database (PPMM or BLMI), or that it is manually loaded and automatically unloaded, this will need to be set to 91. Machine Class 91 means that the washer formula and the dryer formula correspond. For example, if the washer processes “Shop Towels” formula 45, the dryer must also be set up for Dry Class 91 and be programmed for “Shop Towels” at formula 45.

PLEASE NOTE: ON MANUALLY LOADED/AUTOMATICALLY UNLOADED SYSTEMS (MACHINE CLASS TYPE 91), FORMULAS 1 TO 99 WILL GO TO DRYER CLASS 91. FORMULAS 100 TO 128 AUTOMATICALLY GO TO DRYER CLASS 95 WHICH IS USUALLY A DRYER BY-PASS LOCATION. THE SHUTTLE SETUP FOR NO-DRY STATION 1 WILL NEED TO BE SET TO 95. THIS SETUP WILL ALSO CORRESPOND WITH THE CALIBRATED SHUTTLE POSITION FOR NO-DRY STA. 1/POS.

Sequence Priority #
The sequence priority establishes the manner in which machines are selected for loading and unloading. Machines with a sequence priority of zero will rotate priority according to how long the machines have been waiting to load or unload. Machines with a sequence priority greater than zero attain a higher priority of selection than those units with a sequence priority of zero. A sequence Priority of 1 is the highest priority. The available machine with the smallest non-zero priority will be selected preferentially. Machines with the same priority will be handled in a shortest path algorithm, meaning that the machine closest to the current position of the shuttle or the first machine in a rail queue will be handled first.

Minimum Weight
This establishes the minimum weight that a machine will accept for a load.

Maximum Weight
This establishes the maximum weight that a machine will accept for a load.

Lo Formula Range 1
This establishes the minimum formula number for a formula range 1 that a machine will accept for a load. Three acceptable ranges can be established.

Hi Formula Range 1
This establishes the maximum formula number for formula range 1 that a machine will accept for a load.

Lo Formula Range 2
This establishes the minimum formula number for formula range 2 that a machine will accept for a load.

Hi Formula Range 2
This establishes the maximum formula number for formula range 2 that a machine will accept for a load.

Lo Formula Range 3
This establishes the minimum formula number for formula range 3 that a machine will accept for a load.

Hi Formula Range 3
This establishes the maximum formula number for formula range 3 that a machine will accept for a load.

Interference Pos. Lo
This establishes the first position for a machine where the automatic movements of the machine’s door and/or chutes have a mechanical interference potential with shuttles. If the system has been designed without mechanical interference’s, this setup may be programmed to 0. PLEASE NOTE: THE INTERFERENCE POS. MUST BE A POSITION IN WHICH THERE IS NO MECHANICAL INTERFERENCE OF THE MACHINE’S DOOR AND/OR CHUTES WITH THE SHUTTLE.

Interference Pos. Hi
This establishes the last position for a machine where the automatic movements of the machine’s door and/or chutes have a mechanical interference potential with shuttles. If the system has been designed without mechanical interference’s, this setup may be programmed to 0. If the positive stop position is equal to a machine’s Interference Position Hi, program 64 for this setup. PLEASE NOTE: THE INTERFERENCE POS. MUST BE A POSITION IN WHICH THERE IS NO MECHANICAL INTERFERENCE OF THE MACHINE’S DOOR AND/OR CHUTES WITH THE SHUTTLE.

Loading Height
This establishes the height that a scissors shuttle should be positioned at to load the machine. A height of 0 is the lowest height and a height of 99 is the highest height. If the system does not utilize a scissors shuttle, this setup may be programmed to 0.

Loading Depth
This establishes the depth that a scissors shuttle should be positioned at to load the machine. A depth of 0 is the depth of the shuttle when positioned at the shuttle’s southern limit. Depth may increase to a maximum of 99. Depth’s greater than the shuttle’s middle limit establish positioning towards the shuttle’s northern limit. If the system does not utilize a scissors shuttle, this setup may be programmed to 0.

Unloading Height
This establishes the height that a scissors shuttle should be positioned at to load the machine. A height of 0 is the lowest height and a height of 99 is the highest height. If the system does not utilize a scissors shuttle, this setup may be programmed to 0.

Unloading Depth
This establishes the depth that a scissors shuttle should be positioned at to unload the machine. A depth of 0 is the depth of the shuttle when positioned at the shuttle’s southern limit. Depth may increase to maximum of 99. Depth’s greater than the shuttle’s middle limit establish positioning towards the shuttle’s northern limit. If the system does not utilize a scissors shuttle, this setup may be programmed to 0.

IF A WASHER IS LOCATED TO THE NORTHERN LIMIT (DRYER SIDE) OF THE WASH ISLE, THIS SETTING MUST BE SET AT 99. IF THE SYSTEM DOES NOT UTILIZE A SCISSORS SHUTTLE, THIS SETUP MAY BE PROGRAMMED TO 0.

AutoPulse Automatic Operation

When the system enters automatic operation, the washers may move unexpectedly at any time. The LED displays will begin flashing once a second indicating that the washer and the system are in automatic mode. Automatic mode will only be entered if all local machine safeties are proven on the machine. Automatic mode may be suspended on a machine for one minute by pressing a key on the keypad. Automatic mode may be suspended on a machine indefinitely by pressing the emergency stop button. After all safeties are returned to the proven position, the machine will enter automatic mode in one minute. Automatic mode may also be suspended on a machine by assigning it Machine Class Type 99. The machine may be operated manually without the machine entering into automatic mode. In order to prevent the shuttle from loading a washer with two loads, the Softrol AutoPulse system does not consider a washer to be empty until it has moved to the rear up unloading position and the door is opened. If manual intervention prevents a washer from reaching the unloading position after the termination of a formula, then the operator may inform the Softrol AutoPulse system that the washer is empty by pressing the [CLR] and [ENT] keys simultaneously after the washer displays the “Waiting for Washer to Receive Load” message. This procedure may also be used if a washer is in automatic mode (LED displays blinking) and “Waiting for Washer to Receive Load” is displayed but the shuttle never loads the washer.

NOTE: IF THIS IS SEQUENCE IS PERFORMED PREMATURALLY WHILE A MACHINE IS STILL LOADED, THE SOFTROL PLANT MONITOR DATABASE WILL ASSUME THE MACHINE IS READY TO RECEIVE A LOAD AND CAN BE LOADED.

For Shuttle Loaded Washers
The shuttle can be loaded two ways, either by an automatic loading conveyor or by an operator. Loading the shuttle with an automatic loading conveyor is all done automatically and is covered in the Pocket Loader section. For an operator loading system, the operator can request to load either by pressing the Request Load button on the podium, or by pressing the [ENT] and the [NO] keys simultaneously On the shuttle. This will prompt the shuttle to travel to its programmed load position for loading. When at the position, the shuttle will retract for loading. While the operator is loading the shuttle, pressing the UP arrow will advance the belt. After the operator has loaded the shuttle, the following information will be prompted.

1 = Wash Process Data:
Selects washer process data for entry
Group # =: Key in Wash Group
Formula # =: Key in Wash Formula

2 = Process Data:
Selects dryer process data for entry
Group # =: Key in Dryer Group
Formula # =: Key in Dryer Formula

3 = Specific Data:
Selects item specific data for entry
Item #: Key in Item Number
Lot #: Key in Lot Number
Customer #: Key in Customer Number
Count: Key in Item Count
Weight: Key in Item Weight
Destination: Key in Post. Dest.

When a washer extractor is empty, it will attempt to sequence to the front tilted up, door open position to wait for a load. It does this by first tilting to the load position. The door is then checked to see if it is open. If the door is required to open, the washer will wait until the shuttle(s) are at a position of rest. When the shuttle(s) have stopped moving, the machine will check its interference position range and determine whether it is safe to open the door.

If it cannot open the door, the machine will wait until the shuttle(s) are at the home position, where there are no mechanical interference’s.

The door will then open, completing the necessary sequence to prepare for loading. If the system has been designed with no mechanical interference’s, then the doors on the machines will operate without regard to the position of the shuttle(s).

When a washer is in the front tilted up, door open position waiting for a load, it will respond to a shuttle when a shuttle is looking for a washer to load.
If the washer is selected for load, the respective shuttle will position itself according to the washer’s loading position and initiate the load sequence.
The washer will begin to rotate in balance speed. The shuttle will then extend to the washer and index the loading conveyor until the load is in the washer. The shuttle will then retract away from the washer and send the washer the necessary processing information for the load.

Once the shuttle(s) have returned to a position of rest, the door will close automatically. On systems designed without mechanical interference’s, the door will close immediately after loading. Once the door is closed, the machine will return to the horizontal position and begin execution of the selected formula automatically.

When the wash formula is completed, the washer will return to the front tilted up position. When tilted up, it will wait for the shuttle(s) to be at a position of rest and then automatically open the door to prepare for unloading. On systems designed without mechanical interference’s, the door will open immediately.
Once the washer is tilted up with the door open, it is available for unloading onto a shuttle and will respond to a shuttle’s request to unload washers. If the washer is selected for unload, the respective shuttle will position itself according to the washer’s unloading position and initiate the unloading sequence. The shuttle will first retract to the washer. The washer will then return to the horizontal position and then continue to the rear up unloading position. Once this position is achieved, the washer will begin the automatic unloading sequence.

The rotation of the cylinder during unload is described by the last formula executed. The shuttle will index the unloading belt to accept the load from the washer. The photo-eye on the shuttle will indicate when a load has been put on the shuttle.

When a washer is in the front tilted up, door open position waiting for a load, it will respond to a shuttle when a shuttle is looking for a washer to load.

If the washer is selected for load, the respective shuttle will position itself according to the washer’s loading position and initiate the load sequence.

For Bag Loaded Washers
When a washer extractor is empty, it will attempt to sequence to the front titled up, door closed, chute door open position to wait for a load.

On systems with mechanical interference’s, the washer extractor does this by first returning to the horizontal position. The door is then checked to see if it is closed. If the door is required to close, the washer will wait until the shuttle(s) are at a position of rest.

When the shuttle(s) have stopped moving, the machine will check its interference position range and determine whether is safe to close the door. If it cannot close the door, the machine will wait until the shuttle(s) are at the home position, where there are no mechanical interference’s. The door will then close.

After closing the door, the machine will attempt to sequence to the load position. Once the machine is at the load position, the door will be opened, completing the sequence.

If the system has been designed with no mechanical interference’s, then the doors and the chutes on the machines will operate without regard to the position of the shuttle(s).

When a washer extractor is in the ready to load state, it will respond to a Softrol Plant Monitor Database requesting a load.

If the washer is selected for load, the PPMM will signal the bag system to sequence the loading process. The PPMM will send the washer the necessary processing information for the load.

The bag will position itself according to the washer’s loading position in the bag queue and initiate the load sequence. The washer will begin to rotate in balance speed and command that chute water be added during loading.
The bag will then automatically open and load the washer. The washer will respond by closing the door to see if the bag fully entered into the machine. If the loading chute is clear (indicated by the door closed switch) the door opens to prepare for the next bag. If more than one bag is to be loaded, the bag system will sequence through the remaining bags to be loaded. When all of the bags have been loaded into the washer, the bag system signals the loading interface that the loading sequence is over. Once the loading sequence has ended, the washer will close it’s door and the machine will return to the horizontal run position and execute the selected wash formula automatically.

When the wash formula is completed, the washer extractor is available for unloading onto a shuttle and will respond to a shuttle’s request to unload washers.

If the washer is selected for unload, the respective shuttle will position itself according to the washer’s unloading position and initiate the unloading sequence.

The shuttle will first retract to the washer. The washer will then begin to open up its door. When the door has been sensed open for 5 seconds, the washer will begin to tilt the rear up to the unloading position while continuing to open the door to the door open position.

Once this position is achieved, the washer extractor will begin the automatic unloading sequence. The rotation of the cylinder described by the last formula executed.

The shuttle will index the unloading belt to accept the load from the washer. The photo-eye on the shuttle will indicate when a load has been put on the shuttle.

The shuttle will then extend away from the washer. The washer will then proceed to the horizontal position door closed position. The washer will begin closing of the door one second after titling begins. When the washer is at the horizontal position, the machine will tilt back to the loading position, ending the unloading process.

Dryers
The dryers in an AutoPulse Automation System are always equipped with the necessary options for automatic machine movement. This usually is embodied in the two doors, front tilt options. Proximity sensors for all machine positions are strongly suggested.

As with the washers, the ArcNet communications card is also necessary. The coaxial cable connecting this card to the Plant Monitor network is the only required inter-machine connections. The Plant Monitor network communicates all the necessary information for automatic operation of the system. No complex wiring system is employed.

Dryer Softrol AutoPulse Setups
To include a machine into a Softrol AutoPulse system all that is required is to install the ArcNet card, connect it to the PPMM Network, and then answer the AutoPulse setups on the machine. These AutoPulse setups contain the important operation information necessary for proper operation of the AutoPulse. The setups for the dryer are similar as for the washer. Please see the setups as detailed in the washer section for explanation of each setup. In place of the Interference Lo and Interference Hi setups, the dryer prompts the following setups:
Belt System
This setup determines whether the dryer will be unloading onto a shared flat belt conveyor (East/West type) and/or a shuttle belt system. If the dryer is to unload automatically onto a flat belt conveyor, answer YES. When unloading onto a flat belt conveyor, unloading position indicates which direction to run the belt when unloading the dryer. If the dryer is to unload automatically onto a scissors shuttle, answer YES.

Idle At Load Position
This setup determines whether the dryer will be positioned at the horizontal rest position with doors closed or the accept load position when waiting for a load from the shuttle. In some climates, it is preferable to have the dryer waiting in the horizontal door closed position to prevent cold and/or hot air from entering into climate-controlled environments. If the dryer is to sequence to the Load Position At Idle, answer YES. Otherwise, answer NO.

AutoPulse Automatic Dryer Operation
When a dryer is empty, it will be in the horizontal position, with doors closed. If Idle At Load Position is selected, the dryer will be in the loading position with the load door open.

If the dryer does not have a belt interface, it must be put into the loading position by the operator on the unload side of the dryer after unloading of the dryer is successful. This is accomplished by commanding the dryer to move horizontal and closing the unload door from the unload side of the dryer. If the dryer does have a belt interface, it will position itself in the loading position automatically.
In order to prevent the shuttle from loading a dryer with two loads, the AutoPulse system does not consider a dryer to be empty until it has moved to the unloading position and the discharge door is opened.

If manual intervention prevents a dryer from reaching the unloading position after the termination of a formula, then the operator may inform the AutoPulse system that a dryer is empty by pressing the [CLR] and [ENT] keys simultaneously after the dryer displays the “Waiting for Dryer to Receive Load” message.

This procedure may also be used if a dryer is in automatic mode (LED displays blinking) and “Waiting for Dryer to Receive Load” is displayed but is never loaded by the shuttle.

When a dryer is in the waiting for a load position, it will respond to a shuttle when a shuttle is looking for a dryer to load. If the dryer is selected for load, the respective shuttle will position itself according to the dryer’s loading position and initiate the load sequence.

The dryer will tilt to the loading position, open the dryer load door, and begin to rotate in the forward direction. If Idle At Load Position is selected, the dryer will already be in the loading position.

The shuttle will then extend to the dryer and index the loading conveyor until the load is in the dryer. The shuttle will then retract away from the dryer and send the dryer the necessary processing information for the load. The dryer will then close its load door and return to the horizontal run position and begin execution of the selected dry code automatically.

At the conclusion of the drying process, the dryer will check the unloading conveyor or Belt Interface to see if it can accept a load. If the conveyor or Flat Belt can accept a load, the dryer will open the discharge door and tilt to the unload position. Automatic unloading will begin if selected in the dryer formula. Automatic unloading is not desirable when unloading onto carts.

When the dryer is unloaded, the operator must put the dryer back into operation by returning the dryer to the horizontal position and closing the unload door from the control panel on the back of the dryer.

On some units, a push-button is provided on the unloading sort conveyor for remote operation. When a dryer unloads onto a shared Softrol AutoPulse Belt Interface, the dryer will return to service automatically. When the dryer is put in the horizontal position with the doors closed, the AutoPulse Data Record is sent to the PPMM database computer. The database computer optionally prints out the AutoPulse tracking sheet and/or enters the AutoPulse Data Record into the tracking database. The dryer then begins the sequence over again.

Shuttles
The shuttles in an AutoPulse system are always the main interface for the automatic loading and unloading of the machinery. The shuttle system incorporates all the necessary safety limits to determine if the system is in a safe posture for automatic operation. When all safeties are simultaneously enabled, a safety-reset procedure may be performed to enter into automatic operation. Interruption of any one of these safeties results in the exit from automatic operation.

A coordinate system must be established before setting up a shuttle system. The shuttle system may have up to 64 positions or coordinates defined for loading, unloading, and idle positions. These positions are always numbered from left to right, facing the wash aisle from the washer’s perspective.

Therefore the far-left position is always position 0. The far right position can be up to position 64. Each position in the system is defined by installing a metal object in the floor (such as a metal washer) at each desired stop position for the shuttle system to sense. Metal flat bars installed in the floor define the far left and right positions.

On scissors shuttles, the coordinate system is extended to include height and depth of the conveyor beds. Height is established as being 0 when the scissors bed is all the way in the down position. Depth is established as being 0 when the scissors bed is retracted all the way to the South extent (viewed from the above perspective). Photo-eye establishes the height and depth by “counting” the relative movement of the beds.