B9: Package Drops & AFC Issues

by Alex Johnson 31 views

Hey everyone! Let's dive into a sticky situation involving our [B9] system. We're talking about packages taking a tumble after leaving the infeed, specifically due to some problems with the AFC (Automatic Flap Control) component. This issue has thrown a wrench into our operations, so let's break down what's happening and how we're tackling it.

The Breakdown: What's Going Wrong?

First off, the core problem is that the AFC flaps aren't closing completely. This is a big deal because these flaps are crucial for guiding packages smoothly onto the conveyor. If they're not fully closed, things get dicey quickly. To make matters worse, the electromagnets are failing to latch as they should. These electromagnets are the muscle that keeps everything locked in place, and if they're not doing their job, well, your package is likely going for a ride – a ride straight to the floor.

This whole situation is categorized as non-functional for the AFC. Essentially, it's completely down. This is impacting our overall system, putting us in a degraded state where things are only partially functional. It’s like having one arm tied behind your back during a race – you can still run, but you're not at your best. The issue started on October 10, 2025, and we're actively working to resolve it.

The Root Cause: Identifying the Culprit

Pinpointing the exact root cause has been a bit tricky, which is reflected in the 'Poor' clarity rating of the issue. We're missing some critical information like steps to reproduce and detailed error logs/screenshots. Without these, it's like trying to diagnose a car problem without opening the hood. However, based on the observations, we can infer some potential causes.

One possibility is mechanical issues with the flaps themselves. Perhaps there's debris interfering with their movement, or maybe they're slightly misaligned. Another angle to consider is the electromagnets. Are they receiving enough power? Are there any loose connections or internal faults? The lack of complete closure of the AFC flaps could be caused by the motor or the upper limit switch, the switch might be triggering before the flaps completely close, this could be because of misalignment or some mechanical issue that prevents the flap from closing completely.

The fact that the electromagnets fail to latch suggests a power delivery issue or an issue with the electromagnet itself. Testing the voltage or current delivered to the electromagnets can help reveal if they are receiving sufficient power. Regular maintenance and checks on the electromagnets are also essential to ensure that they are functioning correctly.

The Fix: Taking Action and Implementing Solutions

Given the high impact of this issue, it's been given a P1 - High priority. It's a major problem that has a workaround, so we are focused on getting this resolved quickly. The team has already implemented some code updates, and these are a crucial piece of the puzzle. The goal of this code is to ensure the flaps are perfectly latched with the electromagnets, so that the package does not fall incorrectly.

Our initial fix involves a code update across all bots to include a delay in the system. The delay ensures that the motor keeps running for a set time, even after the upper limit switch is pressed. This extended operation helps ensure that the flaps are completely latched with the electromagnets. Essentially, we're giving the system a little extra nudge to make sure everything lines up perfectly. This approach is similar to adding extra time to ensure all the elements are in place before a package is dispatched.

Further investigation may be required to get more information about the root cause of the package drop. Analyzing error logs and gathering information from the error reports will also help identify if the motor itself is at fault. The maintenance team can also be called to check the mechanical components to see if any mechanical intervention is required. Regularly checking the systems and error logs would provide a good insight into the problem and can prevent a similar situation from arising again.

Next Steps: Staying Proactive

While the current fix is a good starting point, we need to remain proactive. We should prioritize these actions:

  • Gather more data: Collect detailed error logs and screenshots. This is crucial for gaining clarity. Knowing what went wrong will help to prevent similar issues in the future.
  • Review mechanical components: Conduct a thorough inspection of the flaps and electromagnets. Mechanical issues are often the culprit. Ensuring that all the mechanical components are in good condition and are working optimally.
  • Continuous monitoring: Keep a close eye on the system's performance, especially after the code update. If similar issues arise, or even if the system is working perfectly, it is still very important to continuously monitor the system.

By following these steps, we'll ensure that our system runs smoothly and efficiently, preventing future package drops and keeping operations running smoothly. We should stay focused on monitoring the system to make sure that the fix is effective, and if there are any new problems, we need to gather as much information as possible to prevent similar future issues.

In summary, our immediate focus is to get the AFC working perfectly again, ensuring all the packages are delivered in the right place. We'll keep you updated on our progress.

For more information on the conveyor systems and automation, check out these links: