In need of a counter that can keep track of the total number of products being shipped out, while alerting workers of surplus products, ATG Precision Products contacted DC-Digital for a solution. A new addition to our collection of package counter: This custom DC-10C-PKG-ANDON Full Box Max Counter is designed to help production teams accurately manage and control the maximum number of boxes being produced in a process. Built for industrial environments, this system provides a clear, reliable way to set a target count, automatically track each box as it passes the sensor, and immediately alert operators when the maximum count has been reached. By combining an easy-to-read digital display, a diffusive area reflective sensor, an ANDON light, and an audible alarm, this solution supports consistent workflow control and helps prevent overproduction.

At the core of the system, the operator sets a desired maximum count that acts as the production threshold. Once this maximum is defined, the diffusive area reflective sensor detects each box and increments the counter by one. When the preset maximum is reached, the system responds instantly by activating the ANDON light, which flashes red, and triggering the piezo alarm. This provides both visual and audible confirmation that the limit has been met, ensuring the condition is noticed immediately on the floor. After acknowledgment, the count can be reset back to zero using the environmentally sealed junction box, allowing production to resume smoothly and efficiently.

Setting and adjusting the maximum count is straightforward using the push button switches located on top of the enclosure. These buttons allow operators to fine-tune the count quickly without external programming or software. The second button increments the maximum count one value at a time, making it ideal for precise adjustments. For faster setup, the third button functions as the “set count” control, automatically incrementing the value without repeated presses. Pressing it again stops the auto-increment. If the count needs to be reduced, the first button decrements the maximum value, and pressing and holding it for three seconds resets the maximum count back to zero. Once the desired maximum is set, the display returns to zero and is ready to begin counting detected boxes up to that threshold.

When the sensor detects the set number of boxes, the system clearly signals completion. The piezo alarm mounted at the back of the enclosure sounds, and the ANDON light flashes red to indicate that the maximum count has been reached. To stop the alarm and reset the system, the operator presses the large red button on the environmentally sealed junction box. This action silences the alarm and resets the counter back to zero. The junction box also includes a dedicated decrement button, allowing the maximum display count to be reduced by one directly from the remote enclosure if adjustments are needed during operation.

Key operational highlights include:

• Automatic counting of boxes using a diffusive area reflective sensor
• Visual alert via a red flashing ANDON light at maximum count
• Audible alert through an integrated piezo alarm
• Simple reset and control using an environmentally sealed junction box
• On-enclosure push buttons for fast maximum count setup and adjustment

From a hardware standpoint, the DC-10C-PKG-ANDON Full Box Max Counter is built to withstand industrial use while remaining easy to read and install. The system is housed in a 14-gauge, black powder-coated aluminum enclosure that offers durability and a professional finish. The one-inch display can be viewed from up to 25 feet away, making it suitable for open production areas. With four digits, the counter can count up to 9,999 in single increments, providing flexibility for a wide range of applications. Power is supplied through a 120 to 240 VAC wall adapter with a six-foot power cord, allowing for straightforward installation.

Accessories and integrated components are designed to support reliable operation:

• Diffusive area reflective sensor with a 10-foot detection range
• Nine-foot sensor cable connected internally via terminal block
• Environmentally sealed junction box with 25-foot cabling to the opto base board
• Multicolored ANDON light configured to flash red at maximum count
• Piezo alarm connected directly to the ANDON light for synchronized alerts
• Three top-mounted push buttons dedicated to maximum count control

Overall, the DC-10C-PKG-ANDON Full Box Max Counter provides a dependable and user-friendly solution for managing box counts in production environments. Its combination of automatic detection, clear alerts, and simple operator controls helps ensure production limits are met consistently while maintaining efficiency and visibility on the floor.

See similar product: DC-10C-PKG

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