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Modern Materials Handling
Conveyor E-Newsletter Vol 5
In many ways, integration of a new conveyor system is like preparing for the
big game. Think of yourself as the coach. The goal is to have your new conveyor
communicate and coordinate with other materials handling equipment and existing
information systems. Your game plan is to seamlessly integrate all of the
individual components of the new materials handling team. Software and controls
are your playbook.
In this scenario, "The entire network infrastructure needs to be planned
well in advance," says Randy Hardeman, vice president of research and
development for Fortna, Inc. Fortna is a materials handling distributor and
integrator headquartered in Wyomissing, Pa.
Hardeman says that the first step of integration is to define all of the
information that needs to pass to and from the host system, the conveyor, and
other materials handling equipment. The host may be a warehouse management
system, a manufacturing execution system, or other management software. Every
piece of equipment that has a need for some type of control also needs to be
identified.
"There are lots of thinking machines on the floor that control
equipment," adds Hardeman.
A control vendor has to be selected along with a connection system.
Ethernet-based controls are ideal for the factory or warehouse floor, as they
can be easily monitored or controlled from a PC located just about anywhere in
the facility or even offsite.
"TCP/IP is really the language of the world now,' says Hardeman. "It
allows control of just about anything."
In some cases this may mean upgrading legacy systems to assure they will work
with Ethernet. Programmable controllers, for instance, may be replaced with
PC-based controls. A serial connection may also be required to integrate a
legacy system.
Hardeman next develops a functional document that details the required
communications specifications. This includes information flowing to and from the
hosts, control requirements, and data rate specs. One communications server is
usually designed to handle routing of the information.
The data transfer rates are extremely important, as the integrator needs to make
certain they will be adequate for the desired throughput.
"If you need to get 100 boxes out the door each minute, but you can message
only 98, you are in trouble," observes Hardeman. Once all the integration
planning is completed, it is time to test the system. Fortna uses simulations
for some of its testing and also evaluates individual modules before shipping
product.
"You want to make sure that all the information gets to where it needs to
go before you ever get on site," adds Hardeman.
New modular designs introduced in recent years make testing and troubleshooting
problems much easier.
The final step in integration comes after installation, during the startup
period. Throughput testing makes sure that the system matches the design
parameters. The control code helps here to uncover any flaws in the system.
"The control code is the front line of troubleshooting," adds Hardeman.
"If you have good control code you can find any problems in the pneumatics,
electronics, and mechanical systems that may exist at start-up."
If all works as designed, productivity should follow, and you have won the big
game. Next month: Installation considerations
Conveyor E-Newsletter Vol 1: New
standards for conveyor industry
Conveyor E-Newsletter Vol 2: Ten
questions to consider before starting your new conveyor project
Conveyor E-Newsletter Vol 3: What
you need to know before you select a conveyor system
Conveyor E-Newsletter Vol 4: Conveyor
choices
Conveyor E-Newsletter Vol 5: Investigate
before you integrate
Conveyor E-Newsletter Vol 6: Ten
things to know before installing your new conveyor system