Intralogistics: pallet patterns, sway and conveyors tuned on site
Palletisers, conveyors and sorters are tuned on site and sway at speed. How simulation and motion optimisation shorten commissioning and cycle times.
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Pallet patterns and sway limit the cycle time
What happens. A palletiser has to place cases or sacks in many patterns. At speed the load swings, the gripper arm vibrates, and the programmer slows the motion until the stack no longer shifts.
What it costs. Cycle time and throughput of the line, and a gap between the nominal speed in the brochure and the speed customers actually get.
Why the usual fix fails. Reducing acceleration by hand finds a safe speed for one product but leaves time unused for the next. Stiffer mechanics make the machine heavier and more expensive.
How a fixed-price remote diagnosis checks it. From axis and drive logs and a few measured motions I identify the sway of the load and compute a motion that is as fast as the dynamics allow. The fixed-price remote diagnosis shows how much cycle time is available for your palletisers before changes to the mechanics.
Background: Optimal paths and setpoint plans
Digital twins and virtual commissioning of conveyors
What happens. Makers of conveyor and material-handling systems are asked for digital twins and software-in-the-loop tests, so that large installations can be commissioned in a simulated environment before the first belt is mounted.
What it costs. Without it, faults appear at the customer, and each day on site is costly. With a twin that does not match reality, the team is falsely confident.
Why the usual fix fails. A twin made only to show an animation does not test the controls. Building a physical model of drives, belts and sensors takes people who are in short supply.
How a fixed-price remote diagnosis checks it. I check which parts of a conveyor system need a dynamic model for pre-tuning to be meaningful: drives, accumulation, motion between sections. The fixed-price remote diagnosis shows what a simulation for your system types must contain and how much commissioning time it could save.
Motion control and emulation of sorting systems
What happens. A sorting system moves hundreds of parcels or items with tilting trays, cross belts or pushers, all timed to the millisecond. The motion control must be built, emulated and integrated with the rest of the system.
What it costs. Mis-sorts, jams and slow ramp-up when the system is first run at full speed. Engineers who understand both motion control and the logistics software are hard to find.
Why the usual fix fails. Testing on the real machine finds timing problems late. Emulation of only the signals does not show whether a drive can follow the motion profile.
How a fixed-price remote diagnosis checks it. From drive data, speed profiles and timing requirements I check whether the planned motion is achievable by the drives and what emulation should cover. The fixed-price remote diagnosis tells you where the risks in your sorter design are before integration.
Background: Optimal paths and setpoint plans
More problems that concern this industry
These problems are described on the page of the industry where they matter most:
- Conveyors: accumulation and gaps in the product flow (Packaging machine builders)
Check it on your plant first: a fixed-price remote diagnosis
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Within a fixed scope and at a fixed price, I review your data, control structure and measurements remotely and tell you whether the problem on this page is behind your symptoms and what fixing it would take. You get a short summary for decision-makers and a technical report for your engineers.