To resolve the issue of random, uneven throughput, the company’s electrical team incorporated pulse and photo-eye sensors; a CompactLogix processor, PowerFlex 525 drives; servo motor controllers and VFD’s, to develop a new merge concept solution that alleviated the big gaps between product while allowing for more consistent spacing.
A virtual axis measures “pocket length” on the merging conveyor and a pulse is generated in specified inch increments of travel. A product is then released to the pulse on a FIFO basis. Whichever one arrives first is released first, but to the pulse.
This technology repotedly allows the company to have the same merge throughput running at 70 percent of the conveyor speed required previously. To invert that, it could merge 30 percent more product at the previous conveyor speed.
To view the product video, visit https://youtu.be/JSzgSW5tbfo.