IDC's Low Cost Wireless Bar Code Solution for Conveyor Control Cuts Maintenance Costs & Boosts Operating Flexibilty

IDC’s low power ZigBee wireless technology is providing a simple, low cost solution for reducing maintenance costs and improving operating flexibility in plants with large conveyor control schemes, where a central PLC controls a line of several conveyors in sequence. With these multiple systems it is often a problem to run a single conveyor drive motor independently for maintenance purposes, such as tensioning the conveyor belt. However, with IDC’s new ZB111 bar code reader, with integrated keypad and screen, independent running of individual conveyors can be achieved simply and quickly with high levels of safety compliance.

IDC’s ZigBee system is a low cost wireless network that has minimal power requirements. It is easy to install and extend using a Gateway and routers. The wireless gateway connects to PLCs using standard Modbus TCP/IP protocol, and to PCs via a standard OPC connection.

The mechanics of IDC’s system involve the fitting of a simple unique barcode to each conveyor drive motor. The ZB111 is then used to scan the barcodes and show the drive details on its integrated LCD display. The Maintenance Engineer confirms details using keypad and selects maintenance mode. This operation can be integrated with normal/maintenance key-switch arrangements on electrical control cabinets for added safety. When the maintenance mode is confirmed, the engineer is able to stop and start the conveyor drive independently to perform maintenance.

Importantly, the ZB111- based system is easily configured for variable speed drives and increased safety applications, using a wireless heartbeat update that stops the drive automatically in case of wireless network failure. The device can also be integrated with wireless beacons and push buttons for a wider range of operations.

As part of these wider operations, the ZB111 can be used to improve operations in the manufacturing/materials handling facilities, by enabling system alarms to be received by specific operators during normal day- to- day operations.

For example, maintenance operatives can receive alarms generated by the control system for motor overload or low air pressure and take immediate action. Similarly a supervisor can receive an alarm or warning condition for potential delays, such as conveyor jams and chute full conditions.

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