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20/08/2010
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IDC wireless bar code readers are helping to minimise maintenance downtime and costs at a major new distribution centre recently automated by the company.
 The devices are the battery-powered ZB111, and the unnamed organisation says that they are enabling supervisors and maintenance engineers to get instant notification of problems, such as conveyor jams and chute full conditions.
In brief detail, IDC's latest retailer DC project has 250 variable speed conveyor drives, as well as 20 print and apply labelling machines, 10 Omni barcode scanning points, 25 line scanners and 75 handheld barcode readers.
The conveyor drives are controlled from a central PLC, which controls the conveyors in sequence using photocells to detect when a box is present on each conveyor.
The problem normally arises when one of the conveyor drive belts needs to be adjusted, all others in the line have to be independently stopped and restarted.
However, in this latest DC project, IDC has overcome such problems and made tensioning quicker and safer, using the wireless barcode reader.
IDC reports that its device connects over a ZigBee wireless network to the site server, and then to the PLC in its central control panel. The company explains that, as part of the system, each electrical control panel at the DC has a maintenance/normal run keyswitch, while each drive has a barcode.
In operation, the maintenance engineer first selects the 'maintenance' position, before going to the drive and scanning the barcode he wants to control. Its LCD display then shows the drive number and the conveyor is started using the keypad.
Importantly, the system can be configured for variable speed drives and increased safety applications, using a wireless 'heartbeat' update that stops the drive automatically in case of a wireless network failure.
Incidentally, the same wireless bar code reader is also being used by maintenance engineers to receive plant alarms and prompt remedial action – for example, on motor overload or low air pressure.
Similarly, supervisors can receive alarms or warning conditions for potential delays, such as conveyor jams and chute full conditions.
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Author
Brian Tinham
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