Distributed control aids conveying applications

The Simplicon distributed control system can substantially reduce the overall project costs and complexity associated with centralised control systems in conveying applications.

The Simplicon distributed control system can substantially reduce the overall project costs and complexity associated with centralised control systems in conveying applications.

Simplicon provides the ideal control solution for modern conveyor control systems from simple, single line conveyors to sophisticated merging and sorting systems.

The intelligent, networked system is also ideal for materials handling, palletising, intelligent picking and routing operations.

"What makes Simplicon superior to existing technology is not the obvious advantages of reduced cabling costs, or quicker installation time but the hidden benefits that extend throughout the whole lifecycle of a project", says Kevin Buckley, founder and Managing Director of IDC.

These fall into seven basic categories.

Project tendering and estimating can be much more accurately defined.

Bid interpretation, defining an offer and presenting a control solution can be much more easily quantified and qualified.

Software complexity and program size are both greatly reduced.

Hardware, mechanical, electrical and control elements can be built and tested independently before shipment.

Documentation is standard for each element and definable.

Existing installations can be easily upgraded or extended where cabinet space would otherwise prohibit.

And with Simplicon commissioning is a tuning rather than debugging exercise.

"What we have achieved with Simplicon is a system that reduces cost, time and risk in the project management of control systems both complex and simple.

By developing a control methodology that is modular in both hardware and software, we are able to fix the costs of control systems early in a project and facilitate standardisation of designs and documentation, from initial design proposal through to final commissioning".

"In addition, with our multiprocessor Windows-based Simplinet software we have overcome cost and dependency on high-level software programming skills and in-depth communications knowledge.

Simplinet is incredibly easy to use and the fact that it is modular eliminates repetition, whilst the provision of preprogrammed functions provide the control system designer and system user with the benefits of tested designs and proven performance".

"The building blocks of our system are intelligent Simplicon modules that simplify control system design by distributing intelligence throughout a plant rather than by consolidating it at a central point such as a PLC.

This methodology overcomes the issue of growing software complexity and program size with centralised control systems, enabling even the most complicated machine sequences to be broken down into simple, separate control tasks, where each task has its own intelligent processor relating to the mechanical sub assembly or plant section being controlled.

Once this is achieved, each module is networked to provide a true multi-processor system solution, the peer-to-peer system resulting in a more efficient communication network where traffic is reduced as a result of decisions being taken locally".

"In contrast to PLCs, we have not adopted a broad, 'Jack of all trades' policy in respect of Simplicon technology, rather we have decided upon the optimum technology platform for typical applications such as conveyor control.

Because most conveyor applications can be broken down into simplistic operations, we have opted for using well-proven high-speed low-cost 8bit processors.

Moreover, in a distributed architecture system such as Simplicon, communications are obviously critical, so we employ an RS485 based protocol, which optimises bandwidth between Simplicon micro and pico units.

For larger systems employing several micro units a communications module is fitted which provides high speed Ethernet communication as standard, with Profibus and DeviceNet options to be developed later".

"We have also designed our own IEC61131 compliant, Windows-based multiprocessor Simplinet software, which is probably most important element of the Simplicon system".

"Simplinet is the synergistic element that actualises the Simplicon distributed control approach.

Extremely simple to use, it enables the realisation of single cells associated with individual tasks, naturally breaking down the complexity of a machine and providing the control engineer with the ability to quickly design and configure his control system".

"Once a system is configured the software is downloaded to the network automatically.

In instances where independent equipment assembly testing has taken place, additional configuration may be downloaded (eg interface parameters for communication with other equipment assemblies).

The parameters of the system during installation and commissioning can then be optimised via the LCD panel and keypad user interface.

Alternatively, parameters can also be modified using the configuration host PC", concludes Buckley.

The Simplicon range is being launched to the world market in the first quarter of 2004.

Back to top