Problem:     A major supplier of precision conveyor systems needed to provide a system that would allow very precise movements. The system needed to be modular, easily adaptable to multiple configurations, to comply with some of the prevalent CE control systems and be low cost.

Solution:     The system provided used a distributed set of stepper motor controls that employed microstepping to achieve both smooth motion and precision movement. These motor drives were connected together within a particular conveyor segment using a CAN communications system. The result was a system that could be allow for flexibility of configuration, reliable operation, and low cost.

Several different controllers were developed. A single motor controller for straight line conveyor segments, a dual motor control for two way motion control, (used at corners or conveyor intersections), and a discrete I/O interface to allow limit switches, optical sensors, and other types of sensors and actuators to be controlled. Finally, we provided a Profibus to CAN gateway that allowed for a given conveyor subsystem to be controlled from a Siemens or compatible PLC.

The system had strict size limitations that resulted in the electronics boards being surface mount cards approximately 2 inches square.

The conveyor was powered from voltages between 20V and 40V (AC or DC). A proprietary high efficiency switching power supply was developed to provide the necessary voltages needed within the conveyor segment.