The challenge
A conveyor system capable of moving CHEP pallets through five manual assembly stations at up to 75 units per hour with precise speed control, SKU based throughput targets, and seamless changeover between product variants.
The system had to perform reliably in a live production environment with low-skill operators, integrate safely with MHE at the take-off end, and remain remotely accessible for ongoing diagnostics and support.
The Solution
Cable Automation designed and delivered a fully integrated control system built around a Beckhoff PLC running TwinCAT 3 — providing synchronised control of five AC motors via Modbus-connected Invertek drives. SKU-based throughput targets, and belt sequencing logic were all managed programmatically.
- Beckhoff TwinCAT 3 PLC with Modbus control of five synchronised AC motor drives
- Web-based remote HMI with live digital twin showing real-time sensor, lamp, and e-stop states
- Automated pallet load sequencing with sensor-driven belt logic and operator alerting
- Integrated safety circuits and e-stop network
The HMI was built to be operable at any skill level, with clear operator instructions, SKU preset selection, and CPH speed adjustment via simple digital controls. Remote access over a secure data connection allows diagnostics and support without requiring an on-site visits.