Marston Gate. January 2025
The challenge
A multinational transport & logistics client approached Elmleigh to support the installation and communising of a new system to boost the site's production capabilities. We had previously worked with the client and site, on commissioning the original chute system, which included an upgraded conveyor system, 3 bespoke control panels, made at our in-house control panel workshop, integration of a third-party camera tunnel with an Intralox belt, to feed parcels to 16 new sortation chutes.
The control panels were situated at integral intervals along the line. Each panel was unique housing a varying amount of 0.37kW Schneider ATV320 drives, 15.0kW Schneider ATV320 drives, 0.37kW DOLs, and 0.75kW DOLs with a Siemens ET200SP I/O Rack in each. The 3 panels were connected to 57 product detection photocells and 100 estop buttons. The process worked beyond the client’s expectation, the new gate system providing the client with traceability for their product,
The new challenge our engineers faced was that the chutes were getting backlogged, causing unforeseen issues within the production line. As throughput increased within the factory, the chutes started to backlog. The unforeseen accumulation of product was partially due to previously not designating the cutes as accumulation zones.
The Teams
The solution
To overcome the backlog being created at the chutes, 16 new strategically placed PEC sensors were installed, and connected to the conveyor system via bespoke bracketry, manufactured by our in-house design and mechanical fabrication team. The brackets were crafted to be ergonomically less intrusive and situated at strategic points, communicating to the control logic that the chutes were operable until the backlog was removed. Adding these extra sensors meant alterations to the main centralised control panel; upon the sensors being triggered, 3 conveyor motors switch off in a staggered fashion enabling the operator to control the flow at an improved rate.
The outcome
As our Project manager supporting the project had experience with installing camera tunnels, they were familiar with the layout of the system. The resolution was implemented during the factory’s scheduled periods, enabling the system to be functional, and causing no loss of production capabilities.
Find out how Elmleigh can help
We are dedicated to ensuring each job we deliver not only is at the highest professional standard but also supports your future production growth. Our Project managers strive to build and maintain strong rapport with our clients, through these strong bonds, we have built safe work environments whilst supporting the developments of their process.
Enquire now by filling out the form on our contact page. Alternatively, contact us on 01455 847045. We are open to all queries you might have about our services and how we can help you.
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