Case Studies

Order Consolidation System, UK

System Type: Tote conveyor with miniload

The order consolidator system receives totes containing picked orders from various parts of the warehouse and routes them to the relevant pick faces to allow the operator to group items together in an order-tote in readiness for shipping.

Control is performed via a Siemens S7-400 PLC with distributed control of seven high-speed servo-controlled lifts connected via profibus. Visualisation is integrated into the existing site wide Wonderare SCADA system allowing the operator to drill down to perform detailed fault analysis. Totes are identified at each decision point around the system by a network of bar code scanners. A telegram exchange takes place between the Ge-Mac system and the WMS and a destination is assigned to the tote. The Ge-Mac system interfaces to the crane control via ethernet to handle the physical transfer of the totes to and from the crane.