Fixed path: Global retailer reduces downtime, improves diagnostics for tilt-tray sorters

In 2012, one of the world’s largest retailers decided to upgrade the control system at a key Pennsylvania DC. After replacing an outdated PC-based control system, the company improved visibility into machine diagnostics, production statistics and product tracking information for its high-speed tilt-tray sorters.

The tilt-tray sorters, also known as loop sorters, are highly sensitive to the timing at which internal switches need to fire (within 50 milliseconds). Missing the switch fire window would shut the entire sorter down. In addition to eliminating shutdowns, the retailer needed a solution to synchronize more than 70 motors on each of the four packing-sorter lines.

The retailer also was concerned with lost product in the sorter and its inability to track to particular store locations. This lack of insight and product tracking resulted in high rates of product shrinkage, which collectively cost the retailer hundreds of thousands of dollars in lost inventory annually.

The new industrial control system is driven by programmable automation controllers (PACs) in place of the legacy PC control system. Over the course of multiple weekends, the supplier installed eight PACs—two to control each of the four primary packing sorters. The controllers are networked to the devices on the sorting line, which provides ongoing feedback to the controller. The controller then communicates over EtherNet/IP with the new warehouse control system (WCS).

The new control system immediately delivered a significant reduction in lost inventory by tracking merchandise from the induction point to packing chutes and highly detailed reporting capabilities. Time devoted to preventive maintenance and troubleshooting was also reduced because controllers do not require regular software updates and aren’t accessible to multiple networks, thus decreasing exposure to viruses, malware and other PC complications.

Pyramid Controls
513-679-7400
http://www.pyramidcontrols.com

Rockwell Automation
440-646-3434
http://www.rockwellautomation.com