Summary
DMC programmed a high-throughput robotic automated order-fulfillment machine, including interfacing with the end-user’s order-fulfillment database and integrating Fanuc CRX robots and barcode readers. In addition to being fully integrated with the on-premises MES, the software allows for dynamic setup of new products and machine tooling from the user interface—no code changes required. DMC based its software architecture on Beckhoff’s SPT Application Framework, which was successfully adapted for several successive machines for the same customer.
Customer Benefits
Higher Technician Efficiency
Replaced a manual process, which freed up technicians from the menial task of scanning and labeling products—allowing them to focus on other operational duties.
Increased Throughput
Exceeded the customer’s throughput goal, surpassing the existing manual process and providing capacity for higher order volumes.
Flexible Order Prioritization
Enabled dynamic prioritization of high-volume orders through HMI configuration, allowing the system to adapt to changing production needs.
Scalable Software Framework
Developed a software framework that supports multiple machines, enabling easier standardization and future scalability.
Solution
DMC had previously worked with the client to implement an automated order fulfillment system that could only dispense, label, and inspect a single type of product. This second system has significantly increased complexity by supporting multiple products of varying shapes and sizes and, as a result, has required a much more complicated tracking and order-fulfillment process. DMC worked extensively with the client to understand the client’s order management system and to integrate this new cell to read order data and match it to a tote. This involved setting up an internal database to track upcoming orders, monitor the progress of current orders, indicate when orders were not filled, and update the client’s order management system when orders were completed.
The need to support many different products meant that a new system had to be developed to track available product types. DMC programmed a system for tracking product types in the machine, as well as processes for swapping products, adding new ones, and managing machine tooling to support different products. The machine was integrated with a label printer, applicator, and barcode scanner, which worked at high speed to label and validate each product before it was dispensed.
The project involved a wide range of automation hardware and communication protocols that DMC had to integrate, including IO-Link, Serial, Fanuc Robotics, Stepper Motors, Servos, and even USB devices.
Key Technologies
- Beckhoff PLC with TwinSAFE Safety Control
- TwinCAT HMI for Visualization
- Fanuc Robotics
- MSSQL Database Connectivity
- Beckhoff AX5000 Servos
- SMC JXCE1 Stepper Motors
- IFM IO-Link Master with IFM Barcode Scanners
- RS232 RFID Readers
Learn more about DMC’s Manufacturing Automation expertise and contact us for your next project.