Rapid Deployment of Assembly Lines Using the Smart Distributed System™

The Smart Distributed System™(SDS) offers companies that implement automated assembly lines the opportunity to cost-effectively respond to high-growth opportunities and quickly changing market conditions. Companies in dynamic businesses are continuously faced with changing capacity, and with how to ensure that their existing facilities are flexible and cost-effective. These companies also need to continually improve the information available from their assembly lines, and have pertinent data available throughout their business systems. Once a system is installed it also becomes critical to detect and remedy problems quickly.

This white paper describes how “Smart” control systems based on SDS and personal computers (PC) decrease design and installation costs, reduce operating costs and enable the use of an assembly line sooner than was previously possible. It explains the SDS architecture and describes some of the components that make up a Smart System. The paper closes with real-world examples.

The Benefits of Motor-Driven Roller Control

The use of 24-volt Brushless DC Motor-Driven Rollers (MDR) (also known as motorized roller or powered roller) in material handling systems continues to grow as users seek the benefits provided by a powered roller system, including:

  • Reduced power consumption
  • Improved control over each zone in the system
  • Lower noise levels
  • Improved safety from low voltage

Taking full advantage of the benefits provided by MDR requires the proper control configuration to evolve. Holjeron’s ZoneLink™ system provides users with three different levels of control:

  • Simple, Zero Pressure Accumulation (ZPA)
  • Smart Interface to ZPA
  • Individual Zone Control

This white paper explains how these architectures can be mixed within a material handling system to provide maximum flexibility to the user.

The Oregon State University Industrial Assessment Center recently completed an energy assessment of Xerox Corporation’s printer manufacturing facility in Wilsonville, OR. Among the findings was a determination that upgrading their current Belt-Driven Live Roller conveyor to a 24VDC powered roller conveyor system, similar to their system in the boxing area, would offer exceptional energy and maintenance savings.

This white paper presents how, in a comprehensive study of energy use in the facility, the OSU team discovered several opportunities to decrease energy use and increase productivity. Among the items featuring the best return on investment was retrofitting the existing Belt-Driven Live Roller conveyor with Holjeron 24 VDC Microroller powered rollers. Citing an estimated 1.4 year payback period, the assessment makes a strong case for the project. Originally set at a 2.1 year payback, several energy subsidy programs would help fund the project, resulting in 1/3 less payback time. In addition, the project would effectively renew a ten year old system to new active components and controls with a very small investment.

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