Low-Latency Roaming for Conveyor Vehicles on the Production Line
In automotive manufacturing, conveyor vehicles move workpieces along large production lines. These vehicles are equipped with battery-powered mobile workstations that must remain reliably connected to the central control system at all times.
- Client
- U.S. automobile manufacturer
- Cooperation partners
- Conductix-Wampfler, DACS and LESCO
- Project area
- North America, USA, Illinois
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Task Description
The mobile workstations on the conveyor vehicles needed to communicate securely and continuously via radio with the main control system (PLC). Both the reliability of the control system and compliance with functional safety requirements play an important role here.
A wired data connection to the moving stations was not possible due to the length of the route. A wireless solution was therefore an absolute prerequisite for the newly built system.
Implementation
R3 Solutions was commissioned to implement the wireless connection in this newly built environment. Safety data (BBH DSI), control data (LJU UDP), and non-time-critical data (TCP/IP) are transmitted in parallel over the wireless network.
The network comprises a total of 124 devices and covers a 660-meter-long production line. Seamless roaming ensures that there are no interruptions even when switching between radio cells—while maintaining continuous real-time control.
“A truly cutting-edge solution: a fully wireless skillet system using radio communication and battery-powered technology instead of traditional busbar or inductive systems. What makes this technology remarkable is not only its reliable, low-latency wireless communication and data transfer, but also its ability to transmit critical safety signals—such as E-stops—wirelessly with the responsiveness and reliability of a wired system.”
Rafael Orozco
Conductix-Wampfler Automation
Result
Thanks to careful advance planning, the components could be installed quickly and easily. Future maintenance requirements will remain low, as the wireless components used are not subject to wear and tear. In addition, the wireless connection offers a high degree of flexibility for future adjustments to the production line.
Project Data
| Network size: | 124 devices |
|---|---|
| Real-time protocol: | BBH DSI (Security), LJU UDP (Control) |
| Other data transmission: | TCP/IP (non-time-critical) |
| PLC cycle time: | 50 ms (control) and 96 ms (safety) |
| Coverage: | 660 m production line |
| Roaming: | Yes, seamless with real-time control |
| Monitoring: | No |
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