Modularized Control Algorithm for Automated Material Handling Systems

Automated material handling systems are widely used in industry due to high throughputs and good process quality. In order to fully utilize their potential, these systems have to be custom-built, requiring individually created control software. The engineering process of the control software includes extensive manual programming, because a modular structure of the control algorithm with predefined modules is often not available. We describe one such modular control algorithm, based upon a two-layer architecture that separates the hardware control from the material flow control. Our modular control algorithm allows predefined modules for both the conveyor hardware and material flow elements to be created and then assembled in the needed configuration. As a result, the control software for a custom-built material handling system can be created by arranging predefined modules and setting their parameters, thus without manual programming. The proper functionality of our control algorithm is demonstrated by a simulation example using emulated hardware.