Start Small and to Build to a System of 32 Loaders; New Material Handling Control from Conair Offers High-End Capabilities in Simple, Low-Cost Package

The new FLX material handling control from The Conair Group, Inc., gives users the ability to build a system of up to 32 loaders and ten pumps, including such high-level functions as multi-source/multi-destination loading, ratio loading, reverse convey for regrind recovery, fill sensing, and more. They can start with a basic system of just 8 loaders and 2 pumps (with one back-up pump), and increase capacity and capabilities in manageable increments when necessary, simply by adding input and output cards.

The PLC-based system has a 5.6-inch color touch screen operator interface on the central control box. The graphical display is easy to read, easy to use and requires minimal, if any, operator training. Color-coded icons let operators know the status of connected equipment at a glance. Any interruptions to optimum processing are clearly signaled for fast resolution with no nuisance alarms. Alarms can be programmed as active (disabling the device being alarmed) or passive, allowing operation to continue until maintenance staff can identify the problem. Built-in help screens simplify troubleshooting.

To give production personnel convenient access to set-up and data screens, remote human-machine interface units (HMIs) can be connected to the system. The FLX system is also Ethernet-capable and has a built-in webserver, so any personal computer on the same network can display the system status as a web page.

While designed to be affordable and easy to install and expand, even a relatively modest system can have many advanced capabilities. For instance, loader calls for material are handled on a first in/first out (FIFO) basis. Most other controls simply poll every loader sequentially, which means some loaders may actually run out of material before they can be filled. With the FLX control, however, demands are filled in the order received. Certain loaders can even be given priority status, becoming the next receiver filled regardless of what other requests may exist in the system.

When configured for ratio loading, the control can be programmed to load either virgin or regrind first. Layering sequences can be calculated automatically or manually.