IEN: Has there been a shift to COTS solutions in the MH sector? How are vendors meeting such demands?
Guernsey: COTS solutions are being utilized in the MH sector, but not as much as one would expect. There has not been more of a shift because most COTS solutions don''t work well in all systems. Therefore, you are still required to work in the complete system and not just as a standalone solution.
There are some situations, however, in which a COTS solution works well by itself. When this happens, you have an "island" of automation that is very happy doing its thing all by itself. But what we see most of the time is the need to incorporate the COTS solution into the overall system.
The main COTS solutions in use today are the ones that are compatible with an industry standard fieldbus such as DeviceNet or PROFIBUS. These systems are much easier to integrate into a complete system. No matter what the system is, there is always a need to communicate with the COTS components -- whether this is necessary for sending or receiving carton ID information, instructions, or just status information. There is usually a need to communicate with the system. When the COTS system uses a proprietary communication system or has none at all, it becomes very difficult to fit it into the system.
Many COTS systems like to "see" things a certain way. That is, if they need data, they need it in their own format. However, not all systems are that accommodating. At Tompkins Associates, we have developed the Tompkins Control System (TCS), designed to deal with many different automated systems (COTS) and manage them all as a unified system. By using distributed control throughout a system, TCS allows COTS systems to function as if they were standalone systems. TCS controls and monitors the complete system without the need to manage the details of the COTS system.
An example of this is Motorized Drive Roller (MDR) conveyor. The zone controller onboard the MDR module takes care of the MDR I/O. As with an MDR divert mechanism, TCS just tells the MDR which direction to divert a box without the need to control the details of the divert itself.
IEN: What innovations are in store for users of MH vehicles, equipment, systems, components, and software? Simulation? Wireless applications? RFID?
Guernsey: When it comes to difficult situations with conveyors, turn to an MDR solution first. Through extensive research at the Emerging Technology Center (ETC), a vast library of MDR programs has been developed using the Allen Bradley bulletin 1799 zone controller in combination with the TCS. This allows us to solve some of the most demanding material handling requirements. One of the unique features of this combination of MDR and TCS is the ability for the user to pinpoint a problem or jam when it occurs, right down to the 30 in. zone location and not just on a line of conveyor. Also, the MDR can still function normally downstream of the jam and automatically accumulate upstream from the jam. Often, the operator can fix the problem via any one of the GUI screens throughout the system. This is very helpful when the conveyor is 22 ft in the air! Recently, the ETC has developed an RFID encode, print, and apply solution using the TCS and MDR combination.
IEN: How do you cope with the pressure of evolving standards?
Guernsey: All companies that want to stay current need a research facility like the ETC to evaluate and incorporate new standards and new COTS developments.
Evolving standards require a system designed to handle change. Through PC-based control, fieldbus-connected devices, distributed control, event logging, system reports, and an easy-to-use GUI screen, the TCS can handle just about anything. Typically, TCS can update or change a system or program at a customer''s site without ever having to leave the office. This is truly coping with evolving standards in real-time.