Abstract: An automated overhead follower (AOF) system for a picking process includes an overhead rail, a motorized trolley configured to engage the rail and translate along its longitudinal axis in response to position control signals, a light projector connected to the trolley that emits a light beam in response to lighting control signals, and a radio frequency (RF) transmitter connectable to a tray. An electronic control unit (ECU) receives three-dimensional (3D) position signals from the transmitter as the tray moves along a bin aisle, identifies a bin zone in the aisle using the 3D position signals, and transmits the position control signals to a motor to command the trolley to move to the identified bin zone. The ECU also transmits the lighting control signals to the projector to illuminate one of more bins in the identified bin zone.

Abstract: A method and control system control a process line by providing a PLC with control screens each having a unique screen number. Each HMI device is provided access to a first set of the control screens, with displayed buttons labeled with a corresponding one of the control screens. Input signals are received from a requesting HMI device that identifies the requesting HMI device and requests a control action or a monitoring action for a corresponding workstation. Additionally, the requesting HMI device is provided access to a second set of the control screens based on the received input signals, such that the HMI devices share an HMI control template that is also dynamically and individually scalable to the requesting HMI device. The process line is then controlled via the PLC in response to control signals from the HMI devices corresponding to selections from the control screens.

Abstract: A position control system for a manual picking workstation having a plurality of component bins includes a light device and a process controller. The light device projects a light beam along a plane. The process controller includes a processor and memory containing a calibrated assembly sequence and predetermined bin coordinates for each of the component bins. The process controller executes a method to detect, via the light device, an instance of beam breakage wherein the light beam is interrupted or broken, and to determine two-dimensional (2D) coordinates of the beam breakage. The process controller also determines corresponding bin coordinates of an expected bin via the calibrated assembly sequence, compares the determined 2D coordinates to the corresponding bin coordinates, and executes a control action when the determined coordinates do not match the corresponding bin coordinates. The light device may be an oscillating laser scanner or fixed lasers.

Abstract: A position control system for a manual picking workstation having a plurality of component bins includes a light device and a process controller. The light device projects a light beam along a plane. The process controller includes a processor and memory containing a calibrated assembly sequence and predetermined bin coordinates for each of the component bins. The process controller executes a method to detect, via the light device, an instance of beam breakage wherein the light beam is interrupted or broken, and to determine two-dimensional (2D) coordinates of the beam breakage. The process controller also determines corresponding bin coordinates of an expected bin via the calibrated assembly sequence, compares the determined 2D coordinates to the corresponding bin coordinates, and executes a control action when the determined coordinates do not match the corresponding bin coordinates. The light device may be an oscillating laser scanner or fixed lasers.