The challenge
Moving heavy bar between bending stations by hand is slow and a real injury risk. The line needed material to index between operations reliably without an operator inside the working area.
How we approached it
Conveyor and transfer sequence controlled from a single PLC for deterministic handover
Position and presence sensing at each transfer point to confirm the bar before the next move
Interlocking so a transfer cannot start while a station is occupied
Fault handling that stops cleanly and reports the station rather than dumping the line
The outcome
Bar indexes between stations without manual handling
Operators stay outside the working area during normal running
Faults report by station, cutting diagnosis time
Applications
Conveyor ControlAutomated TransferSensor Integration
Industries
Construction