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Warehouse Upgrade Replaces 28 Controllers with 1 Beckhoff IPC

Writer's picture: Doug SchuchartDoug Schuchart

Layer Seven Automation delivers an open control system to reduce maintenance costs, increase efficiency, and future-proof operations for a major Australian office supply vendor

Warehouse with magenta metal racks and conveyor belt. Box and wrapped package on conveyor. Industrial setting, vibrant colors.

From paper and staplers to desktop PCs and desk chairs, the Australia-based retailer Officeworks ships a broad range of products that help workplaces run. Like other major retailers with a mix of brick-and-mortar and e-comm sales, warehouse logistics is part of the critical infrastructure.


The company operates more than 100 stores across Australia as well as an online store with more than 40,000 products. At the main distribution center, the stored goods are removed from shelves and packed into boxes, then transported along various conveyor lines, and prepared for shipping. The conveyor system stretches for nearly half a mile (700 meters) across 28 distribution stations.


A stretch of conveyor in the distribution center for Officeworks
In Officeworks’ extensive central warehouse, Layer Seven Automation replaced the proprietary, outdated warehouse logistics control technology with EtherCAT and PC-based control from Beckhoff.

While the conveyor lines had operated reliably for many years, the systems were reaching the end of their service life. Malfunctions were occurring more frequently, and the required spare parts had become increasingly difficult to obtain and more expensive due to the age of the system.


The office equipment retailer commissioned Layer Seven Automation to develop a concept to modernize the warehousing system. Based in Bella Vista (in the Sydney metropolitan area), Layer Seven specializes in warehousing and logistics projects. The automation expert’s evaluation found that the mechanics of the main conveyor belt remained solid, but the control system required replacement.


“One of the disadvantages of the conveyor system was its proprietary structure,” says Lucky Thommadura, Co-Founder and Chief Engineer at Layer Seven Automation. “Every part had to be purchased from the manufacturer, which would have made it even more difficult to expand the system.”


Upon further analysis of the system and the end user’s requirements, Layer Seven recommended configuring an open system based on off-the-shelf products, explains Thommadura: “This would offer a future-proof solution and reduce maintenance costs.”

 

How one industrial PC replaced 28 controllers


A Beckhoff C6920 used in an intralogistics application
A single C6920 control cabinet Industrial PC (left), which controls all the stations in the extensive logistics system via EtherCAT, replaced the decentralized control technology of the 28 stations.

The original system configuration was based on one controller and one barcode scanner for each distribution station. Layer Seven Automation’s aim was to create a centralized control architecture that would increase the efficiency of the system and reduce costs.


The barcode scanners at each station are essential for recording the contents of the boxes. Here, Layer Seven Automation opted for scanners that can be configured via an EtherCAT interface and have integrated I/Os for simple control functions. The inputs detect the boxes via opto sensors, for example, while the outputs switch the switches or pushers according to the destination station.


First, a single distribution station was converted and its scanner was connected to a C6920 control cabinet Industrial PC (IPC) from Beckhoff via EtherCAT. Following successful tests, all 28 stations were migrated in stages and daisy-chained to the C6920 in a linear structure, which easily supports the necessary redundancy to keep warehouses moving.


Man in yellow vest smiles in a warehouse aisle, surrounded by boxes and conveyors. Bright lighting, red shelving, and region signs visible.
Lucky Thommadura, co-founder and chief engineer at Layer Seven Automation, sees incredible advantages in integrating TwinCAT with its existing IP and IT infrastructures. 

“The technicians of the logistics company and I were surprised by the compactness of the solution, the fast update rates of the EtherCAT network, and the overall speed of the controller,” Thommadura says.


After all, the barcode on the box has to be scanned and forwarded to the IPC via EtherCAT. There, the application determines whether the switch of the corresponding station needs to be energized and sends this information back to the barcode scanner via EtherCAT.


“The Beckhoff Industrial PC manages the extensive calculations in around 100 µs, which is phenomenally fast,” says Thommadura enthusiastically, “and yet we still have reserves.”

 

PC-based control: Secure, open, and flexible


The engineering team at Layer Seven Automation has extensive experience in software development – for example, in setting up databases or creating web servers. The fact that TwinCAT is integrated into Microsoft Visual Studio® was another reason for the chief engineer to invest in Beckhoff and EtherCAT.


“I really believe that this is the way automation technology needs to go – away from closed systems with Ladder Diagram programming and outdated signal processing. We need to take established software design and architecture practices and combine them with automated testing so that we can deliver our solutions more effectively,” Thommadura adds.



A major advantage of PC-based control, according to Layer Seven Automation, is a control architecture that’s easier to integrate into existing IT systems. This was another pleasant surprise for Thommadura.


Conveyor system using PC-based control technology from Beckhoff
Barcode scanners with an EtherCAT interface detect incoming packages via integrated I/Os and receive the positioning commands for controlling the switches from the central control computer.

“Many IT departments have very strict security requirements, but Windows is always easy to integrate. The firewall, security settings, and global user administration have made our work here much easier," he says.


The option to use Windows, along with TwinCAT/BSD and Linux operating systems, has enabled Layer Seven Automation to run its own programs alongside TwinCAT software. For example, an SQL database was integrated via TwinCAT 3 Database Server (TF6420), which archives the details of a box every time it is scanned. This action is permanently recorded and logged in the TwinCAT 3 EventLogger.


In addition, Layer Seven created a dedicated message queue system based on the ADS (Automation Device Specification) protocol. This system uses ADS to extract data and ultimately link it to the RabbitMQ message broker software.


“ADS technology from Beckhoff offers almost unlimited possibilities,” adds Thommadura. “We use ADS to collect the recorded volumes of data and distribute them both horizontally and vertically. It can also be used to easily integrate almost any MES or ERP system.”


How can advanced automation get your conveyor applications moving in the right direction? Contact your local Beckhoff sales engineer to learn more.


 

Doug Schuchart of Beckhoff Automation

Doug Schuchart is the Global Intralogistics Industry Manager for Beckhoff Automation

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Beckhoff Automation LLC

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Savage, MN 55378

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