Converse Distribution Center, ONTARIO, CA
KDC Systems provided electrical and control system expertise to install and automate the Converse Distribution Center’s Conveyor Control System (CCS). The CCS consists of several different conveyor areas. Full Case conveyor transports all full cases directly to a Sawtooth merge. The Picking area consists of two levels, each with four pick fingers. After Split Cases pass through all necessary pick fingers, they too travel to the Sawtooth merge. The discharge of the Sawtooth merge feeds a twenty-three lane sorter consisting of 1 bypass lane, 1 Parcel shipping lane, 12 Value-Added Service (VAS) lanes, 1 error lane, and 8 shipping lanes. Two Case Sealers are fed by the sorter bypass lane and the VAS takeaway lanes. Case Sealer discharge merges with the sorter recirculation before reintroduction back to the Sawtooth merge.
Electrical work included: three-door Motor Control Panel (MCP) fabrication in our UL Panel Shop; installation of MCP and Operator consoles; installation of all photo sensors, scanners, safety, and other control equipment; conduit installation and wiring to all motors, sensors, scanners, and other control equipment.
Control system work included: designing, procuring, testing, and commissioning MCP c/w Allen Bradley Programmable Logic Controller (PLC), Variable Frequency Drives (VFDs) and Human Machine Interface (HMI) control hardware; interfacing with 10 Datalogic barcode scanners and data multiplexer; programming and commissioning all control system PLC, HMI, and database control logic; interfacing with Manhattan Warehouse Management System (WMS); and training personnel on control system database, configuration, operation, troubleshooting, and system recovery.