Controlling Actuators and Devices in Motion on Multicarrier Systems

Multicarrier systems are revolutionizing industrial automation by enabling flexible and independent movement of carriers within production lines. These systems are being adopted across various industries to enhance scalability and operational flexibility. The ability to precisely control actuators and devices while in motion is crucial to optimizing performance and ensuring smooth workflows.

Traditional conveyor systems that have long been used in automation often lack the precision and adaptability required for modern production needs. Multicarrier systems address these limitations by providing greater control over individual carriers.

While packaging applications are among well-known use cases, industries such as electric vehicle (EV) battery assembly, solar panel assembly, e-commerce logistics, and pharmaceutical manufacturing are also leveraging these advanced systems.

Key Takeaways

• Multicarrier systems revolutionize automation by enabling precise, independent movement of carriers
• Traditional wired control methods limit adaptability, introduce maintenance challenges, and can impact real-time responsiveness.
• Wireless communication solutions like IO-Link Wireless enhance actuator and device control by reducing wiring constraints, improving flexibility, and enabling machine designs unattainable before.
• Industries such as packaging, EV battery assembly, and logistics benefit significantly from multicarrier systems enhanced by IO-Link Wireless

Understanding Multicarrier Systems

A multicarrier system consists of independently controlled carriers that move along a track, guided by electromagnetic or linear motor technology. These systems allow for precise positioning, acceleration, and deceleration of individual units each moving in a variable pitch. This makes them ideal for high-speed and high-precision applications.

Unlike conventional conveyor belts or rotary systems that move all items at a uniform speed, multicarrier systems allow dynamic and independent motion. This enables customized workflows, efficient sorting, and adaptive process management.

Challenges in Controlling Actuators and Devices in Motion

The main challenges factories face when controlling actuators and devices in motion are: 

Synchronization and Real-Time Communication

Achieving precise synchronization between moving carriers and actuators requires seamless real-time communication. Even minor latency can result in misalignment, reduced accuracy, and operational inefficiencies.

Traditional Wired Limitations

Conventional control methods rely on wired connections such as slip rings and cable tracks, which introduce several challenges:

• Cable Wear and Maintenance: Continuous movement leads to cable fatigue, requiring frequent maintenance and replacements.
• Limited Flexibility: Hardwired systems restrict adaptability, making it difficult to modify workflows, requiring manual changeovers for supporting multiple product types, and complex for modifying machine design and retrofitting.
• Limited Speed: systems requiring high speed motion that are constrained by cables can be limited by speed 
• Large Footprint: cabled communication machine design dictates a larger machine footprint and also requires more external equipment (such as robotic arms and delta robots) along the multicarrier system track.

Flexibility Constraints

Multicarrier systems often need to accommodate a wide range of applications, each with unique motion control requirements. Rigid control architectures can limit system adaptability, making it difficult to optimize performance for diverse operational scenarios.

Wireless Solutions for Effective Actuator and Device Control

Wireless & Contactless Communication on Multicarrier Systems is crucial for creating fully automated, innovative, and competitive machine designs not possible before, for packaging, assembly, logistics, and material handling. Industrial wireless solutions like IO-Link Wireless eliminate the constraints of traditional wired systems. It enables fast and reliable communication between actuators, sensors, and controllers. 

Wireless communication on the mover enables devices (e.g., grippers, pumps, valves) to perform actions while in motion. By wirelessly controlling these, the reliance on external equipment, such as robots and delta robots, is eliminated, enabling the flexible processing of diverse products/packages through a seamless and uninterrupted high-speed workflow. 

Traditional solutions require manual changeover and dedicated/custom tools to suit the specific product size and form factor. All of these can be eliminated by using IO-Link Wireless. Real-time wireless control for continuous actuation while in high-speed motion enables changing multiple product types (shape, size, material) on the fly.

Independent control of each mover allows changing package variations while in constant motion without external robotics. Wireless control of devices, such as servo motors, on the movers enables the adjustment of product orientation during motion.

Benefits – Adaptive, Efficient, Sustainable

Some of the benefits of IO-Link Wireless for effective device control in motion include:

• Reduced Changeover Time: Support multiple product and package variations on a single machine with automatic changeover and maximum flexibility, while eliminating manual changeovers.
• Reduced Maintenance: No physical wear and tear from moving cables.
• Faster Setup and Reconfiguration: Eliminates the need for extensive wiring, allowing for rapid deployment.
• Scalability: Easily integrates additional devices without extensive modifications. A combination of sensors and actuators can communicate wirelessly on a single mover.
• Cost Effective: no need to use multiple carriers for gripping products in motion. Sustainable & cost-effective design reduces external automation equipment and machine footprint, energy consumption, and number of machines.
• Increases ROI by maximizing machine throughput and utilization.

AI and Predictive Analytics

Artificial intelligence (AI) and predictive analytics further enhance multicarrier system performance by:

• Anticipating Equipment Failures: Detecting early signs of actuator wear and proactively scheduling maintenance.
• Optimizing Motion Profiles: Continuously adjusting movement parameters for maximum efficiency.
• Enhancing Quality Control: Identifying and correcting deviations in real time to maintain product quality.

IO-Link Wireless supports predictive analytics by providing the tools necessary to collect data in motion. Analysis of data collected wirelessly from the moving components improves quality, reduces waste, increases speed, and prevents unplanned downtime. Multiple sensors (e.g., vibration, vacuum, load cell) connected wirelessly on each mover enable predictive maintenance and increased visibility.

Solution Architecture Advantages

Integrating IO-Link Wireless for control and monitoring in Multicarrier Systems also brings architectural advantages, such as:

• Vendor agnostic – compatible with any multicarrier system type 
• Multiple devices – a combination of sensors and actuators can be connected simultaneously on a single mover.
• Device agnostic – converts any IO-Link, Digital, or Analog device to IO-Link Wireless.
• Scalability – supports hundreds of wireless devices on a single machine.
• Unrivaled performance – cable-grade reliability without trading off speed, while coexisting with other wireless networks 

Industry Applications 

Multicarrier systems play an important role in many industries. Enhanced by IO-Link Wireless, they can help manufacturers achieve exceptional results and make smart conveying systems flexible and smarter than ever. 

Packaging & F&B

Multicarrier systems in packaging manufacturing are used to enhance the flexibility and efficiency of material handling and transport within production lines. They enable the independent movement of multiple carriers (or shuttles) on a single-track system, which allows for precise positioning, sorting, and handling of items in various stages of the packaging process. These systems are particularly valuable in high-speed, high-mix production environments where different packaging sizes, shapes, and types need to be processed simultaneously or sequentially.

Key uses include:

1. Product Sorting and Routing: Multicarrier systems direct products to specific packaging stations based on product type, size, or other criteria, improving the customization of packaging workflows.
2. Increased Throughput: By allowing multiple carriers to operate independently, these systems increase production speed without sacrificing precision or quality.
3. Flexible Manufacturing: Multicarrier systems provide greater adaptability to changing packaging formats and batch sizes, enabling quick changes and reconfiguration to meet market demands.
4. Improved Handling of Delicate Products: They allow for gentle, precise handling of fragile or sensitive items to reduce damage during the packaging process.
5. Optimized Line Efficiency: By streamlining product flow and reducing bottlenecks, multicarrier systems help improve overall operational efficiency in packaging lines.

IO-Link Wireless further enhances these systems. It reduces wiring constraints and improves system adaptability for dynamic packaging processes.

Watch this video of Rotzinger PharmaPack’s packaging machine with IO-Link Wireless, and learn how Rotzinger enabled their line of machines with additional multiple benefits: 

• Adaptive – Full flexibility to support multiple product types (support for different product sizes can be automatically adjusted per mover) and package types (one, two, three or more primary product packages per secondary package).
• Reduced changeover time – eliminate manual changeovers.
• Machine footprint reduction – reduce additional external robots, cables, or other types of equipment.
• Sustainable – less energy, space, and parts need to be used within a machine.
• Handle small batches efficiently – decreased number of machines, as the solution allows for one machine to handle various products and package designs.

EV Battery Assembly Systems

The EV industry requires precise positioning and handling of battery cells and modules. Multicarrier systems provide:

• Accurate Placement: Ensuring correct alignment of cells during module assembly.
• Flexible Production Lines: Allowing for multiple battery configurations on the same system.
• Increased Throughput: Reducing cycle times while maintaining quality control.

By providing seamless, interference-free communication, IO-Link Wireless facilitates real-time monitoring and adaptive adjustments, ensuring precision and efficiency in EV battery production. 

Key benefits include:

• Sustainability – Energy conservation due to smaller clean rooms required for smaller machines
• Flexibility – support a variety of battery sizes, simple sorting, and ejecting of damaged sheets
• Capacity – high-speed movers enable increased capacity

Crossbelt Sortation Systems

In logistics and material handling, crossbelt sorters powered by multicarrier technology offer:

• Efficient Parcel Sorting: Handling diverse package sizes and weights with precision.
• Reduced Processing Time: Minimizing delays in distribution centers.
• Scalable Automation: Adapting to fluctuating demand with minimal system modifications.

IO-Link Wireless ensures reliable sensor communication for high-speed sorting, reducing latency and enabling flexible automation in e-commerce and logistics operations.

Key benefits include:

• Scalability – Modular design enables simple expansion and deployment
• Speed & Precision – Low latency enables the narrowest discharge area for handling small items, increasing resolution and better space utilization
• Reliability –  designed for harsh industrial environments high-speed motion applications
• Cost Effective – reduced maintenance and commissioning effort

Watch this video of crossbelt sorter systems utilizing IO-Link Wireless. 

Other Use Cases

Multicarrier systems are also making a significant impact in:

• Automotive Manufacturing: For moving and assembling various components like engine parts, interior fittings, and other modules, ensuring flexibility in handling different models and configurations.
• Electronics Assembly: Facilitating accurate positioning of small, sensitive parts.
• Pharmaceuticals: Enhancing the accuracy and reliability of medication packaging and handling.

Across these industries, IO-Link Wireless enhances automation by providing real-time, wireless data exchange, reducing downtime, and ensuring high-precision handling of critical components.

Advanced Control with IO-Link Wireless

As industries continue to push the boundaries of automation, multicarrier systems are emerging as a game-changing technology. Overcoming traditional challenges in actuator and device control requires advanced solutions, a key one being wireless communications powered by IO-Link Wireless. 

As industries continue to evolve, investing in these advanced solutions will be key to maintaining a competitive edge and meeting the demands of an ever-changing market.