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Assembly Line Conveyor System Solution in Bangalore, India | Insys Electrical

Assembly Line Conveyor

Advanced Solar Inverter Manufacturing System

Our Projects

ASSEMBLY LINE CONVEYOR

Project-Eleven-Insys-Electrical

Application

Assembly Line Conveyor

Product

PL100 Base Modules, I/O Extension Modules, Proface 7" HMI.

System Overview

30m

Conveyor Length

Total System

8

Control Stations

7 + 1 Master

8

PLC Controllers

Networked

1

Master HMI

7" Proface

Description

It's a 30mtr long conveyor meant for assembling Solar Inverters. Conveyor have 7 stations & 1 main control Station, each station have 1 control panel with PLC base module & extension to control station individually. Each station is equipped with 2 induction Motors, 3 stoppers, 3 push button stations etc. Apart from that 1st & 7th station have popup units. This popup units will take & pass assembling units from bottom conveyor to top conveyor & vice versa.

All the stations are interlinked. HMI is the master control of all the 8 PLCs. Utilized the dedicate RS485 Modbus RTU port to communicate with PLC & HMI.

7-Station Conveyor Layout

Station 1
With Popup
Station 2
Standard
Station 3
Standard
Station 4
Standard
Station 5
Standard
Station 6
Standard
Station 7
With Popup
Master Control Station
HMI Master Control + PLC #8

Station Components

Standard Station (2-6)

Induction Motors: 2 units
Stoppers: 3 units
Push Button Stations: 3 units
PLC Module: PL100 + I/O

Special Stations (1 & 7)

Standard Components: Same as above
Popup Units: 1 unit each
Function: Level Transfer
Direction: Bottom ↔ Top

Communication Network

Master HMI

Proface 7" Display

RS485 Modbus RTU
PLC 1
Station 1
PLC 2
Station 2
PLC 3
Station 3
PLC 4
Station 4
PLC 5
Station 5
PLC 6
Station 6
PLC 7
Station 7
PLC 8
Master

All 8 PLCs interconnected via dedicated RS485 Modbus RTU network

Solar Inverter Assembly Flow

1
Component Loading

Initial component loading with popup unit from bottom conveyor

2-3
Primary Assembly

Core inverter components installation and initial assembly

4-5
Secondary Assembly

Additional components mounting and connection work

6
Quality Check

Assembly verification and quality control inspection

7
Final Transfer

Completed units transferred via popup to top conveyor

Master
System Control

Overall production monitoring and control coordination

Technical Specifications

System Configuration

Conveyor Length: 30 meters
Total Stations: 7 + 1 Master
PLC Controllers: 8 x PL100
Popup Units: Station 1 & 7

Control System

Master HMI: Proface 7"
Communication: RS485 Modbus RTU
Application: Solar Inverter Assembly
Network Type: Interlinked Stations

Used in

Solar Inverter Manufacturing

Complete assembly line automation for solar energy equipment production

Key Features

30m automated conveyor system
8 networked PLC controllers
RS485 Modbus communication
Popup level transfer units
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