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Integrate PLCs, heavy-duty pneumatic cylinders, and variable frequency drives to optimize conveyor indexing, structural mass balance, and cycle repeatability.
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Three integrated components that replace fragmented vendor solutions with a single, field-proven control architecture for conveyor line indexing.
Instead of writing motion sequences from scratch, the PLC‑Integrated Conveyor Controller ships with profiles for common indexing patterns — accumulate, singulate, merge, and divert. Each profile has been tested on 50+ production lines, so you skip the trial‑and‑error phase. The controller also logs cylinder pressure and motor torque in real time, flagging drift before it causes a jam.
Standard pneumatic cylinders drift under load and require external limit switches that fail over time. Our series uses a magnetostrictive sensor inside the barrel, giving the PLC a true position signal every 5 ms. The hard‑anodized barrel and chrome‑plated rod handle 10 million cycles without seal replacement, which is why automotive tier‑1 suppliers specify them for transfer stations.
Most VFDs need a separate cabinet for braking resistors and harmonic filters, adding cost and floor space. The VFD Pack integrates both inside a 75‑mm‑wide enclosure that mounts directly to the conveyor rail. It supports EtherNet/IP and Modbus TCP, so it talks to the PLC without a gateway. The built‑in dynamic brake handles rapid deceleration of heavy belts, keeping cycle repeatability within ±2 mm.
Definitions and scope of application
Motion Control refers exclusively to the integration of programmable logic controllers (PLCs), heavy-duty pneumatic cylinders, and variable frequency drives used to automate conveyor line indexing. It does not include robotic arm manipulation, servo-motor positioning beyond conveyor indexing, or any software layer not directly controlling the described hardware.
Cycle repeatability is stated under standard operating conditions: ambient temperature 10–40 °C, relative humidity below 85 %, and supply air pressure between 5.5 and 7 bar. Deviations outside these ranges may affect repeatability and are not covered by performance claims. Always consult the installation manual for site-specific derating factors.
Structural mass balance optimisation is calculated for straight, single-lane conveyor sections with evenly distributed loads. Curved, multi-lane, or inclined sections require additional engineering analysis. The quoted balance figures assume a load distribution within ±10 % of the nominal value per metre.
The standard warranty covers defects in materials and workmanship for a period of 12 months from commissioning. It does not cover wear items such as seals, piston rod coatings, or brake resistors, nor does it cover damage caused by improper installation, unauthorised modifications, or operation outside the specified environmental limits. Extended warranty terms are available on request.
PLC programs are delivered as pre-configured motion profiles on a secure USB drive or via a direct Ethernet connection. Field updates require a licensed technician and must be performed with the conveyor line in a locked-out state. Converse Leadership does not assume liability for custom program modifications made by third parties.
Yes, the Variable Frequency Drive Pack is compatible with standard three-phase AC induction motors from 0.75 kW to 7.5 kW. However, performance guarantees (efficiency, harmonic distortion, torque linearity) apply only when used with motors listed in the approved compatibility table. For unlisted motors, a site-specific validation test is required.
Explore complementary products and technical guides that support conveyor line indexing and cycle repeatability.
A programmable logic controller module designed for seamless conveyor synchronization. Supports up to 16 axes of coordinated motion, reducing programming time by 40%.
View controller specsDurable pneumatic cylinders rated for 10 million cycles with integrated position sensing. Hard-anodized aluminum barrels and chrome-plated piston rods for extended wear life.
Explore cylinder seriesEnergy-efficient motor control for conveyor belts. Precise speed control for AC induction motors from 0.75 kW to 7.5 kW with built-in dynamic braking and harmonic filtering.
See drive pack detailsTechnical reference for optimizing structural mass balance across indexing stations. Covers PLC timing, cylinder force curves, and VFD ramp profiles.
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