What Happens When You Run 10 Servos, Robots, and Vision on One PLC
Industry - Miscellaneous
AMPS Industrial Controls seamlessly integrates 10 servos, dual cobots, and vision systems into a rotating conveyor for mass-producing automotive trim components.
Summary
This fully automated, rotary indexing assembly machine combines 10 servos, dual collaborative robots, and vision-guided inspection into a single, tightly integrated 12-station system. Built by AMPS Industrial Controls for OEM Inventive Automation, the solution leverages Unitronics UniStream PLC + Servo architecture to synchronize die-cut dispensing, adhesive application, inspection, and part handling.
The result: manual operators replaced with a high-speed, repeatable production line, reduced scrap, and easy remote intervention.
The Company
Founded in 1992 by Harold French, AMPS Industrial Controls (AMPS) is a premier full-service system integrator based in Ohio. Specializing in UL508A panel building and complex control applications, AMPS has a deep history of deploying robust Unitronics solutions. For this project, they partnered with OEM Inventive Automation to deliver a high-capacity assembly solution for Garco Gaskets.
The Challenge: Coordinating Multi-Axis, Multi-System Automation
Garco Gaskets faced a bottleneck in their production of automotive trim pieces. The manual application of double-sided die-cut tape was slow, labor-intensive, and prone to inconsistency. The project required an automated system capable of:
- Managing a complex 12-station sequence; achieving high-precision pick-and-place with tight positional tolerances (X-Y alignment).
- Coordinating robots, vision systems, pneumatics, and motion control in real time over multiple third-party components, including Universal Robots, Keyence vision systems, and specialized adhesive pumping equipment.
- Ensuring easy maintenance and remote support capabilities.
The Solution: PLC-Centric Motion Control
AMPS engineer Alex Foulke deployed a Unitronics UniStream PLC + Servo solution, consolidating machine control, centralized PLC-based Multi-axis motion control, HMI visualization, robot and vision integration into a single, unified platform programmed in UniLogic.
This eliminated the need for external motion controllers or complex middleware, enabling faster development, easier maintenance, and tighter synchronization.
System Architecture
Engineer Foulke designed a comprehensive control architecture powered by the Unitronics UniStream® platform. This system acts as the “brain,” coordinating every movement of the rotating conveyor and its auxiliary robotic cells.
Core Control Platform
- 2 UniStream controllers, 1 PLC + HMI, a ‘Built-in’ model with a 7” touchscreen, 1 UniStream PLC
- Distributed I/O architecture
- Dual-panel design:
- Low-voltage control panel
- High-power motion/servo panel
Motion System
- 10 Unitronics Servo Drives (UMD-0002B-B3)
- 10 Unitronics Servo Motors (UMD-0002BA-B4)
Integrated Subsystems
- 2 Universal Robots UR5e cobots (adhesive + die-cut placement)
- Keyence Vision System (inspection + validation)
- Designetics adhesive system (precision dispensing)
- Pneumatics:
- SMC valve stack
- Electric slides
Machine Topology
- 12-station rotary indexing conveyor
- Dual-lane (left/right part processing)
- Continuous, synchronized workflow
Control + Motion: Inside the 12-Station System
Engineer Alex Foulke developed the entire application within the UniLogic software environment. UniLogic’s “Servo Made Simple” pre-written motion code significantly reduced development time for the 10 Unitronics Servos.
- Station 1-4: Handles parts loading from magazines via Oriental Motor linear actuators and applies adhesive using a UR5e cobot and a Designetics pumping system.
- Station 5-9: Precision tape application. Unitronics servos precisely feed out the liner while pneumatic peelers place the die-cuts. Secondary servos manage the empty liner take-up to keep the workspace clear.
- Station 11-12: A Keyence vision system performs a final inspection, while a pneumatic arm automatically diverts any rework parts into a separate bin.
HMI—Designed in UniLogic
AMPS’ HMI application provides a clear, station-based visualization of the entire assembly process on the 7” high-resolution UniStream touchscreen:
- Real-time station status (12-station layout)
- Alarm indicators and diagnostics
- Production counters and cycle tracking
- Manual/Setup/Diagnostics modes
- Intuitive Start/Stop/Reset controls
Operators and technicians can immediately identify bottlenecks, faults, or inactive stations, reducing troubleshooting time.
Remote Access & Communications
Modern industrial connectivity was a priority.
- Modbus TCP: The backbone of the system, facilitating high-speed communication between the UniStream PLC, the dual Universal Robots, the Keyence vision system, and the Designetics adhesive system.
- Secure VNC Access: Both UniStream PLCs are securely accessible from any VNC-supported device, allowing AMPS or the plant manager to monitor performance or provide remote support from anywhere in the world.
Benefits / Results
- High Precision: The system successfully achieves accurate pick-and-place within tight cross-web tolerances that were previously impossible to maintain manually.
- Increased Throughput: The 12-station rotating design allows for continuous production, with operators only needed to swap out parts magazines.
- Development Efficiency: Using “Servo Made Simple” code saved dozens of engineering hours during the commissioning phase.
- Reliability: The integration of Unitronics servos and controllers provides a unified, rugged hardware stack that minimizes downtime.
Conclusion
By combining Unitronics’ UniStream PLC controllers and servos, with robotic vision and smart HMI design, AMPS Industrial Controls transformed a tedious manual assembly task into a state-of-the-art automated production line.
The UniStream platform proved to be the ideal choice for synchronizing 10 servos and multiple third-party systems into one cohesive, high-performance solution.
“UniLogic’s built-in ‘Servo Made Simple’ motion code was a game-changer for this project. Managing 10 servos across a 12-station conveyor could have been a programming nightmare, but Unitronics made the motion integration seamless and efficient.” — Alex Foulke, Engineer, AMPS Industrial Controls