⟹ PORTFOLIO — SIMULATION
Conveyor Synchronization Multi-Axis Belt Control
Real-time synchronization of multiple conveyor belts using master-slave logic. Speed ratio, tension control, and soft re-synchronization.
Master/Slave Servo PLC Designer Lenze i750 L_TS2P_ElectronicGearboxBase Lenze c520
CONVEYOR SYNC / MASTER-SLAVE v1.0 | Belt Synchronization Controller
● RUNNING
▸ BELT-1 (MASTER)
V 120 mm/s
▸ BELT-2 (SLAVE-1)
V 120 mm/s
▸ BELT-3 (SLAVE-2)
V 120 mm/s
▸ SYNC
RATIO 1.00 x
ERROR 0.0 mm/s
STATUS SYNC
▸ PRODUCTION
OUTPUT 0
TENSION 50 N
▸ AXES
BELT-1 OK
BELT-2 OK
BELT-3 OK
MASTER SPD 120 mm/s
RATIO 1.00 x
MODE:
MC_GearIn · Master-Slave Sync What Does It Do?
- ▸ Transmits master belt speed instantly to slave axis
- ▸ Configurable speed ratio enables differential belt speeds
- ▸ PID tension controller maintains belt tension
- ▸ Soft re-sync after fault prevents abrupt stops
How Does It Work?
- ▸ CODESYS MC_GearIn block for electronic gear synchronization
- ▸ Master encoder value forwarded to slave at 1ms cycle over EtherCAT
- ▸ Tension sensor fed into PID feedback loop
- ▸ Lenze i950 CiA402 profile mode for position/velocity control
Industrial Use Cases
- ⟹ Food packaging & sorting lines
- ⟹ Paper & cardboard manufacturing lines
- ⟹ Textile weaving & dyeing machines
- ⟹ Automotive assembly conveyors
- ⟹ Logistics distribution systems
// Manual Synchronization vs. Servo Synchronization
| Criterion | ❌ Manual / Mechanical | ✅ Servo Sync |
|---|---|---|
| Speed accuracy | ±5% | ±0.1% |
| Start-up time | 5–10 sec | <0.5 sec |
| Product slip | High | Zero |
| Tension control | Manual | Automatic PID |
| Fault recovery | Full stop | Soft re-sync |
// Typical Application Parameters
| Parameter | Value | Unit / Note |
|---|---|---|
| Master speed (max) | 300 | mm/s |
| Speed ratio | 0.1 – 5.0 | x |
| Sync accuracy | ±0.1 | % |
| Tension (nominal) | 50 | N |
| EtherCAT cycle | 1 | ms |
| Servo drive | Lenze i750 | 2-axis |
| Controller | Lenze c520 | Motion PLC |
| Software | PLC Designer | L_TS2P_ElectronicGearboxBase |
// Cycle Phases
START
Master motor ramps to target speed
SYNC
Slave belts lock to master speed
RUN
Synchronized production, error monitoring active
TENSION
PID dancer arm tension control
CORRECT
Speed correction applied if slip detected