A major UK automotive manufacturer in the West Midlands needed to introduce a new long wheelbase vehicle variant into its production programme. The existing conveyor skid buffer system had been designed and programmed around the dimensions and routing requirements of the standard vehicle range, and the existing Allen Bradley Rockwell PLC routing logic didn't account for the additional length of the new variant. Without modification, the buffer wouldn't handle the new vehicles correctly, the routing rules, sequencing logic, and HMI all needed updating to accommodate the new variant safely, without introducing risk to the existing production programme running alongside it.
Duke Control Systems developed the updated routing logic entirely offline before touching the live system, reviewing the existing Allen Bradley Rockwell PLC program in detail and designing, building, and testing the modifications needed to accommodate long wheelbase vehicles in a simulation environment first. HMI screens were updated in parallel to give operators clear visibility of long wheelbase vehicle positions within the buffer from day one. Once offline development was complete, Duke's engineers commissioned the updated software on site, methodically testing edge cases and mixed-variant scenarios to confirm correct behaviour with both standard and long wheelbase variants present. Duke then supported the formal customer buy-off process and remained on site for startup support during the initial production period.
The updated PLC routing logic and HMI were successfully commissioned and signed off by the customer. Long wheelbase vehicles entered the skid buffer system alongside the existing standard range without issue, with the routing logic correctly handling mixed-variant production from the outset. Duke's startup support ensured a smooth transition into live production, and the customer confirmed a successful handover with no production issues arising from the controls changes.
""Introducing a new vehicle variant into an existing production programme is always a careful piece of work. The routing logic has to be right first time, because a buffer fault in the middle of a shift does not just stop one car — it can stop the whole line. Offline development and thorough commissioning are not optional on a project like this.""
Published with the express consent of both parties. The buyer chose to remain unnamed, so they are described by sector only. All quotes are unedited extracts from verified reviews.
