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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