Since its introduction in 2014, the Modular Conveyor Platform (MCP) and the control interfaces at BUS level from Interroll have proven their worth. According to the company, the platform-based modules, consisting of roller conveyors, belt conveyors in various designs, transfers, diverters, curves, lifts and more, can flexibly handle almost any conveying task for objects weighing up to 50 kg. Complex conveyor systems with multiple zones are traditionally controlled using the established ZPA (Zero Pressure Accumulation) method. Alternatively, the IO mode was used, which required additional programming effort for programmable logic controllers (PLCs).

Simpler configuration, decentralized control

With the MCP Play function, an addition to the standard ZPA or IO mode, conveyor systems can now be configured more easily and controlled in a decentralized and embedded manner. MCP Play reduces programming and commissioning effort and eliminates the "one package per zone" limitation, enabling higher throughput and lower energy consumption. In addition, Interroll's new commissioning tool allows integrators and operators to check system status, change configurations and activate tracking functions. All functions and workflows are pre-configured in the Interroll Layouter tool for each MultiControl unit and can be quickly assigned and installed during commissioning. MCP Play thus reduces the complexity and programming effort involved in planning, installing, configuring and analyzing errors in conveyor systems.

Up to 100 percent more throughput

A central innovation of MCP Play is the "Flowing Merge" function. According to Interroll, the innovation lies in the decentralized and embedded control of this functionality - instead of having to program it with a lot of effort, it comes directly "out of the box" and only needs to be configured. Instead of stopping the conveyed goods before merging two conveyor lines, MCP Play reduces the speed in the section before merging and allows the conveyed goods to continue flowing. This approach increases the throughput and consequently increases the overall efficiency of the system. This reduces both energy consumption and connected load by avoiding start-up currents and peak loads while minimizing noise levels and mechanical wear. Last but not least, this also contributes to improved sustainability.

MCP Play increases efficiency and throughput. With the "Adjust to Gap" function, items can be transported at shorter intervals on the conveyor line. According to calculations by Fraunhofer IML, the throughput of the conveyor system can be increased by up to 100 percent compared to the ZPA solution thanks to the continuous material flow, higher average speeds and increased conveying capacity. At the same time, the evaluation has shown that energy consumption can be reduced by up to 30 percent at high throughput rates.

Intuitive software tools

MCP Play is designed as a modular add-on to the MCP hardware and can be applied to both new and existing MCP installations using the 24V/48V RollerDrive in combination with the MultiControl with BUS interface. The software offers an intuitive user interface and supports all major WMS and IoT store floor systems while integrating robust cyber security measures. Decentralized control reduces data exchange within the system environment, resulting in lower latency and improved monitoring, responsiveness and system flexibility.

MCP Play increases the efficiency of conveyor systems, from small applications to high-performance environments. Complex projects that require high throughput or advanced tracking capabilities can be implemented faster. The cost and efficiency benefits optimize the return on investment (ROI) and shorten the payback period, opening up new fields of application for conveyor systems. MCP Play's modular plug-and-play design allows for easy customization of system layouts and settings to meet ever-changing requirements. This feature is particularly beneficial for e-commerce retailers, who often have to cope with seasonal fluctuations in demand, and for third-party logistics providers, who are faced with frequent fluctuations in their customer base. By digitizing the entire process - from planning and ordering to simulation, installation and commissioning - Interroll's MCP Play system integrators can respond more quickly to the specific needs of their customers.
Growth through innovation

"With MCP Play, Interroll is setting new standards in material handling and once again demonstrating its innovation leadership in the market. MCP Play is a key part of our strategic vision to deliver modular and future-proof solutions that enable our customers to grow through innovation, reduce costs and give them a clear competitive advantage," explains Markus Asch, CEO of Interroll.