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Jul 28 15

Panel Fabrication and Design

Excess Equip

Panel fabrication and design involves the planning and implementing of a control panel. Control panels usually involve a flat, vertical box where monitoring displays and devices are used to monitor and control machines within a warehouse environment. There are several stages in the creation of a control panel. Here are a few:


Panel Design

Panel design most often starts with drawings. These drawings are used to specify the unique needs of the person needing the control panel. A high amount of detail is needed in order to ensure that every need is met within this design process. From there, details are listed on how the panel will be created and the selection of the right components goes underway.

Control Panel


Integration and Assembly

Integration and assembly of the control panel is essentially the building of the panel itself. Whoever is building the control panel compares what he/she is doing to the design document that was made, much like a blue print, making sure that the integration follows the design to a ‘T’. Of course, safety and quality requirements are taken into account.



Finally, after the control panel has been assembled, testing is ensued to ensure that the control panel will function exactly as planned in the design.

What We Offer

We offer control panel design and build utilizing UL, CE, and NEC codes and standards for all industrial environments and we are a UL 508A certified shop. Our team of experienced design engineers and technicians provide our customers with safe, robust, and aesthetically appealing systems. We ensure our products are properly labeled and documented to assist in understanding of the systems architecture and function.

To find out more about how we can help design and build a panel for your work environment, contact us, and we would be happy to assist. Also, don’t forget to see our wide selection of used conveyor, where we can provide a variety of services for you!

Jul 21 15

Automated Storage Retrieval Systems (ASRS)

Excess Equip

An automated storage and retrieval system (ASRS or AS/RS) consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations. Automated storage and retrieval systems (AS/RS) are typically used in applications where: there is a very high volume of loads being moved into and out of storage; storage density is important because of space constraints; no value adding content is present in this process; accuracy is critical because of potential expensive damages to the load. AS/RS can be used with standard loads as well as nonstandard loads.


ASRS can come in a few different types: Vertical Lift Modules (VLM), Vertical Carousels, and Horizontal Carousels. Vertical Lift Modules typically operate with small parts storage. They are akin to an oversized cabinet where the “drawers” can be shifted in and out. You can choose a specific tray for the VLM to “lift” up to you to get just what you need.


Vertical carousels act similar to VLM’s except they can stack a lot higher, and the trays with equipment will “rotate” to it’s desired location until you can get what you need. Horizontal carousels act essentially the same only instead of rotating up and down, they rotate horizontally.

horizontal carousel

Whether it’s cluttered aisles, excess inventory, inaccurate records, poor reliability, or low throughput, an AS/RS system might be just what you need. An AS/RS system will transport, store, retrieve, and provide reports on every inventory item with extreme accuracy.

To find out more about how we can help implement ASRS in your work environment, contact us, and we would be happy to assist. Also, don’t forget to see our wide selection of used conveyor, where we can provide turn-key solutions for you!

Jul 14 15

Warehouse Control System

Excess Equip

A Warehouse Control System (WCS), is a software application that directs the real-time activities within warehouses and distribution centers. As the “traffic cop” for the warehouse/distribution center it is responsible for keeping everything running smoothly, maximizing the efficiency of the material handling subsystems and often, the activities of the warehouse associates themselves. It provides a uniform interface to a broad range of material handling equipment such as AS/RS, carousels, conveyor systems, sorters, palletizers, etc.

Control Panel Fabrication

The primary functions include:

  • Interfacing to an upper level host system/Warehouse Management System (WMS) and exchanging information required to manage the daily operations of the distribution center
  • Allocating work to the various material handling sub-systems to balance system activity to complete the requested workload
  • Providing real-time directives to operators and material handling equipment controllers to accomplish the order fulfillment and product routing requirements
  • Dynamically assign cartons to divert locations based on defined sortation algorithms or based on routing/order information received from the Host (if applicable)
  • Generate result data files for reporting and/or upload by the Host system
  • Operational screens (graphical user interface) and functions to facilitate efficient control and management of the distribution warehouse
  • Collect statistical data on the operational performance of the system to enable operations personnel to maintain the equipment in peak performance
  • Live alerts, reporting, and troubleshooting from a separate network location with the all-new WCS Remote Viewer software.
  • Trying to figure out if I have

Each major function is designed to work as part of an integrated process to effectively link the host systems with the lower level control system, while relieving the Host from the real-time requirements such as operator screens and lower level equipment control interfaces.

To find out more about how we can help implement a Warehouse Control System in your work environment, feel free to contact us, and we would be happy to assist. Also, don’t forget to see our wide selection of used conveyor, and we can provide turn-key solutions for you!

Jul 6 15

Test Fixture Development

Excess Equip

A test fixture is something used to consistently test some item, device, or piece of software. There are two major processes for setting up a test fixture: the documentation, and the actual test.

Test Fixture

Documentation can consist of :

  • Design Drawings
  • Manuals
  • Test Procedures
  • Test Metrics
  • Pass/Fail Certificates

While the tests can consist of:

  • Vacuum
  • Hydraulics
  • Pneumatics
  • Electrical
  • Temperature

There are a couple types of tests that are run in test fixtures: physical and software.

Test Fixture

Physical test fixtures hold up the subject which is being tested, and are meant to employ the functions of the subject as though it were the real thing.

Software testing, unlike physical testing, makes use of software and uses that as a baseline for running tests.There is a fixed state or “ideal” that the system needs to align with in order to successfully pass the test.

Test Fixture

Test fixture development is key in figuring out if your device will work properly before making it go underway. Testing such devices can save money and time in the long run.

With thousands of hours of experience in control systems, tracking, communication, and interfacing with Manufacturing systems, we can handle the most complex test interface problems and provide advanced solutions. Contact us today to find out more. Also, don’t forget to see our wide selection of used conveyor!

Jun 30 15

Process Control Systems

Excess Equip

Process control systems maintain the output of a specific function within a desired range through engineering. In practice, process control systems can be characterized as one or more of the following forms: Discrete, Batch and Continuous. Here are descriptions of all three:


Found in many manufacturing, motion and packaging applications. Robotic assembly, such as that found in automotive production, can be characterized as discrete process control. Most discrete manufacturing involves the production of discrete pieces of product, such as metal stamping.


Some applications require that specific quantities of raw materials be combined in specific ways for particular durations to produce an intermediate or end result. One example is the production of adhesives and glues, which normally require the mixing of raw materials in a heated vessel for a period of time to form a quantity of end product. Other important examples are the production of food, beverages and medicine.



Often, a physical system is represented though variables that are smooth and uninterrupted in time. The control of the water temperature in a heating jacket, for example, is an example of continuous process control. Some important continuous processes are the production of fuels, chemicals and plastics.

For more information on how we can provide process control systems for you, get in touch with us. Also, don’t forget to see our selection of used conveyor equipment!

Jun 23 15

How Transformer Equipment Works

Excess Equip

When you carry a good amount of powered conveyors it helps to have equipment that can generate the flow of electricity required to operate. This is where transformer equipment comes in. No, not like the robot heroes with the same name. Transformers are used to transfer an electrical current between two or more circuits. This then can allow for conveyor equipment to function properly through a steady electrical current.

How Transformers Run

Transformers work when a fluctuating electric current flows through a wire, generating a magnetic field all around it. The strength of the magnetic field is directly related to the size of the electric current. Essentially: the the bigger the current, the stronger the magnetic field.

Different Currents and Voltages

Something interesting about electricity is that it can be passed from one wire to another by touching two wires together. Most often wires are wrapped around a core to create a voltage between the two of them. Depending on how you then wrap one wire as opposed to the other, you can create a transformer that goes from a low voltage to a high voltage, or a high voltage to a low voltage.

Transformers equipment are essential in generating electricity. When purchasing equipment, it helps to know you’re getting a good deal. To that, consider visiting our online catalog. If you are not able to find what you’re looking for online, do not hesitate to contact us via online form or by phone, as we carry many products which are not listed online as well.

Jun 16 15

Types of Packaging Systems

Excess Equip

As has been mentioned before, packaging systems are a great way to save on costs, time and hassle within a warehouse. A good packaging system can increase production time which will help your operations run smoothly and effectively while cutting back costs on money you would have otherwise spent training employees or fixing any possible errors. There are a couple packaging systems to choose from which will be discussed here: motion conveyor scales and case sealers.



Motion Conveyor Scales

Motion conveyor scales operate while the conveyor is in motion and are intended for the weighing of individual boxes, cartons, or even unpackaged products. They are intended for use when items need to be weighed while continuing in motion, hence the name. Ideally, they can be used for checkweighing, straight weighing and weight accumulation operations.

Motion Conveyor Scale

Case Sealers and Erectors

Case sealing machines can tape and seal boxes as they move along through conveyor near the end of an assembly line for direct access and easy packaging. There are also packaging systems which take a flat box and “erect” them into a shape ready for packaging automatically.

Case Sealer Taper

These benefits can significantly increase work productivity. If you’re looking for a packaging system for your warehouse operation, considering giving our catalog a visit. We carry some of the most reliable equipment in any warehouse operation, with the added benefit of reduced costs on our products. If you are not able to find what you’re looking for online, do not hesitate to contact us via online form or by phone, as we carry many products which are not listed online as well.

Jun 9 15

Using Programmable Controllers part 3

Excess Equip

Last week we covered the basic definitions of input/output assembly for Programmable controllers. Inputs carry a signal to the controller, while outputs take the transformed signal out into the real world.

As we close these series, we will discuss the power supply of a controller, as well as the programming device/software.

Power Supply

The power supply (unsurprisingly) provides power for the PLC system. It does this through an internal direct current to operate the logic circuitry and input/output assemblies within the processor.  24V DC or 120 VAC are power levels often used within a PLC system.


The logic inside a PLC controller can be manipulate through the use of a specialty programmer or through computer software. Laptops and PCs are often used to control a PLC component through a specific software. On the other hand, older systems used a custom programming device.

By knowing what components the PLC makes use of, you can make a better decision as to what you need. Excess Equip carries a large selection of PLC Components that can be found here. Please feel free to call us with any questions you might have. We’re happy to help!

Jun 1 15

Using Programmable Controllers part 2

Excess Equip

Last week we discussed a couple of the components that Programmable Logic Controllers use. We covered the Central Processing Unit (CPU) of the controller, as well as how you might mount and assemble your PLC.

In this post we will cover the assembly of the input and output of a PLC.


Inputs take information into the PLC to carry out a task by transporting signals from the process into the controller. Input types can include switches, pressure sensors, and operator inputs among others.


On the other end of the input is the output. Outputs are the devices that the PLC uses to send changes out from the controller to wherever you need. This includes features such as motors, lights, relays,  and pumps, and enable to PLC to change to adjust or control the process.

Many types of inputs and outputs can be connected to a PLC, but they essentially are comprised of two major groups – analog and digital. Digital types operate on a “yes or no” function through binary change. Analog change continuously through a wide range of variables such as pressure or temperature.

In our next post, we will cover information regarding the power supply as well as the programming device and/or software. Excess Equip carries a large selection of PLC Components that can be found here. Please feel free to call us with any questions you might have. We also carry more items than what is listed on the site, so do not hesitate to contact us if you cannot find what you’re looking for!

May 27 15

Using Programmable Controllers part 1

Excess Equip

Programmable controllers have many advantages due to ease of programming, wiring, installation, and changing. They cover a wide range of sizes, but generally carry the same components:

  • processor (CPU)
  • rack or mounting
  • input assembly
  • output assembly
  • power supply
  • programming unit or device

In this post we will cover the basic functions of the CPU and Rack/Mounting involved with PLC components.

Central Processing Unit (CPU)

The CPU is essentially the brain of the Programmable Controller. The type and size of the CPU determines the programming functions available, size of the application logic, the amount of memory available, as well as the overall processing speed.

Rack Assembly

In almost every medium to large PLC system, they are assembled so that the individual components are held together as modules within a rack. On the other hand, smaller PLC systems contain all of these components within a single housing (also known as a “brick”or “shoebox”).

In our next post, we will cover information regarding input and output assembly. Excess Equip carries a large selection of PLC Components that can be found here. Please feel free to call us with any questions you might have. We also carry more items than what is listed on the site, so do not hesitate to contact us if you cannot find what you’re looking for – we would be happy to help!