Decision points
An automated warehouse is a network of decision points: conveyor diverts, lift transfers, shuttle aisles, sorter chutes, station ports. At each one, a load arrives and something must decide where it goes.
The material flow controller (MFC):
- Identifies the load, usually by barcode or RFID scan reported by the PLC.
- Looks up its task: storage, retrieval, station, dispatch.
- Chooses a route, avoiding blocked or congested paths (dynamic routing).
- Commands the PLC: “send to branch 3”, “store in aisle 4, level 7”.
- Confirms arrival and updates the record.
MFC and PLC: who does what
| PLC | Material flow controller |
|---|---|
| Drives motors, reads sensors | Decides destinations and sequence |
| Handles safety and motion | Handles priorities and routing |
| Knows one machine | Knows the whole flow |
Standard and mixed equipment
Kulmen’s material flow controller uses standardised telegrams for Acme equipment and adapts to controllers from other vendors, so mixed installations run under one controller. Live data can be read via OPC UA. See PLC integration.