Projeto de automação e simulação de um carro de transferência usando factory I/O

Abstract

Internal material handling is a critical activity in several industrial sectors, directly impacting productivity, operational safety, and process efficiency. In this context, this work presents the development of a conceptual design for an automated transfer cart with embedded intelligence, intended to automate the displacement and positioning of loads in industrial environments. The proposed solution integrates established industrial automation technologies, including Programmable Logic Controllers (PLCs), inductive sensors, laser distance sensors, safety laser scanners, Human-Machine Interfaces (HMIs), and industrial communication through the Modbus TCP/IP protocol. The development process included technical and regulatory requirement analysis, control architecture definition, component selection, and functional validation in a virtual environment. The validation was carried out through the integration of the CODESYS V3.5 development environment with the Factory I/O simulation platform, enabling the simulation of material movement, positioning, classification, and storage routines. The results demonstrated the correct operation of the implemented control strategies, providing accurate positioning, operational repeatability, stable communication between systems, and proper performance of the safety functions defined in the project. The results indicate that the proposed architecture is technically feasible for industrial applications, contributing to reduced operational risks, increased process reliability, and alignment with Industry 4.0 principles. Furthermore, the project establishes a solid foundation for future physical implementation and evolution toward fully autonomous material handling systems. Keywords: Industrial Automation; Transfer Cart; Embedded Intelligence; PLC; CODESYS; Factory I/O; Machine Safety; Modbus TCP/IP.