Control Software

The Middlesex Control Software is the “brain” of our conveyor-based AMHS solutions. It orchestrates every FOUP movement with unmatched reliability, traceability, and scalability - ensuring that no production step is delayed by transport bottlenecks.

Unlike fragile centralized systems, Middlesex uses a modular, distributed architecture. Instead of relying on centralized control, it operates through a network of local modules (TMUs), each responsible for a specific conveyor segment. Local Transfer Management Units (TMUs) independently manage around 50 conveyor zones each. This design eliminates bottlenecks, improves fault tolerance, and enables real-time response across the system.

At the lowest level, each conveyor zone integrates:

• a motor
• position/status sensors
• a local control board

These modules communicate with TMUs via CAN fieldbus, guaranteeing speed and redundancy. At the higher level, TMUs link over TCP/IP Ethernet to a Dispatch Controller, which aggregates all system data: FOUP identifiers, positions, destinations, errors, operational status and many more.

Two key software modules complete the platform:

• A graphical interface for live visualization of every FOUP and conveyor segment
• A native Host Interface that connects directly to the customer’s Factory Host, enabling full integration and external command control

Redundancy, flexibility, continuity, and traceability: the core advantages

The control software is designed for extreme reliability. Thanks to multi-level redundancy and fault- tolerant hardware, the system achieves seven nines uptime (99.999%). Even if a module fails, production continues seamlessly without restarting the entire line.

Any low-level component that may be subject to failure - such as a motor, sensor, or motor controller - can be hot-swapped without requiring a local power shutdown.

In the event of a power failure, the system automatically resumes operation without affecting carriers already in transit or requiring any manual intervention. It also detects and resolves errors autonomously, restoring normal functionality to ensure uninterrupted performance.

Traceability is continuous and RFID-free, thanks to native MCS functionality integrated in the control software. Using smart logic and multiple zone-level sensors, every FOUP is tracked with precision - reducing cost and complexity while ensuring data integrity.

The system intelligently manages and balances destination buffers by grouping I/O ports and dynamically assigning each carrier to the most suitable output buffer within its destination group. This decision is made automatically based on real-time buffer and I/O port status, priority levels and travel distance - optimizing flow efficiency and reducing host-level complexity.

Another key advantage of our system is dynamic scalability: as the factory grows or the system expands, simply add new TMUs and update the configuration - no need to recompile the software. This flexibility results in time savings, higher operational continuity, and reduced management costs.

The Digital Twin feature of our control system creates a real-time virtual replica of the entire conveyor network, enabling simulation, monitoring, and analysis of system behavior without impacting live operations. It allows engineers to test layout changes, optimize flow logic, and predict performance under varying load conditions - significantly reducing commissioning time, minimizing risk, and improving overall system reliability and maintainability. Offsite emulation enables faster commissioning of the installed system by validating configurations and control logic before on-site deployment.