This paper deals with the analysis of a controller used to synchronize two parallel belt conveyors in a packaging plant. A first conveyor carries the products, while the second delivers the packages. The insertion is obtained by a proper mechanical action. The control system is based on a ‘hybrid’ fuzzy logic controller, whose parameters are optimized by using an advanced ‘operational’ genetic algorithm. ‘Hybrid’ means that a conventional fuzzy logic controller is integrated with a set of special rules needed to solve particular situations characterizing the system. An important constraint is given, since the physical structure of the existing control system is to be kept unchanged. It is shown that the controller efficiently governs the belt conveyors when: (a) the distances between goods and the relative packages become higher than a certain value; (b) the performance of the electrical engine deteriorates during working time; and also (c) interference phenomena occur between consecutive good-package couples.
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