Siemens TIA Portal Example: 2 Conveyor Packaging Process

This article discusses a 2 conveyor packaging process example using the Siemens TIA portal. The system consists of two conveyors: the upper conveyor, which drops products into boxes, and the lower conveyor, which automatically moves the boxes. The PLC system operates based on box detection; products are only dropped when a box is in the correct position. The system keeps count of the number of boxes that have been filled with products.

Contents

Program Objective

Siemens TIA Portal Example 2 Conveyor Packaging Process

Automated Packaging System Operation Process:

1. Product Distribution

Conveyor 1 (upper) transports and drops products into boxes
Conveyor 2 (lower) with retaining gate controls box movement

2. Box Filling Process

Boxes collect products from Conveyor 1
Conveyor 2 continues moving boxes forward

3. Full Box Release

When the box reaches capacity:

Conveyor 1 stops
Retaining gate opens
Box proceeds down the line

4. New Box Preparation

The gate automatically closes when sensors detect a new box in the loading position

5. Continuous Cycle

Conveyor 1 reactivates to fill the next box
Process repeats automatically.

IO Mapping

S.No.	Comment	Input (I)	Output (Q)	Memory Bit	Memory Word
1	START	I0.0
2	STOP	I0.1
3	SENS_BOX	I0.2
4	SENS_PRODUCT	I0.3
5	CONVEYOR_PRODUCT		Q0.0
6	CONVEYOR_BOX		Q0.1
7	GATE_BOX		Q0.2
8	COUNTER PRODUCT				MW0
9	COUNTER BOX				MW2
10	SYSTEM_ON			M4.0
11	ILC_PRODUCT			M4.1
12	TEMP_SENS_BOX1			M4.2
13	TEMP_SENS_BOX2			M4.3
14	TEMP_SENS_PRODUCT			M4.4

2 Conveyor Packaging Process

Siemens PLC Program Product Counter and Packing System

NETWORK 1 (START SYSTEM)

In this Network, the memory bit SYSTEM_ON (M4.0) will be set to a HIGH state if the START (I0.0) button is pressed. The memory bit SYSTEM_ON (M4.0) will remain in a HIGH state even after the START (I0.0) button is released. Because it uses latching.

When the STOP (I0.1) button is pressed, then the memory bit SYSTEM_ON (M4.0) will return to a LOW state.

NETWORK 2 (CONVEYOR BOX)

In this Network, the output CONVEYOR_BOX (Q0.1) will turn ON if the NO contact of the memory bit SYSTEM_ON (M4.0) is in a HIGH state and the NC contact of the SENS_BOX (I0.2) sensor is also in a LOW state.

Or, the CONVEYOR_BOX (Q0.1) output will turn ON if the NO contacts of the memory bits SYSTEM_ON (M4.0) and ILC_PRODUCT (M4.1) are in a HIGH state.

Product Counting and Box Filling Project

NETWORK 3 (CONVEYOR PRODUCT & GATE BOX)

The CONVEYOR_PRODUCT (Q0.0) and GATE_BOX (Q0.2) outputs will turn ON if the NO contacts of the memory bit SYSTEM_ON (M4.0) and the SENS_BOX (I0.2) sensor are in a HIGH state.

And, the CONVEYOR_PRODUCT (Q0.0) and GATE_BOX (Q0.2) outputs will turn OFF if the NC contact of the memory bit SYSTEM_ON (M4.0) is in a HIGH state.

NETWORK 4 (PRODUCT COUNTER)

In this Network, because the memory word COUNTER_PRODUCT (MW0) uses an Increment instruction, the value in the memory word COUNTER_PRODUCT (MW0) will increase (+1) if the NO contact of the memory bit SYSTEM_ON (M4.0) and the sensor SENS_PRODUCT (I0.3) are in a HIGH state.

Automated Packaging Line with 2 Conveyors

NETWORK 5 (CONVEYOR INTERLOCK)

The memory bit ILC_PRODUCT (M4.1) will turn to a HIGH state when the NO contact from the memory bit SYSTEM_ON (M4.0) is in a HIGH state and the value of the memory word COUNTER_PRODUCT (MW0) is Equal to “8”.

And, the memory bit ILC_PRODUCT (M4.1) will change to a LOW state when the NO contact of the sensor SENS_BOX (I0.2) is in a HIGH state.

NETWORK 6 (COUNTER BOX & PRODUCT)

The value in the memory word COUNTER PRODUCT (MW0) will be reset to zero “0” When the NO contact of the memory bit SYSTEM_ON (M4.0) and the sensor SENS_BOX (I0.2) are in a HIGH state.

And, because the memory word COUNTER BOX (D2) uses an Increment instruction, then the value in the memory word COUNTER BOX (D2) will increase (+1).

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