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Inst Tools > Blog > PLC Tutorials > Advanced PLC Conveyor Control: Forward and Reverse Rotation

Advanced PLC Conveyor Control: Forward and Reverse Rotation

Advanced PLC Programming for Controlling Conveyor Direction: Facilitating Forward or Reverse Movement Based on Detected Part Size.

Last updated: July 9, 2023 4:43 pm
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PLC Programming for Controlling Conveyor Direction: Facilitating Forward or Reverse Movement Based on Detected Part Size. Identify Each Part’s Size and Ensure its Distribution to the Designated Location.

Contents
Advanced PLC Conveyor ControlPLC Inputs and OutputsProgram DescriptionPLC Programming Conveyor Forward and Reverse Rotation Control

Advanced PLC Conveyor Control

The hopper provides different size objects when the operator presses the pushbutton then the conveyors and sensors are used to separate the objects based on their size.

A pusher is used to separate two different object sizes. The conveyor can move forward and in reverse directions to place the objects as per their dedicated storage trays.

A robot is used to pick and place the objects in medium size boxes.

The below simulation shows the PLC conveyor simulation with different box sizes.

Advanced PLC Conveyor Control Forward and Reverse Rotation

PLC Inputs and Outputs

The below table lists the inputs and outputs of this PLC project.

TypeDevice No.Device nameOperation
InputX0UpperON when the part is detected.
InputX1MiddleON when the part is detected.
InputX2LowerON when the robot is at starting point.
InputX3Detect partON when the part is detected in front of the pusher.
InputX4Starting pointThe conveyor moves forward when Y1 is ON.
InputX5Part on tableON when the part is on the table.
InputX6Robot operation finishedON when the part is detected on the incline.
InputX7SensorON when the part is detected at the right end.
InputX10SensorON when the part is detected at the left end.
InputX11SensorON when the part is detected at the right end.
InputX12SensorON when the robot operation is finished.
OutputY0Supply commandOne part is supplied when Y0 is ON: Wooden part repeats in order L, M, S, M, S, L.
OutputY1Conveyor forwardThe conveyor moves forward when Y2 is ON.
OutputY2Conveyor forwardExtends when Y3 is ON and retracts when Y3 is OFF. The pusher cannot be stopped in the mid-stroke.
OutputY3PusherThe robot moves part to tray when Y4 is ON. A process cycle begins.
OutputY4Unload commandThe conveyor moves forward when Y5 is ON.
OutputY5Conveyor forwardThe conveyor moves backward when Y6 is ON.
OutputY6Conveyor reverseConveyor moves backward when Y6 is ON.

Program Description

When the pushbutton PB1 (X20) on the control panel is pressed, it activates the Supply command (Y0) for the hopper. Once you release pushbutton PB1, the Supply command is deactivated. Whenever the Supply command is engaged, the robot dispenses a part.

When the switch SW1 (X24) on the control panel is activated, the conveyors start moving forward. As soon as you deactivate SW1, the conveyors halt.

The conveyors transport large, medium, and small parts, which are sorted by the Upper (X0), Middle (X1), and Lower (X2) sensors respectively, to designated trays.

  • Large part: Directed to the lower conveyor and delivered to the tray on the right.
  • Medium part: Transferred to the tray by the robot.
  • Small part: Directed to the lower conveyor and delivered to the tray on the left.

When the Detect part sensor (X3) is activated, the conveyor stops, and a large or small part is directed to the lower conveyor.

Note: When the actuating command for the pusher is turned ON, it fully extends. When the actuating command is turned OFF, the pusher fully retracts.

When the Part on the table (X5) sensor in the robot is activated, the Unload command (Y4) is engaged. When the Robot operation is finished (X6) sensor is activated (it activates when a part is placed on the tray), and the Unload command (Y4) is deactivated.

As long as the switch SW2 (X25) on the control panel is ON, a new part is automatically supplied in the following scenarios:

  • When the robot starts to handle a medium part
  • When a small or large part is deposited into a tray

PLC Programming Conveyor Forward and Reverse Rotation Control

Advanced PLC Conveyor Control Forward and Reverse Rotation
PLC Programming Conveyor Forward and Reverse Rotation Control

Source: Mitsubishi Electric

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