Advanced PLC Conveyor Control: Forward and Reverse Rotation

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 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.

Type	Device No.	Device name	Operation
Input	X0	Upper	ON when the part is detected.
Input	X1	Middle	ON when the part is detected.
Input	X2	Lower	ON when the robot is at starting point.
Input	X3	Detect part	ON when the part is detected in front of the pusher.
Input	X4	Starting point	The conveyor moves forward when Y1 is ON.
Input	X5	Part on table	ON when the part is on the table.
Input	X6	Robot operation finished	ON when the part is detected on the incline.
Input	X7	Sensor	ON when the part is detected at the right end.
Input	X10	Sensor	ON when the part is detected at the left end.
Input	X11	Sensor	ON when the part is detected at the right end.
Input	X12	Sensor	ON when the robot operation is finished.
Output	Y0	Supply command	One part is supplied when Y0 is ON: Wooden part repeats in order L, M, S, M, S, L.
Output	Y1	Conveyor forward	The conveyor moves forward when Y2 is ON.
Output	Y2	Conveyor forward	Extends when Y3 is ON and retracts when Y3 is OFF. The pusher cannot be stopped in the mid-stroke.
Output	Y3	Pusher	The robot moves part to tray when Y4 is ON. A process cycle begins.
Output	Y4	Unload command	The conveyor moves forward when Y5 is ON.
Output	Y5	Conveyor forward	The conveyor moves backward when Y6 is ON.
Output	Y6	Conveyor reverse	Conveyor 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: