Inst ToolsInst ToolsInst Tools
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Search
  • Books
  • Software
  • Projects
  • Process
  • Tools
  • Basics
  • Formula
  • Power Plant
  • Root Cause Analysis
  • Electrical Basics
  • Animation
  • Standards
  • 4-20 mA Course
  • Siemens PLC Course
Reading: Basic Conveyor System for Product Handling in Omron PLC
Share
Font ResizerAa
Inst ToolsInst Tools
Font ResizerAa
  • Courses
  • Design
  • PLC
  • Interview
  • Control System
Search
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Inst Tools > Blog > PLC Tutorials > Basic Conveyor System for Product Handling in Omron PLC

Basic Conveyor System for Product Handling in Omron PLC

Basic conveyor system for product handling using Omron PLC including control programming and product counting techniques.

Last updated: October 28, 2024 9:24 pm
Editorial Staff
PLC Tutorials
No Comments
Share
6 Min Read
SHARE

This article discusses a Simple Conveyor Control System used to carry products. This system is widely used in the manufacturing industry to carry the product from production machines to the Packing area. This Conveyor system has 2 Conveyors, the first Conveyor will Run when it receives the product, and the second Conveyor will Run if it has received the product from the first Conveyor. When the product has been successfully delivered, both Conveyors will Stop and the product will be counted.

Contents
Basic Conveyor SystemAddressing of PLC ProgramProduct Handling in Omron PLC

Basic Conveyor System

This PLC program has the following inputs.

  1. The PB_START (0.00) button is used to turn ON the system.
  2. The PB_STOP (0.01) button is used to turn OFF the system.
  3. The RESET_COUNTER (0.02) button is used to Reset the counter data.
Two-Conveyor PLC Control System

In the picture above, we can see that this system has 3 sensors.

When the SENS_1 (0.03) Sensor detects the product, Conveyor CONVEYOR_1 (100.00) will Run.

Next, when Sensor SENS_2 (0.04) has detected the product carried by Conveyor CONVEYOR_1 (100.00), then Conveyor CONVEYOR_2 (100.01) will Start running.

Conveyor CONVEYOR_1 (100.00) and Conveyor CONVEYOR_2 (100.01) will Stop when Sensor SENS_3 (0.05) detects the product. When the SENS_3 (0.05) Sensor is Active, it indicates that the product has arrived at the destination area.

If within 15 seconds after the SENS_1 (0.03) Sensor is Active, the SENS_2 (0.04) Sensor does not detect the product, the Conveyor CONVEYOR_1 (100.00) will Stop.

Products that have arrived at the destination area will be counted and stored in the memory word COUNTER (D0).

Basic Conveyor System for Product Handling in Omron PLC

Addressing of PLC Program

CommentInput (I)Output (Q)Memory WordMemory BitsTimer
PB_START0.00    
PB_STOP0.01    
RESET_COUNTER0.02    
SENS_10.03    
SENS_20.04    
SENS_30.05    
CONVEYOR_1 100.00   
CONVEYOR_2 100.01   
COUNTER  D0  
TIMER_CUTOFF    T0000
SYSTEM_ON   W0.00 

Product Handling in Omron PLC

RUNG 0 (SYSTEM_ON)

In this Rung, if the PB_START (0.00) button is pressed, the memory bit SYSTEM_ON (W0.00) will be in the HIGH state. Because it uses the KEEP(011) instruction, the memory bit SYSTEM_ON (W0.00) will remain in the HIGH state even though the PB_START (0.00) button has been Released.

The memory bit SYSTEM_ON (W0.00) will return to LOW state if the PB_STOP (0.01) button is Pressed.

Conveyor Control System for Product Transfer Automation

RUNG 1 (RESET_COUNTER)

In this rung, if the RESET_COUNTER (0.02) button is pressed, the value in memory word COUNTER (D0) will be Reset to zero “0”. Because the MOV(021) instruction moves the zero “0” value to the memory word COUNTER (D0).

RUNG 2 (CONVEYOR ON)

In this Rung, when the NO contact of memory bit SYSTEM_ON (W0.00) and the SENS_1 (0.03) Sensor in the HIGH state, the CONVEYOR_1 (100.00) Output will be ON. Because it uses the SET instruction, the CONVEYOR_1 (100.00) Output will remain in the ON state even though the SENS_1 (0.03) Sensor is in the LOW state.

Managing Product Flow with PLC

RUNG 3

When the NO contact of Output CONVEYOR_1 (100.00) is ON, the TIMER_CUTOFF (T0000) Timer will start counting. The TIMER_CUTOFF (T0000) timer will Stop counting if the NC contact of Output CONVEYOR_2 (100.01) is ON.

RUNG 4 (CONVEYOR 2 ON)

When the NO contact from Output CONVEYOR_1 (100.00) is ON and the SENS_2 (0.04) Sensor is in the HIGH state, then Output CONVEYOR_2 (100.01) will be ON. Because it uses the SET instruction, the CONVEYOR_2 (100.01) Output will remain in the ON state even though the SENS_2 (0.04) Sensor is in the LOW state.

PLC System for Product Handling

RUNG 5 (CONVEYOR 1 & 2 OFF)

In this Rung, because the Outputs CONVEYOR_1 (100.00) and CONVEYOR_2 (100.01) use the RESET Instruction, the Outputs CONVEYOR_1 (100.00) and CONVEYOR_2 (100.01) will be OFF when the NO contact of memory bit SYSTEM_ON (W0.00) and Sensor SENS_3 (0.05) in the HIGH state.

RUNG 6 (DATA COUNTER)

In this Rung, when the NO contact of memory bit SYSTEM_ON (W0.00) and SENS_3 (0.05) Sensor in the HIGH state, the value in memory word COUNTER (D0) will increase (+1).

Read Next:

  • Simple Conveyor Control PLC Program Example
  • PLC Sequential Control of Three Lights with Reset
  • Allen Bradley PLC to PLC Communication Tutorial
  • PLC Packing Machine Control System Program
  • PLC Batch System for 4 Tanks Mixing Program

Don't Miss Our Updates
Be the first to get exclusive content straight to your email.
We promise not to spam you. You can unsubscribe at any time.
Invalid email address
You've successfully subscribed !

Continue Reading

What is SCADA ? How does SCADA Works ?
Example PLC Program to Control a Pump based on Level Sensors
How to Program PID Control in PLC with Structured Text?
PLC Programming: Sorting and Distribution of Boxes by Height
Electrical and Instrumentation – Automation Pre-engineering Documents
#1 PLC Best Practices – Split PLC Code into Modules
Share This Article
Facebook Whatsapp Whatsapp LinkedIn Copy Link
Share
Leave a Comment

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Stay Connected

128.3kFollowersLike
69.1kFollowersFollow
210kSubscribersSubscribe
38kFollowersFollow

Categories

Explore More

Omron PLC Logic for Washing Machine Automation
Demo of a SCADA Software – Level Control System
Step-by-Step Guide to Choose Right Fuse for a Panel
#4 PLC Best Practices – Use PLC Flags as Integrity Checks
Control Speed of Induction Motor using Analog Output of PLC
PLC Analog Input Scaling
MODBUS ASCII Communication Protocol Explained
UPS Selection Factors for a Control System

Keep Learning

PLC Software Redundancy

Software Redundancy in Siemens PLC – Hardware versus Software

Distributed Control System Interview Questions

Two wire loop powered transmitters

4-20 mA Transmitter Wiring Types : 2-Wire, 3-Wire, 4-Wire

Siemens PLC

#20 PLC Best Practices – Identify Critical Alerts

PLC Program for Automatic Bottle Rejection System

PLC Program for Automatic Bottle Rejection System

Convert Raw Counts to Engineering Units

Raw Counts to Engineering Units : Conversion Formula

PLC Project Examples for EcoStruxure Machine Expert

PLC Project Examples for EcoStruxure Machine Expert

How CPU Execute Program in Siemens PLC?

How CPU Execute Program in Siemens PLC?

Learn More

DC Machine

DC Machines Construction

Safety Considerations in PLC System Design

Safety Considerations in PLC System Design

What is Capillary Tubing

What is Capillary Tubing? – Advantages and Disadvantages

Suspended Particulate Matter

Basics of Suspended Particulate Matter (SPM) Analyzers

Do You Need a VPN on Your Home Computer?

Do You Need a VPN on Your Home Computer?

Safety interlock for motor starters in Siemens PLC

Motor Starter Logic using Siemens PLC Tia Portal

Transistor Failure Rate Calculation

Transistor Failure Rate Calculation

Electrical Machines Questions and Answers

Non-Salient Pole Machines Quiz

Menu

  • About
  • Privacy Policy
  • Copyright

Quick Links

  • Learn PLC
  • Helping Hand
  • Part Time Job

YouTube Subscribe

Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Welcome Back!

Sign in to your account

Username or Email Address
Password

Lost your password?