This article will discuss the products sorted based on weight, like 10g, 15g, and 20g, using Omron PLC programming. The PLC system will sort products and collect them in containers according to their weight classification. The system classifies product weights into three categories (10 grams, 15 grams, and 20 grams). The products will first undergo a weighing process and then be transported by a conveyor to the designated container. The system will count the number of sorted products, and the product counter data can be reset.
Program Objective
System sequence:
- When the system is turned on, all system components will be in Standby state.
- When the product is detected in the weighing area, a weighing process will be carried out for 4 seconds.
- Next, Actuator-A will push the product onto Conveyor-A, and Conveyor-A will run to carry the product.
- If the product weighs 10 grams, Actuator-B will activate to push the product onto Conveyor-B. Conveyor-B will operate to carry the product to the 10-gram collection container.
- If the product weighs 15 grams, Actuator-C will activate to push the product onto Conveyor-C. Conveyor-C will operate to carry the product to the 15-gram collection container.
- If the product weighs 20 grams, Actuator-D will activate to push the product onto Conveyor-D. Conveyor-D will operate to carry the product to the 20-gram collection container.
- All conveyors and actuators will turn OFF once the product has been placed into the collection container.
- The system will count the products in each collection container.
Omron PLC Exercise
IO Mapping
| S.No. | Comment | Input (I) | Output (Q) | Memory Bit | Memory Word | Timer |
|---|---|---|---|---|---|---|
| 1 | PB_START | 0.00 | ||||
| 2 | PB_STOP | 0.01 | ||||
| 3 | SENS_PRODUCT | 0.02 | ||||
| 4 | LS_OPEN_ACT1 | 0.03 | ||||
| 5 | SENS_OUT1 | 0.04 | ||||
| 6 | SENS_OUT2 | 0.05 | ||||
| 7 | SENS_OUT3 | 0.06 | ||||
| 8 | RESET COUNTER | 0.07 | ||||
| 9 | ACTUATOR_A | 100.00 | ||||
| 10 | CONVEYOR_A | 100.01 | ||||
| 11 | ACTUATOR_B | 100.02 | ||||
| 12 | CONVEYOR_B | 100.03 | ||||
| 13 | ACTUATOR_C | 100.04 | ||||
| 14 | CONVEYOR_C | 100.05 | ||||
| 15 | ACTUATOR_D | 100.06 | ||||
| 16 | CONVEYOR_D | 100.07 | ||||
| 17 | PV_PRODUCT_WEIGHT | D0 | ||||
| 18 | COUNT_PRODUCT_10GRAMS | D10 | ||||
| 19 | COUNT_PRODUCT_15GRAMS | D11 | ||||
| 20 | COUNT_PRODUCT_20GRAMS | D12 | ||||
| 21 | SYSTEM_ON | W0.00 | ||||
| 22 | TIMER1 | T0000 |
Sort Products by 10g, 15g, 20g
RUNG 0 (SYSTEM START)
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 SET 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.
RUNG 1 (SYSTEM STOP)
In this rung, if the PB_STOP (0.01) button is pressed, the memory bit SYSTEM_ON (W0.00) will be in the LOW state. Because it uses the RSET instruction, the memory bit SYSTEM_ON (W0.00) will remain in the LOW state even though the PB_STOP (0.00) button has been released.
RUNG 2 (PRODUCT DETECT & WHEIGING AREA)
In this Rung, if the NO contact of the memory bit SYSTEM_ON (W0.00) and the SENS_PRODUCT (0.02) Sensor are in the HIGH state, then the TIMER1 (T0000) timer will start counting up to 4 seconds.
After Timer TIMER1 (T0000) has finished counting, Output ACTUATOR_A (100.00) will be ON. The ACTUATOR_A (100.00) output will be OFF when the NC contact of the Limit Switch LS_OPEN_ACT1 (0.03) is in the HIGH state.
RUNG 3 (CONVEYOR 1 ON)
In this Rung, the CONVEYOR_A (100.01) output will be ON when the NO contact of the Limit Switch LS_OPEN_ACT1 (0.03) is in the HIGH state. Because it uses Latching, the CONVEYOR_A (100.01) output will remain ON even though the NO contact of the Limit Switch LS_OPEN_ACT1 (0.03) is in the LOW state.
The CONVEYOR_A (100.01) output will be OFF if one of the NC contacts of the SENS_OUT1 (0.04), SENS_OUT2 (0.05), SENS_OUT3 (0.06) sensors is in the HIGH state.
RUNG 4 (LINE PRODUCT WEIGHT 10 GRAMS)
In this Rung, the outputs ACTUATOR_B (100.02) and CONVEYOR_B (100.03) will be ON when the NO contact of the memory bit SYSTEM_ON (W0.00) in the HIGH state and the memory word PV_PRODUCT_WEIGHT (D0) is Equal To “10”. Because it uses Latching, the output ACTUATOR_B (100.02) and CONVEYOR_B (100.03) will remain ON even though the memory word PV_PRODUCT_WEIGHT (D0) is Not Equal To “10”.
The ACTUATOR_B (100.02) and CONVEYOR_B (100.03) outputs will be OFF if the NC contact of the SENS_OUT1 (0.04) sensor is in the HIGH state.
RUNG 5 (LINE PRODUCT WEIGHT 15 GRAMS)
In this Rung, the outputs ACTUATOR_C (100.04) and CONVEYOR_C (100.05) will be ON when the NO contact of the memory bit SYSTEM_ON (W0.00) is in the HIGH state and the memory word PV_PRODUCT_WEIGHT (D0) is Equal To “15”. Because it uses Latching, the output ACTUATOR_C (100.04) and CONVEYOR_C (100.05) will remain ON even though the memory word PV_PRODUCT_WEIGHT (D0) is Not Equal To “15”. Output ACTUATOR_C (100.04) and CONVEYOR_C (100.05) will be OFF if contact NC of Sensor SENS_OUT2 (0.05) is in state HIGH state.
RUNG 6 (LINE PRODUCT WEIGHT 20 GRAMS)
In this Rung, the outputs ACTUATOR_D (100.06) and CONVEYOR_D (100.07) will be ON when the NO contact of the memory bit SYSTEM_ON (W0.00) in the HIGH state and the memory word PV_PRODUCT_WEIGHT (D0) is Equal To “20”. because it uses Latching, the output ACTUATOR_D (100.06) and CONVEYOR_D (100.07) will remain ON even though the memory word PV_PRODUCT_WEIGHT (D0) is not equal to “20”.
The ACTUATOR_D (100.06) and CONVEYOR_D (100.07) outputs will be OFF if the NC contact of the SENS_OUT3 (0.06) sensor is in the HIGH state.
RUNG 7 (COUNTER PRODUCT)
In this Rung, when the NO contact of the memory bit SYSTEM_ON (W0.00) and Sensor SENS_OUT1 (0.04) are in the HIGH state, the value in the memory word COUNT_PRODUCT_10GRAMS (D10) will increase by (+1).
If Sensor SENS_OUT2 (0.05) is in the HIGH state, then the value in the memory word COUNT_PRODUCT_15GRAMS (D11) will increase by (+1).
If the SENS_OUT3 (0.06) sensor is in the HIGH state, then the value in the memory word COUNT_PRODUCT_20GRAMS (D12) will increase by (+1).
RUNG 8 (RESET COUNTER)
In this rung, when the RESET COUNTER (0.07) button is pressed, the values in the memory words COUNT_PRODUCT_10GRAMS (D10), COUNT_PRODUCT_15GRAMS (D11), and COUNT_PRODUCT_20GRAMS (D12) will become zero “0”.
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