PLC Based Product Sorting Machine System

In this advanced PLC program, PLC based product sorting machine system is used to carry different products using the lift to separate the parts based on size.

Contents

Here there are three positions available based on the size like small, medium, and large. The conveyors are used to transfer the products and place them on the trays.

PLC Based Product Sorting Machine System

The below simulation shows the PLC sorting system using the lift operation.

Inputs and Outputs

Type	Device No.	Device name	Operation
Input	X0	Upper	ON when part is detected.
Input	X1	Middle	ON when the lift is at a lower position.
Input	X2	Lower	ON when the part is detected.
Input	X3	Part on lift	ON when the part is detected.
Input	X4	Lower lift position	ON when the lift is at the middle position.
Input	X5	Middle lift position	ON when the lift is at middle position.
Input	X6	Upper lift position	ON when the part is on the lift.
Input	X10	Sensor	ON when the part is detected at the left end.
Input	X11	Sensor	ON when the part is detected at the left end.
Input	X12	Sensor	ON when the part is detected at the right end.
Input	X13	Sensor	ON when the part is detected at the left end.
Input	X14	Sensor	ON when the part is detected at the right end.
Input	X15	Sensor	ON when the lift is at the upper position.
Output	YO	Supply command	One part is supplied when YO is ON: Metal cylinder repeats in order S, L, M, L, M, S.
Output	Y1	Conveyor forward	ON when the part is detected at the right end.
Output	Y2	Lift up command	The lift moves up when Y2 is ON. The lift stops when Y2 is OFF.
Output	Y3	Lift down command	The lift moves down when Y3 is ON. The lift stops when Y3 is OFF.
Output	Y4	Lift rotation command	The conveyor moves forward when Y1 is ON.
Output	Y5	Lower conveyor forward	Lift rotates to transfer part to conveyor when Y4 is ON. Lifts rotates back to the original position when Y4 is OFF.
Output	Y6	Middle conveyor forward	The conveyor moves forward when Y5 is ON.
Output	Y7	Upper conveyor forward	The conveyor moves forward when Y6 is ON.

Program Description

The entire system comprises two components: General Control and Lifter Management.

General Control:

Activating the PB1 (X20) button on the operational panel initiates the Supply command (Y0) for the hopper. Deactivating the PB1 (X20) button turns the Supply command (Y0) off. Upon activation of the Supply command (Y0), the hopper delivers a part.

The conveyors initiate movement when the SW1 (X24) on the control panel is activated. Conversely, the conveyors halt movement when the SW1 (X24) is deactivated.

Upon detecting a part by the sensor X10, X12, or X14 positioned to the left of the conveyor, the corresponding conveyor initiates, transporting the part to the right-end tray. Three seconds post a part passing by the sensor X11, X13, or X15 to the right of the conveyor, the conveyor halts.

Parts of varying sizes (large, medium, small) on the conveyor are sorted by the inputs of the Upper (X0), Middle (X1), and Lower (X2) sensors.

Lifter Management:

Once the Part on the lift sensor (X3) in the lift is activated, the part is transported to one of the following conveyors based on its size: