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This is the logic for the loading and unloading of the pallets. The start light bit is used as a control relay for the rest of the program. The first thing in our program is to control the start and stop functions.
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We look at sequencers in a new way and learn how to write programs to allow users to teach the new sequence.)
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As we progress we introduce additional methods to solve logic.
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(This series takes you through using discrete inputs and outputs to control traffic lights and cylinders. A quick review can be seen on our post: Buiding A PLC Program That You Can Be Proud Of
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Writing the code for the PLC will be the next step in our program development. Etc.ĭevelop the PLC program: (4) – Palletizer PLC Programming Example It will then look at the next step for the input conditions to set the outputs. If our input conditions are true then the outputs are set. Here is our sequence of operations for our PLC programming palletizer example application. Knowing all of these answers upfront is vital in the development of the PLC program. It will help prevent you from continuously re-writing the PLC logic. This step is where you can save yourself a lot of work by understanding everything about the operation. It must also answer questions like the following: What happens when electrical power and/or pneumatic air is lost? What happens when the input / output devices fail? Do we need redundancy?
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Layers – Register – 16 bits Develop a logical sequence of operation: (3) – Palletizer PLC Programming ExampleĪ flow chart or sequence table is used to fully understand the process the needs to be controlled. Layers Button Pushbutton – Normally Open – On/Off Stop Pushbutton – Normally Closed – On/OffĮmergency Stop – Normally Closed – On/Off Reset Pushbutton – Normally Open – On/Off Start Pushbutton – Normally Open – On/Off Define the Inputs and Outputs: (2) – Palletizer PLC Programming Example
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The reset button in the manual mode will also reset the machine and move the elevator to the bottom. This can be reset by hitting the reset in the manual mode. An empty pallet is then moved onto the load conveyor and the process will continue again.Ī counter will be used to track the number of boxes that have been processed. The finished pallet will then move onto the exit conveyor. When the layers of boxes have been obtained, the elevator will move all the way to the bottom. The next layer then can be assembled on the plate. The elevator will then move down to allow the plate to close. The plate will then open putting the layer of boxes onto the pallet. Once the last row is pushed on the plate, a clamp will be used to square up the layer of boxes. A pusher is used to move the rows of boxes to the plate. This will provide a more stable skid.Ī turning device is utilized to orientate the boxes on every other layer.
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Boxes are staggered on each layer so that they will interlock with themselves. The elevator will move the pallet to the top of the elevator where it will be loaded with layers of boxes. Upon starting the pallet conveyors will load a pallet onto the elevator. Watch on YouTube: PLC Programming Example – Palletizer TestingĪ normally open start and normally closed stop pushbuttons are used to start and stop the process in automatic mode. This will demonstrate the pallet layer selection, running, and resetting of the machine. Watch the sequence of operation video below. – Sorting Station (Shift Register) Define the task: (1) – Palletizer PLC Programming Example
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PLC Programming Examples – Five Steps to PLC Program Development In our series on the five steps to PLC program development, we have done some similar practical examples. Our example will allow you to determine how many layers of boxes you want on each skid.ĭeveloping the PLC program is a process that can be clearly defined. We will apply the five steps to PLC program development to a palletizer example.