PLC Simulator

PLC conveyor system

Program the flow, not just the motor.

A complete conveyor programme coordinates drives, sensors, product memory, routing, accumulation, protection and recovery. Build each layer, then prove it on a running 3D line.

Run the 3D conveyor Browse conveyor components
Live 3D conveyor component

Conveyor control in context

Follow one product from drive command to safe recovery.

A complete conveyor program owns motion, detection, tracking, routing, accumulation, fault evidence and restart behavior. These views define the practical boundaries the runnable scenarios teach.

PLC conveyor drive system with gear motor VFD start-stop station and control panel
01Begin with energy and motion: protection, drive command, speed reference, run feedback and defined stopping.
Photoelectric sensors detecting and tracking cartons on a motorized roller conveyor
02Convert sensor edges into product state without double-counting or losing a carton between zones.
Pneumatic conveyor diverter sorting cartons into two lanes under PLC control
03Route the correct product only when classification, position, downstream availability and actuator feedback agree.
Multi-zone accumulating conveyor with occupied and blocked states for each zone
04Zone logic prevents collisions by transferring only when the downstream zone can accept the product.
Conveyor jam diagnosis using sensor states motor current and an HMI alarm
05A useful jam alarm identifies the expected transition, the observed evidence and the affected zone.
Guarded conveyor safe-restart test after jam clearance and emergency-stop reset
06Recovery requires cleared hazards, reset protection, coherent sensors and a controlled restart—not an automatic return to motion.

Control architecture

Four layers make a conveyor system teachable and testable

01

Drive and prove

Issue a run demand only after permissives; compare commanded speed with running and encoder feedback.

02

Detect and track

Debounce sensors, capture arrival edges and preserve product identity between physical detection points.

03

Route and sort

Coordinate stops, pushers, turntables and diverters without colliding loads or losing the tracked destination.

04

Trip and recover

Detect jams, failed feedback and blocked discharge; stop in a defined order and require deliberate reset.

Runnable curriculum

Grow from one belt to a complete sort line

Conveyor Sort

Track products between detection and diversion with counters and timing.

Open scenario

3D Conveyor Sort

See motion, sensor state and diversion on the same editable factory floor.

Open scenario

VFD Conveyor Speed

Command, scale and prove belt speed from analog and discrete signals.

Open scenario

Stop-delay Conveyor

Keep discharge moving long enough to clear the last product safely.

Open scenario

Mining Conveyor Train

Sequence downstream-first and protect a bulk-material line from blockage.

Open scenario

Drive Fault Recovery

Restore the drive only after the unsafe demand and original cause are gone.

Open scenario

Reusable conveyor kit

Open each object to inspect its motion, typed PLC points, failure modes and scenarios before composing the line.

roller conveyorstraight belt conveyorphoto eye sensorproximity sensorrotary encoderconveyor scalerfid readerpneumatic pusher

Engineering boundary

Training models teach sequence, state and fault reasoning. Real conveyor design still requires load, motor, braking, guarding, stop-category, safety distance and manufacturer calculations.