Carton Erector Sequence
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Briefing
A carton erector picks flat blanks from a magazine, erects them, applies hot-melt glue, and ejects formed cartons. Each step requires limit-switch or sensor confirmation before advancing. Magazine empty or glue failure latches a fault and stops the cycle.
Objectives
- START_PB begins the erect cycle if MAGAZINE_FULL and GLUE_OK
- Step 1: MAGAZINE_PICK energises → await CARTON_DETECTED
- Step 2: ERECT_ACTUATOR down → await ERECT_LS_DOWN
- Step 3: GLUE_GUN on for 500ms (timed)
- Step 4: ERECT_ACTUATOR up → await ERECT_LS_HOME
- Step 5: CARTON_EJECT energises → carton dispatched → cycle restarts if STOP_PB not pressed
- FAULT_LAMP latches if MAGAZINE_FULL lost or GLUE_OK lost during cycle
Hints
- Use a STEP counter (0–5) with LS feedback checks at each transition
- Glue step uses a TON timer (500ms) rather than a LS
- FAULT latch clears only with STOP_PB when magazine and glue are both OK
- STOP_PB resets to IDLE at end of any step boundary
I/O Table
Inputs
MAGAZINE_FULLMagazine loaded (blanks available)
BOOL · %I0.0
CARTON_DETECTEDCarton blank present at pick head
BOOL · %I0.1
ERECT_LS_HOMEErect actuator at home (up)
BOOL · %I0.2
ERECT_LS_DOWNErect actuator at down position
BOOL · %I0.3
GLUE_OKGlue system ready and at temp
BOOL · %I0.4
START_PBCycle start push-button
BOOL · %I0.5
STOP_PBCycle stop push-button
BOOL · %I0.6
Outputs
MAGAZINE_PICKPick head vacuum/actuator
BOOL · %Q0.0
ERECT_ACTUATORErect actuator down command
BOOL · %Q0.1
GLUE_GUNHot-melt glue gun
BOOL · %Q0.2
CARTON_EJECTEject conveyor/pusher
BOOL · %Q0.3
FAULT_LAMPFault indicator lamp
BOOL · %Q0.4
Your program will be tested against:
All test cases run automatically when you submit. Assertions are hidden until you pass.
- #1MAGAZINE_PICK energises on START_PB
START_PB with MAGAZINE_FULL + GLUE_OK -> MAGAZINE_PICK
- #2Actuator erects after carton detected
CARTON_DETECTED -> ERECT_ACTUATOR energises
- #3Glue gun fires after erect reaches down position
ERECT_LS_DOWN -> GLUE_GUN on
- #4MAGAZINE_FULL lost mid-cycle latches fault
Magazine goes empty during cycle -> FAULT_LAMP
Related scenarios
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