Basic
30 min

Carton Erector Sequence

packagingsequenceractuatorlimit-switchglue
Carton Erector Sequence scenario preview

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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_FULL

Magazine loaded (blanks available)

BOOL · %I0.0

CARTON_DETECTED

Carton blank present at pick head

BOOL · %I0.1

ERECT_LS_HOME

Erect actuator at home (up)

BOOL · %I0.2

ERECT_LS_DOWN

Erect actuator at down position

BOOL · %I0.3

GLUE_OK

Glue system ready and at temp

BOOL · %I0.4

START_PB

Cycle start push-button

BOOL · %I0.5

STOP_PB

Cycle stop push-button

BOOL · %I0.6

Outputs

MAGAZINE_PICK

Pick head vacuum/actuator

BOOL · %Q0.0

ERECT_ACTUATOR

Erect actuator down command

BOOL · %Q0.1

GLUE_GUN

Hot-melt glue gun

BOOL · %Q0.2

CARTON_EJECT

Eject conveyor/pusher

BOOL · %Q0.3

FAULT_LAMP

Fault 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.

  1. #1MAGAZINE_PICK energises on START_PB

    START_PB with MAGAZINE_FULL + GLUE_OK -> MAGAZINE_PICK

  2. #2Actuator erects after carton detected

    CARTON_DETECTED -> ERECT_ACTUATOR energises

  3. #3Glue gun fires after erect reaches down position

    ERECT_LS_DOWN -> GLUE_GUN on

  4. #4MAGAZINE_FULL lost mid-cycle latches fault

    Magazine goes empty during cycle -> FAULT_LAMP

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