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35 min

Conveyor Sort — 3D Cell

3dconveyorcounterssensorstiming
Conveyor Sort — 3D Cell scenario preview

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Briefing

Boxes travel along a main conveyor. An entry photo-eye announces each arriving box. A second photo-eye mounted at a known height differentiates tall boxes from short ones. Tall boxes must be diverted onto a second conveyor by firing a pneumatic solenoid while the box is passing the diverter arm; short boxes continue past undisturbed. A counter watches the divert lane's limit sensor and lights a lamp once five tall boxes have been successfully diverted.

Objectives

  • START energises MAIN_MOTOR; STOP de-energises it
  • Fire DIVERTER_SOL so that tall boxes are pushed onto the divert lane
  • Leave DIVERTER_SOL off for short boxes
  • Light TALL_COUNT_LAMP once 5 tall boxes have cleared the divert-lane limit sensor
  • Never energise DIVERTER_SOL while ENTRY_PE is still broken — the arm would collide with the box

Hints

  • Use SET/RESET on MAIN_MOTOR driven by START (set) and STOP (reset)
  • SET DIVERTER_SOL on HEIGHT_PE and RESET it on DIVERT_LIMIT — the belt spacing guarantees ENTRY_PE has already cleared before HEIGHT_PE fires
  • Count DIVERT_LIMIT rising edges with a CTU (PV := 5) and drive TALL_COUNT_LAMP from its Q output
  • SHORT_COUNT_LAMP is an optional extension — the 5 test cases only require MAIN_MOTOR, DIVERTER_SOL, TALL_COUNT_LAMP, and the ENTRY_PE safety invariant

I/O Table

Inputs

START

Start push-button (momentary)

BOOL · %I0.0

STOP

Stop push-button (momentary)

BOOL · %I0.1

ENTRY_PE

Entry photo-eye (beam broken by any box)

BOOL · %I0.2

HEIGHT_PE

Height photo-eye (beam broken by tall boxes)

BOOL · %I0.3

DIVERT_LIMIT

Divert-lane limit sensor

BOOL · %I0.4

Outputs

MAIN_MOTOR

Main conveyor motor contactor

BOOL · %Q0.0

DIVERTER_SOL

Pneumatic diverter solenoid

BOOL · %Q0.1

TALL_COUNT_LAMP

Tall-box count ≥ 5 indicator

BOOL · %Q0.2

SHORT_COUNT_LAMP

Short-box count ≥ 5 indicator

BOOL · %Q0.3

Your program will be tested against:

All test cases run automatically when you submit. Assertions are hidden until you pass.

  1. #1Start energises main motor, stop drops it

    START -> MAIN_MOTOR on; STOP -> off

  2. #2Tall box fires the diverter solenoid and is diverted

    Inject a tall box: solenoid pulses for the transit window, box reaches the divert lane

  3. #3Short box passes without firing the diverter

    Inject a short box: diverter solenoid remains off throughout the run

  4. #4Mixed flow counts five tall boxes and passes a short box

    Tall boxes divert while a short box continues on the main conveyor; TALL_COUNT_LAMP energises after the fifth tall box

  5. #5Diverter never fires while a box still breaks the entry beam

    Inject a tall box; assert the solenoid was never energised while ENTRY_PE was active

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3D Conveyor Sort PLC Lab — Detect, Count and Divert Parts