2019. 04. 12.

PLC Programming Example – Palletizer | Acc Automation

COMMUNICATION, DO-MORE, DO-MORE DESIGNER, FACTORY IO, MODBUS TCP, PLC, PLC LEARNING

PLC PROGRAMMING EXAMPLE – PALLETIZER

NOVEMBER 6, 2017 | GARRYS | 9 COMMENTS

We will apply the ve steps to PLC program development to a palletizer example. Our example will allow you to
determine how many layers of boxes you want on each skid.

Developing the PLC program is a process that can be clearly de ned. In our series on the ve steps to PLC
program development we have done some similar practical examples.
PLC Programming Examples – Five Steps to PLC Program Development
– Press
– Process Mixer
– Shift Register (Conveyor Reject)
– Paint Spraying
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– Delay Starting of 7 Motors

– Pick and Place
– Sorting Station (Shift Register)

De ne the task: (1)

Watch the sequence of operation video below. This will demonstrate the pallet layer selection, running and
resetting of the machine.
Watch on YouTube : PLC Programming Example – Palletizer Testing

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A normally open start and normally closed stop pushbuttons are used to start and stop the process in automatic
mode. Upon starting the pallet conveyors will load a pallet onto the elevator.

The elevator will move the pallet to the top of the elevator where it will be loaded with layers of boxes. Boxes are
staggered on the each layer so that they will interlock with themselves. This will provide a more stable skid.

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A turn device is utilized to orientate the boxes on every other layer. A pusher is used to move the rows of boxes
to the plate.

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Once the last row is pushed on the plate, a clamp will be used to square up the layer of boxes. The plate will then
open putting the layer of boxes onto the pallet. The elevator will then move down to allow the plate to close. The
next layer then can be assembled on the plate.
When the layers of boxes have been obtained, the elevator will move all the way to the bottom. This will align
with the exit conveyor. The nished pallet will then move onto the exit conveyor. An empty pallet is then moved
onto the load conveyor and the process will continue again.
A counter will be used to track the number of boxes that have been processed. This can be reset by hitting the
reset in the manual mode.
The reset button in the manual mode will also reset the machine and move the elevator to the bottom.

De ne the Inputs and Outputs: (2)

Inputs:
Pallet at Entry – Sensor – On/Off
Pallet at Exit – Sensor – On/Off
Pallet loaded – Sensor – On/Off
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Box at Entry – Sensor – On/Off

Pusher Limit – Sensor – On/Off
Plate Limit – Sensor – On/Off
Clamped – Sensor – On/Off
Elevator Moving – Sensor – On/Off
Start Pushbutton – Normally Open – On/Off
Reset Pushbutton – Normally Open – On/Off
Stop Pushbutton – Normally Closed – On/Off
Emergency Stop – Normally Closed – On/Off
Auto / Manual – Switch – On/Off
Layers Button Pushbutton – Normally Open – On/Off

Outputs:
Pallet Feeder – Contactor – On/Off
Load Pallet – Contactor – On/Off
Exit Conveyor – Contactor – On/Off
Move to Limit – Contactor – On/Off
Elevator Up – Contactor – On/Off
Elevator Down – Contactor – On/Off
Box Feeder – Contactor – On/Off
Turn – Contactor – On/Off
Push – Contactor – On/Off
Load Belt – Contactor – On/Off
Clamp – Contactor – On/Off
Open Plate – Contactor – On/Off
Warning Light – Contactor – On/Off
Start Light – Contactor – On/Off
Reset Light – Contactor – On/Off
Stop Light – Contactor – On/Off
Counter – Register – 16 bits
Layers – Register – 16 bits

Develop a logical sequence of operation: (3)

A ow chart or sequence table is used to fully understand the process the needs to be controlled. 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?

This step is where you can save yourself allot of work by understanding everything about the operation. It will
help prevent you from continuously re-writing the PLC logic. Knowing all of these answers upfront is vital in the
development of the PLC program.
Here is our sequence of operation for our palletizer application.

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If our input conditions are true then the outputs are set. It will then look at the next step for the input conditions
to set the outputs. Etc.

Develop the PLC program: (4)

Writing the code for the PLC will be the next step in our program development. A quick review can be seen on
our post: Buiding A PLC Program That You Can Be Proud Of
(This series takes you through using discrete inputs and outputs to control traf c lights and cylinders. As we
progress we introduce additional methods to solve logic. We look at sequencers in a new way and learn how to
write programs to allow users to teach the new sequence.)
The rst thing in our program is to control the start and stop functions. This is done through a latching circuit.
The start light bit is used as a control relay for the rest of the program.

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This is the logic for the loading and unloading of the pallets. You will notice that we have an off delay timer for
the exit conveyor.

The elevator movement to move the elevator all the way to the top or bottom is to activate the move to limit and
the elevator up or down output at the same time.

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The elevator position is monitored by bit C10. If this is on then the elevator is at the top with a pallet and ready
to load boxes.

Number of layers on the pallet is done with counter 0.

The boxes are staggered on the layer. A counter is set up for the number of boxes in the row and the number of
rows on the layer.

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The boxes in the rows and the number of rows are staggered. This code will set up the counters and turn on the
turn output.

The box feeder and load belt will move the boxes into the pusher area.

The pusher will push the boxes in the row onto the plate.

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This section of the code will clamp the boxes and open the plate once the layer of boxes has been made.

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The number of layers on the pallets can be set between 1 and 4.

The total number of boxes are counted using an INC increment instruction. The reset button when in manual will
reset the number to 0.

This is the end of our program.

Test the program: (5)

We will be using Factory IO to test the program. This communicates Modbus TCP Client (Master) to our BRX
Series PLC (Modbus TCP Server (Slave)).

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We will now add the inputs and outputs to our program for communication to our scene in Factory IO. The
output coils from Factory IO will set the actual input addresses in our PLC. See the following post on
Understanding the PLC Program Scan. This will demonstrate how we can set the actual PLC inputs.

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The inputs from Factory IO will be set by the actual outputs from our PLC.

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The rst step in testing out the program is to ensure that the inputs and outputs of the PLC are wired correctly.
We would usually turn each input on manually and see the corresponding input of the PLC turn on. The same
applies to the output devices. We would turn on each of the outputs to determine if they have been wired

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correctly.
Next we will try our manual operations programmed into the process. If everything is working then we will start
running our program in automatic mode.

Test the program for things that can go wrong. Unplug a sensor or remove a box after the sensor has seen it. The
program should be able to react.

Watch the video below to see an explanation and test of the program using Factory IO.

You can download the program and Factory IO scene here.

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Watch on YouTube : PLC Programming Example – Palletizer

PLC Programming Example – Palletizer

If you have any questions or need further information please contact me.
Thank you,
Garry

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9 THOUGHTS ON “PLC PROGRAMMING EXAMPLE – PALLETIZER”

oussama
FEBRUARY 23, 2018 AT 10:03 AM

Hello
I want to ask you if you have the grafecet for palletizer can you send it to me please

 garrys
FEBRUARY 23, 2018 AT 10:12 AM

Hi Oussama,
I do not have the grafecet for the program, but I have added the excel le to the download for the
program. It can be downloaded at the following location. (Or above in the post.)
https://www.dropbox.com/s/cvjqwefspcmw0g9/PLC%20Programming%20Example%20-
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%20Palletizer.zip?dl=0
Regards,
Garry

oussama
MARCH 7, 2018 AT 9:56 AM

hi
can u explain to me how to display a number on digital displayer in grafcet

 garrys
MARCH 7, 2018 AT 11:24 AM

Hi Oussama,
What do you mean by a digital displayer? Do you have a model number?
If you are using the Factory IO display, then you would just reference the address for the number. The
program that is written in ladder or grafcet would determine how the number is changed.
Regards,
Garry

oussama
MARCH 9, 2018 AT 4:22 PM

Hi garrys
thank you for reply

Bert
OCTOBER 18, 2018 AT 3:15 PM

How do I make it so when I press stop it will end the thing its doing and continues after pressing start again?

 garrys
OCTOBER 18, 2018 AT 3:42 PM

Hi Bert,
You will notice that in the sequence table we have the start and stop circuit outputs. These are inputs to
the sequence table. When you hit the stop button the outputs will remain at their last state. Hitting start
again will continue the sequence.
Regards,
Garry

Bert
OCTOBER 18, 2018 AT 3:50 PM

Hey, I thanks for responding so fast. What I actually meant to ask was if there is a way to make it stop
right after the action it is currently doing. So it would complete the action even after pressing stop.

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 garrys
OCTOBER 18, 2018 AT 4:05 PM

Hi Bert,
According to the sequence tables, it should stop the outputs from advancing to the next step. If you
need it to advanced to the next step when stopping then place an off delay on the stop signal. I’m not
sure I actually follow what you want to do. The output will depend on what is being done. If you are
controlling a cylinder and it is moving out when the stop is hit, the cylinder will continue until it is out.
Regards,
Garry

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