Background information

The theoretical conveyor system used in the lab 2 exercise is now a real-world device and must be programmed to function accordingly.  It is now equipped with a PLC to control the system and a NI-USB6008 data acquisition device to monitor the current state of I/O signals. 

 

Objective

Program the conveyor system to activate and deactivate using the start and stop buttons, respectively.  Upon starting the system, the conveyor belt will begin moving and will do so until the zone-transition sensor is true.  It will then pause for 5 seconds to allow the operator to place a new part on the belt.  A good part will only activate the lower sensor at station 1, while a bad part will activate both the lower and upper sensor.  All parts will activate the zone transition sensor located between station one and station 2.  The in-position sensor is located at station 2 where the parts will be “cleaned”.  Station three, four and five will spray, heat and remove bad parts, respectively.  The actions of cleaning, spraying, and heating should only become active if a good part is in position at the corresponding station.  Also, only bad parts should be removed at the end of the run.  This is accomplished via a stepper motor.  The diverter should be activated through a 40 degree angle, pause 2 seconds, and return to the original position. A shift register function should be implemented into your PLC program to accomplish the tracking of good/bad parts. 

Create a LabVIEW program to monitor the current status of the inputs and outputs of the system.  The DAQ unit will be acquiring digital signals wired in parallel to the PLC.  Create a task using the Measurement and Automation software and configure the input signals accordingly. 

 

Logical addresses

PLC                                                                            DAQ

I0.0 – Start switch                                                                                P0.0 – Good part sensor

I0.1 – Stop switch                                                                                P0.1 – Bad part sensor

I0.2 – Good part sensor                                                                       P0.3 – Zone transition sensor

I0.3 – Bad part sensor                                                                         P0.4 – In position sensor

I0.4 – Zone transition sensor                                                             P0.5 – Clean

I0.5 – In position sensor                                                                     P0.6 – Spray

                                                                                                                P0.7 – Heat                                                                           

Q0.0 – Stepper motor coil 1                                                                P0.8 – Divert part

Q0.1 – Stepper motor coil 2

Q0.2 – Stepper motor coil 3

Q0.3 – Stepper motor coil 4

Q0.4 – Clean

Q0.5 – Spray

Q0.6 – Heat

Q0.7 – Conveyor motor