Figure $1$ below shows an apple packaging plant with two conveyor lines which are semi$-$automated. They make use of an operator and a PLC to complete basic tasks.

In this task, you are required to control the conveyor lines which carry apples and boxes across the factory. A beacon tower attached to the apple conveyor line also needs to be also programmed as part of the task solution.

EN$-$GB

Figure $1$: Distribution Conveyer

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ENG

$01$:$49$

$2024/09/10$ Table $1$ provides the input and output information for the system.

Table $1$: Input $/$ Output Operation

PLC Program Description

The apple conveyor transports apples across the factory to the box conveyor line. At the end of

the apple conveyor line is a part sensor $($SE$1)$ that is used to count the number of apples that

come off the line. The box conveyor carries boxes which collect apples that come off the apple

conveyor line. The position which a box needs to be placed at in order to collect apples is marked

by a box sensor $($SE$2).$ conveyor line. The position which a box needs to be placed at in order to collect apples is marked

by a box sensor $($SE$2).$

Plant Initial State:

The boxes in place to collect apples coming off the apple conveyor are empty.

Both conveyor lines are off.

The apple conveyor is started using an Apple Conveyor Start Button $(\%$I$1).$ The apple conveyor

can ONLY start if the counter is less than $15$ and box conveyor is off and Box sensor High. The

apple conveyor is stopped using an Apple Conveyor Stop Button $(\%12)$ or Apple Counter equals

The Apple Counter is incremented by SE$1(\%$IO$\mathrm{.}3)$ and reset by Apple Counter Reset Button $(\%$

$.$ The Apple Conveyor line prioritizes Start over Stop!

The box conveyor starts using a Box Conveyor Start Button $(\%13).$ The box conveyor can ONLY

start if Box Apple Counter equals $15$ and apple conveyor is off. The box conveyor only starts

moving $5$ seconds after all the start conditions are met. This means that the box conveyor line

will only move $5$ seconds after being started. The box conveyor can be stopped using a Box

Conveyor Stop button$(\%14)$ or when Box Sensor is High. The Box Conveyor line prioritizes Stop

over Start! Led Beacon Tower

The apple conveyor line makes use of a Beacon Light that gives the operator information according to its

colours. The meaning of the colours is still to be established by the line manager and safety officer. At the

moment, led beacon tower just operates as follows:

Led Beacon Tower Operation

Figure $1$ Beacon Light

When the apple counter is $<mn\; id="EditorElement\_2649581">1</mn><mn\; id="EditorElement\_2649582">5</mn>$ then Blue light on$.$

When the apple counter is $=15$ then Orange light on$..$

When the apple counter is $>15$ Red light flashes @ $1$ HzWhen the apple counter is $>15$ Red light flashes @ $1$ Hz

$\backslash$table$[[$Inputs$,$Contact,Address$],[$Apple Conveyor Start,Normally Open,$\%11],[$Apple Conveyor Stop,Normally Closed,$\%12],[$Box Conveyor Start,Normally Open,$\%13],[$Box Conveyor Stop,Normally Closed,$\%14],[$SE$1,$Normally Open,$\%15],[$SE$2,$Normally Open,$\%$I$7],[$Box Counter Reset Button,Normally Open,Address$],[,\%$Q$1],[$Outputs$,$Details,$\%$Q$2],[$Apple Conveyor,Conveyor driven by motor.,$\%$Q$3],[$Box Conveyor,Conveyor driven by motor.,$\%$Q$4],[$Blue Light,Indicator,$\%$Q$5],[$Orange Light,Indicator,$],[$Red Light,Indicator,$]]$

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