PLC circuits
Production Line Counting with a PLC
What is production line counting with a PLC?
It is a PLC application in which products on a production line are counted by a sensor, a cycle is completed at a set number, and the system stops itself if the line stays empty too long. The product count, cycle count and idle time are shown on the operator panel.
Where is it used?
It is used for production tracking, on packaging and filling lines, for end-of-shift reporting and to monitor line efficiency. Stopping an idle line automatically saves energy.
PLC wiring and ladder program
The conveyor motor runs through a contactor; the inductive sensor and buttons go to PLC inputs. The program uses two counters and a timer together. The count not being cleared even when the system stops shows the importance of retentive data in a PLC.
What it teaches
Nested counters, timeout control and showing data to the operator are the basis of Industry 4.0 and production monitoring systems.
Parts used
- Motor 3~
- M1
- PLC
- PLC1
- Start button (NO)
- S2, S3
Run it in the simulator.
This circuit is ready in the CoilPath library. Open it, press the buttons and follow the current. It also comes with a wiring view and a panel layout.