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P1000 Drum or Sequencer for linear actuator control

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  • P1000 Drum or Sequencer for linear actuator control

    The Project:
    I am building a machine that "pre-arranges" a case of beer from two incoming conveyors (either ringed 4 or 6-packs from one conveyor, or 12-pack cartons from the other), then pushes it onto another conveyor "pre-assembled", where it goes in to a tray former which forms a box around it and glues it.

    Per SMC's recommendations, I have two pneumatic pistons (PISTON1 and PISTON2), each with their own solenoid, to extend or retract each piston individually. They're physically bolted together onto a carriage (one is left side, the other is right side, but they do the exact same job at the exact same time, every time). These pistons are for actually pushing the product from one conveyor to another. There's a third piston (PISTON3) that opens and closes a "gate" to not allow product in while the first two pistons are doing their job. There's several packaging configurations (6x4-pack, 4x6-pack, 2x12-pack, 3x8-pack), and I want to have a recipe for each, as the pistons will all have to behave differently.

    All 3 pistons are each equipped with 5 sensors, to tell the PLC the piston position. I've called them A B C D and E - A is fully extended, E is fully retracted, and B C and D are in the middle (SENSOR1A, SENSOR2D, SENSOR3B, etc...).

    There's also product sensors, A B C and D - they are to tell the PLC when that position is "full".

    The machine is nearly complete, and it's now programming time.

    Click image for larger version

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    My questions:

    What is the best way to control these pistons? Essentially, I need it to accomplish the following: (I'll only give one recipe example)
    • Set Piston 3 to position B (Block conveyor 2, allow conveyor 1 in)
    • (product comes in on Conveyor 1)
    • Sensor A detects product steadily for 1.5s
    • Set Piston 3 to Position A (Block both conveyors)
    • Set pistons 1 and 2 to Position C (stage it on dead conveyor 2), return to position A
    • Set piston 3 back to position B (to allow product in)
    • Sensor A detects product steadily for 1.5s (again) but sensor C sees the first product still, so this time:
    • ...Set pistons 1 and 2 to position E (pushing all 24 cans onto conveyor 3 "pre-assembled"
    • ...and start all over.

    Other recipes will be slight variants - this is the most complex (and isn't really complex at all...) I'm taking a stab at it with drums and sequencers, but I don't want to make unnecessary cumbersome code if i don't have to.

    Your help is much appreciated. And as always, if you're ever in Massachusetts, stop in for a cold beer on me.

  • #2
    Are you set on the P1000? You can do this with drum but staging in BRX is nice for sequential operations like this.

    Comment


    • #3
      Originally posted by RBPLC View Post
      Are you set on the P1000? You can do this with drum but staging in BRX is nice for sequential operations like this.
      Yes, the aforementioned Tray Former has the P1000 inside. I wanted to go with P2K or even P3K, but couldn't justify the budget expenditure at the time. Tempted to repurpose the P1K for another project and get a more robust PLC, but now isn't exactly the time... There's already not a lot of money in beer, and now the state has closed our taproom and 100% of our draft sales, so we're hanging by a thread as it is. This is a "make it work for now and we can upgrade later" project; I spent like $4000 on materials to build the thing, then a few days later our governor (rightfully so... nobody is disputing that) declared all bars and restaurants "non-essential".

      So here I sit, with a rad pile of parts, my welder, and Productivity Suite.

      Comment


      • #4
        https://accautomation.ca/productivit...-instructions/
        The above link will show you the drum instruction in the P1000 PLC.
        If the drum instruction does not work then the array functions might be another choice on the controller.
        https://accautomation.ca/productivit...ctions-part-1/

        The entire P1000 programming series can be found here.
        https://accautomation.ca/series/productivity-1000-plc/

        Regards,
        Garry
        _________________________________________________
        Garry
        ACC Automation
        https://www.accautomation.ca
        Connect with us on Facebook: facebook.com/accautomation/

        Comment


        • #5
          Originally posted by Garry View Post
          https://accautomation.ca/productivit...-instructions/
          The above link will show you the drum instruction in the P1000 PLC.
          If the drum instruction does not work then the array functions might be another choice on the controller.
          https://accautomation.ca/productivit...ctions-part-1/

          The entire P1000 programming series can be found here.
          https://accautomation.ca/series/productivity-1000-plc/

          Regards,
          Garry
          Hi Garry, thanks for the links. I've read this content already and have watched the videos, but that Drum example is a simple "do this for this long" drum, like a player piano, and not really dynamic... I need it to do certain things when certain conditions are satisfied, and other things if not.

          I threw this little bit together, and haven't tested yet... I'm going to try getting a few buttons and lights connected to "test". I really wish ProductivitySuite had a simulator like Do-More (and many others...)

          Click image for larger version

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          • #6
            Look at the Sequencer just below the drum. Each step can be a time event, a Bit event, Time and Bit or Time or Bit event. Use rungs to do the more complex logic and then set a bit to move the Sequencer along. Each step also has output control going into the step and output control exiting the step. Something that can be very useful. One got ya. When Sequence is enabled the first step outputs become active.

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