We designed a conveyor system that would inspect different parts.   The system uses a DVT vision system that is used to take pictures of the parts.  The camera takes pictures when one of two sensors is tripped.  One of the sensors is a proximity sensor and the other is a photo eye sensor.  We also have an Allen Bradley PLC with a 13 slot rack, SLC 5-03 CPU, 115 VAC input card, 24 DC sinking input card and a triac output card.  The software in the camera is used to determine which part is being sent down the conveyor and then based on this result it determines whether or not the part passes the required inspection.  Script was written to determine which part is present.  There are three lights on the system along with an opto push button used for the cycle start/reset input.  The three lights on the system are part pass, part fail and system out of control.  The system would become out of control if an unrecognized part is detected. 

OUTPUTS:

O:03/01    -    Motor On

O:03/03    -    Pass Lamp

O:03/07    -    Fail Lamp

O:03/05    -    Unrecognized Part Lamp

INPUTS:

I:01/04      -    E-Stop Pushed

I:02/00      -    Cycle Start/Reset

I:02/01      -    Part Pass

I:02/03      -    Part Fail

I:02/05      -    Unrecognized Part

I:02/07      -    Motor (For Future Use)

I:02/09      -    Pulley (For Future Use)

RUN STATE:

• Motor on
• If good part turn on pass lamp for 3 seconds
• If bad part turn on fail lamp for 3 seconds

OUT OF CONTROL STATE:

• Motor off
• Turn on unrecognized part lamp
• Wait for reset to go back into run mode

To download the RS LOGIX program file for the PLC click here or in PDF format click here

To download the scripts for the softsensors click here

To view pictures of our completed project click here