Sorting station

Task
Assemble, wire and tube the production line on the profile plate according to the following
guidelines and the provided technical manual.

Develop a program and commission the production line.

Your task is complete when:

1. The production line has been mechanically assembled, correctly wired, connected and its
correct operation is guaranteed (based on evaluation using the simulation box).
2. Correct execution of the program with PLC activation (based on evaluation/PLC board) is
guaranteed.
3. The system meets the specifications (in accordance with the 'Agreement on Professional
Practice' which has been handed out separately).
Wiring of the I/O Terminal

Connector I/O Comment Connector I/O Comment

Terminal (IN) Terminal (OUT)

DI 0 Part Available DO 0

DI 1 Inductive Sensor DO 1 Conveyor motor

DI 2 Rectro Reflective Sensor DO 2 Stopper Cylinder

DI 3 Gate 1 Cylinder Retracted DO 3 Gate/Branch 1

DI 4 Gate 1 Cylinder Extanded DO 4 Gate/Branch 2

DI 5 Gate 2 Cylinder Retracted DO 5 Lamp Green

DI 6 Gate 2 Cylinder Extanded DO 6 Lamp Yellow

DI 7 Optical Sensor DO 7 Lamp Red

Description Evaluation

Function to be checked using simulation box and wiring of the I/O Done Max points
Terminal for the station(Distribution station)

Preparation: Connect the simulation box to the I/O terminal (Output 0 – 7: signal 1 or 0); (Input 0 – 7: signal 1 or 0)

Connector I/O Terminal (IN) Comment (1 signal indicates)

DI 0 Part Available

DI 1 Inductive Sensor

DI 2 Rectro Reflective Sensor

DI 3 Gate 1 Cylinder Retracted

DI 4 Gate 1 Cylinder Extanded

DI 5 Gate 2 Cylinder Retracted

DI 6 Gate 2 Cylinder Extanded

DI 7 Optical Sensor

Connector I/O Terminal (OUT) Comment (1 signal set)

DO 0

DO 1 Conveyor motor

DO 2 Stopper Cylinder

DO 3 Gate/Branch 1

DO 4 Gate/Branch 2

DO 5 Lamp Green

DO 6 Lamp Yellow

DO 7 Lamp Red

SimuBox total

Description Evaluation

Function to be checked using PLC board Done Max. Points

Preparation: Remove all workpieces from the stations, connect the PLC board to the I/O terminal, start
the PLC.

Signal lamp RED isflashing with 0.5s ON, 0.5s OFF

At any time only one lamp of the signal column is on.

Press RESET button

Reset button at the control panel of the sorting station
System move to initial position

Signal lamp YELLOW is flashing with 0.5s ON, 0.5s OFF

At any time only one lamp of the signal column is on.
If any workpiece present on the conveyor belt will be rejected at the Third slide
Press START button

Signal lamp GREEN is ON

At any time only one lamp of the signal column is on.
A: Place a workpiece on the conveyor belt manualy

Conveyor transport workpiece to slider

Partial points

Final position of the workpiece as follow:

 Slide1 Done Max.Points Slide2 Done Max.Points Slide3 Done Max.Points

Black Red Silver

Black Red Silver

Black Red No-wp

Partial points Partial points Partial points

Partial points

Ifworkpieces is on the slide, then sorting station is in initial position

When Sorting station is in initial position, signal lamp YELLOW is flashing with 0.5s ON, 0.5s OFF

At any time only one lamp of the signal column is on.

Continue with A:

Evaluation of each slide:

Slide1 consist of 3workpieces, no additional workpieces is slide into Slide 1

Slide 2 consist of 3workpieces, Signal Red is ON

Slide 3 consist of 2workpieces, Signal Yellow flashing with 0.5s ON, 0.5s Off

All Slide consist of workpieces, signal Green and Red running FLIP FLOP

** At any time only one lamp of the signal column is on

Conveyor belt is OFF

Partial points

PLC board total

* Red, black or silver workpiece will be chosen by the evaluation team.

The Stop button is not used.