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PLC programming challenges
Challenge 05 · Code it · Pro

Pack six, then pause

Count six bottles, stop for the pusher, then go again.

Count each bottle once as it arrives at BottlePresent. At the sixth, stop ConveyorOn and light PackReady for 2 seconds while the pusher takes the pack. Then run the belt again and count the next six from zero. Run OFF stops the belt but keeps the count.

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The 3D filling line this challenge runs on Pro challenge
Test replay

Six bottles make a pack

Test 1 of 4
Set by the testChecked by the testStep 15 of 15 · 3.1 s
Level
Medium · 20 points
Kind
Code it
Time
About 18 min
Pass rate
New
Machine
3D filling line
Siemens
LAD and SCL
Rockwell
Ladder and Structured Text
Beckhoff
Structured Text
Automatic checks

What the checks test

  1. Each bottle counts once, however long it sits on the .
  2. The sixth bottle stops the belt and lights PackReady for 2 s.
  3. After the pause the belt runs and the next pack counts from zero.
  4. Run OFF stops the belt; the bottles counted so far still count.

The checks run 4 tests on the machine, scan by scan: Six bottles make a pack; A bottle sitting on the sensor counts once; The next pack starts from zero; Run OFF stops the belt and keeps the count.

On site

Where you’d find this

A bottling line groups bottles into packs of six. The belt pauses while a pusher moves each pack onto the shrink wrapper.

Counting one bottle twice, or missing one, sends short packs to the customer and jams the wrapper.

The machine

How it should behave

Count
One count per bottle arriving at the sensor.
Pack
At six: belt stops, PackReady for 2 s.
Run
Run OFF stops the belt and keeps the count.

Press Run and watch the bottles. After the sixth the belt pauses for 2 s, then the next pack starts.

Keep going

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