Bottling line: fill, cap, reject

The brief

Client

Cranmore Drinks

Site

Bottling line 4

Work order

CD-2618

Industry

Food and drink

Task code

PLC-18

Difficulty

Intermediate

Type of work

Programming

Stop the line for each bottle at the filler, fill it for a set time, check every bottle for a cap, count good and rejected bottles once each, reject uncapped bottles after a travel delay, and stop the line when a batch is done.

What you do

1. Read the client brief and the tag table: 14 tags, 7 inputs and 4 outputs.
2. Write the logic in ladder, Structured Text or SFC.
3. Press Simulate and watch the plant answer your program.
4. Run the factory acceptance test and fix what fails.

Skills you practise

• Sequence with timers
• One-shot counting
• Delayed reject output
• Batch counting and reset
• Sensor and presence interlock

What the test checks

The factory acceptance test runs 6 numbered tests against your program. The numbers in the brief are drawn per learner. The tests are:

• Start, Stop and E-stop run the Conveyor
• Stops at the filler and fills for 2000 ms, once per bottle
• Counts good bottles once each
• Rejects a bottle with no cap 800 ms after it arrives
• Batch of 7: the line stops, Reset clears the counts
• Stop and E-stop switch everything off and drop a waiting reject

In this lab

• Ladder, Structured Text and SFC in one studio
• A plant that answers: motors, tanks, conveyors
• Numbered tests mark your program