πŸ“¦ Project 1: Conveyor Reject System with Consecutive Bad Part Lockout

This project simulates a real-world reject conveyor using Rockwell Studio 5000 and RSLogix Emulate 5570. The system automatically tracks and rejects bad parts using diverter logic and halts the conveyor after 10 consecutive rejections. Fault reset logic ensures safe operator recovery. It’s a modular, scan-based design fit for packaging, inspection, and pharma automation lines.


🧠 System Overview

  • Start/Stop logic using pushbuttons with seal-in structure
  • Simulated part sensor and manual bad part detection
  • Diverter pulse control for rejecting bad parts
  • CTU and RES instructions track consecutive bad parts
  • Conveyor stops automatically on 10 consecutive rejects (Batch_Fault)
  • Manual fault reset through Sys_Reset
  • Built using structured routines: Map_IO, Process_Logic, Faults_and_Reset

πŸ“„ Project Report

πŸ“˜ Summary Documentation

Explains logic flow, tag structure, fault control, and scan behavior.

πŸ“₯ Download Summary PDF


πŸ’‘ Ladder Logic Overview

PDF of seal-in, diverter pulse, reject counter, and fault lockout.

πŸ“₯ Download Logic PDF



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