π¦ 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. Itβs a modular, scan-based design fit for packaging, inspection, and pharma automation lines.
π§ 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
π Project Report
π Summary Documentation
Explains logic flow, tag structure, fault control, and scan behavior.
π‘ Ladder Logic Overview
PDF of seal-in, diverter pulse, reject counter, and fault lockout.