Smart Conveyor System with Automated Inspection & Reject Handling
Technologies: Rockwell Studio 5000 Logix Designer · ControlLogix 5570 Emulator
Key Concepts: Modular PLC Programming · UDTs & AOIs · FIFO Part Tracking · Alarm Handling
📌 Overview
A multi-zone conveyor system that detects, inspects, and automatically rejects defective parts — built and tested entirely in Studio 5000 with the ControlLogix 5570 Emulator (no physical I/O required).
The project models an industrial inspection line such as those used in packaging or assembly plants.
🎯 Highlights
- Auto / Manual Modes — safe start/stop sequencing and full manual jog control.
- Reusable Motor Control —
AOI_ConveyorMotorfor each conveyor zone. - FIFO Queue Tracking — keeps part order from entry to exit.
- Automated Inspection — checks label, seal, and weight; rejects failures.
- Scalable Alarm Handling — modular
AOI_Alarmwith trip, latch, and acknowledge. - Structured Codebase — routines split for IO mapping, modes, conveyor control, inspection, FIFO, and alarms.
🧪 Testing
- Fully simulated and validated in the Studio 5000 Emulator.
- Functional test matrix covers auto start/stop, inspection pass/fail, reject actuation, alarms, and manual jogging.
- No physical chassis or wiring required — ideal for a learning environment and portfolio demonstration.
📂 Project Files
1. Project Overview
2. Ladder Logic
3. AOIs
💡 Learning Outcomes
This project demonstrates OEM/integrator-style PLC design — modular, data-driven, and scalable — and shows ability to design, test, and document complete control systems without physical hardware.