PLC-Controlled Conveyor
System for Apple Packaging
R Raghda Hassa Parardhya Cornika 23/511502/PA/21810
Ali Rabbani Rasyidin Baadilla 23/516139/PA22057
Manafad Aulia Lananggalih 23/511416/PA/21790
LOCALLY ROOTED,
GLOBALLY RESPECTED Programmable Logic Controller - IEL
Introduction
The increasing demand for speed and accuracy in industrial packaging
processes makes automation essential. In this project, we developed a
Programmable Logic Controller (PLC)-based control system to automate
apple packaging using sensor-triggered conveyors. This presentation
focuses specifically on the apple conveyor subsystem—ensuring that
exactly 10 apples are loaded into each box, using input sensors,
counters, and PLC logic.
System Requirements
The system is operated using two push buttons: a START button (PB1) and a
STOP button. Pressing PB1 activates the entire system, while pressing STOP
halts all operations.
When the system is ON:
A Box Detector Sensor detects the presence of an incoming empty box on
the box conveyor.
The box conveyor (Output Q:100.01) moves the detected box forward.
Each time a box is detected, a Box Counter (Counter C0000) increments.
The Apple Conveyor (Output Q:100.02) is activated only when a box is
present and the system is ON.
As apples are dropped into the box, an Apple Counter Sensor detects and
counts each apple.
Once 10 apples have been counted, the apple conveyor automatically stops.
The Apple Counter then resets, preparing for the next box.
🔘 1. Start/Stop Logic (System Control)
Start Button (PB1: I:0.00): Activates the system
when pressed.
Stop Button (I:0.04): Halts the system when
pressed.
Latching Relay (Q:100.00) is used to keep the
system ON after PB1 is released.
Logic Description:
When PB1 is pressed and STOP is not active,
Q:100.00 (System ON bit) is energized.
The latch maintains the ON state until STOP is
pressed.
📦 2. Box Detection & Conveyor Activation
Box Sensor (I:0.01) detects an incoming box.
Box Conveyor (Q:100.01) moves the box forward.
Box Counter (C0000) counts the number of boxes.
Logic Description:
When the system is ON and a box is detected,
the box conveyor starts.
Simultaneously, the Box Counter (C0000) is
incremented.
🍎 3. Apple Detection & Conveyor Control
Apple Sensor (I:0.03) detects apples dropping into the
box.
Apple Conveyor (Q:100.02) moves apples forward into the
box.
Apple Counter (C0000) counts the number of apples
(preset to 10).
Logic Description:
The Apple Conveyor runs only when the system is ON,
a box is present, and the Apple Counter is less than 10.
Every detected apple increments C0000.
Once C0000 reaches 10, the apple conveyor stops.
🔁 4. Reset for Next Box
Once 10 apples are loaded (C0000.DN is high) and a new
box is detected, the Apple Counter (C0000) is reset
automatically.
This allows the system to start loading apples into the
next detected box.
✅ System Behavior Summary
The entire process is automated using Start/Stop logic for
power control, box and apple counters for precise
tracking, and sensor-driven conveyor activation for
material handling.
Ensures exactly 10 apples per box before moving to the
next.
Conclusion
This PLC-based control system successfully automates apple loading
into boxes with precision. The combination of sensors, counters, and
condition-based logic ensures high efficiency and consistency in
operation. The system is easily scalable and can be integrated with larger
industrial processes. Improvements could include adding jam detection,
alert systems, or multi-box management.
Thank you, any
questions?
LOCALLY ROOTED, GLOBALLY RESPECTED ugm.ac.id
