Sortation with diverts and a lift transfer
Barcode-driven sortation: an induct belt, a scanner, three pop-up wheel diverts and a lift transfer, with an end-of-line reject.
Watch the simulator run.
A top view replayed from the simulator run: carton positions and the program's signals every 100 ms.
Recorded from the simulator run of the example program (same rung text as the L5X) against a simple carton model. Cartons drawn at a nominal size.
How the parts work together.
- The induct belt meters cartons with SOL_Gap so the scanner sees one at a time.
- When a carton clears the scanner eye, SOL_SortTable turns its code into a lane, and SOL_Tracking inducts it with that lane and the position from SOL_Encoder, a virtual encoder from the PowerFlex 525 speed.
- When the carton has travelled its lane's distance, tracking fires the lane. Lanes 1 to 3 use a SOL_Divert pop-up wheel, which confirms on the lane eye. Lane 4 uses a SOL_LiftTransfer, which holds the sorter belt while it lifts the carton off at 90 degrees.
- A no-read, a multi-read, a code with no rule, or a full lane sends the carton to the end-of-line reject.
The scanner register names in this example are stand-ins, to be mapped to the real scanner on site.
Results.
In the simulator run, 14 cartons sorted with no missorts: lanes 1/2/3/4 received 3/2/3/2 and 4 went to reject. Those four were the unreadable label, the multi-read, the unmatched code and the carton that arrived while lane 2 was full.
Tested in simulation; not yet run on a controller.
PLC, AOI instances, field devices, HMI.
HMI screens and faceplates.
Rendered from the HMI Library definitions with values from the simulator run.
