![]() ![]() You cannot control the Scrap Box Fill very accurately using only one Counter. The bottles are two different sizes, with the Large Bottle being equal to 1.5 times the mass volume of the Small Bottles. Does this give you an idea of what you need to do next? The Scrap Box will hold the equivalent of 15.5 Small Bottles. In my program, I used two counters, Small and Large Broken Bottle Counters. Then I used some math functions to calculate the Combined Box Fill = (15 x Large Count) + (10 x Small Count). The extra factor of 10 is to eliminate fractional numbers in an Integer-only PLC. ![]() Then for the Scrap Conveyor Motor, I set up parallel comparison instructions: IF COMBINED BOX FILL >= 145 AND NEXT BROKEN BOTTLE IS LARGE, OR IF COMBINED BOX FILL >=150 THEN START SCRAP CONVEYOR. The logic for the above is if the next broken bottle is Large, then its volume = 15 and will not fit into a box with level of 145 already, since full = 155. Then if the level = 150, a small bottle will not fit either. I leave it to the student to set up a bit that anticipates the next broken bottle BEFORE IT ARRIVES AT THE SCRAP GATE. This method will fill the box 100% about 95% of the time, and within 95% the remainder. ![]()
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