Control IO Warehouse

Summary

In this instructional video, Will demonstrates the setup and control of an automated warehouse using Factory IO software. He guides viewers through the process of organizing and storing pallets on a conveyor system, utilizing sensors and actuators. The video covers the use of edit mode, run mode, and various control signals for the automated system. Will also explains the programming logic using Control IO, including the use of timers, flip flops, and function block diagrams for efficient warehouse automation.

Takeaways

• 🏭 The video is a tutorial on an automated warehouse system using Factor IO, which stores pallets in structured pads.
• 🔢 The warehouse has a capacity of nine pallets per row, with additional rows for more storage, starting with pad one behind the control panel.
• 📹 The video demonstrates the use of edit mode in Factor IO to arrange conveyors and other parts without making changes to the existing setup.
• 📈 The presenter explains the use of run mode to observe the automated processes, including the forced activation of emitter and remover systems.
• 🔴 The importance of signals in controlling the automated system is highlighted, with the use of sensors and actuators to manage the flow of pallets.
• ⏸️ The video shows how to pause, reset, and adjust the speed of the simulation for better control and observation of the system's operation.
• 🛠️ The tutorial includes a step-by-step guide on programming the automated warehouse, emphasizing the use of signals and timing diagrams.
• 🔄 The process involves moving pallets to specific positions using conveyors, sensors, and actuators, with careful control of the forklift mechanism.
• 🔢 The use of a counter to keep track of the loading positions in the warehouse is explained, with incrementation for each new pallet placed.
• 🔧 The video discusses troubleshooting and adjusting the logic in Control IO, including the use of RS flip-flops and timers for signal management.
• 🔄 The final program logic is demonstrated, showing how to control the automated warehouse system using function block diagrams in Control IO.

Q & A

What is the main purpose of the automated warehouse system discussed in the video?

The automated warehouse system is designed to store pallets in a structured manner, with each pallet placed on designated pads, and it is controlled using the Factory IO software.

How many pads are there per row in the automated warehouse system?

There are nine pads per row in the automated warehouse system.

What is the significance of the 'run mode' in Factory IO software?

The 'run mode' in Factory IO software allows the simulation to operate, demonstrating how the automated warehouse functions with the configured settings and components.

What does the 'remover' in the automated warehouse system do?

The 'remover' in the system is responsible for the removal process of the pallets from the warehouse structure, and it is indicated by a red arrow when active.

How can the simulation speed be adjusted in Factory IO software?

The simulation speed in Factory IO can be adjusted to normal speed, half speed, or one-tenth speed, allowing for better control and observation as the system approaches sensors or performs actions.

What is the function of the '30-day free trial' mentioned in the video?

The '30-day free trial' is an offer for users to try out Factory IO software, allowing them to explore and utilize its features without cost for an initial period.

What is the role of the 'timing diagram' in programming the automated warehouse system?

The 'timing diagram' is used to layout the sequence of signals and the actuators they influence, which helps in visualizing and programming the control logic for the automated warehouse system.

What does the 'AT Load' sensor indicate in the automated warehouse system?

The 'AT Load' sensor indicates the position where the pallet is to be lifted onto the conveyor system, changing from gold to white to signal the system to initiate the lifting action.

How does the 'forks left' signal function in the automated warehouse system?

The 'forks left' signal controls the movement of the forklift mechanism to slide under the pallet, preparing it for lifting and transport within the warehouse.

What is the purpose of the 'AT Middle' signal in the automated warehouse system?

The 'AT Middle' signal ensures that the forklift mechanism is in the correct central position before moving the pallet to the designated storage location within the warehouse structure.

What is the significance of the 'Target Position' in the automated warehouse system?

The 'Target Position' determines the specific location within the warehouse structure where the pallet is to be moved and placed, with the system incrementing this position as it fills up slots.

How does the 'Next Box' signal function in the control logic of the automated warehouse system?

The 'Next Box' signal serves as a trigger to increment the position counter, indicating that the system is ready to process the next pallet and move it to the next available storage position.

What is the role of the 'Mode Counter' in the automated warehouse system?

The 'Mode Counter' keeps track of the current state or mode of operation in the automated warehouse system, such as loading pallets into the structure or returning to the home position.

What is the purpose of using RS flip-flops in the control logic of the automated warehouse system?

RS flip-flops are used in the control logic to maintain the state of signals, turning the output high when the set input is high and turning it low when the reset input is high, which helps in managing the on/off states of various components in the system.

Outlines

00:00

🤖 Introduction to Automated Warehouse Simulation

Will introduces a video tutorial on an automated warehouse system using Factory IO software. The automated warehouse is composed of a structure that stores pallets on individual pads, with nine pads per row. The video will demonstrate the setup and operation of the warehouse, including the use of conveyors and sensors. Will mentions the software's features like edit mode, run mode, and the ability to control signals for the emitter and remover. He also highlights the software's 30-day free trial and the capability to step through programs for better understanding and control.

05:00

🔧 Configuring and Controlling Conveyors and Sensors

The video script explains how to configure and control the automated warehouse's conveyors and sensors. Will demonstrates how to use the simulation's pause and reset features, as well as adjusting the speed of the system. He details the process of moving a pallet using the entry and load conveyors, explaining the significance of sensors and actuators, such as the retro reflector and the emitter. The script also covers the use of the 'at load' sensor to determine when the pallet is in the correct position for loading.

10:01

📚 Automated Pallet Handling and Storage

Will continues the tutorial by showing how to handle and store pallets in the automated warehouse. He describes the use of a device similar to a forklift to move pallets to the shelving area. The script explains the process of using sensors to detect the pallet's position and the use of signals to control the movement of the forks. It also covers the importance of the 'at middle' signal for correct positioning before placing the pallet on the structure.

15:05

🔄 Incrementing Storage Positions and Returning Home

The script outlines the process of incrementing storage positions as pallets are loaded into the warehouse. It explains the use of a counter to keep track of the positions and the need to return the system to a 'home' position after loading pallets into their slots. The video also discusses the signals for moving the system in the X and Z directions and the logic behind returning the system to the home position.

20:05

🛠️ Setting Up the Control Logic for the Automated System

Will presents the logic for controlling the automated warehouse system using Control IO. The script details the use of RS flip-flops and SR flip-flops in creating the start and stop logic for the system. It also covers the use of signals and timers to ensure the correct sequence of operations, such as the emitter signal, the entry conveyor, and the load conveyor.

25:06

🔄 Advanced Control Logic and Signal Timing

The script delves into the advanced control logic required for the automated system, including the use of timers and logic gates to manage the movement of the forks and the pallet's position. It explains the use of a counter to keep track of the load position and the logic for moving the system to the correct position in the rack. The video also addresses the challenges of ensuring the correct timing for signals and the use of assigned bits to manage the source position.

30:08

🔄 Refining Control Logic for Home Position and Fork Movement

Will refines the control logic for returning the system to the home position and moving the forks to the correct position. The script explains the use of AND gates and the importance of the 'at middle' signal for mode three operations. It also covers the logic for setting the target position and the use of timers to ensure the system has enough time to switch to the load position.

35:10

🔄 Finalizing Control Logic and Testing the System

The script finalizes the control logic for the automated system, including the logic for moving the forks to the right position and setting the system down in place. It explains the use of a mode counter to determine the current mode of operation and the logic for the 'next box' signal to control the sequence of loading boxes. The video includes testing the system at normal speed and troubleshooting a mistake with the 'next box' signal.

40:13

🔄 Completing the Automated Warehouse Cycle

Will concludes the tutorial by demonstrating the complete cycle of the automated warehouse system. The script shows the system filling up the first row of the rack and preparing to move to the second row. It highlights the importance of incrementing the position counter and the logic for loading boxes in a specific order. The video also discusses the possibility of loading boxes based on their weight or type and the need for additional logic and sensors to manage this.

45:15

🛠️ Reflecting on the Automated System's Performance

In the final part of the video script, Will reflects on the performance of the automated system and the challenges faced during the setup. He discusses the use of time delays to ensure the system works correctly and encourages viewers to experiment with the logic to potentially eliminate the need for these delays. The script also invites viewers to consider different loading strategies and the potential use of sensors to identify the type of boxes being loaded.

Keywords

💡Automated Warehouse

An automated warehouse is a system that uses technology to control and manage the storage and retrieval of goods with minimal manual intervention. In the video, the automated warehouse is depicted as a structure that stores pallets on designated pads, showcasing the efficiency of automated systems in logistics and storage management.

💡Control Panel

A control panel is an interface used to operate or manage a system. In the context of the video, the control panel is the primary interface for the automated warehouse, allowing the operator to control various functions such as starting and stopping the system, as well as adjusting the speed of the conveyor belts.

💡Conveyors

Conveyors are mechanical devices used to transport goods or materials from one place to another within a production or distribution process. In the video, conveyors are integral to the automated warehouse, moving pallets to and from storage positions and playing a key role in the automation process.

💡Sensors

Sensors are devices that detect and respond to some type of input from the environment. In the video, sensors such as the 'at entry' and 'at load' sensors are used to detect the presence of pallets and trigger actions within the automated system, ensuring the correct positioning and movement of pallets.

💡Actuators

Actuators are components that are responsible for moving or controlling a mechanism or system. The video script mentions actuators such as the entry conveyor and load conveyor, which are activated to move pallets within the automated warehouse, demonstrating how actuators facilitate the physical movement in automated systems.

💡Simulation

A simulation is a virtual representation of a system or process. The video discusses the use of a simulation mode to test and observe the automated warehouse's operation, allowing the viewer to understand the system's behavior before implementing it in a real-world scenario.

💡PLC (Programmable Logic Controller)

A Programmable Logic Controller is a digital computer used for automation of industrial processes. In the video, the PLC is implied to be the brain behind the automated warehouse, controlling the logic and timing of the system's operations, such as the movement of pallets to specific storage positions.

💡Signal

In the context of automation, a signal is an electrical or optical representation of information that triggers a response in a system. The video script frequently refers to signals controlling the state of sensors and actuators, such as turning on and off the conveyors or detecting the presence of a pallet.

💡Retro Reflector

A retro reflector is a device that reflects light back towards its source with minimal scattering. In the video, the retro reflector is used in conjunction with a sensor to detect the presence of a pallet by reflecting a signal back to the sensor, indicating that a pallet is in position.

💡Control IO

Control IO refers to the input and output interfaces of a control system. The video script discusses the use of Control IO for programming the automated warehouse, emphasizing the importance of understanding the signals and actuators involved in the system's operation.

💡Logic Gates

Logic gates are basic units of digital logic circuits that represent Boolean functions. The video script mentions logic gates such as AND, OR, and NOT gates, which are used to create complex logical operations within the automated warehouse's control system, determining the sequence of actions based on input signals.

Highlights

Introduction to the automated warehouse and its structure, which stores pallets in a specific arrangement.

Explanation of how the control panel interacts with different rows and columns in the warehouse.

Description of the initial setup and run mode for the automated warehouse in Factorio.

Details about how the emitter and remover work in the system, including visual indicators.

Steps to control the simulation speed and pause the system to observe signal behavior.

Demonstration of how to reset and manipulate the system using the control panel and sensors.

Explanation of the different conveyors (entry and load conveyors) and their roles in the warehouse.

Illustration of the forklift-like device that moves pallets within the warehouse, including its sensors and positions.

Detailed steps to move the pallet to the shelving using the forks, including lifting and positioning.

Description of how to program the system to handle pallet positions and movements automatically.

Explanation of the RS and SR flip-flops used in the control logic and their differences.

Overview of the start-stop logic and how to set up signals to control the warehouse automation.

Discussion on how to manage the emitter, conveyors, and forks using the control logic.

Insights into using timers and delays to ensure proper signal transitions and movements in the system.

Final demonstration of the complete control logic, highlighting the importance of accurate programming and troubleshooting.

Transcripts

hi this is will and today we're going to

take a little video of

this automated warehouse and the

automated warehouse

is just a regular this is from the

regular scenes from factor io

um this is is it's a

structure that stores pallets in each of

these

little little pads i guess

and the first pad is right here right

behind the control panel then the second

third fourth fifth sixth it goes up to

nine per

uh row and then over here in the second

column

i guess second row up is number ten

and it's a fairly nice

challenging little project now um

we start off when we get into the scenes

in the uh

edit mode and you can see that you have

these palettes for if you wanted to

change things around you can put in

different

parts of conveyors and whatnot we're not

going to do that we're just going to

go with what we have so we're going to

put in the run mode

now you can see as soon as that appears

we see a box

and the reason we see that is factor i o

it always forces the emitter and the

remover

on and you can see the removers on

because it's

kind of lit up red arrow and we can show

that here but

if we dock all the tags

you can see that the emitter is forced

on

and the remover is forced on so if i

release it

and we're looking at the remover here if

i release it by

clicking on what these glasses are but

for the

remover you'll see this turn off

and see how that turns off and

we can do the same thing with the

emitter

so normally i like to do the programs

where i control

all the signals so we don't really need

that

now i'm just going to quickly say here

this is where we can pause the

simulation so we can stop it at certain

points and look at

how the signals are behaving we can

reset it so if i reset it the box will

disappear

or the pallet will disappear and this

last thing is where we can slow down the

speed of the system so this would be

normal speed here

then we can go at half speed and then we

can go at 10th

speed one tenth of the speed and that's

just so you can

get better control as it's approaching

sensors

and you know the thing that i think is

really valuable about factory i o well

the two things are

you get a 30-day free trial if you want

to try it out it's great

you can also step through the program

and you can see

what signals you need to control and

then you can write the program

so you can pretty much and we'll kind of

show this is

you can lay out the timing diagram for

what the signals

happen and what actuators they influence

and then you write the program so

to do this the first thing we're going

to do

well let me show you one thing first

so right here this ad entry

and the ad entry is here now all these

orange circles with the circle inside

the circle those are our sensors

and the fact that it's lit up where some

of these aren't

means that the signal is high and that's

also by the gold here

and if you hover on it it'll say it's a

sensor

now if i hover on the entry conveyor it

tells you it's an actuator

and this one is high so it's receiving a

signal it's because it's a retro

reflector and so the sensor is sending

out a signal which bounces off this

optical mirror and then comes back to

the sensor that's why it's turned on

now the conveyors are turned off so

that's why they're white

now if i put

an emitter in here by forcing it on and

forcing it on

is when we click on the little

actuator symbol that's associated with

the emitter

so i'll just click on that you can see

that the add entry went from

gold to white that's because the sensor

is now blocked

so the first thing we can do

well we can release this because we

don't want boxes coming

after each other you know one after

another after another

but we can see that the actuator is the

entry conveyor

and then we see a load conveyor and

those are the first two

that we're going to do so to try to get

it right i'm also going to slow down the

speed to half speed

and what i want to do is move the pallet

down to about this point here so we've

got

the entry conveyor which are these full

length rollers and then we have the load

conveyor which are these little

pint-sized rollers on either side of the

conveyor

so i want to stop it right about here

then i'm going to turn on the load

conveyor

and let's try to get that and when i

stop it i'm going to stop it with the

pause

so i'm just going to click on this

positive simulation

and so i'm going to force on the entry

conveyor

okay and stopped it a little late but

that's okay

um so now what i'm going to do is i'm

going to turn on the load conveyor

and i'm going to keep it on until i see

this at load now the at load is this is

the sensor this is the retro reflector

and i'm going to um

turn on the load conveyor until i see

this go from

gold to white and then i'm going to

pause it again

so here's my load conveyor now i'm going

to unpause it

when i see this go white i'm going to

reposit

okay so now what we have and

let me try to click on a little

different view of this

this device right here is kind of like a

forklift without the

fork truck and you can see it's got

forks right

and forks left it also has an at right

and you can't see it but there's an at

left uh signal down here

and then there's also an at middle so

right now it's sitting in the middle

and anytime we want to move the pallet

to the shelving over here

it has to be at the middle position

otherwise we're going to hit

the structure either here or here

so and we can release the conveyors we

don't need them anymore

and just to show you the first thing we

need to do is we need to go

fort's left and watch where this

forks go underneath the pallet

and i'll un pause it and you can see

they go right underneath the

pallet and now the at left signal goes

high

now what we can do is we can lift it up

because we need to and let me show this

a little better

we need to lift it off the conveyor

so if we hit the left signal

you can see that it lifted off the

conveyor now that we have it lifted up

we can take the forks left

signal off and we can wait until we get

to the

at middle signal so what we can

what we want to do is we're going to

release this

and we're going to wait until we get the

at middle signal go high

so we release it

at middle signal right here so it's at

the middle

so now we can move it into position now

this part is important

down here is something called target

position and that means where do you

want to move it to

now we said what we're going to do is

we're going to move it to this first

position

so i'm going to change that to a one

and you can see it's forced on now as

soon as i click anywhere

outside of the box here it's going to

move to the position

right here so

okay you can see that now what i need to

do

is i need to move the forks to the right

position

which is towards the structure

okay so now it's in position

so now what i and you can see it's at

right and you have to make sure

that it gets all the way you know if

you're going left

you have to see the at left if you're

going to the middle it's got to be

at middle but now what i can do because

it is at right

i can release the lift signal and it's

going to set it

down on the structure

okay and now that it set it down on the

structure

i can also release the forks right

signal and again i'm looking for it to

go

back to at middle

so when it gets back to add middle

okay now here's the other important

thing so

you know what we're going to do is we're

going to increment all these

positions you know we want to fill one

then two then three

but when you want to go back home you've

got to fill this

with spot 100

okay and again when i click anywhere

outside here it's going to go back to

that position

okay now the other thing you need to

know

is there's these two signals moving x

and moving z and the way we're going to

set it up

is um well first if i do lift

you'll see them well at least the moving

z because it'll just be going straight

up

but that'll turn on and you can see it

right here

you can see it turns on for a little bit

and then it'll turn off

and if i release it it'll do the same

and if i go to a position and i'll just

i don't know i'll pick one that i know

it makes it

go for quite some time

and now you see both x and z go high

until it gets into the position

so they're both high and it's moving

into position

and

so z went off and now x went off

and i'm going to go back home so to go

back home

is again it's always 100 that

is not going to change and you'll see

these go high

and then when it gets back home they'll

again go low

okay they're high and then they went low

now that's going to be how we're going

to

approach this project and

i'm going to pause it here and then turn

on our timing diagram and you can see

the steps

that i have put in here and then you can

put in there and

you know program your plc

doesn't have to be this way and i'm not

saying mine is the best way but

this is an approach you can use

okay so this is the way where our

signals are gonna work here

um or at least in my little version of

it

we start off we're going to send out an

emitter signal

and when we get that emitter signal

we're going to get the at entry sensor

the add entry sensor is going to turn on

the load conveyor

now this is a signal that i was playing

around with originally but we're not

going to use anymore

and what we have is

we're then going to turn on

the load conveyor and when it gets to

the at load signal

which is a signal like right at the

lift point we're going to turn off both

conveyors

so when we get to the at load point

what we're going to do is we're going to

take our forks we're going to make them

go left

when they get to the at left signal

um then we're going to lift

and we're going to lift it up

now remember when we finish moving

and this says move z but it's really

move z or move x when it stops moving

what we're going to do is we're going to

have a counter

that counts and i call it mode here

but every time it stops moving we're

going to have it count

so the first time it moves we're just

lifting it up

okay and then

what we're going to do when it gets to

the at middle

is we're going to load it with the

position we need to go to

so the first position is going to be

position one

now as soon as we put a different

position in there it's going to start

moving

by itself to that position okay

so it moves to the first

place where it can store when that gets

finished we're going to

move in a two and the first thing we

we're going to increment the counter and

it'll go to two now the first thing

we're going to do is we're going to

you know set it in position so we've got

to move the forks right

when the forks are right what we do

is we're going to um you know

set it down on the rack

so when we get to the at right point

what we're going to do is we're going to

get rid of that lift point

or pulse so we start the lift when we

you know first have the forks underneath

it

all the way over to here and then when

we get to the forks

are at right is when we turn off

the lift signal and

again when we'll send the lift down will

happen automatically and when the lift

goes all the way down

again what we're waiting for because

we'll get rid of

the at right signal or i mean we'll

turn off the fork's right signal so

again

it'll move towards the middle when it

gets at

the middle that's when we're going to

load in

the position that says go home which is

position 100

so this position will

just be incremented every time we load

it in a different slot

then over here when we're going home

it's always 100.

so i'm just because it's uh

already kind of a long video i'm going

to just make

most of the

logic in control i o and i figure

people who are looking at this video

probably use the control i o

and know how to use it i will show some

of the very last logic because there is

a couple

things that i kind of found found

unusual

and we can take a look at that and then

we can take a look at the full logic and

we can explain that

okay so now this is the logic that we

have um

and right here is start stop logic

and what we mainly use are these

rs flip flops and their set reset

and set turns the output high reset

turns the output low and you can think

of it as on

off now there is this rs

there's also this sr and let me see if i

can

put them in here

so this is an rs

and this is the sr and they look very

similar

now if you zoom in on these guys

the only difference is

the reset set flip flop the rs you can

see it says

reset one and the set reset

flip flop you can see that it says set

one now what that means

is if both of these are one at the same

time

the the reset is the dominant one here

and the set is a dominant one here

so if these are both one at the same

time this will be

a zero because you've reset it if these

are both one at the same time the output

is going to be one it's going to be high

typically you don't want that and you

want to make sure that you're not using

this one you want to make sure that

you're using the one that has the reset

dominant

now you know when you do the logic

correctly they should never be the same

they should never be high at the same

time

so having said that let's take a look at

our logic the start

when we hit the start push button

this output is going to go high and i

always have a signal that i call start

process

and it's also going to turn on the start

light

and it's because this is not it's going

to turn off the stop light

and you can see here and what i like

doing for the

control i o is i like putting the

control i o

right kind of in the middle

of the

the actual factory i o so let me just

minimize this for a second

so these are the sensors for

the factory i o and you can see the ones

that are high

are lit up the ones that are off are not

lit up

these are the outputs or the actuators i

like putting

you know my factory i o in between those

two

so i can look at those and

come out

so i can see like for instance stop is

high

now you can see stop is higher here

because this is also lit up

now we haven't hit start yet so that's

not lit up

the emergency stop which i put in here

is also high and you can see that here

the emergency stop is high

the stop is high so that's just the

start logic

and then i use the start process to say

when that happens

and the start bit occurs

you know we're going to get our first

emitter

and then i also have this as emitter bit

and we're going to set it with either

when we press the start and the start

process is high

or we have this signal next box so we're

going to automatically keep

the machine moving and we're going to do

it with this next box signal

now the signal that turns this off

is this reset signal and

that's when it gets to you know we have

it at the add

entry now because the ad entry is

normally high we have to

you know knot it uh to get the low

signal

so when it goes low this will go high

and that will turn

off the emitter signal

and we have the entry conveyor

which that also turns on the entry

conveyor and what turns it off is when

it's at the at load

and we have the load conveyor which

we're going to turn on

again when we're at add entry and we

have

an emitter and then we're going to turn

it off again when we get to the at load

now when we get to that load we're also

going to start the forks going

left and we're going to use that

this is the falling trigger and that

means

when the signal as soon as it falls

we're going to send out

a pulse that's one scan wide that will

be high for one scan

and that will trigger this to turn it

off and it'll trigger the force to turn

on

now

again we're going to reset this with the

move complete

so when the move is complete

um you know this signal will turn

off the force left and

again the first time we move it is the

lift signal

so this is really when the first

lift signal

you know we've lifted it up and now

after

we've completed that move is when the

forks left

will be turned off and

here's the lift signal so when we're at

left

we lift it up and then when we're at

right

is when we set it down on the structure

and over here yep

now here's where we have our counter

now this is our mode counter so this is

mode

this is counter up when we get the mode

complete is when we count

when we get our next box is when

we reset it and we've just set the

preset to 4.

now here

is where we just have our load position

and this is the position

in the rack in the structure that we are

going to

keep incrementing every time we fill up

you know we fill up position one

then we fill up position two we fill up

position three

um and so on and this is just a counter

that we're

going to count the positions and i've

just put the terminal count at

54. and i think that's

about right

and so this is the load position that

we're going to aim

for now this

is part of

the uh logic that i got a little problem

with

but um so when we when we're in mode one

or mode two

and these are just uh equals

let me try to zoom in a little bit so

these are equals so

when it when mode is one or modis two

and this is an or gate what we're going

to do and

first we have this assigned you know the

one odd thing with

this control i o is you don't have a way

to move

um like you normally would i wanted to

move like a number

six into a certain spot because over

here

is what we're going to have the source

position

so the source position you know when

we're at home

is position 0 and when we're moving

to the load position where we want to

load it

we have to put that into our source

position or what i call

source position now the way you move it

is

there's this assigned bit and

let me show you what this has if you go

in the documentation for factory i o

they have pretty good documentation for

the control i o

and this assign which actually appears

in the extra function

what happens is if this signal

on the input is high you'll be looking

at what

is coming into pt2

if it's off you'll be looking at what's

coming in pt1

okay so

the way i have it set up is

that when the counter

is zero or one which means

you're moving to the position or you're

at the position

that'll be a logic high which means

you're going to be selecting

this load position

otherwise you know presumably you'll be

at home

or going to home will you be at home so

you want to put in

a zero and so this is the logic

that you'd accomplishes that

now the thing that's and i'm not quite

sure

i know the increases i think because

when you switch from this to this

there's a delay

so what i had to do is when the signal

goes high

to give it enough time to switch to the

load position

i had to put a timer in there to

effectively put a delay in there now

this would be a delay of two seconds

so it just gives it a little delay so

there's enough time for the load

position

to get into this source position

if that makes any sense now um

what we're going to do now is we're

going to put in the same type of circuit

um so what i can do is

i can sort of copy this whole thing

and

hopefully we can and you can use control

c

control v and we're going to paste it

down here now everything's still

highlighted so i can move it

now here

what we're going to do

is instead of this well we can get rid

of this guy

because now what we're going to do is

we're only going to be interested in

when we're at mode 3 and mode 3 again

is we are trying to get back home

so we don't really have an or gate here

what we're going to do is we're going to

have what we really need is we need an

and gate so we're going to delete that

we're going to put in a 2 in and

drag it in here

and i don't think we need this timer in

here either

and the other signal that we're going to

have so we're going to have when we're

at

mode 3. now the other signal that we

need and

if we go into our tags we need the at

middle signal

so again when we're in mode three we

have to wait until we're at the middle

signal

and then we can

put this into the assignment now here

what we're going to have is instead of

this being

position zero

delete that is we're going to make that

the source position

and we're going to move that down here

and we can just wire that there and now

this instead of this being the load

position

we can delete that

and we can copy this

put this down here and we can make this

because here we're going home so this is

always going to be

position 100

so let me

100 and now instead of this being this

source position what we're going to have

is this is going to be our target

position

and you don't want to click on this one

over here i made that

mistake what you want to do is you want

to make sure you're picking everything

from

the control i o signals so we want the

target position from here

so what we have is we have a choice

you know this is the final thing that's

going to determine the move

so

when we're in mode one and two

the source position is just incrementing

from spot to spot to spot

when we're in mode three then we're

going to

go to 100. so only in mode 3 is the

signal going to be true

so it's you know if it's not in mode 3

it's going to be looking at the source

position

if it is in mode 3 it's going to be

looking for going home

which again is position 100.

now what we don't have on here

is we've got to put in

the logics for going

moving our forks to the right position

so again and you know the easiest thing

is if you

have the logic and if you can fully

copy it

yeah come on

okay control c control v

so here we're going to

and you know again for forks right

the um when forks right goes high

we're still at um mode

one it's the very end of mode one

and we need two in and

and you know work these there's actually

two sliders there's one to move up and

down for the tags

and then there's one to move up and down

for the full thing

um so we're going to put in two in and

connect that up and the other signal we

want here

is we want our move complete signal

so you know all these purple things here

are just

memories that we've picked so if we go

back up here

to memories and

these here are integers and

what we really need is we need the bool

so now this is picking

the next unused bool but what we really

want

and if you click in here it'll give you

the addresses

what we want for this one is we want to

move complete signal

so that's the one that we want so when

the move is complete and the two in and

we're going to go into

the reset set flip-flop and this will be

controlling

the fort's right signal

so the fort's right is an out there

it's an input over here

so fort's right we can drag it in over

here

and again what

resets that signal is

when we get to mode two

so what we can do is

we can pretty much well and we even need

nand gate too

so we can copy all this with control c

and

ctrl v and

try to move it into the spot now

so the output here is going to reset it

and

let me try to zoom in a little bit so i

can make the connections easier

and this one we're going to

when this gets to a two

is when we're going to reset it and

again we're going to use the

move complete signal as you know the

signal that resets it

so when we lift it down is when we go

from step

or mode two to mode three so when it's

at mode two

the very end of mode two is when we're

going to

set this down in place

and then

our final thing that we need to do we've

got it right now we just have to

put in the signal for the next

box

and again grab them all

so you know we're we're using you know

we're using the mode counter to say what

mode we're in

and um then we're just using

you know these comparisons

we're going to the next box

when we actually count from three to

four

which really wasn't on the timing

diagram but all we're going to do

with the when we count to four which we

actually do count to four when we move

home we're moving home

on count three when it gets to the home

position it goes to count

four um now

again what i had to do

to kind of make it work was go in here

and put in timer that gave it a little

delay here

and

so when we temporarily get that count

four

and i had that set up for

a short period of time

so when you're putting these in these

are the modes so they're just integers

when you're looking at the timers these

are in milliseconds

so right now this is 800 milliseconds

the other timer that was in there was

like 2000 which is two seconds

so this will count out and it'll put in

a delay of

you know 800 milliseconds and what we're

going to do

is um we're just going to create

a bool memory

and we're going to put that on the q

output

so when it times out this signal goes

high

now this signal and again if you click

on the box

it's going to say what do you want to

name that and we're going to name that

next box

and so what does the next box do it does

two things

first off um

the next box is where we have our

counter

[Music]

not that counter that's the position

counter

this is the mode counter so we have the

mode counter we put the next box into

the reset

so as soon as that signal goes high this

will go back to zero

so it counts up one two three a quick

four and then right back to zero

and then the other place that we have

next

box is right here which is

the next box which is the second

and every subsequent emitter

so the first meter is when we press the

start push button

all the other ones are virtue of the

next box

so that is our program for control i o

and let's see we can minimize

that and the control i o

if you go into the drivers well let me

show you here

if you go into file you go into drivers

to set up the control i o

you know you can set it up for all these

different allen bradley stuff

there's some modbus and then there's

siemens

but here's the control i o

so if we go back here we should be

we want to make sure that all our forces

are released

when we start this and again you can see

um when we're in this spot right here

that's the target position of zero

so let's take a look

and i'm going to speed it up

to normal speed

the forks go left they lift it up

go to position one and you can see

target position is position one

okay go and set it down and you can see

every time every time it moves

you're going to see sometimes when it's

just lifting

um oh my next box isn't working

okay i'm going to pause it for a second

and see what's

going okay well i have a next box that i

put as a

bit 4 here and i'm going to have to

pause this

but up here let's see

um

i actually have

the next box

as three

so and let's see what it is at this

counter

this next box

is also three so i've got that wrong

so make that three now sometimes just to

make sure

everything is good we'll have to reset

everything

reset here

and take it off pause

now when we take it off pause it goes

off pause here too so let's

see if that was our mistake

and this should be pretty quick to

confirm

so again that's going into spot one

now you can see when we go back um

to our position it goes to one hundred

and here's the second box so i think

that was our

little um mistake my fault

happens a lot when you're doing this

kind of live

should pay better attention to this

stuff but you know you can see it'll

just keep going

back and forth position 100 to go back

home

i'm going to get another emitter box

and then you'll see this go to spot 3

which it should

that's three you load it in place

and again you know the this stuff is

you know you can walk through what

position what you need to control

um and then you write the logic to do it

and you know control i o is all this

what they call

function block diagrams um it's not

ladder logic

but if you wanted to write this in

lighter logic then you're going to need

some poc software

to do that in lighter logic but this is

good

way to learn how to do it

a function block diagram is used

it you know not as much as ladder logic

ladder logic is used primarily because

it's all visual and you can see what's

turned on what's turned off

but function block diagram is probably

the second

most used type of logic that there is

there are other types but

for the other types you certainly are

going to need the plc software to

be able to use it and so i think what

we're going to do here is we're just

going to wait until it

fills up the first row and then we'll

just see it go into the second row

and again it's it it's going to be the

same thing because we're just

incrementing each spot so let's see

wrap one two three four five six

so two one two three four five

six seven okay seven eight

nine and then that'll be ten um once we

start on the second row i think we'll

kind of leave it at that because this is

a

long video right now

i can't imagine how long it would have

been if i would have shown all this

all the software or i mean making all

the connections for the

control i o but

you know you can take a look at it um

you know see if you can

uh put together all the

logic that you need see if

you know i'm still not convinced that i

needed all those

time delays in there but uh

you know it seemed like uh that was the

only way i could get it to work

maybe you can do better and get it to

work without those delays

so give it a shot and see what it looks

like

um and you don't really have to uh

load it in order you know for instance

there could be something that says

you know maybe you want um

you know like maybe you want all these

heavy boxes on the first row

and then maybe because you know you get

the packages

you know right now it's eight to one

ratio so maybe

you say well i'll load these steel

things

down in the first row and then um

you know the regular boxes starting up

in like

i don't know row three four five and six

but then you'll need extra logic to

control

uh you know what position you're loading

into

and you'd also need some type of sensor

to say oh

this is a metal box and they do have uh

you know what you'd use well now we're

getting all metal boxes so maybe i'm

wrong

but uh they do have inductive sensors

where you can

just look for metal objects

now at some point you'd have to put a

sensor

where before you started lifting it up

you could identify it to be metal or not

metal

but uh you know you might want to give

it a try

so anyway uh now it's all metal boxes

anyway um you know take a look at it is

kind of challenging

um it's a good test of your

programmabilities good luck

thank you