AUTOMATED MINI BELT CONVEYOR SYSTEM – PLC PROGRAMMING & HMI DESIGN
Developed PLC programming and HMI design for an automated mini belt conveyor, delivering precise motion control, sensor-based sequencing, safety interlocks, and real-time monitoring.
Milestone PLM provided complete PLC programming and HMI interface design support for an Automated Mini Belt Conveyor System installed at remote logistic area. The scope focused on developing structured Ladder Logic routines for automated conveyor motion control, product presence detection, precise pickup/drop stop sequencing, timing interlocks, and operator screen visualization.
What Made This Project Complex
Developing robust control logic for a mini belt conveyor operating in a high-throughput pickup and drop area required precise management of sensor inputs and multi-stage sequence timing. The key engineering challenges included establishing accurate product detection using photoelectric sensors at both pickup and drop locations, developing safe conveyor motor start/stop sequencing with interlocks to prevent belt overtravel and product accumulation jams, structuring Ladder Diagram (LD) code into modular routines for easier maintenance and troubleshooting, and designing intuitive HMI screens to support manual jog overrides, automatic cycle execution, real-time product counting, and alarm notifications.
How Milestone PLM delivered
Milestone PLM applied a systematic automation logic engineering approach to develop a reliable, high-performance control package. The team developed structured Ladder Logic code covering the main conveyor drive logic, feeder interlocks, and pickup/drop sequence timers. Standardized I/O address mapping was implemented for digital sensors, including part presence, travel limits, and emergency stop signals, along with actuator outputs. Clear HMI screen layouts were designed with main process status views, product counter displays, fault indicators, and manual control functions. In addition, complete software documentation packages and fully commented source code files were prepared to support seamless deployment, maintenance, and future system modifications.
- Complete automation software ownership eliminated client dependency on internal resources and accelerated overall project delivery.
- Structured, well-commented Ladder Logic code enhanced system maintainability and simplified troubleshooting for maintenance technicians.
- Interlocked pickup/drop logic guaranteed zero product collisions and ensured smooth material transfer across operations.
- User-friendly HMI interface gave operators clear real-time process visibility and flexible manual/auto operation controls
- Detailed operational documentation provided a clear technical baseline for operator training and future conveyor system expansions.
Project Execution Process
Phase 1 - Sequence & Requirement Review
Analyzed mechanical pickup/drop motion cycles, sensor positions, belt speed requirements, and control standards.
Phase 2 - I/O Allocation & Mapping:
Created structured digital and analog I/O address assignment lists, mapping field sensors, pneumatic stoppers, and motor starter signals.
Phase 3 - Ladder Logic & HMI Development
Wrote clean Ladder Diagram (LD) routines for sequential indexing, pickup/drop interlocks, timers, and HMI operational screens.
Phase 4 - Simulation & Logic Verification
Performed rigorous offline software simulation tests to verify sequence timing.
Phase 5 - Final Software Delivery
Delivered fully commented source code with back ups files and HMI project backups.
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