PLC Ladder Logic Capstone Project
An automated warehouse package sorting system implemented in Allen-Bradley-style ladder logic. Demonstrates industrial automation concepts including motor control, sensor integration, conveyor diversion, and data logging.
Being built progressively as a 12-week PLC/SCADA study program using Allen-Bradley instruction set conventions.
| Component | Status | Implementation |
|---|---|---|
| Master Motor Control | ✅ Complete | Seal-in circuit with start/stop logic |
| Package Photoeye Counting | ⏳ In Progress | Debounce logic for accurate counting |
| Multi-Lane Diversion | ⏳ Pending | Directional gate control based on size |
| Analog Sensor Integration | ⏳ Pending | Weight measurement calibration |
| Temperature Monitoring | ⏳ Pending | Analog input scaling and alarms |
| Batch Tracking | ⏳ Pending | Math operations for FIFO queue |
| Data Logging | ⏳ Pending | FIFO/LIFO buffer implementation |
| HMI Simulation | ⏳ Pending | Operator interface mockup |
| Specification | Detail |
|---|---|
| PLC Architecture | Allen-Bradley-style ladder logic |
| Programming Language | Ladder Diagram (LD) per IEC 61131-3 |
| Safety Standards | OSHA 10 Construction certified implementation |
| Step | Process | Output |
|---|---|---|
| 1 | Conveyor Start | Motor running |
| 2 | Photoeye Detection | Package detected |
| 3 | Counter Increment | Count updated |
| 4 | Size Classification | Category assigned |
| 5 | Buffer Queue | Package queued for diversion |
| 6 | Lane Selection Logic | Target lane determined |
| 7 | Divert Gate | Package sorted to lane |
| Skill | Application |
|---|---|
| PLC Ladder Logic | Allen-Bradley instruction set programming |
| Sensor Integration | Photoeyes, proximity sensors, analog inputs |
| Conveyor Control | Motor control, timing, sequencing |
| Data Structures | FIFO/LIFO buffer implementation |
| Industrial Safety | OSHA 10, NFPA 70E awareness |
| Sequential Design | Function chart organization |
This capstone project follows a structured 12-week PLC curriculum:
- Weeks 1-2 — Basic relay logic, seal-in circuits
- Weeks 3-4 — Timer and counter instructions
- Weeks 5-6 — Analog input scaling
- Weeks 7-8 — Data manipulation and math instructions
- Weeks 9-10 — Subroutine organization
- Weeks 11-12 — HMI integration and testing
To interact with this project:
- Familiarity with PLC programming concepts
- Understanding of industrial control systems
- Basic electronics knowledge
MIT License - See LICENSE file for details.
Built as a capstone project by Jon Gill - BS Computer Science
Transitioning to industrial automation and robotics engineering