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Application Example: Two-Lane Production Counting with Coolmay PLC and HMI
Illustrative application | Coolmay PLC/HMI | Not a completed customer case
A production team may need separate totals for two lanes without replacing the entire line-control system. A PLC and HMI arrangement can be considered for that task, using suitable detection inputs and project-specific counting logic. This example explains the design questions; it does not describe a verified customer deployment.
The application concept
Each lane supplies a detection signal to a compatible PLC input. The program maintains separate counters and presents the agreed totals on an HMI. The operator may also need shift, batch or lifetime totals, but those functions must be included in the programming scope rather than assumed from the presence of a touchscreen.
Counting the right event
The key design decision is what constitutes one product. Product spacing, shape, transparency, speed and the sensor mounting position can affect detection. Input pulse rate and duration must suit the selected PLC. A slow software scan or repeated detection of one item can produce an incorrect total even when the screen appears normal.
Define resets and exceptions
Before selecting hardware, specify who may reset a total, whether totals must survive loss of power and how rejected or reversed products should be treated. Decide whether the task is simple observation or part of machine control. Counting equipment should not be assumed to provide a machine safety function.
What to test
A proposed acceptance test should compare observed items with displayed counts across normal and maximum operating speeds, close product spacing, stop/start cycles and power recovery. Check each lane independently and together. If reports or network access are required, verify those features for the exact selected equipment and software scope.
Starting point
ProSense lists a Coolmay two-lane counting PLC/HMI kit as a starting point for a project-specific arrangement. Confirm the current inclusions, sensor interfaces, programming, enclosure, installation and commissioning scope before ordering. No throughput improvement or counting accuracy is claimed for this illustrative example.
Related equipment and source material
Planning a similar application? Contact ProSense on 1800 560 854 or sales@prosense.com.au with your measurement points, site conditions and reporting requirements.
