Bottle sorting system

Description

This function block controls a bottle sorting system with automatic type recognition for glass bottles and large and small plastic bottles. The integrated switch control and clearly structured step-chain logic ensure a reliable sorting process.

Note: All modules are designed exclusively as a learning and optimization basis and are not approved for live operation. System modules, in particular, must be finally tested and commissioned by qualified personnel before productive use.

How it works

At the beginning, the controller performs a safety check. If an emergency stop or stop signal is detected, the entire process is immediately stopped, all actuators are deactivated, and the sequence is reset to the start step.

In automatic mode, the process starts with the start button:

1. The conveyor belt brings a bottle to the detection unit.
2. As soon as a bottle is detected, sensors identify the type: glass, large or small plastic bottle.
3. Depending on the type, the corresponding switch is activated and held in position for a defined time.
4. Afterwards, all switches automatically return to the neutral position and the process begins again.

If a stop signal or an empty storage tank is detected, the system switches to a safe state and an alarm flag is set.

Technical details

• Step chain control with integer step counter
• IEC timer controls the duration of the switch setting
• Edge detection for bottle inlet and timer end
• Switches: WeicheGlas , WeicheKstGross , WeicheKstKlein
• Conveyor belt: Foerderband (TRUE/FALSE)
• Alarm flag indicates emergency stop, stop signal or empty tank
• Parameters such as timer duration and sensor limits can be flexibly adjusted

Possible applications

Ideal for sorting stations in:

• Beverage bottling
• Recycling centers
• Logistics and packaging lines

The module also clearly shows in training systems how FSM controls are combined with sensor integration and safety logic.

compatibility

• Siemens S7-1200 and S7-1500 controllers
• TIA Portal from version V13
• For simulation and visualization: Version V16+ with PLCSIM and HMI

Scope of delivery

• .scl file with complete declaration of all inputs/outputs
• Including trigger, step logic and timer
• Header comments with notes on adjustments (sensor, timer, security)
• Download link available immediately after purchase

Support

I am happy to help you with:

• the adjustment of sensor parameters
• the extension to include further sorting criteria (e.g. weight)
• integration into existing control systems or HMIs

Simply contact me via email or shop support – I am available at any time for individual extensions.