I need help designing a program on Studio 5000 for my PLC course. See attached file for details.

Palletizing Fish Finders

A robot (Robot 1) is to place brand new Fish-finders into a case of 6 finders. The Fish-finders will be coming in from 2 different conveyor belts. A sensor will be mounted to each conveyor, and when a Fish-finder crosses the sensor the conveyor belt will stop until the robot has picked up the box. The robot controller (Robot 1) will control the motion of Robot 1.

When a case has been filled another robot (Robot 2) will be signaled by the PLC to place a full case on a wooden pallet that holds 8 cases. A sensor will indicate that the wooden pallet is in place. If the wooden pallet is not in place the conveyors will be disabled until the wooden sensor again goes true.

When a pallet is full (8 cases) disable the conveyors, and turn on an amber indicator light to inform a forklift driver to remove the full pallet. When an empty pallet is put in place the system conveyors will be allowed to run again.

Create a start stop station to start the palletizing cell. The palletizing cell may only be disabled (shutdown) with the stop button, NOT the pallet sensor.

Controls:

Out puts:

System running- Green light

Conveyor 1- White light

Conveyor 2- Amber light

Pallet full indicator- Amber

Output to Robot 2- Blue light

Inputs:

Start- N.O. Push button

Stop- N.C. Push Button

Conveyor 1 sensor- Toggle switch

Conveyor 2 sensor- Toggle switch

Pallet switch- Toggle switch