Hi everyone,
You can download the scene here:
And here is the setup:
I challenge the entire Factory I/O community—students, teachers, and even the creators—to answer the following question: how many sensors or detectors do you think are needed in this scene for it to work according to the setup?
You can reply here or, if you prefer, via private message.
Regards
Hello;
Let’s look at this project with a specific constraint: the fewer sensors or detectors you use to operate the scene, the better a programmer you will be. So far, I haven’t used any—though you must implement it exactly as shown in the videos, meaning it must display the machine’s real-time status.
In this first part, we build the distribution line; next come the inclines, then the exits, HMIs, and so on.
Regards.
Hello:
NOTE that there are no sensors or detectors involved; it relies entirely on programmed logic. Using sensors or detectors would make the task much simpler, as they would indicate the path to follow; essentially, this involves replacing physical detectors with code. As you can see, the conveyor belt section deactivates as the pallet passes, and the incline conveyors activate only when needed—switching off again once the pallet has moved past.
Another advantage of FACTORY IO is that it is not perfect, which requires devising solutions that are often more instructive than the programming itself…
This represents a significant challenge for advanced students or instructors willing to take it on; remember, the more sensors or detectors used, the more complex the programming becomes. Let’s move on to the outputs.
Regards.
What this project does is strip away everyone’s sensors. The lights go out, the pianist sits down, and a melody begins with perfect mathematical timing. The dancers cannot see one another or the floor, yet because they are all counting seconds at the exact same rhythm in their heads, they execute their steps at the precise millisecond. No one touches or collides with anyone else, and the choreography flows with the precision of a Swiss watch amidst the darkness. The dark room represents Factory I/O, the pianist is the Schneider PLC, and the melody consists of bits moving through memory.
Hi there. That response was generated by AI—I like to query it now and then, acting as either a student or a teacher (I know people do this often), just to see what kind of answers come back. It discusses the advantages and disadvantages of this system; I recommend asking it about this project—believe me, it provides interesting insights that any student or teacher ought to know.
Feel free to share the responses you get in the comments below.
Best regards.
Interesting project. I would just be careful with the word “control” in the title. In automation, control usually means measuring a process variable and correcting any deviation.
Running conveyor zones, especially with pallets, based only on timing can be unrealistic and risky in a real application. The project is useful as an educational exercise, but I would mention that it is intended for training and not as a real industrial control method.
Hello Riveraedgardo2512,
I assume you’ve seen the video and the comment that reads as follows:
“Obviously, this project is only suitable for specific use cases; for instance, it wouldn’t work for an elevator—where two to six people of varying weights might enter—because a single detector would stop the elevator at a precise point. There is also the issue that if a box gets jammed, the system wouldn’t detect it and would simply continue operating as usual. Furthermore, it doesn’t work if an operator picks up a pallet and sets it down 10 cm further back or forward, as this alters the calculation. Nevertheless, it is interesting to learn about the project and how these types of calculations are handled in a PLC.”
The key here is understanding the programmed logic; however, if you master this field, you can apply it to parts of projects where it is actually useful. That’s the idea behind consulting AI and—based on its input—opening a discussion on the pros and cons of this project. Yet, as we can see here—and indeed everywhere else—any real engagement or participation resulting from these types of comments and invitations is conspicuously absent.
Regards
Hello:
This entire process is known as Time-Based Control with Tolerance Window Validation.
Time-Based Control with Tolerance Window Validation is an advanced automation strategy.
It is used to monitor sequential processes, ensuring that each stage occurs exactly within a specific time interval.
The PLC already “knows” mathematically where the pallet is at any given second.
Now we will install sensors, keeping the following in mind:
The physical sensor does not initiate any action; it is there solely to “signal approval.”
If the pallet fails to trigger the sensor at the precise moment required to turn off the control bit, the system issues an alarm.
The HMI must display a precise message: “Synchronization failure in section X.”
As you can see, there is no need to clutter the Factory I/O scene with dozens of expensive sensors that overwhelm the PLC’s input cards;
using the absolute minimum hardware at strategic, critical points is sufficient.
Regards.
PD:Riveraedgardo2512, What do you think of the system now?..
Hello:
We control the system using two detectors, one at the start and one at the end. To reiterate, these sensors verify that the pallet passes the designated point within the timeframe calculated by the PLC; if this does not happen within 5 seconds, an alarm is triggered, distinguishing between the entry and exit points.
Quite an original challenge for the students, thanks to FACTORY I/O, otherwise, this wouldn’t be possible…
Regards