Automated Stacking of Metal Plates Using PLC-Based System: A Safer and Efficient Manufacturing Approach

Stacking is a critical operation in various manufacturing sectors, including food, pharmaceuticals, and cosmetics, where precise arrangement of products is essential. Manual stacking, the traditional approach, is labor-intensive, error-prone, and poses safety risks. To address these challenges, this paper proposes a PLC-based automation solution for stacking metal plates. The system utilizes two conveyors, with the first activated by a sensor upon metal plate detection. Plates are then stacked on the second conveyor until reaching the desired count value, at which point they are moved to the destination. Safety features include photoelectric sensors, temperature sensors for conveyor motors, weight and vibration sensors, and an infrared object sensor for counting plates. The ladder logic control algorithm, implemented using ISPsoft software, is validated through animation in DSPsoft. The automated process incorporates a counter and timer, with user-defined inputs for stacking requirements. Successful implementation and testing in the ISPsoft and DSPsoft environment demonstrate the effectiveness of the proposed automated stacking system.