Automated Assembly Line for Manufacturing

PROGRAM ASSEMBLY_CONTROL
VAR
    // Station Sensors
    station1_part_present : BOOL;
    station2_part_present : BOOL;
    station3_part_present : BOOL;
    operation_complete : ARRAY[1..3] OF BOOL;

    // Outputs
    conveyor_move : BOOL;
    station_clamp : ARRAY[1..3] OF BOOL;
    station_tool : ARRAY[1..3] OF BOOL;

    // State Machine
    state : INT := 0;  // 0=Wait, 1=Process, 2=Transfer
    timer : INT := 0;

    // Operation Times (100ms cycles)
    OPERATION_TIME : ARRAY[1..3] OF INT := [50, 80, 60];
    TRANSFER_TIME : INT := 20;

    // Part Tracking
    parts_completed : INT := 0;
    cycle_time : INT := 0;
END_VAR

timer := timer + 1;
cycle_time := cycle_time + 1;

CASE state OF
    0: // Wait for all stations ready
        conveyor_move := FALSE;

        // Check if all stations have parts and completed previous operation
        IF station1_part_present AND station2_part_present AND
           station3_part_present THEN
            state := 1;
            timer := 0;
            // Clamp all parts
            station_clamp[1] := TRUE;
            station_clamp[2] := TRUE;
            station_clamp[3] := TRUE;
        END_IF;

    1: // Process all stations simultaneously
        // Activate tools based on timer
        FOR i := 1 TO 3 DO
            IF timer < OPERATION_TIME[i] THEN
                station_tool[i] := TRUE;
            ELSE
                station_tool[i] := FALSE;
                operation_complete[i] := TRUE;
            END_IF;
        END_FOR;

        // When all operations complete
        IF operation_complete[1] AND operation_complete[2] AND
           operation_complete[3] THEN
            state := 2;
            timer := 0;
            // Release clamps
            station_clamp[1] := FALSE;
            station_clamp[2] := FALSE;
            station_clamp[3] := FALSE;
        END_IF;

    2: // Transfer parts to next station
        conveyor_move := TRUE;

        IF timer > TRANSFER_TIME THEN
            state := 0;
            timer := 0;
            parts_completed := parts_completed + 1;
            cycle_time := 0;  // Reset for next cycle

            // Reset operation flags
            operation_complete[1] := FALSE;
            operation_complete[2] := FALSE;
            operation_complete[3] := FALSE;
        END_IF;
END_CASE;