Automated Assembly Line for Manufacturing

PROGRAM ASSEMBLY_LINE_STATION_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;


    // Production Tracking
    Production_Count : INT := 0;
    Target_Production : INT := 1000;
    Production_Rate : REAL;  // Units per hour
    Shift_Start_Time : DATE_AND_TIME;

    // Predictive Maintenance
    Vibration_Level : REAL;  // mm/s RMS
    Bearing_Temperature : REAL;
    Runtime_Hours : REAL;
    Maintenance_Due : BOOL;
    Next_PM_Date : DATE;

    // Energy Monitoring
    Power_Consumption : REAL;  // kW
    Energy_Total_Daily : REAL; // kWh
    Energy_Per_Unit : REAL;    // kWh per part
    Peak_Demand_Alarm : BOOL;

    // Material Tracking
    Material_Batch_ID : STRING[20];
    Material_Quantity : REAL;
    Scrap_Count : INT;
    Scrap_Percentage : REAL;

    // Machine Status
    Machine_State : STRING[20];
    Idle_Time : TIME;
    Run_Time : TIME;
    Utilization_Percent : REAL;
END_VAR

// ==========================================
// BASE APPLICATION LOGIC
// ==========================================

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;

// ==========================================
// MANUFACTURING SPECIFIC LOGIC
// ==========================================

    // Production Rate Calculation
    Production_Rate := Production_Count / Runtime_Hours;

    // Utilization Tracking
    Utilization_Percent := (Run_Time / (Run_Time + Idle_Time)) * 100.0;

    // Predictive Maintenance Alert
    IF (Vibration_Level > Normal_Vibration * 2.0) OR
       (Bearing_Temperature > Normal_Temp + 20.0) OR
       (Runtime_Hours >= PM_Interval_Hours) THEN
        Maintenance_Due := TRUE;
        Machine_State := 'MAINTENANCE_REQUIRED';
    END_IF;

    // Energy Efficiency Monitoring
    Energy_Per_Unit := Energy_Total_Daily / Production_Count;

    IF Power_Consumption > Peak_Demand_Limit THEN
        Peak_Demand_Alarm := TRUE;
        // Implement load shedding if needed
    END_IF;

    // Scrap Rate Tracking
    Scrap_Percentage := (Scrap_Count / Production_Count) * 100.0;

    IF Scrap_Percentage > Target_Scrap_Percent THEN
        Quality_Alert := TRUE;
    END_IF;

// ==========================================
// MANUFACTURING SAFETY INTERLOCKS
// ==========================================

    // Production Enable
    Production_Allowed := NOT Maintenance_Due
                          AND (Material_Quantity > Min_Material)
                          AND NOT Emergency_Stop
                          AND NOT Peak_Demand_Alarm;