Automotive Gear & Inspection System
System Overview
This system is designed for washing and inspection of automotive gear components.
It integrates dual PLCs via a CC-Link network to coordinate multiple subsystems including hydraulic units, heaters, and washing pumps.
The control sequence ensures safe and efficient operation with interlocks and diagnostic functions for maintenance support.
Key Features
Centralized control using 2 PLCs with CC-Link communication
HMI operation via 3 GOT terminals
Temperature and pressure monitoring with safety interlocks
Automatic sequence for washing, conveying, and inspection
Data logging capability for production monitoring
Software / Control
Sequence control, alarm handling, and interlock logic
Analog input scaling for temperature sensors
Output regulation for heater units via SSR
Error detection and retry sequence management
Control Panel Layout
The control panel was designed with a modular structure to simplify wiring and maintenance.
Each component group—PLC, relays, and safety circuits—is organized by function for easier troubleshooting.
Dual PLCs (Master/Slave) communicate via CC-Link to manage the washing and inspection processes.
This distributed design allows efficient synchronization between hydraulic, washing, and inspection subsystems.
HMI (GOT) Interface
Operators can monitor the washing sequence, heater temperatures, and alarms through the GOT screen.
Diagnostic screens were implemented to assist in identifying sensor or interlock errors during operation.
The operation monitoring screen displays the real-time status of each washing and inspection stage.
Operators can visually confirm the progress of the process, including active actuators, cylinder positions, and operation completion signals.
This interface improves visibility and helps prevent downtime by allowing quick identification of abnormal conditions.
PLC Configuration Diagram
The operating conditions for each device are consolidated in a single section,
making the ladder logic easier to read and maintain.
This structure helps engineers quickly understand the interlocks and sequence flow.
Internal relays are arranged in numerical order,
which improves visibility and consistency throughout the program.
This systematic layout simplifies troubleshooting and logic updates.
Timers are grouped in a single section to ensure stable operation and improve overall readability of the ladder program.
Centralizing timer control also makes it easier to adjust sequence timing and verify process behavior.
Summary / Conclusion
This project was developed to automate the washing and inspection process for automotive gear components,
improving reliability and reducing manual workload.
By integrating dual PLCs via a CC-Link network and centralizing control logic, the system achieves stable operation and efficient troubleshooting.
The design emphasizes clarity, maintainability, and safety — key principles that support long-term system reliability in industrial automation.