Industrial Pick-to-Light Control System

An advanced Pick-to-Light (PTL) system implementation using IEC 61131-3 structured text programming with MQTT integration for industrial automation applications.

🚀 Features

• Real-time control of 4 PTL stations with color-coded feedback
• MQTT-based communication for distributed system integration
• Automated error detection and recovery system
• Color-coded visual feedback system:
  • Green: Active pick location
  • Red: Error indication (wrong pick)
• Timer-based state management
• Comprehensive debug monitoring
• Industrial I/O interface integration

📋 System Requirements

Software Requirements

• CODESYS Development System V3.5 or later
• CODESYS MQTT Library
• Network connectivity for MQTT communication

Hardware Requirements

• PLC/Controller compatible with CODESYS Runtime (TBEN-S2-2COM-4DXP Controller from Turck)

• 4 PTL110S-FF100TD3-QPS150 devices from Bannerengineering.

• PLC supporting IEC 61131-3 Structured Text

• MQTT Broker (tested with broker running at port 1883)

• Digital I/O capabilities for PTL hardware interface

• Network connectivity for MQTT communication

🔧 Development Environment Setup

1. Install CODESYS Development System
2. Install MQTT Library:
   • Download the library from CODESYS-MQTT Repository
   • In CODESYS, go to Tools → Library Repository
   • Install the downloaded library
   • Add library reference to your project

🏗️ Project Structure

├── src/
│   ├── PLC_PRG.st          # Main program file
│   ├── FirstPublish.st     # MQTT publishing function block
│   └── FirstSubscription.st # MQTT subscription function block
├── docs/
│   └── hardware_setup.md   # Hardware configuration guide
└── README.md

🌐 MQTT Communication

Topics

• Publish: Test/PTL_touch - Reports touch events
• Subscribe: Test/PTL_1 - Receives control commands

Message Format

• Simple integer-based protocol
• Values 1-4 correspond to PTL stations

💻 Implementation Details

Color Codes

• 0: Off
• 1: Red (Error)
• 2: Green (Active)

State Management

• Real-time touch detection
• Automatic error state recovery (1-second timeout)
• Persistent state tracking
• MQTT state synchronization

🚀 Getting Started

1. Clone this repository
2. Configure your PLC development environment
3. Set up MQTT broker (default: broker.emqx.io:1883)
4. Upload the program to your PLC
5. Configure I/O mapping according to your hardware setup

📝 Configuration

Update the following parameters in PLC_PRG.st:

URL := 'broker.emqx.io:1883'  // MQTT broker address
Topic := ADR('Test/PTL_touch')  // MQTT publish topic

🤝 Contributing

Contributions are welcome! Please feel free to submit a Pull Request.

📄 License

This project is licensed under the MIT License - see the LICENSE file for details.

🔗 Contact

For questions and support, please open an issue or contact the maintainers:

• Email: [email protected]
• LinkedIn: armanruet

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Made with ❤️ by Arman