Reading a process description, and breaking each output's run condition down into it's minimum set of component parts, is an acquired skill.
For example, the counters have no
direct effect on when Conveyor 1 motor should run, although when either box conveyor's counter reaches its limit, then that box conveyor should start and indirectly that should cause Conveyor 1 to stop. This can be reduced down to the following statement:
The Conveyor 1 motor is running
when the following is true:
- The pilot light is on, AND
- Conveyor 2 motor is not running, AND
- Conveyor 3 motor is not running.
Note that, because those individual conditions are ANDed,
when any of them are false (e.g. pilot light is
not on, or either box conveyor
is running), Conveyor 1 will be stopped.
The key thing to see here is that the counter values are not needed to directly choose when the Conveyor 1 motor is running or stopped; it is enough for the counters and box photo switches to control
when the box conveyor motors run or not, which must be done anyway, and then the value of the box conveyor motors will feed back to this rung to control the Conveyor 1 motor.
Translating that Conveyor 1 motor logic into a rung is even simpler than the Start/Stop circuit. Each of those individual conditions needs but a single contact, whether XIC/NO or XIO/NC. Connecting them to implement the logical ANDs, and then connecting the result of those logical ANDs to the Conveyor 1 motor output, is all that remains.
The Diverter is active
when a large bottle is present at Limit Switch 1, and inactive at all other
times.
The Conveyor 2 motor runs
when the Conveyor 2 count value is 3, and continues running, even
after the count value is reset to 0,
until the Photo Switch 4 input value changes from 1 to 0. It might be possible to use the Start/Stop Circuit pattern here, but that might not start the motor if the Photo Switch 4 input value is 0 (i.e. not 1)
when the count value reaches 2, so the State Coil/Fault Coil pattern might be a better choice here. Also,
at some point once the count value reaches 3 you will need to reset the counter value back to 0, but if you reset it too
soon then the motor may not be started.
The Conveyor 3 motor output will be similar to the Conveyor 2 motor output, but have a different counter, and count value (preset) to trigger it.
That, plus my previous post, covers the five outputs. I leave it to you to write the rungs that drive the various counters, reset each box counter when its box is full, and reset all counters when the Reset button is pressed.