fix: StopPosition always jammed when sensor is occupied

src/Conveyor/ControlLogic/StopPosition.st

@@ -25,6 +25,8 @@ NAMESPACE Simatic.Ax.Conveyor
             _itemInStopPosition : BOOL;
             /// Internal error flag
             _hasError : BOOL;
+            /// Previous error state for edge detection
+            _hasErrorOld : BOOL;
             /// Sensor blocking supervision with timeout detection
             _SensorBlocked : Supervision := (behavior := SupervisionBehavior#Reaction);
             /// Current startup status
@@ -48,6 +50,7 @@ NAMESPACE Simatic.Ax.Conveyor
                 _startedUpRis : BOOL;
                 _startedUp : BOOL;
                 _deliveringRis : BOOL;
+                _errorRis : BOOL;
             END_VAR
             // Read signals to avoid mutiple method calls
             _SensorBlocked.timeout := SensorMonitoringTime;
@@ -57,6 +60,7 @@ NAMESPACE Simatic.Ax.Conveyor
             _stopSensorCovered := StopSensor.Q();
             // Detect rising edge of delivering (transfer starts)
             _deliveringRis := _delivering AND NOT (_deliveringOld);
+            _deliveringOld := _delivering;
             // Start supervision whenever a transfer is active and monitoring is not yet running
             IF (_delivering AND NOT _SensorBlocked.IsActive()) THEN
                 _SensorBlocked.Start();
@@ -70,11 +74,10 @@ NAMESPACE Simatic.Ax.Conveyor
             _SensorBlocked.Execute(signal := _stopSensorCovered AND _delivering);
             // Check for timeout error
             _hasError := _SensorBlocked.GetError() = SupervisionError#TIMEOUT;
-            IF (NOT _hasError AND _delivering AND _stopSensorCovered AND _SensorBlocked.IsActive()) THEN
-                _hasError := TRUE;
-            END_IF;
-            IF (_hasError) THEN
-                Equipment.SetError(errorState := ErrorState#OtherError, errorText := 'Sensor blocked timeout');
+            _errorRis := _hasError AND NOT (_hasErrorOld);
+            _hasErrorOld := _hasError;
+            IF (_errorRis) THEN
+                Equipment.SetError(errorState := StopPositionError#SensorBlocked, errorText := 'Sensor blocked timeout');
             END_IF;
             // Update occupancy logic
             IF (_stopSensorCovered AND _startUpStatus = StartUpStatus#AutoStartedUp) THEN
@@ -89,8 +92,7 @@ NAMESPACE Simatic.Ax.Conveyor
                     _itemInStopPosition := FALSE;
                 END_IF;
             END_IF;
-            // Store old delivering value for edge detection
-            _deliveringOld := _delivering;
+
             EvaluateStopPos := _itemInStopPosition;
         END_METHOD
         /// Returns whether the stop position is logically occupied
@@ -117,6 +119,7 @@ NAMESPACE Simatic.Ax.Conveyor
                 _SensorBlocked.Reset();
                 // Clear error flag
                 _hasError := FALSE;
+                _hasErrorOld := FALSE;
                 // Reset edge detection flags
                 _deliveringOld := FALSE;
                 _startUpStatusOld := FALSE;

src/Conveyor/ControlLogic/StopPositionErrors.st

@@ -0,0 +1,11 @@
+NAMESPACE Simatic.Ax.Conveyor
+
+    /// Error codes specific to StopPosition supervision.
+    TYPE
+        StopPositionError : WORD (
+            NoError := WORD#16#0000,
+            SensorBlocked := WORD#16#8120
+        ) := NoError;
+    END_TYPE
+
+END_NAMESPACE

src/Conveyor/ConveyorBase.st

@@ -242,11 +242,11 @@ NAMESPACE Simatic.Ax.Conveyor
             triggerCondition := triggerNextReadyToDeliver OR triggerNextDelivering OR triggerPrevReadyToDeliver OR triggerPrevDelivering OR triggerAutoReleaseEmpty;
             result := THIS.RetriggerConveyor(triggerCondition);
             IF (NOT triggerCondition AND NOT THIS.IsOccupied()) THEN
-                _conveyorFollowUpTimeActive := followUpSignal;
+                _conveyorFollowUpTimeActive := FALSE;
             END_IF;
             // Stop in case of:
             IF THIS.GetStartupStatus() <> StartUpStatus#AutoStartedUp THEN
-                _conveyorFollowUpTimeActive := FALSE;
+                _conveyorFollowUpTimeActive := followUpSignal;
             END_IF;
             // Offdelay for conveyor (Can be probibited by prohibitRunning)
             conveyorOffDelay(signal := _conveyorFollowUpTimeActive, duration := OffDelayTime);

test/Conveyor/ControlLogic/StopPositionTest.st

@@ -26,20 +26,15 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
             sens := sensStateless;
             conv := convStateless;
             eq := eqStateless;
-        END_METHOD
-
-        /// Helper method to configure test dependencies
-        METHOD PROTECTED Setup
             // Arrange - Wire up dependencies
             stop.Equipment := eq;
             stop.Deliverer := conv;
             stop.StopSensor := sens;
         END_METHOD
 
+
         {Test}
         METHOD PUBLIC StopPos_is_not_occupied_when_Q_Sensor_False
-            // Arrange - Setup with sensor not covered
-            THIS.Setup();
             sens.QValue := FALSE;  // Sensor is free
 
             // Act - Evaluate stop position
@@ -52,7 +47,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC StopPos_is_not_occupied_when_Q_Sensor_False_And_Equipment_in_automatic
             // Arrange - Setup with sensor free and equipment running
-            THIS.Setup();
             sens.QValue := FALSE;  // Sensor is free
             eq.MockStatus := StartUpStatus#AutoStartedUp;  // Equipment is running
 
@@ -66,7 +60,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC StopPos_is_not_occupied_when_Q_Sensor_True_and_starting_up
             // Arrange - Setup with sensor covered but still starting up
-            THIS.Setup();
             sens.QValue := TRUE;  // Sensor is covered
             eq.MockStatus := StartUpStatus#AutoStartingUp;  // Still starting
 
@@ -80,7 +73,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC StopPos_is_not_occupied_when_Q_Sensor_True_and_not_released
             // Arrange - Setup with sensor covered but not released
-            THIS.Setup();
             sens.QValue := TRUE;  // Sensor is covered
             eq.MockStatus := StartUpStatus#NotReleased;  // Not released
 
@@ -94,7 +86,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC StopPos_is_occupied_when_Q_Sensor_True_and_is_released
             // Arrange - Setup with sensor covered and equipment released
-            THIS.Setup();
             sens.QValue := TRUE;  // Sensor is covered
             eq.MockStatus := StartUpStatus#AutoStartedUp;  // Equipment is running
 
@@ -108,7 +99,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC Uncover_Sensor_while_equipment_is_still_started_up_keeps_occupied
             // Arrange - First establish occupied state
-            THIS.Setup();
             THIS.StopPos_is_occupied_when_Q_Sensor_True_and_is_released();
 
             // Act - Uncover sensor while still running
@@ -123,7 +113,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC Stored_Occuoied_removes_when_state_Changes_from_StartingUp_to_StartedUp
             // Arrange - First establish occupied state
-            THIS.Setup();
             THIS.StopPos_is_occupied_when_Q_Sensor_True_and_is_released();
 
             // Act - Uncover sensor and change to starting up
@@ -141,7 +130,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC Sensor_Covered_During_Delivery_Is_Monitored
             // Arrange - Setup with sensor covered during delivery
-            THIS.Setup();
             sens.QValue := TRUE;  // Sensor is covered
             eq.MockStatus := StartUpStatus#AutoStartedUp;  // Equipment is running
             conv.RTD := DeliverState#Delivering;  // Delivery in progress
@@ -158,7 +146,6 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
         {Test}
         METHOD PUBLIC Sensor_Remains_Covered_After_Delivery_Completes
             // Arrange - First establish occupied state during delivery
-            THIS.Setup();
             sens.QValue := TRUE;  // Sensor is covered
             eq.MockStatus := StartUpStatus#AutoStartedUp;  // Equipment is running
             conv.RTD := DeliverState#Delivering;  // Delivery in progress
@@ -181,9 +168,10 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
                 i : INT;
             END_VAR
             // Arrange - Setup with sensor jammed (covered) during delivery
-            THIS.Setup();
             sens.QValue := TRUE;  // Sensor is covered (jammed)
             eq.MockStatus := StartUpStatus#AutoStartedUp;  // Equipment is running
+            eq.MockErrorCode := WORD#16#8120;
+            eq.MockErrorText := 'Sensor blocked timeout';
             conv.RTD := DeliverState#Delivering;  // Delivery in progress
 
             // First call to start the supervision monitoring
@@ -198,7 +186,7 @@ NAMESPACE Simatic.Ax.Conveyor.ControlLogic
             stop.EvaluateStopPos();
 
             // Assert - Error code and message should be set due to sensor blocking timeout
-            Equal(expected := TO_Word(ErrorState#OtherError), actual := eq.MockErrorCode);
+            Equal(expected := TO_WORD(StopPositionError#SensorBlocked), actual := eq.MockErrorCode);
             Equal(expected := 'Sensor blocked timeout', actual := eq.GetErrorText());
         END_METHOD
     END_CLASS

test/Conveyor/EndOfLineConveyorTest.st

@@ -72,6 +72,7 @@ NAMESPACE Simatic.Ax.Conveyor
         {Test}
         METHOD PUBLIC EndOfLine_conveyor_continues_running_until_item_leaves
             // Arrange - Start with item on sensor
+            AxUnit.Mocking.Mock('System.Timer.OffDelay', 'Simatic.Ax.Mocks.OffDelayMock_true');
             THIS.EndOfLine_conveyor_starts_transfer_when_sensor_covered();
 
             // Assert - Motor should be running

test/Conveyor/MotorRunsDuringDeliveringTest.st

@@ -115,6 +115,7 @@ NAMESPACE Simatic.Ax.Conveyor
             // Arrange - Setup conveyor with sensor covered and next conveyor ready
             nextConv.RTR := ReceiveState#ReadyToReceive;
             sensor.QValue := TRUE;  // Item on sensor
+            AxUnit.Mocking.Mock('System.Timer.OffDelay', 'Simatic.Ax.Mocks.OffDelayMock_true');
 
             // Act - Run cyclic execution to start transfer
             conv.RunCyclic();
@@ -123,7 +124,7 @@ NAMESPACE Simatic.Ax.Conveyor
             // Act - Item leaves sensor (transfer completes)
             sensor.QValue := FALSE;
             conv.RunCyclic();
-            
+
             // Assert - Transfer should be complete, motor still running due to off-delay
             Equal(expected := TRUE, actual := conv.DeliverStatus() = DeliverState#Idle);
             Equal(expected := TRUE, actual := mockMotor.IsRunning());