PLC BASED AUTOMATIC BOTTLE FILLING

AND CAPPING SYSTEM

A SEMESTER PROJECT REPORT

Submitted by

In Partial Fulfillment of the Requirements

For the Degree of

B. S. c in Engineering

Research Scholar Research Supervisor

SOLOMON BEKELE Mr. DESALE N.

DEPARTMENT OF ELECTRICAL & COMPUTER

ENGINEERINGCOLLEGE OF ENGINEERING AND
TECHNOLOGY
AKSUM UNIVERSITY
AKSUM
ETHIOPIA.

JUNE-2014
 COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING
AKSUM UNIVERSITY

UNDERTAKING FROM THE CANDIDATE

This is to certify that My, SOLOMON B. have completed the B.Sc. Semester project work

on the topic “plc. based automatic bottle filling and capping with user defined volume

selection in a conveyor system” under the guidance of Mr.Desale. N for the partial fulfillment

of the requirement for the degree of B.Sc. in Engineering, Department of Electrical and computer

engineering, College of Engineering and Tech, Aksum University. This is an original piece of

work and WE have not submitted it earlier elsewhere.

Student Name ID No

Solomon Bekele ……………………… 1341/03

 DECLARATION

I, Solomon B., certify that the work embodied in this B.Sc. Semester project is my own

Bonafide work carried out by me under the supervision of Mr.Desalegn N. for a period of

4Months from 1stMarch, 2014 to 1st July, 2014 at Aksum University. The matter embodied in

this Project has not been submitted elsewhere for the award of any other degree/diploma.

We declare that we have faithfully acknowledged, given credit to and referred to the

research workers wherever their works have been cited in this text and the body of the thesis.

We further certify that I have not willfully lifted up some other’s work, para, text, data,

results etc. reported in the journals, books, magazines, reports, dissertations, theses, etc., or

available at web-sites and have included them in this project thesis and cited as my own work.

Student Name ID No

Solomon Bekele ……………………… 1341/03

 COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING
AKSUM UNIVERSITY

WORK COMPLETION CERTIFICATE

This is to certify that ‘Group- 2 students ’ is a bonafide research scholars of this University,

has satisfactorily completed the course work requirements which is a part of his/her B.Sc.

program.

Student Name ID No . Sign. Of Research Scholar 1.

Solomon Bekele ………………... 1341/03

(Signature of the Supervisor) (Signature of the Head of Dept.)

Name: Mr.Desalegn Name: Mr. Solomon Kiros

Designation- Lecture ECED HOD& Lecture
Dept. of ECED
 COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING
AKSUM UNIVERSITY

COPYRIGHT TRANSFER CERTIFICATE

Title of the Semester Project “PLC. based automatic bottle filling and capping with user
defined volume selection in a conveyor system”

Research Scholar Name: Group-2 students

Copyright Transfer

The undersigned hereby assigns to the Aksum University all rights under copyright that may

exist in and for the above thesis submitted for the award of the B.Sc. degree.

(Signature of Researc

Student Name ID No . Sign. Of Research Scholar

1. Solomon Bekele ………………... 1341/03

Note: - However, the author may reproduce or authorize others to reproduce material

extracted verbatim from the thesis or derivative of the thesis for author’s personal use provided

that the Source and the University’s copyright notice are indicated.
 ACKNOWLEDGEMENT

Firstly, we would like to convey our deep sense of gratitude and thanks to our respectful
Research Guide, Mr.Desalegn N. for his excellent support, supervision and guidance without
whom we would not have been able to complete our thesis work successfully
Secondly, we would like to express our thanks to our colleagues at our work place who gave
us strength and confidence to complete our thesis work successfully on time. Last but not the
least, we would like to convey our love and respect to our parents and our family members who
supported us and encouraged us to complete us thesis work without any obstacles.
Finally, it is our privilege to acknowledge the help rendered to us for typing the thesis by our
assistants who spent time with our and helped us in completing the tasks successfully.
We would like to convey my special thanks to the V.KRISHNANAIKPh.D. Asst.Professor
project coordinator: G.VIVEKANADNA, Dept. head of dept. SOLOMON KIROS, ECED,
CET, Aksum University who provided suitable guidelines which greatly helped me as a
Researcher and preparation of Technical Repot to complete my Research work with a
professional bent of mind.
Also, it is my duty and moral responsibility to express my respect and thanks to Dean
MR.WELDIE, college of Engineering & Tech, Aksum University, and President
DR.MEBRTHUM who inspired all the Research Scholars of Aksum University by giving us a
lot of confidence and assurance to complete the B.Sc. program me successfully on time.

Student Name ID No . Sign. Of Research Scholar

1. Solomon Bekele ………………... 1341/03

 TABLE OF CONTENTS
Title Page No
 LIST OF FIGURES
List of figure Page No

Figure 1.1: conveyor system ......................................................................................................... 3

Figure 2.1 block diagram description ......................................................................................... 7
Figure2. 2 simple ladder diagrams .............................................................................................. 8
Figure 2.3 simple ladder diagrams .............................................................................................. 9
Figure 2.4 simple ladder diagrams .............................................................................................. 9
Figure3. 1 Block Diagram of Bottle Filling System ................................................................. 10
Figure3. 2. Simple IR proximity sensor .................................................................................... 11
Figure 3.2.1: Final signal conditioning circuitry ...................................................................... 12
Figure3. 3 Diagram of the programmable logic controller ..................................................... 12
Figure3. 4 A PLC Illustrated With Relays ............................................................................... 13
Figure3. 5 a simple relay controller........................................................................................... 14
Figure3. 6 The inner workings of an LED, showing circuit (top) and band diagram
(bottom) ........................................................................................................................................ 15
Figure3. 7 LEDs are produced in a variety of shapes and sizes ............................................. 15
Figure3. 8 Driver circuit (a) simulation (b) practical .............................................................. 17
Figure 3.8.1. SCADA System General Layout (Components and General Configuration). 18
Figure3. 9 Working Of Bottle Filling System ........................................................................... 18
Figure3. 10 capping operation ................................................................................................... 20
Figure3. 11 Flowchart of the system ......................................................................................... 21
Figure 3.11.1 LOGO! 230 RC software .................................................................................... 23
Figure3. 12 Model of PLC Based Automatic Bottle Filling System ....................................... 24
 LIST OF ABBREVIATIONS/SYMBOLS

List of Abbreviation/symbols Page No

PLC- programmable logic controller……………………………………………. 1

SCADA- supervisory control and data acquisition …………………………………. 2
I/O unit- input/output unit………………………………………………………….......3
FBD- functional block diagram……………………………………………………..4
LD- ladder diagram…………………………….............……………………….. 4
ST- structure text………………………………………………………………..... 4
IL- instruction list ……………………………………………………………….. 4
SFC- sequential function chart………………………………………………………4
IR sensor infrared sensor………………………………………………………………….8
NO- normally open…………………………………………………………………11
NC- normally closed………………………………………………………………..11
LED- light emitting diode………………………………………………………….....14
LLS- low level sensor……………………………………………………………........ 17
HLS- high level sensor……………………………………………………………… 17
Q1- output port1…………………………………………………………………. 20
Q2- output port2 ………………………………………………………………… 20
 ABSTRACT
Filling is a task carried out by a machine that packages liquid products such as cold drinks or
water .Traditional methods of bottle filling involved placing bottles onto a conveyor and filling
only one bottle at a time. This method is time consuming and expensive. Our paper aims at
filling and capping bottles simultaneously. The filling and capping operation takes place in a
synchronized manner. It also includes a user-defined volume selection menu through which the
user can input the desired volume to be filled in the bottles. The entire system is more flexible
and time saving. The filling and capping operations are controlled using a Programmable Logic
Controllers (PLC’S). This is because PLC’s are very flexible, cost effective, space efficient and
reduces complexity. By programming the PLC we control the entire system. SCADA
(Supervisory Control and Data Acquisition) is used to monitor the process.

The present work briefs about a machine that used to prepare automatic filling of liquid in to the
bottle of different height is fully controlled by the plc. Which acts as the heart of the system. The
system sequence of operation is designed by ladder diagram and the plc. Programming software.
Sensor usually plays its vital part as an input signal transmitter for the plc. In the system. During
this project sensor has been used to detect the bottle position that move along the conveyor belt
at the low speed while the machine operates. The input signal that has been sent from the sensor
to the plc. Has being made as a reference. Signal in order to determine the output signal that
exactly a same with the plc. Programming language based on the user requirement. The entire
system is more flexible and time saving.
 CHAPTER-1

INTRODUCTION
1.1. INTRODUCTION TO THE PROJECT
Automation is the use of control systems and information technologies to reduce the need
for human work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provided human operators
with machinery to assist them with the muscular requirements of work, automation greatly
decreases the need for human sensory and mental requirements as well. Automation plays an
increasingly important role in the world economy and in daily experience.
PLC plays an important role in the world of automation industry. It acts a major function in
the automation field. PLC has replaced the wiring and cabling system that was used in the
previous. Its soft wiring feature makes changes in the control system easy and cheap. So in
today’s world it is very important to study PLC. The application of PLC in many sectors of our
country is increasing day by day.
The versatility and prospect of automation is so important that it could bring radical
development in almost every aspect. And in case of automation PLC could be a vital tool.
I have specially chosen the PLC based system and the goal is to study and test its applicability in
aspect of Bangladesh. For this I have directly applied a PLC based control system in an
automatic bottle filling station. The field of automation has had a notable impact in a wide range
of industries beyond manufacturing. For these kinds of applications, the trend is moving away
from the individual device or machine toward continuous automation solutions. Totally
Integrated automation puts this continuity into consistent practice. Totally Integrated Automation
covers the complete production line, from receipt of goods, the production process, filling and
packaging, to shipment of goods.
 1.2. AUTOMATION AND CONVEYOR DEFINETION

1.2.1. What is Automation system?

Automation: - is the use of control systems and information technologies to reduce the need for
human work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provided human operators
with machinery to assist them with the muscular requirements of work, automation greatly
decreases the need for human sensory and mental requirements as well
.
1.2.2. What is Conveyor system?

Conveyor systems: - are used widespread across a range of industries due to the numerous
benefits they provides. Conveyors are able to safely transport materials from one level to
another, which when done by human labor would be strenuous and expensive. They can be
installed almost anywhere, and are much safer than using a forklift or other machine to move
materials. They can move loads of all shapes, sizes and weights. Also, many have advanced
safety features that help prevent accidents.
Our project is also an application of automation wherein we have developed a bottle filling
and capping system .The various processes are controlled using a PLC (Programmable Logic
Controller) and is monitored using SCADA (Supervisory Control and Data Acquisition).

1.3. The Purpose of Automation system

Purpose of automation plays an increasingly important role in the world economy. One of the
important applications of automation is in the soft drink and other beverage industries, where a
particular liquid has to be filled continuously. For these kinds of applications, the trend is
moving away from the individual device or machine toward continuous automation solutions.
Totally Integrated Automation puts this continuity into consistent practice. Totally Integrated
Automation covers the complete production line, from receipt of goods, the production process,
filling and packaging, to shipment of goods.

1.4. The purpose of conveyor system

 Conveyors are able to safely transport materials from one level to another, which when done
by human labor would be strenuous and expensive. They can move loads of all shapes, sizes and
weights. Also, many have advanced safety features that help prevent accidents.

Figure 1.1: conveyor system

A conveyor system is a common piece of mechanical handling equipment that moves
materials from one location to another. Conveyors are especially useful in applications involving
the transportation of heavy or bulky materials. Conveyor systems allow quick and efficient
transportation for a wide variety of materials, which make them very popular in the material
handling and packaging industries many kinds of conveying systems are available, and are used
according to the various needs of different industries. There are chain conveyors (floor and
overhead) as well. Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free,
and hand pushed trolleys.

1.5. What is programmable logic controller (PLC)?

PLC is a solid state device. They are well adapted to a range of automation tasks .All control
operations are done using the PLC. The entire bottling process is automated by feeding the
necessary conditions into the PLC using ladder logic. Ladder logic is one of the methods of
programming a PLC. Thus, depending on the logic developed the filling of bottles is done. PLC
consists of an I/O unit, central processing unit, and a memory unit

1.6. Scope of the project

Automation is much relevant in industrial sector. It increase the volume of work, making work
much more precise and accurate, increase the quality and durability of the products and, most
importantly, is giving factory owners the much-needed breathing space. In our project we are
intended to design and control a system satisfying industrial needs.

1.7. Objective

Our objective is to implement automatic system for bottle filling and how much accurately and
precisely we are able to do that.

CHAPTER TWO

LITERATURE REVIEW
• Background
This background of the project shows the need for improvement in the current on fallen or
misaligned bottles. Traditional methods of bottle filling involved placing bottles onto a conveyor
and filling only one bottle at a time. This method is time consuming and expensive Research on
current operations of other facilities, patent research, and analysis of the current process are
included. By studying the current process and comparing it with processes from other plants a
general concept formed of what needs to be altered to achieve improvement. The goal of this
literature review is to provide automatic system with a selection of possible design changes or
redesign alternatives including a detailed model for each system. This chapter gives a detailed
explanation of the various processes taking place in a complete bottling system. The filling and
capping operations take place in a sequential manner as shown in FIG II. When no bottles are
kept in the input the system is reset. Depending on the number of bottles fed into the input side,
the corresponding bottles are filled and capped. The process is also provided with a user defined
volume selection menu.

• PROBLEM DESCRIPTION

This system is designed to filling 2 type of liquid to their bottle randomly in a single machine.
This project will reduce the usage of man power because all of the work will be done by
machine. Human held filling process will cause inexact volume of liquid into the bottle. So using
automated system will set the volume of the liquid exactly the same for each bottle. If all the
process is done manually, it will cost lot of time to complete the task. This system will also
reduce the human error while doing this process manually. If the machine has to fill different
type (size) of container then again the operator has to set the filling amount for each container.
Time taken for filling will become more in such conditions. Sometimes in special environments
which are dangerous and not conductive for human operation, the operator cannot go and set the
filling amount. By this the rate of production was affected due to the use of manual inspection
systems. Sometimes in special environments which are dangerous and not conductive for human
operation.
 • BLOCK DIAGRAM DISCRIPTION

In our project we are designing a machine that is used to automatically fill water into the bottle. For
controlling purpose we are using PLC. The system sequence of operations is designed by ladder diagram and is
being programmed using software.
Nowadays, the application of PLC is widely known and its application is obviously applied at the
industrial sector. Normally, the PLC’s that have been used at the industrial field is usually to
control a mechanical movement either of the machine or heavy machine in order to create an efficient production
and accurate signal processing. Sensor usually plays its vital part as an input signal transmitter for the PLC in
this system. During this project sensor has been used to detect the bottle position that move along the conveyor belt
while the machine operates. The input signal that has been sent from the sensor to the PLC has being made as a
reference. The output signal generated using PLC programming language is based on the user requirement.
Through this project, the bottle will move on the conveyor belt. The conveyor will be stopped
automatically after the infrared sensor detected the presence of the bottle. The controller will switch on the
pumps when the conveyor stops to move. The water pump will start to fill into the bottle. The filling process
will be stopped automatically by using the timer. This system will repeat the process continuously.

• BLOCK DIAGRAM
 Figure 2.1 block diagram description

• Hardware Part
Our proposed device is consisted of a PLC (LOGO 230 RC) , 24V DC Relay, 220V AC Relay,
Sensor (PUYON KS-G22) , Solenoid valve, Single-phase induction motor, conveyer belt, 24 V
DC Source, ON-OFF button and some connectors. The ON-OFF button works as the input
device. The PLC controls the input and output according to the program provided to it.

• Software Part
There are five main programming languages for programmable control systems: Thus a
1. Function block diagram (FBD)
2. Ladder diagram (LD)
3. Structured text (ST; similar to the Pascal programming language)
4. Instruction list (IL; similar to assembly language) and
5. Sequential function chart (SFC).

• Ladder diagram (LD)

These techniques emphasize logical organization of operations. In out proposed device
Ladder Diagram (LD) is used. The program is to interface the ON-OFF button and all the hard-
ware parts with the PLC. Ladder diagrams (sometimes called "ladder logic") are a type of
electrical notation and symbology frequently used to illustrate how electromechanical switches
and relays are interconnected The two vertical lines are called "rails" and attach to opposite poles
of a power supply, usually 120 volts AC. L1 designates the "hot" AC wire and L2 the "neutral"

(grounded) conductor. Horizontal lines in a ladder diagram are called "rungs," each one
representing a unique parallel circuit branch between the poles of the power supply. Typically,
wires in control systems are marked with numbers and/or letters for identification. The rule is, all
permanently connected (electrically common) points must bear the same label.

Ladder diagrams are specialized schematics commonly used to document industrial control logic
systems. They are called "ladder" diagrams because they resemble a ladder, with two vertical
rails (supply power) and as many "rungs" (horizontal lines) as there are control circuits to
represent. If we wanted to draw a simple ladder diagram showing a lamp that is controlled by a
hand switch, it would look like this:

Figure2. 2 simple ladder diagrams

The "L1" and "L2" designations refer to the two poles of a 120 VAC supply, unless otherwise

noted. L1 is the "hot" conductor, and L2 is the grounded ("neutral") conductor. These designations
have nothing to do with inductors, just to make things confusing. The actual transformer or
generator supplying power to this circuit is omitted for simplicity. In reality, the circuit looks
something like this:

Figure 2.3 simple ladder diagrams

Typically in industrial relay logic circuits, but not always, the operating voltage for the switch
contacts and relay coils will be 120 volts AC. Lower voltage AC and even DC systems are
sometimes built and documented according to "ladder" diagrams
 Figure 2.4 simple ladder diagrams
So long as the switch contacts and relay coils are all adequately rated, it really doesn't matter
what level of voltage is chosen for the system to operate with. Note the number "1" on the wire
between the switch and the lamp. In the real world that wire would be labeled with that number
using heat-shrink or adhesive tags, wherever it was convenient to identify. Wires leading to the
switch would be labeled "L1" and "1," respectively. Wires leading to the lamp would be labeled

"1" and "L2," respectively. These wire numbers make assembly and maintenance very easy. Each
conductor has its own unique wire number for the control system that it's used.

CHAPTER THREE

METHODOLOGIES

• SYSTEM ANALYSIS& DESCRIPTION

The basic block diagram (as shown in Fig.1) of the process and its explanation is given as
follows:

Figure3. 1 Block Diagram of Bottle Filling System

• INPUT MODULE
The input module includes the IR sensors and level sensors. There are four pairs of IR sensors
whose output is given as an input to the PLC. Three pairs of IR sensors which are used to detect
the bottles at the input and one more are used to sense the bottles for filling and capping
operations. The 3 IR pair sensors kept near the input side, where the bottles are fed into the
conveyor, is called detection sensors and the one used for stopping the conveyor at the filling and
capping operation side is called the stop sensor. There are seven levels sensors used.
Two level sensors are used in tank 1 (concentrate tank) to denote the high level and low level and
similarly two sensors are used in tank 2 (tank containing water). Three level sensors are used in
the process tank to denote the low, middle and high levels. Thus, these are the inputs given to the
input module.
 Figure3. 2. Simple IR proximity sensor

• SIGNAL CONDITIONING

The output of the sensors cannot be given directly to the PLC as the input voltage to the PLC
should be 24V. Hence they are given through signal conditioning circuits which condition the
input signals and in turn give it as an input to the PLC. For safety purposes the inputs are not
given directly to the PLC. They are given through relay circuits. The relay consist of 3 terminals
common, NO and NC. The 24V which is to be inputted into the PLC will be available in the
common terminal. Hence depending upon the necessary signals, the circuit closes or opens
thereby connecting to the PLC.

Figure 3.2.1: Final signal conditioning circuitry

• PLC
PLC is a solid state device. They are well-adapted to a range of automation tasks .All control
operations (filling and capping) are done using the PLC. The entire bottling process is automated
by feeding the necessary conditions into the PLC using ladder logic. Ladder logic is one of the
methods of programming a PLC. Thus, depending on the logic developed the various operations
take place and the filling and capping of bottles are done. PLC consists of an I/O unit, central
processing unit, and a memory unit.

Figure3. 3 Diagram of the programmable logic controller

The input/output unit of the PLC acts as an interface to the real world. Inputs from real work are
given to the input unit which is manipulated based on the programming, and the results are given
back to the real world through the output unit of the PLC. All logic and control operations, data
transfer and data manipulation operations are done by the central processing unit. The results and
statuses are stored in the memory of the PLC. PLC’s are used for a wide range of applications
especially in the field of control and automation. The example in Figure 3 does not show the
entire control system, but only the logic. When we consider a PLC there are inputs, outputs, and
the logic. Figure 4 shows a more complete representation of the PLC. Here there are two inputs
from push buttons.
We can imagine the inputs as activating 24V DC relay coils in the PLC. This in turn drives
an output relay that switches 115V AC, which will turn on a light. Note, in actual PLCs inputs
are never relays, but outputs are often relays. The ladder logic in the PLC is actually a computer
program that the user can enter and change. Notice that both of the input pushbuttons are
normally open, but the ladder logic inside the PLC has one normally open contact, and one
normally closed contact. Do not think that the ladder logic in the PLC needs to match the inputs
or outputs. Many beginners will get caught trying to make the ladder logic match the input types.
 Figure3. 4 A PLC Illustrated With Relays

• OUTPUT RELAY DRIVE UNITS

The operating voltage of the output devices is low when compared to that of the PLC. The output
of the PLC is 24V whereas output devices such as gear motors and pump require only 12V for
their operation. Hence the output signals from the PLC are given through a relay drive unit
which drives the output devices by supplying the optimum voltage required for their operation.
The 12V required for their operation is available at the common terminal of the relay unit.Many
relays also have multiple outputs (throws) and this allows an output relay to also be an input
simultaneously. Relays are used to let one power source close a switch for another (often high
current) power source, while keeping them isolated. An example of a relay in a simple control
application is shown in Figure 3. In this system the first relay on the left is used as normally
closed, and will allow current to flow until a voltage is applied to the input A. The second relay
is normally open and will not allow current to flow until a voltage is applied to the input B. If
current is flowing through the first two relays then current will flow through the coil in the third
relay, and close the switch for output C. This circuit would normally be drawn in the ladder logic
form. This can be read logically as C will be on if A is off and B is on.
 Figure3. 5 a simple relay controller

The circuit shown in Figure 5 is an example of this, it is called a seal in circuit. In this circuit
the current can flow through either branch of the circuit, through the contacts labeled A or B.
The input B will only be on when the output B is on. If B is off, and A is energized, then B will
turn on. If B turns on then the input B will turn on and keep output B on even if input A goes off.
After B is turned on the output B will not turn off.

• OUTPUT MODULE

The various output devices used in the bottling process are gear motors, pumps, actuators and
LED’s. These are connected to the output module. The gear motor is used to run the conveyor in
forward direction. There are totally five pumps used for the filling process. Three pumps are
connected to the process tanks and the other two pumps are connected to the concentrate (tank 1)
and water tank (tank 2) respectively. Actuators are used for capping the bottles. The actuator
applies a force on the caps which in turn corks the bottles tightly. These are the various output
devices used in the bottling process. DC motor was used to move the conveyor which is
transferring the product between stations. This motor will operate at the voltage of 12 V DC,
with the starting current 1.2A and running current of 0.85A.

• LIGHT-EMITTING DIODE (LED)

A light-emitting diode (LED) is a two-lead semiconductor light source that resembles a basic
pn HYPERLINK "http://en.wikipedia.org/wiki/Pn-junction"-junction diode, except that an LED
also emits light. When an LED's anode lead has a voltage that is more positive than its cathode
lead by at least the LED's forward voltage drop current flows. Electrons are able to recombine
with holes within the device, releasing energy in the form of photons. This effect is called
electroluminescence, and the color of the light

Figure3. 6 The inner workings of an LED, showing circuit (top) and band diagram
(bottom)

Figure3. 7 LEDs are produced in a variety of shapes and sizes

• ACTUATOR
An actuator is a type of motor for moving or controlling a mechanism or system. It is
operated by a source of energy, typically electric current, hydraulic fluid pressure, or pneumatic
pressure, and converts that energy into motion. An actuator is the mechanism by which a control
system acts upon an environment. The control system can be simple (a fixed mechanical or
electronic system), software-based (e.g. a printer driver, robot control system), or a human or
other agent.
Operating Conditions:-Actuators are commonly rated using the standard IP rating system.
Those that are rated for dangerous environments will have a higher IP rating than those for
personal or common industrial use.
Durability:-This will be determined by each individual manufacturer, depending on usage
and quality.
 • DRIVE CIRCUIT
This page links to unipolar and bipolar stepper motor driver pages. The drivers are designed
for simple requirement applications and are made with parts that are available from a variety of
sources. Both of the stepper drivers are use a 74194 - Bidirectional Universal Shift Register
from the 74LS or 74HC - TTL families of logic devices to produce the stepping function. A
diagram at the bottom of this page shows the difference between the 74194 - unipolar and bipolar
stepping pattern generations. These stepper drivers have only basic control functions: Forward,
Reverse and Stop and Step rate adjustment. The calculated Step rate adjustment range of the
drivers is 0.72 (1.39 sec) to 145 steps per second. (Lower and higher step rates are also possible.)
The only step angle for these drivers is the design step angle of the motor itself. 'Half-stepping' is
not possible with either of the driver circuits.

(a)

(b)
Figure3. 8 Driver circuit (a) simulation (b) practical

3.1.9. SCADA
 SCADA systems integrate data acquisition systems with data transmission systems and HMI
software to provide a centralized monitoring and control system for numerous process inputs and
outputs. SCADA systems are usually designed to be fault-tolerant systems with significant
redundancy built into the system architecture. SCADA systems are designed to collect field
information, transfer it to a central computer facility, and display the information to the operator
graphically or textually, thereby allowing the operator to monitor or control an entire system
from a central location in real time. Based on the sophistication and setup of the individual
system, control of any individual system, operation, or task can be automatic, or it can be
performed by operator commands. SCADA is not a full control system, but rather focuses on the
supervisory level. SCADA is used for gathering, analyzing and to storage real time data.
SCADA systems are designed to collect field information, transfer it to a central computer
facility, and display the information to the operator graphically or textually, thereby allowing the
operator to monitor or control an entire system from a central location in real time. Based on the
sophistication and setup of the individual system, control of any individual system, operation, or
task can be automatic, or it can be performed by operator commands. SCADA is not a full
control system, but rather focuses on the supervisory level. SCADA is used for gathering,
analyzing and to storage real time data. SCADA systems consist of both hardware and software.
Typical hardware includes an MTU placed at a control center, communications equipment (e.g.,
radio, telephone line, cable, or satellite), and one or more geographically distributed field sites
consisting of either an RTU or a PLC, which controls actuators and/or monitors sensors. The
MTU stores and processes the information from RTU inputs and outputs, while the RTU or
PLC controls the local process.
The communications hardware allows the transfer of information and data back and forth
between the MTU and the RTUs or PLCs.
 Figure 3.8.1. SCADA System General Layout (Components and General Configuration)

• HOW SYSTEM WORKS?

The mechanism in which the bottle filling are done is shown below figure3.9

Figure3. 9 Working Of Bottle Filling System

• BOTTLE DETECTION USING SENSORS

Bottles are kept in position in their respective holders which are fixed to the conveyor at the
input side. IR sensors are used to detect the presence of bottles in the holder. Depending on the
output of the sensors the filling and capping operation takes place. A time delay is given in order
to set the status of the bottles. If bottle 1 is present the corresponding status bit in PLC is set to 1
else it is set to 0. The outputs of these sensors are given to the PLC and depending on this output
the filling and capping process for the bottles takes place. Thus if all the n bottles are present in
the input side then the sensor gives the corresponding output to the PLC which in turn switches
ON the corresponding pumps for filling operation to take place. If a particular bottle is not
present the corresponding pumps remain OFF.

• FILLING OPERATION

Once the bottles are detected in the input side the conveyor motor switches ON and it starts
moving in the forward direction. The bottles then reach the desired position for filling and the
conveyor stops. The corresponding pumps in process tank switch ON and filling operation takes
place. For e.g. if only bottle 1 is present then pump 1 switches ON and pump 2 and pump 3
remain switched OFF. There are three tanks present in the filling side namely: process tank,
concentrate tank (tank 1) and tank to store water (tank 2).Tank 1 and tank 2 have low level and
high level sensors (LLS and HLS) respectively. Process tank has three level sensors (LLS, HLS
and MLS).MLS is used to denote the middle level of the tank. When the liquid in the process
tank reaches below low level (LLS) pumps in tank 1 and tank 2 switches on and the process
tanks get filled. When the level of liquid reaches high level (HLS) the pumps in tank 1 and 2
switch off.
• USERDEFINED VOLUME

The filling operation is accompanied with a user defined volume selection menu. The desired
volume is fed into the PLC and depending on the volume the filling of liquid takes place. The
filling is done using timing operations. Thus the pump remains on for the preset value of the
timer and switches off once time is out. Once the filling process is done the conveyor starts
moving again.
The filling tank was design on top of the bottle while filling process because the liquid easily
flow through to the bottom according to gravity principle. The measurement of the bottles was
6.7 cm height, 4.7 cm wide which will cover the capacity 350ml of fluid. With this amount of
fluid, it can full up to 3 bottles at a time. The total time for the valve to open and full 3 bottles at
a time is 5 seconds. This section use feed valve to flow the fluid into bottle.
 • CAPPING OPERATION

The bottles are transported to the capping arrangement. IR sensors are kept to stop the bottles in
the desired position for capping to take place. Once the bottles reach the position the conveyor
motor switches OFF. The capping of bottles is done using actuator arrangement. Three actuators
which move in forward and reverse directions are used to cap the bottles. The actuator applies a
force on the caps which are placed in their respective holders. This force helps the caps to fit into
the bottles at the required position. Similar to filling, if a particular bottle is not present it does
not get capped. Thus the capping is done and the conveyor starts moving again. When the
capping operation for one batch is done simultaneously the filling operation for another batch
takes place. The entire sequence of operations continues until there are not bottles present in the
input side. All these are automatically coordinated using the PLC. PLC gets the input from the
input devices and sends the signals to the various output devices depending on the conditions
that are fed into the PLC. Thus bottles get filled and capped.

Figure3. 10 capping operation

• FLOWCHART DIAGRAM

The flowchart which described the working operation of Bottle Filling

System is schematically shown in following Figure3.11
 Figure3. 11 Flowchart of the system

When the bottle is under the solenoid valve, the bottle is sensed and the motor hence the
conveyer belt stops. Then the solenoid valve operates and the bottle starts filling with water.
When the bottle is filled then the solenoid valve is closed and the motor hence the conveyer belt
starts moving and carrying the bottle away from the solenoid valve. If another bottle is sensed
then the above process will be repeated. When stop button is pushed then the entire process will
be stopped and reset the circuit.
 CHAPTER FOUR
• SYSTEM SPECIFICATION& RESULTS

• SYSTEM SPECIFICATION
The details specification and system details are as follows,
• Input: 220 V AC
• Maximum bottle height: 6.7cm’’
• Maximum bottle diameter: 4.7cm’’
• Maximum pressure: 1 bar
• 1 filling Nozzle
• Automatic shut off when bottle is full
• Best liquid: Water

4.2.1. SELECTION OF PLC

There are some main factors to choose a PLC for any application. Different
PLCs have different number of I/O ports. And in some, adding external I/O cards can increase
number of I/O ports. Memory Size is the memory amount available for the code of PLC. In some
PLCs, adding external flash cards can increase memory size. Serial and networked connections
allow the PLC to be programmed and talk to other PLCs. The needs are determined by the
application. Human machine interface and it is a very important feature of PLC. Using this one
can see the whole operation of the PLC program graphically. Speed is also an important factor in
choosing PLCs. But Now-a-days PLCs are rapid enough for any kind of operation. In the
proposed device LOGO! 230 RC is used. In LOGO! 230 RC, there are 8 inputs and 4 relay type
outputs. 4ms full pro-grams scan time and memory was more than enough for the automatic
bottle filling station.
 Figure 3.11.1 LOGO! 230 RC software
• The various advantages of using PLC is as follow
• Expandability
• High power Handling
• Reduce Human Effort
• High reliability
• Small space requirements
• Computing capabilities
• Reduced costs
• Ability to withstand harsh environments
 • MODEL OF PLC BASED AUTOMATIC BOTTLE FILLING STATION

Figure3. 12 Model of PLC Based Automatic Bottle Filling System

The PLC is powered by a 220V AC power supply through its line (L) and Neutral (N) port.
A Push button is connected from the same source to the input card terminal I1. A sensor is
powered by a 24V DC power supply and its output is connected to a 24V DC Relay coil. I2 input
of the PLC is connected to the NC terminal of the 24V DC relay. A 220V AC relay coil is
connected with the PLC relay type output port Q1 and from the NC terminal of this relay the 1-
phase motor of the conveyer belt is connected. A solenoid valve is directly connected with the
PLC relay type output terminal Q2. When the ON push button is pressed then the PLC input port
I1 gets a pulse and for this the PLC relay type output Q1 is energized and the motor starts. Now
when the sensor senses a bottle then it gives a pulse to the DC relay hence the DC relay operates.
So the I2 input of the PLC gets a pulse and for this the relay type output Q1 is de energizes and
Q2 energizes ac-cording to the Ladder logic of the PLC. So the motor stops and the solenoid
valve operates for certain period of time assigned in the Ladder logic of the PLC. After the
assigned time PLC relay type output Q1 again energizes and Q2 de-energizes. So the motor
again starts running and the solenoid valve be-comes OFF.

• SYSTEM DETAILS
• Conveyor system with motor for movement of bottle.
• Proximity sensor for sensing bottle positions.
• Liquid filling Operation.
• Bottle count operation
 • Solenoid valve for control of liquid filling.
• Control panel for visual indication of process.

• ADVANTAGES
• Compact Ergonomic Design.
• User friendly self-explanatory systems.
• Leak proof Safety Measures, study piping & Robust Construction.
• Enhanced Electrical Safety Considerations.
• Training Manuals & mimic Charts for Operation Ease.
• M.S. powder coated cubical plant with standard Instrument Mountings.
• Inbuilt Safety Measures to avoid improper usage.
• Computer Interface (Optional).

• RESULTS
A lot of additional features like user defined volume specification etc. were added in the
different stages in our work and the desired results were obtained different specification this
system. We can implement this system if we get an access depend on our specification. We
were obtained different specification but we are not simulating it because we didn’t get the
software on time and also we have no enough knowledge about plc due to those purpose we
tried to specify different components of the system as shown in the report. PLC was used to
control the various operations and monitoring was done using SCADA. More features can be
added to this system when the users implement depending on the size, shape and weight of
the bottles.

CHAPTER FIVE

CONCLUSION AND FUTURE SCOPE

• CONCLUSION
The main objective of this paper was to develop a bottle filling and capping system based on
certain specifications. This was successfully implemented. I consider this paper as a journey
where I acquired knowledge and also gained some insights into the subject which I have shared
in this report. A lot of additional features like user defined volume specification etc. were added
in the different stages in our work and the desired results were obtained. PLC was used to control
the various operations and monitoring was done using SCADA. More features can be added to
this system as follows: depending on the size, shape and weight of the bottles, filling and capping
operations can be implemented. Capping operation can be improvised using a piston
arrangement. The PLC based control system has been studied along with its prospects in this
seminar. A PLC based control system was applied to the automatic bottle filling station
previously specified and the performance was measured. All the results lead to a conclusion that
the potential of PLC in perspective of Bangladesh is very inspiring. The device can fill up 2
bottles of maximum height of 6.7’’ and maximum bottle diameter of 4.7” in 1 minute at 1 bar
pressure. So it can be used commercially in various coffee shops, juice shops, cold drink shops
etc. and reduce human effort. So the practical research result is very much satisfactory. It also
helps to understand the necessity of PLC in industrial automation and also to realize the
necessity of studying it.

5.2. FUTURE SCOPE

Using appropriate pump, jet nozzle and strong solenoid valve in which case precise timing would
be needed can increase productivity. A guide way could be used in case of vibration. A non-
intrusive water level sensor could be used instead of depending on the valve timing. An extended
capping section could also be introduced. Another sensor could be used in the beginning, which
can sense the bottle and start the conveyer belt automatically. More flexibility can be introduced
in nozzle positioning. The system could be redesigned for increased bottle size and productivity

REFERENCES

[1] Shaukat.N, PLC based automatic liquid filling process, Multi Topic Conference 2002, IEEE
publications.
[2] Dunning Gray (1998) - ‘Introduction to Programmable Logic Controllers’ - Delmar
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[3] Petruzella, Frank D. (2010) ‘Programmable logic Controllers Tata McGraw Hill Education’,
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[5] Rehg, James A. Glenn J Satori (2009) – ‘Programmable Logic Controllers’- Pearson prentice
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[6] "Advantages of Using Programmable Logical Controller [PLC] in the Construction Industry."
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[7] Petruzella, Frank D. (2010) - ‘Programmable logic Controllers’ - Tata McGraw Hill
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