1

CHAPTER 1

INTRODUCTION

1.1 Background of study

The field of automation has had a notable impact in a wide range of industries
beyond manufacturing. Automation is used in control system and information
technologies to reduce the need for human work in production of goods and
services. In the scope of industrialization, automation is a step beyond
mechanization. Whereas mechanization provides human operates with
machinery to assist them with the muscular requirements of work, automation
will greatly decrease the need for human sensory and mental requirements as
well. [1]

Automation plays an increasingly important role in world economy. One of

the applications of automation is in the beverage industries, where particular
liquid has to be filled continuously. Totally Integrated Automation(TIA) that
invented by Siemens Company puts this continuity into consistent practice.
Totally Integrated Automation covers the complete production line from the
production process, filling and packaging to shipments of goods. [2]

This project is also an application of automation wherein I have to develop a

liquid filling to bottles of different height. The operations are controlled using
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Programmable Logic Controller (PLC). One of the advantage using PLC are
easily programmed and have an easily understood programming language. This
project is aiming to control the liquid flow to fill a container. The liquid flow is
monitored where it can fill an empty container with liquid automatically without
human intervention. The fills of liquid is depends on the volume given by the
user. Accurate flow control pump is used to accurately fill the liquid volume into
the container for a specified time and filling time. In addition, this project also
included a conveyor system which carries the container to the filling station and
out of the filling station. The conveyor system is also controlled by the PLC.

The working principle of the project is described as below:

Sensor
Conveyor
Container detect and Liquid filling
move and
place on the measure the into the
repeat the
conveyor size of container
process
container

Figure 1.1: Working principle of the system

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1.2 Problem Statement

The problem that existing in the present machines are that it can only a particular
type of containers of certain height and the filling amount is set by the operator.
If the machines have to fill different type (size) of container, then again, the
operator has to set the filling amount for each container. Time taken for willing
become more in such conditions. Sometimes in special environments especially
that involves dangerous chemical, this could be dangerous and not conductive
for human operation. This will affect the rate of production due to use of manual
inspection system.

1.3 Project Objective

The works undertaken in this project are aiming on the following objectives:

a) To design a low cost automatic liquid filling system to be applied in small

industries.
b) To optimize the system that will provide the accurate volume of liquid in the
container requested by the user.
c) To develop a conveyor system carrying the container to the filling station and
out of filling station.

1.4 Project Scope

The framework of this project are divided into 3 parts:

a) Design and developments of automatic liquid filling machine that can fill the
liquid desired by the user accurately with minimum error possible
b) Design and development of conveyor system to be integrated with liquid filling
machine
c) Develop an algorithm program using CX programmer as the controller to control
the operation of liquid filling machine and conveyor system.
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1.5 Expected Outcomes of the Project

This project expects to have following outcomes by the end of the project.

a) This project could help people especially people in small industries especially in
soft drinks, beverages and etc.
b) Build a prototype conveyor and could be used for education purpose.
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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

This chapter gathers information that allow us to gain knowledge about technologies that
have been used relative to this project. In order to gain knowledge, several papers are
reviewed. These papers consist of PLC and sensor that has been used in the project. The
entire projects more focus at PLC as a controller. The research and previous work is included
in Related Studies. In addition to that, some of the software will be used include XC
Programming. This programming used for creating the ladder diagram that has to download
to the PLC.

2.2 Programmable Logic Control System

A programmable logic controller (PLC) is a special form of microprocessor based

controller that uses a programmable memory to store instructions and to implement
functions such as logic, sequencing, timing, counting and arithmetic in order to
control machines and processes and are designed to be operated by engineers with
perhaps a limited knowledge of computers and computing languages [3].
Programmable Logic Controllers (PLC) are used in almost every aspect of the industry
to expand and enhance production. Where the older automated systems would use
hundreds or thousands of electromechanical relays, a single PLC can be programmed
as an efficient replacement. The functionality of the PLCs has evolved over the years
to include capabilities beyond typical relay control. Motion control, process control,
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distributive control systems, and complex networking have now been added to the
PLC’s functions [4]. Therefore, this type of control provides huge advantages
including increased reliability, more flexibility, lower cost, communication capability,
faster response time and convenience to troubleshoot. The PLC process block
diagram shown in figure 2.1 below and the function of each block.

Figure 2.1 PLC block diagram

1. The processor unit or central processing unit (CPU) is the unit containing the
microprocessor and this interprets the input signals and carries out the control
actions, according to the program stored in its memory, communicating the
decisions as action signals to the outputs.
2. The power supply unit is needed to convert the mains a.c. voltage to the low d.c.
voltage (5 V) necessary for the processor and the circuits in the input and output
interface modules.
3. The programming device is used to enter the required program into the memory of
the processor. The program is developed in the device and then transferred to the
memory unit of the PLC.
4. The memory unit is where the program is stored that is to be used for the control
actions to be exercised by the microprocessor and data stored from the input for
processing and for the output for outputting.

5. The input and output sections are where the processor receives information from
external devices and communicates information to external devices. The inputs
might thus be from switches other sensors such as photo-electric cells, as in the
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counter mechanism in temperature sensors, or flow sensors, etc. The outputs might
be to motor starter coils, solenoid valves, etc.

6. The communications interface is used to receive and transmit data on

communication networks from or to other remote PLCs. It is concerned with such
actions as device verification, data acquisition, synchronisation between user
applications and connection management.

2.3 PLC as controller

In the past, humans were the main methods for controlling system as manual
controller. When the operator operates the process to desired condition, then it carries
out the corrective action to be manual control. Nowadays PLC have widely used as a
controller of industries. One of the application is liquid mixture control system. The paper in
previous work by Azman Bin Abdul Rahman. In this project, two or more types of liquids with
different PH values. PH sensor is used to detect PH value of the mixture, which this signal is
fed to analogue input PLC terminal, that to be used for comparing PH value required as a
product. It consists of six tanks, with one mixture motor and also five pumps are used to control
the system via PLC [5].

Besides that, one of the application is a movable conveyor driven into and out of the
trailer. The paper in previous work by Liping Guo was used as a control. This conveyor is used
in distribution centers to load boxes onto trailers. It moves along a good track in the floor and
can be driven in and out of the trailer. The conveyor is operated with one push button for
forward and the other for reverse movement. The push button must be held down the entire
time when the conveyor is moving. Inputs of the system include the diffuse type photoelectric
sensors on the front and back of the conveyor to prevent a collision, and inductive proximity
switches at the bottom of the front and back to prevent over travel condition [6].

Next, PLC used widely especially in beverage industries. One of the application is
automatic bottle filling system. The paper in previous project by Md. Mahadi Hassan. In this
project, bottles are required to be filled-up with a pre-determined amount of liquid. The filling
process is usually kept automated to ensure a higher production rate and to lessen the burden
on human resources, since the human operator is required to take only a supervisory role here.
The whole process of bottle filling is therefore performed automatically through machines
which are controlled by PLCs [7].
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Manufacturing industries always having a problem with man power which to

pay their salary and thus this project will be invented to overcome the problem by
reducing the number of employees and at the same time save the cost. Using this
project by Jamaludin Sapii PLC also can use as a controller for to develop a vibrator
loader for the contact lenses cup project. PLC functioned to control the power window
and DC motor based on the signal from the infrared sensor. The DC motor is functional
to vibrate the spiral shape vibrating feeder bowl to feed the contact lens carp to singular
conveyer. Despite loading process, the sensor also being attached to sense the quality
of the lens cup that being fed into the vibrating bowl. The sensor will send the signal
to the motor whenever it detects the existence of the contact lens cup so the motor will
rotate and move the conveyor. The average time for single contact lenses to finish for
the whole process is faster compared to industrial technique nowadays [8].

2.4 Configuration of automatic filling bottles system

2.4.1 Processing Unit

Processing unit is the main component that control the whole operation of the project.
Behaviour of the developed system is defined or determined by the program designed
in the processing unit. The type of PLC that will be used in the project will be discussed
in this section.
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2.4.1.1 CP1L (OMRON)

In this project, to implement the control logic of the system, PLC will be used. Here I
have Cpm1a which is manufactured by Omron Company. This PLC is manufactured
to industrial standards. It’s communication with input and output component is fast.
Figure 2.2 shows the PLC unit that used in the project which has 10 I/O.

Figure 2.2: PLC module

There are several models of central processing unit (CPU) available with different
models of CP1L. The PLC that being used in this project is CPM1A-10CDR-A-V1.
The PLC dimension is show in Figure 2.3.
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Figure 2.3: Dimension of PLC

It is a compact high-performance CPU and has an integrated power supply of 24 VDC.

It is built-in input terminals which has 6 inputs and 4 outputs. Control method is stored
program method while the program language that being used is ladder diagram. It has
10K steps program capacity with common processing time 0.4ms. This PLC also have
1 analog input with resolution: 1/256 and memory backup flash memory or battery
backup. Flash memory will save the programs, parameters (such as the PLC Setup),
comment data, and the entire DM Area can be saved to flash memory as initial values
while battery backup for example The Holding Area, DM Area, and counter values
(flags, PV) are backed up by a battery.

2.4.2 Sensing Unit

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In this project, only used 1 type of sensor which is call photo retro-reflective sensor.
Figure 2.4 shows the reflective sensor used in the project to detect the arrival of a bottle
at the filing station and the size of container. The photoelectric sensor acts as a non-
contact object detector. The photoelectric sensor is cylindrical and its diameter is 18
mm. The operating voltage is 10-30 VDC.

Figure 2.4: Reflective sensor

2.4.3 Data Storage Unit

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There are several memory elements in a PLC system:

1. System read-only-memory (ROM) to give permanent storage for the

operating system and fixed data used by the CPU.
2. Random-access memory (RAM) for the user’s program.
3. Random-access memory (RAM) for data.
This is where information is stored on the status of input and output devices and the
values of timers and counters and other internal devices. The data RAM is sometimes
referred to as a data table or register table. Part of this memory, i.e. a block of
addresses, will be set aside for input and output addresses and the states of those
inputs and outputs. Part will be set aside for data and part for storing counter values,
timer values, etc.
4. Possibly, as a bolt-on extra module, erasable and programmable read-only-memory
(EPROM) for ROMs that can be programmed and then the program made
permanent.

The programs and data in RAM can be changed by the user. All PLCs will have
some amount of RAM to store programs that have been developed by the user and
program data. However, to prevent the loss of programs when the power supply is
switched off, a battery is used in the PLC to maintain the RAM contents for a period
of time.

2.5 Hardware requirement

2.5.1 Power Window Motor

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The power window motor consists of a motor, connector and gear. Two Hall effect
switches are set in the connector. The Hall effect switch utilizes magnets set on a
rotating axis to sense the power window motor rotation, and outputs a synchronized
pulse to the power window main switch [9]. Hall effect switch No. 1 outputs one pulse
cycle for each rotation of the power window motor axle. Power window acts as the
main switch that will detects the rotational speed of the power window motor. It will
detect the rotational direction of the power window motor by the difference between
high and low pulse points from Hall effect switch No. 1 and 2.

Figure 2.5: Construction of Power Window

1. Motor
2. Connector
3. Gear
4. Hall effect switch No 1
5. Hall effect switch No 2
6. Shaft
7. Magnet

2.5.2 Solenoid Valve

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A solenoid valve is an electromechanical device used for controlling liquid or gas flow.
The solenoid valve is controlled by electrical current, which is run through a coil.
When the coil is energized, a magnetic field is created, causing a plunger inside the
coil to move [10]. The plunger will either open or close depends on the design of the
valve. There are two common parts in solenoid valve which is an inlet and outlet. For
advanced designs, it could have three or more ports. Modern solenoid valves offer fast
operation, high reliability, long service life and compact design. The illustration in
Figure 2.6 below show the basic components of solenoid valve. This type of solenoid
valve is the simplest and easy to understand the principle of the operation.

Figure 2.6: Basic Components of solenoid valve

1. Valve body: This is the frame or the body of the valve which solenoid valve is
connected. Usually the valve is connected in process flow pipeline to control the flow
of certain fluid like liquid or air. The valve is controlled by the handle but in automatic
valve it might be connected with the solenoid valve.

2. Inlet port of the body: This is the port through which the fluid enters inside the
automatic valve and from here it can enter into the final process.

3. Outlet port: The fluid that is allowed to pass through the automatic valve leaves the
valve through the outlet port. The solenoid valve controls the flow of the fluid from
 15

inlet port to the outlet port. The outlet port is eventually connected to the process
where the fluid is required.

4. Coil/ Solenoid: This is body of the solenoid coil. The body of the solenoid coil is
cylindrical in shape, and it is hollow from inside. The body is covered with steel
covering and it has metallic finish. Inside the solenoid valve there is solenoid coil.

5. Coil windings: The solenoid consists of several turns of the enamelled wire wound
around the ferromagnetic material like steel or iron. The coil forms the shape of the
hollow cylinder. Externally this coil is covered with the steel covering and inside the
hollow part there is a plunger or the piston, whose motion inside the hollow space is
controlled by the spring.

6. Lead wires: These are external connections of the solenoid valve that are connected
to the electrical supply. The current is supplied to the solenoid valve from these
wires. When the solenoid valve is energized, the current flows through these wires
to the solenoid valve and when the solenoid valve is de-energized the flow of current
stops.

7. Plunger or piston: This is the solid round metallic part cylindrical in shape and placed
in the hollow portion the solenoid valve. When the electrical current is passed
through the solenoid valve, the magnetic field is generated inside the hollow space.
Due to this the plunger tends to move vertically in the hollow space. When the
electrical current is stopped to the solenoid valve, the magnetic field is stopped and
the plunger is remains the existing place due to the force of the spring

8. Spring: The plunger moves inside the hollow space due to the action of the magnetic
field against the action of the spring. The magnetic field generated inside the
solenoid valve tends to move the plunger, but the spring tends to stop the motion of
the plunger in which ever the position it is. This action of the spring against the
magnetic field helps keeping the plunger in the position where the flow of current to
the solenoid valve is stopped. The spring performs very crucial action inside the
hollow space.
9. Orifice: The orifice is an important part of the valve though which the fluid is flowing.
It is the connection between the inlet and the outlet port. The flow of fluid from the
inlet port to the outlet port takes place from this port. In the ordinary valves, this
 16

port is covered with the valve disc at the bottom of the stem of the valve to which
the handle is connected.

Working Principle of Solenoid Valve

Initially the sensor senses the process towards the outlet side of the solenoid valve.
When it senses that certain quantity of the flow of the fluid is required, it allows the
current to pass through the solenoid valve. Due to this the valve gets energized and the
magnetic field is generated which triggers the movement of the plunger against the
action of the spring. Due to this the plunger moves in upwards direction, which allows
the opening of the orifice. At this instant, the flow of the fluid is allowed from the inlet
port to the outlet port.

2.5.3 Relay

A relay is an electrically operated switch. Many relays use an electromagnet to operate

a switching mechanism mechanically, but other operating principles are also used [11].
Relays are used where it is necessary to control a circuit by a low-power signal, or
where several circuits must be controlled by one signal [12]. Figure 2.7 show a
structure of the relay.

Figure 2.7: Relay Construction

Relays have the exact working of a switch. So, the same concept is also applied. A
relay is said to switch one or more poles. Each pole has contacts that can be thrown in
mainly three ways. They are:
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▪ Normally Open Contact (NO) – NO contact is also called a make contact. It

closes the circuit when the relay is activated. It disconnects the circuit when
the relay is inactive.
▪ Normally Closed Contact (NC) – NC contact is also known as break contact.
This is opposite to the NO contact. When the relay is activated, the circuit
disconnects. When the relay is deactivated, the circuit connects.
▪ Change-over (CO) / Double-throw (DT) Contacts – This type of contacts is
used to control two types of circuits. They are used to control a NO contact and
also a NC contact with a common terminal. According to their type they are
called by the names break before make and make before break contacts.

Figure 2.8: Relay Working Concept

The diagram Figure 2.8 shows an inner section diagram of relay. An iron core is
surrounded by control oil. As shown, the power source is given to the electromagnet through
a control switch and through contacts to the load. When current starts flowing through the
control oil, the electromagnet starts energizing and thus intensifies the magnetic field. Thus,
the upper contact arm starts to attract to the lower fixed arm and thus closes the contacts
causing a short circuit for the power the load. On the other hand, if the relay had been already
de-energized when then the contacts were closed, then the contact move oppositely and
make an open circuit.
As soon as the coil current is off, the moving armature will be returned by a
force back to its initial position. This force will almost equal to half the strength of the
magnetic force. This force is mainly provided by two factors. They are the spring and
also gravity.
The relay is mainly for two basic operations. One how is low voltage
application or the other is high voltage. For low voltage applications, more preference
 18

will be given to reduce the noise of the whole circuit. For high voltage application,
they are mainly designed to reduce a phenomenon called arcing.

2.5.4 DC Motor Pump

Figure 2.9 shows the DC motor with pump assembly used in my project. This motor
has a pump assembly attached to it to pump liquids. The motor used in our project is
rated at 12 V DC and draws about 3.5 A current.
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Liquid Outlet

Power Cable

Liquid inlet

Figure 2.9: DC motor pump

2.6 Software requirement

To control a process using PLCs, it is required to program the PLC according to the
desired control logic. One of the reasons for PLCs gaining so much popularity is that,
they can be programmed using simple and intuitive programming technique. In this
project, ladder diagrams is used to implement the control logic. Every PLC
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manufacturer provides their own software interface to program the PLCs. The software
provided by Omron Company is named ‘CX-Programmer’. This software is user
friendly and provides efficient functions for configuring and programming the PLC
using ladder diagram.

2.6.1 CX- Programmer

CX-Programmer, the programming software for all Omron's PLC series, is fully
integrated into the CX-One software suite. CX-Programmer includes a wide variety of
features to speed up the development of your PLC program. New parameter-setting
dialogues reduce setup time, and with standard function blocks in IEC 61131-3
structured text or conventional ladder language, CX-Programmer makes development
of PLC programs a simple drag & drop configuration.

Figure 2.10: CX-Programmer Software

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CHAPTER 3

METHODOLOGY

3.1 Introduction

This chapter provides the explanation of methodology used for developing automatic
filling bottles system. The purpose of the methodology is to provide the working
principle, development and methods for the whole project to works. This
methodology leads to achieving the project objective. There are a few major steps
need to followed as shown in Figure 3.1.

Design and
Literature
Planning Materials
Review Study
gathering

Testing and Result,Analysis

Build the system
troubleshooting and Conclusion

Figure 3.1: Project Development Steps

3.2 Project methodology

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As shown in Figure 3.2, this project consists of four main phases, which are planning,
design, experiment work, result and analysis. The most crucial part to start the project
is to plan the project well and ensure the process is able to progress smoothly. The
project from planning, designing, experiment work and result analysis. The detail of
the steps is explained on the following sub-chapter.

• Literature review study

Planning • List of Hardware

• Software Development
Design • Hardware Development

• Performance Testing
Experiment Work • Troubleshooting

Result and • Record result

Analysis • Analysis result

Figure 3.2: Content of methodology

3.3 Planning

Planning the whole process for the development of this project by gathering
information about the hardware and software used is needed. In this planning phase,
the major elements that need to discuss that is literature review study of the existing
water usage monitoring system to know the concept of the system.

3.3.1 Literature Review

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Study the previous work that was done is an important task to be done because of the
studies it can explain and understand the advantages and disadvantages using the
component that will be used. Therefore, before starting any new project it will be a
benefit to study project that is completed.

3.3.2 List of Hardware in Project

Below is the list of hardware in order to complete the project and make the automatic
filling bottles system function well. Some of them hardware is readily available so they
are not listed such as laptop for ladder diagram coding. Table 3.1 shows the hardware
required in order to complete this project.

Table 3.1: List of Hardware

No Item Quantity
1 PLC Module 1
2 Conveyor Belt 1
3 Reflective sensor 3
4 Power window motor 1
5 Dc pump motor 1
6 Valve 1
7 Tank 1
8 Bottles with different size (230ml,350ml,600ml) 1

3.4 Design
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The design of the system can be divided into several parts. It will divide into two main
parts which is development of hardware and software.

3.4.1 Software Development

3.4.1.1 Block Diagram

Figure 3.3: Block diagram of the system

3.4.1.2 Control panel wiring diagram

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Figure 3.4: Control panel wiring diagram

Pb = Push Button

Rb = Reset / Stop Button

S1, S2, S3 = Retro Reflective Sensor

R1= Relay for Power Window Motor

R2= Relay for Dc Motor Pump

Pw = Power Window Motor

Pm = Dc Pump Motor

3.4.1.2 Flowchart Process

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Flowchart for bottles sensing and filling system

Start
No

Conveyor runs Sensor

with empty bottle detects
bottle

Yes

Conveyor Stop

Delay

Solenoid Valve Open

Bottle Filling Start

Conveyor starts Delay

running with filled
bottle

Solenoid Valve Closed

Delay Bottle Filling Stop

Figure 3.5: Flowchart for bottles sensing and filling system

Flowchart for bottle size detection

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Sensor Measure
Size of Bottle

No

Sensor
1

Yes

Valve Open
Sensor 2
= 8 sec
No

Yes

Valve Open Sensor 3 Valve Open

= 20 sec = 14 sec
Yes No

Done

Figure 3.6: Flowchart for bottle size detection

3.4.1.4 CX-Programmer
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It is a program that uses to draw a ladder diagram. This ladder diagram uses to give
instruction to the PLC. All the PLC programming must install by this program. A
debugging environment equivalent to the actual PLC system environment can be
achieved by simulating the operation of virtual PLC on the computer. Allows program
debugging in a single PLC before the actual system has been assembled. Reduces the
total lead time required for machine/equipment development and startup.

1. Starting CX-Programmer

- CX-Programmer is activated from the Search button in Microsoft Windows

taskbar

Figure 3.7: Starting open CX program

- Once activated, a CX-Programmer window is displayed

Figure 3.8: The basic form of interface

2. Create new the project

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- Click File > New or

- Check setting for PLC:
1. Device Type: Cpm1a
2. Device Type Settings: CPU20
3. Network Type: SYSMAC WAY

Figure 3.9 : Setting for PLC

Figure 3.10: The Main Element in CX Programmer Window

3. Work Online and Upload PLC program

This part is explaining how to work online and upload the program to the PLC. To
work online just click icon or Ctrl + W. After successful online, to upload the
program click “PLC” in menu bar “transfer” to PLC or Ctrl + T.
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Figure 3.11: Transfer program to PLC

3.4.2 Hardware Development

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In the development of hardware, it consists of three major subtopic which is schematic

diagram of the process, bottle detection mechanism and development of conveyor belt.

3.4.2.1 Schematic diagram of automatic filling bottle system

Figure 3.12 shows the schematic diagram of automatic filling bottles system of this
project. The PLC will control all of the input and output operation. This machine has
3 type of power supply; it is 24VDC for PLC and relay,12VDC power window motor
and dc motor pump.

Figure 3.12: Schematic diagram of PLC controlled automatic bottle filling system

3.4.2.2 Bottle Detection Mechanism

The task of bottle detection is performed using a photoelectric sensor. Photoelectric

sensors are placed beside the conveyor belt at the filling station to detect the presence
of a bottle. The sensor has an infrared light transmitter and a receiver. When a bottle
is brought in front of the sensor by the conveyor belt, the infrared light emitted from
the emitter gets reflected from the bottle, which is then received by the receiver of the
sensor. When no object is in front of the transmitter, the receiver does not receive any
signal.

3.4.2.3 Development of conveyor belt

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In order to design the conveyor belt, Solid Word 2017 are used to design the base of
conveyor and roller. The length of conveyor is 1000mm, while the height is 230mm
and the width is 100mm. Design of conveyor are shown in Figure 3.13 to 3.16.

Figure 3.13: The length of conveyor

Figure 3.14: The width of conveyor

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Figure 3.15: The height of conveyor

Figure 3.16: Full design of base conveyor

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The length of the belt is 2000mm and the diameter of roller is 50mm.

Figure 3.17: Length of conveyor belt and diameter of roller

Below is detail information about the size of the roller:

Figure 3.18: Detail size of the roller

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Figure 3.19: Side view of the roller

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Chapter 4

Result and Analysis

4.1 Introduction

In this chapter, all the hardware equipment is being assembly and several kinds of data
in automatic liquid filling with different type of bottles are analysed to ensure that the
performance of the system is in stable and desired condition. The result of this project
is observed and recorded in the table form and snapshot figure for easier data analysis.
Based on the result and data analysis of system, it helps user to analyse the
performance of the system and check the function of the system.

Figure 4.1: Size of the bottles, from left (250ml,500ml,600ml)

 37

Table 4.1: Time taken to filled up the bottles

Size of the bottle Time taken for filling up the bottle

250 ml 8 seconds

500 ml 14 seconds

600 ml 20 seconds

4.2 Prototype of the system

Figure 4.2: Control Panel

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Figure 4.3: View inside the control panel

Figure 4.4: Front view

 39

Figure 4.5: Side View

4.3 Simulation of program

In this section will explaining how the program work for each of the bottle to be filled
up. The size of the bottle already fixed which is 230ml, 350ml and 600ml. The
conveyor will detect one bottle at one time. The ladder diagram indicated how the
program works. Here how the program works when sensor 1 detects which is for
230ml

Figure 4.6: Start and Reset button is turn On

 40

At first, when push and reset button turn On, it will energize internal relay 200.00 and
200.01. After internal relay 200.01 is energized it will turn on the power window and
the conveyor belt will start running.

Figure 4.7: Sensor 1 detected the presence of the bottle

Figure 4.3 show when sensor 1 detects the presence of the bottle it will automatically
turn off the power window motor. This will stop the conveyor belt. After 3 seconds
delay it will open the valve for 8 seconds. This delay used to fill up the bottle with
water. After finish the filling, it will delay for 3 second. This delay used to avoid the
water spill out from the bottle after finish the filling station. After 3 second, power
window motor will turn on back and the conveyor belt will bring the bottle out from
filling station. Figure 4.4 show internal relay 200.04 energized and will turn on power
window motor.
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Figure 4.8: Power window is turn on back after complete filling station

The process will repeat for different size of bottle, the difference is time taken for the
bottle to fill up. The bigger the size of the bottle, will increasing the time.

4.4 Sensitivity of sensor to filled up the bottle

In this part will analyse on efficiency of sensor to filled up the bottle. It will divide
into two different analysis which is testing the sensor with same size of bottles and
different size of bottles.

4.4.1 Sensitivity of sensor on same size of bottle

This test is conducted in order to ensure the sensitivity of sensor using same size of
the bottle. This test to determine the accuracy and the sensitivity of sensor to detect
the bottle.

Table 4.2: Result sensitivity of sensor with 250ml bottle

Sensitivity of sensor to detect the

No Size of presence of the bottles
bottle
(ml) Test 1 Test 2 Test 3

1 250 Detect Detect Detect

2 250 Detect Detect Detect
3 250 Detect Detect Detect
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Table 4.3: Result sensitivity of sensor with 500ml bottle

Sensitivity of sensor to detect the

No Size of presence of the bottles
bottle
(ml) Test 1 Test 2 Test 3

1 500 Detect Detect Not Detect

2 500 Detect Not Detect Detect
3 500 Detect Detect Detect

Table 4.4: Result sensitivity of sensor with 600ml bottle

Sensitivity of sensor to detect the

No Size of presence of the bottles
bottle
Test 1 Test 2 Test 3
(ml)

1 600 Detect Detect Detect

2 600 Not Detect Detect Detect
3 600 Detect Not Detect Detect

Based on the result in table 4.2 it shows that the sensor can detect all the presence of
bottle, while in table 4.3 and 4.4 some of bottle cannot be detect. This happen because
the sensor is not being placed properly and the red line from sensor cannot detect the
presence of the bottle.
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4.4.2 Sensitivity of sensor on different size of bottle

In this section will repeat the same test but with different size of bottle to ensure all
sensor can functioning well.

Table 4.5: Result sensitivity of sensor with different size of bottle

Size of Sensitivity of sensor to detect the presence of the bottles

No bottle
(ml) Test 1 Test 2 Test 3 Test 4 Test 5

1 250 Detect Detect Detect Detect Detect

2 500 Detect Not Detect Detect Detect Not

Detect
3 600 Detect Detect Not Detect Not Detect Not
Detect

Table 4.6: Result of sensitivity of sensor with different size of bottle

Size of Sensitivity of sensor to detect the presence of the bottles

No bottle
(ml) Test 6 Test 7 Test 8 Test 9 Test 10

1 250 Detect Detect Detect Detect Detect

2 500 Detect Detect Detect Detect Detect

3 600 Detect Detect Detect Detect Detect

Based on result on table 4.5 and 4.6, it shows that some of the bottle sensor cannot
detect the presence of the bottle but after a few tests the sensors can detect all the
presence of the bottles. This problem can be solved by setting or adjust the red line of
reflective sensor to detect the presence of the bottle.
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4.5 Analysis on cost of the project

In this part will explain on cost of the project. It will the divide into 4 main parts
which is conveyor belt, electrical equipment, mechanical equipment and others.
Below is the table about the total cost of the project.

4.5.1 Conveyor Belt

Table 4.7: Conveyor belt cost

Description Quantity Price (RM)
Aluminium Profile 1m length 4 296.00
L-Block + Bolt & Nuts 12 120.00
End Cover 8 24.00
Roller 2 250.00
Belt (2 meters) 1 350.00

Perspex 1 80.00
Total 1120.00

4.5.2 Electrical equipment

Table 4.8: Electrical equipment cost

Description Quantity Price (RM)

Retro reflective sensor (sick-wl100-p1432) 3 405.00

Fuse 5 10.00

Circuit breaker 3 35.00

24V Relay 2 23.00

Socket relay 2 15.00

Terminal Block 16 0.80

CPM1a PLC,10 I/O (Second hand) 1 200.00

Total 688.80
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4.5.3 Mechanical equipment

Table 4.9: Mechanical equipment cost

Description Quantity Price (RM)

Host (1 meter) 1 3.00

Dc motor pump 1 20.00

Dc supply 1 59.75

Power window motor with coupling 1 34.00

Total 117.75

4.5.4 Others

Table 4.10: Others cost

Description Quantity Price (RM)

Project box 1 55.00

Cable connector 13 5.00

Hole square bar (19 x 10 mm) 1 3.90

Total 63.90

4.5.5 Total Cost

Table 4.11: Total cost of the project

Description Price (RM)
Conveyor Belt 1120.00
Electrical Equipment 688.80
Mechanical Equipment 117.75
Others 63.90
Total Cost 1990.45

From table 4.11 it shows that the total cost for the project is RM1990.45.
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4.6 Troubleshoot

Troubleshoot is form of solving errors that occur during conducting the project. There
are two types of error that happen during conducting the project which is:

1. Sensitivity of sensor to detects the bottle

The effect when the sensor cannot detect size of the bottle is the conveyor might
continuously run and the time taken to fill up the bottle will be different. To solve this
error is the bottle need to be cover with tape and adjust the position of sensor. The red
light on sensor will turn on which indicate the sensor detect the presence of bottle.

2. Connection between the terminal block and electrical equipment

This is usual things that happen during the project, it happens because the connection
between the terminal might be difference or no current flow through the equipment.
To solve the problem, use multimeter to check the continuity either the equipment
good or bad, besides multimeter also can use to check the current flow between the
equipment.
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CHAPTER 5

CONCLUSION

5.1 Conclusion

In conclusion, this project presents an automated liquid filling to bottles of different

height using PLC. A total control is made in a filling is achieved. The present system
will provide a great deal of applications in the field of automation, especially in mass
production industries where there are large number of components to be processed
and handled in a short period of time and there’s need for increased production. The
programming to this system developed is flexible, quickly and easily. This will
increase the total production output; this increase in production can yield significant
financial benefits and savings. This concept can be used in beverage and food
industries, milk industries, medicine industries, mineral water, chemical product
industries and manufacturing industries.
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5.1 Future Development

For the future work, there are several improvements that can be made significant to
this project:

▪ Bottle capping system: This system facilitates the bottle capping after the liquid
is filled. A stepper motor operated capper can be used for bottle capping.

▪ Robotic arm system: This system can be used to move and place a bottle to a
required position. It can be used in both placing the bottle on the conveyor belt
and removing from the conveyor belt to the packaging system.

▪ Packaging system: To box a particular number of bottles the packaging system

can be used. This system can be facilitated by the help of robotic hand.