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CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

Nowadays in the modern world, technologies are constantly changing,

needing us to be able to keep up with the latest and upcoming technologies.

Rather than using conventional methods, we are now using programmable logic

controller or better known as Plc for automation of electromechanical processes,

such as control of machinery on factory assembly lines, amusement rides, or

lighting fixtures.

Unlike general-purpose computers, the Plc is designed for multiple inputs

and output arrangements, extended temperature ranges, immunity to electrical

noise, and resistance to vibration and impact. Programs to control machine

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operation are typically stored in battery-backed or non-volatile memory. A Plc is

an example of a real time system since output results must be produced in

response to input conditions within a bounded time, otherwise unintended

operation will result.

However, students in educational institutes such as polytechnic itself are

unable to understand what is Plc or how does it operates. Plc based training kit

are a simple and easy way to be used in all educational institutes in order to

understand on how the plc program works and operates. It is important for

students to have a firsthand knowledge and experience regarding Plc. Based on

this we designed a bottled water assembly line which uses plc program as its

operating system.

Our project involves four stations which respectively are loading the

bottle into the assembly line, filling water into the bottle, capping the bottle and

the final one is unloading it out into the assembly line.

First a pneumatic cylinder will push the empty bottle into the bottle

holder. The bottle holder will bring the empty bottle to water filling station. A

sensor is placed at the second station to monitor water level. After filling process,

it will go to capping station. At the capping station, bottles are made to be fitted

with cap where pneumatic system will be used to punch the caps. Finally the

bottle will enter the final station where it will be pushed out into an assembly line
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1.2 PROBLEM STATEMENT

Since there are not many Plc based training kit and pneumatic based

training kit that are available for students to be used in polytechnics, we have

decided to create a training project that is based on plc and pneumatic system

infused in a single system by using a bottled water assembly line as the

application. The rationales on why we created this project are listed below:

1. Students does not know how to program and operates Plc system

2. Students have difficulty in understanding how pneumatic system

functions

3. To fit each station into a smaller assembly line and more transportable.

1.3 OBJECTIVE

For the project objective, we have listed several objectives such as:

1. Design an application that fully uses Plc as its control system.

2. Create a mechanism that uses pneumatic system to move objects.

3. Create a rotary type assembly line that is smaller and easier to be

moved.
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1.4 SCOPE OF PROJECT

When we select the project title, we have a few guidelines on how to

accomplish our project. The main guideline of our project is to be able to teach

other students on how a plc system can be used as a control system in a project

thus giving them a firsthand experience on how the programs function. We will

have four stations in our design where each station has its own purpose and

function which is operated using Plc. As the end product the assembly line will

be able to produce at least 4 bottles per minute. We are designing this project to

operate at a slower pace in order to give students a better view on what is

happening and for them to be able to learn. In this training kit we will be using

500 ml sized bottles.

Below are the specifications of the bottle and the cap:

1. Mineral water bottle (plastic)

• Material type - PET (Polyethylene terephthalate)
• Capacity - 500ml
• Height - 208mm
• Diameter - 62mm
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2. Mineral water bottle cap (plastic)

• Material type - PET (Polyethylene terephthalate)
• Height - 30mm or below
• Diameter - 14mm

Figure 1.1 cap Figure 1.2 plastic bottle