CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

TECHNOLOGICAL UNIVERSITY OF THE CENTER OF

VERACRUZ

EDUCATIONAL MAINTENANCE PROGRAM INDUSTRIAL AREA

Project's name:

CONTROL AND FILLING OF WATER TANK WITH AUTOMATED CONTROL

It presents:

OMAR MACEDA GARCÍA 10855

RAFAEL RAMOS ROSALES 10222
JOSUÉ MANUEL GONZÁLEZ TENORIO 11205
FRANCISCO URIEL PARRA HERNÁNDEZ 9935

Teacher:
Miguel Ángel Huerta Páez
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

Contenido
SUMMARY .......................................................................................................................... 1
INTRODUCTION .................................................................................................................. 2
CHAPTER 1 ......................................................................................................................... 3
PROBLEM STATEMENT ....................................................................................................... 3
1.1 Problem Statement ................................................................................................................ 3
1.2 Objectives ................................................................................................................................ 3
1.3 Project Justification ................................................................................................................. 3
1.4 Limitations and Scope ............................................................................................................ 3
EPISODE 2 .......................................................................................................................... 4
BACKGROUND ................................................................................................................... 4
CHAPTER 3 ......................................................................................................................... 5
THEORETICAL FRAMEWORK ............................................................................................... 5
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

SUMMARY
In all industries today are looking for automation and control of all processes
and the company, but nevertheless, automation in most companies do not
know how to run or do not know how to perform an automation. In this
prototype or project that we are going to do will be a sample of how to run
an automated water system, this can generate more company efficiency
depending on the area that is used the water system. Automation can
reduce the work of staff in performing tired or dangerous work, as some
companies are manual controls, which can create danger for workers. For
example in a company to which this project was based was a cherry coffee
processing company, in this company it is necessary to pass the water from
several water containers, these have been very separated, causing delays in
the production systems and In addition to putting the person at risk since the
valves are manual, which causes the rupture of the pipes and causes
openings in the containers, which causes large leaks of water under high
pressure, so the best of this system is to perform an automation.
Automation within the industry is the use of computerized and
electromechanical systems or elements to control machinery or industrial
processes. As a broader engineering discipline than a control system, it
encompasses industrial instrumentation, which includes sensors, field
transmitters, control and monitoring systems, transmission and data
collection systems, and software applications in Real time to monitor and
control the operations of plants or industrial processes.

1
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

INTRODUCTION

The automation of a system in which production tasks are transferred, which

are normally performed by human operators to a set of technological
elements and used to increase the quality of products, eliminate forced
labor and increase safety. The process of bottling drinkable products has
marked the industries because of the great mass consumption of the
market, the manufacturers need facilities that guarantee in total the
efficiency of its production and stable costs. A filling machine is by no means
an independent unit but is part of a system of mesh components which have
to be exactly harmonized with each other. As a central core of the filling and
sewing lines, Filling machines have a great impact on the capacity and the
productive and economic potential of the company that uses them.
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

CHAPTER 1

PROBLEM STATEMENT

1.1 Problem Statement

Choose a situation or topic that needs attention, analysis or proposals
for its implementation or improvement.

Part of a doubt, that is, it is necessary to ask a question to guide the

development of the work.

1.2 Objectives
The main objective of the project is a collection of more than one
student to a more real industrial system, which is an experience to put
into practice the knowledge acquired in the care of the quarter.

1.3 Project Justification

Our project was based on a problem found in a company where one
of the team members works, so that's why we decided to do this
project to give an idea to the company on how to solve this problem.

1.4 Limitations and Scope

Describe the extent to which it applies and the impact generated by
the project within the areas of companies using water systems.
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

EPISODE 2
BACKGROUND

Automate the filling process of containers by controlling the flow of

liquids through precision digital tools that allow the user of the system
to optimize resources. The word process is used in a very general sense,
understanding that it is the set of physical phenomena that determine
the production of controlled variables. From the mathematical point
of view, the process will be represented by a set of fundamental
relations, through all controlled variables remain functions depending
on the types of independent variables:
1. Random Variables
2. Manipulated variables
The random variables are those variables that escape any control or
possibility of manipulation, that is, they adopt the values that can
vary at random within certain practical limits, they constitute
perturbations, and the desired values in the controlled variables have
been obtained, Tends to take them away from them. Manipulated
variables if the whole process includes only the random variables,
there would be no degree of control over it and the value of the
controlled variables, too.
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

CHAPTER 3
THEORETICAL FRAMEWORK

Controller The part of the system that synthesizes the manipulated

variables is the controller, it contains the necessary program to
introduce the variations in the manipulated variables, in order to
obtain the desired behavior of the controlled variables. For this the
controller can have different types of information:
1. Reference
2. Rewards
3. Feedback Reference values.
These values, which may be constant or time-varying, represent the
desired behavior in the controlled variables, so they are also referred
to as desired values or command values. If the system has a perfect
degree of control, ideally the values of the controlled variables are
adjusted at all times to the reference values. In the case of manual
control, the functions assigned to the controller in an automatic
system, the values of the reference are those present in the intentions
of the operator, and constitute their idea around the desirable results
of the process. In the presence of a disturbance, the controller must
initiate a corrective action by working with the manipulated
variables, a fin to eliminate the effect of the disturbance on the
controlled variables.
In order to fulfill this function, two techniques are completely different
in their approach, although compatible with each other,
differentiating themselves in the information relative to the random
variables and the controlled variables.
1. Reward
2. Feedback.
The study of automatic controls is considered because it provides a
basic understanding of all dynamic systems, as well as appreciation
and use of the fundamental laws of nature. We must take into
account:
There are 2 types of control systems in different loops of open and
closed type.
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

Open-loop and closed-loop controls the two basic control techniques,

in the input to the controller of the random variables and the
controlled variables, give rise respectively to open loop and closed
loop systems. The distinction between both types of systems is based
on the existence or absence of a feedback path through which
controlled variables enter the controller; If this path exists, the system
will be closed loop; otherwise; Will be open loop.
Open loop control systems specify that the output does not have a
control effect, in the output variable is not measured or performed for
comparison with the input. For any control system operating on a
time base this corresponds to an open loop control system. Accuracy
depends on system calibration, calibration means that you must
establish a relationship between the input and output variables in
order to obtain data with certain accuracy. The cost of this type of
systems is economical, although it has as disadvantages the sensitivity
to the disturbances, contrary to this function correctly. Because of the
simplicity and economy makes open loop systems reliable as well as
fulfilling a useful function. In closed loop systems the signals are
controlled to be thus as compared to the values of the input, as well
as a signal for the decrease of the errors and to correct the final
output.
Container filling process In its most literal sense, the filling process
consists of the production of containers of liquid products such as
beverages and water, says the company OCME. The filling of the
containers is caused by the transfer of the liquid from the main
container tank to the bottle.
Arduino boards can measure environmental values by receiving
information from a variety of sensors and affecting their surroundings
by controlling lights, motors and other actuators.
Cards can be manufactured casually or purchase a preassembled
and tested card, the software can be downloaded for free. Reference
designs are available under an open source license, so anyone is free
to tailor the design to their needs. Arduino has the advantage that it
does not need any type of programming card like happens with the
microcontrollers, but the same plate is connected via serial to the
computer using a USB cable and the programs can be fully loaded
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

live, without risk of damaging the Card due to its additional

protection.
The code is extremely friendly and has its own high level language
called Processing, it also contains the largest libraries for virtually any
external component that you want to dock (we will discuss this in the
next section of Shield and add-ons) making it unnecessary to learn the
datasheet Of the component and develop the necessary software to
acquire the values of a digital temperature sensor for example, we
are 99.9% sure that there is already a library with predefined
functions for optimal use of the peripherals, although it is super
necessary to know how they work for questions Engineering and
problem solving, not reinventing the wheel is essential. If Arduino
differs from other development platforms, it is the multitude of boards
with different features offered to the market. Depending on the needs
of the developer will choose different plates that have variable
attributes of memory, capacity, number of I / O ports, microcontroller
among others.

Sensors and Actuators a sensor is any device that detects a certain

external action. Sensors have always existed, and never better,
because man has them included in his body and of different types.
The man experiences sensations like heat or cold, hard or soft, strong
or loose, pleasant or unpleasant, heavy or not. And little by little he
has been adding adjectives to these sensations to quantify them as
frigid, fresh, warm, temperate, hot, and torrid. That is to say, that
every day has needed the use of measurable magnitudes more
accurate. Electronic sensors have helped not only to measure the
magnitudes more accurately but to be able to operate with these
measurements. But you cannot talk about the sensors without their
signal conditioners since the sensors usually offer a very small signal
variation and it is very important to balance the characteristics of the
sensor with those of the circuit that allows you to measure, condition,
process, and act with said measurements.
Sensor: A device that receives a signal or stimulus and responds with
an electrical signal. In addition, the sensors can be active or passive.
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM
Active sensor: A sensor that requires an external source of excitation
such as RTD or load cells.

Passive sensor: It is a sensor that does not require an external source of

excitation like thermometers or photoresists.

Transducer: It is a converter from one type of energy to another.

Transducers are circuits that transform a physical quantity into an
electrical signal. They can be classified into two groups: Assets and
liabilities. Active transducers are those that have to be connected to
an external source of electrical energy so that they can respond to the
physical quantity to be measured, such as photoresists and
thermosensors, and are passive ones that directly give an electrical
signal in response to the physical magnitude Such as photodiodes and
pH probes. It is called the transfer function of a transducer to the
mathematical relationship between the physical magnitude and the
electric response.
This function can be of different types.
A linear transfer function has the expression S = a + bs where S is the
electrical signal, a and b are constants and s is the physical signal
specific to each transducer. The functions of non-linear transfers can
also be of different types: logarithmic, such as S = a + b L n s;
Exponential, such as S = a and bs; Polynomials such as S = a + b s + c s2
+ d s3 + ..., etc.
Valve solenoid
A solenoid valve is an electrical valve used to control the passage of
gas (pneumatic systems) or fluids (hydraulic systems). The opening or
closing of the valve is based on electromagnetic pulses of a solenoid
(an electromagnet) working next to a spring designed to return the
valve to its neutral position when the solenoid is deactivated. These
types of valves are often used in difficult-to-access sites, in multi-valve
systems and in hazardous environments. Solenoid valves provide full-
open or closed-off functions and cannot be used to regulate gas or
fluid flow. There are solenoid valves that can work with alternating
current (AC) or direct current (DC) and use different voltages and
operating cycle durations.
Solenoids are very useful for remote actions on gas and fluid control
valves. A solenoid is a coil of conductive material whose operation is
 CONTROL AND FILLING OF WATER TANK WITH AUTOMATED SYSTEM

based on electromagnetic fields. By passing an electric current through

the coil, an electromagnetic field of some intensity is generated in the
interior. A plunger made of ferrous metal is drawn by the magnetic
force towards the center of the coil, which provides the necessary
movement to actuate the valve. The valve can be opened or closed,
there is no middle term, so you cannot use this system for flow
regulation. Once the solenoid is activated, the valve will remain open
or closed, depending on the design, until the electric current is cut off
and the electromagnetic field of the solenoid disappears. At this time,
a spring or spring pushes the plunger back into its original position by
changing the valve status.