Design and Fabrication of PLC Controlled Bottle

Dispensing Unit

Authors

Sana Ullah 28512

M.Munib 28432
Syed Faraz Ali 28465
Sultan Din Muhammad
Birahamdagh Bugti
Salman Saddique 29309

A thesis submitted in partial fulfillment of the requirements for the degree of

BS Mechanical Engineering

Thesis Supervisor:

Engr. Monaza Shaheen

External Examiner Signature:___________________________________________

Thesis Supervisor Signature: ___________________________________________

Chairperson Signature: ________________________________________________

Dean Signature: _____________________________________________________

Department of Mechanical Engineering

Faculty of Engineering & Architecture
Balochistan University of Information Technology, Engineering and
Management Sciences, Quetta

September 2018

i
 ABSTRACT

Design and Fabrication of PLC Controlled Bottle Dispensing Unit

Sana Ullah, M.Munib, Syed Faraz Ali, Sultan Din Muhammad, Birahamdagh Bugti &
Salman Saddique
Thesis Supervisor: Engr. Arshad Ali

Chairperson Department of
Mechanical Engineering, BUITEMS

ii
 UNDERTAKING

We certify that research work titled “Design and Fabrication of PLC Controlled Bottle

Dispensing Unit” is our own work. The work has not been presented elsewhere for

assessment. Where material has been used from other sources it has been properly

acknowledged / referred.

Signature of Student: Signature of Student:

Name of Student: Kashif Liaqat Name of Student: Hassan Zaib

Registration Number: 29725 Registration Number: 28649

Signature of Student: Signature of Student:

Name of Student: Aimal Khan Name of Student: M. Shayan Ali Siddique

Registration Number: 28321 Registration Number: 29095

Signature of Student: Signature of Student:

Name of Student: Mehar Ullah Name of Student: Shafiullah Bugti

Registration Number: 29865 Registration Number: 29596

Dated:

iii
ACKNOWLEDGEMENTS

iv
 TABLE OF CONTENTS

Abstract ............................................................................................................................... ii
Undertaking........................................................................................................................ iii
Acknowledgements ............................................................................................................ iv
List of figures .................................................................................................................... vii
List of tables ....................................................................................................................... ix
Chapter 1 Introduction ...................................................................................................... 1
1.1 Objective of the Project: ......................................................................................... 1
1.1.1 Main Feature of This Work: ......................................................................... 1
1.2 Conveyor System .................................................................................................... 1
1.2.1 History and Background ............................................................................... 2
1.2.2 Industrial Revolution .................................................................................... 3
1.2.3 Components of conveyor belt system: .......................................................... 3
1.2.3.1 Conveyor Belt ........................................................................................ 3
1.2.3.2 Conveyor belt supports .......................................................................... 4
1.2.3.3 Drive Unit .............................................................................................. 4
1.2.4 Types of Conveyor Systems Available ......................................................... 5
1.2.4.1 Gravity Conveyor systems..................................................................... 5
1.2.4.2 Powered Conveyor systems ................................................................... 6
1.2.4.3 Pneumatic conveyor systems ................................................................. 7
1.2.4.4 Vibrating conveyor systems .................................................................. 7
1.2.4.5 Flexible conveyor systems..................................................................... 7
1.2.4.6 Vertical conveyor systems and spiral conveyors ................................... 8
1.2.5 Maintenance and safety of conveyor belt systems ........................................ 9
Chapter 2 Design and Calculations................................................................................. 10
2.1 Type Main Heading .............................................................................................. 10
2.1.1 Type Subheading ........................................................................................ 10
2.1.1.1 Type one more level down heading ..................................................... 10
Chapter 3 Hardware Components .................................................................................. 12
3.1 Bill of Materials .................................................................................................... 12

v
 3.2 Components .......................................................................................................... 13
3.2.1 Frame, Conveyor Belt Assembly and Drive Mechanism ........................... 13
3.2.2 Motor........................................................................................................... 15
3.2.3 PLC and Sensor........................................................................................... 17
3.2.4 Solenoid valve ............................................................................................. 18
Chapter 4 Control System ............................................................................................... 19
4.1 PLC (Programmable Logic Control) .................................................................... 19
4.1.1 Controllers................................................................................................... 21
4.1.2 PLC Operation ............................................................................................ 22
4.1.3 Programmable Logic Control vs Microcontrollers ..................................... 22
4.2 Ladder Logic ......................................................................................................... 23
4.3 Software ................................................................................................................ 24
4.3.1 GX Developer ............................................................................................. 24
4.3.2 Bottle filling Process ................................................................................... 25
4.3.2.1 Ladder Logic Program ......................................................................... 25
Chapter 5 Result, Discussions and Cost Estimation ..................................................... 29
6.1 Results and Discussions ........................................................................................ 29
6.2 Cost Estimations ................................................................................................... 30
Conclusion ........................................................................................................................ 31
Future Work and Developments ................................................................................... 32
References ......................................................................................................................... 33

vi
 LIST OF FIGURES

Number Page

Fig 1.1: Conveyor system [2].............................................................................................. 2

Fig 1.2: Gravity Conveyor systems .................................................................................... 5

Fig 1.3: Powered Belt Conveyor systems ........................................................................... 6

Fig 1.4: Vibrating conveyor systems .................................................................................. 7

Fig 1.5: Flexible conveyor systems .................................................................................... 8

Fig 1.6: Vertical Conveyor system ..................................................................................... 8

Fig 3.1: Frame ................................................................................................................... 14

Fig 3.2: PV Flat Belt ......................................................................................................... 14

Fig 3.3: Spur Gear ............................................................................................................. 14

Fig 3.4: Roller Assembly .................................................................................................. 15

Fig 3.5: Bearing with Kit .................................................................................................. 15

Fig 3.6: Geared Motor....................................................................................................... 16

Fig 3.7: Motor Assembling supports ................................................................................ 16

Fig 3.8: PLC Model .......................................................................................................... 17

Fig 3.9: Switches ............................................................................................................... 17

Fig 3.10: Sensor ................................................................................................................ 18

Fig 3.11: Solenoid valve ................................................................................................... 18

Fig 4.1: Diversity of Tasks that PLC can handle .............................................................. 20

Fig 4.2: Controller working .............................................................................................. 21

Fig 4.3: Why PLC? ........................................................................................................... 21

Fig 4.4: PLC Operation ..................................................................................................... 22

vii
Fig 4.5: GX Developer Working Environment................................................................. 25

Fig 4.6: Bottle filling Process ........................................................................................... 26

Fig 4.7: Ladder Logic for bottle filling development stage .............................................. 27

Fig 4.8: Final Ladder Logic Diagram of Project............................................................... 28

viii
 LIST OF TABLES

Number Page

Table 3.1: Bill of Material ................................................................................................ 12

Table 3.2: Dimensions of Components............................................................................. 13

Table 5.1: Cost Estimation[9],[10] ................................................................................... 30

ix
 Chapter 1

Introduction

1.1 Objective of the Project:

The main objective of this project is the design and fabricates of bottle dispensing unit and

calculates optimum parametric values for variable at its maximum operating condition for

this purpose we use infrared red sensor that sense the presence of bottle at specific point

and then this bottle is filled to specific point and the processes continues for the nest bottle

upcoming.

1.1.1 Main Feature of This Work:

 Systematic design based on programmable logic control FX1S.

 Based on dc motor supply.
 Power supply of 24 volt is used.
 Reduction of human efforts.
 Lower power consumption and batter efficiency.
1.2 Conveyor System

Conveyor belt system often called conveyor system is material handling equipment which

is widely used to move materials and products from one location to another. Conveyor

system is being widely used in transportation of heavy material from one place to another

easily and efficiently. These systems are very popular in industrial applications like

manufacturing and packaging of products. Numerous types of conveying systems are

available and are used per application in various industries. Conveyor systems can easily

be installed almost everywhere.

1
Belt conveyors are the most commonly used power-driven conveyors because they are the

most versatile and the least expensive than other conveying systems. Conveyor systems

reduce the cost of labor because most of the systems are made automatic so less human

interaction is required which lowers the cost of production. These systems are installed for

the précised and efficient transportation of material regardless its size and shape. Conveyor

belt systems are being used widely in industries especially in food industry for packaging

and dispensing purposes.

1.2.1 History and Background

Conveyor system that is used to convey the material and product from one place to another

place were used as early as the late 1700’[1]. Farmers use the conveyor system to load

grains on ships they use the simplest form that was made up of wooden structure and the

belt used was lather or cotton, the length of these belt was short and was powered by crank

that are operated manually.

Fig 1.1: Conveyor system [2]

Factories starts adopting conveyor system in the early 1900’s to move product from one

point to another during material handling unit the modification of this system was done by

2
the engineers latter for the transportation of goods through long distance in Roaring 20’s.

That was the first time that cotton and rubber cover were use at that time.

1.2.2 Industrial Revolution

The dramatic transition accord in the period of about 1840 to 1960 during this period the

concept of assembly line was introduced in manufacturing industries moreover the

advancement in technologies and appearance of various new technologies updated the

older process and provide new concept. The implementation of these advanced methods

starts replacing the labor instead of these the mechanical modules are used this lead the

economic benefits for various industries they start the production of goods at lower cost

and due to the introduction of new technologies labor start working more efficiently. The

matter of fact is that all these changes not only affected the use of conveyor and other

mechanical system, but they open the way for upgrading of older systems. The requirement

of new system became necessary to dominate the market this provide the adequate reasons

to industries and manufacturer to adopt the systematic approach for the movement of

material from one place to another, so the use of conveyor system starts increasing.

1.2.3 Components of conveyor belt system:

A complete conveyor belt system consists of following parts.

1.2.3.1 Conveyor Belt

Belt is the essential element of conveyor belt system. Belt usually comprises of one or more

layer of material. Mostly belts have three layers’ top and bottom covers and carcass in

between top and bottom layers. The main purpose of carcass is to provide the linear strength

and maintain definite shape and profile of belt. The materials which are usually used for

carcass are nylon, polymer, steel and cotton. The covers are usually made of compounds

3
of rubber and plastic specified by the application and requirement. Besides this when high

strength is needed then steel belts are used for better outcome. Conveyor belt selection is

very important as there are many types of conveyor belts available per material and

application. Many parameters are analyzed before selecting belt e.g. thickness and width

of belt.

1.2.3.2 Conveyor belt supports

Carrying rollers acts as support to conveyor belt. They are installed on the groove shape

frame. Conveyor belt supports includes premium quality bearings. These rollers rotate

along with the belt carrying the load. Sometimes belt is used underneath to turn the rollers

to carry load. There are many factors which should be considered before selecting rollers

or conveyor bearings. There are three types of conveyor bearings per speed and load

requirements if these are low or moderate non-precision bearings are appropriate. If the

speed is more than 400 rpm then semi precision bearings will work, but if we high speed

and heavier loads are required then precision bearings will be used in this case. Precision

bearings are usually sealed.

1.2.3.3 Drive Unit

Drive unit is the necessary part of conveyor system. The main function of drive unit is to

run the contraption. The drive unit is used to operate the conveyor system depending on

the requirement the drive unit could be used to run the system continuously, reverse, and

adjust direction repeatedly. For variable load instead of conventional drive variable drive

are used in modern conveyor system that provide variable frequency converter connected

with gear box in a result the efficiency increases and wear in a system due to variable load

4
decreases. The selection of drive unit is based on load carrying capacity, environmental

condition, temperature, high pressure, intense heat…etc.

1.2.4 Types of Conveyor Systems Available

As there is different variety of industries around the world, similarly there are many types

of conveyor systems. The design and mechanism of a conveyor system Depends upon the

product, that is to be transferred and the path it must follow. Among these systems the most

important and common ones are discussed as:

1.2.4.1 Gravity Conveyor systems

As its name suggests, it uses gravity to transfer the objects thus, the conveyor has a slight

incline to take advantage of gravity. These conveyors have metal rollers that roll on a shaft

(fixed) and the rollers are spaced to allow free movement and by placing the rollers closer,

the capacity can be increased, and the rolling can be smoothen [3].

Fig 1.2: Gravity Conveyor systems

5
1.2.4.2 Powered Conveyor systems

A conveyor system by any mean other than gravity is called powered conveyor system.

There are several types of Powered Conveyor Systems.[3] They are powered by a

mechanical device that moves materials or products along a conveyor line or by manually

pushing the payload. Power Conveyors are typically roller conveyors (and are also referred

as “live roller conveyors”) that use motor powered rollers to move the payload. The

conveyor rollers are powered by belts, chains, or O-rings depending on the load.

Examples of Powered Conveyor systems are:

1. Live Roller Conveyors

2. Powered Belt Conveyors
3. Accumulation Conveyor
4. Chain Driven Live Rollers
5. Drag Chain Conveyor
6. Hinged Steel Belt
7. Sortation Conveyors
8. Overhead Conveyor
9. Medium-Duty Modular Monorail
10. Vertical Reciprocating
11. 24 Volt Conveyors

Fig 1.3: Powered Belt Conveyor systems

6
1.2.4.3 Pneumatic conveyor systems

Conveyor systems that use air pressure or vacuum to transport materials or items in or

through closed tubes or ducts or along surfaces are known as Pneumatic / Vacuum

Conveyors are material handling systems. Applications of this system are primarily in

materials handling applications such as dust collection, paper handling, ticket delivery, etc.

and in processes such as chemical, mineral, scrap, and food.

1.2.4.4 Vibrating conveyor systems

Vibrating Conveyors use rotary or linear vibration to move material along their system

beds. Key features include the intended application, load capacity, and throughput, along

with the physical dimensions and electrical requirements[4]. Move dry, bulk materials such

as aggregate, gravel, coal, etc. are the applications of this system.

Fig 1.4: Vibrating conveyor systems

1.2.4.5 Flexible conveyor systems

A flexible conveyor offers a more adjustable way of transferring goods rapidly, easily and

safely. These extendable conveyor systems are rolled out, stretched and positioned to suit

the needs in seconds. It is based on a conveyor beam in aluminum or stainless steel, with

7
low friction slide rails guiding a plastic multi-flexing chain Products to be conveyed travel

directly on the conveyor or on pallets/carriers.

Fig 1.5: Flexible conveyor systems

1.2.4.6 Vertical conveyor systems and spiral conveyors

Vertical conveyor / freight lifts / material lifts / Spiral conveyors are conveyor systems

used to raise or lower materials to various levels of an industry during the handling process.

Examples of these conveyors applied in the industrial assembly process include

transporting materials to different floors.

Fig 1.6: Vertical Conveyor system

8
1.2.5 Maintenance and safety of conveyor belt systems

Maintenance is very important for the life of any system. Maintenance is necessary to keep

the system running without any trouble. Preventive maintenance should be done to avoid

breakdown of the system. All components of conveyor belt system should be inspected and

replaced timely. Lubrication is necessary for some parts lack of lubrication will cause

wearing and tearing of component. It’s important to constantly inspect your conveyor

system to ensure it’s running efficiently to reduced stretching in belt high quality material

belt should be used which will result in less maintenance for tension adjustment of belt.

9
 Chapter 2

Design and Calculations

2.1 Type Main Heading

2.1.1 Type Subheading

2.1.1.1 Type one more level down heading

(From Styles: Use Head 2 for main heading and Head 3 and 4 for following subheadings)

(update the table of content once finished working0

10
11
 Chapter 3

Hardware Components

Based on the calculation of previous chapter the hardware components procured or

manufactured are discussed in this chapter.

3.1 Bill of Materials

The primary elements of the system are conveyor, PLC and Motor. The secondary

components include bearing, rollers and nut bolt etc. Table 3.1 provides a summary of the

components and their dimensions respectively.

Table 3.1: Bill of Material

S/No Name Description Quantity

1. Roller 2
2. Frame 1
3. Bearing 1 2
4. Bearing 2 2
5. Bearing Kit 2
6. Sensors Infra-red sensor 2
7. PLC Mitsubishi Fx-1 1
8. Belt PV Material flat belt 1
9. Motor GTR HFM-15R-15-T25 1
10. Solenoid Valve Uni-D Model UD-8 1
11. Gear Spur Gear 2

12
Table 3.2: Dimensions of Components

Dimensions
Name
(mm)
Length 102
Roller Outside Diameter 45
Inside Diameter 17
Length 699
Frame Width 114
Thickness 2
Outside Diameter 40
Bearing 1
Inside Diameter 17
Outside Diameter 35
Bearing 2
Inside Diameter 17
Outside Diameter 56
Bearing Kit
Inside Diameter 35

3.2 Components

The detail information about the component is given as:

3.2.1 Frame, Conveyor Belt Assembly and Drive Mechanism

A frame is designed to carry the belt and to assemble the drive mechanism with it. The

frame is the backbone of the prototype system and all the parts are assembling to it. The

belt is a PV material flat built type supported with two rollers on both sides to rotate it. On

of the roller is adjustable for variating the built tension as per requirement. For drive

mechanism two spur gears of equal size are used to transfer the power from motor to the

conveyor assembly. Other components are bearings within the roller assembly and in a

bearing kit to support the roller.

13
 Fig 3.1: Frame

Fig 3.2: PV Flat Belt

Fig 3.3: Spur Gear

14
 Fig 3.4: Roller Assembly

Fig 3.5: Bearing with Kit

3.2.2 Motor

A right-angle inductance motor of model GTR HFM-15R-15-T25 is selected to supply the

required power. It is Speed control gearmotor which enables to select speed freely in the

15
wide range of speed, 50～1400rpm(50Hz) or 50～= 1700rpm(60Hz) through the exclusive

speed controller, by attaching the Rate Generator (AC generator) for speed detection to the

motor part of gearmotor.

Fig 3.6: Geared Motor

Fig 3.7: Motor Assembling supports

16
3.2.3 PLC and Sensor

The selected PLC is manufactured by Mitsubishi Technologies. We have used model FX-

1S for our project. For bottle detection the system is integrated with an infrared IR sensor.

The sensor detects the bottle and sends a signal to plc which than stops the motor, hence

drive for a specified time and in the same time the solenoid valve opens for filling the bottle.

The system is also incorporated with two switches that are used to turn the system ON and

OFF.

Fig 3.8: PLC Model

Fig 3.9: Switches

17
 Fig 3.10: Sensor

3.2.4 Solenoid valve

To control the flow of liquid a solenoid valve is used that is operated through PLC when

the sensor detects a bottle. A solenoid valve is an electromechanical device in which the

solenoid uses an electric current to generate a magnetic field and thereby operate a

mechanism which regulates the opening of fluid flow in a valve.

Fig 3.11: Solenoid valve

18
 Chapter 4

Control System

For development of control system for an automatic bottle filling unit, there are several

types of controllers that can be utilized. These controllers include microcontrollers such

Arduino UNO and Raspberry Pi, Embedded controllers and Programmable logic controller

(PLC). Each of these controllers have their own kind of programming e.g. Arduino UNO

is based on C++, while python is the working language for Raspberry Pi and PLC systems

are based on ladder logic programming. The difference between these systems is electrical

power ranges. Programmable logic controllers are more suitable for higher powers. Amid

the reason that most of the industrial automation is based on PLC controllers, this system

also uses PLC controller for automation of the bottle filling process.

4.1 PLC (Programmable Logic Control)

It is a controller device that is programmable and build to exchange mechanical relays,

mechanical timers and similar counters. PLCs are dominantly brought into use by different

industries for control related purposes. The PLC controller is used to control the bottle

filling unit with the assistance of ladder logic. As ladder logic could be a one in all the ways

of PLC’s programming. Using this type of controllers, various assignments of automation

will be enforced betting on the definition of the matter.

The development of ladder logic language was for the reason to to alter the assignments of

programming a programmable logic control system. Input unit and output unit, central

process unit (CPU) and storage/memory are the components of a typical PLC system. The

components acting as the real time interface for PLC are input and output units. central

19
processing unit finishes all the logic and control commands, manipulation and transfer of

information. PLC have benefits of great dependability of operational work, techniques of

control are flexible, little area and computing needs, it can handle high powers, human

work is minimum and full programming in an exceedingly plant[5].

Fig 4.1: Diversity of Tasks that PLC can handle

PLC can also be defined as a computer i.e. digital and can be utilized industrial tasks

automation, such as converting a manual production line to a fully automated assembly

line. Multiple arrangements of the input and output can be incorporated within a PLC. PLC

contains a memory or storage that is integrated with a backup battery and is also non-

volatile, programs that are used to control a process are saved within this storage. Invention

of PLC has supplanted the needs of circuits of relays that were previously used for

controlling purposes. A diverse range of tasks can be adopted by PLC. Every task of the

bottle filling is system are controlled using PLC. Ladder logic is the way to transfer

information to the PLC system. The most dependable and mostly utilized control device in

the industrial sector is PLC. The forceful controller can be integrated with SCADA to

provide monitoring as well. While choosing a PLC the variable to be considered are

financial/economic life and duration, program, features and requirements for design[6].

20
4.1.1 Controllers

As defined earlier PLC is a controller, in the field of automation or control system

development/engineering, Controllers are the components that have the function of acting

upon a physical variable utilizing an actuator while considering the process variable that

has been analyzed with true mathematical definitions within an analog and closed circuit.

Following figure illustrates a typical controller process:

Fig 4.2: Controller working

PLC controllers can be merged with various form of technologies to supply a classy management,

monitoring and controlling scheme. Fig 1.3 illustrates the reason for choosing PLC as the controller.

Fig 4.3: Why PLC?

21
4.1.2 PLC Operation

PLC operation is comprised of basically four steps; Input Scan being the first of them,

followed by Program Scan and Output Scan, Housekeeping is the final step. The PLC

continuously keeps following all these steps.

Steps Explained

1.) Input Scan steps function is to detect every input device’s state i.e. connected with the

Programmable logic control.

2.) Executing the program logic generated by the user lies under the program scan step.

3.) Output Scan includes the energizing and de-energizing of all the PLC connected output

devices.

4.) Housekeeping is responsible for internal diagnostics and for communicating with

program terminals.

Fig 4.4: PLC Operation

4.1.3 Programmable Logic Control vs Microcontrollers

PLC is used to automate different industries. It can control machines to perform the

required functionality. Ladder Logic is easy to design in comparison to coding in

microcontroller because of the Ladder Logic Programming that is used to program a PLC

22
is much known to the people working in the field of automation. People having background

in Electrical and Electronics are familiar with ladder logic. On the other hand, a

microcontroller can be programmed with assembly or C programming languages which are

more difficult to learn and modify the code. Another major advantage of a PLC as

compared to microcontroller is the modular nature of PLC. Addition of modules is possible

to a PLC to increase its I/O Ports[7]. Whereas, we cannot increase outputs of

Microcontroller.

In industrial environment it’s difficult to read and modify the program that is written. The

person who wrote the program understands the working of the program but other persons

who are mostly the technicians don’t know how to change or read program [9]. If any

problem occurs in the working of controller and person who wrote the program is not

present at the spot, then there would be great problem and we may need to shutdown

industry which can cause huge amount of loss while a PLC can be programmed by any

person who knows ladder logic.

4.2 Ladder Logic

In the start programming of PLC was done with relay logic wiring based techniques. The

need to teach computer programming to Engineers and Electricians was eliminated by

adapting this method. Today, this method has been in use since and is the most commonly

way for PLC program development. It was a strategic decision to use relay logics. For

Engineers and traders, the retraining required has been significantly decrease by the

selection ladder logic. Although its rarely that relays are used for logic today, but the state-

of-the-art systems still include them.

23
4.3 Software

Programming of desired control logic is needed to control a system using a PLC device.

Simple and intuitive technique of programming is the one of the many reasons of PLCs

attaining such a high popularity. Within this project, ladder diagrams is used to install the

logics for control. Selection of a PLC software depends upon the manufacturer of that

particular PLC. For our project we are using Mitsubishi’s PLC model “Fx 1s”. Each

manufacturer of PLC also provides a software for their PLCs. In our case we are using GX

Developer to develop the logics and to implement.

4.3.1 GX Developer

The GX-DEVELOPER- FX is a simple programming software that supports the entire PLC

range. It is a cost effective cut down version of GX developer, specifically designed for

micro FX PLCs. GX developer supports all MELSEC controllers from the compact PLCs

of the MELSEC FX series to the modular PLCs including MELSEC System Q. This

software shines with a simple, intuitive interface and a short learning curve. GX Developer

supports the MELSEC instruction list (IL), MELSEC ladder diagram (LD) and MELSEC

sequential function chart languages. You can switch back and forth between IL and LD at

will while you are working. You can program your own function blocks (MELSEC

QnA/QnAS/System Q series), and a wide range of utilities are available for configuring

special function modules for the MELSEC System Q. The package includes powerful

editors and diagnostics functions for configuring your MELSEC networks and hardware,

and extensive testing and monitoring functions. Before control logic is programmed into

the PLC, it needs to be configured in the software. After configuration, the ladder diagram

is constructed and simulated to control the liquid filling system.

24
 Fig 4.5: GX Developer Working Environment

4.3.2 Bottle filling Process

The system is turned ON and the conveyor starts running. Bottles are placed on the belt.

When these bottles reach the infrared IR Sensor, the sensor raises a signal in the feedback

loop to PLC and the conveyor is stopped. The solenoid valve automatically opens, and

liquid is filled in the bottles. After the process has lasted specified amount of time the

solenoid valve closes, and the conveyor belt starts running towards the other end. The

figure 1.6 illustrated this process in the form of a flow chart.

4.3.2.1 Ladder Logic Program

The ladder diagram (LAD) of the PLC controlled automated bottle filling system is shown

in Fig 1.7 and 1.8. We have used both “Normally Open” and “Normally Close” type LAD

contacts[8] which correspond to the physical contact signals from sensor of our project and

are directly wired to the “I” (input) terminals on the PLC. The “Normally Open” contact is

loosed (ON) when the assigned bit value at its address is equal to 1 and the “Normally

25
Close” contact is closed (ON) when the assigned bit value at its address is equal to 0. These

LAD contacts use the memory identifier “I” and bit value are read from the process image

register. Input signals are continuously scanned by the PLC device and the system

continuously updates the corresponding state values in the process-image register. We have

used different combinations of the LAD contacts to implement the control logic of the

project.

Fig 4.6: Bottle filling Process

26
 Fig 4.7: Ladder Logic for bottle filling development stage

Several LAD output coils have also been used, which contain the memory identifier “Q”.

The output signals for the actuators and valves are connected to the “Q” terminal of the FX

1s. The CPU system continuously scans the input signals in the running mode, input signals

are processed by CPU with respect to the logic of the program, after that the new value of

output state are reacted in process-image out register by CPU. Although “Normal” and

“Inverted” type output coils are available, we have used Normal type. The value of output

bit is 1, If power is allowed to flow through a normal type output coil and is 0 if no power

flown, then its corresponding bit is set to 0. New output state reactions that are stored in

the process-image are transferred to wired output after execution of each program cycle.

Moreover, we needed to use “pulse timer (TP)” as well as “On-delay timer (TON)” to

create time delays within the program.

27
Fig 4.8: Final Ladder Logic Diagram of Project

28
 Chapter 5

Result, Discussions and Cost Estimation

6.1 Results and Discussions

The designed components were assembled successfully and then the program developed

using PLC software GX developer was incorporated with the prototype setup. Several test

runs were conducted for the sake of optimizing the parameters for best performance.

Initially there were a lot of disturbances within the system that were not allowing the

process to be smooth.

The whole system was found to be working as: When the push button is pressed, the system

turns ON and the built starts moving until the sensor detects a bottle or an object. The PLC

produces a sound which indicates that the solenoid valve has been opened for filling the

bottle. The valve remains open for the time which has been specified within the program

and conveyor does not move during that time. When the desired period of time is reached

the PLC again generates a sound and the valve closes. Simultaneously, the conveyor starts

to run again and transfers the filled bottle to the other end.

The motor has been integrated with a dimmer to vary its speed. Test runs were conducted

at various speeds, so that the user can achieve the desired rate of filling with smooth process

and not much vibrations/disturbances within the conveyor system.

There were several problems that were identified and solved during the test runs stage. In

the initial test runs the system was found to be fluctuating and bottles were vibrating on the

belt due to looseness of the built. The problem was then supplanted by adjusting the belt

tension using the adjustable roller.

29
Similarly, initially, the time of delay was found not to be in proportion with the liquid level

of bottle. The calibration between the delay time and filling level was done through hit and

trial method. At the end it was optimized to fill the liquid to a desired level.

6.2 Cost Estimations

The complete setup is consisted of two types of components and these are the components

that have been either purchased and assembled or are manufactured specially for this

project according to the designed values and dimensions. Table 6.1 gives the summary of

the cost estimation.

Table 5.1: Cost Estimation[9],[10]

Price
S/No Name Quantity
(Pkr)
1. Roller 1000 2
2. Frame 5000 1
3. Bearing 1 300 2
4. Bearing 2 300 2
5. Bearing Kit 300 2
6. Sensors 700 2
7. PLC 15000 1
8. Belt 1500 1
9. Motor 20000 1
10. Solenoid Valve 2000 1
11. Gear 1000 2
Total 48400/-

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 CONCLUSION

Industrial automation is an important aspect or reason of the modern day very well

development industries. Industries have increased their production and have also reduced

significant amount of cost by transferring to the automation related technologies. Conveyor

belts that are automatic can be considered as the basic elements of automation. There are

several production industries which use a conveyor system for different purposes. Our aim

was to use this way of automation to fill bottles with liquid automatically. We built a PLC

controlled automatic bottle filling system. PLC based automated liquid filling and control

system is a part of industrial production system. This system is suitable for liquid

production where we need certain amount of liquid. The automated liquid filling process

is operated in such a way that it saves both time and cost. A lot of industries can get benefit

from such a technology. To mention a few, like Beverages, milk, water and other kitchen

related.

Actually this project has both mechanical and electrical part. The mechanical part of the

project required drawing of the mechanical system; welding and fabricating process. The

electrical part consisted of electrical wiring, programming and some other electrical

methods.

As a result we have gained knowledge of mechanical system along with electrical system.

It can be said that by doing this project successfully we were able to understand how to the

construct industrial systems.

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Future Work and Developments

Our project involves the filling process of liquid and the water pump system. But these are

only a part of the total system. There are additional operations like overhead tank system,

bottle capping system, automatic packaging or labeling system, monitoring system etc.

 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.

 Monitoring system: Several monitoring systems can be placed in this project to

monitor the number and sensing of bottle, quantity of liquid in the bottle etc.

32
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[8] “Boys, Walt (18 August 2009). ‘Back to Basics: SCADA’. Automation TV:

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[9] “1pc Mitsubishi Programmable Controller Fx1s-14mr-es/ul PLC 1year,” eBay.

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