Automatic Bottle Filling and Capping System using PLC and HMI

This project aims to reduce human efforts and physical work by introducing complete automatic technology &  the purpose is to control the system with less human interference. Traditional methods of bottle filling being used are resulting in low production outputs and

Project Title

Automatic Bottle Filling and Capping System using PLC and HMI

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

This project aims to reduce human efforts and physical work by introducing complete automatic technology &  the purpose is to control the system with less human interference.

Traditional methods of bottle filling being used are resulting in low production outputs and losses through spillages.

This project aims to develop a smooth bottle filling and capping system ensuring that there will be no spillage of water.

The objective of implementing this project is to solve the energy crisis factor present in the country. When there is any load shedding or any emergency shut down in the industry the whole system is disturbed and when the energy is restored the PLC starts its execution from the beginning instead of that state when the execution stopped due to the shutdown. We claim to design a logic that will help PLC retaining its previous state.

For example, Our project is running smoothly and load shedding occurs in the industry when our bottle is filled only 25%. When the energy will be restored the PLC will instruct the solenoid valve to fill the remaining 75% instead of filling from 0%, thus avoiding wastage of the natural resource.

Automated bottling process: A brief review

• The Feeding stage: receives and aligns on the conveyor belt all the cleaned bottles ready to be filled

• The Filling stage: dispenses the intended liquid into the bottles

• The Capping stage: places and tightens caps on each filled bottle

Project methodology includes three main portions:

1. First is the hardware section.

- PLC is interfaced with every component of the bottle filling system.

2. Second is programming the PLC.

- Ladder logic is used for programming the PLC.

3. Third is Human Machine Interface.

- HMI is used for monitoring and control of the entire system.

Project Objectives

The objective here will be to meet the demand and to develop the "Automatic bottle filling and capping system using PLC and HMI." The intention will be to obtain the requirement in the industries to get an excessively high percentage output and with low power consumption to get the high accuracy. The project is developed in accordance to meet the requirements in industrial automation and to provide solutions to the energy crisis factor present in the industries. Also, since the project uses the PLC, its maintenance is less as compared to the devices which obtain the same output but uses a controller other than PLC.

The objectives can be summarized as following:

1. To implement an automatic bottle filling machine.

2. To reduce the man power and to reduce interrupt in production system of industry.

Project Implementation Method

As Start is a push button which generates a momentary command only, if Start command is pressed then the output System ON will be activated. The System ON signal Normally Open contact, Level Switch NC contact and Proximity NO contact is mainly used to control the solenoid valve. Proximity switch used because the filling has to be started when the bottle placed in correct position. By the time the bottle arrives under solenoid valve, NO contact becomes NC), after all the logics are healthy then solenoid valve will be activated and starts filling. After filled bottle has moved out and filling again will start when next bottle comes under solenoid Svalve. Proximity switch NC contact is used and System ON signal NO contact is used here to control the Motor. Both proximity & Full signals are enabled then Motor will be started and conveyor will start running and bottle will start move. When the bottle is filled, the bottle moves to the other end and then motor starts at the same time. It is used to control the solenoid valve operation. If solenoid activated then it starts filling the bottle and if solenoid valve de-activates then the filling will be stopped. Following table describes the relationship between the inputs and outputs to the following data

 Inputs 

Start

Stop

Proximity Switch 

Level Switch 

Outputs 

System ON 

Solenoid 

Motor 

Full 

Benefits of the Project

1. To learn the interface between PLC and HMI and their programming 

 2. Required less time

3. Low power consumption

4. Accuracy is improved

5. Uninterrupted Process

6. Solution for the energy crisis present in industries

7. Consistency and reliability

8. Interface with HMI

9. No spillage of water hence no wastage of natural resource

10. It reduces labour power.

Technical Details of Final Deliverable

Final Deliverables:

Software:

It includes PLC Ladder Diagram and simulation.

It will be monitored and controlled through HMI (Human     Machine Interface).

Hardware Model:

The hardware part is the real time model of bottle filling system containing all the modules and sensors controlled by PLC and HMI.

Step 7 Micro-Win  is program used for programming the PLC according to the Hardware model in ladder logic program.

Brief Explanation of Operation of the Project:

Water filling in the bottles is the key job of this project via automatic system. This operation starts with keeping bottles on the top of a conveyor belt, also pouring liquid at the same time in one bottle. Filling is controlled and managed by PLC by means of ladder logic programming method. Initially, the whole conveyor system will be rotating on pressing start button as motors starts. Then PLC gets feedback from sensor and controls the solenoid valve timing as well as controls the conveyor belt accordingly. Sensor has a significant importance in the whole setup. A sensor is used to sense the bottle placed under the tank which in turn placed over the conveyor. Thus, filling is done by using motor, sensors, conveyor belt, PLC, solenoid valve. This can be explained more precisely by following algorithm:

Step 1 The bottle filling machine starts when the push button switch (start button) is pressed and this caused working of the DC motor, which further caused conveyor belt to move.

Step 2 The bottles move on the conveyor belt until the first bottle reaches under the solenoid valve where a photoelectric sensor is present. And its function is to sense or detect the bottle and gives a control signal to the PLC.

Step 3 This leads to stopping the DC motor, and hence the conveyer belt stops, and the solenoid valve operates and the bottle starts filling the water (using timer in PLC, i.e., solenoid valve will remain open till time t seconds).

Step 4 When the bottle is fully filled with water, the solenoid valve gets closed and the motor starts working to move the conveyor belt again to carry the bottle away from the solenoid valve. Step 5 If another bottle is detected under the valve, the process will be repeated and when the stop button is pressed, the whole process will be stopped.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Energy

Other Industries

Manufacturing

Core Technology

Others

Other Technologies

Robotics

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com