Automatic Bottle Filling System Using PLC

Project Title

Automatic Bottle Filling System Using PLC

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

The objective of our project is to design, develop and monitor “Automatic bottle filling system using PLC”. This work provides with a lot of benefits like low power consumption, low operational cost, less maintenance, accuracy and many more. This project is based on Industrial automation and is a vast application used in many industries.

Filling is the task that is carried out by a machine and this process is widely used in many industries. In this project, the filling of the bottle is controlled by using a controller known as PLC which is also the heart of the entire system. For the conveyor system, AC motor has been selected for better performance and ease of operation. A sensor has been used to detect the position of the bottle. Ladder logic has been used for the programming of the PLC, which is the most widely used and accepted language for the programming of the PLC. The PLC used in this system is a Siemens S7 – 200 which makes the system more flexible and easier to operate.

Project Objectives

• Understood as a way to increase efficiently and to improve productivity, predetermined sequence of operation with little or no human labor
• To reduce labor cost
• Control the speed of Ac machine by changing the frequency
• With the help of PLC, we control the filling of bottle of different types and liquid

Project Implementation Method

At first, the auto selection switch is selected so that the entire system operates automatically. Then the “Auto start push button” (toggle switch is used here) is selected and the motor starts and the conveyor belt starts moving.

The 24W AC motor used is a AC geared type motor whose shaft is coupled directly with the shaft of the roller. Then bottles are placed simultaneously on the conveyor belt. Now as the bottle approaches towards the photoelectric sensor, the sensor senses the bottle and the conveyor stops running

As the conveyor stops the solenoid valve 1 gets energized and the blue water from tank 1 starts filling in the bottle. After a given time period is over, then the solenoid valve gets de energized completely and water flowing through the valve is stopped and the conveyor belt starts moving. The valve remains de energized until the bottle 2 is sensed by the sensor again. As the bottle 2 approaches to senser, conveyor stops the solenoid valve gets energized and the red water from tank 2 starts filling in the bottle. After a given time period is over, then the solenoid valve gets de energized completely and water flowing through the valve is stopped and the conveyor belt starts moving again

Then as this process is continued for both tanks the water level in the tanks keeps on decreasing with course of time. A water float switch is used which is dipped into the tanks filled with water. The entire length of the equipment is 2m. It has an input voltage of 250V A.C with an input current of 15A. It has both NO & NC contacts

It is dipped into the tank filled with water so it floats over the water and on decrease in water level the float switch falls down completely towards the ground due to low level of water which then closes the circuit connection with the relay. As a result, the pump that is interfaced with the entire system then gets completely energized and the water from the reservoir is pumped directly to the water tank and it is filled with water and gradually the water level starts rising and the float switch gradually starts to float over water. After the water is filled up to a certain level and the float switch starts floating over water, then the circuit breaks and the pump gets de energized simultaneously

EMERGENCY SWITCH has also been introduced in the system which works like a circuit breaker which disconnects the entire PLC system whenever any unfavorable conditions arise.

 A ladder logic (LAD) has been implemented using the SIEMENS software in order for the better understanding of the system, so that when the machine is online, we can keep record of which part of the machine is online as per as requirement.

Benefits of the Project

The satiation in which the exact amount of automation is necessary to be implemented is governed by certain number of concepts, which are time, safety, flexibility and quality. The concepts and how they affect the system are considered below:

 • Time: This concept is typically associated with the level of automation and how this level affects the productivity. The higher the automation the faster the production is and thus it saves time

• Money: This concept considers the relation between the identification between the degree of automation and the costs and savings. The basic concept is associated with the relation in which the normal operator is replaced by an automatic system, which is reduction in the cost, because the human worker is considered to be the most expensive part of the system

• Safety: This concept is oriented mostly in automation, because the automation is limiting the human participation in hazardous and dangerous processes

• Quality: The quality concept is regarding the automation as the source of improving the product quality. The introduction of computers, robots and intelligent machines into the productivity quality is improved.

• Efficiency: the efficiency of the system while using PLC is increased as there in no man power which cause human error etc.

Technical Details of Final Deliverable

This bottle filling automation system is used to increase productivity, better quality and quantity of liquid in a given time. The main purpose of this whole system is to control the plant with less human interference and also cost is minimized so that it can be used in small scale industries. Thus, requirement of full automation is to be attained by using PLC. The aim is also to make this system more flexible than other, more reliable, time saving so that productivity will be improved.

Finally, a prototype of the given system is prepared which mimic the behaviour of orignal system used in industry.

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Food , Health Core Technology Augmented & Virtual RealityOther Technologies Robotics, OthersSustainable Development Goals Good Health and Well-Being for People, Clean Water and Sanitation, Decent Work and Economic Growth, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	74900
Water Float Switch	Equipment	2	900	1800
Photoelectric Sensor	Equipment	5	1500	7500
AC Machine for Conveyor	Equipment	1	5000	5000
Solenoid Valves	Equipment	3	1500	4500
Submersible Water Pump	Equipment	2	1000	2000
Water Tank	Equipment	2	1000	2000
Control Relays	Equipment	4	850	3400
Conveyor Assembly	Equipment	1	6500	6500
PLC (S7 200)	Equipment	1	24500	24500
PLC Wires	Equipment	25	120	3000
PLC Connectors	Equipment	30	130	3900
Power Supply	Equipment	3	750	2250
Controller Board	Equipment	1	1750	1750
IR Sensor	Equipment	4	450	1800
Printing and Other Expenses	Miscellaneous	1	5000	5000