Autonomous Bottle Filling System
Nowadays, the application of PLC (Programmable Logic Controller) is widely due to its uses in industrial world. A programmable logic controller (PLC) is a specialized computer used for controlling, operating and processing machinery and manufacturing processes. The PLCs are used in industrial world
2025-06-28 16:30:30 - Adil Khan
Autonomous Bottle Filling System
Project Area of Specialization Wearables and ImplantableProject SummaryNowadays, the application of PLC (Programmable Logic Controller) is widely due to its uses in industrial world. A programmable logic controller (PLC) is a specialized computer used for controlling, operating and processing machinery and manufacturing processes. The PLCs are used in industrial world to control the mechanical movement of the machinery or combined machines in order to produce accurate products. PLC’s are very flexible, space efficient and reduces complexity. In this project our design is about implementation of automatically filling of liquids of different viscosities into a bottle using programmable logic controller (PLC). The function of the machine is to fill two different types of fluids based on different viscosities automatically into bottles through a running conveyor belt. The machine is fully controlled by PLC, which acts as the brain of the system. The process consists of conveyor belt which is normally in stationary condition. The system is switch on by an operator in filed working environment. The conveyor belt is running via 12V DC gear motor. Bottle is placed by an operator at sending end. When bottle is placed in front of IR (Infrared Sensor NPN), conveyor stops via gear motor. Fluid 1 of viscosity 1 flows through solenoid operating valve and projects in the bottle. After the time defined by the user through Timer Fluid 1 through DC pump stops and meanwhile fluid 2 of viscosity 2 flows through solenoid valve via DC pump 2 and projects into the bottle. After a few seconds the contact of solenoid valve closes and conveyor belt again starts running by DC gear motor commanded by PLC controller. Now at the receiving end of conveyor belt another IR2 (infrared sensor NPN) is placed. When the filling bottle is placed in front of the IR2 sensor conveyor belt will stop. The process is keeping on moving. HMI (Human Machine Interface) for controlling and monitoring the working environment.
Project Objectives- To design a closed system that controls the conveyor belt by Infrared Sensor
- To make sure that the bottle does not over flow while filling
- The conveyor belt must stop as long as desired
- To limit the water flow into the bottle using water level sensor or using timing in ladder logic
Autonomous Bottle Filling project is based on three main classes. First one is sensor that takes input from real world in the form of position of a bottle. Second one is programmable logic controller PLC which acts as the brain of automated project and is used to control the mechanical parts of the project via ladder logic diagram. Third one is the DC gear motor which drives the conveyor belt.
Benefits of the Project- Beverage Industry
- Chemical Industry
- Bottle filling (cold drinks) Industry
- Pharmaceutical Industries
- Fruit juices industry
- Coffee and mixed flavor industry
- Paint industry
Sensor is available in two or three wire. Model is available in PNP and NPN. 24 V dc IR Sensor is available in different diameter and ranges depending upon applications. The front of the sensor is called sensor face from where the infrared radiation enters. The infrared sensor consists of photoelectric materials made up of one or more pixels. An infrared sensor measures the heat of an object as well as detects the motion of an object. Many objects radiate some sort of thermal radiations which are invisible to human eye but can be detected by the sensor. So we have to modify our sensor in such a way that it only detects motion. The sensor pixels are wired in such a way that they are opposite inputs to a differential amplifier.
Liquid Pump
The liquid pumps that we use to carry liquid are DC motor driven pumps. These small liquid pumps have the advantage that they can be mounted at any position. These pumps are suited for medical, consumer and laboratory products because of the small size. These pumps have a lot of torque because of DC motor. It consists of a clover pattern of rollers which presses on the tube as the motor turns. This motor does not need to be primed because of its small size it can prime itself with a little bit of water. We can also alter the flow rate if we connect the motor other way around the fluid directions will also reverse.
Solenoid Valve
A valve is a device by which the flow of liquid (liquids, gases, slurry or loose materials) can be started, stop, diverted and regulated. Valves are used widely in industries. These are also found in the human body which is used to control the flow of human blood. The oil, gas, power generation, mining, sewerage and chemical manufacturing industries use valves. Valves can also be operated manually, either by hand or a wheel or they can be operated automatically, by changes in pressure temperature etc. The main types of valves are:
- Isolation valve: Basically operates in two positions; either fully opened.
- Switching valve: Used to converge and divert the flow of liquid in pipes.
- Control valve: This type of valve regulates the flow of fluid in a piping system.
DC gear motor
The conveyor belt that we used is moved by a DC motor. To run our conveyor belt we have used DC gear motor because we required a smooth and slow running motor, with no jerks at all while stopping of conveyor belt. This motor increases torque and decreases speed thus making the conveyor smooth and no change of spillage of liquid.
Basic specifications of DC gear motor:
- 12 V DC with input power: 0.1 to 2.5 W
- 1.1 – 200 rpm
Conveyor Belt
Conveyor belt is used to carry load and it has wide applications in our everyday life.
Dimensions of conveyor belt
- Length: 2 inches (2 feet 4 inches)
- Width: 5 inches (0.417 feet)
- Two 3.5 inches Rollers
- Belt 6 feet straight
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 48985 | |||
| Programmable logic controller (PLC) | Equipment | 1 | 19000 | 19000 |
| Motor | Equipment | 1 | 750 | 750 |
| Dc water pump | Equipment | 3 | 550 | 1650 |
| Conveyor belt | Equipment | 1 | 1600 | 1600 |
| Rollers | Equipment | 2 | 200 | 400 |
| IR sensor | Equipment | 3 | 850 | 2550 |
| PLC programming cable | Equipment | 1 | 2200 | 2200 |
| Conveyor mechanical structure | Equipment | 1 | 1000 | 1000 |
| Robot arm (future work enhancement) | Equipment | 1 | 2500 | 2500 |
| Screws, nails, nuts and copper wires | Equipment | 1 | 500 | 500 |
| Motor joint | Equipment | 1 | 350 | 350 |
| Push buttons | Equipment | 4 | 150 | 600 |
| Led PLC connected | Equipment | 1 | 35 | 35 |
| Solenoid valve | Equipment | 1 | 850 | 850 |
| Supply circuits | Equipment | 1 | 500 | 500 |
| HM1 Monitoring | Equipment | 1 | 14500 | 14500 |