Design and Development of Cloud Monitoring Base Batch Filling Station using Bar-code
?PLC based batch filling? system; this work will provide low operational cost, low power consumption, accuracy and flexibility to the system and at the same time it will provide accurate volume of liquid in containers like bottle, glass etc. by saving operational time. The process of this system is
2025-06-28 16:31:21 - Adil Khan
Design and Development of Cloud Monitoring Base Batch Filling Station using Bar-code
Project Area of Specialization Information & Communication TechnologyProject Summary“PLC based batch filling” system; this work will provide low operational cost, low power consumption, accuracy and flexibility to the system and at the same time it will provide accurate volume of liquid in containers like bottle, glass etc. by saving operational time. The process of this system is controlled by PLC. PLC is a heart of the system and the system is controlled according to the programmed instructions. PLC will be interfaced to the cloud system. It sends data to cloud, where we can monitor parameter of our plant by mobile access or from our home connection.
The plant we are using is basically a “filling” plant of different solutions, to be filled in bottles with the help of barcode. The techniques we are using is mainly concerned to that type of plant which is supposed to be placed at remote areas, where man power faced difficulty to be reach and monitor the plant constantly and every time. So, our project provides a solution to this situation, through which we can easily monitor our plant, configure it, troubleshoot it, diagnose and debugging of PLC. In-short, we can easily achieve our industrial objective i.e. production requirements by just monitoring of our plant, just from our home, office or anywhere in the world using the technology of Cloud computing.
Finally, although PLCs have built-in control system and through which we can easily control and monitor any on-site plant. But, we can now do the same operation to any plant which is placed thousands of miles away from the control room, wirelessly by using our techniques of cloud computing.
Project Objectives- To design and development batch filling station using PLC
- The main objective of this project is implement the technology of Cloud in industrial sector, which is basically a core part of Industry 4.0.
- To interface barcode reader over RS-232 standard using communication module CM-1241 in batch filling process.
The filling mechanism of our plant is based on two types of Solution i.e. Solution-A and Solution-B which are distinguished on the bases of their Colors. The filling of these liquids into the bottles can only be done, if their respective assigned Barcode is detected. At first, we will assign a unique barcode to the Solution A and B. Then, the bottles which were moving on Conveyor and detected by the Barcode sensor, connected to PLC controller, then stopped and filled by their respective solution on behalf of their barcode. The accuracy and flexibility of the system is carried through, by using the feature of Industry 4.0 that is, Cloud Computing. The Live monitoring of our Plant is done by using the Webserver communication protocol on to our designed website.
The whole process continues, as because of the automation control system techniques which will be carried through Programmable Logic Controller (PLC) which will provide supervisory control and data acquisition onto our plant.
Perhaps one of the most appealing benefits would below costs when the infrastructure is outsourced into the cloud. And with that taking the advantage of the environment of the cloud provider such as: processing power, storage capacity, security measures, maintenance service, etc. There is also a main beneficiary point of our project that leads the industrial sector to a new era and that is, the remote monitoring, configuring and upgrading of any plant or system which is placed thousands of miles away from the control system, using the technology of Cloud computing to the PLC.
Technical Details of Final DeliverableIn order to detect the barcodes, placed on the bottles, we will use barcode sensor which performs Point-to-Point (PtP) serial communication protocol to the PLC over the RS-232 port. The bottles are moving on the conveyor belt, detected by the proximity sensors for stopping them and perform the filling process.
The filling plant is carried through solenoid valves which are attached to two containe rs, in which two types of solutions are present i.e. Solution-A and Solution-B. These solutions are distinguished on behalf of their colors.
Float switches are also placed in the containers, for indicating to PLC the lower limit of the liquid.
For Cloud monitoring, we will perform webserver communication which will display our plant parameters and its performance onto our designed webpage.
Furthermore, PC based Human Machine Interfaced (HMI)/L.C.D will be used for monitoring process of detection of bottles, conveyor movement, filling process, Number of bottles filled of respective solution.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 79000 | |||
| PLC | Equipment | 1 | 25000 | 25000 |
| Power Supply for PLC | Equipment | 1 | 1500 | 1500 |
| Communication Module | Equipment | 1 | 18000 | 18000 |
| Barcode Sensor | Equipment | 1 | 17000 | 17000 |
| Tanks | Equipment | 2 | 1000 | 2000 |
| solenoid valve | Equipment | 2 | 750 | 1500 |
| Conveyer belt | Equipment | 1 | 2000 | 2000 |
| Float Switches | Equipment | 2 | 500 | 1000 |
| Proximity Sensor | Equipment | 2 | 500 | 1000 |
| Others | Miscellaneous | 1 | 10000 | 10000 |