PLC Based Automatic Bottle Filling and Capping System

Project Title

PLC Based Automatic Bottle Filling and Capping System

Project Area of Specialization RoboticsProject Summary

Programmable Logic Controller ( PLC ) is an electronic device used in many industries to monitor and control building systems and production processes.

A Programmable Logic Controller, PLC, is a digital computer used for automation of typically industrial electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures.

• The purpose of this project is to design and monitor “Bottle Filling and Capping Process using PLC”.
• In filling, the product in used is a water and it will be transfer into the bottle that comes under filling section.
• When the filling process completes, the conveyor will be function as a transport to bring bottle had been filled to do capping process.

We have used Fatek PLC (FBs-24MAR) which is the brain of whole system all processes  are controlled using PLC.

We have used NPN Photoelectric Sensors for detection of bottle under Filling and Capping section .

We have also used Level Sensor (XKC-Y25-T12V) for achieving exact liquid level inside bottle and we have also made it compatible with PLC.

We have used two motors in capping section, one for up and down motion using crank shaft mechanism and the other motor for Tightening of cap onto bottle.

Project Objectives

• Control overall process using sensors to reduce the human intervention in the process.
• Continues process by introducing conveyor belt.
• Use of liquid level sensor to maintain exact level of liquid inside bottle.
• To develop cost effective filling section by using constant pressure pump for filling process.
• To develop cost effective capping process.

Project Implementation Method

Software Implementation:

• First we implemented the Ladder Logic in WinProLadder Software and test it in software.

• We have also made CAD model of our complete project

Hardware Implementation:

• We first made base of the project and then made structure of the whole project.
• We then set up filling section in which we use big water storage tank to store water and used pump to fill water into bottle. Level sensor stops pump and fill water upto specific level inside bottle.
• We made a magazine in which caps are stored and bottle carry cap while moving under the magazine.
• We then set up Cap Tightening section in which we use two motors one to move the cavity up and down and other motor to rotate that cavity which tight the cap onto bottle.

Benefits of the Project

It Reduce the human intervention.

Continues process by introducing conveyor belt.

High realiability.

Reduce Cost.

Technical Details of Final Deliverable

First we have run this by placing only one botttle on a conveyer and checked the Filling and Capping process.

Then,we run our systen by placing (6-7) bottles at a time and checked the Filling and Capping process.

We have used 12V DC motor and also used a Pulley system to reduced the speed of conveyer belt.

We have also used a Metallic Rollers of same size and same diameter.

Final Deliverable of the Project Hardware SystemType of Industry Others Technologies OthersSustainable Development Goals Clean Water and SanitationRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	31030
Metallic Pipes for Convener Structure	Equipment	33	110	3630
12 V DC Motor	Equipment	1	500	500
Proximity Sensors	Equipment	2	600	1200
Level Sensor	Equipment	1	3000	3000
PLC	Equipment	1	18000	18000
Water Pump	Equipment	1	600	600
Rollers	Equipment	2	1000	2000
Pulleys	Equipment	2	100	200
Convener Belt	Equipment	1	700	700
Cap Tightening Motors	Equipment	2	300	600
Panaflex	Miscellaneous	1	600	600