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Design and Implementation of Bottle Filling Automation System for Food
Processing Industries using PLC
Article · June 2019
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International Journal of
Power Electronics Controllers and Converters
eISSN: 2456-1614
Vol. 4: Issue 1
www.journalspub.com
Design and Implementation of Bottle Filling Automation System
for Food Processing Industries using PLC
Komal Manhas*, Meenakshi Dogra, Rajinder Tiwari, Jamini Sharma
Department of Electronics and Communication, Model Institute of Engineering and
Technology, Jammu, India
ABSTRACT
The prime target behind this work is to build an automated bottle filling conveyor handing
system using PLC (MITSUBISHI) or programmable logic controller. The purpose is to
automate the working of a conveyor system. The working of conveyor system includes two
main tasks to be accomplished. The primary job is starting and stopping of the conveyor
using motor. The secondary task is to fill the bottles in a particular time period (in seconds)
so as to attain same quantity of liquid in all bottles. The world full of technologies demands
high rate of production, especially in industries where automation is required. A PLC is
known well for real time applications, therefore used to control various devices and PLC is
the device that has tendency to operate with multiple inputs and outputs as well as operates
in extreme environmental conditions. Thus, the main hardware part used is PLC. This system
is controlled by ladder programming (software part) consists of simulation and
implementation of program using GX Work 3 which will control and automate the conveyor
system. The hardware parts used for this system are PLC (MITSUBISHI), sensors
(photoelectric sensor), control valve (2/2 solenoid valve), motor (12V) and some connectors.
The entire work is to be done to obtain results on the agreement of parameters set in program
as well as hardware of the system. The material of conveyor belt used is PVC as it is highly
durable, water resistant and affordable. The main purpose is to develop automated conveyor
system with low cost, minimum maintenance, more efficient and friendly system for users.
Keywords: PLC, human intervention, automation system, control system, ladder logic,
photovoltaic sensors, solenoid valve, PVC, GXWork3
*Correspondence for Author
E-mail: komal.74ece15@mietjammu.in
INTRODUCTION
This project aims on designing an automatic
filling of bottle along with conveyor system
using PLC or programmable logic controller
(MITSUBISHI). It deals with controlling
and managing time as well as speed of the
system. The significant target is to achieve
more efficiency and flexibility, as these
factors are reliable as well as required in the
industries such as food processing industries,
packaging industries, etc.
This is already known that automation has a
vital role in the economy of the world, and
hence used in this project. For the same,
there are number of systems exist in the
market which are in use in various
industries. These systems are based on
various different algorithms of the
controllers that could be PID, AI, DCS,
PLC, etc. Out of these methods, PLC is the
most common in use due to its flexible
features such as accuracy, ruggedness,
IJPECC (2019) 1–9 © JournalsPub 2019. All Rights Reserved
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Design and Implementation of Bottle Filling Automation System
reliability, etc. However, electromagnetic
relays were used for this purpose earlier for
designing such systems, but because of
occurrence of complexity within the system
and low response in the execution, these
were replaced by PLC. Other than PLC,
some more hardware parts are also used in
this project such as sensors, control valve,
motor and some connectors. Filling is the
process in which a machine packs the liquid
products such as water, cool drinks, etc. This
method includes placing bottles upon a
conveyor belt and filling one bottle within a
given time.
PROPOSED HARDWARE PARTS
There are number of hardware parts used in
this paper which are listed as follows:
•
PLC(MITSUBISHI)
•
Sensor (photoelectric sensor)
•
Control valve(solenoid valve)
•
Relay and motor
•
ON-OFF buttons
•
Power supply and some connectors
•
Conveyor belts
Programmable Logic Controller
PLC is a distinctive type of computer which
has functions like controlling and operating
manufacturing process and machinery in
various industries. The PLCs are behaving
as heart as well as brain of the automation
systems
which
are
designed
and
implemented in various domains of the
applications such as factory, home,
industrial plant, etc. A PLC is an example of
a real time application, and therefore used to
control various devices simultaneously.
These systems carry out many services such
as provision of different analog and digital
input and output interfaces, processing of
signal, conversion of data, etc. PLC can
execute a program by executing at a time
single instruction. For instance, when the
first input is set ON, then it will turn the first
output ON. Further, it knows which input is
Manhas et al.
already on/off, so with respect to the
previous process, PLC modifies the value of
the outputs accordingly. PLC analyzes and
scans the input by a user-defined program.
The whole process in terms of program is
executed, and finally it checks the output
status.
Sensor (Photoelectric Sensor)
It is a device that determines the distance of
object and also checks for absence or
existence of the object on the conveyor belt
by using a photoelectric transmitter and
receiver. They are mostly used in industrial
practices. Operating voltage is 6–36 V DC
and its output current is 300 mA. Its
response frequency is 0.5 kHz and output
type is n-p-n 3-wire (Black, Blue and
Brown). It is usually made of brass or
plastic. In this paper, diffused photoelectric
sensor is being used so as to sense the
existence of bottles on the conveyor belt.
However, various sensors are used to check
presence of the object on the basis of
appearance such as opaque, transparent or
coloured object; so as to detect the plastic
bottle, diffused photoelectric sensor is to be
used here.
Features of photoelectric sensor are as
follows:
•
Long distance measuring
•
Quick response time
•
Non-contact sensing
•
Easy adjustment
•
Color identification
•
High resolution
•
Almost no sensing object constraints
Solenoid Valve
Solenoid valve is an electromechanical
device in which the solenoid uses an electric
current to produce a magnetic field and
thereby drives a mechanism which controls
the opening of fluid flow in a valve. It is
operated to control pouring of liquids in a
specific time by automatic opening and
IJPECC (2019) 1–9 © JournalsPub 2019. All Rights Reserved
Page 2
International Journal of Power Electronics Controllers and Converters
eISSN: 2456-1614
Vol. 4: Issue 1
www.journalspub.com
closing. Several types of applications are
accomplished by using this solenoid valve.
Parts of solenoid valve:
1) Valve body
2) Inlet port
3) Outlet port
4) Coil/solenoid
5) Coil windings
6) Lead wires
7) Plunger or piston
8) Spring
Fig. 1. Solenoid valve [10].
Relay and Motor
A relay is an electrically operated switch
which depends on the magnetic field
strength that develops within the coil. This
device can be very easily understanding with
the help of NC (normally closed) and NO
(normally open). Since under normal
condition, this switch is NO and as the input
is fed to the switch, a field is developed
which changes its position to NC which in
turn switch ON the machine connected at its
output, i.e., DC motor.
DC motor is a type of rotatory electrical
machine which convert electrical current
into mechanical motion. In this project, DC
motor is exercised to start the conveyor belt
(in rotating motion) to shift the bottle under
the valve first and later after filling, it will
shift further away from valve. This DC
motor operates at 12 V DC supply with gear
box which is used to increase the torque and
reduce the speed as required. This motor has
an input current of 600 mA to 14 A and noload speed is 50 rpm. The reason behind the
selection of this motor is its high torque at a
constant speed.
Conveyor Belt
It must be strong, long-term and unaffected
to an extensive range of temperatures,
moisture, chemical, etc. There are some
materials that are used to make conveyor
belts such as: thermoplastics, leather, rubber,
metal and fabric. The material used in this
paper is a rubber composite, as it is stretchy,
resistant, unbroken and smooth. Plastics
consist of polyester, polyethylene, polyvinyl
chloride and silicone. In case of bulk
material manufacturing and production, steel
made conveyor belts are preferred because
of their high strength.
BLOCK DIAGRAM OF THE PROJECT
The project includes inputs (start and stop
buttons,
a
photoelectric
sensor),
PLC(programmable logic controller by
Mitsubishi), power supply, programming
tool (GX Works3), outputs (motor and
solenoid valve). The block diagram of whole
system is given below:
PROPOSED SOFTWARE PART
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
IJPECC (2019) 1–9 © JournalsPub 2019. All Rights Reserved
Page 3
Commented [p1]: AU: Please cite all the figures in the text.
Design and Implementation of Bottle Filling Automation System
Manhas et al.
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:
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.
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
Ladder Programming
Though, there are many languages for
operating PLC, but the program for this
project has been written using ladder
programming because it is quite simple to
learn and less complex than other languages.
This programming language is specifically
designed for processing Boolean signals (1 ≡
TRUE or 0 ≡ FALSE). There are basically
five different approaches to operate the PLC
for any system properly, i.e.,
• Ladder diagram approach (LD)
• Functional block diagram approach
(FBD)
• Sequential function chart approach
(SFC)
• Structured text approach (ST)
• Instruction list approach (IL)
Fig. 2. Block diagram of the project.
IJPECC (2019) 1–9 © JournalsPub 2019. All Rights Reserved
Page 4
International Journal of Power Electronics Controllers and Converters
eISSN: 2456-1614
Vol. 4: Issue 1
www.journalspub.com
Fig. 3. Flowchart of the system.
Fig. 4. Basic symbols of ladder programming.
Out of the above-mentioned languages,
ladder programming is used for operating
PLC. The program is to be written in
GXWorks3 (software). Basic symbols for
ladder programming that are used in this
program are given as:
Designing Program and Simulation Part
Program Part
This project comprises of both hardware
and software parts. A program is
developed using GXWorks3 software
(latest generation programming software
IJPECC (2019) 1–9 © JournalsPub 2019. All Rights Reserved
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Design and Implementation of Bottle Filling Automation System
provided by Mitsubishi). This program has
developed using these above
basic
symbols such as normally open (NO),
normally closed (NC) and output.
Where,
Inputs are given as:
X0 → START BUTTON INPUT
X1 → STOP BUTTON INPUT
X2 → SENSOR INPUT
Outputs are given as:
Y0 → solenoid valve
Y1 → motor
Program Description
First Rung
In first rung, there are two input push
button controls X0 and X1, one start
button and one stop button. If start
button is pressed, memory bit (M0) is
ON and even if start button is OFF,
position of the memory bit continues to
be ON. To stop the conveyor system,
stop button is used so the output relay
will disconnect the power of the memory
bit. The above technique is called
latching and unlatching.
Second Rung
In second rung there are two inputs,
Manhas et al.
memory bit (M0) and sensor input (X2).
And (X2) and (T0), timer bits are in OR
gate logic. When memory bit gets latched,
motor (Y0) is turned ON if sensor input is
0 or timer bit (T0) is set. Motor will be
turned OFF if the sensor input is 1.
Third Rung
In third rung, there are two inputs, one
latched memory bit (M0) and one sensor
input (X2). When sensor input (X2) is 1
and if motor (Y0) is turned off, the
solenoid valve (Y1) is opened and timer
also starts counting. The On-Delay timer
(TON) instruction counts time when the
sensor input becomes ON. When the
current value is equal to the present time
(K), the timer bit (T0) is SET and motor
gets turned ON again. The On-Delay timer
current value is cleared when the sensor
input is OFF.
Simulation Part
The simulation process includes LEDs as
outputs and in this project, there are two
outputs (first one is motor and another one
is solenoid valve). Figures 5 and 6 are
showing two outputs accordingly.
Fig. 5. Program.
IJPECC (2019) 1–9 © JournalsPub 2019. All Rights Reserved
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International Journal of Power Electronics Controllers and Converters
eISSN: 2456-1614
Vol. 4: Issue 1
www.journalspub.com
MOTOR OUTPUT
Fig. 6. LED showing output of motor.
Solenoid
valve
output
Fig. 7. LED showing output of solenoid valve.
Fig. 8. Experimental view of this project.
RESULT AND CONCLUSION
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 (MITSUBISHI). The aim
is also to make this system more flexible than
other, more reliable, time saving so that
productivity will be improved.
IJPECC (2019) 1–9 © JournalsPub 2019. All Rights Reserved
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Design and Implementation of Bottle Filling Automation System
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Cite this Article: Komal Manhas, Meenakshi Dogra, Rajinder Tiwari,
Jamini Sharma. Design and Implementation of Bottle Filling
Automation System for Food Processing Industries using PLC.
International Journal of Power Electronics Controllers and
Converters. 2019;5(1) 1–9p:
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