Automatic Bottle Filling System Using PLC Conveyor Model

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AUTOMATIC BOTTLE FILLING WATER SYSTEM USING PLC WITH CONVEYOR MODEL
A thesis submitted in fulfillment of the

requirement for the award of the degree of
Bachelor of Engineering (Electronics & Instrumentation)
Faculty of Electronics & Instrumentation Engineering

Aarupadai Veedu Institute of Technology (Vinayaka Mission
University)
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DECLARATION
I hereby declared that this thesis titled Automatic Bottle Filling Water System Using PLC is
the result of my own effort except as clearly stated in references the source of reference
Signature
:-
Name of Author :- ......
Date
:- .....
ii
iii
To my beloved father, mother, brother and sister
iv
ACKNOWLEDGEMENT
First of all, I would like to thank Lord KRISHNA for HIS firm hands in guiding me in the course of completing
this thesis writing. It is by HIS grace and mercy that I am able to obtain the research on planning project within such as
limited time.
Second, I would like to express my gratitude and thanks to my Faculty Assistants, Mrs. M.CHITRA & L.Chitra, for his
professional guidance, wisdom, endurance, advices motivation and encouragement during his supervision period.
Thank you so much for the insights and encouragement she has given to me. Without his patience and valuable
assistance, the project and thesis would not have been the same as presented here.
Besides that, I would like to convey my thanks to my beloved parents, Mr. Umesh Prasad Singh and Mrs.
Poonam Singh for the advice and give all support to me in developing this project.
My fellow friends should also be recognized for their support at various conditions. Their views and tips are useful
indeed. Unfortunately, it is not possible to list all of them in this limited space. And last but not least, I am grateful to all
my family members.
v
ABSTRACT
Nowadays, the application of PLC is widely known and use in this digital world PLCs application is obviously
applied at the industrial sector. Normally, the PLCs that have been used at the industrial field is usually to control a
mechanical movement either of the machine or heavy machine in order to create an efficient production and accurate
signal processing. In this project, a discussion about PLC application will be explained in more details and specified.
Whereby, a machine that used to prepare automatic filling water into the bottle is fully controlled by the PLC CPM2A,
which acts as the heart of the system. The system sequence of operation is designed by ladder diagram and the
programming of this project by using CX-Programmer software. Sensor usually plays its vital part as an input signal
transmitter for the PLC in this system. During this project sensor has been used to detect the bottle position that move
along the conveyor belt at the low speed while the machine operates. The input signal that has been sent from the
sensor to the PLC has being made as a reference. Signal in order to determine the output signal that exactly a same
with the PLC programming language based on the user requirement. Beside that, the electronics and electric devices
that usually been controlled by the PLC are like a motor, pump, sensor, conveyor belt, buzzer and the others devices.
vi
TABLE OF CONTENTS
CHAPTER TITLE
PAGE
TITLE PAGE
i
DECLARATION
ii
DEDICATION
iii
ACKOWLEDGEMENT
iv
ABSTRACT
v
TABLE OF CONTENTS
vi
LIST OF TABLES
ix
LIST OF FIGURES
x
LIST OF APPENDIXS
xii
1
1
BACKGROUND OF PROJECT
1.1
Introduction
1
1.1.1 Open-Loop Systems
2
1.1.2 Close-Loop Systems
3
1.2
Problem Statement
5
1.3
Project Objective
6
1.4
Scope of Project
6
1.5
Implementation of Project
7
1.6
Thesis Outline
8
2
10
LITERATURE REVIEW
2.1
10
2.2
12
2.3
13
2.3.1
14
2.3.2
15
2.4
17
2.5
18
2.6
19
History of PLC
What is PLC?
Ladder Logic
Ladder Logic Input
Ladder Logic Output
Programming
Operation of PLC
Time Response
3 METHODOLOGY
22
3.1
22
3.2
24
3.3
25
3.1.1
25
3.1.2
26
3.1.3
27
Methodology Overview
How Does the System Work
Hardware Design
Conveyor System
Motor
Infrared Sensor
Vii
CHAPTER TITLE
4
29
4.1
29
4.2
32
4.3
33
4.3
35
ELECTRIC DESIGN
DC Input
AC Input
Relay Output
Transistor Output
PAGE
5 PROGRAMMING DEVELOPMENT
37
5.1 A Systematic Approach of Control System Design

37
5.2 State Diagram
40
5.3 Assignment of Inputs and Outputs
41
5.4 Ladder Diagram
42
6
44
6.1
44
6.2
46
6.3
47
7
49
7.1
49
7.2
50
FINAL RESULT
The Prototype
The Wiring System
The Hardware Design
CONCLUSION AND RECOMMENDATION

Conclusion
Future Recommendation
REFERENCES
51
APPENDIX
53
viii
LIST OF TABLES
TABLE NO.
PAGE
5.1
41
5.2
41
TITLE
Assignment of Inputs.
Assignment of Outputs.
ix
LIST OF FIGURES
FIG. No.
PAGES
1.1
2
1.2
3
1.3
7
2.1
12
2.2
14
2.3
15
2.4
16
2.5
17
3.1
23
3.2
24
3.3
25
3.4
27
4.1
29
4.2
30
4.3
31
4.4
32
4.5
33
4.6
33
4.7
34
4.8
35
TITLE
Block diagrams of open-loop system

Block diagrams of closed-loop system
Project Flow Chart
Typical of PLC
A Simple Relay Controller
Ladder Logic Inputs
Ladder Logic Outputs
A Simple Ladder Logic Diagram
Design of Project
Conveyor Design
DC Motor
Basic IR receive/transmit
Output for NPN and PNP sensor
Internal DC input circuit diagram
Wiring of AC input
Internal input circuit diagram
Wiring of Relay Output
Internal Relay Output Diagram
Wiring of Transistor for NPN Type
Internal Output Circuit Diagram for NPN Type Output
5.1
38
5.2
39
5.3
40
5.4
42
6.1
44
6.2
44
6.3
44
6.4
45
6.5
45
6.6
46
6.7
46
6.8
46
6.9
47
A Systematic Approach to Programmable
Control Design Flow Chart
State Diagram of the Operation.

Block Diagram of Plant
Ladder Diagram
The system from side view
The system from top view
The system from front view
The PLC electrical wiring system
The external power supply
The conveyor system
The buzzer circuit
The IR sensor circuit
The process of the filling water
X
LIST OF APPENDICES
APPENDIX
PAGE
TITLE
A
53
Data Sheet of CPM2A
B
68
Circuit of IR Emitter and Detector
C
70
Data Sheet of LM324
CHAPTER 1
BACKGROUND OF PROJECT
1.1
Introduction
Control engineering has evolved overtime. In the past, humans were the main method for
controlling a system. More recently, electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relay to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable
Logic Controller (PLC). The advent of the PLC began in the 1970s, and has become the most
common choice for manufacturing controls. [1].
PLC has been gaining popularity on the factory floor and will probably remain predominant for
some time to come. Most of this because of the advantages:-
Cost effective for controlling complex systems

Flexible and can be reapplied to control other systems quickly and easily
Computational abilities allow more sophisticated control
Trouble shooting aids make programminng easier and reduce downtime.
Reliaable componnents make these likely to operate for years before failure.
Control systems are an integral part of modern society.It consists of subsystems and processes
assembled for the purpose of controlling the outputs of the processes.There are many
numerous applications that using control system around us. A control system provides an output
or response for a given input or stimulus.The reason that control system was built isfor power
amplification, remote control, convenience of input form; and compensation for disturbances.
Today control systems find widespread application in the guidance, navigation, and
control of missiles and spacecrafts, as well as planes and ship at sea. The applications also
throughout the process control industry, regulating liquid level tanks, chemical concentrations in
vats, as well as thickness of fabricated material.
2.2 What is a PLC?

A Programmable Logic Controller, PLC is a digital computer used for automation
of industrial processes, such as control of machinery on factory assembly lines.
Unlike general-purpose computers, the PLC is designed for multiple inputs and
output arrangements, extended temperature ranges, immunity to electrical
noise, and resistance to vibration and impact. Programs to control machine
operation are typically stored in battery-backed or non-volatile memory. A PLC is
an example of a real time system since output results must be produced in
response to input conditions within a bounded time, otherwise unintended
operation will result.[8]
A PLC (i.e. Programmable Logic Controller) is a device that was invented to

replace the necessary sequential relay circuits for machine control. The PLC
works by looking at its inputs and depending upon their state, turning on/off its
outputs. The user enters a program, usually via software, that gives the desired
results. PLC are used in many real world applications. If there is industry
present, chances are good that there is a plc present. Almost any application
that needs some type of electrical control has a need for a PLC. [8]
2.3 Ladder Logic
Ladder logic is the main programming method used for PLC. As mention before,
ladder logic has been developed to mimic relay logic. The decision to use the relay logic
diagrams was strategic one. By selecting ladder logic as the main programming method,
the amount of retraining needed for engineers and trades people was greatly reduce. [8]
Modern control systems still include relay, but these are rarely used for logic. A
relay is a simple device that uses a magnetic field to control a switch. Relay are
used to let one power source close a switch for another power source, while
keeping isolated. An example of a relay in a simple control application is shown
in Figure2.2. In this system the first relay on the left is used as normally closed,
and will allow current to flow until a voltage is applied to the input A. The second
relay is normally open and will not allow current to flow until the voltage is
applied to the input B. If current is flowing through the first two relay then
current will flow though the coil in the third relay, and closed the switch for
output C. This circuit would normally be drawn in the ladder logic form. This can
be read logically as C will be on if A is off and B is on. [6]
2.3.1 Ladder Logic Inputs

PLC inputs are easily represented in ladder logic. In Figure 2.3 there are three
types of inputs shown. The first two are normally open and normally closed
inputs, discussed previously. The IIT (Immediate Input) function allows inputs to
be read after the input scan, while the ladder logic is being scanned. This allows
ladder logic to examine input values more often than once every cycle. (Note:
This instruction is not available on the Control Logic processors, but is still
available on older models.) [6]
2.3.2 Ladder Logic Outputs

In ladder logic there are multiple types of outputs, but these are not consistently
available on all PLC. Some of the outputs will be externally connected to devices
outside the PLC, but it is also possible to use internal memory locations in the
PLC. Six types of outputs are shown in Figure 2.4. The first is a normal output,
when energized the output will turn on, and energize an output. The circle with a
diagonal line through is a normally on output. When energized the output will
turn off, this type of output is not available on all PLC types. When initially
energized the OSR (One Shot Relay) instruction will turn on for one scan, but
then be off for all scans after, until it is turned off. The L (latch) and U (unlatch)
instructions can be used to lock outputs on. When an L output is energized the
output will turn on indefinitely, even when the output coil is reenergized. The
output can only be turned off using a U output. The last instruction is the IOT
(Immediate Output) that will allow outputs to be updated without having to wait
for the ladder logic scan to be completed. [6]
Figure 2.4 Ladder Logic Diagram
2.4 Programming
Programming software CX-Programmer has been utilized in this project. CXProgrammer is a PLC programming tool for the creation, testing and
maintenance of programs associated with OMRONs CPM2A series. It provides
facilities for the support of PLC devices and address information and for
communications with OMRON PLCs and their supported network types. An
example of ladder logic can be seen in Figure 2.5. To interpret this diagram
imagines that the power is on the vertical line on the left hand side, we call this
the hot rail. On the right hand side is the neutral rail. In the figure there are two
rungs, and on each rung there are combinations of inputs (two vertical lines)
and outputs (circles). If the inputs are opened or closed in the right combination
the power can flow from the hot rail, through the inputs, to power the outputs,
and finally to the neutral rail. An input can come from a sensor, switch, or any
other type of sensor. An output will be some device outside the PLC that is
switched on or off, such as lightswww.final-yearproject.com

or motors. In the top rung the contacts are
normally open and normally closed. This means if input A is on and input B is off,
then power will flow through the output and activate it. Any other combination
of input values will result in the output X being off. [7]
Figure 2.5: A Simple Ladder Logic Diagram
2.5 Operation of PLC

A PLC works by continually scanning a program. We can think of this scan cycle
as consisting of 3 important steps. There are typically more than 3 but we can
focus on the important parts and not worry about the others. Typically the
others are checking the system and updating the current internal counter and
timer values. [5]
Step 1-CHECK INPUT STATUS-First the PLC takes a look at each input to determine if it is on or
off. In other words, is the sensor connected to the first input on? How about the second input? How
about the third... It records this data into its memory to be used during the next step.
Step 2-EXECUTE PROGRAM-Next the PLC executes your program one instruction at a time.
Maybe your program said that if the first input was on then it should turn on the first output. Since it
already knows which inputs are on/off from the previous step it will be able to decide whether the
first output should be turned on based on the state of the first input. It will store the execution results
for use later during the next step.
Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the status of the outputs. It updates
the outputs based on which inputs were on during the first step and the results of executing your
program during the second step. Based on the example in step 2 it would now turn on the first output
because the first input was on and your program said to turn on the first output when this condition is
true.
After the third step the PLC goes back to step one and repeats the steps continuously. One scan time
is defined as the time it takes to execute the 3 steps listed above.
2.6 Time Response
The PLC can only see an input turn on/off when its looking. In other words, it
only looks at its inputs during the check input status part of the scan.
In the diagram, input 1 is not seen until scan 2. This is because when input 1 turned on, scan
1 had already finished looking at the inputs. Input 2 is not seen until scan 3. This is also because
when the input turned on scan 2 had already finished looking at the inputs.
Input 3 is never seen. This is because when scan 3 was looking at the inputs, signal 3 was not
on yet. It turns off before scan 4 looks at the inputs. Therefore signal 3 is never seen by the plc. Now
lets consider the longest time for an output to actually turn on. Lets assume that when a switch turns
on we need to turn on a load connected to the plc output.
The diagram below shows the longest
delay (worst case because the input is not
seen until scan 2) for the output to turn on after the input has turned on.[8] The
maximum delay is thus 2 scan cycles 1 input delay time.
Pulse stretch function. This function extends the length ofthe input signal until the plc looks at the
inputs during the nextscan.( i.e. it stretches the duration of the pulse.)
Interrupt function. This function interrupts the scan toprocess a special routine that you have
written. i.e. As soon as the input turns on, regardless of where the scan currently is,the plc
immediately stops what its doing and executes aninterrupt routine. (A routine can be thought of as a
miniprogram outside of the main program.) After its done executing the interrupt routine, it goes
back to the point it leftoff at and continues on with the normal scan process.
CHAPTER 3
METHODOLOGY
This chapter will mainly discuss about the methodology of the project and also the aspect or
factors that must be taken into consideration during the development process. All this factors were
very important to make sure the projectwww.final-yearproject.com

will achieve it objective. Moreover, this chapter will also
discuss about the designation stage on this project including electronic design, hardware design and
material selection.
3.1 Project Overview
In this section, it will discuss an overall overview of Automatically Filling Water
System Using PLC project. The introduction to system task will also briefly
explain in this chapter. Finally, the entire decision making will be addressed in
this section.
Basically, software and
hardware design will be used in order to implement this project. In addition,
there some methods must be executed to keep this project implemented
successfully.
3.2 How Does the System Work?
Figure 3.1: Design of Project

Through this project, the bottle will move on the conveyor belt. The conveyor
will be stopped automatically after the infrared sensor detected the presence of
the bottle. The controller will switch on the pumps when the conveyor stops to
move. The water pump will start to fill into the bottle. The filling process will be
stopped automatically by using the timer and will be turn on and buzzer will
sound for five seconds subsequently. This system will repeat the process
continuously.
3.3 Hardware Design
In the hardware design part, overall component such as conveyor system, motor,
infrared sensor, pump and buzzer circuit will be integrated to form the complete prototype.
The hardware components are the backbone of the system. More detailed information of each
section will be discussed in the following sections.
3.3.1 Conveyor System
Figure 3.2: Conveyor Design

The dimension of the prototype is approximately 19 inch of length and three inch of width. This
prototype consist of motor, trek, gear and other electronic circuit. It presents a continually moving
surface that is designed to move objects from one location to another. Conveyor belt is a long loop of
rubber or plastic (usually combined with steel for strength, just like tire treads), that is wrapped
around a set of motorized rollers. A simple conveyor belt will be stretched between two rollers, one
driven roll which powers it and one idle roll which is free to spin as the belt moves.
3.3.2 Motor
Motor is a small electronic device that can move if the power supply connect. It is a main part to
make the conveyor belt moves perfectly. There are many type of DC Motor at market such as gear
DC motor, motor servo and stepper motor but in this project DC motor will be used because it can
spin 360 continuously. Moreover, it is strong enough to move the trek.
Figure 3.3: DC Motor
Figure 3.3 above shows the sample
of the DC motor. DC motor or direct current motor is
the most common motor. There are many types of DC motor likes 5-pole motor, servomotor,
brushless motor, coreless motor, fix magnet motor and many more. DC motor takes direct current
voltages as input and converts it into a rotational movement.
DC motor basically have two wires, and can directly powered from a battery or
other DC power supply. DC motor also can be power from the driver circuit that
can regulate the speed and direction of the motor. The usual voltages of the DC
motor use are 6V and 12V. The current rating depends on the make of the
conveyor build for and it is usually between IA and 3A. Varying the voltage input
to the motor will varies the speed of motor accordingly.
DC motor has ability to turn at high
revolution per minutes (RPM) but has low torque. The most significant limitation
of the DC motor is the low output torque. The speed can be reduced and the
torque increase by adding gear rain to the output shaft. For the purpose of
conveyor belt building, DC motor is the cheapest compare to stepper motor or
servo motor.
3.3.3 Infrared Sensor

This sensor provides the system with ability to detect the presence of object position. The
theory is the IR emitter emits infrared light. If an object presence the signal will be reflected back to
the receiver. Then, the IR detector implemented will detect the reflected light. Then, the
correspondence signal sends to the PLC for being analyze. [8]
Based on the measurement of the intensity of the reflected light from the target
area such a bottle, it has a light source sending light to the moving target and a
light sensor receiving the light. The output signal from the sensor decreases
exponentially with the increase of the distance to the measured object. Infrared
light-emitting diodes (LED's) and photosensitive diodes are used in this
transducer. The sensor output is inversely proportional to the amount of
occupation. A multilink array of light sensitive elements and a light-beam
scanning technique determines and qualifies the shape of the measured object
by processing data from the elements.
Figure 3.4 shows the electro optical displacement transducers, a = transducer

with moving target, b = dimension sensor; f = displacement, 1 = moving target
with light reflector, 2 = light source, 3 = light sensor, 4 = object to be gage.
CHAPTER 4
ELECTRICAL DESIGN
Electrical design of the Automatic Filling Water System involves the electrical components used, and
the installation of the electrical components on the system. Before all connection was established all
the input and output devices to PLC, the concept on how the input and outputs circuits of PLC must
be understood. The wiring of the DC input, AC input, relay output, and the transistor output is
discussed.
4.1 DC Input
Typically, dc input modules are available that will work with 5, 12, 24, and 48V. the connections of
the DC input modules is either PNP( sourcing) or NPN( sinking) transistor types devices. For a
regular switch (i.e. toggle or pushbutton, etc), typically no need to worry about whether wire it as
NPN or PNP. Most PLCs not allow mix NPN and PNP devices on the same modules.
The difference between the two types is whether the load switched to ground or
positive voltages. An NPN types sensor has the load switches to ground
whereas a PNP device has the load switches to positive voltage. Figure 4.1 is
shown the output for NPN and PNP sensor.
Figure 4.1: Output for NPN and PNP sensor

On the NPN sensor, one output is connected to the PLC input and the other output to the power
supply ground. If the sensor is not powered from the same supply as the PLC, both grounds should
be connected together.
On the PNP sensor, connect one output to positive voltages and the other output to the PLC input. If
the sensor is not powered from the same supply as the PLC, both V+s should be connected together.
The common terminal either gets connected to V+ or ground where its connected depends upon the
type of sensor used. When using NPN sensor this terminal is connected to V+, when using a PNP
sensor this terminal is connected to 0V(ground).
A common switch (i.e. limit switch, pushbutton, toggle etc) would be connected to the input
in similar way. One side of the switch would be connected directly to V+. The other end goes to the
PLC input terminal. This assumes the common terminal is connected to 0V (ground). If the common
is connected to V+ the simply connect one end of the switch to 0V (ground) and the other end to the
PLC input terminal.
The photo couplers are used to isolate the PLCs internal circuit from the inputs
as shown in Figure 4.2. This eliminates the chance of any electrical noise
entering the internal circuitry. They
work by converting the electrical input
signal to light and then by converting the light back to an electrical signal to be
processed by the internal circuit.
Figure 4.2: Internal DC input circuit diagram

4.2 AC Input
An ac voltage is non-polarized, means that there is no positive and negative
polarity. Typically, ac input modules are available that will work with 24, 48,
110, and 220V an ac device is connected to input PLC as shown in Figure 4.3
Figure 4.3: Wiring of AC input

Commonly the ac hot wire is connected to the switch while the neutral goes to the PLC
common. The ac ground (3rd wire) should be connected to the frame ground terminal of the PLC. AC
connection is typically color code. In US is commonly white (neutral), black (hot), and green (3rd
wire ground when applicable). Outside the US its commonly coded as brown (hot), blue (neutral),
and green with yellow stripe (3rd wire ground when applicable).
A common switch (i.e. limit switch, pushbutton, toggle, etc) would be connected
to the input terminals directly as shown in Figure 4.4. One side of the switch
would be connected directly to PLC input. The other end goes to the ac hot wire.
This assumes the common terminal is connected to neutral.
Figure 4.4: Internal input circuit diagram

4.3 Relay Output
One of the most common types of outputs available is the relay outputs. A relay can be used with
both AC and DC loads. Some forms of a load are a solenoid, buzzer, motor, etc. Always check the
specifications of the load before connecting it to the PLC output and make sure that the maximum
current it will consume is within the specifications of the PLC outputs.
Some types of loads are very deceiving. These deceiving loads are called
inductive loads. These have a tendency to deliver a back current when they
turn on. This back current is like a voltage spike coming through the system.
Typically a diode, resistor, or other snubbed circuit should be used to prevent
any damage to the relay.
Figure 4.5: Wiring of Relay Output

Figure 4.5 is a typical method of connecting the outputs to the PLC relays. AC
supply or DC supply can be used as well connected to the output. A relay is nonpolarized and typically it can switch either AC or DC. Here the common is
connected to one end of the AC power supply or DC power supply and the other
end of the supply is connected to the load. The other half of the load gets
connected to the actual PLC outputs.
The relay is internal to the PLC. Its circuit diagram is shown in Figure 4.6. When
ladder diagram tells the outputs to turn on, the PLC will internally apply a
voltage to the relay coil. This voltage will allow the proper contact to close.
When the contact close, and external current is allowed to flow through our
external circuit. When the ladder diagram tell the PLC to turn off the output, it
will simply remove the voltage from the internal circuit thereby enabling the
output contact to release the load will than have an open circuit and will
therefore be off.
4.4 Transistor Output
The next type of outputs is transistor type outputs. Typically a PLC will have either NPN or PNP
type outputs. It is important to note that a transistor can only switch a dc current. For this reason it
cannot be used with an ac voltage.
A transistor is a solid-state switch or an electrical switch. A small current applied
to the transistor base (i.e. input) and switch a much larger current through its
outputs. The PLC applies a small current to the transistor base and the transistor
output close. When its closed, the devices connected to the PLC output will be
turn on.
Figure 4.7: Wiring of Transistor for NPN Type

Figure 4.7 shows how to connect the output devices to the transistor output for
NPN type transistor. If it were a PNP type, the common terminal is connected to
V+ and V- would connect to one end of the load.
Figure 4.8: Internal Output Circuit Diagram for NPN Type Output
There is a photo coupler isolating the real world from the internal circuit as
shown in Figure 4.8. When the ladder diagram call for it, the internal circuit turn
on the photo coupler by applying a small voltage to the LED side of the photo
coupler. This make the LED emit light and the receiving part of the photo
coupler will see it and allow current to flow. This small current will turn on the
base of the outputs transistor connection to output 0500. Therefore, whatever is
connected between COM and 0500 will turn on. When the ladder tell 0500 to
turn off, the LED will stop emitting light and hence the output transistor
connected between 0500 and COM will turn off.
CHAPTER 5
PROGRAMMING DEVELOPMENT
A systematic approach of control system design using programming logic controller is presented in
this chapter. As a rule, the layout of the entire of Automatic Filling Water System using PLC is
designed before implementing programming development process. The machine sequences of
operation will be discussed. Next, the assignment of input and outputs are shown in tables. Finally,
the ladder diagram design using CX-Programmer are shown.
5.1 A Systematic Approach of Control System Design.
In general, a control system is a collection of electronic devices and equipment
which are in place to ensure the stability, accuracy and smooth transition of a
process or a manufacturing activity. Every single component in a control system
plays an important role regardless of size.
Before programming, the concept of controlling a control
system is introduce, which is the systematic approach of control system design
using a PLC. The operation procedure of the system approach is shown in Figure
5.1
Figure 5.1: A Systematic Approach to Programmable Control Design Flow Chart
5.2 State Diagram
The general state diagram of the sequences of operation is shown in Figure 5.2
below.
Figure 5.2: State Diagram of the Operation

5.3 Assignment of Inputs and Outputs
After the system sequence of operation is determine, all external input and
output devices connected to the PLC must be determined and assigned the
number corresponding to the input and output number. Table 5.1 and 5.2 shows
the assignment of inputs and outputs.
Table 5.1: Assignment of Inputs.
Table 5.2: Assignment of Outputs.
Figure 5.3: Block Diagram of Plant

5.4 Ladder Diagram
A ladder diagram is produced according to the state diagram of the system and based on the system
operation and condition. Figure 5.3 shows the ladder diagram of the system.
The system in the ladder diagram form will be programmed into PLC. Once the
programs have been downloaded into PLC, it can be monitored in the Diagram
Workspace during execution. Furthermore, the CX-programmer provides on-line
editing functions during execution. Note that the on-line editing is not possible
in Run mode. All activities occurs can be observed using the CX-programmer.
Figure 5.4: Ladder Diagram
CHAPTER 6
FINAL RESULT
As mentioned in Chapter 4 and Chapter 5, all the system of the desired project was implemented and
the results of the systems illustrated in this Chapter 6. During the operation, all activities that occur
can be observed by computer using CX-Programmer. The system needs to debug along the way and
fine tune if necessary. Test run the system thoroughly until if is safe to be operated.
6.1 The Prototype
The prototype was mainly built by combining the mechanical design and the
electrical designs. The system require three external DC power supply for input
output devices, two AC power supply for supplying pump and PLC, and one 9V
battery for buzzer.
The pictures below show that the prototype of system from different view:-
6.2 The Wiring System
Before running the system, thoroughly ensure that the input and wiring are
correctly connected according to the I/O assignment to avoid any unwanted
accidents. Once confirmed, the operation of the Automatic Filling Water System
using PLC can be started.
CHAPTER 7
CONCLUSION AND RECOMMENDATION

An Automatic Filling Water System using PLC has been successfully constructed
and designed by applying all the concept of control system at this project. The
system that is produced can be modified to be better if some of the electrical
devices and system are upgraded and improved.
7.1 Conclusion
The theory and concept of the automatic filling water system is based on the
control system. In electrical design, the features and functions of the electrical
components are required to determine the system requirement. Furthermore,
the theoretical of the wiring system is required for connecting the inputs and
outputs devices to PLC. In programming design, understandings of the desired
control system and how to use the Ladder Diagram to translate the machine
sequence of operation are the most important parts, because it have direct
effect on the system performance. The main aim in this process is to apply PLC
to design automatic filling water system and all objectives in this project were
successfully done as planned. Finally, the basis control system and logic design
apply in this project can be used as a references to design other applications of
automation system, and also can be used as a teaching material for the
Industrial Control subject.
7.2 FUTURE RECOMMENDATION
Actually, a lot of weakness from the project can be taken as future works so that the improved system
will be better in terms of performance. So that, there are several recommendations or suggestions that
we can take to increase performance in this project. The performance of Automatic Filling Water
System can be increased based on two recommendations which are;
The system that is proposed now is using only one sensor that is IR sensor to detect position
of bottle. It will be better if we add more sensors in this system like a flow sensor to detect water
flow or use level sensor to detect water level. Thus, the system will be more sensitive as there will be
more sensing points
Besides using PLC as controller, the other controller can be used in this future work is like
Microcontroller. However, many factors must be considered like cost, practically and others.
REFERENCES
[1] Siemens. Basic Of PLCs STEP 2000 series, Siemens Technical Education Program.
[2] Norman S. Nice Control System Engineering. Third Edition. California State Polytechnic
University Pomona. John Wiley & Son, Inc, 200
[3] Colin D. Simpson
Programmable Logic Controllers Regents Prentice Hall.
[4] Noel M. Morris
Control Engineering Mc GRAW-HILL Book Company (UK) Limited.
[5] Lug, J. Y. S., Walker, M. W., and Paul, R. P. (1980b). Resolved-Acceleration
Control of Mechanical Manipulators. IEEE Trans. Automatic Control.
[6] Bateson, N.R. Introduction to Control System Technology, Sixth Edition, United State of
America: Prentice Hall.1999.
[7] Manual book, A Beginners Guide to PLC, version 2.1. Singapore: Omron.2001.
[8] http:\\ www.plcs.net\default.html
[9] http:\\ www.sea.siemens.com\step\default.html
[10] http:\\ www.seacheng.co.uk\articles\pla\index.html
[11] http: \\ www.omron-ap.com
APPENDIX
A
APPENDIX
B
APPENDIX
C

Automatic Bottle Filling System Using PLC Conveyor Model

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A thesis submitted in fulfillment of the

Faculty of Electronics & Instrumentation Engineering

To my beloved father, mother, brother and sister

5.1 A Systematic Approach of Control System Design

CONCLUSION AND RECOMMENDATION

Block diagrams of open-loop system

State Diagram of the Operation.

Data Sheet of CPM2A

Circuit of IR Emitter and Detector

Data Sheet of LM324

Cost effective for controlling complex systems

2.2 What is a PLC?

A PLC (i.e. Programmable Logic Controller) is a device that was invented to

2.3.1 Ladder Logic Inputs

2.3.2 Ladder Logic Outputs

Figure 2.4 Ladder Logic Diagram

switched on or off, such as lightswww.final-yearproject.com

Figure 2.5: A Simple Ladder Logic Diagram

2.5 Operation of PLC

very important to make sure the projectwww.final-yearproject.com

3.2 How Does the System Work?

Figure 3.1: Design of Project

3.3.1 Conveyor System

Figure 3.2: Conveyor Design

Figure 3.3: DC Motor

3.3.3 Infrared Sensor

Figure 3.4 shows the electro optical displacement transducers, a = transducer

Figure 4.1: Output for NPN and PNP sensor

Figure 4.2: Internal DC input circuit diagram

Figure 4.3: Wiring of AC input

Figure 4.4: Internal input circuit diagram

Figure 4.5: Wiring of Relay Output

Figure 4.7: Wiring of Transistor for NPN Type

Figure 5.1: A Systematic Approach to Programmable Control Design Flow Chart

5.2 State Diagram

Figure 5.2: State Diagram of the Operation

Table 5.1: Assignment of Inputs.

Table 5.2: Assignment of Outputs.

Figure 5.3: Block Diagram of Plant

Figure 5.4: Ladder Diagram

6.2 The Wiring System

CONCLUSION AND RECOMMENDATION

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