Chapter 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.
Control of conveyor using PLC and sensors is a closed loop control system.
This system is broadly used to fill different types of liquid such as water,
syrup, cold drinks, soft drinks, hard drinks, milk, etc in to the bottle. This
system consists of rubber conveyor belt, DC motor, proximity sensors, and
liquid filling device as solenoid valve, programmers as PLC, and other
devices such frame structure on which the complete system will stand. The
system sequence of operation is designed by ladder diagram and the
programming of this is done by using Programmer software. Sensor usually
plays its vital part as an input signal transmitted to the PLC in this system. In
this scheme, sensor will be used to detect the bottle presence that move
along the conveyor belt at the low speed while the machine operates .The
input signal will be sent from the sensor to the PLC will be considered as a
reference. Signal in order to determine the output signal that is according to
the PLC programming language based on the user requirement. Besides that,
other devices also controlled by the PLC are like a motor, pump, sensor,
conveyor belt and the others devices.

BLOCK
DIAGRAM: 1: AUOMATIC BOTTLE FILLING MACHINE USING PLC

1.1

Overview

Nowadays, the application of PLC is widely known and used 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. A
machine that used to prepare automatic filling water into the bottle and
dispatching using the arrangement is fully controlled by the PLC, which acts
as the vital part of the system. The system sequence of operation is
2

designed by ladder diagram. Sensor usually plays vital role as an input signal
transmitter for the PLC in this system. Here, sensor has been used to detect
the bottle position that move along the conveyor belt at the low speed while
the machine operates. Besides that, the electronics and electric devices that
usually been controlled by the PLC are like a motor, pump, sensor, conveyor
belt and the others devices. The assemblies of these all elements work
together and make a complete system known as CONTROL OF CONVEYOR
SUSTEM USING PLC AND SENSORS.

1.2

Statement of Problem

To design a close loop system which can control conveyor.

To make sure that the bottle doesnt overflow and conveyor must be stopped as long as
sensors and filling process is in work.

To design a controller system that limits the water flow in to the bottle.

To make sure that the bottle does not fall from the conveyor in the empty condition at the
starting of conveyor.

1.3

Purpose:

The main objective of this system is to apply PLC to design automatic filling liquid system.

To drive the main objectives, there are several supporting goals are required to be
achieved.

To perform a filling liquid process into the bottle using PLC programming

To make a proper program for PLC in order to perform the activities.

To construct the actual working model of the complete system

1.4

Applications of the research

A small PLC will have a fixed number of connections built in for inputs and
outputs. Typically, expansions are available if the base model has insufficient
3

I/O. Modular PLCs have a chassis (also called a rack) into which are placed
modules with different functions. The processor and selection of I/O modules
are customized for the particular application. Several racks can be
administered by a single processor, and may have thousands of inputs and
outputs. Bottle filling system is an application of automation where we
developed a bottle filling and counting system.

1.5

Theoretical bases and Organization

The thesis consists of five chapters. A short explanation is introduced here:

Chapter 1: Introduction
This chapter discuss about the issue relating to the background of the thesis objectives
and research structure.
Chapter 2: Literature Review
This chapter discusses mainly about the automatic bottle filling ways.
Chapter 3: Tools and Techniques
This chapter discusses all the tools and software used for the project making
Chapter 4: Methodologies
The chapter 4 will focus on mainly to the procedure, method, and theory implementation
through simulation designing and of automatic bottle filling machine using PLC related
to the thesis topic.
Chapter 5:Result and Analysis
The automatic bottle filling machine using PLC is practically tested, and verified.
Chapter 6: Conclusion
Finally, a conclusion on the obtained results is presented. This also includes the novelties
within the work.

Chapter 2
LITERATURE REVIEW
2.1 What is a PLC?
A PROGRAMMABLE LOGIC CONTROLLER is a solid state control system that
continuously monitors the status of devices connected as inputs. Based
upon a user written program, stored in memory, it controls the status of
devices connected as outputs.

A digital electronic device that uses a programmable memory to store

instructions and to implement specific functions such as logic,
sequence, timing, counting and arithmetic to control machines and
process.

It uses a programmable memory to store the instructions and specific

functions that include On/Off control, timing counting, sequencing,
arithmetic and data handling.

A PLC is a computer designed to work in an industrial environment.

FIGURE: 1: PLC PROCESS

FIGURE: 2: CONTROL SYSTEM

2.2 History of PLC:

During the late 1960s, General Motors (USA) was interested in the
computer application to replace the hardwire systems.

Bedford Associates (Modicon) and Allen Bradley responded to General

Motors.

The name given was Programmable Controllers or PC.

Programmable Logic Controller or PLC was a registered trademark of

the Allen Bradley.

Later, PC was used for Personal Computer and to avoid confusion

PLC for Programmable Controller and PC for a personal computer.

2.3 Need for PLC:

Hardwired panels were very time consuming to time, debug and
change.
The following requirements for computer controllers to replace
hardwired panels.
1. Solid-state not mechanical.
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2. Easy to modify input and output devices.

3. Easily programmed and maintained by plant electricians.
4. Be able to function in an industrial environment.

2.4 Hardwire System and PLC:

FIGURE: 3: HARDWARE AND PLC

2.5 Comparison:
2.5.1 Hardware:

The functions are determined by the physical wiring.

Changing the function means changing the wiring.

Can be contact-making type (relays, contactors) or electronic type

(logic circuits)

2.5.2 PLC:

The functions are determined by a program stored in the memory.

The control functions can be changed simply by changing the program.

7

Consist of a control device, to which all the sensors and actuators are
connected.

2.6 PLC function:

FIGURE: 4: PLC FUNCTION

2.7 PLC Operating Cycle:

Four Steps in the PLC Operations

Input Scan

Program Scan

Processes the program logic

Output Scan

Scan the state of the Inputs

Energize/de-energize the outputs

Housekeeping

This step includes communications, Internal Diagnostics,

etc.

The steps are continually repeated - processed in a loop.

2.8 How Does a PLC Work:

The sensors are connected to the INPUT MODULES
The processor in the CPU MODULE executes the program and scans the
individual input for presence or absence of voltage Depending on the state of
the inputs, the processor directs the OUTPUT MODULES to switch voltages
The ACTUATORS or ANNUNCIATORS are switched ON or OFF according to
the

voltage

states.

FIGURE: 5: PLC WORKING

2.9 PLC Signal Flow:

FIGURE:
SIGNAL

6: PLC
FLOW

2.10
Ladder Diagram:
Very similar to traditional circuit diagrams, but the current paths are
arranged
horizontally

instead of

vertically.

FIGURE: 7: LADDER DIAGRAM

2.11 List of items required when working with

PLCs:
1. Programming Terminal - laptop or desktop PC.
2. PLC Software. PLC manufacturers have their own specific software and
license key.
3. Communication cable for connection from Laptop to PLC.
10

4. Backup copy of the ladder program (on diskette, CDROM, hard disk,
flash memory). If none, upload it from the PLC.
5. Documentation- (PLC manual, Software manual, drawings, ladder
program printout, and Seq. of Operations manual.).

2.12 PLC Applications:

Originally hardwired arrays of relays were used to control the operation

of heavy machines that contain motors and other high power devices.

PLCs were originally used to substitute the switching relay networks

used in industrial applications, but now they can also be used
implement other tasks such as timing, delaying counting, calculating,
comparing and processing of analog signals.

2.4

Summary

This section described all the theory and history of all the terms related to the automatic bottle
filling machine.

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Chapter 3
Software:
The software used in our project is following:

MIKRO C PRO Compiler

Proteus VSM

3.2.1 MIKRO C PRO :

3.2.1.1
Introduction to Compiler:
The C Compiler was developed exclusively for the PIC MCU - making it the most optimized
compiler for Microchip parts. The compiler has a generous library of built-in functions,
preprocessor commands, and ready-to-run example programs to quickly jump-start any project.
Drivers for real-time clocks, LCDs, A/D converters, and many more are innate features to the C
Compiler.

3.2.1.2

MIKRO C PRO Compiler Features:

Built in libraries that work with all chips for RS232 serial I/O, I2C, discrete I/O and
precision delays.

Integrates with MPLAB IDE and other simulators and editors for source level debugging.
Standard HEX file and debug files ensure compatibility with all programmers.

Formatted printf allows easy formatting and display in HEX or decimal.

Efficient function implementation allows call trees deeper than the hardware stack.

Source code drivers included for LCD modules, keypads, 24xx and 94xx serial
EEPROM's, X10, DS1302 and NJU6355 real time clocks, Dallas touch memory devices,
DS2223 and PCF8570 serial SRAM, LTC1298 and PCF8591 A/D converters,
temperature sensors, digital pots, I/O expander and much more.

12

Access to hardware features from easy to use C functions, timers, A/D, EEPROM, SSP,
PSP, USB, I2C and more.

1, 8, 16 and 32 bit integer types and 32 bit floating point.

Assembly code may be inserted anywhere in the source and may reference C variables.

Automatic linking handles multiple code pages.

Inline functions supported to save stack space; Linker will automatically determine the
best architecture or it can be manually specified.

Compiler directives determine if tri-state registers are refreshed on every I/O or if the I/O
is as fast as possible.

Constants (including strings and arrays) are saved in program memory.

Standard one bit type (Short Int) permits the compiler to generate very efficient Bit
orientated code.

#BIT and #BYTE will allow C variables to be placed at absolute addresses to map
registers to C variables.

Reference parameters may be used to improve code readability and inline function
efficiency.

PCW has both an integrated editor/compiler and command line compiler.

Special windows show the RAM memory map, C/Assembly listing, and the calling tree.

Interrupt functions supported on PCM/PCH. The compiler generates all startup and clean
up code as well as identifying the correct interrupt function to be called.

Plenty of ready to run example programs included.

Updates via the internet for 30 days included.

3.2.1.3

Benefits of MIKRO C PRO Compiler:

It provides a complete integrated tool suite for developing and

debugging embedded applications running on Microchip.
13

It produces a range of compilers that cover all 8 bit PICs and a few of
the higher spec chips.

The compiler quietly handles all sorts of complications and provides

you with a range of functions that handle most of the peripherals that
come integrated on a PIC chip.

3.2.2 Proteus VSM :

3.2.2.1
Introduction to Proteus:
PROTEUS VSM allows professional engineers to run interactive simulations of real designs,
and to reap the rewards of this approach to circuit simulation.
And then, a range of simulator models for popular micro-controllers and a set of animated
models for related peripheral devices such as LED and LCD displays, keypads, an RS232
terminal and more. It is possible to simulate complete micro-controller systems and thus to
develop the software for them without access to a physical prototype.
Structurally, Proteus 6 Professional separated into two main components, which are ISIS 6
Professional and ARES 6 Professional. ISIS 6 Professional mainly involved on circuit designing
and simulation.
ISIS 6 Professional: Circuit designing & simulation
ARES 6 Professional: PCB prototyping

3.2.2.2

Proteus VSM Features:

It provide features such as,

Fully featured schematic capture

Highly configurable design rules

Interactive spice circuit simulator

Extensive support for power plane.

14

3.2.2.3

Designing Circuit using ISIS Professional:

Following are the step to be followed to start designing a circuit:

Run ISIS Professional program by clicking ISIS Professional icon on desktop or go to

start windows>all programs>Proteus Professional>ISIS Professional. A splash screen will
appear.

A window appears once ISIS Professional is running, asking user whether to view
example of functional circuits or not. Since we going to design a new circuit then choose
NO.

The next step is to select all components needed. To choose a component, click the icon
button for component mode. Then click on P to pick from library. A window will open
where we can browse and choose components from the library browser.

In this component library browse, type any character of component and it will appear
automatically.

To place the components, click on a selected component list in devices box then single
click on the drawing area. The image of the selected component will appear. Then just
click on any part of drawing area to place the component.

To move a placed component just place the cursor on the component until the move icon
appear, then click hold and move the component anywhere in drawing areas.

To change the component orientation, just right click on the component and choose the
orientation you want.

Now place all the components needed in drawing area with right quantities to design
circuit.

To make wire connection, just place the cursor on component pin until red square appear,
then click on the component pin and wire mode start. Click again on the pin of other
component to join the wire. Join the wire to all components according to the circuit
designs.

15

To remove the wrong connection made, right click on the wire connection and choose
delete wire or just double right click on the wire.

To edit the wire, just select the selection mode and select the wire. We can drag or drop.

After done editing the design, you must save it. Now the ISIS design is ready for making
PCB design. To making PCB design, select tool and then select Netlist to ARES and
click. ARES Professional window will soon after we click on it.

A blank workspace will appear in ARES professional. To import all components from
ISIS design, select component mode on ARES professional. All components used in ISIS
design will be listed in component box. A listed component will disappear from
components box once we place it in the workspace.

To begin with, first we must set border for PCB design. To do so select 2D graphic board
mode and go to layer selector and choose board edge.

Then draw the border inside the ARES professional workspace. Do not worry about the
size of the board we draw because it can be adjusted afterward.

Now select component mode again, then select the component and place it in the board
edge we have drawn earlier. To place, delete and edit position of components, the method
is the same as in the ISIS. Green lines show the connection between components that has
been designed in ISIS.

If the drawn board border is not big enough, we can edit the size just by clicking on the
border line until green rectangles appear on the border line. Click, hold, drag and release
the line. To exit border editing mode just click on the workspace.

After placing all components, try to design a more suitable design by repositioning the
components and minimizing the space.

Now we have to route the design. Select track mode, then we can place the copper
connection in the design. The width of copper traces connection can be edited by
selecting the traces type in traces box by clicking E (edit) or right click mouse on selected
trace type and choose edit. A editing windows will appear. To create a new type of trace
just click C (create). A creating window will appear.
16

Make sure to change the traces selector to bottom copper for single layer PCB board.

Select the traces type you want and make the copper connection route. The method is
similar to wire connection in ISIS. Make sure the copper connections do not intercept
each others. Use the green line as guide to make copper connection.

If you want to delete the entire route just click outside the board border and select all
designs, the press delete button on keyboard.

After deleting the entire route, you can begin to reroute the copper connection again.
There is auto routing function to automatically route all the copper connections. Select
Tools on menu bar and click auto router.

3.2.2.4

Proteus VSM Advantages:

The Proteus Design Suite is wholly unique in offering the ability to cosimulate both high and this Virtual System Modeling facility, you can
transform your product design cycle, reaping huge rewards in terms of
reduced time to market and lower costs of development.
If one person designs both the hardware and the software then that person
benefits as benefits as the hardware design may be changed just as easily as
the software design.
In short, Proteus VSM improves efficiency, quality and flexibility throughout
the design process.

17

Chapter 4
METHODOLOGIES
4.1

Circuit Theory:

4.1.2.2

Block Diagram Explanation:

The block diagram covers the three basic parts of the bottle capping mechanism. Starting from
the infrared sensor that senses the presence of the bottle under the capping motor. Then the
robotic arm manages the position of the bottle right under the cap. Then the plc activates the
capping motor to perform the task.

4.1.3.3

Circuit Function:

The circuit includes the system of the sensors as for the time when no bottle is found on any
specified place the belt will rotate and for the time when the bottle found on any required
position the system motor will stop the belt for the required time.

4.1.1 Infrared sensing system:

18

This section includes a microcontroller that simply gets the infrared signals
from the model and performs the required tasks.

4.1.4.1

Block Diagram:

BLOCK DIAGRAM: 6: INFRARED SIGNAL SYSTEM

4.1.4.3

Circuit Function:

The circuit includes allt eh wiring required for the infrared sensing system. The sensor output is
interfaced with the PLC so that at every signal reception the PLC works as per requirement.

4.1.2 Temperature and humidity M & C system:

19

This section describes the function of temperature and humidity values. This
circuit performs the regulation of the environmental conditions.

4.1.4.1

Block Diagram:

BLOCK

DIAGRAM: 7:
T & H MEASUREMNET AND CONTROL SYSTEM

4.1.4.2

Block Diagram Explanation:

The block diagram includes temperature sensor humidity sensor, relay control system and LCD
module on which all current and set values would be shown.the microcontroller is the brain of
the system that measures and compares the values with the set values and performs the control
tasks.

4.1.4.3

Circuit Function:

The circuit processes the temperature and humidity values of the current time and compares
those values with the set ones. For any inconvenience the PLC system would be stopped so that
no loss occur while both or any one of those parameters are not in range.

4.2

Software designed for Control Systems:

20

4.2.1 T & H measurement and control system:

4.3.1.1

Overview:

This section includes the software writing of the circuit temperature and humidity control system
The circuit performs the t &h measurement and hence if the TH is higher then set values it
performs control process to overcome this system loss.

4.3.1.2

What We Want To Do:

The system is required to maintain a specific temperature and humidity level for the process so
that the other devices dont get burned or damaged while working on the inappropriate
environmental conditions.

4.3.1.3

Software Description:

4.3.1.3.1

Function Set Variables:

Set the temperature and humidity variable values

4.3.1.3.2

Function Of Delay:

Give 500ms delay.

Then restart the remaining portion.

4.3.1.3.3

Display Routine:

Take the variables values.

Then set it to the 4 bit mode data.

Then transfer it to the LCD display registers for display purpose.

4.3.1.3.4

Main Function Steps:

Initialize ports.

Initialize the displays.

Then take value of the temperature and humidity.

21

Then update the variables

Then compare with the set values

Then control the PLC function accordingly

Then display all the value over LCD screen

22

4.3.1.3

Software State Machine:

in itialize
p orts

d isp lay valu es on lcd

an d co ntrol relays

Initialize
b uiltin
libraries

decod e the
valu es into
decim als

g et bytes of
tem p erature an d
h um idity

STATE MACHINE: 1: STATE MACHINE OF T & H M & C SYSTEM

23

Chapter 5
RESULTS AND ANALYSIS
5.1

Presentation of the findings

The results as hardware and as simulations are shown below.

5.2

Discussion of the findings

Reduces the labour errors Introduces automation

Reduces overall processing time Each important individual part required for
autoclaving/sterilization can be removed easily

Can run in dry and wet conditions.

PLC gives ease of operation and it is flexible because can be used for other devices too.
Machine height can be adjusted to match with other machines so as to synchronize with
each other efficiently.

Useful in food processing industries, Pharmaceuticals, Cosmetic applications and other

relevant companies / industries

24

5.3

Limitations

Too much congested bottle positioning is not accommodated in this pattern.

The size and shape of bottles is defined and specific so not for random bottles.

Water cane do not have automatic refilling system

5.4

Recommendations

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.

5.5

Summary

This chapter discusses all the software and hardware results of the power factor improvement
system using static capacitors

25

Chapter 6
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.

26

REFERENCES

http://ijsr.net/archive/v3i7/MDIwMTUxNg%3D%3D.pdf

http://ijiere.com/
(X(1)S(kvypfqqopo5sussk2wk1o2e0))/FinalPaper/FinalPaper2014112873628814.pdf

http://www.slideshare.net/ShankarJothyraj/plc-basic

http://www.slideshare.net/mehviish/industrial-automation-22756789

http://www.omronkft.hu/nostree/pdfs/plc/zen/z211-e1-03.pdf

www.scribd.com/doc/52072959/Automatic-Bottle-Filling-System-Using-Plc-s-WithConveyor-Model

//www.scribd.com/doc/38241228/Project-Work-on-Automatic-Control-of-Bottle-FillingSysstem-by-Using-PLC-With-Conveyor-Model

http://electrical-engineering-portal.com/download-center/books-and-guides/electricalengineering/plc-theory-and-implementation

27

APPENDICES
Appendix A

28

Appendix B

29