International Conference on Advances in Human Machine Interaction (HMI - 2016),

March 03-05, 2016, R. L. Jalappa Institute of Technology, Doddaballapur, Bangalore, India

Vision based Bottle classification and Automatic

Bottle Filling System
K.Thiyagarajan Meenakshi.R Suganya.P
M.Tech Control&Automation M.Tech Control&Automation M.Tech Control&Automation
SELECT School SELECT School SELECT School
VIT University,Vellore-14 VIT University ,Vellore-14 VIT University,Vellore-14
thiyagarajreddy@gmail.com meenakshir734@gmail.com suganya19193@gmail.com

Abstract— A method is proposed in which the camera III. IMPLEMENTATION

captures the logo of the bottles continuously to fill the bottles
with different liquids on a single conveyor based on logo of the Our paper gives brief explanation about various processes
bottles. We have used cross correlation image classification involved in this automatic bottle filling system. Our system is
method to classify the logo image of the bottle. Accordingly, we composed of hardware and software module. The software
have filled the liquids in the bottle. In this system, we interface module consists of MATLAB and PLC Ladder diagram. The
the result of image in MATLAB R2013 with PLC using Arduino. hardware module consists of arduino, PLC, IR sensors, motor,
camera and valves. The process involved in this project is
Keywords— MATLAB, PLC, Arduino, Vision, Bottle filling. explained below.
A. Block Diagram
I. INTRODUCTION
Image processing
Nowadays, bottle filling in industries requires automation
for optimization and precise filling. In this work, instead of WEBCAM MATLAB ARDUINO
manually filling liquids in the bottles, we are filling it Control signal 5V
automatically using PLC. In other work [2],100% quality
inspection is required for reliable filling, Many additional
RELAY
features like calculating the number of bottle, user defined 24V
volume selection in percentage using PLC were discussed in
the work [3], In the work [4], they have proposed a system to 24V
fill the liquids in to the bottle of different height fully PLC
controlled by PLC, They have proposed a method to fill the
bottles with same liquid and they have discussed about the
automatic bottle filling system using PLC based on the user Fig.1.A block diagram for interfacing part
defined volume selection in the work [5]. In our proposed
method, automatic filling system is introduced based on the
vision system. Here we allocate the different timing interval to Input modules Output modules
positioning the bottles at corresponding valves position.
Arduino MOTOR
II. METHODOLOGY
In this method, we are fixing the web camera at an optimum
location. Where the camera captures the images of logo on the
bottle, then logo of the bottle is compared with the reference IR Sensor 1 PLC VALVE 1
logo by cross correlation method to classify image. If it is
matched, then conveyor starts and by interfacing the
MATLAB with arduino, where arduino gets the signal and it
sends the signal to the PLC program. After that, PLC allocates VALVE 2
time for positioning the bottle to the corresponding valve IR Sensor 2
position. If bottle is positioned at particular valve, then the
valve opens for given specified time based on user defined Fig.2.A block diagram for hardware module
volume selection, to fill the liquid in the bottle.

978-1-4673-8810-8/16/$31.00 ©2016 IEEE

 International Conference on Advances in Human Machine Interaction (HMI - 2016),
March 03-05, 2016, R. L. Jalappa Institute of Technology, Doddaballapur, Bangalore, India

First, camera is fixed in a suitable position. It starts

capturing the images continuously. When it captures the image C. Flow Chart
of the logo then captured image is compared with sample
image by normalization method using cross correlation START
technique. Camera and Arduino is interfaced with MATLAB.
If camera captures the image like sample one, then arduino
gets the signal from MATLAB and arduino port gives 5V
output as shown in the fig 1. This output is connected with Camera
PLC by means of relay. Then according to the ladder logic
program, the process is executed based on input & output
module as given in fig 2.
Captured image
B. Steps Involved

Step 1:
At first, camera and arduino is interfaced with Loading image in
MATLAB. Then images of logo are captured by camera. Here MATLAB
we consider two different logo of the bottle that is sample 1
and sample 2 for comparison.

Step 2: Image processing

The captured image is converted to grayscale image from is done
RGB. After that, we compute the normalized cross correlation
of the matrices sample and gray scale image of captured one.
The matrix of gray scale image must be larger than the matrix
of sample image for meaningful normalization. The values of Arduino is interfaced
the sample cannot be same. The resulting matrix contains the with PLC
correlation coefficients, which can range in value from -1 to 1.
Resulting matrix = normxcorr2 (sample, gray scale image
of captured one);
Object detector
Step 3:
If the maximum of resulting matrix is greater than or
equal to 0.8, then arduino gets the signal and gives 5V output.
If the camera captures the logo like sample 1, then arduino Motor
port 5 will enable and gives 5V for 5 sec. If the camera runs
captures the logo and it is matched with sample 2, then
arduino port 6 will enable and gives 5V output for 5 sec.

Step 4:
Arduino port is interfaced with input module of PLC.
When arduino gives output, then motor start to run and then it IR
moves the conveyor belt. If the arduino port 5 is enabled, that Sensor is
triggers the object detector 1 in the ladder logic. If port no 6 of
detected
arduino is enabled, that triggers the object detector 2 in the
ladder logic program. Yes No
Step 5:
When the object detector 1 gets the signal, the motor
runs until the IR sensor 1 is sensed. When IR sensor 1 is Stops the motor & Run the motor until the
sensed, stops the motor and opens the valve 1 for 5secs. the valve is opened sensor is detected
Likewise if the object detector 2 gets the signal, the motor
runs until the IR sensor 2 is sensed. When IR sensor 2 is get
sensed, stops the motor and opens the valve 2 for 5secs to fill Stops the motor and
the liquid. The above described steps are shown in fig 3. After time delay
dispatch, after some
again runs the motor
delay

Fig.3.Flow chart of the entire system

978-1-4673-8810-8/16/$31.00 ©2016 IEEE

 International Conference on Advances in Human Machine Interaction (HMI - 2016),
March 03-05, 2016, R. L. Jalappa Institute of Technology, Doddaballapur, Bangalore, India
IV. RESULT & DISCUSSION
Simulation was carried in Siemens PLC S71200, with the
help of Ladder logic diagram written in Siemens TIA portal
V13. Using web camera, we continuously captured the image.
When it captures the logo of the bottle, it starts comparing that
captured one with samples. If MATLAB detects the logo, then
runs the motor by sending signal to the arduino port. Sample
logo and Captured image of logo is given in figure 4 & figure
5 respectively. The results were as good as expected and
shown in the figure.
Fig.4.Sample 1 and Sample 2
Fig.5.Captured image of the logo 1 and 2 respectively
When motor runs, bottle starts moving on conveyor
belt. When bottle with logo1 is detected by IR sensor 1, stops
the motor, opens the solenoid valve 1 and waits for 5 sec to fill
the liquid. Similarly if logo 2 is detected, then corresponding
valve 2 will be open. After bottle filling, again motor runs for
some time and then stops & dispatch the bottle at the end.
The hardware arrangement of automatic bottle filling
system is given in fig 6.
Fig.6. Automatic bottle classification and filling system
978-1-4673-8810-8/16/$31.00 ©2016 IEEE
CONCLUSION
We have done cross correlation algorithm in MATLAB
and we have obtained fine result. The proposed method can
use more samples for filling different liquids. This application
can be useful to fill different volume selection also. Many
features can be added to this system depending on shape, size
and weight of the bottle and filling operation can be processed.
References
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