Automatic Bottle Filling System Using Programmable logic

controller

Author(s)
Mashal Noreen Hashmi UET-15A-APCOMS-BSc-EE-15
Mehmood-Ur-Rehman UET-15A-APCOMS-BSc-EE-54
Muhammad Ikram Ashraf UET-15A-APCOMS-BSc-EE-76

Supervisor

Engr Yasir Siddique Anjum

Assistant Professor

DEPARTMENT OF ELECTRICAL ENGINEERING

ARMY PUBLIC COLLEGE of MANAGEMENT AND SCIENCES
Affiliated with
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
TAXILA

June 2019
Automatic Bottle Filling System Using Programmable logic
controller(PLC).

Authors

Mashal Noreen Hashmi UET-15A-APCOMS-BSc-EE-15

Mehmood-Ur-Rehman UET-15A-APCOMS-BSc-EE-54
Muhammad Ikram Ashraf UET-15A-APCOMS-BSc-EE-76

A thesis submitted in partial fulfillment of the requirements for the degree of

B.Sc. Electrical Engineering

Thesis Supervisor:

Engr Muhammad Yasir Siddique Anjum

Assistant Professor-Department of Electrical Engineering

External Examiner Signature:___________________________________________

Thesis Supervisor Signature: ___________________________________________

DEPARTMENT OF ELECTRICAL ENGINEERING

ARMY PUBLIC COLLEGE of MANGAEMENT AND SCIENCES
Affiliated with
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
TAXILA
July 2019
 ABSTRACT

This paper emphasis on the major component of industries, we will build a

Programmable Logic Control (PLC) controlled automatic bottle filling system. We will
make a mechanical model of the industrial filling system, complete with sensors, motors,
actuators, capping unit etc, and will control the whole process of bottle-filling using the
PLC. This system consists of an assembly line, and when a bottle reaches the filling
station, a fixed amount of liquid is filled into the bottle, and then it moves towards the
end of the assembly line to make way for another bottle to be filled-up and finally a
capping unit will close the respective bottle by using robotic hand. Although this type of
PLC controlled systems already exist in the industries but over project is an advanced
version of it. we are designing and implementing the system that can fill bottles of
different size and heights, we obtained experience on how to design practical industrial
systems and control those using PLCs.
Keywords: PLC, Assembly line, robotic hand

i
 UNDERTAKING

I certify that research work titled “PLC controlled automatic bottle filling system” is my

own work. The work has not been presented elsewhere for assessment. Where material

has been used from other sources it has been properly acknowledged / referred.

Signature of Student

Mashal Noreen Hashmi

UET-15F-BSc-EE-APCOMS-15

Signature of Student

Mehmood-Ur-Rehman

UET-15F-BSc-EE-APCOMS-54

Signature of Student

Muhammad Ikram Ashraf

UET-15F-BSc-EE-APCOMS-76

ii
 ACKNOWLEDGEMENTS

First of all, we are grateful to the almighty Allah for giving us this opportunity to
complete the project.

We would like to thank Sir Yasir Sidduue Anjum, Assistant Professor, Department of
Electrical Engineering (EE), APCOMS (Army Public college of management and
sciences) Rawalpindi, our supervisor, for her constant guidance, supervision, constructive
suggestions and constant support during this project work. We are extremely thankful abd
indebted to him for sharing expertise, and sincere valuable guidance and encouragement
extended to us. I take this opportunity to express gratitude to all of the Department of
faculty members for their help and support.

At last we want to thank our parents and all our friends for their moral support and
helpful discussion during this project work.

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 TABLE OF CONTENTS

Sample is given below:

Abstract ................................................................................................ ………...i

Acknowledgement ..............................................................................................iii

List of Figures ..................................................................................................... vi

List of Tables......................................................................................................vii

Abbreviations ....................................................................................................viii

Chapter I: Introduction ......................................................................................... 1

1.1 Statement of the Problem ..................................................................... 1

1.2 Objective ............................................................................................... 1

1.3 PLC Controlled Automatic Bottle Filling System…………………2

1.4 Features of the Proposed System ……………………………………..2

1.5 Components………………………………………………………….3

1.5.1 PLC………………………………………………………………..3

1.5.2 Conveyor belt………………………………………………………..4

1.5.2 Sensors………………………………………………………………5

1.5.2.1 Photoelectric sensor……………………………………………….5

1.5.2.2 Liquid level sensor…………………………………………………6

Chapter II: Literature review…………………………………………………7

Chapter III: Block diagram and flow chart…………………………………..10

3.1 Block Diagram Explanation……………………………………………10

3.2 Flow Chart ………………………………………………………………11

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3.2.1 Flow Chart Explanation……………………………………………………..12

Chapter IV: Methodology………………………………………………………....13

4.1 Description of the Proposed System…………………………………………..13

4.1.1 Conveyor Belt Mechanism …………………………………………….....13

4.1.2 Bottle Detection Mechanism ……………………………………………..14

4.1.3 Liquid Flow Control Mechanism from Overhead Tank to the Bottle ……14

4.1.4 Liquid Level Maintaining Mechanism at the Overhead Tank ……………14

4.2 Major Components of the System …………………………………………......15

4.2.1 PLC Module……………………………………………………………….15

4.2.2 Conveyor Belt …………………………………………………………….16

4.2.2.1 Steel Panel……………………………………………………………..16

4.2.2.2 Rollers and bearings……………………………………………………..16

4.2.3. Sensor ……………………………………………………………………..17

4.2.3.1 Photoelectric sensor……………………………………………………...17

4.2.3.2 Liquid level sensor………………………………………………………….17

4.2.4 Motors………………………………………………………………………...18

4.2.4.1 DC gear motor……………………………………………………………....18

4.2.4.2 DC pump motor……………………………………………………………..19

4.2.5 Solenoid valve………………………………………………………………...20

4.2.6 Reservoir………………………………………………………………………20

4.2.6.1 Overhead tank……………………………………………………………….20

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4.2.6.2 Main reservoir ..................................................................................................20

4.2.7 Arduino Uno…………………………………………………………………….21

Chapter V: Software…………………………………………………………………..22

5.1Ladder logic diagram………………………………………………………………22

5.2 Data collection and experiment on hardware……………………………………..26

5.2.1 Height of Bottles……………………………………………………………….26

Chapter VI: Hardware Construction………………………………………………….27

6.1 Construction of Conveyor Belt…………………………………………………...27

6.2 Conveyor belt motor connection………………………………………………….27

6.3 Construction of the Filling Station………………………………………………..27

6.4 Photoelectric sensor connection…………………………………………………..28

6.5 Liquid level sensing………………………………………………………………28

6.6 Solenoid valve connection………………………………………………….…….28

6.5 Construction of Main Reservoir with DC Motor Pump…………………………..29

6.6 Capping unit……………………………………………………………………....29

Chapter VII: Conclusion……………………………………………………………...30

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 LIST OF FIGURES

Fig 3.1 Block diagram overall system ...........................................................11

Fig 3.2 Flow chart of the bottle sensing and filling system………………. 12

Fig4.1 PLC Module …………………………………………………….... 17

Fig 4.2 Photoelectric sensor ...........................................................................18

Fig 4.3 DC gear motor. ..................................................................................19

Fig 4.4 DC Pump Motor…………………………………………………….20

Fig 5.1 Ladder Logic diagram……………………………………………….24

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LIST OF TABLES

Tab 4.1 DC pump motor specifications…………………………………… 19

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 CHAPTER 1

INTRODUCTION
The current scenario in industries is to embrace new technologies and to proceed towards
automation. The same vision is exercised in bottle filling industries like Beverages
industries and Mineral water industries. Industries mainly focus on innovative
technologies that can make their system more efficient and reduce their labor. Industries
embrace technologies which are less expensive and can replace expensive machineries.
To meet the customer demands and accelerate the filling of bottles, all operations are
nearly automated. One of the important applications of automation is in the soft drink and
other beverage industries, where a particular liquid has to be filled continuously. The
automation in bottle filling industry comes with increased electrical components.
Essential requirements of each components in the system is important to be studied in
ordered to understand how each part works in coordination with other part in the system.
For these kinds of applications the trend is moving away from the individual device or
machine toward continuous automation solutions. Totally Integrated Automation puts this
continuity into consistent practice. Our project is also an application of automation
wherein we have developed a liquid filling to bottles of different height.

1.1 Problem Statement

The problems that are existing in the present machines are that it can fill only a particular
type of bottle of certain height, and the filling amount is as set by the operator. If the
machine has to fill different type (size) of bottle then again the operator has to set the
filling amount for each bottle. Time taken for filling will become more in such
conditions. Sometimes in special environments which are dangerous and not conductive
for human operation, the operator cannot go and set the filling amount. By this the rate of
production was affected due to the use of manual inspection systems. In some industries
filling stations are separate for different bottles so this makes it expensive and space
consuming.
1.2 Objective

The main objective of this project is to design and develop a system with programmable
logic controller which can fill different sizes of bottles on the bases of height. We aimed
to develop a system whose principle can be used in different industries like medicine, oil,
chemical industries for filling liquid to different sized component by machine. Cost is a
crucial factor to keep in mind when designing a system. We also aimed design a system
with less cost.

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Many industrial processes are now dependent on automatic machinery. The transition
from manual systems to automatic systems was necessary to optimize the rate and
capacity of production . To control an industrial process, a special microprocessor based
controller called the programmable logic controller (PLC) is used. There are many
advantages of using PLCs in process control. These controllers are built to withstand the
harsh environment of industry floor (i.e. protected against dust, moisture, hot and cold
temperatures etc.), so these do not need special housing or protection. The PLCs are also
built in a way so that the electronic circuitry of the controllers is not affected by moderate
amount of noise.

1.3 PLC Controlled Automatic Bottle Filling System

As part of our project, we have developed a hardware model of a liquid filling system,
and the process is controlled using a PLC. It is an automatic process where empty bottles
are first placed on the conveyor belt. As an empty bottle is brought to the filling station,
the belt stops to let the bottle fill-up with a fixed amount of liquid. The liquid is kept at an
overhead tank near the filling station. After the bottle is filled-up, the belt starts again to
move away the filled-up bottle and to bring another empty bottle to the filling station.

The whole process consists of three tasks:

• Filling bottles one after another with the desired level of liquid. 


• Timely refilling the overhead tank to continue smooth operation. 


• Controlling of the liquid flow from the reservoir to overhead tank.


 1.4 Features of the Proposed System 


Our proposed system has the following features: 


• Detection of the presence of a bottle using sensor 


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 • Timer based automatic bottle filling 


• Control of the liquid level of the overhead tank 


1.5 Components

1.5.1 PLC
A programmable logic controller (PLC) is used for automation of electromechanical
processes, such as control of machinery on factory assembly lines, amusement rides, or
lighting fixtures. PLCs are used in many industries and machines. 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.
All PLCs have the same basic components. These components work together to bring
information into the PLC from the field, evaluate that information, and send information
back out to various field. Without any of these major components, the PLC will fail to
function properly.
The basic components include a power supply, central processing unit (CPU or
processor), co-processor modules, input and output modules (I/O), and a peripheral
device.

There are six major advantages of using PLCs over relay systems as follows:

 Flexibility
 Ease of troubleshooting
 Space efficiency
 Low cost
 Testing

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  Visual operation

Flexibility: One single PLC can easily run many machines.

Ease of Troubleshooting: Back before PLCs, wired relay-type panels required time for
rewiring of panels and devices. With PLC control any change in circuit design or
sequence is as simple as retyping the logic. Correcting errors in PLC is both fast and cost
effective.
Space Efficient: Fewer components are required in a PLC system than in a conventional
hardware system. The PLC performs the functions of timers, counters, sequencers, and
control relays, so these hardware devices are not required. The only field devices that are
required are those that directly interface with the system such as switches and motor
starters.
Low Cost: Prices of PLCs vary from few hundreds to few thousands. This is minimal
compared to the prices of the contact, coils, and timers that companies pay to match the
same things. Using PLCs also saves on installation cost and shipping.
Testing: A PLC program can be tested, evaluated, and validated in a lab prior to
implementation in the field.
Visual observation: When running a PLC program a visual operation displays on a screen
or module mounted status lamps assist in making troubleshooting a circuit quick, easy,
and relatively simple.

Some other features of PLC are•

• A PLC performs only a single set or sequence of tasks, with greater reliability and
performance, except when it is under real-time constraints. This is in contrast to regular
PCs and smartphones that are designed to execute any number of roles simultaneously
within the Windows framework.
• The PLC has a number of features that you don’t find in normal computers, such as
protection from the open area conditions like heat, dust and cold.
• It is low cost compared with other microcontroller systems. When you’re using a PLC
in various applications, you only need to change the software component for each
application. With other microcontroller systems however, you would have to change the
hardware components too with different applications.

1.5.2 Conveyor belt

One of the basic tools in material handling industry, belt conveyors are most commonly
used in transportation of bulk materials (grain, salt, coal, ore, sand, etc.).
Belt conveyor systems consist of two or more pulleys (a.k.a. drums). An endless loop of
carrying medium—the conveyor belt— rotates about them. To move the belt and the
material it carries forward, one or both pulleys are powered. The powered pulley is called
“drive pulley,” the unpowered one is known as “idler pulley.” Belt conveyors in general
material handling such as those moving boxes along inside a facility form a different
class of belt conveyors from those that are used to transport large volumes of resources
and agricultural materials.
Based on the proposed use, conveyor belts are manufactured using either PVC or rubber.
The belt consists of one or more layers of material. Most belts in general material
handling consist of two layers. Carcass is the name of the under layer that provides linear

4
strength and shape, while cover is the name of the over layer. Polyester, nylon and cotton
are used most often to create the carcass, while a variety of rubber or plastic compounds
specified by use of the belt are used to create the cover.

1.5.2 Sensors
1.5.2.1 Photoelectric sensor
A photoelectric sensor is an instrument designed to detect the distance, absence, or
presence of an object by using a light transmitter such as an infrared, and a photoelectric
receiver. They are also referred to as photo eyes.

Photoelectric sensors are widely used in the industrial manufacturing sector as they
provide a huge variety of problem solving alternatives in the industrial sensor market.
Photoelectric technology has advanced a lot and a sensor is now able to detect a target
less than 1 mm in diameter. Photoelectric sensors can be easily incorporated into an
endless array of applications.

Photoelectric sensors contain the following components:

 Emitter - A light source such as an LED or laser diode

 Photodiode/phototransistor receiver - To detect the light source

5
  Supporting electronics - For amplifying the signal relayed from the receiver.

A photoelectric sensor is an instrument designed to detect the distance, absence, or

presence of an object by using a light transmitter such as an infrared, and a photoelectric
receiver. They are also referred to as photo eyes.

Photoelectric sensors are widely used in the industrial manufacturing sector as they
provide a huge variety of problem solving alternatives in the industrial sensor market.
Photoelectric technology has advanced a lot and a sensor is now able to detect a target
less than 1 mm in diameter. Photoelectric sensors can be easily incorporated into an
endless array of applications.

Photoelectric sensors contain the following components:

 Emitter - A light source such as an LED or laser diode

 Photodiode/phototransistor receiver - To detect the light source
 Supporting electronics - For amplifying the signal relayed from the receiver

1.5.2.2 Liquid level sensor

For sensing the level of liquid in the overhead tank, we made a sensor ourselves. It uses
the electricity conducting property of liquids. We used three nodes to sense the level of
liquid, (a) the upper level node, (b) the lower level node, and (c) the common node. The
common node is connected to one end of a 24 V DC supply. These sensors are basically
S.S. nut bolts which are wired in such a way that, when the liquid in the tank is in contact
with the common node and any other (upper/lower level) sensors, an electrical circuit is
completed. This condition is detected by the PLC to understand whether the overhead
tank is low in liquid, or has sufficient liquid.

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7
 CHAPTER 2

Literature Review
In order to work our project, we have examined many projects related to our idea. Many
projects related to our idea have been implemented but we are now bringing innovative
technique to implement our idea.
The automation of bottle filling involves use of PLC for control but it is costly. Despite
of all such advance technologies in small industries are still involved in manual filling of
bottles. They might be discouraged to adopt to new technology due to high cost involved
in automation. The study emphasis on reduction in cist using PLC. The PLC is relatively
economical and widely available. In small industries bottle filling operation is done
manually. The manual filling process has many shortcomings like spilling of water while
filling it in bottle, equal quantity of water ay not be filled, delay due to natural activities
of human etc. This work generally emphasis in small industries. it aims to eliminate
problem faced by small scale bottle filling system. With this system that operates
automatically, every process can be smooth and the process of refilling can reduce the
men power cost and operation time.

In past, manual involvement were the main way for controlling a system. More recently,
Electricity has been used for control and electrical control is based on PLC purposes like
medicines, pharmaceutical plants, chemical plants etc. There PLC control the complete
working of the system. It is common to use PLC to make simple logical control decision.
The automation in bottle filling industry comes with increased electrical components.
Essential requirements of each component in the system is important to be studied in
ordered to understand how each part works in coordination with other parts in the system.
This study mainly includes design, fabrication and control system for automated bottle
filling system. The main part is control system which includes programming in PLC to
control various components in system. A conveyor belt system with sensors and valve is
fabricated for this purpose. The entire sequence of operation is controlled by PLC.

An attractive feature which made PLCs so popular is that, the same PLC can be re-
programmed (using only software) to perform another task or control another process.
Before the introduction of PLCs, electrical relays were used to automate processes, and
the relays needed to be physically re-wired if these were intended to control another
process. PLCs can be programmed many times to do different tasks. Besides in
industries, PLCs are also used in building management systems (BMS), amusement
parks, mills, water and waste treatment plants etc. The PLCs read the input states of
switches, sensors etc. and can drive motors, relays, solenoids etc.

One of the many uses of PLCs in industries is in assembly lines involving packaging.
Especially in pharmaceuticals, beverage industries, mineral water packaging plants etc., it

8
is required to fill-up a bottle with a certain amount of liquid. In these systems, empty
bottles are put on a conveyor belt which brings these to the filling station. At the station,
the bottles are automatically filled-up and then moved along the conveyor for further
stages to perform other tasks such as cap fitting or packaging etc.

In Industrial Area, where liquid is used as a product, offers opportunities that can be
transformed into success only by those companies that have technology to take it beyond
competition. High degree of flexibility is it’s prior need. Also industries face many other
challenges. The pressure to continually increase production volumes has stressed older
systems and has increased maintenance requirements. For manufacturers, this creates two
problems: higher costs and increased efficiency. Production managers are being
challenged to reduce cost and wastage. New technologies are required that will reduce
water usage, increase energy efficiency and minimize time cycle in high-speed beverage
production environment. Increasing competitive pressures, even more stringent legal
regulations, raising costs of commodities and energy and consumers whose preferences
are subject to rapid change. beverage companies today are forced to increase their
flexibility and operate with maximum efficiency at the same time. The key to this
problem is an integrated process approach. After all, if all processes are perfectly
coordinated with each other and reliable communications have been established between
all parts of the manufacturing plant, it is much easier to address the big challenges. In
small industries, the refilling system usually operates in manual mode and even this is
true for some other industries also. Literature suggests PLCs are being used in these
industries as it brings a cost effective and economical solution for controlling the process.
We have used two types of sensors: Photoelectric sensor and liquid level sensor.
Photoelectric sensor is used to detect the presence of bottle and liquid level sensor is used
to determine the level of liquid. The operating voltage of photoelectric sensor is 10-30V
DC.
Bottles are kept over a conveyor belt; they are sensed to detect their presence.
Photoelectric sensors are used for sensing the bottles. Depending on the output of the
sensor the corresponding valve switch on and filling operation takes place. If particular
bottle is not present then the valve switch on and filling operation takes place. If the
particular bottle is not present then the valve in that position that is switched off, thereby
avoiding wastage of the liquid. The filling process is done based on timing. Depending on
the present value of the timer the valve is switched on for that particular period of time
and the filling is done.
In filling scenarios, filling unit consist of overhead tank, photoelectric sensor, flow
control (solenoid) valve connected to liquid tank. After inspection done by inspection
unit the container comes below the valve and when it sense the container the conveyor
stops, then the solenoid valve get ON and fills the liquid to the component based on the
inspection given. Y inspection unit(i.e. which size container has to be filled). Liquid will
continue to flow as soon as the conveyor stops. The input to solenoid valve is given by
PLC. Liquid flow is controlled by timer. The timing of solenoid valve and conveyor
stopping is set by the timers. The overhead tank will supply liquid to the solenoid valve.
After filling liquid to container the solenoid valve gets OFF and conveyor starts to run
and automatically cycle repeats.

9
Different projects are based on different conveyors. Conveyors can be made according to
our needs and demands. Their lengths and widths can be changed to our requirements.
Conveyors vary according to products. Containers or bottles have different conveyors as
compared to other products. Conveyors makes it easy for us to move objects in the types
of projects. Many functions can be performed when objects are on conveyor.

10
 CHAPTER 3

Block Diagram and flow chart

3.1 Block Diagram Explanation

The block diagram of this project is given below.

Figure 3.1

The above diagram shows the entire process of our project.

11
3.2 Flow chart

Figure 3.2 shows the flow chart of the bottle sensing and filling system.

12
3.2.1 Flow chart Explanation

When the system is powered on, the conveyor belt starts running. The conveyor belt
keeps running if the photo electric sensor does not detect the presence of any bottle in
front of it. If the sensor detects any bottle then the conveyor belt stops, solenoid valve
opens and bottle filling starts. We control the amount of liquid filling with a timer.
Depending on the timer’s time duration, the opening of the valve is decided. The solenoid
valve then closes and after some time delay conveyor belt starts again with the filled
bottle and carries the bottle to the other end where in capping unit task of bottle capping
is performed by a robotic arm and then the bottle is collected by an attendant.

3.2.2 Flow chart for maintaining liquid level at the overhead tank

13
 CHAPTER 4

Methodology
Bottles are kept in a position over a conveyor belt. Conveyor belt rotates continuously

until the photoelectric sensor detects the bottle. Bottles are sensed to detect their

presence. Photoelectric sensors are used for sensing the bottles and their heights. Then

after detecting a specific bottle, filling process take place according to its heights. Filling

time has been set according to their height.

4.1 Description of the Proposed System

The design of the system can be divided into several parts. They are (1) the conveyor belt
mechanism to move the bottles from one end of the assembly line to the other, (2) the
mechanism for accurate positioning of the bottles under the overhead tank to be filled up
by liquid, (3) the mechanism for controlling the flow of liquid to the bottle, and (4) liquid
level maintaining mechanism at the overhead tank.

4.1.1 Conveyor Belt Mechanism

The conveyor belt mechanism consists of a belt and rollers with DC gear motor. It is
coupled with two rollers and runs continuously with the support of a DC gear motor
when a start button is pressed. The conveyor belt carries the bottle along the assembly
line to be filled up with liquid up to a particular level and then the conveyor belt runs
again to take the filled up bottle to the other end to be collected by an attendant.

4.1.2 Bottle Detection Mechanism

The task of bottle detection is performed using a photoelectric sensor. A photoelectric

sensor is placed beside the conveyor belt at the filling station to detect the presence of a
bottle. The sensor has an infrared light transmitter and a receiver. When a bottle is
brought in front of the sensor by the conveyor belt, the infrared light emitted from the
emitter gets reflected from the bottle, which is then received by the receiver of the sensor.
When no object is in front of the transmitter, the receiver does not receive any signal.

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4.1.3 Liquid Flow Control Mechanism from Overhead Tank to the Bottle

When the bottle is detected by the photoelectric sensor, the task of filling the bottle with
liquid starts. A solenoid valve is used to control the flow of liquid from overhead tank to
the bottle. The solenoid valve is positioned at the filling station. When a bottle stops
underneath the valve, it gets a command from the PLC to open the valve and liquid flows
from the overhead tank to the bottle. The level up to which a bottle should be filled is
controlled by a timer of the PLC, i.e., after a certain time period, the timer gives a signal
to close the valve. The opening duration of the valve depends on the timer which can be
modified easily using PLC software.

4.1.4 Liquid Level Maintaining Mechanism at the Overhead Tank

Our designed overhead tank holds about 1.8 liters of liquid. Due to continuous filling of
the bottles, the amount of liquid at the overhead tank gets depleted. So it is crucial to
maintain a minimum level of liquid at the overhead tank to continue the smooth operation
of the bottle filling task. On the other hand, while refilling the overhead tank with liquid,
care should be taken so that it does not overflow. Therefore, the option for sensing the
minimum and maximum liquid levels has been provided. Two sensors, i.e., the upper
level and the lower level sensors are placed as shown in Figure. There is also a common
node placed below the lower level sensor. The sensors work on the conductivity property
of liquid. The common node is connected to the 24 V DC power supply of the PLC
module. When liquid level at the overhead tank goes below the lower level sensor, the
circuit between the lower level sensor and common node gets opened and a signal is
sensed at the PLC providing the information on inadequate amount of liquid at the
overhead tank and consequently a command is sent from the output of the PLC to start a
pump to refill the overhead tank from the main reservoir. On the other hand, when the
liquid level goes above the upper level sensor, due to the conductivity property of the
liquid, a circuit is completed between the upper level sensor and the common node.
Consequently, a signal is sensed at the PLC, providing the information on overflow of
liquid at the overhead tank. Therefore, a command is sent from the output of the PLC to
stop the pump.

4.2 Major Components of the System

The major components used in our project are listed below:

15
1) PLC module 


2) Conveyor Belt 


3) Sensor

4) Motors

5) Valve

6) Reservoir

These components are briefly described in the following section.

4.2.1 PLC Module

In our project, to implement the control logic of the system, we used a PLC. Here we
have used SIMATIC S7-1200 which is manufactured by Siemens Corporation. This PLC
is manufactured to industrial standards. It’s communication with input and output
component is fast. In this unit, up to eight additional signal modules can be connected.

There are several models of central processing unit (CPU) available with different models
of SIMATIC S7-1200. The PLC in our lab has the CPU model number 1214C. It is a
compact high performance CPU, and has an integrated power supply of 24 V DC, 14
integrated digital inputs and 10 integrated digital outputs. It also has 2 analog inputs, 50
KB work memory and 2 MB of load memory which is expendable to 24 MB using
Siemens memory card. The maximum current consumption (at 24 V DC) per input is 4
mA, and the maximum current available (at 24 V DC) per output pin is 400 mA. The
power supply module is used to provide 24 V DC stabilized power to the SIMATIC S7-
1200. Its input is 120/230 V AC and output is 24 V DC and 2.5 A.

16
4.2.2 Conveyor Belt

The conveyor belt we used has two layers, the outer layer is made of rubber and the inner
layer is made of woven fabric with wrap and weft which is also known as carcass. The
material for the conveyor belt that we used is of industrial standard. It is about 2.5 feet
long and 4 inch wide. Its thickness is about 2 mm.

4.2.2.1 Steel Panel:

The steel panel has two rollers on which the conveyor belt rests. The panel is 3 feet long
and about 7 inches wide. To adjust the tension of the conveyor belt, an adjustment screw
is used to adjust the roller on one side while the other roller is kept fixed.

4.2.2.2 Rollers and Bearings:

Figures show the rollers and the bearings. The bearings act as the supports for the rollers,
and enable the rollers to rotate smoothly. The diameter of the rollers that we used is about
2 inches. Of the two rollers used to roll the conveyor belt, one roller has a smooth
surface, while the other has a roughed surface to avoid the belt from slipping over the
rollers.

4.2.3. Sensor

In our project we have used two kinds of sensors. These are (1) photoelectric sensor and
(2) liquid level sensor.

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4.2.3.1 Photoelectric sensor:

Figure 2.9 shows the photoelectric sensor used in our project to detect the arrival of a
bottle at the filing station. The photoelectric sensor acts as a non-contact object detector.
The photoelectric sensor is cylindrical and its diameter is 18 mm. The operating voltage
is 10-30 V DC.

The photo-electric sensor actually uses the target as the “reflector”, such that detection
occurs upon reflection of the light off the object back onto the receiver.

4.2.3.2 Liquid level sensor:

For sensing the level of liquid in the overhead tank, we made a sensor ourselves. It uses
the electricity conducting property of liquids. We used three nodes to sense the level of
liquid, (a) the upper level node, (b) the lower level node, and (c) the common node. The
common node is connected to one end of a 24 V DC supply. These sensors are basically
S.S. nut bolts which are wired in such a way that, when the liquid in the tank is in contact

18
with the common node and any other (upper/lower level) sensors, an electrical circuit is
completed. This condition is detected by the PLC to understand whether the overhead
tank is low in liquid, or has sufficient liquid.

4.2.4 Motors

In our project we used two types of motors, one is DC gear motor to drive the conveyor
belt, and the other is DC motor which acts as a liquid pump.

4.2.4.1 DC gear motor:

Figures show the DC gear motors used in our project. A DC gear motor is a type of DC
motor that has a gear assembly attached to the motor . As a result, the motor can run at a
high torque and can carry heavy loads. The operating voltage of motor is 24 V DC that
can drive up to 15 kg of load with maximum output speed of 41.6 rpm. It draws about 1
A current.

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4.3.2.2 DC motor pump:

Figure shows the DC motor with pump assembly used in our project. This motor has a
pump assembly attached to it to pump liquids. The motor used in our project is rated at 12
V DC and draws about 3.5 A current. Since it was difficult to make a light weight pump
assembly needed for our project, we used a motor pump which is used in cars to supply
water on the car’s front glass and known as wiper washer pump.

Table 4.1

Pump rate 3 liters per minute

Power 6V - 12V

Current 2.5 A

Connection 2 wire

Outer diameter 22mm

Inner diameter 13mm

Height diameter 66mm cross 31 mm

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4.2.5 Solenoid Valve

A valve is a device that controls the flow of liquid. It can be opened and closed to control
the flow of fluid. Valves can be hydraulic or electrical. In a hydraulic valve, the valve
opens or closes depending on the liquid or air pressure. In electrical valves, an electric
signal is used to open or close the valve. In our project we used a solenoid valve that
operates by electric signal When it receives an electrical signal, the valve is opened,
otherwise it is left closed. The solenoid valve that is used in our project operates at 220 V
AC. As PLC configuration has 24 V DC output, we used relay for switching in order to
provide 220 V AC. It has a pipe that is connected with overhead tank.

4.2.6 Reservoir

Our project consists of an overhead tank and a main reservoir.

4.2.6.1 Overhead tank:

We have used a bottle to simulate overhead tank. The overhead tank is situated at a
vertical distance from solenoid valve. It has a pipe connected with the solenoid valve.
The overhead tank passes liquid through the solenoid valve to fill bottles. It takes up to
45 seconds to fill the overhead tank used in our project, which can hold up to 1.8 liters of
liquid. The electrical liquid level sensing system is incorporated in the overhead tank.
The sensing system operates on 24 V DC. The system allows maintaining the level of
liquid in the overhead tank which is very important to continue bottle filling.

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 4.2.6.2 Main Reservoir:

A five liter plastic pail is used as a main reservoir in our project. It is situated at ground.
It has a pipeline connection with the overhead tank through a DC motor pump. The DC
motor pump extracts liquid from main reservoir to overhead tank through pipeline. It
takes 45 seconds to fill the overhead tank.

4.2.7 Arduino Uno

We have used Arduino in capping unit.

Arduino Uno is a microcontroller board based on the ATmega328P. It has
14 digital input/output pins (of which 6 can be used as PWM outputs), 6
analog inputs, a 16 MHz quartz crystal, a USB connection, a power jack,
an ICSP header and a reset button. It contains everything needed to
support the microcontroller; simply connect it to a computer with a USB
cable or power it with a AC-to-DC adapter or battery to get started. There
are many other microcontrollers and microcontroller platforms available for
physical computing. Parallax Basic Stamp, Netmedia's BX-24, Phidgets, MIT's
Handyboard, and many others offer similar functionality. All of these tools take
the messy details of microcontroller programming and wrap it up in an easy-to-
use package. Arduino also simplifies the process of working with
microcontrollers, but it offers some advantage for teachers, students, and
interested amateurs over other systems:

 Inexpensive - Arduino boards are relatively inexpensive compared to other

microcontroller platforms. The least expensive version of the Arduino module
can be assembled by hand, and even the pre-assembled Arduino modules cost
less than $50
 Cross-platform - The Arduino Software (IDE) runs on Windows, Macintosh
OSX, and Linux operating systems. Most microcontroller systems are limited
to Windows.
 Simple, clear programming environment - The Arduino Software (IDE) is easy-
to-use for beginners, yet flexible enough for advanced users to take advantage
of as well. For teachers, it's conveniently based on the Processing programming
environment, so students learning to program in that environment will be
familiar with how the Arduino IDE works.

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 Open source and extensible software - The Arduino software is published as
open source tools, available for extension by experienced programmers. The
language can be expanded through C++ libraries, and people wanting to
understand the technical details can make the leap from Arduino to the AVR C
programming language on which it's based. Similarly, you can add AVR-C
code directly into your Arduino programs if you want to.
 Open source and extensible hardware - The plans of the Arduino boards are
published under a Creative Commons license, so experienced circuit designers
can make their own version of the module, extending it and improving it.

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 CHAPTER 5

Software
Software we are using for our simulation is TLP Logic pro Simulator

5.1 Ladder Diagram for the System

The ladder diagram (LAD) of the PLC controlled automated bottle filling system is
shown in Figure 3.4. We have used both “Normally Open” and “Normally Close” type
LAD contacts [2] which correspond to the physical contact signals from different sensors
of our project and are directly wired to the “I” (input) terminals on the PLC. The
“Normally Open” contact is closed (ON) when the assigned bit value at its address is
equal to 1 and the “Normally Close” contact is closed (ON) when the assigned bit value
at its address is equal to 0. These LAD contacts use the memory identifier “I” and bit
value is read from the process image register. The PLC system scans the wired input
signals and continuously updates the corresponding state values in the process-image

24
register. We have used different combinations of the LAD contacts to implement the
control logic of the project.

Several LAD output coils have also been used, which contain the memory identifier “Q”.
The output signals for the actuators and valves are wired to the “Q” terminals of the S7-
1200. In RUN mode, the CPU system continuously scans the input signals, processes the
input states according to the program logic, and then reacts by setting new output state
values in the process-image output register. Although “Normal” and “Inverted” type
output coils are available, we have used Normal type. If there is power flow through a
normal type output coil, then the output bit is set to 1 and if there is no power flow
through the output coil, then its corresponding bit is set to 0. After each program
execution cycle, the CPU system transfers the new output state reaction stored in the
process-image register to the wired output terminals.

Moreover, we needed to use “pulse timer (TP)” as well as “On-delay timer (TON)” to
create programmed time delays. The pulse timer generates a pulse with a preset width
time and the On-delay timer output is set to ON after a preset time delay. Each timer uses
a structure stored in a data block to maintain timer data.

25
Figure 5.1 shows the ladder diagram of our program. The control logic implemented
through each of the rungs of the ladder diagram has been explained below.

Figure 5.1
• The lower and upper level sensor outputs are connected to the input ports of the
PLC with addresses I0.1 and I0.2 respectively. The first rung of the ladder
diagram indicates that both I0.1and I0.2 LAD contacts are normally closed type
that enables the DC pump (Q0.0) to operate as long as the upper level sensor does
not come in contact with liquid. When the liquid level in the overhead tank
crosses the upper level sensor the LAD contact addressed I0.2 breaks. 


• The second rung indicates the control logic to stop the conveyor belt. The
conveyor belt continues to run as long as both the photoelectric sensor output and

26
solenoid valve status stored at the bit addresses “I0.1” and “Q0.2” respectively is
low. If either one of the bit logics in these addresses becomes high the conveyor
belt stops. This situation occurs if the photoelectric sensor detects the presence of
the bottle or if the solenoid valve is open 


• The third rung shows the control logic to open or close the solenoid valve. The
solenoid valve opens on the condition that the conveyor belt is in stop position
and it remains open for 25 seconds as set by the TP timer. 


• The control logic at the fourth rung ensures that the conveyor belt does not start
running again as soon as the solenoid valve gets closed. A delay of 2 seconds has
been introduced by a TON timer to ensure that there is no spill over of the liquid
on the conveyor belt. 


27
5.2 Data collection and experiment on hardware
We started our experiment from finding the heights of half liter. One liter and one and
half liter bottles, by knowing their heights we placed our photoelectric sensor from where
their direction is good. We did experiment on range of photoelectric sensor for how long
they can detect well, we got the result by increasing its sensitivity that it was detecting
well at the distance of 5 inches, So we placed the bottle at distance of five inches from
Photoelectric sensor.

5.2.1 Height of Bottles

Different companies have different lengths and widths of bottle. But their values are
almost closer to each other.

1500 ml 1000 ml 500 ml

We have measured lengths of bottles in centimeters

1.5 liter 33cm

1 liter 28cm

½ liter 23cm

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 CHAPTER 6

Hardware Construction

There are several hardware components in the system. Most of the components had to be
custom made due to lack of availability of components at the local market. Our project
required the construction of the conveyor belt, the filling station (with the liquid level
sensing mechanism of the overhead tank and the solenoid valve) and the main reservoir
(with DC motor pump and pipelines).

6.1 Construction of Conveyor Belt

The steel panel is made up by attaching four steel angles with wielding machine. A small
angle is also welded with the main panel that supports the DC electrical motor. Holes are
drilled in the panel to place the bearings for the rollers.

The two rollers are put at a distance with each other to keep the conveyor belt taut. As
mentioned in chapter 2, there are two rollers, one of which can be moved horizontally to
adjust the tension of the conveyor belt The conveyor belt is placed on the two rollers with
a melamine board guide. Finally, it is covered with a melamine board structure.

6.2 Conveyor belt motor connection:

The conveyor belt has a DC gear motor of 24 V. The DC gear motor is placed with the
roller in such a way that the motor is able to revolve the roller. The 24 V is supplied from
PLC I/O port module. The DC gear motor has two wire; red and black. One wire is
connected to the PLC output module and other wire is connected to the ground.

6.3 Construction of the Filling Station

A long melamine structure is placed vertically with the help of a steel panel. The solenoid
valve and the overhead tank are attached firmly with the melamine structure using
adjustment screws.

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6.4 Photoelectric sensor connection:

There are two types of connection of the sensor: light on and dark on. If a sensor output is
high while no light is received at the sensor then this is called a dark-on output. On the
other hand, if the output is on while the receiver detects the light from the emitter, the
sensor would have a light-on output [4]. But we have used only light on for connection.
The black colored wire is the output that contributes 200 mA to the PLC input. In the
presence of object the sensor’s input (which 10-30 V DC) is switched to output.

In our project, the photoelectric sensor operates at 24 V. The sensor is mainly connected
to the PLC input port and power supply module. The sensor input blue is grounded and
other two inputs white and brown are connected to the 24 V DC supply of the PLC
module. The sensor output black (wire) is connected to the PLC input port module. When
bottle comes in front to the sensor the sensor sends a signal to the PLC input port to give
the information of the bottle’s presence.

6.5 Liquid level sensing:

Liquid level sensing is made up with three nut bolts in a 2 liter bottle hanged upside
down and attached with melamine stand as an overhead tank The three nut bolts are
heated and screwed into three levels of overhead tank.

The three nut bolts are considered as three nodes; common node, lower level node and
upper level node. The nut bolts are wired and connected with PLC module for sensing.

6.6 Solenoid valve connection:

The solenoid valve operates at 220 V. But the PLC I/O port module can only supply 24
V. So a relay is used as a switch to operate the valve at 220 V AC.

The switching is done from the PLC output port module. When the photoelectric sensor
sends a signal to the PLC input module, the PLC module also gives a corresponding
output to the PLC output module for switching the relay.

6.5 Construction of Main Reservoir with DC Motor Pump

The main reservoir is placed at a distance from the conveyor belt. Beside the main
reservoir at ground level, a DC motor pump is screwed tightly into the reservoir.

30
6.6 Capping unit

At capping station, task of bottle capping is accomplished. When bottles are placed on
conveyor belt and detected by photoelectric sensor , solenoid valve open and bottle is
filled. After that bottle is being capped by a robotic arm at capping station. At other end
bottle is collected by attendant.

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 CHAPTER 7

Conclusion
We built a PLC controlled automatic bottle filling system. PLC based automated liquid
filling and control system is a part of industrial production system. This system is suitable
for liquid production where we need certain amount of liquid. The automated liquid
filling process is operated in such a way that it saves both time and cost.

Actually this project has both mechanical and electrical part. The mechanical part of the
project required drawing of the mechanical system; welding and fabricating process. The
electrical part consisted of electrical wiring, programming and some other electrical
methods. As a result we have gained knowledge of mechanical system along with
electrical system.

By doing this project successfully we were able to understand how to the construct
industrial systems.

32
References

[1] Automation [Online]. Available:

http://encyclopedia2.thefreedictionary.com/AutomatedControlSystems,
[Accessed: June, 2013]. 


[2] The Siemens SIMATIC S7-1200 [Online]. Available:

https://c4b.gss.siemens.com/resources/images/articles/e20001-a2100-p272-x-
7600.pdf, [Accessed: June, 2013]. 


[3] Conveyor Belt [Online]. Available: http://en.wikipedia.org/wiki/Conveyor_belt,

[Accessed: July, 2013]. 


[4] Photoelectric sensor [Online]. Available: http://ibestchina2010.en.made-in-

china.com/product/LeaEHbUlhkVF/China-M18- photo-sensor-photoelectric-
sensor-Photocell-IBEST-.html, [Accessed: June, 2013]. 


[5] Photoelectric sensor [Online]. Available:

http://www.clickautomation.com/o/photoelectric-sensor.php, [Accessed: July,
2013]. 


[6] DC gear motor [Online]. Available:

http://aavoleemets.com/nor/Noritsu_diferent_spare_parts/nor_3.html, [Accessed:
January, 2013]. 


[7] Wiper Washer Pump [Online]. Available: http://cnsamara.en.made-in-

china.com/product/hezEnVFvkjWO/China-Car- Headlamp-Wiper-Washer-Pump-
SM-W001-.html , [Accessed: July, 2013]. 


[8] Water, Air-Oil-Solenoid-Valve [Online]. Available:

http://www.aliexpress.com/item/Brass-2W025-06-Water-Air-Oil-Solenoid-Valve-
1- 8-BSPP-Threaded/464483767.html, [Accessed: July

33
ABBREVIATIONS

LAD: Ladder Diagram

34