PLC BASED AUTOMATIC BOTTLE FILLING SYSTEM ON A ROUND CONVEYOR BELT

Presented by
Under the guidance of
Annapurna Bai Namitha Jayadev Pallavi N R Sowjanya G C
B N Harish Assisstant Professor Electrical & Electronics Department PES College of Engineering

Index
Abstract

Introduction
Block diagram & its explanation Ladder programming Applications Advantages Conclusion

Abstract
The PLC that have been used at the industrial field is to control and monitor the electrical devices in order to create an efficient production. The bottles are placed on the pre-determined position over the circular conveyor belt. The system sequence of operation is designed by the ladder programming. Sensor is used to detect the bottle position which moves along the circular conveyor belt. The input signal that has been sent from the sensor to the PLC is taken as a reference. Signal in order to determine the output signal that exactly a same with the PLC programming language based on the user requirements. Besides that, the electronics and electric devices that usually been controlled by the PLC are like a motor, pump, sensor, conveyor belt, buzzer and the other devices.

Introduction
Nowadays, the application of PLC is widely known and use in this digital world. PLCs application is obviously applied at the industrial sector PLCs offer ease of installation, ease of programming and ease of communications to other systems . 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 ,which acts as the heart of the system. It has a reduced wiring connection, flexibility, easy replication, hardwire reduction, easy maintenance, easy debugging and complexity is reduced and a very high durability.

Inherent features Solid-state components Programmable memory

Benefits High reliability Simplifies changes Flexible control

Small size
Microprocessor-based Software control relays Modular architecture

Minimal space requirements

Higher level of performance Multifunctional capability Reduce hardware/wiring cost Reduce space requirements Installation flexibility Reduces hardware cost Expandability Controls a variety of devices Eliminates customized control

Variety of I/O interfaces

Quick I/O disconnects

Modular I/O interface

Service without disturbing wiring

Neat appearance of control panel Easily maintained

Block diagram

Block diagram explanation

The ladder program for this system is loaded into the PLC through an external CPU. The overall process of automatic bottle filling is done based on the programme loaded. Through this project, the bottle will move on the conveyor belt. When the bottles are placed on the predetermined position over the circular belt, then conveyor will be stopped automatically after the infrared sensor detected the presence of the bottle. IR sensor emitter emits infrared light. If an object presence, the signal will be reflected back to the receiver. Then the IR detector will detect the reflected light. Then, the signal will be sent to the PLC for being analyzed.The controller will switch on the pumps when the conveyor stops. 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. This system will repeat the process continuously. A buzzer circuit can be used in order to recognize the level of main container. The main aim in this process is to apply PLC to design automatic bottle filling system.

ABB PLC:

The AC 31 brings accessibility to beginners and experienced automation users alike, for any application with 14 to 1000 inputs / outputs and more, using the same set of basic components. From a compact machine fitted with a few automated functions to large installations. It is therefore possible to realize distributed applications throughout a site, a workshop, or a machine where each component (input / output unit, central unit) is close to the sensors /actuators. The whole setup is connected by a single twisted pair over which all information from the sensors is sent after processing by the central unit to the actuators, as well as distributed intelligent units.

ABB AC 31

Ladder programming

Ladder logic is widely used to programme PLCs, where sequential control of a process or manufacturing operation is required. It is useful for simple but critical control systems or for reworking old hardwired relay circuits. As programmable logic controllers became more sophisticated it has also been used in very complex automation systems.

Applications
Hospitals or health cares Small scale filling stations In all bottle filling stations to have efficient task completion.

Advantages

Automation increases productivity, which in turn brings economic progress. The role of PLC in automation is basically controlling the whole system. The installation cost is not so cheap but in the long run the reliability and performance of the system makes up to the investment . More features can be added to this system depending on the size, shape and weight of the bottles, filling operation can be implemented. Efficient replication. Growing with technology and faster scan times (about), capability, quick i/o disconnect that aid in quick field servicing . Online programming. Extension capability.