AUTOMATIC BOTTLE
FILLING SYSTEM USING PLC
By:
Mithun M Sanjeev
Nandhagopan K R
R S Abhi Krishna
What is PLC ??
A digitally operating electronic apparatus which uses a programmable
memory for internal storage of instructions
Implement specific functions, such as logic, sequencing, timing, counting
and arithmetic operations
Control various types of machines or process through digital or analogue
input/output.
Architecture
Central Processing Unit
It is a micro-controller based circuitry. CPU consists of ALU ,program
memory, internal timers and counters
CPU performs the tasks necessary to fulfil the PLC functions. This tasks
include
Scanning
I/O bus traffic control
Program Execution
Periferral and External device communication
Data handling
Self Diagnosis
Input Modules
These modules act as interface b/w real time status of process variable and
CPU
Analog input module : Typical inputs to this modules are 4-20 mA , 0-10 V
Ex : Pressure Flow, Temperature
Digital input module : Typical inputs to this modules are 24V DC or 48V DC
Switches , push button and relay
OUTPUT MODULE
These modules act as interface b/w CPU and the output devices in the field
Analog output module : Typical outputs from this modules are 4-20 mA , 0-
10 V
Ex : Control Valve , Speed and Vibration
Digital output module : Typical outputs from this modules are 24V DC or 48V
DC
Solenoid Valve, actuator, pump valve ON/OFF control
POWER SUPPLY
Powder Supply gives the voltage required for electronic modules (I/O
module ,CPU ,memory Unit)
The Power Supply Provides Isolation Necessary to protect the solid state
devices from high voltage
As I/O is expanded , some PLC require additional power supply.
PLC Operating Cycle
PROGRAMMING
In case of PLC , following types of programming are prevalent:
Lower level
(a) Ladder diagram
(b) Boolean mnemonics
Higher Level
(a) Functional block
(b) English Statements
Ladder Diagram
Relay logic operation
Let us consider all the relay ladder instruction commonly available:
Normally open contact -| |-
Normally closed contact -|\|-
Energize coil ( Turn on output) -( )-
De-energize coil (turn off output) -(\ )-
Latch coil -(L)-
Timer and counter operation.
Operation of both timer and counter is same as:
Timer operates like counter
Bot the timer and counter maintain two values in their internal
registers:
Pre-set value and the count value.
Counter
Up Counter
Each time programmed event occurs , the count increment increments
by one , When pre-set equal the count , output is energized. The count
can be reset instruction.
Down Counter
Each time programmed event occurs , the count decrement increments by one
, When pre-set equal the count , output is energized. The count can be reset
instruction.
Counter Reset
When logic continuity is established , addressed counter is reset
AUTOMATIC WATER FILLING SYSTEM
This is based upon closed loop control system.
A Closed-loop Control System, also known as a feedback control
system is a control system which uses the concept of an open loop
system as its forward path but has one or more feedback loops
(hence its name) or paths between its output and its input. The
reference to “feedback”, simply means that some portion of the
output is returned “back” to the input to form part of the systems
excitation.
Block diagram of Closed Loop control
system
AUTOMATIC WATER FILLING SYSTEM
BLOCK DIAGRAM
PANEL DIAGRAM
COMPONENTS USED:
DC SERVO MOTORS
PHOTO ELECTRIC SENSORS
CONVEYOR BELT MOTORS
ELETRO MAGNETIC RELAY
AC & DC TERMINAL BLOCKS
MCB & SMPS
WORKING
When the start button is pushed, the motor starts hence the conveyer belt
starts moving.
When the bottle is under the solenoid valve, the bottle is sensed and the
motor stops hence the conveyer belt stops.
Then the solenoid valve operates and the bottle starts filling the water.
When the bottle completes filling process, the solenoid valve is closed and
the motor starts, the conveyer belt starts moving and carries the bottle
away from the solenoid valve.
If another bottle is sensed then the above process will be repeated. When
stop button is pressed or activated then the entire process will be stopped.
PROGRAM USED IN THIS PROJECT
INPUTS
X0 ------WATER LEVEL SENSOR
X1--------PUSH BUTTON
X2-----CONVEYOR BELT SENSOR
OUTPUTS
Y0 ------RESERVOIR MOTOR
Y1--------WATER TANK MOTOR
Y2 & Y3 -----------CONVEYOR BELT MOTOR
M0,M1,M2-----------MEMORY BITS
T0,T1-------------TIMERS
MERITS
Less man power required.
Less time taken.
Fast and accurate.
Less wiring.
Easier and faster to make changes.
APPLICATIONS
Stand alone water bottle booth system.
Ink filling industry.
Soft-drink & water filling industries.
Beer and wine industries.
Olive oil industries.
