Automatic Bottle Filling and Capping using PLC

Project Title

Automatic Bottle Filling and Capping using PLC

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Our SDP lies in area of Control in which we automate and control the Bottle Filling and Capping process using PLC Controller. A bottle filling system with PLC allows the user to fill the bottle till a desired level without wastage of the liquid. Ladder logic is used to control the sequence of the PLC. The system is controlled by Mitsubishi PLC which operates on 24V DC and is a compact PLC which has a fixed number of inputs and outputs. The small-scale industries require large amount of labor to perform the operations such as manufacturing of bottles, filling with liquid and capping the bottles. To increase the production rate the low-cost industrial automation process is best suitable for small scale industries. This is achieved through electric circuits, relays, pneumatic actuators, limit switches, sensors, solenoid valves and Electropneumatic which are controlled by electrical impulses. 

Project Objectives

a) Maximum integration
b) Design (prototype)
c) Implementation

d) Fault Alarming

e) Low Operational Cost

f) Monitoring

Project Implementation Method

The Project includes Conveyer, Filling and capping process. The Conveyer System can be done by using a DC Motor, Conveyer Belt, Gear and an aluminum frame. The speed should not be much higher that an empty bottle drops and also not enough low that it goes out from economy boundary Once a bottle is in conveyer it moves towards Filling Process where bottle is detected by a sensor. The bottle is stopped at the bottom of water solenoid valve. Water Solenoid valve turns on. Once bottle is filled to desired level then valve is turned off and at same time conveyer starts moving. The bottle is stopped again at the bottomof capping process. The cap drops over the bottle from slider and a cap is tightened using actuator and motor. Filling speed can be increased using a dc pump connected with solenoid valve. All this process is controlled and done with the help of PLC.

Benefits of the Project

This work provides with a lot of benefits like low power consumption, low operational cost, less maintenance, accuracy, knwoledge about PLC and automation techniques.

Technical Details of Final Deliverable

A conveyor belt is used on which the bottles are placed. The position of the bottle is sensed through IR sensor. IR sensor gives output as logic ‘1’ or logic ‘0’ and depending upon its output corresponding motor turns ON. The filling operation is done
with automatic detection of volume of bottle and selection the amount of liquid to fill
the bottle. The filling process is done based on timing. Timer is used for defining the
time according to that the preset value is set and depending on the preset value the
pump is switched ON. The input module includes IR sensors. There are three IR sensors one is used to detect the position of the bottle on the conveyor belt and two pairs of IR sensor are used to detecting the volume and also for detecting the position of the bottle for filling process. The input of conveyor belt where the bottles are fed the first IR sensor is placed. This sensor is used to detect the proper position on the conveyor. The other two pairs are kept at the filling operation to detect the proper position for filling operation and simultaneously for detecting the volume. These sensors also help to stop the conveyor. Hence inputs are given to input module.
12VDC Relay DC motor and pump are the output devices used for the bottle filling process. These are connected to the output module. The DC motor is used to run the conveyor in forward direction. 

Flow Chart is attached here:

Link: Flow Chart

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther IndustriesCore Technology RoboticsOther Technologies Clean TechSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	51700
PLC	Equipment	1	8000	8000
Relay	Equipment	5	300	1500
Water Solenoid Walve	Equipment	1	500	500
DC Water Pump	Equipment	1	500	500
Stepper Motor	Equipment	1	2500	2500
DC Geared Motor	Equipment	2	2500	5000
Conveyer Belt	Equipment	1	2000	2000
Conveyer Mechanical Design	Equipment	1	7000	7000
Actuator	Equipment	1	1500	1500
Sensors	Equipment	3	1000	3000
Cap Hopper	Equipment	1	1000	1000
Metal Discs	Equipment	2	500	1000
Steel Plates	Equipment	3	400	1200
Wires & Connecting Terminals	Equipment	1	2000	2000
HMI - LCD	Equipment	1	15000	15000