Design and Development of Cloud Monitoring Based bottle filling and capping station using bar code scanner on the basis of industry 4.0

Project Title

Design and Development of Cloud Monitoring Based bottle filling and capping station using bar code scanner on the basis of industry 4.0

Project Area of Specialization Cloud InfrastructureProject Summary

Condition monitoring and controlling plant parameters in processing industries is very difficult and time consuming if it take place manually so for this purpose; this project aims to introduce the concept of automatic control and condition monitoring based on cloud monitoring which is a core part of industry 4.0. It is the current trend of automation and data exchange in manufacturing technologies, including cyber physical system industry 4.0 perform a vital role in cyber security of a system or in industrial sector.

HMI (Human-Machine-Interface) will be designed to see the real time parameters , the PLC is used for controlling purpose further data will be send on internet from internet server we can easily check the present information of plant at any time. Data will be saved on Drive Storage where one can check the history or trend of any parameters. Fig.1 shows process of cloud monitoring.

Fig.1: Process of cloud monitoring

images/Design and Development of Cloud Monitoring Based bottle filling and capping station using bar code scanner on the basis of industry 4.0 _1582923946.png

Project Objectives

• To reduce manual work in processing industries.

• To design and development batch filling and capping station using PLC.

• To Interface bar code scanner over RS-232 port on PLC.

• To Implement the technology of cloud and web server in industrial sector.

• To design a cyber-secure system.

Project Implementation Method

The system consist of three different types of solution for filling purpose , for each type of solution a bar-code will generated and paste on the bottle, than barcode scanner will scan the particular bar code and fill the solution accordingly. The system also includes packing of bottles after filling, timers will be implemented according to filling and capping time of bottle. Stepper or DC motor will be used to move the conveyor belt. Filling is controlled by control valve through PLC. PLC will be programmed using ladder logic and functional block logic. In the bottle filling process the PLC takes the sensor feedback and control the solenoid valve as well as controls the conveyer belt. By programming of the PLC the entire system is being controlled. The PLC is considered as heart of any system. The whole system is made more reliable , time saving and use friendly . In this way, implemented system is used to reduce the human work and helps us in increasing the efficiency of products.  Fig.2 shows the whole process of filling on conveyor belt.

Fig.2(a)  : Methodology for filling process

images/Design and Development of Cloud Monitoring Based bottle filling and capping station using bar code scanner on the basis of industry 4.0 _1582923947.png

Fig.2(b) : Whole system control through PLC

images/Design and Development of Cloud Monitoring Based bottle filling and capping station using bar code scanner on the basis of industry 4.0 _1582923951.png

Benefits of the Project

• Reduce the human work in processing industries.

• More efficient and accurate

• System can be monitor from anywhere in the world through servers.

• Automatic level and temperature monitoring.

• System can be designed for multiple solutions which can be fill in its particular type of bottle.

• Facilitate the monitoring of ongoing process of HMI and Wireless Local Area Networking.

• Includes cloud based data logging feature that keeps the record of the filling process.

• Develop a cyber-secure system on both field as well as the Networking side. 

• Security, accuracy and time dependent system.

Technical Details of Final Deliverable

This project comprises of STEP7 software and hardware PLC, for multiple application. PLC work as a controller to control all the mechanism. A HMI(Human-Machine-Interface) will design by using WINCC software for checking the real time data logging on screen and it is connected to PLC. A Gmail account will be created for drive storage to save our monitor data in it, for taking average of our plant with respect to time. Plant’s data will be monitored through server using Microsoft Azure infrastructure, that’s why we will be able to monitor or detect our plant’s information from anywhere. Three different types of bar-codes will be generated using Honeywell software for three different types of solutions. 

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Food Core Technology Cloud InfrastructureOther Technologies Internet of Things (IoT)Sustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	60005
PLC (siemens S7-300)	Equipment	1	30000	30000
Bar-Code Scanner	Equipment	1	1500	1500
Capacitive sensor	Equipment	1	1000	1000
Photoelectric sensor	Equipment	1	800	800
Arduino UNO	Equipment	1	500	500
Solenoid Valve	Equipment	4	1500	6000
Submersible Pump	Equipment	3	1500	4500
Node MCU	Equipment	1	800	800
DC Motor	Equipment	9	545	4905
Designing of Plant. (conveyor,tanks,wiring connections,pipes,wooden	Miscellaneous	1	10000	10000