Implementation of Industrial Automation & Monitoring for Liquid Filling System using Raspberry-Pi
e>-To solve the automation and control issues, industries use the ever-changing technologies in control systems for efficient production or manufacturing processes. These requires the high quality and reliable control systems. Our Project Industrial Automation & Monitoring for Liquid Filling Sy
2025-06-28 16:27:47 - Adil Khan
Project Title
Implementation of Industrial Automation & Monitoring for Liquid Filling System using Raspberry-Pi
Project Area of Specialization Internet of ThingsProject Summary-To solve the automation and control issues, industries use the ever-changing technologies in control systems for efficient production or manufacturing processes. These requires the high quality and reliable control systems. Our Project Industrial Automation & Monitoring for Liquid Filling System using Raspberry-Pi will provide some following things for the growth of industrial systems: -Increase the Productivity -Reduce the Production Cost -Increase the Flexibility -Operator Friendly. -Improves the Safety.Project Objectives
-The main objective of this project is to design a smart system that provides more efficient use of electronics, improved safety, shorter workweeks for labour, remote monitoring and reduced factory lead times. -This automation will make all errors of manual liquid filling process solved, it will provide the time benefit, efficient working with no wastage and real time tank level monitoring. -Management can use this system with ease remotely.
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Project Implementation Method-First we set the quantity of liquid to be filled on the bottles according to their sizes (based on time). Then the filling system will start when the "Start" button is pressed. -The conveyor also start moving. Now the first "Infrared sensor" detects the bottle and stop the conveyor thorugh which the bottle stops under the filling nozzle. Now the pumps start to fill the bottle and automatically stops when the bottle is filled, as we have already set the quantity of bottle before. Another infrared sensor is placed at the middle of conveyor which function as counter. When the bottle moves by the sensor it will increment the bottle's count and sends the data to "ThingSpeak cloud". -Now the conveyor again starts moving until the next bottle came under the filling nozzle. And when it detects the bottle, the whole process again repeats. -An ultrasonic sensor is placed with the liquid source tank/container, which measure the liquid level inside the tank and sends realtime monitoring data about the tank level to ThingSpeak cloud. So that we can remotely monitor the tank level. -Apart from our filling system, two more sensors "Fire detector" and "Smoke detector" are placed in our project. They will look for any kind of fire or smoke in the factory and if found then trigger the emergency bell in factory and send warning to ThingSpeak as well. -All of this ThingSpeak data can also be viewed in a mobile application named "ThingView".Benefits of the Project
-Errors of manual filling system like overflow or sometimes below the level filling will be solved. -Management will get to know the real time level of liquid in the source tank. -This automation will provide safety for workers. -Last but not least that this sytem will also provide emergency alert if industry's environment detects smoke or fire.Technical Details of Final Deliverable
-Requirements Documentation. -Design Documents. -Testing of Web & Mobile App. -Monitoring of hardware through mobile App(ThingSpeak Platform). -Project report.Final Deliverable of the Project Hardware SystemCore Industry ITOther Industries Manufacturing Core Technology Internet of Things (IoT)Other Technologies RoboticsSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 79980 | |||
| 12v DC Power supply | Equipment | 1 | 4500 | 4500 |
| 5v adapter | Equipment | 1 | 1200 | 1200 |
| Diaphragm pump | Equipment | 1 | 3200 | 3200 |
| Raspberry pi 4 | Equipment | 1 | 34500 | 34500 |
| Stepper motor | Equipment | 1 | 2200 | 2200 |
| Stepper Motor driver | Equipment | 1 | 2500 | 2500 |
| Ultrasonic sensor | Equipment | 1 | 1000 | 1000 |
| Infrared sensor | Equipment | 2 | 140 | 280 |
| Conveyor frame | Miscellaneous | 1 | 5000 | 5000 |
| Tank | Miscellaneous | 1 | 2000 | 2000 |
| 12mm pipe | Miscellaneous | 1 | 500 | 500 |
| Fuel | Miscellaneous | 1 | 2000 | 2000 |
| Acrylic Base | Equipment | 1 | 9000 | 9000 |
| Push Button | Equipment | 15 | 30 | 450 |
| PCB | Equipment | 1 | 7000 | 7000 |
| 12mm Non return valve | Equipment | 1 | 1800 | 1800 |
| 16x2 LCD | Equipment | 1 | 350 | 350 |
| I2C module and Wire | Equipment | 1 | 2000 | 2000 |
| Others | Miscellaneous | 1 | 500 | 500 |