PLC controlled automatic bottle filling system using robotic arm

we have built a PLC controlled automatic bottle filling system. We made a mechanical model of the industrial filling system, complete with sensors, motors, actuators etc. and controlled the whole process of bottle-filling using the PLC. The system consists of an assembly line, and when a bottle reac

Project Title

PLC controlled automatic bottle filling system using robotic arm

Project Area of Specialization

Wearables and Implantable

Project Summary

we have built a PLC controlled automatic bottle filling system. We made a mechanical model of the industrial filling system, complete with sensors, motors, actuators etc. and controlled the whole process of bottle-filling using the PLC. The system consists of an assembly line, and when a bottle reaches the filling station, a fixed amount of liquid is filled into the bottle, and then it moves towards the end of the assembly line to make way for another bottle to be filled-up.

The whole process consists of three tasks:

•   Filling bottles one after another with the desired level of liquid.

•   Timely refilling the overhead tank to continue smooth operation.

•   Controlling of the liquid flow from the reservoir to overhead tank.

• Our proposed system has the following features:

  •   Detection of the presence of a bottle using sensor

  •   Timer based automatic bottle filling

  •   Control of the liquid level of the overhead tank

Project Objectives

Many industrial processes are now dependent on automatic machinery. The transition from manual systems to automatic systems was necessary to optimize the rate and capacity of production . To control an industrial process, a special microprocessor based controller called the programmable logic controller (PLC) is used. There are many advantages of using PLCs in process control. These controllers are built to withstand the harsh environment of industry floor (i.e. protected against dust, moisture, hot and cold temperatures etc.), so these do not need special housing or protection. The PLCs are also built in a way so that the electronic circuitry of the controllers is not affected by moderate amount of noise.

A more attractive feature which made PLCs so popular is that, the same PLC can be re- programmed (using only software) to perform another task or control another process. Before the introduction of PLCs, electrical relays were used to automate processes, and the relays needed to be physically re-wired if these were intended to control another process. PLCs can be programmed many times to do different tasks. Besides in industries, PLCs are also used in building management systems (BMS), amusement parks, mills, water and waste treatment plants etc. The PLCs read the input states of switches, sensors etc. and can drive motors, relays, solenoids etc.

One of the many uses of PLCs in industries is in assembly lines involving packaging. Especially in pharmaceuticals, beverage industries, mineral water packaging plants etc., it is required to fill-up a bottle with a certain amount of liquid. In these systems, empty bottles are put on a conveyor belt which brings these to the filling station. At the station, the bottles are automatically filled-up and then moved along the conveyor for further stages to perform other tasks such as cap fitting or packaging etc.

we have developed a hardware model of a liquid filling system, and the process is controlled using a PLC. It is an automatic process where empty bottles are first placed on the conveyor belt. As an empty bottle is brought to the filling station, the belt stops to let the bottle fill-up with a fixed amount of liquid. The liquid is kept at an overhead tank near the filling station. After the bottle is filled-up, the belt starts again to move away the filled-up bottle and to bring another empty bottle to the filling station.

Project Implementation Method

The design of the system can be divided into several parts. They are (1) the conveyor belt mechanism to move the bottles from one end of the assembly line to the other, (2) the mechanism for accurate positioning of the bottles under the overhead tank to be filled up by liquid, (3) the mechanism for controlling the flow of liquid to the bottle, and (4) liquid level maintaining mechanism at the overhead tank.

 Conveyor Belt Mechanism:-

The conveyor belt mechanism  consists of a belt and rollers with DC gear motor. It is coupled with two rollers and runs continuously with the support of a DC gear motor when a start button is pressed. The conveyor belt carries the bottle along the assembly line to be filled up with liquid up to a particular level and then the conveyor belt runs again to take the filled up bottle to the other end to be collected by an attendant.

 Bottle Detection Mechanism:-

The task of bottle detection is performed using a photoelectric sensor. A photoelectric sensor is placed beside the conveyor belt at the filling station to detect the presence of a bottle. The sensor has an infrared light transmitter and a receiver. When a bottle is brought in front of the sensor by the conveyor belt, the infrared light emitted from the emitter gets reflected from the bottle, which is then received by the receiver of the sensor. When no object is in front of the transmitter, the receiver does not receive any signal.

Liquid Flow Control Mechanism from Overhead Tank to the Bottle:-

When the bottle is detected by the photoelectric sensor, the task of filling the bottle with liquid starts. A solenoid valve ( is used to control the flow of liquid from overhead tank to the bottle. The solenoid valve is positioned at the filling station. When a bottle stops underneath the valve, it gets a command from the PLC to open the valve and liquid flows from the overhead tank to the bottle. The level up to which a bottle should be filled is controlled by a timer of the PLC, i.e., after a certain time period, the timer gives a signal to close the valve. The opening duration of the valve depends on the timer which can be modified easily using PLC software.

 Liquid Level Maintaining Mechanism at the Overhead Tank:-

Our designed overhead tank holds about 1.8 liters of liquid. Due to continuous filling of the bottles, the amount of liquid at the overhead tank gets depleted. So it is crucial to maintain a minimum level of liquid at the overhead tank to continue the smooth operation of the bottle filling task. On the other hand, while refilling the overhead tank with liquid, care should be taken so that it does not overflow. Therefore, the option for sensing the minimum and maximum liquid levels has been provided.

Benefits of the Project

In our project we are are converting manual system of bottle filling into automatic. our project can

1. Reduce the human efforts and physical work.
2. Replacing human work by technologies.
3. Economy improvement.
4. Perform the tasks which are beyond the human

capabilities of size, weight, speed.

5.low power consumption

6. low operational cost

7.less maintenance

8. accuracy

9. At capping station, a robotic arm is attached which can perform the task of bottle capping automatically.

Technical Details of Final Deliverable

•In our project, at input , PLC require 220V AC supply or 24v DC supply. voltage, commonly 24 volts.

•The operating voltage of DC motor is 24 V DC. It draws about 1 A current.

•The DC motor pump used in our project is rated at 12 V DC and draws about 3.5 A current.

• The power supply module is used to provide 24 V DC stabilized power to the SIMATIC S7-1200. Its input is 120/230 V AC and output is 24 V DC and 2.5 A

Final Deliverable of the Project

Hardware System

Type of Industry

Education

Technologies

Others

Sustainable Development Goals

Decent Work and Economic Growth

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com