March 3, 2013

Project Title: PLC BASED AUTOMATED FILLING SYSTEM

Project Guide: GURUPRASAD L Asst. Professor

Project Group Members: Rakesh S K, Shruthi A, Vinay K

Maharaja Institute of Technology

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Agenda

Project definition/description

Design details
Project completion time lines

Implementation

Results demo,
Report writing, Project review and closure.

Any risks/difficulties in completion of the project. Conclusions

Project Definition/Description
Theme of the project deals with simplified approach to develop an automated

system for filling and capping.

Automated system for filling and capping is operated through Programmable

Logic Control using ladder logic

Containers are confined in position over a conveyor and conveyor is driven

by 24volts DC geared motor.

Containers are sensed by capacitive sensor and issue a command to PLC to

stop the conveyor at predefined position and filling process is started.

Inductive sensor determine the quantity of material filled in the container and

the container is directed for capping process.

Capping process is done by the help of handling device.
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System block diagram

CONTROL LOGIC CAPACITIVE SENSOR

PHTOELECTRIC SENSOR

PROGRAMMABLE LOGIC CONTROLLER

INDUCTIVE SENSOR

PNEMATIC CYLINDER

HANDLING DEVICE CONVEYOR (DC MOTOR)

Block diagram of PLC

network

Communication module

RAM

E-EPROM

Programming tool

CPU

power cord

Power supply

Input modules

Output modules

Machine
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Design details

Indracontrol L20 PLC

Technical Data
Processor Output voltage retentive memory Compact Flash RAM Onboard interfaces Onboard I/O Local extension Special features Dimensions
approx. 175 mm

STM ST40 / 166 MHz 24V DC 64 K Byte 128 M Byte (3 partitions) 16MB PROFIBUS DP, Ethernet, RS232 DI8/DO8 32 Byte RTC, Display 120 x 175 x 76mm

Connectivity
1 x Ethernet TCP/IP 1 x Profibus 1 x RS232 3 MB (1 MB Code / 2 MB Data) typ. 150 s / 1000 instructions

Performance
User memory Processing time

SENSORS

INDUCTIVE SENSOR

Technical Data Operating voltage Current rating Short circuit protected Reverse polarity protected Voltage drop Sensing range Operating temperature 10 36V 250mA yes yes <2.5V 0 - 6.5mm -25 80C

CAPACTIVE SENSOR

Technical Data Operating voltage Current rating Short circuit protected Reverse polarity protected Voltage drop Sensing range Operating temperature 10 36V 250mA yes yes <2.5V 0 - 6.5mm -25 80C

PHOTOELECTRIC SENSOR

Technical Data
Operating voltage Current rating Short circuit protected Reverse polarity protected Voltage drop Sensing range Operating temperature
DC MOTOR

10 36 V 250 mA yes yes <2.5 V 0 1200 mm -25 80 C

Technical Data
Operating voltage Current rating No load speed Torque Max. sleeve bearing load 24 V 6 mA 4110 rpm 33.1 mNm .5 N

HANDLING DEVICE

Handling device is equipped with 3 axis. Two linear axis and one rotating axis. Lifting is done by a double acting Pneumatic cylinder. Air presser in pneumatic cylinder is controlled by compressor.

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PNEUMATIC CYLINDER

Pneumatic cylinders are mechanical devices which uses the power of compressed gas to produce a force required for linear motion Gas forces a piston to move in the desire direction and piston road transfers the force to the object to be moved

Operation diagram of a double acting cylinder

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RESULTS DEMO

Sequence of movements:
Conveyor start

Hopper

Filling process
Container filled Container rotted for capp.

Empty Container

Inductive Sensor

Capacitive Sensor Conveyor direction

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RESULTS DEMO

Animation:

Sequence of movements:

slide left move down & vacuum on move up slide right move down vacuum off move up

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Project review and closure

PHASE 1

PROJECT SELEC.

PHASE 2 LEARNING PLC BASICS

LADER PROGRAMING

PHASE 3

COMPN. SURVEY

PHASE 4
INTERFACIN G

PHASE 5

FINAL DEMO

SYNOPSIS PREPR. PROJECT IMPLEM. PLAN

MODEL MAKING

CODING

FINAL REPORT

FINAL REPORT

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Risks/Dependencies
Risks:

Learning PLC concepts because its new for us.

Dependencies:

Trine from BOSCH group.

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Conclusion

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