AUTOMATIC BOTTLE

FILLING SYSTEM USING PLC

By:
Mithun M Sanjeev
Nandhagopan K R
R S Abhi Krishna
What is PLC ??

 A digitally operating electronic apparatus which uses a programmable

memory for internal storage of instructions

 Implement specific functions, such as logic, sequencing, timing, counting

and arithmetic operations

 Control various types of machines or process through digital or analogue

input/output.
Architecture
Central Processing Unit

 It is a micro-controller based circuitry. CPU consists of ALU ,program

memory, internal timers and counters
 CPU performs the tasks necessary to fulfil the PLC functions. This tasks
include
 Scanning
 I/O bus traffic control
 Program Execution
 Periferral and External device communication
 Data handling
 Self Diagnosis
Input Modules

 These modules act as interface b/w real time status of process variable and
CPU

 Analog input module : Typical inputs to this modules are 4-20 mA , 0-10 V
 Ex : Pressure Flow, Temperature

 Digital input module : Typical inputs to this modules are 24V DC or 48V DC
 Switches , push button and relay
OUTPUT MODULE

 These modules act as interface b/w CPU and the output devices in the field

 Analog output module : Typical outputs from this modules are 4-20 mA , 0-
10 V
 Ex : Control Valve , Speed and Vibration

 Digital output module : Typical outputs from this modules are 24V DC or 48V
DC
 Solenoid Valve, actuator, pump valve ON/OFF control
POWER SUPPLY

 Powder Supply gives the voltage required for electronic modules (I/O
module ,CPU ,memory Unit)

 The Power Supply Provides Isolation Necessary to protect the solid state
devices from high voltage

 As I/O is expanded , some PLC require additional power supply.

PLC Operating Cycle


PROGRAMMING

 In case of PLC , following types of programming are prevalent:

 Lower level
(a) Ladder diagram
(b) Boolean mnemonics
 Higher Level
(a) Functional block
(b) English Statements
Ladder Diagram

 Relay logic operation

 Let us consider all the relay ladder instruction commonly available:

 Normally open contact -| |-

 Normally closed contact -|\|-
 Energize coil ( Turn on output) -( )-
 De-energize coil (turn off output) -(\ )-
 Latch coil -(L)-
Timer and counter operation.

 Operation of both timer and counter is same as:

 Timer operates like counter
 Bot the timer and counter maintain two values in their internal
registers:
 Pre-set value and the count value.
Counter

 Up Counter
 Each time programmed event occurs , the count increment increments
by one , When pre-set equal the count , output is energized. The count
can be reset instruction.
 Down Counter
 Each time programmed event occurs , the count decrement increments by one
, When pre-set equal the count , output is energized. The count can be reset
instruction.
 Counter Reset
 When logic continuity is established , addressed counter is reset
AUTOMATIC WATER FILLING SYSTEM

 This is based upon closed loop control system.

 A Closed-loop Control System, also known as a feedback control

system is a control system which uses the concept of an open loop
system as its forward path but has one or more feedback loops
(hence its name) or paths between its output and its input. The
reference to “feedback”, simply means that some portion of the
output is returned “back” to the input to form part of the systems
excitation.
Block diagram of Closed Loop control
system
AUTOMATIC WATER FILLING SYSTEM
BLOCK DIAGRAM
PANEL DIAGRAM
COMPONENTS USED:

 DC SERVO MOTORS
 PHOTO ELECTRIC SENSORS
 CONVEYOR BELT MOTORS
 ELETRO MAGNETIC RELAY
 AC & DC TERMINAL BLOCKS
 MCB & SMPS
WORKING
 When the start button is pushed, the motor starts hence the conveyer belt
starts moving.
 When the bottle is under the solenoid valve, the bottle is sensed and the
motor stops hence the conveyer belt stops.
 Then the solenoid valve operates and the bottle starts filling the water.
 When the bottle completes filling process, the solenoid valve is closed and
the motor starts, the conveyer belt starts moving and carries the bottle
away from the solenoid valve.
 If another bottle is sensed then the above process will be repeated. When
stop button is pressed or activated then the entire process will be stopped.
PROGRAM USED IN THIS PROJECT
 INPUTS
 X0 ------WATER LEVEL SENSOR

 X1--------PUSH BUTTON
 X2-----CONVEYOR BELT SENSOR

 OUTPUTS
 Y0 ------RESERVOIR MOTOR

 Y1--------WATER TANK MOTOR

 Y2 & Y3 -----------CONVEYOR BELT MOTOR

 M0,M1,M2-----------MEMORY BITS

 T0,T1-------------TIMERS
MERITS

 Less man power required.

 Less time taken.
 Fast and accurate.
 Less wiring.
 Easier and faster to make changes.
APPLICATIONS

 Stand alone water bottle booth system.

 Ink filling industry.
 Soft-drink & water filling industries.
 Beer and wine industries.
 Olive oil industries.