AUTOMATIC LIQUID FILLING USING PROGRAMMABLE

LOGIC CONTROLLER(PLC)

Vinod Jiddi
Assistant Professor,Dept.of EEE,B.L.D.E.A.’S CET,vijayapur karnataka

Abstract— This paper presents to design, develop and monitor “Bottle filling and capping with
PLC”. This work provides with a lot of benefits like low power consumption, low operational cost,
less maintenance, accuracy and many more. This project is based on Industrial Automation and is a
vast application used in many industries like milk industries, chemical, food, mineral water and
many industrial manufactures.Filling is the task that is carried out by a machine and this process is
widely used in many industries. In this paper, the filling of the bottle is controlled by using a
controller known as PLC which is also the heart of the entire system. For the conveyor system, a
stepper motor has been selected for better performance and ease of operation. Various sensors have
been used to detect the position of the bottle. Ladder logic has been used for the programming of the
PLC, which is the most widely used and accepted language for the programming of the PLC. The
PLC used in this system is an Rexroth system which makes the system more flexible and easy to
operate.

Keywords— PLC ladder diagram, bottle filling,Automation.

I. INTRODUCTION
Automation is used for all control systems and the technologies in PLC is use to reduce the human
work and helps in increasing the production. PLC plays an important role in the world of automation
industry. It acts a major function in the automation field which tends to reduce the complexity,
increases safety and cost efficient. In this system we have applied a PLC based control system in an
automatic bottle filling station. The project is divided into several sections where the first phase of
the project explains the description of the product. The second phase then gives the functional
description of the product. PLC (Programmable Logic Controller) acts as a major function in
automation fields where, small PLC has a fixed number of built-in connections for inputs and
outputs. A bottle filling system with PLC allows the user defined selection volume in percentage
which uses the ladder language. Ladder logic is used to control the process.

A bottle filling system with PLC allows the user to fill the bottle till a desired level without wastage
of the liquid.

II. PLC SYSTEM

A. PLC HARDWARE
A programmable logic controller consists of the following components:
• Central Processing Unit (CPU).
• Memory.
• Input modules.
• Output modules and
• Power supply.

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Volume 03, Issue 07; July – 2017 [ ISSN: 2456-401X]

A PLC hardware block diagram is shown in Figure. The programming terminal in the diagram is not
a part of the PLC, but it is essential to have a terminal for programming or monitoring a PLC. In the
diagram, the arrows between blocks indicate the information and power flowing directions.

Fig. 1 Block Diagram of PLC

B. Central processing unit (CPU)

Like other computerized devices, there is a Central Processing Unit (CPU) in a PLC. The CPU,
which is the “brain” of a PLC, does the following operations:

Updating inputs and outputs. This function allows a PLC to read the status of its input terminals and
energize or re energize its output terminals.

Performing logic and arithmetic operations. A CPU conducts all the mathematic and logic operations
involved in a PLC.

Communicating with memory. The PLC’s programs and data are stored in memory. When a PLC is
operating, its CPU may read or change the contents of memory locations.

Scanning application programs. An application program, which is called a ladder logic program, is a
set of instructions written by a PLC programmer. The scanning function allows the PLC to execute
the application program as specified by the programmer.

Communicating with a programming terminal. The CPU transfers program and data between itself
and the programming terminal.

Memory
Memory is the component that stores information, programs, and data in a PLC. The process of
putting new information into a memory location is called writing. The process of retrieving
information from a memory location is called reading.
The common types of memory used in PLCs are Read Only Memory (ROM) and Random
Access Memory (RAM). A ROM location can be read, but not written. ROM is used to store
programs and data that should not be altered. For example, the PLC’s operating programs are stored
in ROM.

C. Input modules and output modules

A PLC is a control device. It takes information from inputs and makes decisions to energize or de-
energize outputs. The decisions are made based on the statuses of inputs and outputs and the ladder
logic program that is being executed.

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The input devices used with a PLC include pushbuttons, limit switches, relay contacts, photo sensors,
proximity switches, temperature sensors, and the like. These input devices can be AC (alternating
current) or DC (direct current). The input voltages can be high or low. The input signals can be
digital or analog. Differing inputs require different input modules. An input module provides an
interface between input devices and a PLC’s CPU, which uses only a low DC voltage. The input
module’s function is to convert the input signals to DC voltages that are acceptable to the CPU.
Standard discrete input modules include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V
DC, 120 V DC, 220 V DC, and transistor-transistor logic (TTL) level.

D. Power Supply
PLCs are powered by standard commercial AC power lines. However, many PLC components, such
as the CPU and memory, utilize 5 volts or another level of DC power. The PLC power supply
converts AC power into DC power to support those components of the PLC.

III. PROPOSED PLC based Liquid Filling

A. Power Circuit Operation
OBJECTIVE
To develop and design a Bottle filling and Capping plant using various sensors to reduce the human
intervention in the processes. Also to design the visualization screen for the monitoring of the
purpose.

A. Model Description
The model consist of
• Solenoid valve
• Conveyer
• SMPS
• Relays
• Regulated Power supply
• Proximity sensors
• Hydraulic capping system
• Description of Materials

B. Solenoid Valve

Fig.2 Solenoid Valve

A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric

current through a solenoid: in the case of a two-port valve the flow is switched on or off; in the case
of a three-port valve, the outflow is switched between the two outlet ports. Multiple solenoid valves
can be placed together on a manifold.

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C. SMPS (Switch mode power supply)

Fig.3. SMPS

A switched-mode power supply (switching-mode power supply, SMPS, or switcher) is an electronic

power supply that incorporates a switching regulator to convert electrical power efficiently. Like
other power supplies, an SMPS transfers power from a source, like mains power, to a load, such as a
personal computer, while converting voltage and current characteristics.

D. IR Sensor

Fig.4 IR sensor

An IR transmitter or source converts an electrical signal to an optical signal. A receiver or detector

converts optical power into electrical current by detecting the photon flux incident on the detector
surface.

E. Regulated power supply

Fig-5 Regulated power supply

Power supplies are designed to convert high voltage AC mains to a suitable low voltage supply for
electronic circuits and other devices. In our project the various electronic modules are being used for
which power supply requirement is +5V DC. The Microcontroller unit needs a pure regulated +5V
DC.

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F. Relay

Fig-6 Relays

Relay is a mechanical switch which uses electromagnetic signals to operate; it is typically used in
high voltage circuits or to connect several circuits which are being controlled by one signal. Whereas
PLC (Programmable Logic Controller) is widely used for Industrial purpose which deals with
Machines.

G. Conveyers

Fig-7 Conveyers

A conveyor belt consists of two or more pulleys, with a continuous loop of material - the conveyor
belt - that rotates about them. One or both of the pulleys are powered, moving the belt and the
material on the belt forward. The powered pulley is called the drive pulley while the unpowered
pulley is called the idler. There are two main industrial classes of belt conveyors; those in general
material handling such as those moving boxes along inside a factory and bulk material handling such
as those used to transport industrial and agricultural materials, such as grain, coal, ores, fines, and
lumps material

PLC (BOSCH REXOROTH L-20 V4)

Process Description
Fig 8. BOTTLE DETECTION USING SENSORS

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Bottle is kept in position in their respective holder which are fixed to the conveyor at the input side.
IR sensor is used to detect the presence of bottle in the holder. Depending on the output of the sensor
the filling and capping operation takes place. A time delay is given in order to set the status of the
bottle. If bottle 1 is present the corresponding status bit in PLC is set to 1 else it is set to 0. The
output of this sensor is given to the PLC and depending on this output the filling and capping process
for the bottle takes place. Thus if the bottle is present in the input side then the sensor gives the
corresponding output to the PLC which in turn switches ON the corresponding pump for filling
operation to take place. If a particular bottle is not present the corresponding pump remains OFF.

H. FILLING OPERATION
Once the bottle is detected in the input side the conveyor motor switches ON and it starts moving in
the forward direction. The bottle then reach the desired position for filling and the conveyor stops.
The corresponding pump in process tank switch ON and filling operation takes place. Tank have low
level and high level sensors (LLS and HLS) respectively. Process when the liquid in the process tank
reaches below low level (LLS) pump in tank switch on and the process tank get filled. When the
level of liquid reaches high level the pumps in tank switch off.
USER-DEFINED VOLUME

The filling operation is accompanied with a user defined volume selection menu. The desired volume
is fed into the PLC and depending on the volume the filling of liquid takes place. The filling is done
using timing operations. Thus the pump remains on for the pre set value of the timer and switches off
once time is out. Once the filling process is done the conveyor starts moving again.

I. CAPPING OPERATION
The bottles are transported to the capping arrangement. IR sensors are kept to stop the bottles in the
desired position for capping to take place. Once the bottles reach the position the conveyor motor
switches OFF.
The capping of bottle is done using actuator arrangement. The actuators which move in forward and
reverse directions are used to cap the bottle. The actuator applies a force on the caps which are
placed in their respective holders. This force helps the caps to fit into the bottles at the required
position.
Similar to filling, if a particular bottle is not present it does not get capped. Thus the capping is done
and the conveyor starts moving again. When the capping operation for one batch is done
simultaneously the filling operation for another batch takes place.
The entire sequence of operations continues until there are not bottles present in the input side. All
these are automatically coordinated using the PLC. PLC gets the input from the input devices and
sends the signals to the various output devices depending on the conditions that are fed into the PLC.
Thus bottles get filled and capped.
Process Diagram

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Simulation process diagram

ALGORITHM:
STEP I : Press the “START” Push Button.
STEP II : Then the “MOTOR” starts and the container moves forward.
STEP III :If the container is made up of any metal (eg: tin, silver etc.) the bottle will be pushed by
the piston.
STEP IV :If the container is made of non-metal (eg: plastic) then is will move forward will stop
below the solenoid valve.
STEP V :After some delay the valve will turn “ON” and the bottle will get filled.
STEP VI :After the bottle is filled, a delay is provided and then after the delay the motor
STEP VII :As the bottle is moving forward, the cap will be placed by the cap hopper automatically.

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STEP VIII :After the cap is placed the bottle will move further and the bottle will stop below the
capping piston.
STEP IX :After some delay the capping piston will come down and the cap will be placed tightly.
STEP X : After the cap is placed he bottle will go further for different processes in industry.

IV. CONCLUSION
Automation systems are used to increase productivity, which in turn brings economic progress. The
main purpose of PLC in automation is used to control the whole system. The cost of installation is
not cheap but it can efficiently run for a long period of time. The performance, flexibility and
reliability is based on the investment. A PLC based control system was applied to the automatic
liquid filling station previously specified and the performance was measured. The entire system is
more reliable, time saving and user friendly.
FUTURE SCOPE
By the installation of jet nozzle and strong solenoid valve can reduce the time to fill bottles and can
efficiently increase productivity. A guide way could be used in case of vibration. A capping section
could also be introduced. The nozzle positioning must be given more care and concentration. The
system could be redesigned for increased bottle size and productivity. And also we can make several
bottle can fill at a time by adding multiple solenoid valves to the tank.

REFERENCES
1. "PLC Based Automatic Bottle Filling and Capping System With User Defined Volume Selection “ T.Kalaiselvi ,
R.Praveena, Assistant professor, Easwari Engineering College, Chennai. International Journal of Emerging
Technology and Advanced Engineering (ISSN 2250-2459) 2012.
2. “Implementation and performance analysis of bottle filling plant using ladder language” 1 SavitaM.tech,R.N College
of Engineering & Management,Rohtak,India.2 Lokeshwar Assistant Prof, R.N College of Engineering &
management, Rohtak, India. International Journal of Science and Research (ISSN 2319-7064) 2012.
3. “Automatic liquid filling to bottles of different height using programmable logic controller” 1Mallaradhya H M, 2 K
R Prakash1Department of Industrial Automation Engineering, VTU-RO, Mysore, Karnataka, India. 2Department of
Mechanical Engineering, National Institute of Engineering, Mysore, Karnataka,India. International Journal of
Mechanical and Production Engineering, ISSN: 2320-2092, Oct-2013.
4. “Automation of Packaging and Material Handling Using Programmable Logic Controller”, Joanna Marie M. Baroro,
Melchizedek I. Alipio, Michael Lawrence T. Huang, Teodoro M. Ricamara, Angelo A. Beltran Jr. School of
Graduate Studies, Mapua Institute of Technology, Philippines. International Journal of Scientific Engineering and
Technology(ISSN: 2277 – 1581) June 2014.

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