FINAL YEAR PROJECT REPORT

(Automatic Bottle Filling System Using PLC)

Project Advisor
(Mr. Khan M. Nazir)

Submitted by
(Asim Munir Malik 091320063)
(Jasim Munir Malik 091320064)
(Sana Saleem 091320044 )

Department of Electrical Engineering

School of Engineering
University of Management and Technology
(Automatic Bottle Filling System Using PLC)

A report submitted to the

Department of Electrical Engineering

in partial fulfillment of the requirements for the

degree

Bachelor of Science
In

Electrical Engineering

By

(Asim Munir Malik 091320063)

(Jasim Munir Malik 091320064)
(Sana Saleem 091320044 )

University of Management and Technology

April , 2013

Project Advisor Project Co-Advisor

 Abstract

A Programmable Logic Controller (PLC) is a specialized computer used for the control and
operation of manufacturing process and machinery. A PLC implementation and designing,
mainly covers the following topics: PLC hardware components, developing fundamental PLC
wiring diagrams, basics of PLC programming, timers, counters, program control instructions,
data manipulation instructions, PLC installation, editing and troubleshooting. For practicing,
PLC programming we have used RSLogix® from Rockwell Automation. We are able to observe
the operation of the program and make necessary modifications. This project aims to solve
practical process in industrial environments with the help of PLC. The process consists of
conveyor belt which is constantly moving in normal condition. Empty bottles are placed on
conveyer belt. When a bottle is exactly in front of the sensor, the object sensors will sense it and
after few seconds the conveyor belt will stop. When the bottle is exactly under the solenoid
valve, the Solenoid valve will operate after two seconds and the filling of bottle will start. After a
constant time, Solenoid valve will stop and after two seconds conveyor belt will start moving
again. In this way process completes its one cycle.
 Dedication

We would gratefully like to dedicate our Final Year Project Report to our parents
and teachers who guided and supported us through our learning and whose love,
prayers and encouragement helped us to achieve this goal.
 Acknowledgements

All praise and thanks to the Almighty ALLAH, the most gracious, the most merciful who blessed
us with wisdom and knowledge to carry out this project.

We are greatly indebted to our project Adviser Mr. Khan M. Nazir whose guidance and
enlightening ideas helped us at each level of learning. He was kind, gracious and patient in
support of time that we devoted to the project and with his own valuable time.

We offer our regards and blessings to Co-Adviser Mr. Jawadullah who supported us in any
respect during the completion of the project. Without his contribution, it was impossible to
complete our project. He was a constant source of inspiration and encouragement. He fully
contributed his immense intellectual prowess towards originating, shaping and completing this
project.

Lastly, we thank everybody who even contributed a little straw to our newly built raft. But
special thanks to our project committee members Mr. Rauf Ali, Mr. Asim Butt, Mr. Muhammad
Shoib and lab Supervisor Mr. Saleem, who tried to facilitate us in all respects concerned to all
technical work on PLC.
 Contents

INTRODUCTION 1

Chapter # 1 7
HARDWARE 7
1.1 PROCESS 8
1.1.1PLC (PROGRAMMABLE LOGIC CONTROLLER) 8
1.1.2 PLC compared with other control systems 9
1.2 Conveyer belt 10
Specification 11
1.3 Object Sensors (IR SENSORS) 12
1.3.1 WORKING PRINCIPLE 12
1.3.2 Advantages 20
1.3.4 ELECTRONIC CIRCUITRY 20
555 Timer 16
1.4 Relay 16
1.5 Solenoid valve 17
1.5.1 Valve 17
1.5.2 APPLICATIONS of Valves 17
1.5.3 Types of Valves 18
Working Principle 18
1.5.4 Design Considerations 19
1.6Male and female connectors (RS-232) 20
1.7 DC Gear Motor 21
1.7.1 ELECTRIC motor 29
1.7.2 DC Gear Motor 30
Chapter # 2 24
SOFTWARE 24
WPLSoft 08.02 25
2.1 - Introduction 26
2.2 Window instructions 28
2.3 Memory 38
Warning Error! Bookmark not defined.

Chapter # 3 Error! Bookmark not defined.

PLC Error! Bookmark not defined.
(Programmable Logic Controller)
3.1 Introduction Error! Bookmark not defined.
3.2 PLC Overview Error! Bookmark not defined.
3.3 PLC Features Error! Bookmark not defined.
3.4 PLC Programming Error! Bookmark not defined.
3.4.1 PLC Programming Languages Error! Bookmark not defined.
3.4.2 Ladder logic 45
3.5.1 LATCHES 45
3.5.2 Sensors 46
3.5.3 Switch 47
3.5.4 MASTER CONTROL RELAYS (MCRs) 48
3.6 PLC Advantages and Disadvantages 48

Chapter # 4 49
Integration Of The Project 49
4.1 Introduction 50
4.2. Creation of new project 51
4.3 Graphical Programming 53
Connection Of PLC To Computer 56

Chapter # 5 57
TESTING& RESULTS 57
5.1 Initial Testing 58
5.2 Infra-Red Sensors (Object Detection) 58
5.3 Solinoid Valve 58
5.4 Conveyor Belt 59
5.5 DC Gear Motor 60
5.6 Final PLC Testing Error! Bookmark not defined.
CHAPTER # 6 61
Conclusions and Further Recommendations 61
6.1 Extended Idea 62
6.2 Conclusion 63
6.3 Future Recommendation 65

REFERENCES 67
APPENDICES 68
INTRODUCTION

.
The project we design is automatic bottle filling system using PLC which consists of conveyor
belt (Refer to figure 1, Figure 2) which is constantly moving in normal condition, the different
sizes of bottles will move on the conveyor belt. When bottle exactly reach under the solenoid
valve then bottle stop automatically and valve will be open then filling of bottle will start. After
filling the solenoid valve will close and bottle will start moving on conveyor belt again in this
way process completes its one cycle.

Taking liquid in proportion using sensors & valves which is controlled by PLC through serial
port (RS-232) gives the complete control over the rate of flow of the liquid passing through it.
Conveyer belt driven by DC gear motor is used for controlled bottles purposes that provide user
defined rotation of belt in either direction.

The process consists of mainly following hardware components.

1- Conveyer belt assembly.

2- Water tank.

3- DC gear motor.

4- IR sensors.

5- Solenoid valve.
Figure 1: (Block Diagram)
 Mechanical Structure

Transmitter Sensor

PLC
Conveyor
Motor
Belt
Battery

Valve

Figure 2: Block Diagram

The process consists of conveyor belt which is constantly moving in normal condition, the bottle
will move on the conveyor belt that will have choose to fill, when these bottles are exactly front
of sensor, the object sensors will operate and after few seconds the conveyor belt will stop when
the bottle exactly under the solenoid vale, then the Solenoid valve will operate after two seconds
and filling of bottle will start. After a constant time, Solenoid valve will stop and after two
seconds conveyor belt will start moving again. In this way process completes its one cycle.

So we have to control the following parameters for this process.

1- Water Level Control.

2- Conveyor Control.
3- Timing Control.
We are controlling the water level of bottles by using external timer. The timer has different
values in milliliters, We can set it value according to over need. We used this process instead of
level sensor because Level sensors are too expensive and are not commonly available.

There is a conveyer belt which is moved by a DC geared motor. We are using a geared motor to
control the running of conveyer belt because we require a slow and smooth running and also jerk
free stopping of conveyer belt.

We are filling the bottles by exact measurement of time required to fill the bottle. We are using
this technique because it is too simple and cost free. The only equipment required for this
purpose is the Solenoid Valve which will operate for a constant time depending upon size of the
bottle which will we choose.
The Object Sensors consist of laser transmitters and receivers which are connected opposite to
each other on the conveyer belt assembly .They detect the presence of bottles when an object
block the transmitter light and receiver is unable to collect it. We are using IR as a transmitter
while the core of receiver circuit is IR which forces the Relay to operate by controlling the Base
current of Transistor. The IR has maximum resistance in normal state and contains minimum
resistance when it is under the influence of light.

The solenoid valve operates only in two states ON or OFF and it requires a AC supply for its
operation.
CHAPTER # 1

HARDWARE
1.1 PROCESS

The complete mechanism is been driven by switching through PLC which gets a signal from IR
sensors whenever the bottle arrives at the conveyor belt. The process consists of conveyor belt
which is constantly moving in normal condition, the bottle will move on the conveyor belt that
will have choose to fill, when these bottles are exactly front of sensor, the object sensors will
operate and after few seconds the conveyor belt will stop when the bottle exactly under the
solenoid vale, then the Solenoid valve will operate after two seconds and filling of bottle will
start. After a constant time, Solenoid valve will stop and after two seconds conveyor belt will
start moving again. In this way process completes its one cycle.

The process consists of mainly following hardware components.

1.1.1PLC (PROGRAMMABLE LOGIC CONTROLLER)

A digitally operating electronic system, designed for use in an industrial environment, which
uses a programmable memory for the internal storage of user-oriented instructions for
implementing specific functions such as logic, sequencing, timing, counting and arithmetic, to
control, through digital or analogue inputs and outputs, various types of machines or processes.
Both the PC and its associated peripherals are designed so that they can be easily integrated into
an industrial control system and easily used in all their intended functions. A programmable
logic controller is therefore nothing more than a computer, tailored specifically for certain
control tasks. This is shown in fig 1-1.

Fig 1-1 (Block diagram of PLC system)

Input module
Output module

Central Processing Unit

The function of an input module is to convert incoming signals into signals, which can be
processed by the PLC, and to pass these to the central control unit. The reverse task is performed
by an output module. This converts the PLC signal into signals suitable for the actuators. The
actual processing of the signals is effected in the central control unit in accordance with the
program stored in the memory.

1.1.2 PLC compared with other control systems

PLCs are well-adapted to a range of automation tasks. These are typically industrial processes in
manufacturing where the cost of developing and maintaining the automation system is high
relative to the total cost of the automation, and where changes to the system would be expected
during its operational life.

Fig 1-2 (Prior to PLCs, many of hard-wired tasks were solved with contactor or relay controls)

PLC is low compared to the cost of a specific custom-built controller design. On the other hand,
in the case of mass-produced goods, customized control systems are economic due to the lower
cost of the components, which can be optimally chosen.

A computer is optimized for calculation and display tasks

A computer is programmed by specialists

A PLC is designed for (logic) control and regulation tasks

A PLC is programmed by non-specialists

A PLC is well adapted to industrial environment

A microcontroller-based design would be appropriate where hundreds or thousands of units will
be produced and so the development cost (design of power supplies, input/output hardware and
necessary testing and certification) can be spread over many sales, and where the end-user would
not need to alter the control.

Programmable controllers are widely used in motion control, automotive applications,

positioning control and torque control. PLCs may include logic for single-variable feedback
analog control loop, a "proportional, integral, derivative" or "PID controller." A PID loop could
be used to control the temperature of a manufacturing process, for example.

1.2 Conveyer belt

A conveyor belt (or belt conveyor) 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, etc. generally in outdoor locations. Generally companies
providing general material handling type belt conveyors do not provide the conveyors for bulk
material handling. In addition there are a number of commercial applications of belt conveyors
such as those in grocery stores.

Conveyors are used as components in automated distribution and warehousing. Belt conveyors
are the most commonly used powered conveyors because they are the most versatile and the least
expensive. Product is conveyed directly on the belt so both regular and irregular shaped objects,
large or small, light and heavy, can be transported successfully. Belt conveyors can be used to
transport product in a straight line or through changes in elevation or direction. Belt conveyors
are generally fairly similar in construction consisting of a metal frame with rollers at either end
of a flat metal bed. The belt is looped around each of the rollers and when one of the rollers is
powered by an electric motor, the belting slides across the solid metal frame bed, moving the
product. In heavy use applications the beds which the belting is pulled over are replaced with
rollers. The rollers allow weight to be conveyed as they reduce the amount of friction generated
from the heavier loading on the belt.

Specification
Length : 3 feet

Width : 3 inches

Two 3.5 inches ROLLERS

Belt 6 feet straight

Figure 1-3 (Conveyor Belt)

1.3 Object Sensors (IR SENSORS)

1.3.1 WORKING PRINCIPLE

Infrared radiation enters through the front of the sensor, known as the sensor face. The sensor is
often manufactured as part of an integrated circuit and may consist of one (1), two (2) or four (4)
'pixels' of equal areas of the pyroelectric material. Pairs of the sensor pixels may be wired as
opposite inputs to a differential amplifier. In such a configuration, the PIR measurements cancel
each other so that the average temperature of the field of view is removed from the electrical
signal; an increase of IR energy across the entire sensor is self-cancelling and will not trigger the
device. This allows the device to resist false indications of change in the event of being exposed
to flashes of light or field-wide illumination. (Continuous bright light could still saturate the
sensor materials and render the sensor unable to register further information.) At the same time,
this differential arrangement minimizes common-mode interference, allowing the device to resist
triggering due to nearby electric fields. However, a differential pair of sensors cannot measure
temperature in that configuration and therefore this configuration is specialized for motion
detectors

1.3.2 Advantages
This sensor can be used for most indoor applications where no important ambient light is present.
For simplicity, this sensor doesn't provide ambient light immunity, but a more complicated,
ambient light ignoring sensor should be discussed in a coming article. However, this sensor can
be used to measure the speed of object moving at a very high speed, like in industry or in
tachometers. In such applications, ambient light ignoring sensor, which rely on sending 40 Khz
pulsed signals cannot be used because there are time gaps between the pulses where the sensoris
'blind'.

1.3.4 ELECTRONIC CIRCUITRY

Design: Low range, Always ON:-

As the name implies, the sensor is always ON, meaning that the IR led is constantly emitting
light. This design of the circuit is suitable for counting objects, or counting revolutions of a
rotating object, that may be of the order of 15,000 rpm or much more. However this design is
more power consuming and is not optimized for high ranges. in this design, range can be from 1
to 10 cm, depending on the ambient light conditions.

• The sender is composed of an IR LED (D2) in series with a 470 Ohm resistor, yielding a
forward current of 7.5 mA.
• The receiver part is more complicated, the 2 resistors R5 and R6 form a voltage divider
which provides 2.5V at the anode of the IR LED (here, this led will be used as a sensor).
When IR light falls on the LED (D1), the voltage drop increases, the cathode's voltage of
D1 may go as low as 1.4V or more, depending on the light intensity.
• This voltage drop can be Detected using an Op-Amp (operational Amplifier LM358).
You will have to adjust the variable resistor (POT.) R8 so the the voltage at the positive
input of the Op-Amp (pin No. 5) would be somewhere near 1.6 Volt. if you understand
the functioning of Op-Amps, you will notice that the output will go High when the volt at
the cathode of D1 drops under 1.6. So the output will be High when IR light is detected,
which is the purpose of the receiver.
• The Object Sensors consist of laser transmitters and receivers which are connected
opposite to each other on the conveyer belt assembly .They detect the presence of
objects when an object block the transmitter light and receiver is unable to collect it. We
are using Laser LED as a transmitter while the core of receiver circuit is LDR which
forces the Relay to operate by controlling the Base current of Transistor. The following
figure shows the receiver circuit.
Figure 1-4 IR Object sensor
PIN DESCRIPTION PURPOSE

1 Ground DC Ground

2 Trigger The trigger pin triggers the beginning of the timing

sequence. When it goes LOW, it causes the output pin to go
HIGH. The trigger is activated when the voltage falls below
1/3 of +V on pin 8.

3 Output The output pin is used to drive external circuitry. It has a

"totem pole" configuration, which means that it can source or
sink current. The HIGH output is usually about 1.7 volts
lower than +V when sourcing current. The output pin can
sink up to 200mA of current. The output pin is driven HIGH
when the trigger pin is taken LOW. The output pin is driven
LOW when the threshold pin is taken HIGH, or the reset pin
is taken LOW.

4 Reset The reset pin is used to drive the output LOW, regardless of
the state of the circuit. When not used, the reset pin should
be tied to +V.

5 Control Voltage The control voltage pin allows the input of external voltages
to affect the timing of the 555 chip. When not used, it should
be bypassed to ground through a 0.01uF capacitor.

6 Threshold The threshold pin causes the output to be driven LOW when
its voltage rises above 2/3 of +V.

7 Discharge The discharge pin shorts to ground when the output pin goes
HIGH. This is normally used to discharge the timing
capacitor during oscillation.

8 +V DC Power - Apply +3 to +18VDC here.

555 Timer

Figure 1-5 (555 timer)

1.4 Relay

A relay is an electrical switch that opens and closes under the control of another electrical
circuit. In the original form, the switch is operated by an electromagnet to open or close one or
many sets of contacts. Because a relay is able to control an output circuit of higher power than
the input circuit, it can be considered to be, in a broad sense, a form of an electrical amplifier.
When an electric current is passed through the coil, the resulting magnetic field attracts the
armature and the consequent movement of the movable contact or contacts either makes or
breaks a connection with a fixed contact. If the set of contacts was closed when the relay was de-
energized, then the movement opens the contacts and breaks the connection, and vice versa if the
contacts were open. Since relays are switches, the terminology applied to switches is also applied
to relays. A relay will switch one or morepoles, each of whose contacts can be thrownby
energizing the coil in one of three ways:

Normally-open (NO) contacts connect the circuit when the relay is activated; the circuit is
disconnected when the relay is inactive. It is also called a Form A contact or "make" contact.
Normally-closed (NC) contacts disconnect the circuit when the relay is activated; the circuit is
connected when the relay is inactive. It is also called a Form B contact or "break" contact.
Change-over (CO), or double-throw (DT), contacts control two circuits: one normally-open
contact and one normally-closed contact with a common terminal. It is also called a Form C
contact or "transfer" contact ("break before make"). If this type of contact utilizes” make before
break" functionality, then it is called a Form D contact.

1.5 Solenoid valve

1.5.1 Valve
A valve is a device that regulates the flow of a fluid (gases, liquids, fluidized solids, or slurries)
by opening, closing, or partially obstructing various passageways. Valves are
technically pipe fittings, but are usually discussed as a separate category. In an open valve, fluid
flows in a direction from higher pressure to lower pressure. Valves are also found in the human
body. For example, there are several heart valves which control the flow of blood in
the chambers of the heart and maintain the correct pumping action. Valves are used in a variety
of contexts, including industrial, military, commercial, residential, and transport.
The industries in which the majority of valves are used are oil and gas, power
generation, mining, water reticulation, sewerage and chemical manufacturing.

Valves may be operated manually, either by a hand wheel, lever or pedal. Valves may also be
automatic, driven by changes in pressure, temperature, or flow. These changes may act upon a
diaphragm or a piston which in turn activates the valve, examples of this type of valve found
commonly are safety valves fitted to hot water systems or boilers.

1.5.2 APPLICATIONS of Valves

Valves vary widely in form and application. Sizestypically range from 0.1 mm 60 cm (2 ft).
Special valves can have a diameter exceeding 5 meters. Valve cost ranges from simple
inexpensive disposable valves to specialized valves cost thousands of US dollars per inch of
diameter. Disposable valves may be found inside common household items including mini-pump
dispensers and aerosol cans.

1.5.3 Types of Valves

Valves are quite diverse and may be classified into a number of basic types. Valves may also be
classified by how they are actuated:

Hydraulic

Pneumatic

Manual

Solenoid

Motor

Working Principle
A solenoid valve is an electromagnetic valve for use with liquid or gas controlled by running or
stopping an electric current through a solenoid, which is a coil of wire, thus changing the state of
the valve. The operation of a solenoid valve is similar to that of a light switch, but typically
controls the flow of air or water, whereas a light switch typically controls the flow of electricity.
Solenoid valves may have two or more ports: 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.
Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut
off, release, dose, distribute or mix fluids. They are found in many application areas. Solenoids
offer fast and safe switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design. A solenoid valve has two main parts: the
solenoid and the valve. The solenoid converts electrical energy into mechanical energy which, in
turn, opens or closes the valve mechanically.
 Figure 1-6(a) Solenoid Valve

1.5.4 Design Considerations

When the operation of your system or process requires the remotecontrol of liquid, air, gases or
vacuum, the proper selection of a solenoid valve can make a significant difference in the final
performance of the machine or process. KIP solenoid valves, operators and manifolds have the
versatility and design features to fulfill all types of applications. Some consideration should be
given to the following design parameters to help you with the selection process:

• Valve Type
• Media
- Temperature
- Lubrication
- Cleanliness
- Isolation
• Flow Rate
• Pressure
• Power Consumption
• Duty Cycle
• Material of Construction
• Electrical Termination
• Porting
• Mounting

A solenoid valve is an electromagnetic valve to use with liquid controlled by running or stopping
an electric current through a solenoid, which is a coil of wire, thus changing the state of the
valve. Whenever package arrives then Conveyor belt would stop and valve would be given an
ON signal through PLC. As this project is size based so every size of the package has its own
timer on the constant flow rate, so as soon as the time is completed then valve will close
&conveyor belt would again put into the running condition. So the opening and closing of valve
depends upon whenever package arrives and its size.

Figure 1-6 (b) Solenoid valve

1.6Male and female connectors (RS­232)
The terms "slot" and "socket" are often used for "female" connectors,
and "plug" and "pin" for "male" connectors while the term “jack” is used for both female and
male connectors.

Figure 1-7(a):15 pin female Figure 1-7(b): 48 pin male

. connector connector

A connector in a fixed location is a jack, and a moveable connector is a plug. It is common

practice to use female connectors for jacks. These connectors are available in different number

1.7 DC Gear motor

(DRIVING CONVEYOR BELT)

1.7.1 ELECTRIC motor

An electric motor converts electrical energy into mechanical energy.Most electric motors operate
through the interaction of magnetic fields and current-carrying conductors to generate force. The
reverse process, producing electrical energy from mechanical energy, is done by generators such
as an alternator or a dynamo; some electric motors can also be used as generators, for example,
a traction motor on a vehicle may perform both tasks.
A DC motor is designed to run on DC electric power. By far the most common DC motor types
are the brushed and brushless types, which use internal and external commutation respectively to
reverse the current in the windings in synchronism with rotation.
Electric motors are everywhere! In your house, almost every mechanical movement that you see
around you is caused by an AC (alternating current) or DC (direct current) electric motor.
A simple motor has six parts:
• Armature or rotor
• Commutator
• Brushes
• Axle
• Field magnet
• DC power supply of some sort.

1.7.2 DC Gear Motor

The conveyer belt is moved by a DC gear motor. We are using a DC gear motor to control the
running of conveyer belt because we require a powerful, slow and smooth running ,and also jerk
free stopping of conveyer belt. A Gear motor has a gearbox that increases torque and decreases
speed. DC motors might run in the thousands of RPMs, and if you want to do anything slower
and with more torque, you need a gearbox.

Figure 1-8 (DC Gear Motor)

Basic Specification :-
1. 12V DC, 24V DC Input power: 0.1~2.5W
2. 1.1-200 rpm
3. Direction of Rotation: CW, CCW range of reduction
ratio: 1:30, 1:60, 1:90, 1:180, 1:270
No Load Specification :-
1. NO Load Current: 75 mA max
2. No Load Speed: 100±10%

ON Load Specification:
1. ON Load Torque: 1.0kg.cm
2. ON Load Current: 450 mA max
3. ON Load Speed: 80±10%

Stall Specification:-
1. Stall Torque: 10kg.cm
2. Stall Current: 900 mA max