AUTOMATIC BOTTLE FILLING AND CONVEYOR SYSTEM

USING PLC

A PROJECT REPORT
Submitted by
NAME REG NO

SEENIVASAN.R 623521105046

SETHU ARAVINTH.K 623521105047

SATHISH KUMAR.S 623521105045

SABARI RAJAN.M 623521105303

SOWMIYA.R 623521105050

SIVA RANJINI.M 623521105049

BACHELOR OF ENGINEERING IN
ELCTRICAL AND ELECTRONICS ENGINEERING

Guided by
Mrs.K.VIMALA Msc.IT
PLC Trainer
 AVS COLLEGE OF TECHNOLOGY

CHINNAGOUNDAPURAM,SALEM.

BONAFIDE CERTIFICATE

Certified that this project report “AUTOMATIC BOTTLE FILLING

ANDCONVEYOR SYSTEM USING PLC” is the bonafide workdone by

NAME REG NO
SEENIVASAN.R 623521105046

SETHU ARAVINTH.K 623521105047

SATHISH KUMAR.S 623521105045
SABARI RAJAN.M 623521105303
SOWMIYA.R 623521105050
SIVA RANJINI.M 623521105049

INTERNAL GUIDE HOD OF THE DEPARTMENT

INTERNAL EXAMINAR EXTERNAL EXAMINAR

 TABLE OF CONTENTS

S.NO TOPIC
1 Introduction

1.1 Introduction of Automatic Bottle Filling and Conveyor System

1.2 Role of PLCs in Automation

1.3 Overview of WPLSoft

2 Objectives

3 System Overview

3.1 Components of the System

4 Working Principle

4.1 System Initialization

4.2 Bottle Detection

4.3Filling Process

4.4 Conveyor Movement

4.5 Error Handling

5 System Design and Implementation

5.1 PLC Programming

5.2 Design Of PLC Ladder Logic

5.3 Electrical Wiring

5.4 Mechanical Setup

6 Advantages of the System

7 Challenges and Solutions

8 Applications

9 Conclusion
1. Introduction
Introduction of Automatic Bottle Filling and Conveyor System

Automation plays a crucial role in modern industrial processes, especially in

manufacturing, where high precision and efficiency are required. One common application
of automation is the bottling industry, where liquids are filled into bottles in large quantities.
Manual bottling processes can be time-consuming, prone to errors, and often costly. To
address these challenges, automated systems such as the ‘‘Automatic Bottle Filling and
Conveyor System Using PLC’’ have been developed.

This system uses ‘‘Programmable Logic Controllers (PLC)’’ to control and

manage the movement of bottles along a conveyor belt while filling them with a
predetermined quantity of liquid. The system ensures accurate filling, reduces human errors,
and operates continuously at high speeds, increasing productivity. This report provides an in-
depth look at the working principle, design, and implementation of the system, along with its
applications, benefits, and challenges.

Role of PLCs in Automation

A Programmable Logic Controller (PLC) is a specialized digital computer used in

industrial automation processes to monitor inputs and outputs and make logic based

decisions in real time. PLCs are highly reliable, flexible, and can be easily programmed to

perform complex tasks. In a drilling machine, the PLC can handle multiple operations, such

as controlling the drill motor, managing the feed rate, and ensuring that the work piece is

positioned correctly.

PLCs are programmed using various software platforms, with WPLSoft being one
of the most commonly used for Delta PLCs. This software allows users to develop and
simulate control logic using ladder diagrams, a visual method of programming that replicates
the look and feel of electrical relay logic.
 Overview of WPLSoft

WPLSoft is a programming tool used for Delta PLCs, which offers a user friendly

interface for writing ladder logic programs. It supports simulation, enabling users to test their

programs before deployment. WPLSoft also includes features such as I/O mapping,
timer/counter functions, and communication protocols that make it an excellent choice for

industrial automation tasks like bottle filling.

2. Objectives
The key objectives of the automatic bottle filling and conveyor system are to:

 Automate the process of bottle filling to improve speed and accuracy.

 Utilize a PLC to control the conveyor system and manage the filling operation.
 Minimize human intervention, thereby reducing errors, operational costs, and potential
contamination risks.
 Ensure flexibility to accommodate different types of liquids and bottle sizes.
 Provide real-time monitoring and troubleshooting capabilities.

3. System Overview
The “Automatic Bottle Filling and Conveyor System” consists of several key
components that work together to achieve the automated filling process. These include the
conveyor belt, filling mechanism, sensors, motors, solenoid valves, and the PLC. Each of
these components has a specific function that contributes to the overall efficiency and
performance of the system.
 Components of the System

1. PLC (Programmable Logic Controller)

The central control unit that governs the overall functioning of the system. It
processes input signals from sensors and commands the actuators (such as motors and
valves) to execute the desired operations.

2. Conveyor Belt

Transports empty bottles to the filling station and moves filled bottles to the
packaging section. It is driven by a motor and controlled by the PLC, which adjusts the
speed according to the filling cycle.

3. Sensors

Detects the position of bottles on the conveyor. Proximity sensors, typically

infrared or capacitive types, are placed at key points to signal the PLC when a bottle is in the
correct position for filling or when it has left the filling station.

4. Solenoid Valves

Controls the flow of liquid from the storage tank to the bottles. The solenoid valve
opens when the bottle is detected in the correct position and closes once the required quantity
of liquid is filled.

5. Motors

Drives the conveyor belt and ensures smooth movement of bottles between different
stages. Motors are controlled by the PLC, allowing dynamic adjustments to the conveyor's
speed.

6. Human-Machine Interface (HMI)

Provides a user-friendly interface for operators to monitor the system, set parameters
(e.g., liquid volume, bottle size), and troubleshoot problems.
7. Liquid Reservoir and Pump

The liquid reservoir stores the liquid to be dispensed into the bottles. The pump
ensures a steady flow of liquid to the filling nozzles.

4. Working Principle
The automatic bottle filling and conveyor system follows a systematic process that
is controlled by the PLC, ensuring that each bottle is accurately filled and transported through
the production line. The steps involved in the working process are,

System Initialization

The operator starts the system using the HMI. Initial parameters such as bottle size,
filling volume, conveyor speed, and sensor calibration are set before beginning the operation.

Bottle Detection

As bottles move along the conveyor, proximity sensors detect when a bottle reaches
the designated filling station. Once detected, the PLC receives an input signal from the sensor
and halts the conveyor.

Filling Process

The PLC opens the solenoid valve to release the liquid into the bottle. The amount of
liquid dispensed is controlled by timing or volume sensors. After the required quantity is filled,
the valve closes to stop the flow of liquid.

Conveyor Movement

Once the filling process is complete, the PLC signals the conveyor motor to move the
filled bottle to the next stage (e.g., capping or labelling) and bring the next empty bottle into
position. This cycle continues automatically.

Error Handling

If any error occurs, such as a bottle not being detected or the filling process
malfunctioning, the PLC is programmed to stop the system, and an alarm is triggered on the
HMI. The operator can then resolve the issue and restart the process.
5. System Design and Implementation
The system design integrates both mechanical and electrical components, controlled
by the PLC. The implementation requires precise coordination between sensors, motors, and
valves to ensure the proper functioning of the entire operation. Below are the essential
aspects of the system design:

PLC Programming

PLC programming forms the core of the system. The program is typically written
in ‘‘Ladder Logic’’or ‘‘Function Block Diagrams (FBD)’’ to execute the predefined tasks.

Key functions include:

 Bottle Detection Logic: Ensures that the conveyor stops when a bottle reaches the
filling station.
 Filling Control Logic: Controls the opening and closing of the solenoid valve based
on the liquid volume required.
 Conveyor Movement Logic: Moves the conveyor after filling is complete and
prepares the system for the next cycle.
 Error Handling: Handles unexpected situations such as sensor malfunction, liquid
spillage, or conveyor jams.

Design Of PLC Ladder Logic

Step 1: Bottle Detection

 Input X0 represents the proximity sensor. When a bottle is detected, the conveyor
motor (output Y1) stops to hold the bottle in place.

Step 2: Start Filling

 When X0 is active, the timer T0 starts. The pump or valve (output Y0) turns on during
this time to fill the bottle.

Step 3 : Filling Completed

 When the timer T0 finishes, it turns off the pump (output Y0) and restarts the conveyor
(output Y1) to move the next bottle in place.

Step 4 : Timer Settings

 In WPLSoft, you can configure timers with K values to specify the time duration. For
example, K 50 represents a specific time interval (50 x the base timer unit, often
milliseconds or 0.01 seconds).
 Adjust the timer duration (T0) to match how long it takes to fill a bottle.
Step 5 : Adding HMI (Optional)

 If using an HMI with Delta’s DOPSoft, you can configure an HMI screen to monitor
the filling process, start or stop the system, and adjust the filling time.
 The HMI can display status (e.g., "Filling", "Waiting for Bottle") and allow operators
to change parameters.

Step 6 : Simulation and Testing

 Simulate the logic within WPLSoft to ensure the program works as expected before
deploying it to the actual hardware.

Step 7 : Test each part of the system

 Ensure the conveyor stops when a bottle is detected.

 Ensure the pump or valve runs for the correct amount of time.
 Ensure the conveyor moves the next bottle after filling.

Electrical Wiring

The system's sensors, valves, motors, and the PLC must be properly wired to ensure
effective communication. Each sensor and actuator must be connected to the appropriate
input/output (I/O) terminals on the PLC. Proper grounding and shielding are essential to
avoid electrical noise and interference, ensuring reliable system performance.

Mechanical Setup

The conveyor system is designed to accommodate different bottle sizes and move at
adjustable speeds. The conveyor is driven by a motor connected to a ‘‘Variable Frequency
Drive (VFD)’’, which allows speed control. The filling station is equipped with multiple
nozzles to fill several bottles simultaneously.

6. Advantages of the System

The Automatic Bottle Filling and Conveyor System offers several significant benefits
for industries, including
 Increased Efficiency

Automated systems can operate continuously without breaks, leading to

significantly higher production rates compared to manual operations.

Precision and Accuracy

The use of PLC ensures that each bottle is filled with the exact volume of liquid,
reducing waste and inconsistencies.

Cost Savings

By automating the process, labor costs are reduced, and fewer human errors result
in lower material wastage.

Flexibility

The system can be easily reprogrammed to handle different bottle sizes, shapes, and
liquid volumes, making it highly versatile for various applications.

Improved Safety and Hygiene

Automation reduces the risk of contamination by minimizing human contact with

the product. It also ensures safety by automating hazardous tasks.

7. Challenges and Solutions

Sensor Malfunctions

Sensor malfunctions can lead to errors in bottle detection. To avoid this, periodic
sensor maintenance and calibration are recommended. Redundant sensors can be used as
backups.

Liquid Spillage

Liquid spillage can occur due to improper valve control or bottle misalignment. To
mitigate this, precise control algorithms can be implemented to ensure the valve operates at
the correct time. Additionally, bottle positioning can be improved with better sensor
placement.
 System Downtime

Mechanical or electrical failures can result in unplanned downtime, affecting

production. A predictive maintenance strategy, driven by PLC data logging, can help predict
and address potential issues before they lead to failure.

8. Applications
The Automatic Bottle Filling and Conveyor System is widely used in industries
where liquid products are packaged in bottles. Some of the key application areas include

 Food and Beverage Industry: For filling bottles with water, juice, soft drinks, milk,
and other beverages.
 Pharmaceutical Industry: For filling medicinal liquids such as syrups, solutions, and
tonics.
 Cosmetic Industry: For filling lotions, creams, and oils.
 Chemical Industry: For filling chemicals, solvents, and cleaning agents.

9. Conclusion
The ‘‘Automatic Bottle Filling and Conveyor System Using PLC’’ represents a
significant step forward in the automation of manufacturing processes, particularly in the
bottling industry. The system’s accuracy, speed, and flexibility make it an indispensable tool
in high-demand production environments. With the integration of a well-programmed PLC,
the system operates seamlessly, offering increased productivity and reduced operational
costs.

By implementing this system, manufacturers can achieve consistent and reliable

production with minimal human intervention, ultimately improving product quality and
meeting higher production demands.
References
1. Bolton, W. (2015). *Programmable Logic Controllers*. 6th ed. Elsevier.

2. Petruzella, F. D. (2011). *Programmable Logic Controllers*. 4th ed. McGraw Hill.

3. John, K., & Duff, B. (2016). *Industrial Automation Technologies*. Springer.

4. Hassan, R. (2018). *Industrial Automation and Control: Concepts and Applications*.

Wiley.

5. Jack, H. (2010). *Automated Manufacturing Systems with PLCs*. Pearson Education.