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MTR FA 2 Final

The report outlines the design and implementation of an automated empty bottle detection and rejection system using PLC and PID-based control strategies to enhance manufacturing efficiency. It addresses the problem of manual inspection inefficiencies and aims to automate the identification and removal of empty bottles on a conveyor system. The system demonstrated superior performance with the PID controller, minimizing waste and improving product quality.

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7 views10 pages

MTR FA 2 Final

The report outlines the design and implementation of an automated empty bottle detection and rejection system using PLC and PID-based control strategies to enhance manufacturing efficiency. It addresses the problem of manual inspection inefficiencies and aims to automate the identification and removal of empty bottles on a conveyor system. The system demonstrated superior performance with the PID controller, minimizing waste and improving product quality.

Uploaded by

skbackup2004
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering

Mechatronics
Formative Assessment-II
Part A & B

Name PRN
Mohit Hinge 122B1G071
Sudarshan Kashid 122B1G081
Aryan N. Kawade 122B1G082
Om Parekh 122B1G129

Guide: Dr. R. A. Gujar Sir


Report: Automated Empty Bottle Detection and
Rejection System Using PLC and PID-Based Control
1. Introduction
In manufacturing industries, especially those in bottling, the automation of
production lines plays a crucial role in increasing throughput and ensuring product
quality. Empty or defective bottles can result in significant material wastage,
increased costs, and reduced consumer trust. The challenge is to detect these
empty bottles and remove them from the production line without causing
disruption. This report presents the design and implementation of an automated
empty bottle detection and rejection system that uses a Programmable Logic
Controller (PLC) and various PID-based control strategies (PI, PD, and PID
controllers) to automate the process and ensure consistent product quality.

2. Problem Statement
In the absence of an automated system, empty bottles are often missed during
production, leading to issues in downstream processes like labeling, capping, and
packaging. If these bottles are not detected and removed quickly, they contribute
to material wastage and pose a risk to the overall product quality. Manual
inspection for empty bottles is inefficient and prone to errors, especially in high-
speed environments. This system needs to automate the process of identifying and
removing empty bottles on a conveyor system, ensuring that only filled bottles
proceed further along the production line.
3. Objectives
The primary objectives of this project are as follows:

• To design a PLC-based control system that continuously monitors and


controls the rejection of empty bottles.
• To integrate a pneumatic cylinder mechanism for the physical removal of empty
bottles.
• To evaluate different control strategies (PI, PD, and PID) to optimize system
performance and response time.
• To ensure the synchronization of sensor data, bottle movement, and rejection
mechanism.

4. System Description
4.1 Components
• Sensor Unit: Photoelectric or capacitive sensors are used to detect the
presence of empty or filled bottles.
• PLC Unit: The PLC receives input from sensors and processes the data
using ladder logic to control system outputs.
• Pneumatic Cylinder: A pneumatic cylinder is used to push the empty
bottles off the conveyor.
• Solenoid Valve: The solenoid valve, controlled by the PLC, operates
the pneumatic cylinder.
• Conveyor System: The conveyor system moves the bottles along the
production line, passing through the detection zone and the rejection
zone.

4.2 Process Flow


1. Bottles move along the conveyor belt.
2. The sensor detects the status of each bottle (empty or filled).
3. If an empty bottle is detected, the PLC logic triggers the solenoid valve
to actuate the pneumatic cylinder.
4. The cylinder extends and pushes the empty bottle off the conveyor.
5. The remaining bottles continue moving along the production line.
5. Control Strategies
5.1 PI Controller
A Proportional-Integral (PI) controller is used to improve steady-state error
correction. The proportional component (P) determines the speed of the
actuation, while the integral component (I) eliminates any steady-state errors
over time. This control strategy is particularly effective for systems with moderate
inertia.

5.2 PD Controller
A Proportional-Derivative (PD) controller is implemented to achieve better response time and
damping. The derivative component (D) helps to anticipate changes in the system’s state,
reducing overshoot and improving the system’s ability to reach its target position quickly. This is
ideal for fast-moving conveyor systems.

5.3 PID Controller


The PID controller combines proportional (P), integral (I), and derivative (D)
actions to provide a robust and flexible control strategy. The P action adjusts the
speed of the cylinder, the I action eliminates steady-state errors, and the D action
minimizes oscillations. The PID controller is ideal for complex systems with
multiple variables, ensuring accurate and smooth actuation.
6. PID Tuning
Tuning the PID controller is a critical step for achieving optimal system
performance. The following parameters are adjusted during the tuning process:

• Proportional (P): Controls the system's response speed. A higher P


value results in faster actuation but may cause overshoot.
• Integral (I): Eliminates steady-state errors. A higher I value can help
reach the target position precisely but may introduce system lag.
• Derivative (D): Provides damping to prevent oscillations and overshoot. It
is especially useful for systems with quick responses.

Tuning can be achieved using methods such as the Ziegler-Nichols method or


through trial and error, adjusting each parameter to achieve a balance between
speed, accuracy, and stability.

7. Transfer Function of the System


The system dynamics are modeled using a third-order transfer function:

Where:

• τv : Valve time constant


• ζ : Damping ratio
• ωn: Natural frequency
• K: Gain

This transfer function models the combined dynamics of the solenoid valve and
pneumatic cylinder. By analyzing the system’s response using this transfer
function, we can determine the optimal control strategy and fine-tune the PID
parameters.
8. Implementation
The PLC logic was implemented using ladder programming to:

• Monitor sensor inputs and detect empty bottles.


• Calculate the bottle position using timers and encoders.
• Trigger the solenoid valve to extend or retract the pneumatic cylinder.
• Log the rejection events and system status for monitoring.

The system was tested in a laboratory setting using a conveyor system to simulate
real-world conditions. The results demonstrated that the system could reject empty
bottles consistently with minimal delay and high accuracy.
8.1 MATLAB Simulink Code :
9. Results and Discussion
9.1 Performance Analysis
The system successfully detected and rejected empty bottles with a high degree of
accuracy. The PID controller demonstrated superior performance compared to the
PI and PD controllers. The PID controller minimized overshoot, reduced settling
time, and ensured that the cylinder reached the desired position quickly and
smoothly.

9.2 Control Strategy Comparison


• The PI controller provided good steady-state error correction but had
slower response times.
• The PD controller was faster but sometimes overshot the target
position, leading to oscillations.
• The PID controller balanced both speed and accuracy, providing the
best overall performance with smooth, precise actuation.

10. Conclusion
The integration of PLC-based control with PID algorithms significantly enhances
the efficiency and reliability of the empty bottle rejection system. This approach
reduces manual labor, minimizes material waste, and improves the overall quality
of products moving through the production line. The system is scalable, allowing
for future expansions and improvements in detection and rejection mechanisms.

11. References
1. Smith, O. J. M. (2005). "The PID Control Handbook." Springer.
2. Ziegler, J. G., & Nichols, N. B. (1942). "Optimum Settings for Automatic
Controllers."
Transactions of the ASME.
3. PLC manufacturer datasheets and programming manuals.

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