Question

Company X currently producing bottled fruit juice for local markets and the demand is growing amidst COVID 19 pandemic. The company were unable to meet the increasing demand due to the bottleneck experienced at labelling station as it is manually executed. Recommend an automated PLC base solution to the problem. Your solution should include;

a. Detail sketch of propose automated bottle labelling station.

b. PLC connection to the system.

c. Descriptions on how your propose solution works.

Answer 1

The objective of our project is to design, develop and monitor “Automatic bottle filling system
using 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 manufacturers. A prototype has been developed to illustrate the project.

Filling is the task that is carried out by a machine and this process is widely used in many
industries. In this project, 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 dc motor has been selected for better performance and ease of operation. A sensor has been used to detect the position of the bottle. In our project we have used less number of system hence the overall cost has been reduced to an extent. 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 a Siemens S7 – 1200 which makes the system more flexible and easy to operate.

Overview
The project is based on industrial automation and PLC is the heart of automation. The hardware and the software are the two important areas in our project.

1) HARDWARE DESCRIPTION:
In this project, Siemens PLC SIMATICS S7 1200 is used for controlling the inputs and
outputs. Input supply to the PLC is given through a SMPS. The rating of the SMPS is
24V DC 5Amps. The PLC used here is a compact PLC which has fixed number of inputs
and outputs. In this kind of PLC model, the CPU contains 14 digital inputs and 10 digital
outputs. One diffused photoelectric sensor has been used for the positioning of the
bottles. A geared DC motor has been used for running the conveyor system. The ratings
of the DC motor is 12V and 50 RPM speed with a high starting torque of 70 Kg-cm (at
no load). Toggle switches are used to serve the purpose of some inputs to the PLC.

2) SOFTWARE DESCRIPTION:
There are five important languages which are used for the programming of the PLC. The
list of the methods are as follows:
 Functional block diagram (FBD)
 Structure text
 Instruction list
 Flow chart
 Ladder diagram
Out of these five languages, ladder diagram is the most widely used language and is
simple as compared to other languages. Ladder diagram has been used for the
programming of this PLC

Literature Review
A brief survey of technologies explored during the past decade and some of them is given below to provide an understanding of the level of research interest in this domain. In this paper, researcher outlined the various phases of operation involved in the adaptation of a manually operated boiler towards a totally automated boiler. The first part of the paper focuses on passing the inputs to the boiler at a required temperature, so as to constantly maintain a particular temperature in the boiler. The Air pre heater and Economizer helped in this method. And the paper mainly focused on level, pressure and flow control at the various stages of the boiler plant. Thus the temperature in the boiler is constantly monitored and brought to a constant temperature as required by the power plant. The automation is further improved by constant monitoring using SCADA screen which is connected to the PLC by means of communication cable. By means of tag values set to various parameters in SCADA the entire process is controlled. At the automated power plant, the boiler is controlled by Variable Frequency Drive (VFD) to put in action the required processes to be carried out at the boiler. Thus the entire cycle is carried out as a paper and at various stages each phase is detailed out. This paper has proved to be very efficient practically as the need for automation grows day by day.

This paper presented a SCADA system for a plant whose product demand is varying according to the temperature. This paper also gives an automatic method of changing a production from one mode to another. There is no manual shifting required. This paper gives a way to get rid off excess production. It also provides the facility to the user to over ride the any one of the unit hardware operation from the control room.

Researchers developed a design of re-usability using modular modeling techniques. Reimplementation of program of existing PLC program based on formulization and visualization. It is done by transformation of FSM in XML format into IEC 61131-3 POUs and project is to be creating to control machine using new controller.

Prior to the development of data acquisition and control system, collecting data from remote field instruments, distributed throughout the plant in huge manufacturing industries, was a quite challenging and multifaceted task. The team of researcher has been developed an industrial data acquisition and control systems equipped these industries with facilities to gather and process data, and perform control actions right from a centralized location, i.e. control room, without actually going to the plant. They introduction of programmable logic controllers (PLC) as a data acquisition and control hardware in these systems increased its reliability and robustness. This paper highlights the design work carried out to develop a cost efficient, simple, robust and intelligent industrial standard data acquisition and control system for two physical field plants that are 50 meters apart from the control room. This work highlights process control application and indeed is an application of industrial electronics engineering. The work carried out for this data acquisition and control system is in correlation with SCADA, DCS and totally integrated automation, which is meant to optimize processes and manufacturing procedures at the same time. At present, the PLC has been widely used in the industry area. But the shortcoming of this controller appears along with the growth of the industry equipments. Such as inferior compatibility cooperate with the new equipments, poor satisfaction of the high calculation and weak communication and so on. Thus, there need new technology to satisfy the increasing industry demands. The soft PLC comes into the world from on kind of condition. The function of PLC is imitated through software on the PC platform. But the soft PLC has shortage also. The sturdiness and instantaneity is worse than the traditional PLC. Therefore, the embedded PLC combines the advantages of traditional PLC and soft PLC, increase the computing power, express the advantages of ladder diagram and open construction to bring a universal platform to the controlled members.

In this research paper, the group of authors took efforts on the improvement of demonstrating
how industrial temperature automation can be achieves using modest hardware and more refined software details. The prime concern was to generate firing pulse for an HVAC controlling actuator while displacing them at the same time to vary the magnitude of the ac voltage output. The direction of displacement of the pulse was described by the SETPOINT definition from an HMI using AT commands, and FEEDBACK from the temperature sensor installed in the industrial background. The mathematical modeling was done in LabVIEW for investigating the effect of varying firing angle on the magnitude of the ac voltage. This controlled variation of output ac voltage can be subjected to controlling temperature of the particular industrial environment.

With the help of PLC, researcher has been build and implements logic for Industrial Crane
Automation & Monitoring. The soft wiring advantage provided by programmable controllers is
Tremendous. In fact, it is one of the most important features of PLCs. Soft wiring makes changes in the control system easy and cheap. If it want a device in a PLC system to behave differently or to control a different process element, all have to do is change the control Program. In a traditional system, making this type of change would involve physically changing the wiring between the devices, a costly and time-consuming attempt. In future definitely PLC is dominated on all other controlling methods.

The team of authors developed ladder logic in MICROLOGIX software and is verified in Allen
Bradley PLC. A ladder logic program of a typical application often results in complex software
that is difficult to manage during configuration, and especially, during maintenance. The
difficulty lies in a typical problem with real-time control software that is exacerbated by ladder
logic. Individual components of PLC software are characteristically asynchronous, resulting in
unpredictable interactions. This makes the initial configuration of the software (i.e.,
commissioning) extremely difficult and labour-intensive, but also makes reconfiguration risky.
However the system creates a fast, real-time decision making environment. Also the use of
SCADA in the industry will not only allow them to minimize the cost associated with the display and recording instruments but will also account for better quality and higher productivity. The process is adaptable to any changes in production capacity or safety requirements. In short integrated automation process produces a reliable quality hardboard production industry with the help of PLC. This paper focuses on an innovative and intelligent monitoring system of process using SCADA. The main concept of paper is data acquisition & controlling by using SCADA software with the help of PLC. Here PLC is a medium between electrical system & Personal Computer for SCADA to take input and output bits. Automating electrical distributions systems by implementing a supervisory control and data acquisition (SCADA) system is the one of the most cost-effective solutions for improving reliability, increasing utilization, increasing efficiency and saving costs.

This paper presented an automatic control of temperature and level of Continues Stirred Tank
Reactor (CSTR) using PLC and SCADA. The CSTR is heated using heating-coil and its
temperature and level are measured by RTD and float type level sensor respectively. The
accurate control of temperature and level are the realistic feature of this system and balances the process. Automation required gaining the complete control of manufacturing process to achieve consistency in manufacturing with increased productivity by shortening manufacturing time. In this paper we consider both Batch and Continues process control using PLC and SCADA. The PLC and SCADA control the process parameters with good accuracy and results are found to be satisfactorily. This is a simple automated process and can be applied in many mixing processes used in industries. In this research paper, the device temperature parameter of different zones of furnace has been constantly monitored and hence it can be further controlled by using DAQ and control system. The constant monitoring of such different furnace zone temperature can produce data-base for scheduling of the machine servicing, troubleshooting and also for future processing. Due to use of microcontroller the computation task has been handled most effectively. Hence group of authors proposed system has been widely used in automotive engineering, instrumentation and power quality monitoring and control applications. Data acquisition system for monitoring such temperature of brazing furnace provides advantages of design simplicity, portability and less cost.

This paper reveals the design of LabVIEW based SCADA system for centralized control. It
makes use of PLC as a field controller to operate the prototype design of Stenter Machine,
widely used in textile industries. LabVIEW, which is a commonly accepted graphical user
interface environment, also provides HMI front end. The PLC controller and the LabVIEW
based SCADA are communicating through the RS-232 link. The control system is flexible and
modular. Due to the intuitive programming of LabVIEW, this system is cost efficient and
reliable solution for automation of small scale textile industries.

The system introduced by a group of researchers is an experimental study which helps in
controlling the characteristics and ON/OFF states of a control valve. A graphical user Interface has been developed using supervisory control and data acquisition (SCADA) and the programming of the control system has been done using programmable logic control (PLC). A descriptive study has been incorporated in this paper to formulize all factors responsible for the change in valve characteristics. This system gives a clear idea about the opening and closing of three types of valves which may be present as per its requirement in an industry. The user of the system is able to supply input parameters so as to efficiently control the valve. The system is highly efficient and cost effective, as only one interfaced digital system along with a PLC can control many subsequent valves.

Technical Specification of PLC

1. Power connector

2.Memory card slot under top door

3. Removable user wiring connectors (behind the doors)

4. Status LEDs for the on-board I/O

5.PROFINET connector( on the bottom of the CPU

The CPU combines a microprocessor, an integrated power supply, input and output circuits,
built-in PROFINET, high speed motion control I/O and on board analog inputs in a compact
housing to create a powerful controller. After downloading a program, the CPU contains the
logic required to monitor and control the devices in the application. The CPU monitors the
imputs and changes the output according to the logic of the user's program.
The CPU provides a PROFINET port for communication over a PROFINET network.

Power Budget
The CPU has an internal power supply that provides power for the CPU, the signal modules,
signal board and communication modules and for other 24VDC user power requirements.

5VDC logic budget supplied by the CPU and the 5VDC power requirements of the signal
modules, signal boards and communication modules.

The CPU provides a 24 VDC sensor supply that can supply 24 VDC for input points, for relay
coil power on the signal modules, or for other requirements. If your 24 VDC power requirements exceed the budget of the sensor supply, then you must add an external 24 VDC power supply to your system.

Some of the 24 VDC power input ports in the S7-1200 system are interconnected, with a
common logic circuit connecting multiple M terminals. For example, the following circuits are
interconnected when designated as "not isolated" in the data sheets: the 24 VDC power supply of the CPU, the power input for the relay coil of an SM, or the power supply for a nonisolated analog input. All non-isolated M terminals must connect to the same external reference potential.

Digital Inputs and Outputs:-
 Number of inputs: 14
 Rated voltage: 24 VDC at 4 mA, nominal
 Surge voltage: 35 VDC for 0.5 sec
 Logic 1 signal (min.): 15 VDC at 2.5 mA
 Logic 0 signal (max.): 5 VDC at 1 mA
 Number of outputs: 10
 Current (max.): 2A
 Surge current: 7A with contacts closed
 Maximum relay switching frequency: 1 Hz

PLC Concepts
Execution of the user program
The CPU supports the following types of code blocks that allow us to create an efficient
structure for our user program:

 Organization blocks (OBs) define the structure of the program. Some OBs have
predefined behavior and start events, but we can also create OBs with custom start
events.

 Functions (FCs) and function blocks (FBs) contain the program code that corresponds
to specific tasks or combinations of parameters. Each FC or FB provides a set of input
and output parameters for sharing data with the calling block. An FB also uses an
associated data block (called an instance DB) to maintain state of values between
execution that can be used by other blocks in the program. Valid FC and FB numbers
range from 1 to 65535.

 Data blocks (DBs) store data that can be used by the program blocks. Valid DB numbers
range from 1 to 65535.

Execution of the user program begins with one or more optional start-up organization blocks
(OBs) which are executed once upon entering RUN mode, followed by one or more program
cycle OBs which are executed cyclically.

Operating Modes of the CPU
The CPU has three modes of operation: STOP mode, STARTUP mode, and RUN mode.
Status LEDs on the front of the CPU indicate the current mode of operation.

 In STOP mode, the CPU is not executing the program. We can download a project.
 In STARTUP mode, the startup OBs (if present) are executed once. Interrupt events are
not processed during the startup mode.
 In RUN mode, the program cycle OBs are executed repeatedly. Interrupt events can
occur and be processed at any point within the RUN mode.

PLC data type
The PLC data type editor lets us define data structures that we can use multiple times in our
program. We create a PLC data type by opening the “PLC data types” branch of the project tree and double – clicking the "Add new data type" item. On the newly created PLC data type item, we use two single-clicks to rename the default name and double-click to open the PLC data type editor.
We create a custom PLC data type structure using the same editing methods that are used in the data block editor. We then add new rows for any data types that are necessary to create the data structure that we want.

If a new PLC data type is created, then the new PLC type name will appear in the data type
selector drop drop-lists in the DB editor and code block interface editor.

Potential uses of PLC data types:
 PLC data types can be used directly as a data type in a code block interface or in data
blocks.
 PLC data types can be used as a template for the creation of multiple global data blocks
that use the same data structure.

Programming Concepts

Structuring the user program
When we create a user program for the automation tasks, we insert the instructions for the
program into code blocks:

 An organization block (OB) responds to a specific event in the CPU and can interrupt
the execution of the user program. The default for the cyclic execution of the user
program (OB 1) provides the base structure for your user program and is the only code
block required for a user program. If we include other OBs in our program, these OBs
interrupt the execution of OB 1. The other OBs perform specific functions, such as for
startup tasks, for handling interrupts and errors, or for executing specific program code at
specific time intervals.
 A function block (FB) is a subroutine that is executed when called from another code
block (OB, FB, or FC). The calling block passes parameters to the FB and also identifies
a specific data block (DB) that stores the data for the specific call or instance of that FB.
Changing the instance DB allows a generic FB to control the operation of a set of
devices. For example, one FB can control several pumps or valves, with different
instance DBs containing the specific operational parameters for each pump or valve.
 A function (FC) is a subroutine that is executed when called from another code block
(OB, FB, or FC). The FC does not have an associated instance DB. The calling block
passes parameters to the FC. The output values from the FC must be written to a memory
address or to a global DB.

Programming Language

STEP 7 provides the following standard programming languages for S7-1200:

 LAD (ladder logic) is a graphical programming language. The representation is based on
circuit diagrams.
 FBD (Function Block Diagram) is a programming language that is based on the graphical
logic symbols used in Boolean algebra.
 SCL (structured control language) is a text-based, high-level programming language.

Ladder Logic (LAD)
The elements of a circuit diagram, such as normally closed and normally open contacts, and
coils are linked to form networks.

To create the logic for complex operations, you can insert branches to create the logic for parallel circuits. Parallel branches are opened downwards or are connected directly to the power rail. Youterminate the branches upwards.
LAD provides "box" instructions for a variety of functions, such as math, timer, counter, and
move.
STEP 7 does not limit the number of instructions (rows and columns) in a LAD network.

Function Block Diagram
Like LAD, FBD is also a graphical programming language. The representation of the logic is
based on the graphical logic symbols used in Boolean algebra.

Mathematical functions and other complex functions can be represented directly in conjunction with the logic boxes.

STEP 7 does not limit the number of instructions (rows and columns) in an FBD network.

SCL

Structured Control Language (SCL) is a high-level, PASCAL-based programming language for the SIMATIC S7 CPUs. SCL supports the block structure of STEP 7.

SCL instructions use standard programming operators, such as for assignment (:=), mathematical functions (+ for addition, - for subtraction, * for multiplication, and / for division). SCL also uses standard PASCAL program control operations, such as IF-THEN-ELSE, CASE, REPEATUNTIL, GOTO and RETURN. We can use any PASCAL reference for syntactical elements of the SCL programming language. Many of the other instructions for SCL, such as timers and counters, match the LAD and FBD instructions.

We can designate any type of block (OB, FB, or FC) to use the SCL programming language
at the time we create the block. STEP 7 provides an SCL program editor that includes the
following elements:
● Interface section for defining the parameters of the code block
● Code section for the program code
● Instruction tree that contains the SCL instructions supported by the CPU

We enter the SCL code for our instruction directly in the code section. For more complex
instructions, we simply drag the SCL instructions from the instruction tree and drop them into
our program. We can also use any text editor to create an SCL program and then import
that file into STEP 7.

SOFTWARE IMPLEMENTATION

Algorithm

STEP 1 : Press the "START" Push Button.
STEP 2 : Then the "MOTOR" starts and the conveyor movesforward.
STEP 3 : If the sensor detects the presence of bottle which is in position with the solenoid valve, then the conveyor will stop.
STEP 4 : If the sensor does not detects any presence of the bottle, the conveyor keeps on moving.
STEP 5 : After some delay the valve turn "ON" and the bottle will get filled till the timer gets off.
STEP 6 : After the bottle is filler , a d3elay is provide andthen after the delay the motor starts running.
STEP 7 : And the process respects itself repeats itself from step 3

then,

Flow chart & Ladder logic

HARDWARE REQUIREMENT SPECIFICATION

1.Water Float Switch

The entire length of the equipment is 2m. It has an input voltage of 250V A.C with an input
current of 15A. It has a square shape. It is designed to withstand a temperature of 80 degree
Celsius. It has both NO & NC contacts and a cfls 2m cable length. It’s working mechanism is
very simple. When the tank is filled up with water then the float switch “normally opens” (NO)
the circuit and when the tank is empty the float switch “normally closes” (NC) the circuit and
energizes the hardware connected with it (mostly water pump is connected).
In this project, It is dipped into the tank filled with water so it floats over the water and on
decrease in water level the float switch falls down completely towards the ground due to low
level of water which then closes the circuit connection with the water float sensor. As a result,
the pump that is interfaced with the entire system then gets completely energized and the water from the reservoir is pumped directly to the water tank and it is filled with water and gradually the water level starts rising and the float switch gradually starts to float over water. After the water is filled up to a certain level and the float switch starts floating over water, then the circuit breaks and the pump gets de energized simultaneously.

2.Photoelectric Sensor

Operating voltage is 6 – 36 VDC and its output current is 300 mA. It’s response frequency is 0.5 kHz. It’s output type is n – p – n 3 wire (Black, Blue and Brown). It is made of brass or plastic. In this project, It is used to sense the position of the bottles. A round shaped sensor is used which can detect opaque, transparent or any other kinds of objects. In this case it is detecting different plastic bottles. The sensor used here is a diffused reflective type sensor. The range of sensing the objects are 100 mm.

3. DC Geared Motor

The DC motor used is a DC geared type motor whose shaft is interconnected with the shaft of the roller. This motor has an input voltage of 12v with an input current of 600mA to 14A. It’s no load speed is 50 RPM. The reason for selecting this motor is to achieve high torque at a constant speed. It has a torque of 70kgcm which provides sufficient amount of torque for our load.The motor comes with a metal gearbox and centered shaft. Shaft is loaded with bearing for wear resistance. The reason for choosing such a high torque is having such heavy rollers used on the either side of the hardware which is mounted with a conveyor belt.

4.Water Pump

The net weight of the pump is 150 gm. Its dimensions of inlet and outlet are 15 mm O. D. and 5 mm O. D. Its working voltage is 12 V DC and working current is 0.1 – 0.5 A. Its lift is 130 cm at 12 V DC and flow rate is 300L/H.
In this project, the water pump is submerged in the reservoir from where the water will be
pumped up to the main tank if it gets empty.

5.SMPS (Switched Mode Power Supply)

A switched-mode power supply 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 DC or AC source (often mains power) to DC loads, such as a personal computer, while converting voltage and current characteristics. Unlike a linear power supply, the pass transistor of a switching-mode supply continually switches between low-dissipation, full-on and full-off states, and spends very little time in the high dissipation transitions, which minimizes wasted energy. Ideally, a switched-mode power supply dissipates no power. Voltage regulation is achieved by varying the ratio of on-to-off time. In contrast, a linear power supply regulates the output voltage by continually dissipating power in the pass transistor. This higher power conversion efficiency is an important advantage of a switched-mode power supply. Switched-mode power supplies may also be substantially smaller and lighter than a linear supply due to the smaller transformer size and weight.
In this project, 24 V DC and 12 V DC SMPS had been used for the power supply of the different components used. For example, 12 V DC is used to supply power to water pump, DC geared motor and 24 V DC is used to supply power to the solenoid valve, water float switch and photoelectric sensor.

6.Solenoid Valve

Qualified application voltages as following description:
AC 110V AC 380V ; AC 220V DC 24V ±10% ; AC 36V DC 12V Induction coil insulation has qualities of high moistureproof, heat-resistance and succeeded water immersed handling function. Capacity of induction coil sequent electric current and maximum temperature up to 90oC.
In this project, It is normally used to automatically control the flow of the water that shall fill the water bottle. When the water bottle placed over the conveyor belt, which is initially at motion, is sensed by the Photoelectric sensor, the conveyor stops running and at the same time the solenoid valve gets energized and water starts flowing through the valve for a certain time period (depending on the time we set on the timer in the PLC programming).As the time period is over then the solenoid valve gets de energized and water stops flowing through the valve. The conveyor belt starts moving again and the valve remains de energized until and unless the bottle is sensed by the sensor again.

7.Water Tank

The function of the water tank is to store the water which is to be filled in the water bottle via
solenoid valve whenever required. The water tank contains a float switch which is normally used to determine the level of water and whenever the water level in the tank falls it is restored by the water stored into the reservoir with the help of the pump through a narrow pipe which is connected with the tank

8.Switches

The type of switches we used in our project are the toggle switches. Two toggle switches are
used to change the mode: Manual and Auto. Two toggle switches are used for “Auto Start” and “Auto Stop”. For manual mode, Two toggle switches are used for “Conveyor Start” and “Conveyor Stop” and two toggle switches are used for “Solenoid valve Open” and “Solenoid valve close”.
And lastly, one toggle switch is dedicated for the “Emergency” Switch.

9. Relays

10.Conveyor System

Conveyor belt: A belt of length 2*(3ft.2inches) and width is 3.9 inches. The material used
is PVC. Reason for choosing this belt is has low friction and oil resistant.

 Drive roller:

Total net weight of the rollers are 5 Kg. The diameter of the shaft of the roller is taken 1
inch whereas the diameter of the rollers are 3.5 inches. The length of the shaft whose one
side is elongated for coupling with the motor is 3 inches. The length of the roller is taken
4 inches.

Methodology
At first, the auto selection switch is selected so that the entire system operates automatically.
Then the “Auto start push button” (toggle switch is used here) is selected and the motor starts
and the conveyor belt starts moving. The DC motor used is a DC geared type motor whose shaft is coupled directly with the shaft of the roller. This motor has an input voltage of 12v with an input current of 600mA to 14A.The reason for selecting this motor is to achieve a high starting torque at a constant speed. It has a torque of 70kgcm.The motor comes with a metal gearbox and centered shaft. Shaft is loaded with bearing for wear resistance. The reason for choosing such a high torque is having such heavy rollers used on the either side of the hardware which is mounted with a conveyor belt.Then two to three bottles is placed simuntaneously on the conveyor belt. Now as the bottle approaches towards the photoelectric sensor, the sensor senses the bottle and the conveyor stops running.
As the conveyor stops the solenoid valve gets energized and the water starts filling in the bottle. After a given time period is over, then the solenoid valve gets de energized completely and water flowing through the valve is stopped and the conveyor belt starts moving. The valve remains de energized until the bottle is sensed by the sensor again. Then as this process is continued the water level in the tank keeps on decreasing with course of
time. A water float switch is used which is dipped into the tank filled with water. The entire
length of the equipment is 2m. It has an input voltage of 250V A.C with an input current of 15A. It has a squarez shape. It is designed to withstand a temperature of 80degree Celsius. It has both NO & NC contacts and a cfls 2m cable length. It is dipped into the tank filled with water so it floats over the water and on decrease in water level the float switch falls down completely towards the ground due to low level of water which then closes the circuit connection with the relay. As a result, the pump that is interfaced with the entire system then gets completely energized and the water from the reservoir is pumped directly to the water tank and it is filled with water and gradually the water level starts rising and the float switch gradually starts to float over water. After the water is filled up to a certain level and the
float switch starts floating over water, then the circuit breaks and the pump gets de energized
simultaneously. As this process takes place the entire system is turned OFF automatically. It remains in the OFF mode till the tank is refilled with water up to a certain level where the float switch comes to a completely horizontal position. After the tank is completely filled with water the activity of the motor as well as the belt is resumed respectively.

Then the system starts working as mentioned above.
EMERGENCY SWITCH has also been introduced in the system which works like a circuit
breaker which disconnects the entire PLC system whenever any unfavorable conditions arise. The electrical connection of the system interfacing the hardware with the PLC machine has been done.
An Ethernet cable has been used to interface the computer with the PLC machine. A ladder logic(LAD) has been implemented using the SIEMENS software in order for the better understanding of the system, so that when the machine is online we can keep record of which part of the machine is online as per as requirement

Software Test:
According to the working process of the system PLC programming, Ladder logic (LAD)
simulation software TIA V12 is used. PLC programming in the form of Ladder diagram.
Pump Control:
Control of pump to start and stop to fill the liquid tank to run complete system.
Filling process:
As the empty bottle sent in to filling area the position sensor and proximity sensor confirmed the perfect position of bottle for filling. Solenoid valve open for particular time to fill required
amount of liquid in bottle. After filling the bottle sent for next operation.

   As the solenoid valve opening increases the time required to fill 200 ml liquid in bottle decreases. As the valve angle increases the flow rate increases. So for filling different amount of liquid in to the bottle the filling time should be constant but the flow rate will be different.

conclusion

The main objective of this project was to develop a bottle filling system based on certain
specifications. The project presents an automatic filling system controlled by PLC as per the
filling requirement which has simple operation. The system has the advantages as simple
structure and reliable operation. The system is controlled by PLC. This was successfully
implemented. We consider this project as a journey where we acquired knowledge and also
gained some insights into the subject which we have shared in this report.
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 concenteration. The system could be redesigned for increased bottle size and productivity.