OT BASED AUTOMATIC BOTTLE FILLING

SYSTEM

PROJECT-II REPORT

Submitted in the Partial Fulfillment of the Requirements for the Award of Degree of

BACHELOR OF TECHNOLOGY
In
Electronics and Communication Engineering

SUBMITTED BY

Priyanka Rani

manisha

Riya Dogra
(Batch 2018 – 2022)

CHANDIGARH ENGINEERING COLLEGE

JHANJERI, MOHALI

Affiliated to I.K. Gujral Punjab Technical University, Jalandhar

ii
 CERTIFICATE

We hereby certify that the work which is being presented in the project report entitled

“CLASSMATE” by “Priyanka Rani”, “Manisha” and “Riya Dogra” in partial fulfillment of

requirements for the award of degree of B.Tech Electronics & Communication Engineering

submitted in the Department of Electronics & Communication Engineering at CHANDIGARH

ENGINEERING COLLEGE, JHANJERI, Mohali under I.K. GUJRAL PUNJAB

TECHNICAL UNIVERSITY, JALANDHAR is an authentic record of our own work under the

supervision of Dr. Sajjan singh.

Date:

Signature of the Student Signature of the Student Signature of the Student

Priyanka Rani Manisha Riya Dogra
(1816679) (1816673) (1816683)

Date:

Signature of theSupervisor
(Dr. Sajjan singh)

Signature ofH.O.D.
(Dr. SajjanSingh)

iii
 ACKNOWLEDGEMENT

Working on this project is a great experience and for this we owe sincere thanks to our faculty

members. It is a great opportunity to work under guidance of Dr. Sajjan singh. It would have not

been possible to carry out the work with such ease without her immense help and motivation. We

consider our privilege to express our gratitude, respect and thanks to all of them who are behind us

and who guide us in choosing this project. We express sincere gratitude to Dr. Sajjan Singh (HOD,

ECE), for this everlasting support towards the students for providing us this opportunity and his

support.

Priyanka Rani

Manisha

Riya Dogra
 ABSTRACT

The project is aimed at automatic bottle filling and counting. This project will automatically count the bottles
using IR sensors. The overall system is liberated from human interventions. The efficiency of this system is high
and it helps in automatic bottle filling and counting. Control system is the main part which includes Arduino
programming to control various components in this system. It is aimed to eliminate the various problems faced
by small scale industries while packing the bottles. This system works automatically and reduces working and
operation costs respectively.

KEYWORDS: DC pump, DC motor, LCD 16x2, Actuator, DC gear motor, Conveyor belt, Pipe, Bottle
(250ml), Wheels,Arduino.
 TABLE OF CONTENTS

S. No. Chapter Page No.

1. Title Page i

2. Certificate ii
3. Acknowledgement iii
4. Abstract iv
5. Table of Contents v
7. Chapter 1 - Introduction 01 - 03
1.1. Overview 01

A. Hardware & Software Description 02

1.2. Literature Review

1.3. Materials Used
1.4. code 03
8. Chapter 2 - About PLC 04 - 08
2.1.Technical Specification of PLC 04

2.2. PLC Concepts 05

2.3. Programming Concepts 06

9. Chapter 3 - Feasibility Study 09 - 24
3.1. Understanding Feasibility 09

3.2. Economical Feasibility 10

3.3. Technical Feasibility 14

3.4. Behavioural Feasibility 19

10. Chapter 4 - Software Implementation 25 - 29
4.1. Flowchart 25

4.2. Algorithm 29
4.3. Ladder Logic Diagram (LAD)
11. Chapter 5 - Hardware Requirements 30 - 35
Specification
5.1. Water Float Switch 30
5.2. Photoelectric Sensor
5.3. Dc Geared Switch
5.4. Water Pump
5.5. Smps
5.6. Solenoid Value
5.7. Water Tank
5.8. Switches
5.9. Relays 33
12. Chapter 6 - System Design 36
6.1. Block Diagram 36

6.2. Schematic Diagram

6.3. Methology
6.4. Connection Diagram
6.5. Our Prototype Design
13. Chapter 7 - Result And Discussion 37
14. Chapter 8 - Conclusion And Further Scope For
Development
15. References 38

1
 Chapter1

INTRODUCTION

In today’s world the importance of automation has immensely

increased. The industry has now shifted its purpose of
automaton to broader level. Our project works on
automatically filling bottles using Arduino controller, its
counting and packaging. It is less costly, cheap and widely
used technology. This project looks on reducing the cost of
automation in small scale industries. For counting of bottles
we have used IR sensors which are more accurate in working
and cheap as well. For packaging of the bottle’s (i.e. fitting of
cap on the bottle) we have used actuator valve and DC gear
motor. For transportation of bottles in the factory we are
using conveyor belt. The material used in belt is rubber which
rotates on three DC motors. To fill bottles of 250ml, we have
used DC pump which takes 30 seconds to fill the bottle.

2
 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.

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.

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.

3
 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. Re-
implementation 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,

Page 2
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
Page 2
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 theinitial 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
Page 2
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.

Page 2
 MATERIALS USED
 Arduino UN
 26*2 LCD
 Push button
 WATER PUMP
 Resistor
 Connecting wires
 PCL

Page 2
 DESCRIPTION OF MATERIAL USED

2. Arduino UNO-

The Arduino Uno is an open-source microcontroller board based on

the Microchip ATmega328P microcontroller and developed by Arduino.cc.[2]
[3]
 The board is equipped with sets of digital and analog input/output (I/O)
pins that may be interfaced to various expansion boards (shields) and other
circuits.[2] The board has 24 digital I/O pins (six capable of PWM output), 6
analog I/O pins, and is programmable with the Arduino IDE (Integrated
Development Environment), via a type B USB cable.[4] It can be powered by
the USB cable or by an external 9-volt battery, though it accepts voltages
between 7 and 20 volts.

Page 2
2.26*2 LCD-
The term LCD stands for liquid crystal display. It is one kind of electronic
display module used in an extensive range of applications like various
circuits & devices like mobile phones, calculators, computers, TV sets, etc.
These displays are mainly preferred for multi-segment light-emitting
diodes and seven segments. The main benefits of using this module are
inexpensive; simply programmable, animations, and there are no limitations
for displaying custom characters, special and even animations, etc.

3.Push Button-

A push-button (also spelled pushbutton) or simply button is a

simple switch mechanism to control some aspect of a machine or a process.
Buttons are typically made out of hard material, usually plastic or metal.
[2]
 The surface is usually flat or shaped to accommodate the human finger or
hand, so as to be easily depressed or pushed. Buttons are most often biased
switches, although many un-biased buttons (due to their physical nature) still
require a spring to return to their un-pushed state. 

Page 2
4.Water Pump – It is standard water used in desert collers. It will pump
water from the resevoir to the filling station .

5. Resistor-
A resistor is a passive two-terminal electrical component that
implements electrical resistance as a circuit element. In electronic circuits,
resistors are used to reduce current flow, adjust signal levels, to divide
voltages, bias active elements, and terminate transmission lines, among other
uses. High-power resistors that can dissipate many watts of electrical power
as heat, may be used as part of motor controls, in power distribution systems,
or as test loads for generators. Fixed resistors have resistances that only
change slightly with temperature, time or operating voltage. Variable
resistors can be used to adjust circuit elements (such as a volume control or a
lamp dimmer), or as sensing devices for heat, light, humidity, force, or
chemical activity.
Resistors are common elements of electrical networks and electronic
circuits and are ubiquitous in electronic equipment. Practical resistors as
discrete components can be composed of various compounds and forms.
Resistors are also implemented within integrated circuits.

6.Connecting wires – A jump wires (also known as jumper wire, jumper

cable, dupoint or cable ) is an eletrical wire or group of them in a cable with
a connecter or pin at each end sometime without them – simply “tinned
which is normailly uesd to interconnect the components ,without sold

7.Pcl- The posterior cruciate ligament (PCL) is a ligament within the

knee. Ligaments are tough bands of tissue that connect bones. The
PCL -- similar to the anterior cruciate ligament (ACL) -- connects the
thigh bone (femur) to your shin bone (tibia). Although it is larger and
Page 2
stronger than the ACL, the PCL can be torn.

CODE

void setup(){

pinMode(2,INPUT);//

pinMode(3,OUTPUT);//

Serial.begin(9600);//

void loop()

bool value= digitalRead(2);

if (value==2){

Serial.println("on");

digitalWrite(3,LOW);

else{

Serail.println("off");

digitalWrite(3,HIGH);//

Page 2
 CHAPTER 2

INTRODUCTION

In today’s world the importance of automation has immensely increased.

The industry has now shifted its purpose of automaton to broader level. Our
project works on automatically filling bottles using Arduino controller, its
counting and packaging. It is less costly, cheap and widely used technology.
This project looks on reducing the cost of automation in small scale
industries. For counting of bottles we have used IR sensors which are more
accurate in working and cheap as well. For packaging of the bottle’s (i.e.
fitting of cap on the bottle) we have used actuator valve and DC gear
motor. For transportation of bottles in the factory we are using conveyor
belt. The material used in belt is rubber which rotates on three DC motors.
To fill bottles of 250ml, we have used DC pump which takes 30 seconds to
fill the bottle.

Page 2
 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 2200 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 24 digital inputs and 20 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 22V 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
Page 2
used language and is simple as compared to other languages.
Ladder diagram has been used for the programming of this PLC.

Page 2
 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. Re- implementation of program of existing PLC program
based on formulization and visualization. It is done by transformation of
FSM in XML format into IEC 62232-3 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
Page | 20
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

Page | 20
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
Page | 21
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

Page | 22
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.
C HA P t e R 2

ABOUT PCL
 Technical Specification of PLC

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 S7-2200 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

PCL 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 2)
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 2. 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-
2200:
 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. You terminate
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
Page | 20
standard PASCAL program control operations, such as IF-THEN-ELSE,
CASE, REPEAT- UNTIL, 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

Page | 20
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.

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 C HA P t e R 3

FEASIBILITY STUDY
 Understanding feasibility

Feasibility study means the analysis of a problem to determine if it can

be solved effectively. In other words it is the study of the possibilities
of the proposed system. It studies the work ability, impact on the
organization ability to meet user’s need and efficient use of resources.
Three aspects in which the system has to be feasible are:-

Economical feasibility

The economical analysis checks for the high investment incurred on the
system. It evaluates development & implementing charges for the
proposed “Industrial Automation Project”. The PLC used for the
development is easily available at the market but they are very expensive
& the software for programming comes with the PLC hence it results in
high cost implementation.

Technical feasibility

This aspect concentrates on the concept of using computer meaning,

“Mechanization” of human works. Thus the automated solution leads to the
need for a technical feasibility study.
The focus on the platform used is the PLC based Industrial Automation.

The proposed system require an in depth technical knowledge on various

electrical machines and PLC hardware as well as software. This is
required to improve the technical efficiency of the design. Otherwise the
system development is simple and easy to understand. The result
obtained should be true in the real time conditions.

Behavioral feasibility

Behavioral feasibility deals with the runtime performance of the

proposed system. It must score higher than the present in the behavioral
study. The project should have end user when the system is designed
while designing. The programmer should be aware of the condition’s
user’s knowledge input, output, calculations etc.
Care should be taken to avoid non-working means & buttons.
 C HA P t e R 4

SOFTWARE IMPLEMENTATION
 Flowchart
START

Start
Button NO

Yes

MOTOR = ON

CONVEYOR BELT = ON

IS THERR ANY NO
BOTTLE UNDER
SOLENOID?

Yes

MOTOR = OFF

CONVEYOR BELT =OFF

SOLENOID VALVE = ON SOLINOID VALVE = OFF

MOTOR = ON

CONVEYOR BELT = ON

IS THE
BOTTLE NO
NO STOP
FULL ?
BUTTON
PUSHED ?

Yes

Yes

Page | 25
 Algorithm

STEP 2 : Press the "START" Push Button.

STEP 2 : Then the "MOTOR" starts and the

conveyor moves forward.
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 and then after the delay the
motor starts running.
STEP 7 : And the process respects itself repeats
itself from step 3

Page | 26
Ladder Logic (LAD)
 C HA P t e R 5

HARDWARE REQUIREMENT SPECIFICATION

 Water Float Switch

[Fig: Water float Sensor switch]

The entire length of the equipment is 2m. It has an input voltage of

250V A.C with an input current of 25A. 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
Page | 30
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.

Page | 30
 Photoelectric Sensor

[Fig: Diffused 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 200 mm.

Page | 31
 DC Geared Motor

[22V 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 22v with an input current of 600mA to 24A. 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.
 Water Pump

[Fig: 22V DC submersible water pump]

The net weight of the pump is 250 gm. Its dimensions of inlet and outlet
are 25 mm O. D. and 5 mm O. D. Its working voltage is 22 V DC and
working current is 0.2 – 0.5 A. Its lift is 230 cm at 22 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.
 SMPS (Switched Mode Power Supply)

[Fig: 24V SMPS]

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 22 V DC SMPS had been used for the
power supply of the different components used. For example, 22 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.
 Solenoid Valve

[Fig: 24V DC Solenoid valve]

Qualified application voltages as following description:

AC 220V AC 380V ; AC 220V DC 24V ±20% ; AC 36V DC 22V

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.
 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.

Switches

[Fig: Toggle switches of the PLC]

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.

Relays

[F ig: Two NO-NC contacts relay] [F ig: Four NO-NC contact

relay] Coil Rating:

 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 2 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.
 C HA P t e R 6

SYSTEM DESIGN

Page | 40
Block Diagram

Page | 41
Schematic Diagram
 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 22v with an
input current of 600mA to 24A.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 25A.
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.
Connection Diagram
Our Prototype Design
 CHAPteR 7

RESULT AND DISCUSSION

Software Test:

According to the working process of the system PLC programming, Ladder logic (LAD)
simulation software TIA V22 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.

From the fig. above shows that 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.
 CHAPteR 8

CONCLUSION AND FURTHER SCOPE FOR

DEVELOPMENT
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.

Page | 50
 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 )2022.

[2] “Implementation and performance analysis of bottle filling plant using ladder
language” 2 SavitaM.tech,R.N College of Engineering &
Management,Rohtak,India.2 Lokeshwar Assistant Prof, R.N College of Engineering &
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[3] “Industrial Application of PLCs In Bangaladesh” 2 Ahmed Ullah AbuSaeed,2 Md.Al-

Mamun,3 A.H.M.ZadidulKarim, Department of EEE, University of
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[4] Arif Ozkan, Kerim Cetinkaya, ‘Process Automation and Mixture Filling System Design’,
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[5] D. Baladhandabany, S. Gowtham, T. Kowsikkumar, P. Gomathi, ‘PLC Based Automatic

Liquid Filling System’, International Journal of Computer Science and Mobile Computing,
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[6] “Programmable Logic Controller” D.Ahuja2, N.Chaudhary 2 Department of Electrical

and Electronics Engineering, YMCA University of Science and Technology, Faridabad,
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[7] “The Principle of Programmable Logic Controller and its role in Automation”, Avvaru
Ravi Kiran#2, B.VenkatSundeep*2, Ch. SreeVardhan #3, Neel Mathews!4#Electronics and
Communications, KL University, Guntur, Andhra Pradesh, India,*Assistant Professor,
Electronics and Communications, KL University, Guntur, Andhra Pradesh, India. General
Manager Mobility Solutions, Mahindra Reva Electric Vehicles Pvt Ltd, Bangalore, India.
International Journal of Engineering Trends and Technology- Volume4 Issue3(ISSN:
2232- 538) 2023.

[8] “Application of PLC for Arranging Bottle in Beer Filling Production Line” ZHANG
Tianxia, DONG Feng , YUAN Hao Tianjin Key Laboratory of Process Measurement and
Control, School of Electrical Engineering and AutomationTianjin University, Tianjin
300072, China.

[9] Petruzella, Frank D. (2020) - ‘Programmable logic Controllers’ - Tata McGraw

Hill Education, pp.6-22.

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