PLC Based Automatic Bottle Filling System

Abstract

Introducing a cutting-edge solution for beverage industries, our paper unveils a revolutionary bottle filling machine employing state-of-the-art Programmable Logic Controller (PLC) technology. Crafted with simplicity and efficiency in mind, this compact system seamlessly integrates a conveyor belt for bottle transportation and a precision DC pump to regulate water flow with unparalleled accuracy Operating with finesse, an infrared sensor precisely detects bottle positions, triggering the pump to commence filling precisely at the opportune moment. Once the bottle is detected, a secondary sensor halts the conveyor, initiating a 15-second pump operation optimized for filling up to 800ml bottles swiftly and flawlessly. Upon completion, the pump gracefully ceases, and the conveyor resumes its smooth operation Notably, our system is designed with user convenience at its core. A dedicated stop button empowers operators to halt operations instantly, ensuring safety and control. With each component meticulously optimized for performance and reliability, our cost-effective filling machine stands as a beacon of innovation, poised to revolutionize small-scale beverage enterprises, from cozy coffee shops to bustling juice bars and beyond.

Introduction

I. INTRODUCTION

In today's fast-paced manufacturing landscape, automation plays a crucial role across various industries, not just in manufacturing. With advancements in technology, production levels have surged. However, production managers face the challenge of reducing costs while maintaining product quality within tight deadlines. Moreover, the rising consumer demand intensifies competition among manufacturing companies, where factors like cost, accuracy, time, and quality are paramount. To address these challenges, integrated processes in the industry are key. One essential component of industrial automation is the Programmable Logic Controller (PLC). Acting as the brain of industrial applications, PLCs are extensively utilized to control processes, enhancing performance, accuracy, and efficiency, ultimately leading to increased production.This paper focuses on the design and implementation of a water filling machine as a practical example of PLC application in the industry. 

II. SYSTEM DESCRIPTION

In this fully automated system for filling and capping, both hardware and software components are meticulously developed. On the hardware side, there's the mechanical structure providing the framework, the electrical system powered by DC motors, the pneumatic system for air-driven actions, and the essential PLC (Programmable Logic Controller) acting as the central control unit. For software, the focus is on programming the Delta PLC, renowned for its high performance and versatile features. With efficient program editing tools, the Delta PLC ensures streamlined software development, facilitating the seamless automation of the filling and capping processes.The block diagram of this system is shown in Fig. 1

We have successfully developed our project and tested it takes about 1-2 min for the bottle of 500 ml to be filled simultaneously adding a second bottle on the conveyor after the first filled bottle exits the rotary disk. No error was detected while filling the bottle.

Conclusion

This paper explores the efficient use of conveyor systems for moving objects, focusing on the flat belt type for bottle transportation in packaging processes. Conveyors prove particularly beneficial for handling heavy or large materials, streamlining tasks and saving time and effort. The system operates on time-based controls, initiating pulses through sensors for filling and capping processes. Its practical applications extend to various commercial settings like coffee shops, juice bars, and cold drink outlets, relieving human labor. The research findings underscore the effectiveness of conveyor systems and highlight the importance of PLC in industrial automation, emphasizing the need for further study in this area.

References

[1] Frank Petruzella, \"Programmable Logic Controllers\", Fifth Edition, Mc Grawhill Education, (2017). [2] T. Kalaiselvi, R. Praveena, Aakansha. R, Dhanya, ‘‘PLC Based Automatic Water Bottle Filling Capping System with User Defined Volume Selection’’, IJETAE, vol. 2, Issue8, (August 2012). [3] Kevin Collins, \"PLC Programming for Industrial Automation\". [4] Daniel Kandray, \"Programmable Automation Technologies\", Industrial Press, (2010 ISBN 978-0- 8311-3346-7). [5] Prof.Anup G. Dakre, Junaid G. Sayed, Ekata A. Thorat, Md. Aousaf Md. A. Choudhary, \"PLC Based Automatic Bottle Filling and Capping with Metal Can Ejector [6] Ms. Diptee Patil “Automatic Bottle Filling, Capping And Labelling System Using PLC Based Controller” 2021; Vol 20 (Issue 1) [7] Md. Liton Ahmed, Shantonu Kundu, Md. Rafiquzzaman “Journal of Advancement in Mechanics” MAT Journals 2019 Volume 4 Issue. [8] Dr. Pankaj Prajapati, International Research Journal of Engineering and Technology (IRJET) “AUTOMATIC BOTTLE FILLING AND CAPPING SYSTEM USING PLC” e-ISSN: 2395-0056 Volume-1, Issue-1, 2019.

Copyright

Copyright © 2024 M. D. Balsaraf, Wabale Akash Uttam, Madhe Pratiksha Laxman. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.