Automatic Bottle Filling System Using PLC Based Controller

In this paper a bottle filling machine is introduced using Programmable Logic Controller (PLC) based controller in automation industry. The main aim of the paper is to design and fabricate a small and a simple filling system using PLC. The belt conveyor is used for moving the bottle. A dc pump is set to tank to control the flow of water. The position of bottle is detected by infrared sensor so that pump can be functioned at right time. When bottle is under the tank, the pump is started and bottle is filled by water. All the components perform well. This filling machine is cost effective and it can be used in small scale bottle filling systems such as coffee shops, juice shops and other beverage industries. Keyword: Automation, Easy technology, Low cost and smooth operation INTRODUCTION Filling is defined as the method in which liquid is packed into the bottle such as water and other beverages. It can be automated by using Programmable Logic Controller (PLC) or Arduino. In the modern world, Programmable Logic Controller (PLC) is used for this purpose. PLC is the major element of the whole process. It is a powerful device to control the production system. It is used as a digital computer to automate industrial activities. It has many input and output unit, a CPU and a memory. It gives output results according to the condition of input. It is prepared for the replacement of relay circuit. The automation process is controlled according to the logics of programmed PLC. For inputs and outputs, PLC has a definite number of connections. The advantages of using PLC are smooth operation, low cost and high filling speed. To improve filling accuracy, it is necessary to apply PLC in automatic filling system. The process is controlled by ladder logic. Filling is controlled by using various methods using motor, level sensor, proximity sensor, conveyor belt, PLC, solenoid valve. This system can be made with arduino but flexibility will be less. The arduino programming language is more complex than PLC ladder logic. The PLC ladder logic is symbol based that’s why it can be changed easily. Lu, Y.-D., et al developed an automatic beverage filling machine by using PLC [1]. They used PLC to make the system flexible and to improve production rate. The ladder logic can be changed easily so they use PLC instead of arduino. Baladhandabany, D., et al. have studied on the principle of programmable logic controller and its importance on automation [2]. This process involves placing bottle on the conveyor and filling the bottle at a time. The purpose of this paper is to explain the process of filling more bottles at a time. For this purpose, stepper motor is used effectively to run the conveyor. It requires less number of sensor and it was cost effective. They have used ladder logic to control the whole system. M.H. Muhammad Sidik and S.A. CheGhani have made their paper on automatic liquid filling machine by using arduino to measure volume [3]. They studied on automatic filling machine used in food industry. This type of filling machine is available in the market which is hypocritical and expensive to clean up the cylinder piston that requires pneumatic system. They used ultrasonic sensor instead of cylinder piston to make it easy brought to you by CORE View metadata, citation and similar papers at core.ac.uk