BOTTLE FILLING SYSTEM USING PLC (VPAT-04SIE)

BOTTLE FILLING SYSTEM

The bottle filling system is used to control the liquid level in bottle & moved to next bottle, then
maintained the liquid level in process tank, solenoid valve operations which is maintained in
automatically & continuously.

In this processing system, Low-level & High level sensors are used to senses the liquid level in
process tank. Then solenoid valve will open & stepper motor will stop the rotation whenever
Bottle sensor & Bottle position sensor will get the output value. After average value of time fill
the liquid in Bottle, automatically solenoid valve will close & stepper motor rotates now. This
process repeated again and again.

WORKING OF THE SYSTEM

First of all, In the process tank is in low level switch will get control. It causes for switch ON the
motor, then fill the liquid to process tank, liquid level increases continuously. The motor will
goes to OFF state, whenever the liquid level will reach the high level.

Stepper motor is rotating now. It will be stop depends upon two factors such as result of bottle
sensor [Proximity Inductive Sensor] result of bottle position sensor [Opto-Coupler]. If the two
sensors sense the bottle, when the stepper motor is in stop mode, then fill the liquid.
Simultaneously, solenoid valve will open which is depends upon the output value of two sensors.

We will set into particular time-delay in PLC, after the time delay, solenoid valve will move into
close position, which is depends upon the average value of time to fill the bottle.

Simultaneously, stepper motor starts now then rotate the platform, whenever the two sensors will
sense then stop the stepper motor and solenoid valve will open. This process is going on
continuously up to reach the low level of liquid in process tank then starts ON the motor.

Vi Microsystems Pvt. Ltd., [

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BOTTLE FILLING SYSTEM BLOCK DIAGRAM
BLOCK DIAGRAM

BI

BPI
I/P PULSE

Vi Microsystems Pvt. Ltd.,

TO PLC
LL

HL
BOTTLE FILLING SYSTEM USING PLC

PLC POWER SUPPLY

UNIT 1 UNIT 2

STEPPER
MOTOR MOTOR
DRIVER BOARD

I/P PULSE SV UNIT V/I RANGE PURPOSE

RELAY1 UNIT3
TO PLANT
STEPPER MOTOR
1 6V 6AMS
SUPPLY
MOSFET OPERATING
2 15V 1AMS VOLTAGE

SOLENOID VALVE
3 230V 5AMS
OPERATING VOLTAGE
UNIT4 PUMP OPERATING
RELAY2 PUMP 4 12V 4AMS VOLTAGE

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(VPAT-04SIE)
BOTTLE FILLING SYSTEM USING PLC (VPAT-04SIE)

HARDWARE USED

FLOAT SWITCH

It is a sensor, which is used to detect the water level. It is a magnetic type sensor water level is
below the sensor means the sensor output is low. The sensor output is high when the water level
is equal (or) above the sensor. We are using two float switches, first one is used to detect the low
-level & another one is used to detect the high-level of liquid in process tank.

STEPPER MOTOR

It produces the liquid rotating motion to bottle filling system, Stepper motor having 4 coils,
which can be excited with DC current to run the motor in clock-wise direction. By reverse
direction, we will change the phase sequences coil-1, coil-4, coil-3 & coil-2. Four coil of stepper
motor are arranged into rotating for step-wise movement.

Step angle = 360 / Ns NR

PROXIMITY INDUCTIVE SENSOR

This sensor connected vertically detects the presence of bottle on the platform. It monitoring the
proper movement of bottles on the platform and indicates during failures. These sensors also
eliminated the air gap between the bottle and sensor.

POSITION SENSOR

It is nothing but, opto-coupler sensor is a Bottle position-sensor. It senses the exact position of
bottle-mouth, which can be cut the gap of opto-coupler sensors. Then bottles have to be filled up
which are programmed for a certain delay. The delay between the platform rotation and solenoid
valve excitation is held simultaneously whose failure is detected using the position sensor.

SOLENOID VALVE

It is positioned above of the bottle mouth. Filling process of liquid in bottle is carried out through
solenoid valve. Solenoid valve is excited with a supply of 230V. On excitation, liquid passes
through the valve for the time programmed and till up the bottle. After tilling of one bottle is
finished solenoid valve is de-excited to stop the flow of liquid. A device is introduced in between
one DC excitation and the next excitation is after positioning the bottle.

Vi Microsystems Pvt. Ltd., [

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BOTTLE FILLING SYSTEM USING PLC (VPAT-04SIE)

SPECIFICATION

FLOAT SWITCH

Switching voltage - 24V DC

Switching current - 1amp

Current carrying capacity - 1amp

PROXIMITY INDUCTIVE SENSOR

Voltage - 10 (or) 30V DC [PN type]

Current - 100mA

SOLENOID VALVE

Operating voltage - 230V AC

STEPPER MOTOR

Voltage - 6V

Current - 5amp

Torque - 7Kg

Vi Microsystems Pvt. Ltd., [

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BOTTLE FILLING SYSTEM USING PLC (VPAT-04SIE)

EXPERIMENTAL SECTION

AIM

To study the functions and control of Bottle filling system using PLC.

APPARATUS REQUIRED

1. PLC S7-1200
2. Bottle Filling System Controller Kit
3. PC
4. Ethernet cable
5. Patch-Chords

WIRING DIAGRAM

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BOTTLE FILLING SYSTEM USING PLC (VPAT-04SIE)

LADDER LOGIC PROGRAM EXPLANATION

In automatic bottle filling system. In network-5 we will connect the program then automatically
start the motor [Q0.4] because I0.2 & I0.3 are normally closed contact. It is in high level of
liquid in process tank, motor will stop, because they will get open contacts.

If the Bottle sensor & Bottle position sensors output are in high-state, when M0.0 [Open coil]
are energized in rung-1. In rung-2, Q0.5 [Open coil Q5] energized now, because of M0.0 [M0.0-
Memory] is closed contact. That means, output Q5 coil is solenoid value, hence solenoid value
opening now.

In network-3, decided the time-delay of solenoid valve open/close position. FOR ON DELAY-
TIMER in network-3, after reach the preset value or time-delay M0.1 coil is energized now, it
causes for again reset the timer value. Simultaneously, M0.2 [M0.2-coil] is energized now in
network-4 & Causes the solenoid valve OFF state.
In network-6 designed for stepper motor rotation, whenever Q0.4 [MOTOR] & Q0.5 [Solenoid
valve] will move in OFF state.
In network 7, 8,9,10:
Q0.0 [coil1], Q0.1 [coil2], Q0.2 [coil3], Q0.3 [coil4] outputs are energized based on the input
conditions [comparator operator].
CONCLUSION

Thus the study of bottle filling system has been completed.

Program section:

Vi Microsystems Pvt. Ltd., [

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BOTTLE FILLING SYSTEM USING PLC (VPAT-04SIE)

Vi Microsystems Pvt. Ltd., [

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BOTTLE FILLING SYSTEM USING PLC (VPAT-04SIE)

Vi Microsystems Pvt. Ltd., [

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