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Automatic Bottle Filling System Using PLC Conveyor Model
Automatic Bottle Filling System Using PLC Conveyor Model
AUTOMATIC BOTTLE FILLING WATER SYSTEM USING PLC WITH CONVEYOR MODEL
ii
DECLARATION
I hereby declared that this thesis titled Automatic Bottle Filling Water System Using PLC
is the result of my own effort except as clearly stated in references the source of reference
Signature
:-
Name of Author :- ......
Date
:- .....
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iv
ACKNOWLEDGEMENT
First of all, I would like to thank Lord KRISHNA for HIS firm hands in guiding me in the course of completing
this thesis writing. It is by HIS grace and mercy that I am able to obtain the research on planning project within such as
limited time.
Second, I would like to express my gratitude and thanks to my Faculty Assistants, Mrs. M.CHITRA & L.Chitra, for his
professional guidance, wisdom, endurance, advices motivation and encouragement during his supervision period.
Thank you so much for the insights and encouragement she has given to me. Without his patience and valuable
assistance, the project and thesis would not have been the same as presented here.
Besides that, I would like to convey my thanks to my beloved parents, Mr. Umesh Prasad Singh and Mrs.
Poonam Singh for the advice and give all support to me in developing this project.
My fellow friends should also be recognized for their support at various conditions. Their views and tips are useful
indeed. Unfortunately, it is not possible to list all of them in this limited space. And last but not least, I am grateful to all
my family members.
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ABSTRACT
Nowadays, the application of PLC is widely known and use in this digital world PLCs application is obviously
applied at the industrial sector. Normally, the PLCs that have been used at the industrial field is usually to control a
mechanical movement either of the machine or heavy machine in order to create an efficient production and accurate
signal processing. In this project, a discussion about PLC application will be explained in more details and specified.
Whereby, a machine that used to prepare automatic filling water into the bottle is fully controlled by the PLC CPM2A,
which acts as the heart of the system. The system sequence of operation is designed by ladder diagram and the
programming of this project by using CX-Programmer software. Sensor usually plays its vital part as an input signal
transmitter for the PLC in this system. During this project sensor has been used to detect the bottle position that move
along the conveyor belt at the low speed while the machine operates. The input signal that has been sent from the
sensor to the PLC has being made as a reference. Signal in order to determine the output signal that exactly a same
with the PLC programming language based on the user requirement. Beside that, the electronics and electric devices
that usually been controlled by the PLC are like a motor, pump, sensor, conveyor belt, buzzer and the others devices.
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TABLE OF CONTENTS
CHAPTER TITLE
PAGE
TITLE PAGE
i
DECLARATION
ii
DEDICATION
iii
ACKOWLEDGEMENT
iv
ABSTRACT
v
TABLE OF CONTENTS
vi
LIST OF TABLES
ix
LIST OF FIGURES
x
LIST OF APPENDIXS
xii
1
1
BACKGROUND OF PROJECT
1.1
Introduction
1
1.1.1 Open-Loop Systems
2
1.1.2 Close-Loop Systems
3
1.2
Problem Statement
5
1.3
Project Objective
6
1.4
Scope of Project
6
1.5
Implementation of Project
7
1.6
Thesis Outline
8
2
10
LITERATURE REVIEW
2.1
10
2.2
12
2.3
13
2.3.1
14
2.3.2
15
2.4
17
2.5
18
2.6
19
History of PLC
What is PLC?
Ladder Logic
Ladder Logic Input
Ladder Logic Output
Programming
Operation of PLC
Time Response
3 METHODOLOGY
22
3.1
22
3.2
24
3.3
25
3.1.1
25
3.1.2
26
3.1.3
27
Methodology Overview
How Does the System Work
Hardware Design
Conveyor System
Motor
Infrared Sensor
Vii
CHAPTER TITLE
4
29
4.1
29
4.2
32
4.3
33
4.3
35
ELECTRIC DESIGN
DC Input
AC Input
Relay Output
Transistor Output
PAGE
5 PROGRAMMING DEVELOPMENT
37
5.1 A Systematic Approach of Control System Design
37
5.2 State Diagram
40
5.3 Assignment of Inputs and Outputs
41
5.4 Ladder Diagram
42
6
44
FINAL RESULT
6.1
44
6.2
46
6.3
47
The Prototype
7
49
7.1
49
7.2
50
REFERENCES
51
APPENDIX
53
viii
LIST OF TABLES
TABLE NO.
PAGE
5.1
41
5.2
41
TITLE
Assignment of Inputs.
Assignment of Outputs.
ix
LIST OF FIGURES
FIG. No.
PAGES
1.1
2
1.2
3
1.3
7
2.1
12
2.2
14
2.3
15
2.4
16
2.5
17
3.1
23
3.2
24
3.3
25
3.4
27
4.1
29
4.2
30
4.3
31
4.4
32
4.5
33
4.6
33
4.7
34
4.8
35
TITLE
5.1
38
5.2
39
5.3
40
5.4
42
6.1
44
6.2
44
6.3
44
6.4
45
6.5
45
6.6
46
6.7
46
6.8
46
6.9
47
X
LIST OF APPENDICES
APPENDIX
PAGE
TITLE
A
53
B
68
C
70
CHAPTER 1
BACKGROUND OF PROJECT
1.1
Introduction
Control engineering has evolved overtime. In the past, humans were the main method for
controlling a system. More recently, electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relay to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable
Logic Controller (PLC). The advent of the PLC began in the 1970s, and has become the most
common choice for manufacturing controls. [1].
PLC has been gaining popularity on the factory floor and will probably remain predominant for
some time to come. Most of this because of the advantages:-
Control systems are an integral part of modern society.It consists of subsystems and processes
assembled for the purpose of controlling the outputs of the processes.There are many
numerous applications that using control system around us. A control system provides an output
or response for a given input or stimulus.The reason that control system was built isfor power
amplification, remote control, convenience of input form; and compensation for disturbances.
Today control systems find widespread application in the guidance, navigation, and
control of missiles and spacecrafts, as well as planes and ship at sea. The applications also
throughout the process control industry, regulating liquid level tanks, chemical concentrations in
vats, as well as thickness of fabricated material.
2.4 Programming
Programming software CX-Programmer has been utilized in this project. CXProgrammer is a PLC programming tool for the creation, testing and
maintenance of programs associated with OMRONs CPM2A series. It provides
facilities for the support of PLC devices and address information and for
communications with OMRON PLCs and their supported network types. An
example of ladder logic can be seen in Figure 2.5. To interpret this diagram
imagines that the power is on the vertical line on the left hand side, we call this
the hot rail. On the right hand side is the neutral rail. In the figure there are two
rungs, and on each rung there are combinations of inputs (two vertical lines)
and outputs (circles). If the inputs are opened or closed in the right combination
the power can flow from the hot rail, through the inputs, to power the outputs,
and finally to the neutral rail. An input can come from a sensor, switch, or any
other type of sensor. An output will be some device outside the PLC that is
switched on or off, such as lights or motors. In the top rung the contacts are
normally open and normally closed. This means if input A is on and input B is off,
then power will flow through the output and activate it. Any other combination
of input values will result in the output X being off. [7]
Step 1-CHECK INPUT STATUS-First the PLC takes a look at each input to determine if it is on or
off. In other words, is the sensor connected to the first input on? How about the second input? How
about the third... It records this data into its memory to be used during the next step.
Step 2-EXECUTE PROGRAM-Next the PLC executes your program one instruction at a time.
Maybe your program said that if the first input was on then it should turn on the first output. Since it
already knows which inputs are on/off from the previous step it will be able to decide whether the
first output should be turned on based on the state of the first input. It will store the execution results
for use later during the next step.
Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the status of the outputs. It updates
the outputs based on which inputs were on during the first step and the results of executing your
program during the second step. Based on the example in step 2 it would now turn on the first output
because the first input was on and your program said to turn on the first output when this condition is
true.
After the third step the PLC goes back to step one and repeats the steps continuously. One scan time
is defined as the time it takes to execute the 3 steps listed above.
2.6 Time Response
The PLC can only see an input turn on/off when its looking. In other words, it
only looks at its inputs during the check input status part of the scan.
In the diagram, input 1 is not seen until scan 2. This is because when input 1 turned on, scan
1 had already finished looking at the inputs. Input 2 is not seen until scan 3. This is also because
when the input turned on scan 2 had already finished looking at the inputs.
Input 3 is never seen. This is because when scan 3 was looking at the inputs, signal 3 was not
on yet. It turns off before scan 4 looks at the inputs. Therefore signal 3 is never seen by the plc. Now
lets consider the longest time for an output to actually turn on. Lets assume that when a switch turns
on we need to turn on a load connected to the plc output.
The diagram below shows the longest delay (worst case because the input is not
seen until scan 2) for the output to turn on after the input has turned on.[8] The
maximum delay is thus 2 scan cycles 1 input delay time.
Pulse stretch function. This function extends the length ofthe input signal until the plc looks at the
inputs during the nextscan.( i.e. it stretches the duration of the pulse.)
Interrupt function. This function interrupts the scan toprocess a special routine that you have
written. i.e. As soon as the input turns on, regardless of where the scan currently is,the plc
immediately stops what its doing and executes aninterrupt routine. (A routine can be thought of as a
miniprogram outside of the main program.) After its done executing the interrupt routine, it goes
back to the point it leftoff at and continues on with the normal scan process.
CHAPTER 3
METHODOLOGY
This chapter will mainly discuss about the methodology of the project and also the aspect or
factors that must be taken into consideration during the development process. All this factors were
very important to make sure the project will achieve it objective. Moreover, this chapter will also
discuss about the designation stage on this project including electronic design, hardware design and
material selection.
3.1 Project Overview
In this section, it will discuss an overall overview of Automatically Filling Water
System Using PLC project. The introduction to system task will also briefly
explain in this chapter. Finally, the entire decision making will be addressed in
this section.
Basically, software and
hardware design will be used in order to implement this project. In addition,
there some methods must be executed to keep this project implemented
successfully.
Figure 3.3 above shows the sample of the DC motor. DC motor or direct current motor is
the most common motor. There are many types of DC motor likes 5-pole motor, servomotor,
brushless motor, coreless motor, fix magnet motor and many more. DC motor takes direct current
voltages as input and converts it into a rotational movement.
DC motor basically have two wires, and can directly powered from a battery or
other DC power supply. DC motor also can be power from the driver circuit that
can regulate the speed and direction of the motor. The usual voltages of the DC
motor use are 6V and 12V. The current rating depends on the make of the
conveyor build for and it is usually between IA and 3A. Varying the voltage input
to the motor will varies the speed of motor accordingly.
DC motor has ability to turn at high
revolution per minutes (RPM) but has low torque. The most significant limitation
of the DC motor is the low output torque. The speed can be reduced and the
torque increase by adding gear rain to the output shaft. For the purpose of
conveyor belt building, DC motor is the cheapest compare to stepper motor or
servo motor.
3.3.3 Infrared Sensor
This sensor provides the system with ability to detect the presence of object position. The
theory is the IR emitter emits infrared light. If an object presence the signal will be reflected back to
the receiver. Then, the IR detector implemented will detect the reflected light. Then, the
correspondence signal sends to the PLC for being analyze. [8]
Based on the measurement of the intensity of the reflected light from the target
area such a bottle, it has a light source sending light to the moving target and a
light sensor receiving the light. The output signal from the sensor decreases
exponentially with the increase of the distance to the measured object. Infrared
light-emitting diodes (LED's) and photosensitive diodes are used in this
transducer. The sensor output is inversely proportional to the amount of
occupation. A multilink array of light sensitive elements and a light-beam
scanning technique determines and qualifies the shape of the measured object
by processing data from the elements.
CHAPTER 4
ELECTRICAL DESIGN
Electrical design of the Automatic Filling Water System involves the electrical components used, and
the installation of the electrical components on the system. Before all connection was established all
the input and output devices to PLC, the concept on how the input and outputs circuits of PLC must
be understood. The wiring of the DC input, AC input, relay output, and the transistor output is
discussed.
4.1 DC Input
Typically, dc input modules are available that will work with 5, 12, 24, and 48V. the connections of
the DC input modules is either PNP( sourcing) or NPN( sinking) transistor types devices. For a
regular switch (i.e. toggle or pushbutton, etc), typically no need to worry about whether wire it as
NPN or PNP. Most PLCs not allow mix NPN and PNP devices on the same modules.
The difference between the two types is whether the load switched to ground or
positive voltages. An NPN types sensor has the load switches to ground
whereas a PNP device has the load switches to positive voltage. Figure 4.1 is
shown the output for NPN and PNP sensor.
entering the internal circuitry. They work by converting the electrical input
signal to light and then by converting the light back to an electrical signal to be
processed by the internal circuit.
The relay is internal to the PLC. Its circuit diagram is shown in Figure 4.6. When
ladder diagram tells the outputs to turn on, the PLC will internally apply a
voltage to the relay coil. This voltage will allow the proper contact to close.
When the contact close, and external current is allowed to flow through our
external circuit. When the ladder diagram tell the PLC to turn off the output, it
will simply remove the voltage from the internal circuit thereby enabling the
output contact to release the load will than have an open circuit and will
therefore be off.
4.4 Transistor Output
The next type of outputs is transistor type outputs. Typically a PLC will have either NPN or PNP
type outputs. It is important to note that a transistor can only switch a dc current. For this reason it
cannot be used with an ac voltage.
A transistor is a solid-state switch or an electrical switch. A small current applied
to the transistor base (i.e. input) and switch a much larger current through its
outputs. The PLC applies a small current to the transistor base and the transistor
output close. When its closed, the devices connected to the PLC output will be
turn on.
Figure 4.8: Internal Output Circuit Diagram for NPN Type Output
There is a photo coupler isolating the real world from the internal circuit as
shown in Figure 4.8. When the ladder diagram call for it, the internal circuit turn
on the photo coupler by applying a small voltage to the LED side of the photo
coupler. This make the LED emit light and the receiving part of the photo
coupler will see it and allow current to flow. This small current will turn on the
base of the outputs transistor connection to output 0500. Therefore, whatever is
connected between COM and 0500 will turn on. When the ladder tell 0500 to
turn off, the LED will stop emitting light and hence the output transistor
connected between 0500 and COM will turn off.
CHAPTER 5
PROGRAMMING DEVELOPMENT
A systematic approach of control system design using programming logic controller is presented in
this chapter. As a rule, the layout of the entire of Automatic Filling Water System using PLC is
designed before implementing programming development process. The machine sequences of
operation will be discussed. Next, the assignment of input and outputs are shown in tables. Finally,
the ladder diagram design using CX-Programmer are shown.
5.1 A Systematic Approach of Control System Design.
In general, a control system is a collection of electronic devices and equipment
which are in place to ensure the stability, accuracy and smooth transition of a
process or a manufacturing activity. Every single component in a control system
plays an important role regardless of size.
Before programming, the concept of controlling a control
system is introduce, which is the systematic approach of control system design
using a PLC. The operation procedure of the system approach is shown in Figure
5.1
CHAPTER 6
FINAL RESULT
As mentioned in Chapter 4 and Chapter 5, all the system of the desired project was implemented and
the results of the systems illustrated in this Chapter 6. During the operation, all activities that occur
can be observed by computer using CX-Programmer. The system needs to debug along the way and
fine tune if necessary. Test run the system thoroughly until if is safe to be operated.
6.1 The Prototype
The prototype was mainly built by combining the mechanical design and the
electrical designs. The system require three external DC power supply for input
output devices, two AC power supply for supplying pump and PLC, and one 9V
battery for buzzer.
The pictures below show that the prototype of system from different view:-
Before running the system, thoroughly ensure that the input and wiring are
correctly connected according to the I/O assignment to avoid any unwanted
accidents. Once confirmed, the operation of the Automatic Filling Water System
using PLC can be started.
CHAPTER 7
CONCLUSION AND RECOMMENDATION
An Automatic Filling Water System using PLC has been successfully constructed
and designed by applying all the concept of control system at this project. The
system that is produced can be modified to be better if some of the electrical
devices and system are upgraded and improved.
7.1 Conclusion
The theory and concept of the automatic filling water system is based on the
control system. In electrical design, the features and functions of the electrical
components are required to determine the system requirement. Furthermore,
the theoretical of the wiring system is required for connecting the inputs and
outputs devices to PLC. In programming design, understandings of the desired
control system and how to use the Ladder Diagram to translate the machine
sequence of operation are the most important parts, because it have direct
effect on the system performance. The main aim in this process is to apply PLC
to design automatic filling water system and all objectives in this project were
successfully done as planned. Finally, the basis control system and logic design
apply in this project can be used as a references to design other applications of
automation system, and also can be used as a teaching material for the
Industrial Control subject.
7.2 FUTURE RECOMMENDATION
Actually, a lot of weakness from the project can be taken as future works so that the improved system
will be better in terms of performance. So that, there are several recommendations or suggestions that
we can take to increase performance in this project. The performance of Automatic Filling Water
System can be increased based on two recommendations which are;
The system that is proposed now is using only one sensor that is IR sensor to detect position
of bottle. It will be better if we add more sensors in this system like a flow sensor to detect water
flow or use level sensor to detect water level. Thus, the system will be more sensitive as there will be
more sensing points
Besides using PLC as controller, the other controller can be used in this future work is like
Microcontroller. However, many factors must be considered like cost, practically and others.
REFERENCES
[1] Siemens. Basic Of PLCs STEP 2000 series, Siemens Technical Education Program.
[2] Norman S. Nice Control System Engineering. Third Edition. California State Polytechnic
University Pomona. John Wiley & Son, Inc, 200
[3] Colin D. Simpson
Programmable Logic Controllers Regents Prentice Hall.
[4] Noel M. Morris
Control Engineering Mc GRAW-HILL Book Company (UK) Limited.
[5] Lug, J. Y. S., Walker, M. W., and Paul, R. P. (1980b). Resolved-Acceleration
Control of Mechanical Manipulators. IEEE Trans. Automatic Control.
[6] Bateson, N.R. Introduction to Control System Technology, Sixth Edition, United State of
America: Prentice Hall.1999.
[7] Manual book, A Beginners Guide to PLC, version 2.1. Singapore: Omron.2001.
[8] http:\\ www.plcs.net\default.html
[9] http:\\ www.sea.siemens.com\step\default.html
[10] http:\\ www.seacheng.co.uk\articles\pla\index.html
[11] http: \\ www.omron-ap.com
APPENDIX
A
APPENDIX
B
APPENDIX
C