UNIVERSITI KUALA LUMPUR

(MALAYSIA FRANCE INSTITUTE)

REPORT OF MINI PROJECT

(AUTOMATED BOTTLE FILLING)

LECTURER’S NAME: MR. ABU HASSAN BIN DARUSMAN

STUDENT’S NAME: MOHD NAJIB BIN EJI
STUDENT’S ID: 50213119262

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TABLE OF CONTENT

NO. CONTENT PAGE

1 INTRODUCTION 3
2 FLOWCHART OF THE PROCESS 4
3 THE DESIGN OF SCADA HMI 7
4 DEVELOPMENT OF PLC LADDER DIAGRAM 8
5 DEVELOPMENT OF SCADA SIMULATION 13
6 DISCUSSION 15
7 CONCLUSION 15

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 1. INTRODUCTION

Industry is the most important sector of economical growth for each country.
Nowadays, every process in industry has been mostly integrated to automation system
to increase the production. Automation system is a process of innovation made by
engineers to give a significant change in this industry process. In this matter, also can be
related that the automation system with the revolution of Engineering 4.0. Engineering
4.0 involves a crucial change on how the industry process work with less human effort
and increase the quality of the product made. Moreover, when it comes to automation,
it is also significant to the word “Internet of Things (IoT)” where Internet of things is now
commonly known as the automatic base medium. This will involve the usage of
extension of internet connectivity to the physical devices. As they embedded with
internet connectivity, hardware and electronics, they can communicate easily over
internet.

This project will be focusing on one of the important process on production line which is
packaging process. Packaging process is the last process before the product release to
the consumer. The packing become most critical process to avoid delay order for the
customer and to remain the product freshness. The process is divided to three station
which is:
1) Power station
2) Filling station
3) Desiccant insertion station

1.1. Power station

Power station is the main section where the system is going to be controlled before the
process begin. This station is very important to know about the system status of the
process.

1.2. Filling station

This station is where the packaging process is beginning. This station will involve on the
quantity of the product during the tablet insertion in the bottle.

1.3. Desiccant insertion station

This station will be last station of the product. In this station, the desiccant will be insert
after the filling process is done.

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2. FLOWCHART OF THE PROCESS

1) POWER STATION

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 2) FILLING STATION

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 3) DESICCANT INSERTION STATION

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 3. Chapter 1: The Design of HMI Scada

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4. Chapter 2: Development of PLC Program

4.1Input & Output List for the process:

POWER STATION

 Input list of Power station

ADDRESS TAG DATA TYPE DESCRIPTION

0.00 Start Digital Start pushbutton
0.01 Stop Digital Stop pushbutton

 Output list of Power Station

ADDRESS TAG DATA TYPE DESCRIPTION

20.00 System Digital System status
1.00 RedLight Digital Indicator light
1.01 OrangeLight Digital Indicator light
1.02 GreenLight Digital Indicator light
1.03 BottleConveyor Digital Conveyor

FILLING STATION

 Input list of Filling Station

ADDRESS TAG DATA TYPE DESCRIPTION

0.02 BottlePresence Digital Bottle sensor
0.03 TabletLevel Digital Tablet height in
container
0.04 TabletSensor Digital Tablet counting

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  Output list of Filling Station

ADDRESS TAG DATA TYPE DESCRIPTION

1.04 OpenGate Digital
1.05 Vibrator1 Digital
1.06 Vibrator2 Digital
1.09 Vibrator3 Digital
1.07 ExtendStopper Digital
1.08 Cone Digital
1.10 Flap Digital

DESICCANT INSERTION STATION

 Input list of Desiccant Insertion station

ADDRESS TAG DATA TYPE DESCRIPTION

0.10 RollerDessicent Digital Roller sensor
0.11 UncutDessicent Digital Uncut desiccant
sensor
0.12 BottlePresenceD Digital Bottle sensor
(desiccant station)
0.13 Dessicent Digital Desiccant insertion

 Output list of Desiccant insertion station

ADDRESS TAG DATA TYPE DESCRIPTION

2.00 RedLightDessicent Digital Indicator light
2.01 OrangeLightDessicen Digital Indicator light
t
2.02 MotorFeeder Digital
2.06 DessicentConveyor Digital Bottle conveyor
2.03 Cutter Digital
2.04 DessicentFeeder Digital
2.05 StopperBottleD Digital

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 4.2Ladder Diagram

POWER STATION

FILLING STATION

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 DESICCANT INSERTION STATION

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5. Chapter 3: Deployment of the SCADA SIMULATION

First thing before setting up the Scada, we have to make sure the CX-Programmer the
connected successfully to CX-Simulation. In this app, the IP address will be set up to
make the CX-Programmer link to CX-Simulation.

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 Then setup the Scada user, cluster and I/O Devices

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 Finally, install Virtual Serial Port Emulator (VSPE) and setup the VSPE to pair connection
device. Then, connect the CX-Simulation and status on VSPE will appear “Ready”.
Means, the Scada and CX-Programmer are connected. So, simulation can be run on
Scada.

6. Discussion

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 Based on the project, the project must be done by doing the simulation based on the
grafcet given. The simulation needs to be run by using the Scada that link with the CX-
Programmer as the command source. To link the CX-Programmer with the Scada, the CX-
Simulation and Virtual Serial Port Emulator was needed. This project has to be done step by
step to avoid any error may occur during the simulation. The mistake may happen during
declaring variable tag on SCADA so the accuracy very important during data insertion.

The challenged has to face while construct the project setting up some of the
communication of SCADA. After realize there are some mistakes on the addresses, so the
error has to be fix at variable tag. The problem occur cause by the address faulty may take
extra time to troubleshoot the error. So, to avoid the same problem occur double checking
is the must to do to make the project success.

7. Conclusion

To wrap up everything, I finally can conclude few factors on the success on doing this
project. To design an HMI_SCADA, make sure the use of the right address and design the
SCADA as what it should looks like as my lecturer has explained. Besides, I also need to
study and make a simple research on the system to gain the idea of constructing the ladder
diagram. Juggling from good and hard times, I can conclude that PLC is actually a crucial
makeover on automation industries in the future.
In the future, I believe that will be most industries will be using the PLC as the controller to
increase their production to accommodate the human need. Despites challenges faced by
the companies, along the time travelled, I believe that there will be more advanced
invention to be made for the industry’s needs.

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