CHAPTER - 1

INTRODUCTION

1.1 Project Overview

The project is hardware and the software is the two important areas in our project.

1.1.1 HARDWARE DESCRIPTION

In this project, Siemens PLC SIMATICS S7 1200 is used for controlling the inputs and
outputs. Input supply to the PLC is given through a SMPS. The rating of the SMPS is 24 V
DC 5 Amps. The PLC used here is a compact PLC which has fixed number of inputs and
outputs. In this kind of PLC model, the CPU contains 14 digital inputs and 10 digital outputs.
One diffused photoelectric sensor has been used for the positioning of the bottles. A geared
DC motor has been used for running the conveyor system. The ratings of the DC motor is
12V and 50 RPM speed with a high starting torque of 70 Kg-cm (at no load). Toggle
switches are used to serve the purpose of some inputs to the PLC.

1.1.2 SOFTWARE DESCRIPTION

There are five important languages which are used for the programming of the PLC. The list
of the methods is as follows:
 Functional block diagram (FBD)
 Structure text
 Instruction list
 Flow chart
 Ladder diagram
Out of these five languages, ladder diagram is the most widely used language and is simple
as compared to other languages. Ladder diagram has been used for the programming of this
PLC.

1.2 Literature Review

A brief survey of technologies explored during the past decade and some of them is given
below to provide an understanding of the level of research interest in this domain. In this
paper, researcher outlined the various phases of operation involved in the adaptation of a
manually operated boiler towards a totally automated boiler. The first part of the paper

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focuses on passing the inputs to the boiler at a required temperature, so as to constantly
maintain a particular temperature in the boiler. The Air pre heater and Economizer helped in
this method. And the paper mainly focused on level, pressure and flow control at the various
stages of the boiler plant. Thus the temperature in the boiler is constantly monitored and
brought to a constant temperature as required by the power plant. The automation is further
improved by constant monitoring using SCADA screen which is connected to the PLC by
means of communication cable. By means of tag values set to various parameters in SCADA
the entire process is controlled. At the automated power plant, the boiler is controlled by
Variable Frequency Drive (VFD) to put in action the required processes to be carried out at
the boiler. Thus the entire cycle is carried out as a paper and at various stages each phase is
detailed out. This paper has proved to be very efficient practically as the need for automation
grows day by day. This paper growing pace of automation. Automating the routing tasks in
the industries increases the productivity and reduces the probability of error in the system.
Traditional industrial tasks involve Electrical machinery has become the integral part of the
industry as a result of the fast manual operation of machineries and the tasks are dependent
on manual intervention; which can cause error in the process; in addition to being tirne
consuming and expensive. Automation of operations reduces operating costs; production
time and error and improves the product quality.

1.3 Methodology
This paper consist of three containers first container contains chemical A and second
container consist of chemical B with respect to solenoid valve connected only.Middle
container is a mixing and filling container .Mixing container connected with solenoid valve
and level sensor to sense the chemical level in it .When the press the start pushbutton fill
container 1 and container 2 manually container 3starts filling when low level is detected
valve 1 and valve 2will be open .Then container 3 will fill high level sensor detect the liquid
level .Then both valve V1 and V2 will be close .After the water level sensor sense the high
level container 3 mixing motor turns in for few second..The mixing motor turns off conveyor
belts starts moving and bottles move on the conveyor belt. Bottle is sensed by proximity
sensor solenoid valve will be open and bottle will be fill for the set time duration. The bottle
is filled V3 will be closed and motor start again after some delay .The process is continues
until the stop button is press.
In this method, we are fixing the web camera at an optimum location. Where the camera
captures the images of logo on the bottle, then logo of the bottle is compared with the
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reference logo by cross correlation method to classify image. If it is matched, then conveyor
starts and by interfacing the MATLAB with arduino, where arduino gets the signal and it
sends the signal to the PLC program. After that, PLC allocates time for positioning the bottle
to the corresponding valve position. If bottle is positioned at particular valve, then the valve
opens for given specified time based on user defined volume selection, to fill the liquid in the
bottle.

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 CHAPTER – 2
COMPONENTS USED

2.1 Solenoid Valve

A solenoid valve is an electromechanical device in which the solenoid uses an electric

current to generate a magnetic field and thereby operate a mechanism which regulates the
opening of fluid flow in a valve. Solenoid valves differ in the characteristics of the electric
current they use, the strength of the magnetic field they generate, the mechanism they use to
regulate the fluid and the type and characteristics of fluid they control. The mechanism varies
from linear action, plunger-type actuators to pivoted-armature actuators and rocker actuators.
The valve can use a two-port design to regulate a flow or use a three or more port design to
switch flows between ports. Multiple solenoid valves can be placed together on a manifold.
Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to
shut off, release, dose, distribute or mix fluids. They are found in many application areas.
Solenoids offer fast and safe switching, high reliability, long service life, good medium
compatibility of the materials used, low control power and compact design.

Fig-1(Solenoid Valve)

2.2 Dc motor 24V

The DC motors are mainly used for the motion of the robot. The DC motors are mainly
used for the motion of the robot. A simple DC motor has a stationary set of magnets in the

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stator and an armature with one or more windings of insulated wire wrapped around a soft
iron core that concentrates the magnetic field. The windings usually have multiple turns
around the core, and in large motors there can be several parallel current paths. The ends
of the wire winding are connected to a commutator. The commutator allows each armature
coil to be energized in turn and connects the rotating coils with the external power supply
through brushes.
A DC motor like we all know is a device that deals in the conversion of electrical energy
to mechanical energy and this is essentially brought about by two major parts required for
the construction of dc motor, namely.

2.2.1 Stator-
The static part that houses the field windings and receives the supply. The rotating part
that brings about the mechanical rotations.

Fig – 2(Dc Motor)

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 Fig – 3(Dc Motor mechanism)

A DC motor has a stationary set of magnets in the stator and an armature with one or more
winding of insulating wire to wrap around a soft iron core that concentrates the magnetic
field. The windings usually have multiple turns around the core, and in large motors there
can be several parallel current paths. The ends of the wire winding are connected to a
commutator.

2.2.2 Advantages of DC Motor

 Continuous Operating life of 3000 Hours.

 High output: High heat dissipation and heat resistance achieves higher output.
 Low noise and increased insulation due to new resin brush holders.
 Long-life.

2.3 Relay

A relay is an electrically operated switch. Many relays use an electromagnet to mechanically

operate a switch, but other operating principles are also used, such as solid-state relays.
Relays are used where it is necessary to control a circuit by a separate low-power signal, or
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where several circuits must be controlled by one signal. The first relays were used in long
distance telegraph circuits as amplifiers: they repeated the signal coming in from one circuit
and re-transmitted it on another circuit. Relays were used extensively in telephone exchanges
and early computers to perform logical operations. A type of relay that can handle the high
power required to directly control an electric motor or other loads is called a contactor. Solid-
state relays control power circuits with no moving parts, instead using a semiconductor
device to perform switching. Relays with calibrated operating characteristics and sometimes
multiple operating coils are used to protect electrical circuits from overload or faults; in
modern electric power systems these functions are performed by digital instruments still
called "protective relays". A relay is used to switch on a high powered circuit with a small
current Magnetic latching relays require one pulse of coil power to move their contacts in one
direction, and another, redirected pulse to move them back. Repeated pulses from the same
input have no effect. Magnetic latching relays are useful in applications where interrupted
power should not be able to transition the contacts Magnetic latching relays can have either
single or dual coils. On a single coil device, the relay will operate in one direction when
power is applied with one polarity, and will reset when the polarity is reversed. On a dual coil
device, when polarized voltage is applied to the reset coil the contacts will transition. AC
controlled magnetic latch relays have single coils that employ steering diodes to differentiate
between operate and reset commands. It was used in long distance telegraph circuits,
repeating the signal coming in from one circuit and re-transmitting it to another.

Fig-4(Relay)

2.4 Working of Relay

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Basically a relay consists of an electromagnet coil, an armature, a spring and a series of
electrical contacts. The electromagnet coil gets power through a switch or a relay driver and
causes the armature to get connected such that the load gets the power supply. The armature
movement is caused using a spring. Thus, the relay consists of two separate electrical
circuits that are connected to each other only through a magnetic connection, and the relay
is controlled by controlling the switching of the electromagnet.

Fig-5(Relay Mechanism)

The contacts are usually common (COM) – normally open (NO) and normally closed
(NC).The normally closed contact is connected to the common contact if power is not
applied to the coil. The normally open contact is opened if power is not applied to the coil.
When the coil is energized, the common contact is connected to the normally open
contact, and the normally closed contact is left floating. The double-pole versions are
same as the single-pole version except when the two switches open and close together.

2.4.1 Classification of Relay

Generally, relays are classified as

a) Electromagnetic Type Relay
b) Attraction Type Electromagnetic Relays
c) Induction Type Relays

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 2.4.2 Advantages of Relays over other semiconductor

 Relays can work with AC and DC, Semiconductors are DC only.

 Relays have zero closed resistance, Semiconductors have a forward voltage drop
that wastes a little to lots of power.
 Relays have infinite open resistance, Semiconductors have a leakage that can affect
attached electronics.
 Relays can operate at temperature extremes, Semiconductors are limited to 95°C and
a little below zero.
 Relays are much slower at 200 hertz, Semiconductors can operate at (Megahertz)
speeds.
 Semiconductors can be damaged and short due to voltage-peaking, secondary-
breakdown over current, dv/dt and di/dt, Relays are primarily damaged by over-
current.
 Relays have a very high isolation from the control coil, Semiconductors as a rule are
not isolated from the base, gate or trigger.
 Relays have a much shorter mechanical wear-out contact life, Semiconductor
switches almost never wear-out

2.4.3 Application of Relays

 Control a high-voltage circuit with a low-voltage signal, as in some types of modems or

audio amplifiers.

 Control a high-current circuit with a low-current signal, as in the starter solenoid of an

automobile.

 Detect and isolate faults on transmission and distribution lines by opening and closing the
circuit breakers.

 Time delay functions. Relays can be modified to delay opening or delay closing set of
contacts. A very-short delay uses a copper disk between the armature and moving blade
assembly. Typical applications of relays include computer interfaces, telecommunication
systems, traffic control, automotive electrical systems, home appliances, lighting control

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systems, electric motor controllers, tools and machines, air-conditioning and heating
systems, and so on.

2.5 Metal Sensor

A metal detector is an electronic instrument which detects the presence of metal nearby.
Metal detectors are useful for finding metal inclusions hidden within objects, or metal
objects buried underground. They often consist of a handheld unit with a sensor probe
which can be swept over the ground or other objects. If the sensor comes near a piece of
metal this is indicated by a changing tone in earphones, or a needle moving on an indicator.
Usually the device gives some indication of distance; the closer the metal is, the higher the
tone in the earphone or the higher the needle goes. Another common type are stationary
"walk through" metal detectors used for security screening at access points in prisons,
courthouses, and airports to detect concealed metal weapons on a person's body. The
simplest form of a metal detector consists of an oscillator producing an alternating current
that passes through a coil producing an alternating magnetic field. If a piece of electrically
conductive metal is close to the coil, eddy currents will be induced in the metal, and this
produces a magnetic field of its own. If another coil is used to measure the magnetic field
(acting as a magnetometer), the change in the magnetic field due to the metallic object can
be detected. The first industrial metal detectors were developed in the 1960s and were used
extensively for mineral prospecting and other industrial applications. Uses include de-
mining (the detection of land mines), the detection of weapons such as knives and guns
(especially in airport security), geophysical prospecting, archaeology and treasure hunting.
Metal detectors are also used to detect foreign bodies in food, and in the construction
industry to detect steel reinforcing bars in concrete and pipes and wires buried in walls and
floors.

Fig-6(Metal Sensor)

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 2.5.1 Feature

·  Coil technology

·   Coil size

·   Target identification

·  Tone id

·   Low battery indicator

·   Multiple modes

2.5.2 Application

 Widely used in machinery

 Chemicals
 Paper
 Light industry for spacing
 Positioning
 Detection
 Counting
 Guns
 Other sensing applications

2.6 Pump

A submersible pump (or sub pump, electric submersible pump (ESP)) is a device which has

a hermetically sealed motor close-coupled to the pump body. The whole assembly is
submerged in the fluid to be pumped. The main advantage of this type of pump is that it
prevents pump cavitations, a problem associated with a high elevation difference between
pump and the fluid surface. Submersible pumps push fluid to the surface as opposed to jet
pumps having to pull fluids. Submersibles are more efficient than jet pumps. Electric
submersible pumps are multistage centrifugal pumps operating in a vertical position. Liquids,
accelerated by the impeller, lose their kinetic energy in the diffuser where a conversion of
kinetic to pressure energy takes place. This is the main operational mechanism of radial and
mixed flow pumps. The pump shaft is connected to the gas separator or the protector by a
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mechanical coupling at the bottom of the pump. Fluids enter the pump through an intake screen
and are lifted by the pump stages. Other parts include the radial bearings (bushings) distributed
along the length of the shaft providing radial support to the pump shaft. An optional thrust
bearing takes up part of the axial forces arising in the pump but most of those forces are
absorbed by the protector’s thrust bearing.

Fig-7(Pump)

2.7 Conveyor Belt

A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor). A belt conveyor system is one of many types of conveyor systems. A belt
conveyor system consists of two or more pulleys (sometimes referred to as drums), with an
endless loop of carrying medium the conveyor belt that rotates about them. One or both of
the pulleys are powered, moving the belt and the material on the belt forward. The
powered pulley is called the drive pulley while the unpowered pulley is called the idler
pulley. There are two main industrial classes of belt conveyors; Those in general material
handling such as those moving boxes along inside a factory and bulk material handling such
as those used to transport large volumes of resources and agricultural materials, such
as grain, salt, coal, ore, sand, overburden and more.

Fig-8(Conveyor Belt
2.8 Push Button

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 A push-button (also spelled pushbutton) or simply button is a simple switch mechanism
for controlling some aspect of a machine or a process. Buttons are typically made out of
hard material, usually plastic or metal. The surface is usually flat or shaped to
accommodate the human finger or hand, so as to be easily depressed or pushed. Buttons
are most often biased switches, although many un-biased buttons (due to their physical
nature) still require a spring to return to their un-pushed state. Terms for the "pushing" of a
button include pressing, depressing, mashing, slapping, hitting, and punching.

Fig-9(Push Buttons)

2.9 PLC Kit

A programmable logic controller (PLC) or programmable controller is an industrial digital

computer which has been ruggedized and adapted for the control of manufacturing processes,
such as assembly lines, or robotic devices, or any activity that requires high reliability control
and ease of programming and process fault diagnosis. PLCs were first developed in the
automobile manufacturing industry to provide flexible, ruggedized and easily programmable
controllers to replace hard-wired relays, timers and sequencers. Since then, they have been
widely adopted as high-reliability automation controllers suitable for harsh environments. A
PLC is an example of a "hard" real-time system since output results must be produced in
response to input conditions within a limited time, otherwise unintended operation will result.

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Fig-10(PLC Kit)

CHAPTER – 3

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 3.1 About PLC
A programmable logic controller (PLC) or programmable controller is an industrial digital
computer which has been ruggedized and adapted for the control of manufacturing
processes, such as assembly lines, or robotic devices, or any activity that requires high
reliability control and ease of programming and process fault diagnosis.
PLCs were first developed in the automobile manufacturing industry to provide flexible,
ruggedized and easily programmable controllers to replace hard-wired relays, timers and
sequencers. Since then, they have been widely adopted as high-reliability automation
controllers suitable for harsh environments. A PLC is an example of a "hard" real-
time system since output results must be produced in response to input conditions within a
limited time, otherwise unintended operation will result.

3.2 Power Budget

The CPU has an internal power supply that provides power for the CPU, the signal modules,
signal board and communication modules and for other 24VDC user power
requirements.5VDC logic budget supplied by the CPU and the 5VDC power requirements of
the signal modules, signal boards and communication modules. The CPU provides a 24 VDC
sensor supply that can supply 24 VDC for input points, for relay coil power on the signal
modules, or for other requirements. If your 24 VDC power requirements exceed the budget of
the sensor supply, then you must add an external 24 VDC power supply to your system.
Some of the 24 VDC power input ports in the S7-1200 system are interconnected, with a
common logic circuit connecting multiple M terminals. For example, the following circuits
are inter connected when designated as "not isolated" in the data sheets: the 24 VDC power
supply of the CPU, the power input for the relay coil of an SM, or the power supply for a non
isolated analog input. All non-isolated M terminals must connect to the same external
reference potential.

3.3 Concept of PLC

Execution of the user program
The CPU supports the following types of code blocks that allow us to create an efficient
structure for our user program:

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 Organization blocks (OBs) define the structure of the program. Some OBs have
predefined behavior and start events, but we can also create OBs with custom start events.
 Functions (FCs) and function blocks (FBs) contain the program code that corresponds to
specific tasks or combinations of parameters. Each FC or FB provides a set of input and
output parameters for sharing data with the calling block. An FB also uses an associated data
block (called an instance DB) to maintain state of values between execution that can be used
by other blocks in the program. Valid FC and FB numbers range from 1 to 65535.
 Data blocks (DBs) store data that can be used by the program blocks. Valid DB numbers
range from 1 to 65535.
Execution of the user program begins with one or more optional start-up organization blocks
(OBs) which are executed once upon entering RUN mode, followed by one or more program
cycle OBs which are executed cyclically.
Operating Modes of the CPU
The CPU has three modes of operation: STOP mode, STARTUP mode, and RUN mode.
Status LEDs on the front of the CPU indicate the current mode of operation.
 In STOP mode, the CPU is not executing the program. We can download a project.
 In STARTUP mode, the startup OBs (if present) are executed once. Interrupt events are
not processed during the startup mode.
 In RUN mode, the program cycle OBs are executed repeatedly. Interrupt events can occur
and be processed at any point within the RUN mode. PLC data type
The PLC data type editor lets us define data structures that we can use multiple times in our
program. We create a PLC data type by opening the “PLC data types” branch of the project
tree and double – clicking the "Add new data type" item. On the newly created PLC data type
item, we use two single-clicks to rename the default name and double-click to open the PLC
data type editor We create a custom PLC data type structure using the same editing methods
that are used in the data block editor. We then add new rows for any data types that are
necessary to create the data structure that we want.

3.4 Ladder Logic

Ladder logic is the main programming method used in PLC. Ladder logic is based on mimic
relay logic. The relay logic diagrams are difficult, hence we have selected ladder logic as
main programming method. In modern control systems they used relay but these are not used
for logic. A relay is a device that controls a switch using magnetic field. Relays are used as

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one power source close a switch for another power source, while keeping isolated. A simple
ladder logic diagram is shown below.

Fig-11(Ladder logic)

3.5 PLC (Programmable Logic Controller)

A PLC is a user friendly, micro-processor based specialized computer that carries out control
functions of many types and levels of complexity.
PLC (Programmable logic controller) is a device that is designed for use in an industrial
environment, which uses its programmable memory for the internal storage of instructions
for implementing specific functions to control various types of process

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 Fig-12(PLC)

3.6 PLC History

In the late 1960's PLCs were first introduced. The primary reason for designing such a device
was eliminating the large cost involved in replacing the complicated relay based machine
control systems. Bedford Associates (Bedford, MA) proposed something called a Modular
Digital Controller (MODICON) to a major US car manufacturer.
When production requirements changed so did the control system. This becomes very
expensive when the change is frequent. Since relays are mechanical devices they also have a
limited lifetime which required strict adhesion to maintenance schedules. Troubleshooting
was also quite tedious when so many relays are involved. Now picture a machine control
panel that included many, possibly hundreds or thousands, of individual relays.

3.6.1 What is a programmable logic controller (PLC)

A programmable controller is an industrial computer in which control devices such as limit
switches, push buttons, proximity or photoelectric sensors, float switches, or pressure
switches, to name a few, provide incoming control signals into the unit. An incoming control
signal is called an input.
Incoming control signals, or inputs, interact with instructions specified in the user ladder
program, which tells the PLC how to react to the incoming signals. The user programs also

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direct the PLC on how to control field devices like motor starters, pilot lights, and solenoids.
A signal going out of the PLC to control a field device is called an Output.

3.6.2 Why use a PLC?

The question, “why use a PLC?” really should be rephrased to, “Why automate?” The PLC is
the tool that provides the control for an automated process. What will automating a process
do for a company? Automation will help a manufacturing facility to:
 Gain complete control of the manufacturing process
 Achieve consistency in manufacturing
 Improve quality and accuracy
 Work in difficult or hazardous environments
 Increase productivity
 Shorten the time of market
 Lower the cost of quality, scrap, and rework
 Offer greater product variety
 Quickly change over from one product to another
 Control inventory

3.6.3 How do PLCs know what they are supposed to Do

A PLC simply follows the instructions stored in memory. To retain user program
instructions, they are stored in the memory of the PLC for future used and reference. Think of
an instruction as a sentence. Each instruction that is entered will be placed in memory in
ascending order. The list of instructions is called the user ladder program.
The instructions you wish your PLC to carry out of transferred to the memory of the
controller from either handheld programmer is created by the operating pushing the correct
sequence of buttons on a handheld programmer.
A PLC user program user can also be created using a personal or industrial computer. When
using a personal or industrial computer to develop the user ladder program, a PLC ladder
development software package is used. The primary difference between a personal computer
and an industrial computer is that the industrial computer has been hardened to withstand the
factory environment. For now we will use the term “personal computer” for both. When the
entire user ladder program has been developed, entered, and verified for correctness, the next

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step is to download the program into the processor’s memory. Transferring the PLC program
for a personal computer’s memory of PLC memory is called downloading the program.

3.6.4 Selection of PLC

 Sensing inputs or controlling hardware: The sensing section made up of limit
switches, pressure switches, photo electric sensor. push buttons and so forth. These
incoming hardware devices provide input signals.
 PLC input hardware: Compresses of two major areas
1. Physical screw terminals where incoming signals are attach to PLC.
2. The second portion of input section is the PLC’s internal conversion
electronics. The function of the input section’s electronic components is to
convert and isolate the high voltage input level from field devices.
 The controller or CPU: Central processing unit is the brain that control and
supervise the entire process. The CPU solves the user program & update the status of
the output.
 Handling programming device: The programming device is whereby the operator or
programmer can enter or edit the program instruction or data.
 Output PLC hardware: The output section is simply a series of switches, one for
each output point that are controlled by the CPU and are used to turn output field
devices ON or OFF.
 Hardware output device: The devices such as Motor , Valve , Lamps ,Hooters etc
that are controlled by PLC’s output section are defined as PLC hardware devices

Introduction to fixed and Modular PLC Hardware

PLC hardware falls into two physical configurations
1. Fixed PLC: A fixed PLC has all of its components. The input section, CPU and associated
memory, power supply, and output section built into one self contained unit. All input and
output screw terminals are built into the PLC package and are fixed, not removable. This
style of PLC is also called a packaged controller.
2. Modular PLC: The modular PLC comes as separate pieces. A modular PLC is purchased
piece by piece. There may be two or three power supplies to choose from, a handful of
different processors (CPUs), many separate input and output cards or modules, and a
selection of assemblies, called racks, chassis, or base plates to hold the pieces together. When

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purchasing a modular PLC you select and purchase the specific pieces you need to build the
PLC specifically for the needs of your control situation.

Fig-13(Modular PLC)

3.6.5 Architecture of PLC

Programming Device

User Program
I/P table O/P table

Data storage

Fig-14(Architecture of PLC
The Central Processing Unit

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The central processing unit is built into the single-piece, fixed PLC. When working with
modular PLC’s, the CPU is typically a plug-in module just like with an I/O modular unit. The
CPU work like the human brain work to direct the rest of the body. In actuality, the CPU is a
solid-state, microprocessor integrated circuit chip. The microprocessor integrated chip is
placed on a printed circuit board with other supporting and interface chips to build the PLC’s
CPU, or processor module.
The CPU comprises of Two Components.
 Controller
 Memory System

Fig-15(PLC Panel)

Controller:

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The microprocessor, or brain, that supervises all operations in the system. The CPU reads, or
gathers information from external sources like input devices and stores this information in
memory for later use by the CPU. When done solving the user program, the CPU will write,
or send, data out to external devices like output modules and field hardware devices.

Memory System:
The memory system has to provide the following:
1. Storage for the user program.
2. Storage of the input status file data:
The input status file consists of memory location that store the ON or OFF status of
each field input device.
3. Storage of the output status file data:
The output status file consist of memory locations that store the ON or OFF status of
field hardware devices as the result of solving the user program. Data in the output
status file is waiting to be transferred to the output module’s switching device. The
output module’s switching device for each output point will turn power on or off to
each field output device.
4. Data storage:
The data storage area of memory is used to store numerical data that may be used in
math calculations, recipe ingredient weight, bar code data being input to the PLC, and
similar functions.

Programming
Device

Input User Output

Table Program Table

Data
Storage

Input Input/Output Output

Devices System Devices

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 Fig-16(Memory System)

3.6.6 I/O Module

The real world input & output devices are of two types:
 Discrete.
 Analog.
Discrete I/O devices are either ON or OFF, OPEN or CLOSED. Limit switches, push
button etc. are the examples of discrete input devices.
Analog devices have an infinite number of possible values such as temperature probes.
Pressure, indicators etc.

3.6.7 Input Modules

Input modules serve as the link between field devices and the PLCs CPU. Each input
modules has a terminal block for attaching input wiring from each individual field input
device. Typical input modules have 8, 16, 32, 64 and so on input terminals.
 The main function of an input module is to take the field device input signals, convert
it to a signal level on which, CPU can work with, electrically insolate it, and send the
signal, by way of the backplane board, to the CPU.
 The input signal, once received on the CPU module must be stored somewhere to
wait processing by the CPU. The memory storage area input signals is called that
input status file (sometime called the input status table).
 Each input screw terminals on each input module has one memory location in the
input status file. Each memory location stores the binary equivalent of the ON or
OFF status of its associated input signal.
 Discrete input modules:
Come in a wide range of voltages for various applications, i.e. 120 V AC, 240V AC,
24VDC, 12-24V DC. Some manufactures also give their module on AC/DC rating to
increase their flexibility. Input modules come with a wide range of input channels
such as 4, 8, 16, 32, and 64 that determines the number of field devices that can be
connected to the module.
 Analog Input Modules:

24
 are used to convert analog signal from analog devices that sense such variable as
Temp, light intensity, speed, pressure etc. and convert to 16 bit binary coded decimal.
The conversion from analog to digital is accomplished with an analog to digital
converter.
 Switches and Pushbuttons
 Sensing Devices
 Limit Switches
 Photoelectric Sensors
 Proximity Sensors
 Condition Sensors
 Pressure Switches
 Level Switches
 Temperature
 Switches/ Vacuum Switches
 Float Switches
 Encoders

3.6.8 Output Modules

Output Module serve as the link between the PLCs microprocessor and hardware field
devices. Each output module has a terminal block for attaching output wiring to go to each
individual field output devices. Typical output modules have 8, 16, 32, 64 and so on output
terminals.
 The output signal, once received from the CPU, must be stored before being sent to
each output modules output screw terminals. The storage area for output signals is
called the output status file. Each output screw terminal on each output module has
one memory location in the output status file.
 Discrete output modules: are used to control the current flow to real world devices
such as motor relay coils, lights, and control relays and solenoids valves. This also
works on a digital or ON and OFF basis. The output modules works like a remote
control switch that is controlled by the processor for turning output devices ON or
25
 OFF. Output modules are sized by the number of output devices that can be
connected to them. They have a current rating for each channel or connection point as
well as overall rating for the module. The individual current rating indicates the
maximum current or load that can be controlled.
 Analog Output Module: When the processor decides that the output is to be turned
On and sends a signal then the analog module changes the 16 bit binary value used
by the processor into analog signal using a digital to analog converter. These analog
signals can be used for speed controllers, signal amplifiers or valve petitioners.
 Valves
 Motor Starters
 Solenoids
 Actuators
 Control Relays
 Horns & Alarms
 Stack Lights
 Fans/ Pumps
 Counter/Totalize/ Printers

Remote I/O Racks

They allow the input and output modules to be installed closed to the actual operating
equipment. This saves the amount of cable and other associated wiring and labour cost. Only
wiring needed for communication back to the processor is a shielded twisted pair, twin axial
cable, fiber optic cable. The status lights on output module close to the actual equipment
shortens troubleshooting time increase production, eases maintenance and increases
efficiency.

The Guts Inside

The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive
input/output data. We can actually consider the PLC to be a box full of hundreds or
thousands of separate relays, counters, timers and data storage locations. Do these counters,
timers, etc. really exist? No, they don't "physically" exist but rather they are simulated and

26
can be considered software counters, timers, etc. These internal relays are simulated through
bit locations in registers. (more on that later)

3.7 What does each part do?

 Input Relays-(contacts) These are connected to the outside world. They physically
exist and receive signals from switches, sensors, etc. Typically they are not relays but
rather they are transistors.

 Internal Utility Relays-(contacts) These do not receive signals from the outside world
nor do they physically exist. They are simulated relays and are what enables a PLC to
eliminate external relays. There are also some special relays that are dedicated to
performing only one task. Some are always on while some are always off. Some are on
only once during power-on and are typically used for initializing data that was stored.

 Counters-These again do not physically exist. They are simulated counters and they
can be programmed to count pulses. Typically these counters can count up, down or
both up and down. Since they are simulated they are limited in their counting speed.
Some manufacturers also include high-speed counters that are hardware based. We can
think of these as physically existing. Most times these counters can count up, down or
up and down.

 Timers-These also do not physically exist. They come in many varieties and
increments. The most common type is an on-delay type. Others include off-delay and
both retentive and non-retentive types. Increments vary from 1ms through 1s.

 Output Relays-(coils) these are connected to the outside world. They physically exist
and send on/off signals to solenoids, lights, etc. They can be transistors, relays, or
triacs depending upon the model chosen.

 Data storage-Typically there are registers assigned to simply store data. They are
usually used as temporary storage for math or data manipulation. They can also
typically be used to store data when power is removed from the PLC. Upon power-up
they will still have the same contents as before power was removed. Very convenient
and necessary.

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3.8 Programming Language
A Programmer use to develop series of instruction or commands that directs the PLC to
execute action. Types of Language:-
 Ladder Diagram (LD):- A PLC programming system that contains relay logic (NO,
NC) in the form of ladder.
 Functional Block diagram (FBD):- A programming system that uses large function
block for portion of program.
 Structured text (ST):- structure text (ST) is a PLC programming system that uses a
series of steps and description to define a program. Structure text uses a lots of IF,
Else, and TRUE or FALSE.
 Instruction List (LT):- A PLC programming system that consists of series of
sequential statement which define a program.
 Sequential Functional Chart (SFC):- A programming system that uses vertical and
parallel connected blocks and gates used in programming.

A Programming Language rules for combining the instruction so that they produce the
desired action. The most common language used for programming Language is “LADDER
LOGIC”.

3.9 Why ladder logic preferred?

Ladder Logic is a graphical system of symbol and term even those not familiar with relay
wiring diagram can easily learn it.

3.10 Sourcing vs. Sinking Rules

1) Field devices on the positive side (+VDC) of the field power supply are sourcing field
devices.
2) Field devices on the negative side (DC COM) of the field power supply are sinking field
devices.
3) Sourcing field devices must be connected to sinking I/O cards and vice versa.
4) Sinking field devices must be connected to sourcing I/O cards and vice versa.

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 SOURCING Pushbutton SINKING Pushbutton
(PNP) (NPN)

+VD
C
+
+ DC
Power
DC Supply
Power
Supply
-
- DC COM

Fig-17(Sinking and Sourcing)

SOURCING SINKING
(PNP) (NPN)

+VDC
Field
Device IN1 +
DC DC
+ DC Power
Input
DC Supply
Power Module
Input
Supply
Module -
Field
- DC COM Device IN1

Fig-18(Block diagram of sinking and sourcing)

3.11 Electrical Ladder Diagram

 Ladder logic is evolved from electrical logic, which represents how electrical current
flow through the device to complete an electric circuit.
 An electrical diagram consists of two vertical bus lines or power lines, with current
flowing from left to right bus.
 Each electrical circuit in the diagram is considered a RANG.

29
 Every rang has two components:-
 It contains at least one device that is controlled.
 It contains the condition that controls the device.

L2
PB2 Start
PB1 Motor
Stop
Rung M1
M1

Auxiliary Holding Contact

Power Bus
Power Bus

Fig-19(Electrical ladder Diagram)

Ladder diagram
 Ladder Logic closely resembles electrical ladder diagrams
 A Ladder logic program exists only in the PLC’s software.
 In ladder Logic it is not the actual flow of current thru circuits.
 In electrical diagram the devices are described as open or closed(ON or OFF),
where as in Ladder Logic, instructions are either TRUE or FALSE.
 In Ladder Logic Program must contain at least one control instruction (output) and
usually contains one or more conditions (inputs).

L1 Condition Instruction Control Instruction L2

PB1 PB2 Start Motor- M1 L
%Q1
% I11
Stop %I2
Rung
%Q1

Auxiliary Contact

Fig-20(Ladder Diagram)

3.12 Logic Gates

30
INTRODUCTION OF LOGIC GATES USED IN PLC PROGRAMMING
 A Digital Gate is a device that analyzes the digital states of its inputs and puts out an
approximate output state

 digital gate logic keys such as

o AND
o OR
o NOT and others.

 Once logic terms are understood. PLC programming using them can be easily
accomplished.
 Boolean algebra is a shorthand way of writing digital gate diagrams.

 The Boolean algebra symbols are :-

o Dot
o +
o –
o 0
o =

 Some computer-trained persons understand PLC programming best using digital logic

 All gates have one output.

 The outputs are either ON (1) or OFF (0), depending on the logic status of their inputs,
ON (1) or OFF (0).

 A gate on condition is typical when +5 volts DC comes from the output terminal. Off
is typically 0 volts output

31
 3.12.1 AND Gate:- For the AND gate output to be ON (1), all inputs must be ON (1).

A
B OUTPUT
C

Truth Table for two input:-

A*B=O

A B O
0 0 0
0 1 0
1 0 0
1 1 1

3.12.2 OR Gate-

For an OR gate output to be on (1), any one or more of the input must be on (1). For the
output to be off (0), all input must be off (0).

32
 B O
C

Truth table for OR Gate:-

A+B=O

A B O
0 0 0
0 1 1
1 0 1
1 1 1

3.13 NOT Gate: -

It reverse the input logic status, on or off, from the input to the CPU

B
O

Truth Table:-
A=Ā

A O

33
 0 1
1 0

3.14 EXCLUSIVE OR: -

Its outputs are on (1) when one, and only one, of its two input is on (1). If both inputs are on,
the output is off

Truth table:-

A + B

A B O
0 0 0
0 1 1
1 0 1
1 1 0

3.15 EXCLUSIVE NOR: -

Its outputs are on, when both the inputs are either 0 or 1 output is off .

A
O

34
Truth Table:-

A _ B

A B O
0 0 1
0 1 0
1 0 0
1 1 1

3.16 NAND Gate:-

Output of NAND is OFF when both the input are 1 else both output is always HIGH.

A
B
O

Truth Table:-
A.B

A B O
0 0 1
0 1 1
1 0 1
1 1 0

3.17 NOR Gate:-

Output of the NOR Gate is ON when both the input are high else output is always LOW.

35
 A

B O

Truth Table:-
A+B

A B O
0 0 0
0 1 0
1 0 0
1 1 1

36
 CHAPTER – 4

4.1 System Architecture

The system architecture of the automated bottle filling system. This System consists of three
reservoirs; Reservoir Tank-1and Reservoir Tank-2 and Reservoir Tank-3 each containing the
constituent liquids components of the mixture required to be produce; which are to be mixed
in pre-determined proportion. Reservoir Tank -1 and tank 2 is connected to a Pump and
Pump for transferring the liquids to the Overhead Mixing Tank 3 through the solrnoid
valve.The Overhead Mixing Tank contains programming of PLC the liquid level is fixed.
This additional safety has been incorporated to ensure that the automated system works
safely even in the case of failure of the high level sensor. The other end of the conveyor belt
is connected to dc motor.

37
 Fig-21(System Architecture)

4.2 Working of Project

Step 1: Switch ON the pump fill the tank.
Step 2: DC Motor 1 starts and rotate the conveyor belt.
Step 3: metal sensor senses the bottle. If the bottle is detected then the conveyor motor stops.
Step 4: If the bottle is detected then valve 1 and valve 2 will be open for same proportion.
Step 5: After proportion is reached valve 1 and valve 2 will be closed.

38
Step 6: Mixing stirrer motor 2 will be ON and valve 3 will be open for predefined time.
Step 7: After the bottle is filled, valve 3 will be closed.
Step 8: pick bottle.

4.3 Understanding feasibility

Feasibility study means the analysis of a problem to determine if it can be solved effectively.
In other words it is the study of the possibilities of the proposed system. It studies the work
ability, impact on the organization ability to meet user’s need and efficient use of resources.
Three aspects in which the system has to be feasible are:-

4.4 Economical feasibility

The economical analysis checks for the high investment incurred on the system. It evaluates
development & implementing charges for the proposed “Industrial Automation Project”. The
PLC used for the development is easily available at the market but they are very expensive &
the software for programming comes with the PLC hence it results in high cost
implementation.

4.5 Technical feasibility

This aspect concentrates on the concept of using computer meaning, “Mechanization” of
human works. Thus the automated solution leads to the need for a technical feasibility study.
The focus on the platform used is the PLC based Industrial Automation.
The proposed system require an in depth technical knowledge on various electrical machines
and PLC hardware as well as software. This is required to improve the technical efficiency of
the design. Otherwise the system development is simple and easy to understand. The result
obtained should be true in the real time conditions.

4.6 Behavioral feasibility

Behavioral feasibility deals with the runtime performance of the proposed system. It must
score higher than the present in the behavioral study. The project should have end user when
the system is designed while designing. The programmer should be aware of the condition’s
user’s knowledge input, output, calculations etc. Care should be taken to avoid non-working
means & buttons.

39
 CHAPTER – 5

IMPORTANCE OF PLC BASED LIQUID MIXING AND FILLING SYSTEM

5.1 Why PLC Use?

40
 Automation is used for all control systems and the technologies in PLC is use to reduce
the human work and helps in increasing the production. A bottle filling system
with PLC allows the user defined selection volume in percentage which uses the ladder
language. Ladder logic is used to control the process.

5.1.1 Advantages
1. Flexible in Nature: One model of PLC can be used for different operations as per
requirement.
2. Easy to install and troubleshooting: In hard wired relay based systems, installation
time is more as compared to the PLC based control panels.
3. Availability of Large contacts: PLC programming tools contain internal large
number of contacts that can be used for any change induced in different
applications.
4. Cost effective: Advanced technology and large production of PLC makes it cheaper
than the other controller or relay based systems.
5. Simulation feature: PLC programming software comes with the simulation features
by default.
6. Simple programming methods: PLC is provided with simple programming methods
to program the PLC like Ladder or Boolean type of programming.
7. Ease of maintenance: As compared with the control systems like relay based or
micro-controller based systems, maintenance cost of PLC is low.
8.   The programmer can program and print easily the programs of PLC for future use.

5.2 Disadvantages
1. Fixed circuit operation.
2. PLCs manufacturers offer only closed loop architecture
3. PLCs are propitiatory, which means software and parts one manufacturer can’t be
easily used in combination with part of another manufacturer.
4. Number of optional modules must be added to maximize flexibility and performance.

5.3 Applications
• Mobile Monitoring.
• Facility Protection

41
• Loss Prevention
• Employ Safety
• Traffic Monitoring
• Event Video Surveillance
• Operation Monitoring
• Prevent Theft
• Neutralizing threat to human life.
• Can be deployed in Underground mine prone areas.
• Can be used in espionage missions.

CHAPTER – 6
Future Work & Conclusion

6.1. Future Work

42
With the help of the hardware of our project we can extend the process for the packing with
the help of "Pick and Drop Robot". In this project we can also use the multiple colors to mix
the colour and fill it in the bottle.

6.2. Result
The device can fill up to 2 types of liquid by intermixing using solenoid valve switch in just
few seconds. System doesn’t require no any external pumps and only two metallic sensors
are used. It is a time based control by which the pulse is generated in flow sensor and filling
process is done. It be used commercially in various coffee shops, juice shops, cold drink
shops and reduce human effort. So the practical research result is much satisfactory. It shows
the necessity of PLC in industrial automation and also to realize the necessity of studying it.

6.3. Conclusion
The main aim of this project is to develop a PLC based automatic liquid mixing and filling
bottles. We acquire more knowledge for better and advancement of the project in future .Also
know how PLC systems are essential for advancements in electronic gadgets like automatic
liquid mixing systems etc.

References:

43
1. PLC based Automated Liquid Mixing and Bottle Filling System, Mini Sreejethl and
Shilpa Chouhan2, 1st IEEE International Conference on Power Electronics. Intelligent
Control and Energy Systems (ICPEICES-2016)
2. Vision based Bottle classification and Automatic Bottle Filling
System,K.Thyagarajan,Meenakshi.R,Suganya.P, International Conference on Advances
in Human Machine Interaction (HMI - 2016), March 03-05, 2016
3. Designing and Implementation of Chemical Mixing and Filling Bottles Using PLC,
Prasad Birmole, Madhushri Kamble, Sayali Naik, Anjali Sadamate,
Prof.Heenali.V.Korgaonkar, 2nd International Conference on Inventive Communication
and Computational Technologies (ICICCT 2018)
4. Subhankar Chattoraj, Subhro Mukherjee, Rahul Mallick, Ankit Parashar4, Sayandeep
Sen, Karan Vishwakarma “Automatic Bottle Filling System Using PLC and SCADA”,
International Journal of Engineering Research and Development, Volume 12,Issue 10
(October 2016)
5. Courtesy of MATLAB-URL: http://mathworks.in.
6. Yazdi L, Prabuwono AS, Golkar E. “Feature Extraction Algorithm for Fill Level and Cap
Inspection in Bottling Machine”. International Conference on Pattern Analysis and
Intelligent Robotics, 28-29 June 2011, Putrajaya, Malaysia
7. Kunal Uttekar; Rahul Gosavi; Sarthak Lad; Jagruti Kamat; "Implementation of Sensor
Network for Automation of BottleCappingAssembly Station Using IEEE 802.15.4";
2ndInternational Conference on Instrumentation Control and Automation; 15-17
November 2011; Bandung; Indonesia.

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