PLC Industrial Application -- Continuous Bottling Filling System


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Draw the flow chart of any industrial application and implement it using Ladder Logic.

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PLC Industrial Application -- Continuous Bottling Filling System

  1. 1. Zunaib Ali - 09 Muqadsa Iftikhar - 03 1 Lab Report No: 11 Programmable Logic Control (PLC) Apparatus:  Internet Activated PC. Theory: Every system or machine has a controller. Depending on the type of technology used, controllers can be divided into pneumatic, hydraulic, electrical and electronic controllers. Frequently, a combination of different technologies is used. Furthermore, differentiation is made between hard-wired programmable (e.g. wiring of electro-mechanical or electronic components) and programmable logic controllers. The first is used primarily in cases, where any reprogramming by the user is out of the question and the job size warrants the development of a special controller. Typical applications for such controllers can be found in automatic washing machines, video cameras, and cars. However, if the job size does not warrant the development of a special controller or if the user is to have the facility of making simple or independent program changes, or of setting timers and counters, then the use of a universal controller, where the program is written to an electronic memory, is the preferred option. The PLC represents such a universal controller. It can be used for different applications and, via the program installed in its memory, provides the user with a simple means of changing extending and optimizing control processes. The original task of a PLC involved the interconnection of input signals according to a specified program and, if "true", to switch the corresponding output. Boolean algebra forms the mathematical basis for this operation, which recognizes precisely two defined statuses of one variable: "0"and "1. PLC has evolved as an important controller in industries these days because of its simplicity and robustness. It is used for controlling many mechanical movements of the heavy machines or to control the voltage and frequency of the power supplies. The applications include the Continuous bottle filling system, Batch-mixing system, Speed control of dc motor, 3 stage air conditioning system, Control of planar machine and The automatic frequency control of the supply, during induction heating.
  2. 2. Zunaib Ali - 09 Muqadsa Iftikhar - 03 2 LAB TASK: Draw the flow chart of any industrial application and implement it using Ladder Logic. Application: Continuous Bottle Filling System This is one of the important application of PLC in the bottle filling industry where we want our bottles, which are moving on the conveyor belt, to be automatically detected at the appropriate position and get it filled by any desired liquid and also after getting filled the queued bottle gets chance to be filled. If this whole process is carried out manually it will really take a long time and also the quantities will be quite lesser. So PLC becomes requisite controller for these types of industry. Objective- We will implement a control program that detects the position of a bottle via a limit switch then waits for 0.5 secs, and then fills the bottle until a photo detector detects the filled condition of the bottle. After the bottle is filled, the buzzer sounds and the control program will again wait for 0.7secs, before moving to the next bottle. Until the limit switch signals, the feed motor, M1 runs while there are fixed rollers which carries the filled bottles. Motor, M2 keeps running after the process has been started. Fig. 1: Automatic Bottle Filling System
  3. 3. Zunaib Ali - 09 Muqadsa Iftikhar - 03 3 Flow Chart- Start Turn-ON Light (L1) Start Outfeed Motor (M2) LS Signaled Stop feed Motor (M1) Start Solenoid Valve (S1) after 0.5sec Start feed Motor (M1) Yes No PE Signaled Turn-ON Buzzer (B1) Stop Solenoid Valve (S1) Yes Turn-ON FB after a delay of 0.7sec No Fig.2: Automatic Bottle Filling System Flow Chart
  4. 4. Zunaib Ali - 09 Muqadsa Iftikhar - 03 4 Ladder Logic-
  5. 5. Zunaib Ali - 09 Muqadsa Iftikhar - 03 5 Inputs and Outputs Used- Observation- Once the start button is pressed the green light (L1) turns ON and remains ON until stop button is pressed. As light turns ON outfeed motor (M2) starts running. After M2 runs and if either limit switch (LS) has not signaled or filled bottle condition is fulfilled motor (M1) starts. After limit switch has signaled timer, T1 gets activated. After T1 gives done (DN) signal and photoeye detector (PE) is disabled, solenoid valve gets in operation. As PE signals solenoid stops and buzzer (B1) sounds after which timer, T2 gets enabled which stops the process for 0.7 seconds. Once the filled bottle condition is activated the cycle starts again. The ladder diagram was successfully checked in the GMWIN and all the prescribed conditions were observed completely.
  6. 6. Zunaib Ali - 09 Muqadsa Iftikhar - 03 6 Simulations- When Start Button is pressed Light L1, Motor M2 and Motor M1 gets On/Started. When Limit Switch is signaled Motor M1 is stopped and Solenoid Valve S1 is turned- ON.
  7. 7. Zunaib Ali - 09 Muqadsa Iftikhar - 03 7 When photoeye detector is signaled, Solenoid valve is turned-OFF, and after some time Filled Bottle signal is made high and process is repeated again and new bottle is filled.