1. RAJ KUMAR GOEL INSTITUTE OFTECHNOLOGY -
5 Km. Stone , Delhi- Meerut Road , Ghaziabad U.P. (201003)
Department of Mechanical Engineering
DESIGN AND FABRICATION OF WATER BOTTLE FILLING
SYSTEM
Guide Name:- Anand Shekhar Nishad (1803340013)
Mr. Arvind Tiwari Abhishek Kumar Saroj (1803340005)
(Assistant Professor) Pradeep Kumar Singh (1803340047)
Chandan Kumar Bharti (1803340025)
2. Introduction
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 24V DC 5Amps. 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.
There are five important languages which are used for the programming of the PLC. The list of the
methods are 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.
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3. Literature Review
▪ PLC Based Automatic Bottle Filling and Capping System With User Defined Volume Selection -
8th August 2012
In This Research Paper the researchers T.Kalaiselvi, R.Praveena at all.. Have develop an automatic bottle,
filling and capping system with a mechanism using sensors. Automatic filling process for all the bottles
simultaneously with a user defined selection for volume to be filled.
▪ AN AUTOMATED BOTTLE FILLING AND CAPPING PROJECT FOR FRESHMAN
ENGINEERING STUDENTS – June 2005
In this paper the researchers Kala Meah , Timothy Garrison , York College of Pennsylvania at all.. The
students work in small teams and have roughly 12 weeks to design an automated electromechanical system
that first transports three empty bottles, three tennis balls. The machine must fill each bottle. of water, cape
each bottle by covering the top with a tennis ball, and then deliver the capped and filled bottles to an area
outside of the operational zone. PLC(Programmable Logic Controller)
▪ BASED AUTOMATIC BOTTLE FILLING - 3rd may 2015
In This Research Paper the researcher Jaymin Patel Department Of Physics and Electronics of
Hemchandracharya North Gujarat University, Patan has develop a bottle filling system based on certain
specifications. More features can be added to this system as follows: Depending on the size, shape and
weight of the bottles, Filling operations can be implemented.
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4. ▪ AUTOMATIC LIQUID FILLING TO BOTTLES OF DIFFERENTHEIGHT USING
PROGRAMMABLE LOGIC CONTROLLER –14th July 2013
In This Research Paper the researcher MALLARADHYA H M, K R PRAKASH have Design and Develop
an automated liquid filling to bottles of different height using PLC. A total control is made in a filling is
achieved. The programming to this system developed is flexible, quickly and easily.
▪ AUTOMATED MULTIPLE WATER FILLING (AMWF) MACHINE - April 2009
In This Research Paper the researcher RUHAIRI BIN ABDUL RAHIM from University Teknikal Malaysia
Melaka has developed a project to apply filling system where this system can automatically filling 2 type
of liquid into their bottle randomly by using PLC as a controller. The filling system will be using the filling
concept Time Gravity Filler Selection Guide.
▪ PLC BASED AUTOMATIC LIQUID FILLING SYSTEM - March 2015
In This Research Paper the researcher S.Gowtham at all.. From INFO Institute of Engineering, Coimbatore
has developed a bottle filling machine for filling of same size of bottles. The Entire system is reliable and
time saving.
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5. Objective
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The main objective of the project is to Design and Develop a Automatic liquid filling to bottles of different
height with Microcontroller Integration.
1. To design an automated bottle filling system that can fill a particular type of containers of specific
volume.
2. To design an automated transfer unit for the filled bottles.
3. To design and integrate control algorithm for the transfer unit and the filling system
7. Estimated cost
S.NO COMPONENTS No. OF
COMPONENT
PRICE
1 DC MOTOR 3 390
2 BATTERY 1 2000
3 AURDINO UNO 2 1400
4 PUMP 1 550
5 IR SENSOR 2 800
6 RELAY 1 1000
7 OTHER 2000
TOTAL 8540 UPTO
8. METHODOLOGY
At first, the auto selection switch is selected so that the entire system operates automatically.
Then the “Auto start push button” (toggle switch is used here) is selected and the motor starts and the
conveyor belt starts moving. The DC motor used is a DC geared type motor whose shaft is coupled directly
with the shaft of the roller. This motor has an input voltage of 12v with an input current of 600mA to 14A.The
reason for selecting this motor is to achieve a high starting torque at a constant speed. It has a torque of 70
kgcm . The motor comes with a metal gearbox and centered shaft. Shaft is loaded with bearing for wear
resistance. The reason for choosing such a high torque is having such heavy rollers used on the either side of
the hardware which is mounted with a conveyor belt.
Then two to three bottles is placed simultaneously on the conveyor belt. Now as the bottle approaches
towards the photoelectric sensor, the sensor senses the bottle and the conveyor stops running.
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9. As the conveyor stops the solenoid valve gets energized and the water starts filling in the bottle. After a
given time period is over, then the solenoid valve gets de energized completely and water flowing through
the valve is stopped and the conveyor belt starts moving. The valve remains de energized until the bottle is
sensed by the sensor again.
EMERGENCY SWITCH has also been introduced in the system which works like a circuit breaker which
disconnects the entire PLC system whenever any unfavorable conditions arise.
The electrical connection of the system interfacing the hardware with the PLC machine has been done.
An Ethernet cable has been used to interface the computer with the PLC machine. A ladder logic (LAD)
has been implemented using the SIEMENS software in order for the better understanding of the system, so
that when the machine is online we can keep record of which part of the machine is online as per as
requirement.
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10. COMPONENTS Used
ARDUINO UNO
IR SENSOR
RELAYS
WATER PUMP
DC MOTOR
LCD
BATTERY
CONVEYOR SYSTEM
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13. IR SENSOR
IC LM358
Voltage Regulator(7805) 5V
InputVoltage 9V
WorkingVoltage 5V
Max range 10cm
Resistors Variable 150,150,10k Ω
Resistor 10k Ω
Capacitors 1μ, 10μ
18. OPERATION SEQUENCE
STEP 1 Press the "START" Push Button.
STEP 2 Then the "MOTOR" starts and the conveyor moves forward.
STEP 3 If the sensor detects the presence of bottle which is in position with the solenoid valve, then
the conveyor will stop.
STEP 4 If the sensor does not detects any presence of the bottle, the conveyor keeps on moving.
STEP 5 After some delay the valve turn "ON" and the bottle will get filled till the timer gets off.
STEP 6 After the bottle is filler , a d3elay is provide and then after the delay the motor starts
running.
STEP 7 And the process respects itself repeats itself from step 3.
21. REFERENCES
[1] Mallaradhya H M and K R Prakash, Department of Industrial Automation Engineering, VTURO,
Mysore, Karnataka, India , “AUTOMATIC LIQUID FILLING TO BOTTLES OF DIFFERENT”, issued on
14th july 2013
[2] Jaymin Patel Department Of Physics and Electronics, Hemchandracharya North Gujarat University,
Patan, India, “PLC(Programmable Logic Controller) BASED AUTOMATIC BOTTLE FILLING”, during
may-June 2015
[3] T.Kalaiselvi and R.Praveena, Assistant professor, Easwari Engineering College, Chennai, “PLC Based
Automatic Bottle Filling and Capping System With User Defined Volume Selection”, Issue 8, August 2012
[4] Lokeshwar, Assistant Professor, R.N. College of Engineering & Management, Rohtak, India,
“Implementation and Performance Analysis of Bottle Filling Plant Using Ladder Language”, Volume 3
Issue 7, July 2014
[5] Kala Meah Department of B.Sc. from Bangladesh University of Engineering and Technology.” AN
AUTOMATED BOTTLE FILLING AND CAPPING PROJECT ”issued on may 2010.
[6] Ahmed Ullah Abu Saeed, Md. Al-Mamun and A.H.M. Zadidul Karim of International Journal of
Scientific & Engineering Research,” Industrial Application of PLCs in Bangladesh” Volume 3, Issue 6,
June-2012
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