The aim of this project is to design a micro controller Based automatic bottle filling system that sense the presence of bottle and fills it accordingly up to a fixed level.
This document describes a project to develop a PLC-based automatic bottle filling and capping system. The system will include a filling unit with a reservoir, pump, and solenoid valve. An infrared sensor will detect empty bottles on a conveyor belt and activate the filling unit. Once filled, the bottles will continue on the conveyor belt and be capped before exiting. The project aims to create an efficient and low-cost automation solution. A budget of approximately Rs. 3000 is estimated for completion. The goal is to gain experience with industrial automation processes like filling and capping using a PLC.
Here are the key points about stepper motors:
- A stepper motor rotates in discrete step angles in response to an applied digital signal. The motor's position is controlled by pulsing the motor windings on and off.
- Stepper motors can be rotated in both directions in incremental steps, making them ideal for open-loop control applications where precise positioning is required, such as 3D printers and CNC machines.
- They are made up of a rotor with permanent magnets and a stator with wound coils. The stator windings are energized in a sequence to rotate the motor. Different winding sequences produce different step angles.
- Bipolar stepper motors have four or more wires connecting
Plc based automatic bottle filling systemkl university
This document describes a PLC-based automatic bottle filling system that fills bottles simultaneously using sensors and valves. The system uses a programmable logic controller and proximity sensors to detect bottles on a conveyor belt. When a bottle is sensed, the corresponding pump switches on to fill the bottle based on a preset timer value. Once filled, the conveyor moves the bottles to the capping station. The entire process is controlled using a Delta PLC programmed with ladder logic. The system allows for automatic and simultaneous filling of multiple bottles to improve efficiency over traditional single-bottle filling methods.
Automatic bottle filling system using microcontrollerShubham Patel
This document presents an automatic bottle filling system using a microcontroller. The system consists of a conveyor section to move bottles, a filling section with sensors, and a control section using a microcontroller. As bottles pass on the conveyor, IR sensors count them and stop them for filling. A DC water pump then fills each bottle to a user-defined volume before the conveyor moves it along. The microcontroller controls the sensors, pump, and conveyor motor to automate the filling process. The system aims to reduce human effort in filling bottles while allowing customizable fill levels through a simple control interface.
The document describes the design and development of an automated bottle filling system meant for small industries. The system aims to automate bottle filling to eliminate problems with manual filling like spilling and ensuring equal quantities are filled. It uses a conveyor belt powered by a DC motor to transfer bottles through the system. A proximity sensor detects bottle presence and a solenoid valve controls the amount of liquid filled, as directed by a microcontroller. The system was successfully implemented and tested, and found to reduce work, time, and costs compared to manual filling.
Power point presentation on Industrial AutomationJaiPrakash337
This document summarizes a seminar presentation on industrial automation. It discusses automation tools like PLCs and SCADA used to automate industrial processes. It defines automation and describes the advantages it provides like improved accuracy, reduced costs, and increased production. PLCs are described as programmable devices that can automate industrial tasks by reading sensor inputs, running user-defined logic, and controlling outputs. SCADA systems allow remote monitoring and control of distributed industrial processes. The document outlines the components and applications of PLCs and SCADA and concludes that combining them provides an effective way to safely operate and monitor industrial machines.
This document provides an overview of programmable logic controller (PLC) architecture. It discusses PLC components like the memory unit and input/output modules. It describes different PLC types including fixed, modular, and rack PLCs. The document also covers the PLC scan cycle involving input scanning, program execution, and output scanning. Common PLC programming methods like ladder logic and structured text are introduced. Key concepts such as latching and unlatching in PLC programs are defined.
This document describes a project to develop a PLC-based automatic bottle filling and capping system. The system will include a filling unit with a reservoir, pump, and solenoid valve. An infrared sensor will detect empty bottles on a conveyor belt and activate the filling unit. Once filled, the bottles will continue on the conveyor belt and be capped before exiting. The project aims to create an efficient and low-cost automation solution. A budget of approximately Rs. 3000 is estimated for completion. The goal is to gain experience with industrial automation processes like filling and capping using a PLC.
Here are the key points about stepper motors:
- A stepper motor rotates in discrete step angles in response to an applied digital signal. The motor's position is controlled by pulsing the motor windings on and off.
- Stepper motors can be rotated in both directions in incremental steps, making them ideal for open-loop control applications where precise positioning is required, such as 3D printers and CNC machines.
- They are made up of a rotor with permanent magnets and a stator with wound coils. The stator windings are energized in a sequence to rotate the motor. Different winding sequences produce different step angles.
- Bipolar stepper motors have four or more wires connecting
Plc based automatic bottle filling systemkl university
This document describes a PLC-based automatic bottle filling system that fills bottles simultaneously using sensors and valves. The system uses a programmable logic controller and proximity sensors to detect bottles on a conveyor belt. When a bottle is sensed, the corresponding pump switches on to fill the bottle based on a preset timer value. Once filled, the conveyor moves the bottles to the capping station. The entire process is controlled using a Delta PLC programmed with ladder logic. The system allows for automatic and simultaneous filling of multiple bottles to improve efficiency over traditional single-bottle filling methods.
Automatic bottle filling system using microcontrollerShubham Patel
This document presents an automatic bottle filling system using a microcontroller. The system consists of a conveyor section to move bottles, a filling section with sensors, and a control section using a microcontroller. As bottles pass on the conveyor, IR sensors count them and stop them for filling. A DC water pump then fills each bottle to a user-defined volume before the conveyor moves it along. The microcontroller controls the sensors, pump, and conveyor motor to automate the filling process. The system aims to reduce human effort in filling bottles while allowing customizable fill levels through a simple control interface.
The document describes the design and development of an automated bottle filling system meant for small industries. The system aims to automate bottle filling to eliminate problems with manual filling like spilling and ensuring equal quantities are filled. It uses a conveyor belt powered by a DC motor to transfer bottles through the system. A proximity sensor detects bottle presence and a solenoid valve controls the amount of liquid filled, as directed by a microcontroller. The system was successfully implemented and tested, and found to reduce work, time, and costs compared to manual filling.
Power point presentation on Industrial AutomationJaiPrakash337
This document summarizes a seminar presentation on industrial automation. It discusses automation tools like PLCs and SCADA used to automate industrial processes. It defines automation and describes the advantages it provides like improved accuracy, reduced costs, and increased production. PLCs are described as programmable devices that can automate industrial tasks by reading sensor inputs, running user-defined logic, and controlling outputs. SCADA systems allow remote monitoring and control of distributed industrial processes. The document outlines the components and applications of PLCs and SCADA and concludes that combining them provides an effective way to safely operate and monitor industrial machines.
This document provides an overview of programmable logic controller (PLC) architecture. It discusses PLC components like the memory unit and input/output modules. It describes different PLC types including fixed, modular, and rack PLCs. The document also covers the PLC scan cycle involving input scanning, program execution, and output scanning. Common PLC programming methods like ladder logic and structured text are introduced. Key concepts such as latching and unlatching in PLC programs are defined.
This document provides an overview of programmable logic controllers (PLCs). It defines a PLC as a digital computer used for industrial control systems. The document outlines the history of PLCs, their major components including the processor, power supply, and I/O modules. It describes the operational sequence of a PLC including input scan, logic solve, and output scan. Programming methods like ladder logic and functional block diagrams are discussed. Examples are provided of ladder logic programs for starting and stopping a motor. Advantages of PLCs include reliability, flexibility, and cost effectiveness. The document concludes by listing some common industrial applications of PLCs.
This document is a training report submitted by Priya Hada to her faculty supervisor, Ms. Pushpa Gothwal, on the topics of PLC and SCADA. It includes an introduction to automation, sections on PLC components and operation, ladder logic programming, SCADA features and applications. It also describes two student projects using a PLC to automate a pharmaceutical plant and using SCADA software to automate a bottle filling and capping station.
PLC Based Automatic Bottle Filling and Capping Systemijtsrd
Filling is the task that is carried out by a machine and this process is widely used in many industries that produce such as milk industries, chemical, food, mineral water and many industrial manufactures. The objective of this paper is to design, develop and monitor "Bottle filling and capping with PLC". This work provides with a lot of benefits like low power consumption, low operational cost, less maintenance, accuracy and many more. A prototype has been developed to illustrate the system. In this paper, the filling of the bottle is controlled by using a controller known as Programmable Logic Controller PLC which is also the heart of the entire system. For the conveyor system, a DC motor has been selected for better performance and ease of operation. Proximity sensors have been used to detect the position of the bottle. Ladder logic has been used for the programming of the PLC, which is the most widely used and accepted language for the programming of the PLC. Zar Kyi Win | Tin Tin Nwe "PLC Based Automatic Bottle Filling and Capping System" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd28114.pdf Paper URL: https://www.ijtsrd.com/engineering/electrical-engineering/28114/plc-based-automatic-bottle-filling-and-capping-system/zar-kyi-win
PLC is an industrial computer designed for multiple inputs and output arrangements. It is capable of storing the instructions to implement control functions such as sequencing, timing, counting, arithmetic, data manipulation and communication.
This document describes an automatic mixing and filling bottle system that uses a Siemens S7-1200 PLC as the controller. The system uses submersible pumps to transfer water and flavoring from containers into a mixing container. A mixing motor mixes the contents and a solenoid valve fills bottles on a conveyor belt. The PLC programming is done using ladder logic in TIA Portal software. The project aims to design an appropriate model and program the PLC to control the system components for automatic mixing and filling of bottles.
This document provides an overview of a seminar on programmable logic controllers (PLCs). The objectives are to describe PLC components, interpret specifications, apply troubleshooting techniques, convert relay logic to PLC languages, and operate and program PLCs. The contents include the history of PLCs, relay logic, PLC architecture such as CPU and I/O systems, programming concepts, applications, and troubleshooting. PLCs were developed to replace relay-based control systems and are now widely used in industrial automation.
The document provides information about an industrial training project completed by Sudeep Giri at Insulators and Electricals Ltd. It includes an acknowledgement, preface, and table of contents. The content covers topics like the company background, software used, automation, PLC components, programming languages, and a motor start/stop example. It aims to describe PLC programming through ladder logic based on the training received.
The document provides information about Programmable Logic Controllers (PLCs) including:
(1) An overview of PLCs, their history and components. PLCs were developed to replace relays and are used to automate industrial processes.
(2) Details on how PLCs work, including their main components like the CPU, power supply, and input/output modules. Programs are written and stored in memory to control inputs and outputs.
(3) Examples of ladder logic programming including basic logic elements, timers, counters, and latching circuits. Ladder diagrams provide a visual way to program sequences of operations and control flows.
This document provides an overview of programmable logic controllers (PLCs). It describes the basic components of a PLC including the central processing unit, input and output modules, power supply, and programming software. PLCs were developed to provide flexibility compared to traditional hardwired control systems. The document discusses PLC applications, advantages such as ease of programming and modification, as well as some disadvantages like proprietary aspects. It also covers PLC size, history, and leading manufacturers.
This document is a project report submitted by four students at the Sal College of Engineering for their Design Engineering II course. It outlines the development of an automatic bottle filling machine. The project uses various mechanisms like cam and follower, stepper gears, belts, and a water tank to automatically fill bottles on a conveyor system with minimal human intervention. The report includes an introduction on automation, the objectives of the project, a description of the mechanical components, and acknowledgments.
The project is based upon closed loop control system.
A Closed-loop Control System, also known as a feedback control system is a control system which uses the concept of an open loop system as its forward path but has one or more feedback loops (hence its name) or paths between its output and its input.
The reference to “feedback”, simply means that some portion of the output is returned “back” to the input to form part of the systems excitation.
The document discusses washing machines and their components. It begins by showing a block diagram of the input and output devices connected to the controller in an electronic washing machine. It then discusses various aspects of washing machines such as the types of sensors and actuators used, fuzzy logic control, different washing programs, and miscellaneous features. The key components discussed are the controller, motor, sensors to measure speed and detect water level, and actuators like the water valve and heater.
The document provides information about programmable logic controllers (PLCs). It defines a PLC as a digital computer used to automate electromechanical processes. The document then discusses the key advantages of PLCs like being cost-effective, flexible, and able to operate reliably for years. It also describes the basic architecture of a PLC including input and output modules, a central processing unit, and a programming device. Examples of ladder logic programming are also included to illustrate how PLCs can be programmed to control processes like starting motors in forward and reverse directions.
TRAINING REPORT ON INDUSTRIAL AUTOMATION- PLC SCADA, VARIABLE FREQUENCY DRIVEAKSHAY SACHAN
This document provides an overview of a training report on PLC, SCADA, and automation submitted by Akshay Sachan to the Electrical Engineering Department of the National Institute of Technology in Kurukshetra. The report includes an introduction to automation concepts, the history and introduction of programmable logic controllers, the architecture of PLCs including ladder diagrams, programming PLCs using ladder diagrams, applications of PLCs and SCADA systems, SCADA software and architecture, applications of SCADA, variable frequency drives, and a conclusion. Diagrams are provided to illustrate PLC internal architecture, simplified PLC structure, basic PLC sections, and ladder diagrams.
This document discusses Programmable Logic Controllers (PLCs). It provides a brief history of PLCs, describing how they were introduced in the 1960s as replacements for relay logic and have since evolved with the integration of microprocessors. The key components of a PLC like the power supply, processor, I/O modules, and programming device are defined. Common PLC programming languages including ladder logic are explained and examples are provided. Advantages like reliability and flexibility and disadvantages such as proprietary aspects are reviewed. Finally, common industrial applications and leading PLC brands are listed.
Seminar Presentation on Programmeble Logic Controller , By an Engineering Student For doing Professional Presentation like Business Presentation, Industrial Use
This document describes an automatic water level controller that uses four wires submerged in a tank to detect different water levels and indicate the level on an LCD display. It works by detecting conductivity of water with the submerged wires connected to an AT89C51 microcontroller. The microcontroller then displays the water level on an LCD and can control a motor. It lists the hardware components needed including the AT89C51 microcontroller, BC547 transistor, preset, piezo buzzer, and LCD. The software requirements are the Keil uVision 4.0 IDE for coding and Proteus for simulation verification.
The document discusses the history and use of programmable logic controllers (PLCs) in industrial automation. It notes that PLCs were first specified in 1968 by General Motors to provide a solid-state, reusable system for controlling industrial processes more flexibly than relay-based systems. A PLC consists of a central processing unit, power supply, programming unit, memory, and input/output interfacing circuitry. It scans inputs, executes user-programmed logic instructions, and updates outputs on a continuous cycle. Common programming methods for PLCs include ladder logic, functional block diagrams, and structured text. PLCs communicate with field devices and one another using various interfaces and protocols.
This document presents information about automation and its various applications. It defines automation as delegating human control functions to technical equipment to increase productivity, quality and safety while reducing costs. It describes different types of automation including building, office, scientific and industrial automation. It provides details about control systems, programmable logic controllers (PLCs), PLC programming languages and ladder logic. It also discusses supervisory control and data acquisition (SCADA) systems, their features and leading software. Finally, it outlines advantages and disadvantages of automation as well as examples of its applications.
Training Report on PLC SCADA and AUTOMATIONVikash Ranjan
This document provides information about programmable logic controllers (PLCs), including:
- PLCs were developed in the 1960s to replace relay control systems and reduce costs for automakers. They allow flexible control without rewiring.
- PLCs have a CPU that runs a user program to monitor inputs and control outputs based on logic. Ladder logic is a common programming method that resembles electrical diagrams.
- The document discusses PLC components, architecture, programming methods like ladder logic, common instructions, timers, counters and their applications in automation. It also provides an introduction to supervisory control and data acquisition (SCADA) systems.
A presentation on the topic Automatic Bottling System using Arduino 2560 Mega Micro Controller for small scale industry based bottle filling applications.
PLC Industrial Application -- Continuous Bottling Filling SystemZunAib Ali
This document summarizes a lab report on implementing a continuous bottle filling system using a programmable logic controller (PLC). The system uses a PLC to automatically detect bottles on a conveyor belt, fill each bottle with liquid for 0.5 seconds, sound a buzzer when full, and wait 0.7 seconds before filling the next bottle. A ladder logic program was created and tested in simulation software to control motors, valves, lights and more to automate the bottle filling process. The PLC provides a simple way to automate an industrial process that would be difficult to do manually at scale.
This document provides an overview of programmable logic controllers (PLCs). It defines a PLC as a digital computer used for industrial control systems. The document outlines the history of PLCs, their major components including the processor, power supply, and I/O modules. It describes the operational sequence of a PLC including input scan, logic solve, and output scan. Programming methods like ladder logic and functional block diagrams are discussed. Examples are provided of ladder logic programs for starting and stopping a motor. Advantages of PLCs include reliability, flexibility, and cost effectiveness. The document concludes by listing some common industrial applications of PLCs.
This document is a training report submitted by Priya Hada to her faculty supervisor, Ms. Pushpa Gothwal, on the topics of PLC and SCADA. It includes an introduction to automation, sections on PLC components and operation, ladder logic programming, SCADA features and applications. It also describes two student projects using a PLC to automate a pharmaceutical plant and using SCADA software to automate a bottle filling and capping station.
PLC Based Automatic Bottle Filling and Capping Systemijtsrd
Filling is the task that is carried out by a machine and this process is widely used in many industries that produce such as milk industries, chemical, food, mineral water and many industrial manufactures. The objective of this paper is to design, develop and monitor "Bottle filling and capping with PLC". This work provides with a lot of benefits like low power consumption, low operational cost, less maintenance, accuracy and many more. A prototype has been developed to illustrate the system. In this paper, the filling of the bottle is controlled by using a controller known as Programmable Logic Controller PLC which is also the heart of the entire system. For the conveyor system, a DC motor has been selected for better performance and ease of operation. Proximity sensors have been used to detect the position of the bottle. Ladder logic has been used for the programming of the PLC, which is the most widely used and accepted language for the programming of the PLC. Zar Kyi Win | Tin Tin Nwe "PLC Based Automatic Bottle Filling and Capping System" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd28114.pdf Paper URL: https://www.ijtsrd.com/engineering/electrical-engineering/28114/plc-based-automatic-bottle-filling-and-capping-system/zar-kyi-win
PLC is an industrial computer designed for multiple inputs and output arrangements. It is capable of storing the instructions to implement control functions such as sequencing, timing, counting, arithmetic, data manipulation and communication.
This document describes an automatic mixing and filling bottle system that uses a Siemens S7-1200 PLC as the controller. The system uses submersible pumps to transfer water and flavoring from containers into a mixing container. A mixing motor mixes the contents and a solenoid valve fills bottles on a conveyor belt. The PLC programming is done using ladder logic in TIA Portal software. The project aims to design an appropriate model and program the PLC to control the system components for automatic mixing and filling of bottles.
This document provides an overview of a seminar on programmable logic controllers (PLCs). The objectives are to describe PLC components, interpret specifications, apply troubleshooting techniques, convert relay logic to PLC languages, and operate and program PLCs. The contents include the history of PLCs, relay logic, PLC architecture such as CPU and I/O systems, programming concepts, applications, and troubleshooting. PLCs were developed to replace relay-based control systems and are now widely used in industrial automation.
The document provides information about an industrial training project completed by Sudeep Giri at Insulators and Electricals Ltd. It includes an acknowledgement, preface, and table of contents. The content covers topics like the company background, software used, automation, PLC components, programming languages, and a motor start/stop example. It aims to describe PLC programming through ladder logic based on the training received.
The document provides information about Programmable Logic Controllers (PLCs) including:
(1) An overview of PLCs, their history and components. PLCs were developed to replace relays and are used to automate industrial processes.
(2) Details on how PLCs work, including their main components like the CPU, power supply, and input/output modules. Programs are written and stored in memory to control inputs and outputs.
(3) Examples of ladder logic programming including basic logic elements, timers, counters, and latching circuits. Ladder diagrams provide a visual way to program sequences of operations and control flows.
This document provides an overview of programmable logic controllers (PLCs). It describes the basic components of a PLC including the central processing unit, input and output modules, power supply, and programming software. PLCs were developed to provide flexibility compared to traditional hardwired control systems. The document discusses PLC applications, advantages such as ease of programming and modification, as well as some disadvantages like proprietary aspects. It also covers PLC size, history, and leading manufacturers.
This document is a project report submitted by four students at the Sal College of Engineering for their Design Engineering II course. It outlines the development of an automatic bottle filling machine. The project uses various mechanisms like cam and follower, stepper gears, belts, and a water tank to automatically fill bottles on a conveyor system with minimal human intervention. The report includes an introduction on automation, the objectives of the project, a description of the mechanical components, and acknowledgments.
The project is based upon closed loop control system.
A Closed-loop Control System, also known as a feedback control system is a control system which uses the concept of an open loop system as its forward path but has one or more feedback loops (hence its name) or paths between its output and its input.
The reference to “feedback”, simply means that some portion of the output is returned “back” to the input to form part of the systems excitation.
The document discusses washing machines and their components. It begins by showing a block diagram of the input and output devices connected to the controller in an electronic washing machine. It then discusses various aspects of washing machines such as the types of sensors and actuators used, fuzzy logic control, different washing programs, and miscellaneous features. The key components discussed are the controller, motor, sensors to measure speed and detect water level, and actuators like the water valve and heater.
The document provides information about programmable logic controllers (PLCs). It defines a PLC as a digital computer used to automate electromechanical processes. The document then discusses the key advantages of PLCs like being cost-effective, flexible, and able to operate reliably for years. It also describes the basic architecture of a PLC including input and output modules, a central processing unit, and a programming device. Examples of ladder logic programming are also included to illustrate how PLCs can be programmed to control processes like starting motors in forward and reverse directions.
TRAINING REPORT ON INDUSTRIAL AUTOMATION- PLC SCADA, VARIABLE FREQUENCY DRIVEAKSHAY SACHAN
This document provides an overview of a training report on PLC, SCADA, and automation submitted by Akshay Sachan to the Electrical Engineering Department of the National Institute of Technology in Kurukshetra. The report includes an introduction to automation concepts, the history and introduction of programmable logic controllers, the architecture of PLCs including ladder diagrams, programming PLCs using ladder diagrams, applications of PLCs and SCADA systems, SCADA software and architecture, applications of SCADA, variable frequency drives, and a conclusion. Diagrams are provided to illustrate PLC internal architecture, simplified PLC structure, basic PLC sections, and ladder diagrams.
This document discusses Programmable Logic Controllers (PLCs). It provides a brief history of PLCs, describing how they were introduced in the 1960s as replacements for relay logic and have since evolved with the integration of microprocessors. The key components of a PLC like the power supply, processor, I/O modules, and programming device are defined. Common PLC programming languages including ladder logic are explained and examples are provided. Advantages like reliability and flexibility and disadvantages such as proprietary aspects are reviewed. Finally, common industrial applications and leading PLC brands are listed.
Seminar Presentation on Programmeble Logic Controller , By an Engineering Student For doing Professional Presentation like Business Presentation, Industrial Use
This document describes an automatic water level controller that uses four wires submerged in a tank to detect different water levels and indicate the level on an LCD display. It works by detecting conductivity of water with the submerged wires connected to an AT89C51 microcontroller. The microcontroller then displays the water level on an LCD and can control a motor. It lists the hardware components needed including the AT89C51 microcontroller, BC547 transistor, preset, piezo buzzer, and LCD. The software requirements are the Keil uVision 4.0 IDE for coding and Proteus for simulation verification.
The document discusses the history and use of programmable logic controllers (PLCs) in industrial automation. It notes that PLCs were first specified in 1968 by General Motors to provide a solid-state, reusable system for controlling industrial processes more flexibly than relay-based systems. A PLC consists of a central processing unit, power supply, programming unit, memory, and input/output interfacing circuitry. It scans inputs, executes user-programmed logic instructions, and updates outputs on a continuous cycle. Common programming methods for PLCs include ladder logic, functional block diagrams, and structured text. PLCs communicate with field devices and one another using various interfaces and protocols.
This document presents information about automation and its various applications. It defines automation as delegating human control functions to technical equipment to increase productivity, quality and safety while reducing costs. It describes different types of automation including building, office, scientific and industrial automation. It provides details about control systems, programmable logic controllers (PLCs), PLC programming languages and ladder logic. It also discusses supervisory control and data acquisition (SCADA) systems, their features and leading software. Finally, it outlines advantages and disadvantages of automation as well as examples of its applications.
Training Report on PLC SCADA and AUTOMATIONVikash Ranjan
This document provides information about programmable logic controllers (PLCs), including:
- PLCs were developed in the 1960s to replace relay control systems and reduce costs for automakers. They allow flexible control without rewiring.
- PLCs have a CPU that runs a user program to monitor inputs and control outputs based on logic. Ladder logic is a common programming method that resembles electrical diagrams.
- The document discusses PLC components, architecture, programming methods like ladder logic, common instructions, timers, counters and their applications in automation. It also provides an introduction to supervisory control and data acquisition (SCADA) systems.
A presentation on the topic Automatic Bottling System using Arduino 2560 Mega Micro Controller for small scale industry based bottle filling applications.
PLC Industrial Application -- Continuous Bottling Filling SystemZunAib Ali
This document summarizes a lab report on implementing a continuous bottle filling system using a programmable logic controller (PLC). The system uses a PLC to automatically detect bottles on a conveyor belt, fill each bottle with liquid for 0.5 seconds, sound a buzzer when full, and wait 0.7 seconds before filling the next bottle. A ladder logic program was created and tested in simulation software to control motors, valves, lights and more to automate the bottle filling process. The PLC provides a simple way to automate an industrial process that would be difficult to do manually at scale.
The document describes an automatic bottle filling and capping system designed by engineering students. It includes:
1) A rotating table powered by a DC motor that holds bottles in place during the filling and capping process.
2) A filling section that uses a solenoid valve controlled by a PLC to fill bottles.
3) A chute mechanism to guide caps onto bottles below.
4) A capping section that uses worm gears and DC motors controlled by the PLC to rotate and slide caps onto filled bottles.
5) Sensing mechanisms and a PLC program to control the filling and capping processes.
Plc based Robotic Arm and Automated Different Size Bottle Filling SystemRehan Fazal
Well this was going to be our final year project but it got rejected after being accepted by panel members in zeroth review by our HOD mam.
If u want to do this project or use the idea of this project seriously after getting all your formalities done, you can contact me. I will help you in getting all your IEEE papers and relevant papers to this project.
The reason behind sharing this is that I spend my whole one semester for studying theory part of it, and i was unable to do this but i really want someone to do this project.
Automatic Bottle filling system and remote monitoring throughDHRUVIT KHARADI
This document describes an automatic bottle filling system that uses a programmable logic controller (PLC) and remote monitoring via a supervisory control and data acquisition (SCADA) system. The system includes a conveyor belt for bottle transport, a load cell for weight measurements, solenoid valves to control fluid flow, and a relay device to supply appropriate voltages to motors and pumps. Students developed PLC programming to control the system timers and incorporate the load cell measurements. They also configured communication between the PLC and computer software. The system is designed to automatically fill bottles with high accuracy.
PLC based Multichannel Automatic Liquid Level ControllerVijay Badgujar
PLC based Multichannel Automatic Liquid Level Controller aims to control the level of liquid automatically so that water going waste due to overflow of tanks can be saved easily.
In this project , Two liquid level sensors are provided for overhead tanks and source tanks. Those liquid level sensors are low level sensors and high sensors. These sensors sense the level of liquid and operate relays and serves inputs to Programmable Logic Controller (PLC). Programmable Logic Controller (PLC) is programmed to control liquid level and maintain it at specific level in overhead tanks automatically.
This document is a training report on programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems submitted by Priya Hada to her faculty advisor Ms. Pushpa Gothwal. The report includes an introduction to automation and PLCs, describing their history, components, operation, and ladder logic programming. It also covers SCADA systems, their features and uses. The report details two student projects, one using a PLC to automate a pharmaceutical plant and another using SCADA software to simulate a bottle filling and capping station.
In 3 sentences:
John Deere reported record profits and sales in 2008. The company saw strong growth in its agricultural equipment division due to high global demand. While some markets slowed due to economic conditions, all of John Deere's business divisions remained profitable and contributed to increased shareholder value.
This document summarizes two projects completed during a summer training program - a pharmaceutical plant controlled using a PLC and a bottle filling and capping station controlled using SCADA software. The PLC project involved mixing two liquids and heating the mixture for 20 seconds at 100 degrees C. The SCADA project designed a station that filled bottles from three tanks, applied bottle caps, and moved the bottles to storage. Both projects achieved their objectives and future enhancements were proposed, such as integrating recipe management for the PLC project and adding automatic labeling and defect detection for the SCADA project.
The most important aspect of any color industry mixing which is main part which is controlled using PLC. The method that has to be used relies on varied objectives like superior quality, increased efficiency, high profit and other such points depending upon the purpose of the company that implies it. With the prime objective of catering to these necessities and the needs of the industrial sector, significance has been given here to automation.
This document describes an automatic object sorting system that uses image processing and a conveyor belt. The system uses a camera to capture images of objects on the belt and detects the color and shape of each object using MATLAB image processing algorithms. It then sends signals to a microcontroller to control the conveyor belt and sort the objects by moving colored objects to the left or right sides and shaped objects to the left or right based on predetermined criteria. The system is intended to automate sorting in industries to reduce costs and improve efficiency compared to manual sorting.
Kallem Monica Reddy proposes developing an automatic cup filler that uses a microcontroller, IR sensor, motor driver, DC motor, and other components. The automatic cup filler would work by sensing cups of a particular color and filling them with water or coffee to a specific level. Traditionally, bottle filling involved one bottle at a time on a conveyor but new methods allow simultaneous filling and capping in a synchronized process. Programmable logic controllers and supervisory control and data acquisition systems now control and monitor automated bottle filling systems. Reddy is interested in automation and building automated systems to simplify life.
Programmable logic control (PLC) is an important automation technology used to control production processes through logical steps and decisions. PLCs have replaced hardwired logic systems and allow for more flexibility. A PLC uses a programmable memory to store instructions and execute logical control sequences to operate actuators based on inputs from sensors. Ladder logic is a common programming language for PLCs where contacts represent inputs and coils represent outputs. PLCs are widely used in industries to control processes like manufacturing and chemical plants.
automation of waterpump using 8051 microcontrollerParth Joshi
This document describes a project to build an automatic water level controller. It lists 4 project members and their guide. The apparatus includes a water tank, microcontroller, relay, sensors, motor and pump. There are 3 modes - automatic on/off using sensor signals, user-defined on/off using switches, and compensation mode to maintain a specific level. The circuit diagram, programming in KEIL, and hardware design are outlined. Components include a transformer, rectifier, regulator, and sensors to sense water levels and control the motor and pump automatically.
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1. A PROJECT REPORT ON
AUTOMATIC BOTTLE FILLING
Submitted by:
REHAAN YAHYA HAJI MAHMOUD 10
KHAN BASHIR SIRAJ 13
SHAIKH AWESH 29
KUPE SUFIYAN SALAHUDDIN 22
UNDER THE GUIDANCE OF
PROF: KHAN SHUJAUDDIN
DEPARTMENT OF ELECTRONICS AND
TELECOMMUNICATIONS
A-I-ISLAM A.R.KALSEKAR POLYTECHNIC
NEW PANVEL 410206, NAVI MUMBAI
MSBTE
2013-2014
2. AUTOMATIC BOTTLE FILLING SYSTEM
A project report submitted in partial fulfillment for diploma
In
ELECTRONICS & TELECOMMUNICATION
ENGINEERING
By
REHAAN YAHYA HAJI MAHMOUD ROLL NO: 10
BASHIR SIRAJ ROLL NO:13
SHAIKH AWESH ROLL NO:29
KUPE SUFIYAN ROLL NO: 22
UNDER THE GUIDANCEOF
PROF: KHAN SHUJAUDDIN
Department of Electronics and telecommunications Anjuman-I-Islam
A.R.Kalsekar polytechnic
New Panvel 410206, Navi Mumbai
MSBTE
2013-2014
3. A PROJECT REPORT ON
AUTOMATIC BOTTLE FILLING
Submitted by:
REHAAN YAHYA HAJI MAHMOUD
KHAN BASHIR SIRAJ
SHAIKH AWESH
KUPE SUFIYAN SALAHUDDIN
UNDER THE GUIDANCE OF
PROF: KHAN SHUJAUDDIN
DEPARTMENT OF ELECTRONICS AND
TELECOMMUNICATIONS
A-I-ISLAM A.R.KALSEKAR POLYTECHNIC
NEW PANVEL 410206, NAVI MUMBAI
MSBTE
2013-2014
4. CERTIFICATE
This is to certify that this dissertation report “AUTOMATIC BOTTLE FILLING” is a
record of work carried out by
1. REHAAN YAHYA HAJI MAHMOUD (ROLL NO: 10)
2. BASHIR SIRAJ ( ROLL NO: 13)
3. SHAIKH AWESH ( ROLL NO: 29)
4. KUPPE SUFFYAN (ROLL NO: 22)
The student Of DIPLOMA IN ELECTRONICS & TELECOMMUNICATIONS
ENGINEERING class and is submitted to the Mumbai University, Mumbai in partial
fulfillment of the requirement for the Diploma in electronics and telecommunication
engineering. The project report has been approved.
Internal Guide Head of the Department
(PROF: KHAN SHUJAUDDIN) (PROF: ARIF SHAIKH)
Principal
A.I.ARKP Kalsekar Polytechnic
(PROF: IMRAN INAMDAR)
5. APPROVAL OF THE PROJECT
The project entitled “AUTOMATIC BOTTLE FILLING” submitted by
1. REHAAN YAHYA HAJI MAHMOUD ( ROLL NO: 10)
2. KAZI BASHIR SIRAJ ( ROLL NO: 13)
3. SHAIKH AWESH ( ROLL NO: 29)
4. KUPE SUFIYAN ( ROLL NO:22 )
Of “DIPLOMA IN ELECTRONICS AND TELECOMMUNICATION
ENGINEERING” has been accepted in partial fulfillment of the requirement for the
diploma engineering in electronics and telecommunication engineering. This project has
been approved.
(Internal Examiner) (External Examiner)
Date of Approval:
6. DECLARATION
I hereby declare that the project entitle “AUTOMATIC BOTTLE FILLING” submitted
for diploma in electronics & telecommunication engineering under MSBTE, is my
original work and the project has not formed the basis for any award of any degree,
association, fellowship or any other similar titles.
Signature of the student
Place:
Date:
7. TABLE OF CONTENTS
ACKNOWLEDGEMENT
ABSTRACT
CHAPTER 1: INTRODUCTION
1.1 Aim of the project
1.2 Salient features
CHAPTER 2: ELECTRONICS STEPS
CHAPTER 3: DEVELOPMENT STAGES AND PROCESS
3.1 Problem definition stage
3.2 Designing a block diagram
3.3 Implementing circuits and components
3.4 Developing an algorithm for software
3.5 Writing actual code for microcontroller
3.6 Compiling the code
3.7 Burning the hex file into microcontroller with programmer
3.8 Testing and running
CHAPTER 4: DESIGNING A BLOCK DIAGRAM
CHAPTER 5: HARDWARE IMPLEMENTATION
5.1 Microcontroller Card
5.2 Stepper Card
5.3 Relay
CHAPTER 6: DATA SHEET
6.1 SL 100
8. 6.2 Relay
CHAPTER 7: DESCRIPTION OF HARDWARE’S
7.1 Microcontroller
7.2 Stepper motor
7.3 solenoid valve
7.4 Different types of relays
CHAPTER 8: SOFTWARE IMPLEMENTATION
8.1 Program
CHAPTER 9: ADVANTAGE , DISADVANTAGE & APPLICATION
CHAPTER 10: FUTURE SCOPE
CONCLUSION
COMPONENT LIST
BIBLIOGRAPHY
9. ACKNOWLEDGEMENT
This project is spanned over a period of one year and the numbers of people who have
helped us are outstanding. To begin with we would like to thank our project guide
Professor KHAN SHUJAUDDIN who has helped us throughout the period and has
helped us through the times of need. In spite of their busy schedules it was very kind of
them to spare some of their precious time and give us valuable suggestions which
ultimately formed heart of this report. Professor ARIF SHAIKH (H.O.D. of Electronics
and Telecommunication) was a great source of inspiration and allowed us to work in the
lab for extended hours.
The laboratory assistants need a warm mention specially Mr. ANWAR and Mr.
GHULAM and Mr. ANSAR who have helped us all along the way. We also extend our
thanks to all professors of our departments for their valuable guidance. We would also
like to thank our fellow students for their support and good wishes.
Finally we thank entire Electronics and Telecommunication engineering Department for
excellent facilities and encouragement given during the course of project.
10. ABSTRACT
The field of automation has a notable impact in a wide range of industries beyond
manufacturing. Automation is the use of control systems and information technologies to
reduce the need for human work in the production of goods and services. In the scope of
industrialization, automation is a step beyond mechanization. Whereas mechanization
provides human operators with machinery to assist them with the muscular requirements
of work, automation greatly decreases the need for human sensory and mental
requirements as well. Filling is a task carried out by a machine that packages liquid
products such as cold drinks or water. The bottle filling project serves as an
interdisciplinary engineering design experience. It introduces aspects of computer,
electronics and mechanical engineering, including the following five primary knowledge
areas:
Machining & Fabrication
Electronics circuit prototyping and Programming
Sensor and Actuator application
Mechanical design
Project Planning
Presentation Skills.
11. CHAPTER 1
INTRODUCTION
1.1 AIM OF THE PROJECT:
The aim of this project is to design a microcontroller Based automatic bottle filling
system that sense the presence of bottle and fills it accordingly up to a fixed level. In this
project we developed proximity sensor using infrared sensor that detects the presence of
bottle.
1.2 SALIENT FEATURES:
• Based on microcontroller interface using 8051µc.
• Based on stepper card.
• Powered by 24 power supply.
• Reduces human effort.
• For low power consumption.
12. CHAPTER 2
ELECTRONICS STEPS
DAYS WEEKS ELECTRONICS STEPS
2 Project name selection
2 Literature survey
1 Problem definition
1 Block diagram
1 Details of individual block
1 Rough circuit diagram
1 Availability of parts in markets
1 Purchasing parts
2 Testing individual parts
1 Finalizing circuit diagram
1 Pcb designing
1 Soldering parts
1 Testing and troubleshooting of each parts
1 Complete testing of final circuit
2 Initializing of software
3 Final testing of software & hardware
1 Mounting of circuits on board
2 Model development
1 Finalizing the project
4 Report preparation
30 Project delivery
13. CHAPTER 3
Development stages and process
The complete development of this system can be divided into following stages:
• Problem definition stage
• Designing a block diagram
• Implementing circuits and components
• Developing an algorithm for software
• Writing actual code for microcontroller
• Compiling the code
• Burning the hex file into microcontroller with programmer
• Testing and running
3.1 PROBLEM DEFINITION STAGE
It is very first stage to develop any project. It actually defines the aim and concept of the
project. The aim of “Microcontroller based Automatic filling system” is to fill the bottles
automatically without any human effort. This technique is suitable for filling any of the
liquid type.
3.2 DESIGNING A BLOCK DIAGRAM
At this stage we have categorized the whole system into different modules. These
modules (block diagram) will be helpful in understanding the concept and working of the
integrated system.
3.3 IMPLEMENTING CIRCUITS AND COMPONENTS
This is an actual implementation of circuits of each block. At this stage we have actually
designed each block separately and finally integrate them into a complete working
system.
14. 3.4 DEVELOPING ALGORITHM FOR SOFTWARE
To get the logical flow of the software we have analysis the complete system and
organized the algorithm in such a manner that one can understand the complete working
of the software.
3.5 WRITING CODE FOR MICROCONTROLLER
After developing algorithm and software, the next step is to translate them into a C
language for Atmel 89C51H microcontroller so as to get instruction understood and run
as per our requirement, as instruction re in ASCIIC language.
3.6 COMPILING THE CODE
The implementation of code is done on computer with the help of a software named as
“KIEL”. KIEL is a computer aided program which stimulate the working of the
microcontroller in real time without burning the software into actual IC. Finally the
program is converted into a machine language i.e. INTEL HEX format.
3.7BURNING HEX FILE INTO MICROCONTROLLER
WITH PROGRAMMER
At this stage of moment the HEX format is being downloaded into Atmel 89C51H flash
memory microcontroller.
3.8 TESTING AND RUNNING
Finally, the most important and critical stage is testing, after loading the software into the
microcontroller to check wheatear program is working properly.
19. CHAPTER 7
DESCRIPTION OF HARDWARES
7.1MICROCONTROLLER
A microcontroller (sometimes abbreviated as µC, uC or MCU) is a small computer on a
single integrated circuit containing a processor core, memory and programmable input /
output peripherals. Microcontroller are designed for embedded applications, in contrast to
the microprocessor used in personal computers or other general purpose applications.
Microcontroller are used in automatically controlled products and devices , such as
automobile engine controls systems, implantable medical devices, remote controls, office
machine, power tools, toys and other embedded systems.
20. 7.1.1 FEATURES OF MICROCONTROLLER
• 128 bytes of ram
• 128 user defined flags
• Consist of 16 bit address bus
• Consist of 3 internal and two external interrupts
• Less power usage in 8051 with respect to other micro-controller
• Consist of 16-bit program counter and data pointer
• 8051 can process 1 million one-cycle instructions per second
• It consist of 32 general purpose registers each of 8 bits
• Rom on 8051 is 4 kbytes in size
• Consist of two 16 bit timer/ counter
21. 7.1.2 TYPES OF MICROCONTROLLER
Microcontroller are being classified on the basis of its internal bus width, architecture,
memory and instruction set.
The 8-bit microcontroller
When the ALU performs arithmetic and logical operations on a byte (8-bits) at an
Instruction, the microcontroller is an 8-bit microcontroller. The internal bus width of
8-bit microcontroller is of 8-bit. Examples of 8-bit microcontrollers are Intel 8051 family
And Motorola MC68HC11 family.
The 16-bit microcontroller
When the ALU performs arithmetic and logical operations on a word (16-bits) at an
Instruction, the microcontroller is a 16-bit microcontroller. The internal bus width of 16-
bit microcontroller is of 16-bit. Examples of 16-bit microcontrollers are Intel 8096
Family and Motorola MC68HC12 and MC68332 families. The performance and
Computing capability of 16 bit microcontrollers are enhanced with greater precision as
Compared to the 8-bit microcontrollers.
The 32-bit microcontroller
When the ALU performs arithmetic and logical operations on a double word (32-Bits) at
an instruction, the microcontroller is a 32-bit microcontroller. The internal bus Width of
32-bit microcontroller is of 32-bit. Examples of 32-bit microcontrollers are Intel 80960
family and Motorola M683xx and Intel/Atmel 251 family. The performance and
Computing capability of 32 bit microcontrollers are enhanced with greater precision as
Compared to the 16-bit microcontrollers.
23. 7.1.4 PIN DESCRIPTION
Pins1-8: Port 1 each of these pins can be configured as an input or an output.
Pin 9: RS a logic one on this pin disables the microcontroller and clears the contents of
most registers. In other words, the positive voltage on this pin resets the microcontroller.
By applying logic zero to this pin, the program starts execution from the beginning.
Pins10-17: Port 3 Similar to port 1, each of these pins can serve as general input or
output. Besides, all of them have alternative functions:
Pin 10: RXD Serial asynchronous communication input or Serial
synchronous communication output.
Pin 11: TXD Serial asynchronous communication output or Serial synchronous
communication clock output.
Pin 12: INT0 Interrupt 0 input.
Pin 13: INT1 Interrupt 1 input.
Pin 14: T0 Counter 0 clock input.
Pin 15: T1 Counter 1 clock input.
Pin 16: WR Write to external (additional) RAM.
Pin 17: RD Read from external RAM.
Pin 18, 19: X2, X1 Internal oscillator input and output. A quartz crystal which specifies
operating frequency is usually connected to these pins. Instead of it, miniature ceramics
resonators can also be used for frequency stability. Later versions of microcontrollers
operate at a frequency of 0 Hz up to over 50 Hz.
Pin 20: GND Ground.
Pin 21-28: Port 2 If there is no intention to use external memory then these port pins are
configured as general inputs/outputs. In case external memory is used, the higher address
byte, i.e. addresses A8-A15 will appear on this port. Even though memory with capacity
of 64Kb is not used, which means that not all eight port bits are used for its addressing,
the rest of them are not available as inputs/outputs.
Pin 29: PSEN if external ROM is used for storing program then a logic zero (0) appears
on it every time the microcontroller reads a byte from memory.
24. Pin 30: ALE Prior to reading from external memory, the microcontroller puts the lower
address byte (A0-A7) on P0 and activates the ALE output. After receiving signal from
the ALE pin, the external register (usually 74HCT373 or 74HCT375 add-on chip)
memorizes the state of P0 and uses it as a memory chip address. Immediately after that,
the ALU pin is returned its previous logic state and P0 is now used as a Data Bus. As
seen, port data multiplexing is performed by means of only one additional (and cheap)
integrated circuit. In other words, this port is used for both data and address transmission.
Pin 31: EA By applying logic zero to this pin, P2 and P3 are used for data and address
transmission with no regard to whether there is internal memory or not. It means that
even there is a program written to the microcontroller, it will not be executed. Instead, the
program written to external ROM will be executed. By applying logic one to the EA pin,
the microcontroller will use both memories, first internal then external (if exists).
Pin 32-39: Port 0 Similar to P2, if external memory is not used, these pins can be used as
general inputs/outputs. Otherwise, P0 is configured as address output (A0-A7) when the
ALE pin is driven high (1) or as data output (Data Bus) when the ALE pin is driven low
(0).
Pin 40: VCC +5V power supply.
25. 7.2 STEPPER MOTOR
STEPPER MOTOR – an electromagnetic actuator. It is an incremental drive (digital)
actuator and is driven in fixed angular steps.
This mean that a digital signal is used to drive the motor and every time it receives a
digital pulse it rotates a specific number of degrees in rotation.
•Each step of rotation is the response of the motor to an input pulse (or digital
command).
•Step-wise rotation of the rotor can be synchronized with pulses in a command-
pulse train, assuming that no steps are missed, thereby making the motor respond
faithfully to the pulse signal in an open-loop manner.
•Stepper motors have emerged as cost-effective alternatives for DC servomotors
in high-speed, motion-control applications (except the high torque-speed range)
with the improvements in permanent magnets and the incorporation of solid-state
circuitry and logic devices in their drive systems.
•Today stepper motors can be found in computer peripherals, machine tools,
medical equipment, automotive devices, and small business machines, to name a
few applications.
Stepper motors are usually operated in open loop mode.
7.2.1TYPES OF MOTORS AVAILABALE
Brushed Most common. Toys, battery powered tools, electric machines.
Apply power and go!
Brushless Less common. Less efficiency, less friction, less electrical
noise. Requires electronic driver.
Step motor Very common. Requires driver. Very strong when not rotating.
Easy to control rotor position.
Piezo (ultrasonic) Relatively new type. Requires driver. No electrical coils. More
torque with axial load!
Linear Same as brushed or step but it is ‘opened and unrolled’. Moves
load linearly.
26. 7.2.2 ADVANTAGES OF STEPPER MOTORS
•Position error is noncumulative. A high accuracy of motion is possible, even under
open-loop control.
•Large savings in sensor (measurement system) and controller costs are possible when
the open-loop mode is used.
•Because of the incremental nature of command and motion, stepper motors are easily
adaptable to digital control applications.
•No serious stability problems exist, even under open-loop control.
•Torque capacity and power requirements can be optimized and the response can be
controlled by electronic switching.
•Brushless construction has obvious advantages.
7.2.3 DISADVANTAGES OF STEPPER MOTORS
•They have low torque capacity (typically less than 2,000 oz.-in) compared to DC
motors.
•They have limited speed (limited by torque capacity and by pulse-missing problems due
to faulty switching systems and drive circuits).
•They have high vibration levels due to stepwise motion.
•Large errors and oscillations can result when a pulse is missed under open-loop control.
28. The above figure is the cross-section view of a single-stack variable-reluctance motor.
The stator core is the outer structure and has six poles or teeth. The inner device is called
the rotor and has four poles. Both the stator and rotor are made of soft steel. The stator
has three sets of windings as shown in the figure. Each set has two coils connected in
series. A set of windings is called a “phase”. The motor above, using this designation, is a
three-phase motor. Current is supplied from the DC power source to the windings via the
switches I, II, and, III.
Starting with state (1) in the upper left diagram, note that in state (1), the winding of
Phase I is supplied with current through switch I. This is called in technical terms, “phase
I is excited”. Arrows on the coil windings indicate the magnetic flux, which occurs in the
air-gap due to the excitation. In state I, the two stator poles on phase I being excited are in
alignment with two of the four rotor teeth. This is an equilibrium state.
Next, switch II is closed to excite phase II in addition to phase I. Magnetic flux is built up
at the stator poles of phase II in the manner shown in state (2), the upper right diagram. A
counter-clockwise torque is created due to the “tension” in the inclined magnetic flux
lines. The rotor will begin to move and achieve state (3), the lower left diagram. In state
(3) the rotor has moved 15°.
When switch I is opened to de-energize phase I, the rotor will travel another 15° and
reach state (4). The angular position of the rotor can thus be controlled in units of the step
angle by a switching process. If the switching is carried out in sequence, the rotor will
rotate with a stepped motion; the switching process can also control the average speed.
7.2.5 STEP ANGLE
• Step angle of the stepper motor is defined as the angle transverse by the motor in
one step.
• To calculate step angle, simply divide 360 by number of steps a motor takes to
complete one revolution.
• As we have seen that in half mode, the number of steps taken by the motor to
complete one revolution gets doubled, so step angle reduces to half.
29. • Stepper motor rotating in full modes takes 4 steps to complete a revolution, so
step angle can be calculate as..,
Step Angle ø = 3600 / 4 = 900
• In case of half mode step angle gets half, so it is 450
• Knowing the step angle we can calibrate the rotation of motor as well as we can
correct the angular position.
7.2.6 STEP SEQUENCE
• The step angle is the minimum degree of rotation in single steps.
• The various stepper motor have the different step angles such as 0.90, 1.80, 2.00,
2.50 etc. depending on the applications.
• To make the stepper motor works we need to energize coils in sequence.
• Stepper motor can be driven in two different sequence given below :
1. Full step sequence
2. half step sequence
7.2.7 FULL STEP SEQUENCE (1.80
)
In the full step sequence, two coils are energized at the same time and motor shaft rotates.
The order in which coils has to energize is given below:
FULL MODE SEQUENCE HEX VALUE
Step A B C D
0 1 1 0 0 0CH
1 0 1 1 0 06H
2 0 0 1 1 03H
3 1 0 0 1 09H
30. 7.2.8 HALF STEP SEQUENCE ( 0.90 )
In this half step sequence, motor step angle reduces to half the angle in full sequence i.e.
0.90.
Due to this its angular rotation gets increased i.e. number of steps get doubled as that of
full mode.
The order in which the coil has to be energize in half mode is given below:
Half mode sequence Hex value
step A B C D
0 1 1 0 0 C0H
1 0 1 0 0 04H
2 0 1 1 0 06H
3 0 0 1 0 02H
4 0 0 1 1 03H
5 0 0 0 1 01H
6 1 0 0 1 09H
7 1 0 0 1 08H
31. 7.3 SOLENOID VALVE
7.3.1 GENERAL
Solenoid valves are used wherever Fluid flow has to be controlled automatically. They
are used to an increasing degree in ever more varied types of plants and equipment. The
wide variety of different designs which are Available enables the user to choose a valve
specifically to suit virtually any application.
7.3.2 CONSTRUCTION
Solenoid valves are control units which, when electrically energized or de-energized,
either cut off or Permit fluid flow. The actuator is an electromagnet. When the valve is
energized, a magnetic field builds up which pulls a plunger or pivoted armature against
the action of a spring. When de-energized, the plunger or pivoted armature is returned to
its original position by the action of the spring.
7.3.3 VALVE OPERATION
Depending on the mode of actuation, a distinction is made between direct-acting valves,
internally piloted valves, and externally piloted valves. A further distinguishing feature is
the number of port connections or the number of flow paths (“ways”).
DIRECT-ACTING VALVES
In a direct-acting solenoid valve, the seat seal is attached to the solenoid core. In the de-
energized condition, a seat orifice is closed, which opens when the valve is energized.
32. DIRECT-ACTING 2-WAY VALVES
Two-way valves are shut-off valves having one inlet port and one outlet port (Fig. 1). In
the de-energized Condition, the core spring, assisted by the pressure of the fluid, holds
the valve seal on
The valve seat, shutting off the flow. When energized, the core and seal are pulled into
the solenoid coil and the valve opens. The electromagnetic force is greater than the
combined spring force and the static and dynamic pressure forces of the medium.
Fig1
DIRECT-ACTING 3-WAY VALVES
Three-way valves have three port connections and two valve seats. One valve seal always
remains open and the other closed in the de-energized mode. When the coil is energized,
the mode reverses. The 3-way valve shown in Fig. 2 is designed with a plunger-type core.
Various valve operations can be performed according to how the fluid medium is
connected to the working ports in Fig. 2. The fluid pressure builds up under the valve
seat. With the coil de-energized, a conical spring holds the lower core seal tightly against
the valve seat and shuts off the fluid flow. Port A is vented through outlet R. When the
coil is energized, the core is pulled in and the valve seat at Port R is sealed off by the
spring-loaded upper core seal. The fluid now flows from P to A.
33. Unlike versions with plunger-type cores in pivoted-armature valves, all port connections
are in the valve body. An isolating diaphragm ensures that the process fluid does not
come into contact with the coil chamber. Pivoted-armature valves can be used for any 3-
way valve operation. The basic design principle is shown in Fig. 3. Pivoted-armature
valves are provided with manual override as a standard feature.
Fig2 Fig3
INTERNALLY PILOTED SOLENOID VALVES
With direct-acting valves, static pressure forces increase with increasing orifice diameter,
which means that the magnetic force required to overcome the pressure force becomes
correspondingly larger. Internally piloted solenoid valves are therefore employed for
switching higher pressures in conjunction with larger orifice sizes, so in this case, the
differential fluid pressure performs the main work of opening and closing the valve
INTERNALLY PILOTED 2-WAY VALVES
Internally piloted solenoid valves are fitted with either a 2- or 3-way pilot solenoid valve.
A diaphragm or a piston provides the seal for the main valve seat. The operation of such a
valve is shown in Fig. 4. When the pilot valve is closed, the fluid pressure builds up on
both sides of the diaphragm via a bleed orifice. As long as there is a pressure differential
34. between the inlet and outlet ports, a shut-off force is created because of the larger
effective area on the top of the diaphragm. When the pilot valve is opened, the pressure is
relieved from the upper side of the diaphragm. The greater effective net pressure from
below now raises the diaphragm and opens the valve. In general, internally piloted valves
require a minimum pressure differential to ensure satisfactory opening and closing. In
addition, OMEGA also offers internally piloted valves designed with a coupled core and
diaphragm that operate at zero pressure differential (Fig. 5).
Fig Fig5
INTERNALL PILOTED MULTI-WAY SOLENOID VALVES
Internally piloted 4-way solenoid valves are used mainly in hydraulic and pneumatic
applications to actuate double-acting cylinders. These valves have four port connections:
a pressure inlet (P), two cylinder port connections (A) and (B), and one exhaust port
connection (R). An internally piloted 4/2-way poppet valve is shown in Fig. 6. When de-
energized, the pilot valve opens at the connection from the pressure inlet to the pilot
channel. Both poppets in the main valve are thus pressurized and switch over. With port
connection P connected to A, B can exhaust via a second restrictor through R.
35. Fig6
EXTERNALLY PILOTED VALVES
In this type, an independent pilot medium is used to actuate the valve. Fig. 7 shows a
piston-operated angle-seat valve with closure spring. In the unpressurized condition, the
valve seat is closed. A 3-way solenoid valve, which can be mounted on the actuator,
controls the independent pilot medium. When the solenoid valve is energized, the piston
is raised against the action of the spring and the valve opens. A normally-open valve
condition can be obtained if the spring is placed on the opposite side of the actuator
piston. In these configurations, the independent pilot medium is connected to the top of
the actuator .Double-acting versions controlled by 4/2-way valves do not require a spring.
36. Fig7
7.3.4 MATERIALS FOR SOLENOID VALVE
The valve body must be compatible with the fluid; common materials are brass, stainless
steel, aluminum, and plastic.
7.3.5 ADVANTAGE OF SOLENOID VALVE
• Easy control
• Fast operation
• High reliability
• Long service
• Life compact design
• Limited pressure drop
41. CHAPTER 9
ADVANTAGE, DISADVANTAGE AND
APPLICATIONS
9.1 ADVANTAGE
1. High reliability.
2. Small space requirement.
3. Computer capabilities.
4. Reduced cost.
5. Ability to withstand harsh environment.
6. Expandability.
7. High power handling.
8. Reduced human effort.
9. Compact ergonomic design.
10. Leak proof safety measures, study piping and robust construction.
11. User friendly and self-explanatory system.
9.2 DISADVANTAGES
1. Circuit is complex.
2. Unemployment problem.
42. 9.3 APPLICATION
1. In industry
2. Chemical
3. Cosmetic
4. Food
5. Beverage
6. Pharmaceutical
7. Bottled water industry.
43. CHAPTER 10
FUTURE SCOPE
Using appropriate pump, jet nozzle & solenoid valve in which case precise timing is
needed would increase productivity. A non-intrusive water level sensor could be used
instead of timing valve. An extended capping section could be introduced. Another
sensor could be used in the beginning which can sense the bottle and start conveyor belt
automatically. More flexibility can be introduced in nozzle positioning. The system can
be redesigned for increase bottle size and productivity.
CONCLUSION
The system can perform the task of autonomous quality control system used in industrial
production & it is most suitable for small scale industry as definite process is set by
programming. It also helps to understand the necessity of PLC in industrial automation
and also to realize the necessity of studying it.