A complete report on developing & various algorithms that are required to develop a working prototype of factory automated bottle filling application

1. Page 1
Design & Development of Automatic bottle Refilling system
A Mini Project-1 Report
Submitted in Partial Fulfilment of the Requirements for the Degree
Of
BACHLOR OF TECHNOLOGY
IN
ELECTRICAL ENGINEERING
By
Parth K. Patel (14BEE089)
Parth D. Patel (14BEE090)
DEPARTMENT OF ELECTRICAL ENGINEERING
INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
Ahmedabad 382 481
August 2016

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CERTIFICATE
This Is To Certify That The Mini Project-1 Report Entitled “Design & Development Of
” Submitted By Mr. Patel Parth (14BEE089) And Mr.Automatic Bottle Refilling System
Patel Parth (14BEE090) Towards The Partial Fulfilment Of The Requirements For The
Award Of The Degree In Bachelor Of Technology (Electrical Engineering) Of Nirma
University Is The Record Of Work Carried Out By Him Under My Supervision And
Guidance. The Work Submitted Has In Our Opinion Reached A Level Required For Being
Accepted For Examination.
DATE: _ /_ /2016
PROF. AKHILESH NIMJE HOD (EE)
INSTITUTE OF
TECHNOLOGY
NIRMA UNIVERSITY
DEPARTMENT OF
ELECTRICAL ENGINEERING
AHMEDABAD-382481

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ACKNOWLEDGEMENT
I must acknowledge the strength, energy and patience that almighty GOD bestowed upon me
to start & accomplish this work with the support of all concerned, a few of them I am trying
to name hereunder.
I would like to express my sincere respect and profound gratitude to authorities and staff of
Electrical Engineering Department for providing the department facilities for my project
work. I would also like to thank all my friends who have helped me indirectly for the
completion of my dissertation work. I would also like to thank all the teaching and non-
teaching staff for cooperating with me and providing valuable advice which helped me in the
completion of this project.
No words are adequate to express my indebtedness to my parents and for their blessing and
good wishes. To them I bow in the deepest reverence.
- Parth K. Patel (14BEE089)
- Parth D. Patel (14BEE090)

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ABSTRACT
Filling of any kind of liquid in a bottle can be carried out by the machine. In industries
this types of work is done by embedded system. Traditional methods of bottle filling involved
placing bottles onto a conveyor and filling only one bottle at a time. Which is time
consuming and less efficient.
The filling and capping operation takes place in a synchronized manner. It also
includes a user-defined volume selection menu through which the user can input the desired
volume to be filled in the bottles. The entire system is more flexible and time saving.
With the help of this project we are able to implement the older industrial system by
using new control system. In industries PLC (programmable logic control) device and
SCADA (Supervisory Control and Data Acquisition) software is mostly used because they
are very flexible, cost effective, space efficient and reduces complexity. By programming
the PLC we control the entire system.
Our main aim is to implement the present system which now available in the market
and also make a system with the help of mostly used controller board like Arduino.

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CONTENTS
Acknowledgement 3
Abstract 4
List of Figures/Tables 6
Contents
Chapter 1: Industrial Application of Automatic Bottle refilling Plant
1.1 Working mechanism of plant
1.2 Types of controller which can be used in system
1.3 PLC (Programmable Logic Controller)
1.4 Arduino UNO
7
Chapter 2: Components used in this project 10
Chapter 3: Interfacing of Arduino with different components
3.1 Interfacing of Arduino with Servo motor
3.2 Interfacing of Arduino with DC motor
3.3 Interfacing of Arduino with IR sensor
3.4 Interfacing of Arduino with LCD display
3.5 Interfacing of Arduino with all the devices(Review-I)
3.6 Interfacing of Arduino with Steeper motor
Chapter 4: Interfacing of Arduino with all the components
15
21
Chapter 5: Conclusion and future scope of this project 24
References 25

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LIST OF FIGURES
Figure No.
Fig 1.1
Fig 1.2
Fig 1.3
Fig 1.4
Fig 1.5
Fig 1.6
Fig 1.7
Fig 1.8
Fig 3.1
Name of the Figure
Working mechanism of
automatic bottle filling
system
Ladder network used by the
PLC types of devices
Ladder network used by the
PLC types of devices
Pin diagram of Arduino
IR sensor
DC Motor
Servo Motor
Pin Diagram of LCD Display
Steeper motor
Page no.
7
8
9
10
11
12
13
14
20

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Chapter 1: Industrial Application of Automatic Bottle refilling Plant
1.1 Working mechanism of plant
Following figure shows the general mechanism of automatic bottle refilling plant
which can be controlled by any type of Microcontroller. Which is able to control the whole
process and with the help of software we can access the whole plant far from the venue.
Fig 1.1 Working mechanism of automatic bottle filling system
1.2 Types of controller which can be used in system
Generally in the industrial PLC (Programmable logic control) is in practise and some
if the updated software like SCADA (Supervisory Control and Data Acquisition) is used to
control the whole plant but we can also use some another type of microcontroller to do the
same task at different condition which are following.
 PLC (Programmable Logic Controller)
 Microcontroller 8051
 Arduino UNO Board
 Other Microcontroller Board

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1.3 PLC (Programmable Logic Controller)
PLC is the device which used by the different types of industries and this
types of devices are widely available in the market and so many different
modules are also available which are having following characteristics.
 Advantages :
1. Used in most of the industries.
2. User friendly coding.
3. Plug and Play type of device
4. Easily interpretable programming
 Disadvantages :
1. Different type of code is required for coding.
2. Costly than any other microcontroller board.
3. Programming is totally different than other type of microcontroller board.
4. Not much popular in commercial applications.
Fig 1.2 Ladder network used by the PLC types of devices

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Fig 1.3 Ladder network used by the PLC types of devices
1.4 Arduino UNO
Arduino is the microcontroller which is widely used by the common people because
of the following but now also it is not used by the any type of industries because if following
reasons.
 Advantages :
1. It can be easily programmable using C or C++.
2. Easily available in the market.
3. Easy in operation.
4. Most popular microcontroller board used by most of the people.
 Disadvantages :
1. Not used in industrial applications.
2. It requires external DC supply, it can’t work in AC.

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Chapter 2: Components used in this project
Fig 1.4 Pin diagram of Arduino UNO
2.1 Specification of Arduino UNO:
Microcontroller
Operating Voltage
Input Voltage (recommended)
Digital I/O Pins
PWM Digital I/O Pins
ATmega328P
5V
7-12V
14
6
Analog Input Pins
DC Current I/O Pins
DC Current for 3.3V Pin
Flash Memory
6
20
50mA
32 KB

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Fig 1.5 IR sensor
2.2 Specifications of IR Sensor:
IC
Voltage Regulator(7805)
Input Voltage
Working Voltage
Max range
Resistors
LM358
5V
9V
5V
10 cm
150,150,10k Ω
Variable Resistor
Capacitors
10k Ω
1μ, 10μ

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Fig 1.6 DC motor
2.3 Specification of DC motor:
Speed 10 rpm
Working Voltage
Torque
Shaft Diameter
No Load Current
12V
3 kg-cm
6 mm
70 mA(max)

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Fig 1.7 Servo motor
2.4 Specifications of Servo Motor
Speed
Torque
150 rpm @ 4.8V, 220rpm @ 6V
3.2 kg-cm @ 4.8V, 4.1 kg-cm @ 6V

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Fig 1.8 Pin diagram of LCD

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Chapter 3: Interfacing of Arduino with different components
3.1 Interfacing of Arduino with Servo motor
In this project to control the flow of fuel of another filling we are using mini servo
motor which can be simply control by Arduino UNO microcontroller board with the help of
following C code.
#include <Servo.h>
Servo servo;
int pos = 0;
void setup()
{
servo.attach(9);
}
void loop()
{
for(pos = 0; pos<=180; pos = pos + 1)
{
servo.write(pos);
delay(4);
}
delay(1000);
for(pos = 180; pos>=1; pos = pos - 1)
{
servo.write(pos);
delay(4);
}
delay(1000);
}

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3.2 Interfacing of Arduino with DC motor
In this project we are using DC motor to control the conveyer belt which can be
control by Arduino UNO microcontroller board with the help of following C code.
int dcPin=8;
void setup()
{
pinMode(dcPin, OUTPUT);
}
void loop()
{
digitalWrite(dcPin, HIGH);
delay(5000);
digitalWrite(dcPin, LOW);
delay(5000);
}
3.3 Interfacing of Arduino with IR sensor
Here we are controlling Servo motor based on the input given by IR sensor for our
project we are sensing the Bottle which is to be used for filling the material. Above
mechanism can be control by following C code.
#include <Servo.h>
Servo servo;
int pos=0;
int irPin = 7;
void setup()
{
servo.attach(9);
pinMode(irPin,INPUT);
}
void loop()
{

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if(digitalRead(irPin) == HIGH)
{
for(pos = 0; pos<=150; pos = pos+1)
{
servo.write(pos);
delay(10);
}
delay(3000);
for(pos = 150; pos>=1; pos = pos-1)
{
servo.write(pos);
delay(10);
}
delay(3000);
}
}
3.4 Interfacing of Arduino with LCD display
For this project we are using LCD disply to show at current time which process is
running. This can be seen in LCD display by following C code.
#include <LiquidCrystal.h>
LiquidCrystal lcd(1, 2, 4, 5, 6, 7);
void setup()
{
lcd.begin(16,2);
}
void loop()
{
lcd.clear();
lcd.print("LED is ON");
delay(5000);

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lcd.clear();
lcd.print("LED is OFF");
lcd.setCursor(0,1);
lcd.print("Motor is ON");
delay(5000);
lcd.clear();
lcd.setCursor(0,1);
lcd.print("Motor is OFF");
delay(5000);
lcd.clear();
}
3.5 Interfacing of Arduino with all the devices
For automatic bottle filling control we are using several components to control we are
using Arduino UNO microcontroller board. Following C code can be used for controlling of
all the components for the required operation.
#include <Servo.h>
#include <LiquidCrystal.h>
Servo servo;
LiquidCrystal lcd(1, 2, 4, 5, 6, 7);
int pos=0;
int irPin=13;
int dcPin=10;
void setup()
{
servo.attach(9);
lcd.begin(16,2);
pinMode(irPin,INPUT);

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pinMode(dcPin,OUTPUT);
}
void loop()
{
digitalWrite(dcPin, HIGH);
lcd.print("Conveyer is ON");
if(digitalRead(irPin) == HIGH)
{
digitalWrite(dcPin, LOW);
lcd.clear();
lcd.print("Conveyer is OFF");
for(pos = 0; pos<=150; pos = pos+1)
{
servo.write(pos);
}
lcd.setCursor(0,1);
lcd.print("Valve is OPEN");
delay(3000);
for(pos = 150; pos>=1; pos = pos-1)
{
servo.write(pos);
}
lcd.clear();
lcd.print("Conveyer is OFF");
lcd.setCursor(0,1);
lcd.print("Valve is CLOSE");
digitalWrite(dcPin, HIGH);
lcd.setCursor(0,0);
lcd.clear();
lcd.print("Conveyer is ON");
}
}

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3.6 Interfacing of Arduino with Steeper motor
In this project we are using Steeper motor to control the conveyer belt. With the help
of Steeper motor we can accurately control the position of bottle which is to be filled. Steeper
motor can be control by Arduino UNO microcontroller board with the help of following C
code.
Fig 3.1 Steeper motor
int aPin=8;
int bPin=9;
int cPin=10;
int dPin=11;
void setup()
{
pinMode(aPin,OUTPUT);
pinMode(bPin,OUTPUT);
pinMode(cPin,OUTPUT);
pinMode(dPin,OUTPUT);

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}
void loop()
{
digitalWrite(dPin,HIGH);
delay(2);
digitalWrite(dPin,LOW);
digitalWrite(cPin,HIGH);
delay(2);
digitalWrite(cPin,LOW);
digitalWrite(bPin,HIGH);
delay(2);
digitalWrite(bPin,LOW);
digitalWrite(aPin,HIGH);
delay(2);
digitalWrite(aPin,LOW);
}
Chapter 4: Interfacing of Arduino with all the components
#include <Servo.h>
#include <LiquidCrystal.h>
Servo servo;
LiquidCrystal lcd(1, 2, 4, 5, 6, 7);
int pos=180;
int irPin=13;
int aPin=8;
int bPin=9;
int cPin=10;
int dPin=11;

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void setup()
{
servo.attach(12);
lcd.begin(16,2);
pinMode(irPin,INPUT);
pinMode(aPin,OUTPUT);
pinMode(bPin,OUTPUT);
pinMode(cPin,OUTPUT);
pinMode(dPin,OUTPUT);
}
void loop()
{
lcd.clear();
servo.write(pos);
lcd.print("Conveyer is ON");
while(1)
{
if(digitalRead(irPin)==HIGH)
{
break;
}
digitalWrite(dPin,HIGH);
delay(2);
digitalWrite(dPin,LOW);
digitalWrite(cPin,HIGH);
delay(2);
digitalWrite(cPin,LOW);
digitalWrite(bPin,HIGH);
delay(2);
digitalWrite(bPin,LOW);

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digitalWrite(aPin,HIGH);
delay(2);
digitalWrite(aPin,LOW);
}
lcd.clear();
lcd.print("Conveyer is OFF");
delay(2000);
for(pos = 180; pos>=155;pos = pos-1)
{
servo.write(pos);
delay(10);
}
lcd.setCursor(0,1);
lcd.print("Valve is OPEN");
delay(5000);
for(pos = 155; pos<=180; pos = pos+1)
{
servo.write(pos);
delay(10);
}
lcd.clear();
lcd.print("Conveyer is OFF");
lcd.setCursor(0,1);
lcd.print("Valve is CLOSE");
delay(2000);
}

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Chapter 5: Conclusion and Future scope
The main objective of this project to develop an Automatic bottle filling system using
User-friendly controlling system. By using Arduino, this can be successfully implemented.
The present system will provide a great deal of applications in the field of automation,
especially in mass production industries where there are larger number of components to be
processed and handled in a short period of time and there is need for increased production.
More features can be added depending on the size, shape and weight of the bottles,
filling operations can be implemented. Capping operation can be done using piston
arrangement.

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References
 Shaukat.N, PLC based automatic liquid filling process, Multi Topic Conference
2002, IEEE publications.
 Dunning Gray (1998) - ‘Introduction to Programmable Logic Controllers’ -
Delmar publishers, pp.421-428.
 Petruzella, Frank D. (2010) - ‘Programmable logic Controllers’ - Tata McGraw
Hill Education, pp.6-12.
 Rashid, M.H. (2010) – ‘Power Electronics’- British Library of Congress
 Rehg, James A. Glenn J Sartori (2009) – ‘Programmable Logic Controllers’-
Pearson prentice Hall, pp. 230-239.
 Asutkar, Sachin More (2013), “Automated bottle filling using microcontroller
volume correction”, International journal of engineering research and
technology (IJERT). (Vol 2, Issue 3, march-2013).
 A.S.C.S. Sastry, K.N.H. Srinivas (2010), “An automated microcontroller based
liquid mixing system”, International journal on computer science and
engineering. (Volume II, Issue 8, August 2010).
 Geremy blum, Exploring Arduino, Tools and Techniques for Engineering
Wizardy.
 Brain W. evans, Arduino Programming Notebook.
 Matthew Mckinnon, complete beginners guide for Arduino.