The document describes the development of a ladder logic program for a bottle line simulation using LogixPro software. It includes descriptions of the bottle line simulation process, inputs and outputs, conveyors, gates and sensors. The summary provides an overview of the key elements: The document outlines the design of a ladder logic program to control a bottle line simulation involving checking, filling, separating and packaging bottles based on sensor inputs. It describes the LogixPro software used to create the ladder logic and emulate the PLC. The ladder logic is designed to track bottle properties using bit-shifting instructions, operate conveyors and gates based on sensor states, count bottles and boxes, and display production counts. The logic is meant to start and

1. 1 | P a g e
BOTTLE LINE SIMULATION IN LOGIXPRO
ABSTRACT:-
The main objective of this work is to develop the ladder logic for bottle line simulation.
Now a day’s automation plays a crucial role in manufacturing process. Bottle line simulation is
about the continuous operation of checking, filling, separating and packaging and etc… as per
the customer requirement. This project made to develop and check the output of bottle line
simulator for accuracy, reduce the effort of labor costs and for the efficiency.
INTODUCTION TO PLC PROGRAMMING:-
When PLC’S were first developed in the late 1960’s the format for PLC Programming
was based on relay ladder logic line diagrams. There are many different PLC manufacturers with
different hardware and software. All programmable logic controllers are have similar basic
features.
Fig1: relay ladder logic line diagram
The Format was designed that way so that Technicians familiar with relay ladder logic
could easily transition to PLC ladder logic

2. 2 | P a g e
Fig2: PLC Ladder logic
This is the same ladder logic as a line diagram and as a PLC Program
LOGIXPRO:-
LogixPro allows you to practice and develop your RS Logix programming skills where and
when you want. It contains a RS logix editor which allows you to create and edit ladder logic. It
contains a software PLC emulator which we simply call PLC. The PLC have same functionality
as Allen Bradly PLC. It contains pro simll simulations package. This is the collection of
programs using many of the same basic programming instructions utilized by Allen Bradly RS
logix 500software simulations of real world equipment that are graphically depicted on your
system screen.
Edit panel provides easy access to all RS logix instructions and they are simply drag and drop
type. In PLC panel having adjustable speed drive also. This is not a component of normal PLC’s,
but is provided in logixpro so that you may adjust the speed of the simulations to suit your
particular computer.
Set the scan slow enough and you can easily monitor how your program instructions are
responding.
 The control devices are programmed as inputs. The symbols are the same as those for
normally open (NO) and normally closed (NC) contacts.
 The loads are programmed as outputs.
 The physical input and output devices are connected to terminals on PLC I/O cards. The
address indicates whether the connection is an input or an output, the card number and
the number of the termination point.

3. 3 | P a g e
 An address does not have to represent a physical input or output. It can refer to a single
bit in memory that can be used as a control as it changes state (1or0), or it can represent
some other function such as a timer or counter, or it can specify a type of number like
integer or floating point.
A list of input and output type can be viewed in the data table
S2 - STATUS
B3 – BINARY
T4 – TIMER
C5 – COUNTER
R6 – CONTROL
N7 – INTEGER
F8 – FLOAT
Addresses are available from 0 to 15; a 16-bit word. You can select from 100 words; from 0
to 99 and the status of bit can be monitored in the data table.
Fig3: data table with binary table
The address follows a format 𝑇𝑌𝑃𝐸: 𝑊𝑂𝑅𝐷/𝐵𝐼𝑇
E.g. I: 3/5, O: 2/1, T4:5/14…...

4. 4 | P a g e
Fig4: Logixpro screen
The most commonly used elements of LogixPro are displayed below. The Edit
Panel provides easy access to all the RSLogix instructions and they may be simply dragged and
dropped into your program.
Once your program is ready for testing, clicking on the "Toggle Button" of the Edit Panel
will bring the PLC Panel into view. From the PLC Panel you can download your program to the
"PLC" and then place it into the "RUN" mode. This will initiate the scanning of your program
and the I/O of your chosen simulation.
Editing Your Program
If you’re familiar with Windows and how to use a mouse, then you are going to find
editing a breeze. Both Instructions and Rungs are selected simply by clicking on them with the
left mouse button. Deleting is then just a matter of hitting the Del key on your keyboard.
Double Clicking with the left mouse button allows you to edit an instruction's address while right
clicking displays a pop-up menu of related editing commands.
Click on an Instruction or Rung with the left mouse button and keep it held down and you will be
able to drag it wherever you please.

5. 5 | P a g e
In logixpro software having a set of exercises with covering of all elements of instructions. In
this, I am giving detail info about bottle line simulation.
Once you open the software LOGIXPRO in menu bar click on simulations and double
click on bottle line simulation for opening the HMI SCREEN.
After clicking the bottle line simulator open HMI screen on left side of the screen and the
right side of the screen is for designing the ladder logic. The elements require to design are
located in edit panel. Once complete the logic click on toggle switch which is at right top of edit
panel then appears the PLC panel then download your logic to plc and put in on run mode to
check the output.
Before we design a ladder logic for bottle line simulation we have to know some are used
in this instructions which logic.
LIM test is the instruction for test the values within or outside a specified range
depending on how you set the limits.
TOD (convert to BCD) instruction to convert 16 bit integer into BCD value.
BSL instruction is the output instruction that load date into a bit array one bit at a time.
The data is shifted through the array then unloaded one bit at a time.
Bottle line Simuator

6. 6 | P a g e
Fig6: bottle line simulator HMI screen
There are always numerous ways to accomplish tasks in programming, but a quick
review of the Allen Bradley bit shift instructions should surely point to them as an ideal tool for
use in this particular process. In the bottle line simulation, we are faced with detecting and
tracking a few Boolean details having to do with the bottles entering the line. Sensors are
provided to detect the presence of a new bottle, the bottle size, and whether the bottle is fully
intact. Essentially 3 Boolean states describing the properties of each bottle that enters the line. If
we analyze the various ways that we might process these bottles, it should quickly become
apparent that we will have ample information for making such decisions, assuming we keep
track of it.
A single BSR or BSL instruction can be used to track a single Boolean state (0 or 1)
which in-turn can describe a unique property of a product. In the initial exercise you will be
asked to track the 3 Boolean values describing each bottle entering our process line.

7. 7 | P a g e
The Boolean states will be referred to as "Exists", "Large", and "Broken" and these states
are to be tracked by you, utilizing 3 separate BSL (bit shift left) instructions. It can be argued that
"Exists" need not be tracked (=correct), as bottles continuously enter the line, and therefore must
exist. We will even use this fact to strobe our BSL instructions and cause a shifting of our
tracked information. Later when you start diverting broken bottles to scrap however, they will
no-longer Exist. These missing bottles could be detected after they are scrapped by using the
"Broken" state, but for now I want you to track all 3 states using 3 separate bit arrays.
For these exercises please utilize the bits in word B3:0 if and when single bits such as flags etc.
are required.
Utilizing LS1 (Exists), strobe 3 BSL instructions to shift 3 separate bit arrays consisting of two
16 bit words each. Please use files #B3:2, #B3:4, and #B3:6 for this purpose. By restricting you
to these particular files in the binary table, it will be much easier for you, and your instructor to
monitor what is happening with your program using the data table display.
Fig8: BSL instruction for exists, large, brake sensors

8. 8 | P a g e
First we have to check the inputs and outputs for the given task. In this task when the
operator switch on the START button the process starts and whenever he pushes the stop button
the process should be stop at any time of instant. BSL instruction is to control the input given by
sensors. In the hmi screen already assigned the input and outputs to the respective elements.
When you’re designed the logic took the inputs and outputs from the screen just drag from the
screen.
Check the inputs and outputs at HMI screen and what are the elements present in the
screen its purpose. In bottle line simulation screen having sensors, conveyors, motors, gates,
bottles, display, NO, NC push buttons, selector switches, PLC…
I indicate all the elements in the below figure with respective names. They are three
conveyors main conveyor, scrap conveyor, divert conveyor. Each conveyor connected with
motors. And one grinding motor and sensors, display, push buttons for start and stop and etc…
Fig9: sensors in HMI Screen
They are ten different sensors. Each sensor having its specified work. Exist sensor is
to track the bottles, large sensor is to track the bottles with respective sizes, brake sensor is to
track the broken bottles. Fill tube sensor is for check the bottle place for filling. Large, small fill
sensors for fill the liquids by respective sizes. Cap sensor for fixing the caps. Scrap gate sensor is
for diverting the broken bottle to grinder. Divert gate sensor is for divert thee large bottles. Scrap
box sensor is for changing the box when it fills.

9. 9 | P a g e
Fig10: conveyors
They are three conveyors, first is main conveyor, the whole process id done on this
conveyor. It is for moving the bottles in an order. Scrap conveyor is for when the box filled with
crush pieces of bottles for the next box it will moves. Divert conveyor is for diverting the large
bottles from the main conveyor with the help of divert gate.
Fig11: gates & display
They are two gates scrap gate and divert gate. Both are for diverting the bottles from main
conveyor and display is for check the production count.

10. 10 | P a g e
The total input and outputs are listed below
Fig9: input and outputs
OPERATION:-
 Track the bottles by exists sensor.
 Whether the bottle is broken then it goes to scrap.
 Fill the bottles by liquids with their respective sizes.
 After filling process, fixing the caps to the bottles.
 And then separating the bottles by sizes through divert gate.
 Ensure that the main conveyor movement and the filling operations are performed at a
time.
 Once the scrap boxes filled up then the scrap conveyor moves for the next box
 When the operation starts check the display for production count.

11. 11 | P a g e

12. 12 | P a g e
Fig: ladder logic for BOTTLE SIMULATION

13. 13 | P a g e
When start button is ON run, main conveyor and grinder, divert conveyor will starts
because they are continuous operations. For main conveyor, breaking timer (T: 4/0) done bit will
assign due to main conveyor movement is proportional to the process of filling and caping. BSL
instruction is to store the input in binary mode and (R: 6/bit) for controlling. When the brake
sensor senses the bottle the binary bit stores the memory and the scrap gate will open when the
bottle comes to the scrap gate. When the scrap box is fills scrap conveyor moves for the next
box. When the scrap conveyor moving the scrap gate is in closed position. Assign counter (C5:0)
for counting the broken bottles to fill the box. Here limit switch is used for the process will
perform before the main conveyor movement. Here another counter (C5:1) is for counting the
boxes. Once the box changes the two counters are resets by the instruction (RES). Rung 16 to 19
are for display the series connected counter counts the respective elements by its sensors. For the
output TOD is connected. TOD instruction is to convert 16-bit integers into BCD values.
PRECAUTIONS:-
 Check the STOP operation is working are not at any time of process.
 When the scrap conveyor is moving, scrap gate should be close.
 Divert conveyor should be continuous moving.
 Filling operation will perform with in the time period of main conveyor movement from
one bottle to another bottle.
REFERENCES:-
 LOGIXPRO SIMULATOR SOFTWARE
 file:///C:/program%20files%20(x86)/thelearningpit/logixpro/doc/bot/bottle.html
 http://thelearningpit.com.
T.MOHAN KRISHNA,
TECHMATION SOLUTIONS,
HYDERABAD.
THANKYOU