AUTOMATIC BOTTLE FILLING

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

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
Department of Electronics and telecommunications Anjuman-I-Islam
A.R.Kalsekar polytechnic
New Panvel 410206, Navi Mumbai
MSBTE
2013-2014

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
DEPARTMENT OF ELECTRONICS AND
TELECOMMUNICATIONS
A-I-ISLAM A.R.KALSEKAR POLYTECHNIC
NEW PANVEL 410206, NAVI MUMBAI
MSBTE
2013-2014

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)

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:

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:

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

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

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.

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.

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.

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

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.

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.

CHAPTER 4
DESIGNING A BLOCK DIAGRAM

CHAPTER 5
HARDWARE IMPLEMENTATION
5.1 MICROCONTROLLE

CHAPTER 6
DATA SHEET
6.1 SL 100
6.2 RELAY 58-12-2C

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.

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

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.
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.
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.

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.

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.

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.

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.

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.

• 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

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

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.

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.

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

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.

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.

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

7.3.6 DISADVANTAGE OF SOLENOID VALVE
• Control signal must stay on during operation

CHAPTER 8
SOFTWARE IMPLEMENTATION
Program
#include<reg51.h>
sbit nozzle = P3^0;
main()
{
unsigned char steps;
voiddelay_msec(unsigned int);
while(1)
{
for(steps=1;steps<=13;steps++)

{
P2=0xff;
delay_msec(10);
P2=0xff;
delay_msec(10);
P2=0xff;
delay_msec(10);
P2=0xff;
delay_msec(10);
}
nozzle=1;
delay_msec(3000);
nozzle=0;
delay_msec(3000);
}

}
voiddelay_msec(unsigned int x)
{
unsignedint count;
TMOD=0x01;
for(count=0;count<x;count++)
{
TH0=0xfa;
TL0=0xcb;
TR0=1;
while(TF0==0);
TR0=0;
TF0=0;
}
}

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.

9.3 APPLICATION
1. In industry
2. Chemical
3. Cosmetic
4. Food
5. Beverage
6. Pharmaceutical
7. Bottled water industry.

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.

BIBLIOGRAPHY
 http://www.google.com.
 www.microcontrollerproject.com.
 www.alldatasheets.com.
 www.electronicsforu.com.
 www.atmel.com.
 www.wikipedia.com.
 Basic Electronics-B.Ram.
 www.fairchildsemi.com
 Digital Electronics-R.P.Jain.

AUTOMATIC BOTTLE FILLING

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