Automatic Bottle Filling and Capping using PLC

Abstract

PLC plays a vital role in the world of automation. It is the key part which makes system and whole process simpler, flexible and accurate. PLC provides low power consumption, reduces operational cost, increases production rate and Time saving. This project is designed to overcome the issues faced in the conventional industries process problems and also for small-scale industries issues where there is huge number of labors, accuracy issue, production rate, factory shut down issues due to human errors which results in to loss. These problems can be solved by converting the old style manual operated machine into automated, highly  (Programmable Logic Controller).This project involves the Ladders Language used in PLC to automate the bottle filling and capping plant. In first cycle, the bottle is passed through the conveyer belt, stopped at the filling point. The Bottle then filled to the desired level at very high accuracy, using DC pump and solenoid valve. At second cycle, bottle gets into second phase where capping process is done. The bottle is moved to accurate position where the cap is placed on the bottle during movement. Then the cap is tightened using DC motor and actuated piston. All the process from the bottle placement to capping and then to final product is done automatically according to user requirement. Motor over load, over current protection can also be done with the help of PLC. There will be push buttons for the start, stop, emergency stop, fault error indicator LED, also there is a counter for counting of bottles filled. Do counters can also be used at start and end for the detection whether a bottle during the process is dropped or not. Production rate due to this automation is greater than that conventional way of filling. This project also helps us in gaining knowledge about PLC, its coding, connections and uses in different ways.