JAICT, Journal of Applied Information and Communication Technologies, Vol.7, No.

2, 2022
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CONTROL AND MONITOR OF PRODUCT FILLING AUTOMATION SYSTEM IN

PLC-BASED PACKAGING USING HMI OMRON NB7W-TW00B

Sri Kusumastuti1, *Sindung Hadwi Widi Sasono2

1, 2
Electrical Engineering Department, State Polytechnic of Semarang, Central Java 50275, Indonesia

Abstract— This study aims to design and create an automation system for filling products into packaging. PLC CP1E-
N30DR-A system can be controlled and monitored via Omron NB7W-TW00B HMI. HMI programming using NB-
Designer software. The product used is a steel ball. The number of steel balls is set via HMI. The HMI screen display
consists of inputs: Push Button Start, Push Button Stop, input the number of products in the packaging, packaging
sensor, and steel ball sensor; outputs: conveyor and counter display. The test results show that HMI could provide
variations in the number of products in the packaging. The present value counter can be displayed on the HMI. The
control and monitor automation system of filling the product in the packaging worked well.

Keywords— PLC, HMI, counter, sensor

1. Background of products that could vary or according to the user's wishes

set through the HMI
Packing is a coordinated system for preparing goods to
be ready for distribution, storage, and sale. The existence of 2. Device Design
a container or wrapper can help prevent or reduce damage
and protect the product in it from the dangers of pollution The block diagram of the Number of Products in
and physical disturbances (friction, impact, vibration). One Packages is shown in Figure 1.
of the packaging processes is filling the product into the Device controller using PLC Omron CP1E-N30DR-A.
packaging. With the development of technology for filling HMI is used for setting counter values & monitoring
products into packaging, automation systems have been devices. The input consists of a Push Button Start to turn on
used to replace manual processes. Most automation systems the system, a Push Button Stop to turn off the system work,
in the industry use PLC (Programmable Logic Controller) a photoelectric sensor to detect the presence of a container,
devices as controllers. Recently, automation systems have and an inductive proximity sensor to see a steel ball. The
been developed with the HMI (Human Machine Interface). system’s output consists of a conveyor motor and a steel
HMI is a two-way electronic system device that connects ball reservoir motor to drop the steel balls into the
humans and machines. HMI makes the interaction between container/packaging.
the PLC system and the operator possible via a screen with
dynamic icons, numbers, and text. Operators through HMI
can monitor and control the production process.
Research in packaging systems in the form of product
filling into packaging in automation systems has been
widely carried out. Most product-filling devices in the
packaging are designed only to fill a certain amount of
product. The thing that can be done when the industry wants
production with different sizes and packaging contents is to
add sensors or change the program. This is deemed
Fig. 1. Block Diagram
ineffective. From this background, the idea arose to control
the filling of the product into the packaging with the number

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2.1. Work Description The PLC used in this research is PLC Omron CP1E-
N30DR-A.
When the Push Button Start is pressed for a moment,
the conveyor will run carrying the container/package. The The PLC addressing and I/O equipment of the
conveyor will stop when the container/package is detected Curtain Control device are shown in Table 1.
by a photoelectric sensor (the container/package is just
below the steel ball reservoir). The steel ball reservoir Table 1.
motor will rotate, dropping the steel balls into the box. I/O PLC Omron CP1E-N30DR-A
When the steel ball falls into the package, an inductive Input Address Input Device
proximity sensor will be detected and used as an input
pulse calculated by the counter. When the inductive 00.00 Push Button Start
proximity has seen several steel balls according to the 00.01 Push Button Stop
00.02 Photoelectric sensor
setting value counter/number of products entered in the 00.03 Proximity Inductive Sensor
HMI, the motor for the steel ball reservoir will stop. The
container/package conveyor will run again, so the process Output Address Output Device
repeats for the next container/package, and the process will
100.00 Conveyor Motor
stop when the stop button is pressed. 100.01 Steel Ball reservoir Motor

2.3. Time Chart

Figure 4 shows a time sequence diagram of the

system's work.

a. Container/packaging sensors
b. Steel balls sensor
Fig. 2. Product Filling Automation System

2.2. PLC I/O addressing

Fig. 4. Time Chart
The work system controller uses a PLC
(Programmable Logic Controller). PLC is an electronic 2.4. Ladder Diagram
system that operates digitally and is designed for use in
industrial environments. This system uses a programmable Figure 5. Shows the program control ladder diagram
memory for internal storage of instructions that implement of the device.
specific functions such as logic, sequencing, timing,
counting, and operation via modules digital and analog I/O
modules. This PLC is designed to install a sequential relay
circuit in a control system.

Fig. 3. PLC Omron Type CP1E N30DR-A

Fig 5. Ladder Diagram

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3. Result and Discussion

3.1 Photoelectric Sensor

The sensor that detects the presence of

containers/packages is the BYD30-DDT series
photoelectric sensor.

Fig. 8. Physical Form of Proximity

Inductive Sensor

Fig. 6. Physical Form of Photoelectric Sensor Fig. 9. Inductive Proximity Sensor Schematic

Fig. 7. NPN Photoelectric Sensor Schematic

The Photoelectric Sensor wiring picture with PLC is shown

in Figure 10. Fig. 10. Wiring Photoelectric Sensors and
When the Photoelectric sensor detects the presence of Inductive Proximity Sensors
packaging on the conveyor, input 0.02 PLC '1' is used to
stop the conveyor. The Inductive Proximity Sensor detects steel balls that fall
into the packaging. When the Inductive Proximity sensor
Table 2. detects a steel ball input 00.03 PLC '1'. The change of the
Photoelectric Sensor Working Range Test 00.03 PLC input from '0' to '1' is used as the pulse input,
which is calculated by the counter.
No distance packing with in PLC 00.02
photoelectric sensor
(cm) Table 3.
Testing Sensor working range Inductive Proximity
1 1 ‘1’
2 2 ‘1’ No distance packing with in PLC 00.03
3 3 ‘1’ Inductive Proximity sensor
4. 4 ‘0’ (mm)

The maximum working distance of the Photoelectric sensor 1 1 ‘1’

2 2 ‘1’
is 3 cm.
3 3 ‘1’
4. 4 ‘1’
3.2 Steel Ball Sensor 5. 5 ‘1’
6. 6 ‘1’
7. 7 ‘1’
The sensor for detecting the presence of steel balls is 8. 4 ‘0’
an inductive proximity sensor Lj18A3-8-Z/BX, NPN NO.

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The max working range of the Inductive Proximity sensor 3.5 PC, PLC, and HMI Communication
is 8 mm.
The HMI is programmed using a PC via a USB cable
3.3 Conveyor Motor and communicates with the PLC by an RSS232 serial
cable.
The conveyor serves to carry containers/packaging.
The conveyor uses a 12 VDC power window motor drive.
The conveyor works when the output address 100.00 PLC
is on.

Fig. 11. Motor Wiring Circuit on Conveyor

Fig. 13. PC, PLC, and HMI Communication

Table 4.
Conveyor Test Results
The HMI can access the address bits in the PLC to function
voltage Current Condition as buttons or light displays. The HMI can also access the
(V) (mA)
data memory on the PLC to display the data.
12 900 Active Communication between the HMI and the PLC uses COM
Port RS232 on the HMI with a DB9 connector cable
component and wiring provisions, as shown in Figure 12.

3.4 Steel Ball Reservoir Motor

The steel ball reservoir motor drops the steel balls into
the packaging. Motor with 12V working voltage rotates
when 100.01 PLC output is on.

Fig 14. DB9 Male Connector Wiring Diagram

Fig. 12. Motor Wiring Circuit in Steel Ball Reservoir

3.6 HMI display

Table 5. Test Results of Steel Ball Reservoir Motor

The HMI screen display consists of inputs: Push
Button Start, Push Button Stop, input setting value
voltage Current Condition counter/number of products loaded into the package,
(V) (mA) container/packaging sensors, and steel ball sensors; output
12 900 Active
in the form of a conveyor, a steel ball reservoir motor and a
present value counter.

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Figure 17. HMI Control Display & Product Charge Monitor Packaged

Fig. 15. HMI Display Design on designer 4. Conclusion

The HMI display is designed on a PC using the NB Omron CP1E-N30DR-A PLC-based product filling
designer software, then downloaded to the HMI using a automation control and monitor using HMI NB7W-TW00B
USB cable. can work according to its function. The HMI program uses
the NB Designer software. Variation of setting value
counter can be done through HMI. Present value counter
data is displayed on the HMI.

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