Linear Bottle filling system using FATEK
Programmable Logic Controller (PLC).
Industrical Automation
Group Members
Mian Rizwan Ali IA24-C1-05
Ali Hammas IA24-C1-09
Atta-Ur-Rehman IA24-C1-15
Sohail Anjum IA24-C1-20
Session: [2024]
Instructor: Dr. Ali Ahmad
Date of submission: 18th June 2024
Abstract
In the "Dual Bottle Line Assembly using PLC" project, we aim to design and implement
a sophisticated industrial automation system utilizing the Fatek PLC to enhance the precision
and efficiency of bottle filling processes. This advanced system integrates various critical
components, including the E3F-DS10C4 NPN Photoelectric Proximity Switch Sensor for
accurate detection, solenoid valves for precise liquid dispensing, a pump for efficient liquid
transfer from a container to bottles on a conveyor belt, and a DC motor to drive the conveyor
system. Additionally, operational control and indication are facilitated by spring return push
buttons and LEDs. The significance of this research is underscored by the increasing demand
for automated, precise filling systems in the manufacturing sector, where such innovations can
significantly boost productivity, minimize human error, and ensure consistent product quality.
This project not only addresses these industry needs but also sets a benchmark for the
deployment of PLC-based automation solutions, highlighting their potential to revolutionize
production processes by providing high reliability and accuracy in operations.
The primary problem addressed by this project is the inefficiency and inconsistency
inherent in manual bottle filling processes, which often result in significant wastage and quality
control challenges. By implementing a PLC-based solution, the project capitalizes on advanced
sensor technology to accurately detect bottle positions, while solenoid valves and a pump
system ensure precise liquid dispensing. The methodology encompasses programming the
Fatek PLC to orchestrate the synchronized operation of sensors, solenoid valves, the pump,
and the conveyor motor, with user inputs managed through red and green buttons. This
approach has demonstrated notable enhancements in fill accuracy, operational speed, and
overall system reliability. The implications of this project are far-reaching, particularly for
industrial sectors where automated filling systems are essential. It underscores the potential for
widespread adoption of PLC-based automation to boost efficiency, reduce human error, and
uphold high standards of product quality, thereby meeting the growing demands of modern
manufacturing.
Index Terms: PLC, Bottle filling, Control, Fatek PLC, Liquid Filling System.
Introduction
In the realm of modern industrial automation, the quest for efficiency, precision, and reliability
in manufacturing processes has driven significant advancements in technology. Central to this
evolution is the application of programmable logic controllers (PLCs), which have
revolutionized how industrial processes are monitored and controlled. This proposal focuses
on the design and implementation of an advanced industrial automation system using a Fatek
PLC for dual bottle line assembly, specifically targeting the automation of liquid filling
processes. The dynamic manufacturing environment, the integration of advanced automation
technologies has revolutionized industrial processes, offering unparalleled precision,
efficiency, and reliability. Among these technologies, programmable logic controllers (PLCs)
have emerged as a cornerstone for automating complex tasks in various industries, ranging
from automotive assembly lines to pharmaceutical production facilities.
The focus of this proposal lies in the automation of bottle filling processes, a critical operation
in sectors such as food and beverage, pharmaceuticals, and cosmetics. Manual filling methods
are prone to inconsistencies, leading to product wastage and quality control challenges.
Automated systems utilizing PLCs address these issues by enabling precise control over liquid
dispensing, thereby enhancing product quality and operational efficiency.
Fig 1: A pictorial View of Fatek FBS-14MAR2-AC (D24) PLC.
The significance of automating bottle filling operations cannot be overstated. It not only
optimizes production throughput but also ensures uniformity in product specifications, meeting
stringent regulatory standards and consumer expectations. By leveraging PLC-based
automation, manufacturers can minimize human intervention, reduce operational costs, and
mitigate the risks associated with manual handling of liquids.
Previous research [1] has explored the application of Fatek PLCs in automating diverse
industrial processes, such as full-automatic dishwashers, highlighting the versatility and
robustness of PLCs in real-world applications. Studies [2] have also demonstrated the efficacy
of PLC-based systems in automatic liquid filling, underscoring their role in achieving precise
control and operational reliability in manufacturing environments. Furthermore, research [3]
has focused on the implementation and performance analysis of PLCs in bottle filling plants,
emphasizing their capability to streamline operations and enhance production efficiency.
The primary aim of this proposal is to design and implement a sophisticated dual bottle line
assembly system using Fatek PLCs. This system will integrate advanced sensor technology,
solenoid valves, pumps, and conveyor motors to automate the process of filling bottles
accurately and efficiently. By exploring the design considerations, implementation challenges,
and performance metrics of such a system, this proposal seeks to provide valuable insights into:
The integration of PLCs for enhancing control and precision in industrial automation.
The design and functionality of automated bottle filling systems.
Practical implications and benefits of adopting PLC-based automation in manufacturing
settings.
Comparative analysis of existing methodologies and technologies in automated liquid
filling.
Block Diagram
Fig 2: Block Diagram of Bottle Line Simulator Project.
Problem Statement
Manual bottle filling processes in the manufacturing industry are plagued by inefficiencies
and inconsistencies that adversely affect productivity, product quality, and operational costs.
These issues are critical in sectors like pharmaceuticals, food and beverages, and cosmetics,
where precision and reliability in filling operations are essential.
1) Inconsistency in Fill Volumes:
Manual bottle filling often results in varying fill volumes due to human error, leading
to underfilled or overfilled bottles. This inconsistency not only affects the product's
quality and customer satisfaction but also results in wastage of resources.
2) Low Productivity:
The manual filling process is slow and labor-intensive, limiting the number of bottles
filled per unit time and constraining production capacity. Additionally, manual
operations require frequent breaks and are susceptible to fatigue, further reducing
overall productivity.
3) High Labor Costs:
Manual bottle filling is labor-intensive and expensive, requiring skilled workers to
ensure accuracy and consistency. Their wages significantly increase overall costs, and
training new workers adds further expense and complexity to maintaining the manual
filling process.
4) Quality Control Issues:
Manual filling is prone to human error, causing contamination, spillage, and
inconsistent product quality. This lack of precision can compromise product integrity,
lead to potential recalls, and harm the brand’s reputation.
5) Waste and Environmental Impact:
Manual filling often results in inconsistent fill levels and spillage, leading to significant
material wastage. This increases operational costs and negatively impacts the
environment due to the additional waste generated.
6) Health and Safety Concerns:
Manual handling of hazardous or sensitive liquids poses health and safety risks, such
as chemical exposure and repetitive strain injuries. This leads to workplace accidents,
increased health issues, and higher insurance costs.
7) Scalability Challenges:
Scaling up production in a manual filling setup is challenging, requiring more labor,
which is often not feasible or cost-effective. Additionally, the manual process lacks
flexibility to adapt quickly to changes in production volumes or different bottle sizes
and shapes.
Methodology
The methodology for the "Dual Bottle Line Assembly using PLC" project involves creating a fully
automated bottle filling system by integrating various components. The Proximity Switch Sensor
detects bottles precisely on the conveyor belt. Solenoid valves and a pump system, controlled by the
Fatek PLC, dispense exact amounts of liquid into each bottle. A DC motor drives the conveyor, while
red and green buttons with LEDs provide control and status indication. The PLC synchronizes sensor
inputs, valve operations, pump activation, and conveyor movement for smooth and efficient filling.
The system is carefully calibrated and tested to ensure accuracy and reliability, resulting in a fully
integrated automated bottle filling line.
Details of the project are as follows:
Sensor Integration
For sensor integration, the E3F-DS10C4 NPN Photoelectric
Proximity Switch Sensor are installed along the conveyor belt to
detect bottle presence and position. These sensors are connected to
the PLC’s 24V DC input terminals, specifically the X3 terminal,
ensuring they are correctly aligned for accurate detection. The PLC
is then programmed to read these sensor signals (X inputs) to
identify when a bottle is properly positioned for filling.
Valve and Pump System Setup
For the valve and pump system, set up the solenoid valves and pump for
liquid dispensing. Connect both the solenoid valves and pump to a 12V
DC power supply through relays to handle high current requirements.
Wire the relays to the PLC’s output terminal Y4, which controls the timing
and activation of both the valves and pump to ensure accurate liquid
dispensing.
Conveyor System Installation
For the motor and conveyor setup, install the DC motor to drive the
conveyor belt. Connect the motor to a 12V DC power supply
through a relay to manage the high current draw. Wire the relay to
the PLC’s output terminal Y3 to control the motor’s operation,
ensuring smooth conveyor movement.
Control Interface Design
For the control interface installation, mount the red and green buttons
along with the LEDs for operational control and status indication. Connect
the red LED to the PLC’s Y1 output, the green LED to Y0, and the yellow
LED to Y2. Wire the green button to the PLC’s X1 input and the red button
to X0. Configure the PLC to use these button inputs (X) for start/stop
operations and the LEDs (Y) for displaying system status and indications.
PLC Programming
Using WinPro Ladder software, develop the ladder logic diagram to
sequence operations by programming the PLC to manage inputs (X)
from sensors and buttons and outputs (Y) to the motor, valves, and
pump. The PLC model used is the Fatek PLC. Write and upload the
program to handle sensor signals, control the conveyor motor,
manage valve and pump operations, and activate indicators. Finally,
conduct thorough testing and calibration to ensure accurate sensor
readings, precise filling, and reliable system performance.
System Synchronization
In the prototype, system synchronization involves verifying that all inputs (I/O) and components,
including the SMPS and relays, communicate effectively with the PLC. This ensures that sensors,
valves, pumps, and the conveyor operate seamlessly and in harmony for accurate and efficient bottle
filling.
Final Assembly
In the final assembly of the prototype, all components are integrated into a cohesive system within a
controlled working environment. The E3F-DS10C4 sensors are mounted on the conveyor belt,
solenoid valves and the pump are connected to their respective relays, and the DC motor is installed
to drive the conveyor. The PLC is programmed and connected to manage all inputs and outputs,
ensuring precise control of the filling process. After assembly, the system undergoes rigorous testing
to validate its performance, including fill accuracy, operational speed, and system reliability, ensuring
the entire automated bottle filling line functions seamlessly and meets operational standards.
Results
The project achieved significant improvements in fill accuracy and production speed, with
reduced operational costs and enhanced quality control. The system demonstrated high
reliability and consistent performance across all tested scenarios. Details are as follows:
Fill Accuracy Improvement
The automated system significantly improved fill accuracy, achieving a precision rate of 98%
as specified by the E3F-DS10C4 sensor manufacturer. This high level of accuracy ensured that
each bottle received the correct amount of liquid, greatly reducing the risk of overfilling or
underfilling compared to manual processes.
Production Speed Enhancement
The automated filling system substantially increased production speed, processing bottles at a
rate of up to 50 per minute. This boost in efficiency compared to manual filling allowed for
higher throughput and faster turnaround times, optimizing overall manufacturing productivity.
Cost Reduction
The automation system reduced operational costs by minimizing labor needs and material
wastage. By streamlining the filling process and improving accuracy, the system lowered
expenses associated with manual labor and product defects.
Quality Control Efficiency
With precise control and consistent filling, the automated system enhanced quality control,
reducing errors and maintaining high product standards. This resulted in fewer defects and less
need for rework, ensuring a consistent and reliable product quality.
System Reliability and Performance
The system demonstrated high reliability and performance throughout testing, with consistent
operation and minimal downtime. Its robust design and effective integration of components
ensured stable and efficient functioning in real-world production scenarios.
Health and Safety Concerns
The automated system significantly reduced health and safety risks by minimizing manual
handling of hazardous or sensitive liquids. Automation lowered the chances of chemical
exposure and repetitive strain injuries, creating a safer working environment and reducing the
need for stringent safety protocols and related costs.
Conclusions
In conclusion, the "Dual Bottle Line Assembly using PLC" project represents a pivotal
advancement in industrial automation, addressing the inefficiencies and inconsistencies of
manual bottle filling processes with precision and efficiency. Through the integration of
advanced technologies like the Fatek PLC, E3F-DS10C4 NPN Photoelectric Proximity Switch
Sensor, solenoid valves, pumps, and conveyor systems, the project has successfully automated
bottle filling operations to achieve consistent fill volumes and enhance production reliability.
This automated system not only improves operational speed and reduces wastage but also
upholds stringent quality control standards across diverse industries such as food and beverage,
pharmaceuticals, and cosmetics. By promoting sustainable manufacturing practices and
aligning with global initiatives like the Sustainable Development Goals (SDGs), particularly
SDG 9 (Industry, Innovation, and Infrastructure) and SDG 12 (Responsible Consumption and
Production), the project underscores its potential to revolutionize production processes while
ensuring economic efficiency and environmental responsibility.
References
[1] Bai Yan and Zhang Hongwei, "Application of fatek PLC on full-automatic
dishwasher," World Automation Congress 2012, 2012, pp. 1-4
[2] D.Baladhandabany, S.Gowtham, T.Kowsikkumar and P.Gomathi, “PLC based
Automatic Liquid Filling System, International Journal of Computer Science and Mobile
Computing”, Vol.4, Issue.3, March2015.
[3] Savita and Lokeshwar, “Implementation and Performance Analysis of Bottle Filling
Plant Using Ladder Language”, International Journal of Science and Research (IJSR) ISSN
(Online): 2319-7064.
[4] S. Nalini Durga, M. Ramakrishna and G. Dayanandam, “Autonomous Water tank
Filling System using IoT”, International Journal of Computer Sciences and Engineering Open
Vol.-6, Issue-9, Sept. 2018, E-ISSN: 2347-2693.
