AUTOMATED BOTTLE FILLING

PLANTPresented by Jasreen Kaur Mehta Manmeet Singh Himanshu Pruthi Deepak Vyas

AUTOMATION

Automation is used as a control system and information technology to reduce the need of human work for goods and productivity.

Increasing Productivity

Reducing Cost

Reducing Effort

SCADA

SCADA is “Supervisory Control and Data Acquisition” – real time industrial process control systems used to centrally monitor and control remote or local industrial equipment such as motors, valves, pumps, relays, sensors, etc

SCADA systems:

used to monitor and control a plant or equipment in industries

Project Objective : To design a ”Bottle filling and Capping Station” using Wonder ware Intouch SCADA.

Software Used : Wonderware Intouch version 10.1.

PLC

A Programmable Logic Controller (PLC) is an industrial computer centre system that continuously monitors the state of the input devices and makes decisions based upon a custom program to control the state of output devices.

LADDER LOGIC Ladder logic is widely used to program PLCs, where

sequential control of a process or manufacturing operation is required. Ladder logic is useful for simple but critical control systems or for reworking old hardwired relay circuits. 

INTOUCH OVERVIEW

InTouch Application Manager - Is used to create, manage, and select HMI application projects.

InTouch WindowMaker - Is the devleopment environment used to create HMI applications. 

InTouch WindowViewer - Is the runtime environment for applications created in WindowMaker.

DEVELOPMENT MODE

DEVELOPMENT OF BOTTLING PLANT

We see that there are different bottles whereas in the run time we require only one of them. This is done keeping in mind the visibility of each bottle.

RUNTIME OF BOTTLING PLANT

WORKING OF PROJECT

The project is made in Window Maker of Intouch software and executed in Window Viewer. In window viewer, the project would run as:When the switch is turned on, a bottle will be filled to full by a tank filled with liquid as indicated.Liquid poured to the bottle when its presence under the tank is sensed.Then a clamper brings down the cap to the mouth of bottle, places it there and then returns back to its original position. The bottle is capped is then moved to the packaging and storage.

LOG IN

START

STOP

PACKING

LABELING

CAPPING

FILLING

BOTTLE FILLING PLANT

AutomationSensingFillingRejectionCappingLabelingPackaging

AttributesTagsSliderLocationVisibilityBlinkObject sizeColour fill

PROCESS

In the Intouch Application Manager, select file New Create new

Application. This creates a new Intouch application. Double click on this application, it opens Intouch Window maker. In Window maker we select File New Window. A dialog box appears

asking for name, window type, window color and other properties. We name the window as ”bottle fill”, window type as replace , frame

style as single and click on OK. A window appears as per defined by us. Wizard icon Wizard Selection window graphical objects. Wizard Selection window symbol factory option double click In the symbol factory window there are various categories of the

graphical objects like Tanks, Containers etc. We select the different objects as per our requirement.

WINDOW SCRIPT

Since there is no manual work i.e. no slider is being used, window script has to be used for incrementing the value of the counter, whose tag nameis used as the expression for all other objects.

There are two parts in the script:(a) On Show: how the things should appear as soon as the windowviewer is started.(b) While showing: how things will appear once the task starts to runon window viewer.

For all the objects taken from the symbol factory, we perform Break Cell operation so that we are able to change their properties as per our requirement. Following is the figure showing the list of the properties available for each object from Symbol Factory:

LIST OF ANIMATIONS

COMPONENTS

Storage Tank The liquid to be filled in the bottle is pumped into the tank

through which the filling process takes place. Conveyer Belt Conveyer Belt is used for the movement of the bottles to

various station of filling , capping labeling etc. Capping Machine The process of capping is done at the capping station.

Vertical movement of the machine as the bottle approaches to it ensures the capping process by applying a cap over the bottles.

Labeling Machine As the bottle is done with the process of filling and

capping process ,it proceed towards the labeling machine.

Doors They are used for entry and exit purpose which is

required to add bottles to the conveyer belt which then carries it to the different section of the filling plant.

Slider A slider is used to determine the continuous process

of the filling plant. Each movement of the bottle and the process is synchronised with the help of a slider.

Main Switch This ON/OFF switch is the main lever to start the

process and stop at any moment as required by the operator.

LOG IN

START UP

FILLING

Once the bottles are detected in the input side the conveyor motor switches ON and it starts moving in the forward direction. The bottles then reach the desired position for filling and the conveyor stops. The corresponding pumps in process tank switch ON and filling operation takes place

CAPPING

The bottles are transported to the capping arrangement. IR sensors are kept to stop the bottles in the desired position for capping to take place. Once the bottles reach the position the conveyor motor switches OFF. The capping of bottles is done using actuator arrangement.

LABELING

After filling and capping process, the bottle is sent for labeling. A proximity senser is used to detect the bottle and labeling is done.

PACKAGING

After labeling process, bottle is sent for packaging and storage.

STATUS WINDOW

The controller could easily switch over to the different processes that are being done in the plant. He can supervise any part of the process choosing the desired window from the options. Real time data is displayed of the process.

ALARM SYSTEM

An alarm system broke out whenever there is a shortage of liquid in the storage tank or the temperature of the plant began to rise in case of any fire to check the safety of the filling plant.this alarm could easily be turned off by the controller after the shortcoming is met.

CONCLUSION

The design of ”Bottle Filling Plant using SCADA” is successfully implemented in Intouch SCADA.

This project can be implemented practically when SCADA is connected with PLC. More enhanced features can be added up to it. Some features are:

1. Automatic Labeling of Bottles.

2. Defected Bottles such as bottles without cap or less in weight should be automatically removed.

3. Automatic pick up of bottle after filling it up.

REFRENCES

Diac manual www.diac.co.in  www.wikipedia.com www.southlandelectrical.com www.dynamicengineers.co.in www.plcmanual.com

THANK YOU