UNIVERSITI TEKNIKAL MALAYSIA MELAKA

AN AUTOMATIC BOTTLING PROCESS SYSTEM FOR

MONITORING AND CONTROL

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Engineering Technology

(Industrial Power) (Hons.)

by

MUHAMAD FAIDHI ZAKWAN BIN ZANAL ARIFIN

B071210009

900707-08-5049

FACULTY OF ENGINEERING TECHNOLOGY 2016

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: AUTOMATIC BOTTLING PROCESS SYSTEM FOR MONITORING AND

CONTROL

SESI PENGAJIAN: 2015/16 Semester 2 Saya MUHAMAD FAIDHI ZAKWAN BIN ZANAL ARIFIN

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS)

Alamat Tetap:

341 Lorong Taman Long Jaafar

Fasa3/Kampong Boyan,

34000 Taiping Perak,

Tarikh: ________________________

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi:

iii

DECLARATION

I hereby, declared this report entitled “Automatic Bottling Process System for Monitoring

and Control” is the results of my own research except as cited in references.

Signature : ………………………

Name : ………………………

Date : ………………………

iv

APPROVAL

This report is submitted to the Faculty of Engineering Technology of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Engineering

Technology (Electrical Technology Department) (Hons.). The member of the

supervisory is as follow:

……………………………….

(Project Supervisor)

v

ABSTRACT

Nowadays, a lot of automation project had been carried out. So, automatic system

with monitoring system is created to allow the control it. This project is designed to fill the

bottle with water using an automation system with monitoring and control system. The title

of the project “An automatic bottling process system for monitoring and control” is a

system that PLC as heart. The main purpose of the project is to create a system which uses

PLC that can communicate with Visual basic. PLC is the medium which the automation

system can be monitored from long distance. It is used to reduce time and saving the cost.

The CX-Programmer was used to create a ladder diagram.

vi

ABSTRAK

Pada masa kini, banyak projek automasi telah dijalankan. Oleh itu, sistem

automatik dengan sistem pemantauan diwujudkan untuk membolehkan kawalan itu.

Projek-projek ini direka untuk mengisi air ke dalam btol dengan menggunakan sistem

secara automatik dengan kawalan dan pemantauan. Tajuk projek "Proses pengisian air ke

dalam botol secara automatik dengan sistem kawalan dan pemntauan" adalah satu sistem

yang menggunakan PLC sebagai alat yang paling utama. Tujuan utama projek ini adalah

untuk mewujudkan satu sistem yang boleh berkomunikasi dengan asas Visual. PLC adalah

medium yang mana sistem automasi boleh bergerak menggunakan enjin dari jarak jauh. Ia

digunakan untuk mengurangkan masa dan menjimatkan kos. Perisian CX-Programmer

digunakan untuk menghasilkan gambarajah tangga.

vii

DEDICATIONS

Special dedication to my beloved father and mother and also kindhearted supervisor Mr.

Shahrudin Bin Zakaria. Do not forget also to my friends who I love. Love you all.

viii

ACKNOWLEDGMENTS

First of all, I would like to thank for ALLAH for the strength and blessing until I

get to here. In this project I had the opportunity to learn new skills and enhance their

knowledge. I would like to congratulate Mr. Shahrudin Bin Zakaria for giving guidance

and advice will never fail to make a success of this project. His guidance gives a huge role

to fulfill this project.

Special thanks also I dedicate to Universiti Teknikal Malaysia Melaka for

providing equipment like and information sources that assisted my studies until finish my

projects. My sincere appreciation to the lecturers of Faculty Engineering Technology who

put in their effort always nurtures and guides us with useful advices. Thank you for willing

to share those experiences that really helps me.

Last but not least, to my beloved family that has given me moral support and

sharing their love that give me stronger. I really appreciate it. Their encouragement likes an

invisible spiritual pillar that makes me be tough and I can break through all the barriers. To

all my friends thank you very much for the suggestions and laughter encouraged for

improvement and finished in my project. Their method, suggestion and opinion give me

guidance and gave way for me

ix

TABLE OF CONTENTS

DECLARATION .................................................................................................................. iii

APPROVAL ......................................................................................................................... iv

ABSTRACT .......................................................................................................................... v

ABSTRAK ........................................................................................................................... vi

DEDICATIONS .................................................................................................................. vii

ACKNOWLEDGMENTS .................................................................................................. viii

TABLE OF CONTENTS ..................................................................................................... ix

LIST OF FIGURES ............................................................................................................ xiii

LIST OF TABLE ................................................................................................................ xiv

LIST OF SYMBOLS AND ABBREVIATIONS ................................................................ xv

CHAPTER 1 .......................................................................................................................... 1

1.0 Introduction ............................................................................................................. 1

1.1 Background ............................................................................................................. 1

1.2 Problem Statement .................................................................................................. 2

1.3 Objective Study ....................................................................................................... 2

1.4 Scopes of Study ...................................................................................................... 2

CHAPTER 2 .......................................................................................................................... 3

2.0 Introduction ............................................................................................................. 3

2.1 Synopsis of Journal ................................................................................................. 3

2.1.1 Automatic Filling Management System for Industries ................................... 4

x

2.1.2 PLC Based Automatic Bottle Filling and Capping System User Defined

Volume Selection .......................................................................................................... 4

2.1.3 Implementation of Sensor Network for Automation of Bottle-Capping

Assembly Station Using IEEE 802.15.4 ........................................................................ 5

2.1.4 Application of PLC for Arranging Bottle in Beer Filling Production Line..... 5

2.1.5 Temperature Controlling Design Based on VB and PLC................................ 5

2.1.6 Automatic Multivariate Liquid Filling System & Conveyor Control Using

PLC & SCADA ............................................................................................................. 6

2.1.7 Conveyor control and sorting module controlled by programmable logic

controller ........................................................................................................................ 7

2.1.8 The Principle of Programmable Logic Controller and its role in Automation.7

2.1.9 GUI Based Remote ON/OFF Control and Monitoring Single Phase Lamp

Using Microcontroller ................................................................................................... 8

2.1.10 Development of Monitoring System by Serial Port Based on VB Software

and electronic Communication ...................................................................................... 8

CHAPTER 3 ........................................................................................................................ 10

3.0 Introduction ........................................................................................................... 10

3.1 Project Flow .......................................................................................................... 10

3.2 Block diagram of the project................................................................................. 12

3.3 Hardware Development ........................................................................................ 13

3.3.1 Conveyor system ........................................................................................... 13

3.3.2 Power window motor .................................................................................... 14

3.3.3 Programmable Logic Controller (PLC) ......................................................... 14

3.3.4 Power Supply ................................................................................................. 15

3.3.5 Mechanical relay............................................................................................ 16

xi

3.3.6 Inductive Proximity Sensor ........................................................................... 16

3.3.7 Pump System ................................................................................................. 17

3.3.8 Actuator ......................................................................................................... 18

3.3.9 Communication port ...................................................................................... 18

3.3.9.1 RS232 Serial cable ................................................................................. 19

3.4 Software Development ......................................................................................... 19

3.4.1 Programming Using Visual Basic ................................................................. 20

3.4.2 CX-Programmer ............................................................................................ 21

3.4.2.1 Ladder Logic .......................................................................................... 22

3.4.2.2 OR Operation ......................................................................................... 22

3.4.2.3 AND Operation ...................................................................................... 23

3.4.2.4 NOT Operation ....................................................................................... 23

CHAPTER 4 ........................................................................................................................ 25

4.0 Introduction ........................................................................................................... 25

4.1 The Software Development .................................................................................. 25

4.1.1 Design of Visual Basic .................................................................................. 25

4.1.2 Source Code ................................................................................................... 27

4.1.3 MSComm Setting in visual basic .................................................................. 27

4.1.4 Design of Ladder Diagram ............................................................................ 28

4.1.5 CX-Programmer Setting ................................................................................ 29

4.1.6 Overall System .............................................................................................. 30

4.2 Hardware Development ........................................................................................ 30

4.2.1 Control Box ................................................................................................... 30

xii

4.3 Control Process using Visual Basic ...................................................................... 31

4.3.1 PC to PLC GUI Communication ................................................................... 31

4.3.2 ULN2803 circuit ............................................................................................ 32

4.4 Data time analysis ................................................................................................. 33

CHAPTER 5 ........................................................................................................................ 35

5.0 Introduction ........................................................................................................... 35

5.1 Summary of Project .............................................................................................. 35

5.1.1 Summary of Project ....................................................................................... 35

5.1.1.1 Summary of Project ................................................................................ 35

5.2 Achievement of Objectives ................................................................................... 36

5.3 Problems Faced During Implementing Project ..................................................... 36

5.4 Discussion ............................................................................................................. 36

5.5 Suggestion for Future Work ................................................................................. 37

APPENDIX A ..................................................................................................................... 39

APPENDIX B ...................................................................................................................... 40

REFERENCES .................................................................................................................... 49

xiii

LIST OF FIGURES

Figure 2.1: Block Diagram of the Process ............................................................................. 6 Figure 2.2: Control Panel with PLC(grey element in the centre). ......................................... 7 Figure 2.3: Hardware development GUI and Connection with Max232 with computer ...... 8 Figure 3.1: Flowchart to Implement the Project .................................................................. 11 Figure 3.2: Block Diagram of the Project ........................................................................... 12 Figure 3.3: Conveyor System .............................................................................................. 13 Figure 3.4: Power Window .................................................................................................. 14 Figure 3.5: PLC CP1E ......................................................................................................... 15 Figure 3.6: Power Supply .................................................................................................... 15 Figure 3.7: Mechanical relay ............................................................................................... 16 Figure 3.8: Inductive Proximity Sensor ............................................................................... 17 Figure 3.9: Aquarium Pump ................................................................................................ 17 Figure 3.10: CD-ROM ......................................................................................................... 18 Figure 3.11: RS232c with RS232 made .............................................................................. 19 Figure 3.12: Visual Basic 6 ................................................................................................. 20 Figure 3.13: Code Form ...................................................................................................... 20 Figure 3.14: Graphic section form ....................................................................................... 21 Figure 3.15: CX-Programmer Software .............................................................................. 21 Figure 3.16: Relay circuit .................................................................................................... 22 Figure 3.17: Ladder Logic circuit ........................................................................................ 22 Figure 3.18: Relay circuit .................................................................................................... 23 Figure 3.19: PLC Ladder logic circuit ................................................................................. 23 Figure 3.20: Relay Circuit ................................................................................................... 24 Figure 3.21: Ladder Logic ................................................................................................... 24 Figure 4.1: FCS Calculation Coding ................................................................................... 27 Figure 4.2:MSComm Setting ............................................................................................... 27 Figure 4.3: CX-Programmer comm setting ......................................................................... 29 Figure 4.4: ULN2803 .......................................................................................................... 32 Figure 4.5: Complete Serial Port interfacing circuit............................................................ 32 Figure 4.6: Illustration graph on data collection.................................................................. 33 Figure 4.7: Graph of average value ..................................................................................... 34 Figure 0.1: GUI GUIDE ...................................................................................................... 39

xiv

LIST OF TABLE

Table 2-1: Synopsis of Journal .............................................................................................. 3 Table 4-1: Description of GUI ............................................................................................ 25 Table 4-2: Ladder Diagram ................................................................................................. 28 Table 4-3: Ladder Protection and Interrupt ......................................................................... 29 Table 4-4: Control Box sequence ........................................................................................ 30 Table 4-5: Data Collection .................................................................................................. 33

xv

LIST OF SYMBOLS AND ABBREVIATIONS

PLC = Programmable Logic Controller

VB6 = Visual Basic 6

PC = Personal Computer

GUI = Graphical User Interface

I/O = Input or Output

LD = Ladder Diagram

1

CHAPTER 1 INTRODUCTION

1.0 Introduction

Industrial bottling process with automation become more useful and famous among

industrial world reduces the need human work. Automation plays important role closed

loop system. Increasingly on world economy automation plays an important role.

Automation is suitable to all type of beverage. The production will cover all complete

filling and packaging process.

1.1 Background

In new era of industrial, automation is important to build fast machines by human

needs. Seeing from industrial phenomena is increase like competition among Industries

Company. Automation is likely can be used in many sector to develop. A prototype about

bottle filling system is controlled using programmable Logic Circuit (PLC) and the process

is monitored while also controlled using Visual Basic (VB).

This project focused on filling the bottle with water. In addition to this project also

included monitoring system and control system to monitor also control the filling water in

Visual Basic (VB) while conveyor system uses for carries the bottle at filling station.

2

1.2 Problem Statement

i. Most of the filling machine in the market is not fully automatic. This

machine requires human assists to operate properly.

ii. No proper monitoring when a predicted condition happens.

iii. Some workers not know with ladder diagram so cannot monitored properly

iv. If something happen during process the need to go and shut down the

operation at the machine

1.3 Objective Study

The objectives of this project are:

i. To develop a user friendly system by using Visual Basic as the monitor and control

on computer

ii. To design a filling bottle system controlled by PLC

iii. To design a system that can fill the bottle with liquid where the specified quantity.

1.4 Scopes of Study

This project is primarily concerned with every phase to develop an automatic liquid

filling machine. For the first phase, it starts with collecting information about the project in

terms of problem statement, objective and scope. Scope should explain the objective in

more detail and in accordance to the concept.

Scopes of this project are:

i. Using Visual Basic coding which is easy to use as monitor and to control the

operation of the bottling process.

ii. The GUI is use to monitored the process and control the operation.

iii. Design and development ladder diagram using Omron CX-Programmer software

iv. Interface PLC CP1E with visual basic 6 to make simple GUI system with low cost.

v. Build system that can fill water into bottle automatically.

3

CHAPTER 2

LITERATURE REVIEW

2.0 Introduction

This chapter discussed about the literature discourse and review of structural

analysis and some components used in these projects. Research and reference is use

from various source such as journals, internet and previous projects. These items are

use as the key for the whole project.

2.1 Synopsis of Journal

In this part, it involve in finding information from journal, websites and textbooks.

Table 2-1: Synopsis of Journal

No Journal title author

1 Automatic Filling Management System for Industries

Ahuja et al.(2014).

2 PLC Based Automatic Bottle Filling and Capping

System User Defined Volume Selection

T.Kalaiselvi et al.

3 Implementation of Sensor Network for Automation of Bottle-Capping Assembly Station Using IEEE 802.15.4

Kunal Utekar et al.(2011)

4 Application of PLC for Arranging Bottle in Beer

Filling Production Line

ZHANG Tianxia et al.(2014)

5 Temperature Controlling Design Based on VB

and PLC

Yaning sun and Junyu fu,

(2010)

6 Automatic Multivariate Liquid Filling System &

Conveyor Control Using PLC & SCADA

Dheeraj Pongallu and

Prof.S.R.Suralkar(2014)

4

7 Conveyor control and sorting module controlled

by programmable logic controller

G. Sujatha and V.

Perasiriyan (2014).

8 The Principle of Programmable Logic Controller

and its role in Automation.

Avaru Ravi Kiran et al(2013)

9 GUI Based Remote ON/OFF Control and

Monitoring Single Phase Lamp Using

Microcontroller

Mohd Suhaimi B.Sulaiman

et. Al.(2003).

10 Development of Monitoring System by Serial Port

Based on VB Software and electronic

Communication

Yu Tu,Chao Wang, and

Peng Du.(2011).

2.1.1 Automatic Filling Management System for Industries

Ahuja et al. (2014). This paper presents Automatic Filling Management

System for industries how to control the process. A sample of bottling process control

using programmable logic controller (PLC) and the process is monitored using supervisory

control and data acquisition (SCADA). It will tell if there have fault occur.

2.1.2 PLC Based Automatic Bottle Filling and Capping System User Defined

Volume Selection

T.Kalaiselvi et al. (2012) according to this journal, it elaborates and explains about

how the flow of bottle filling involved placing bottle on the conveyor while the first bottle

filling the water at the same time using old version technique . The task will involve any

liquid products water even or cold drink. This task will take time and a little bit quite

costly.

This project aims how to shorten the time and make it in kind with the cost to

become more flexible. Their operation will involve filling water into the bottle and capping

it at the same time and also user can also pouring the water with different volume into the

bottle using volume selection menu. This project becomes multi-tasking.

5

This type of machine will be monitored by SCADA (Supervisory Control and Data

Acquisition) and being control using PLC (Programmable Logic Controllers) which is

more flexible, low complexity, low cost and effective, and reduce space taken.

2.1.3 Implementation of Sensor Network for Automation of Bottle-Capping

Assembly Station Using IEEE 802.15.4

Kunal Utekar et al. (2011) on his journal represented the implemented smart sensor

network to improve the bottling process. The installation period had been reduced and

network capacity is increase. PLC is used as a controller and microcontroller as DSDC to

protect smart sensor network and available to controlling the data. Interlock Logic use to

make sure all mechanical part not easily get damaged while the fault sensor is

implementing from the wire break sensing concept.

2.1.4 Application of PLC for Arranging Bottle in Beer Filling Production

Line

ZHANG Tianxia et al.(2014) according to his article, to an automatic and efficient

production line, the subsection that being control must be optimize. During the first

subsection of production lines it will arrange bottle and its need control function to make

the flow of the operation smooth. PLC (Programmable Logic Controller) is installing to

overcome this automatic problem control in control procedures and system architecture.

Monitoring system is create to collect operation status and the design of the program,

meanwhile system fault is trace and some control treatment create which to make the

automatic and smooth operation of bottling arrangement. Seeing from other state the use of

solenoid valve and motor are key to part as design.

2.1.5 Temperature Controlling Design Based on VB and PLC

Yaning sun and Junyu fu, (2010) for monitoring the temperature of automatic oven

and heating –furnace host personal computer (PC) and send command to PLC through

monitoring interface while controlling the temperature process, PLC will state data of the

6

temperature and upload the temperature when sensor sense. The actual temperature can be

real-time display on monitor. The whole process is controlling using visual basic the

programming real-time control the temperature monitoring system.

Conveniently entitles send and receive data via serial ports. MSComm is design

approach to process communications event communications these process. Timely

response and high reliability.

2.1.6 Automatic Multivariate Liquid Filling System & Conveyor Control

Using PLC & SCADA

Dheeraj Pongallu and Prof.S.R.Suralkar(2014)Bottling plants control volume of the

filling operation. In industry many PLC & SCADA system that been implemented. PLC &

SCADA software interface PC to processing plants and control and monitoring between

computer and hardware. Process prototype had been make using sensor, motor, relays,

serial communication and PLC device. The work consists tree section, first section filling

process, second conveyor process and last capping section.

Figure 2.1: Block Diagram of the Process

(Source: www.ijetae.com)

7

2.1.7 Conveyor control and sorting module controlled by programmable

logic controller

This paper was developed by G. Sujatha and V. Perasiriyan (2014). It used PLC to

investigate a conveyor sorting module controlled. In industrial conveyor plant the conveyor

sorting plant module is necessary. The conveyor belt are mounted so that the object

mounted on first conveyor will fall on second conveyor. It can be applied to sort the

objects in depends to the size and the conveyor will stop if the sequence is wrong.

2.1.8 The Principle of Programmable Logic Controller and its role in

Automation.

Avaru Ravi Kiran et al(2013).Purpose of PLC is requiring “on/off” control. There

are used in many industries and device. The designation consist several input with output

arrangement, PLC input and output recognize in “high” and “low” logical state. PLC read

in analogue input or digital input. Then it the output generate in analogue and digital to

automation system. PLC can connected in many ways to personal computer such as

RS232, RS-485 or RS-422.

Figure 2.2: Control Panel with PLC(grey element in the centre).

(Source: http://www.internationaljournalssrg.org)

8

2.1.9 GUI Based Remote ON/OFF Control and Monitoring Single Phase

Lamp Using Microcontroller

Mohd Suhaimi B.Sulaiman et. Al.(2003). Controller and monitoring now is an

important field these days. From the electric power to the distribution grid based on

automation, data acquisition and control equipment. Microcontroller is used because low

cost to control hardware. Automation like control system and monitoring introduce to help

people from hazardous working phenomena. This technology is efficient and more

flexible.

Figure 2.3: Hardware development GUI and Connection with Max232 with computer

(Source: http://www.enggjournals.com)

2.1.10 Development of Monitoring System by Serial Port Based on VB

Software and electronic Communication

According to Yu Tu,Chao Wang, and Peng Du.(2011). Monitoring system

function as automatic, manual, stop and reset system. The device is connected with RS232

serial port connected to serial port on PC. CPU 226CN and EM223 receive the sensor

signal. Main unit connected to serial port PC receive some command signal to control the

output via monitoring system. Input signal for the main event toward OnComm.

10

CHAPTER 3 METHODOLOGY

3.0 Introduction

This chapter will discuss how the methodology works. Some aspect should be used

while develop this process. This aspect will divide into several parts and important to

overcome the project objective. Furthermore, the parts that consist are materials use,

hardware and software relate.

3.1 Project Flow

To make something new, project flow is important to stabilize the project

smoothly run. That why, hardware part and software is using to create this project. The

purpose is to make this system low cost with biggest function.