bottling plant

Topics: Programmable logic controller, Conveyor belt, Belt Pages: 16 (962 words) Published: October 17, 2014
Abstract 
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In this paper , a method of detecting the faulty bottles in process industry is proposed. Here we analyse the simulaton study of one programmable logic controller (PLC) based control system by building up a program using ladder diagram and different adressing modes of SIEMENS PLC. This paper also presents comprehensive simulation of the performance of the different sensors used for sensing the faulty bottles in the moving conveyer belt monitored by PLC. The outputs can also be observed in supervisory control and data acquisition  (SCADA) window.

The adopted simulation strategy asures a low cost, more reliable, increased flexibility and faster response. Keywords- 
 Proximity sensor, scanner, stepper motor, conveyer belt, ladder diagram, PLC, SCADA. I. INTRODUCTION In industrial purpose there is a recognized hierarchy of damage control measures based on the priciple that loss of production needs to be reduced to an acceptable level by enginnering means. Automation is the use of control systems and information technology to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provides human operator with machinery to assist them with the muscular requirements of work, automation greatly decrease the need for human sensory and mental requirements. In filling industry faulty bottle detection routine is a imperative part being done by several discrete mechanisms working in harmony. It is a endowment of automation [1]-[8] that we can think about this  process. So, in the industry the whole system is done  by many separate machines like faulty bottle detection system, filling machine, capping machine, labelling  process etc. Here the focal argument issue is about detecting the faulty bottle before entering into the main plant. We have used PLC which allows us using implying delay, timers, and counters. II. WORKING PRINCIPLE The main component of the PLC[1] [2] is shown in the Fig. 1. The whole system is built up with two  proximity switch to count bottles passing by, one scanner to scan each bottle and compare with pre-loaded image and one plunger to throw away the faulty Fig. 1. Components of PLC.

 bottle from conveyor belt which carries the bottles. The block diagram of system is shown in Fig. 2. Fig. 2. Block diagram of system.
The bottles are kept in conveyer belt. There are two  proximity switches. Proximity switch 1 senses the  bottle first and counts it. Scanner scans the bottle and compare with default image of bottle. If there is image mismatch then Plunger will switched ON and throw the bottle on the second conveyer. If there is no mismatch, then plunger will not switch ON and  proximity switch 2 counts the number of good bottles. III. VINDICATION OF LADDER LOGIC While building up the required ladder logic we have used different addressing modes [3] of Siemens PLC as mentioned in TABLE I.

 
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TABLE I ADDRESSING MODES
Instruction Mode INPUT I0.0-I0.7 I1.0-I1.7 OUTPUT Q0.0-Q0.7 Q1.0-Q1.7 FLAG M0.0-M0.7 M1.0-M1.7 Required Inputs are: Start_PB [I0.0], Stop_PB [I0.1], Overload Relay[I0.2], Proximity switch1[I0.4], Proximity switch 2[I0.6]. Required Outputs are: Conveyer Motor [Q0.1], Scanner [Q0.2], Plunger [Q0.3]. The control philosophy of this process is as follows: a) After pressing start push button [I0.0] bottles are moving on the conveyer belt.  b) Number of bottles passing through the conveyer were counted by Proximity switch1 [I0.4] and Proximity switch 2[I0.6] also. c) Scanner [Q0.2] detects the faulty bottle by  providing an input pulse. d) When scanner detects faulty bottle then the process should calculate the faulty bottle number by calculating the value of proximity switch 2[I0.6] and  proximity switch1 [I0.4]. e) Now proximity 2 [I0.6] checks the faulty bottle in front of him. When proximity switch [2] detects that faulty bottle then plunger [Q0.3] actuate...
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