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Design and Fabrication of PLC

Controlled Bottle Dispensing Unit.

SUPERVISOR
ENGR. MONAZA SHAHEEN
DEPARTMENT OF MECHANICAL ENGINEERING, FACULTY OF ENGINEERING
BALUCHISTAN UNIVERSITY OF INFORMATION TECHNOLOGY, ENGINEERING AND
MANAGEMENT SCIENCES, QUETTA, BALUCHISTAN.
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GROUP MEMBERS

NAME CMSID
SANAULLAH 28512
MUHAMMAD MUNIB 28432
SYED FARAZ ALI 28465
SULTAN DIN MUHAMMAD 30604
BIRAHUMDAGH BUGTI 28731
SALMAN SIDDIQUI 29309
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CONTENTS

 ABSTRACT
 OBJECTIVES
 PROBLEM STATEMENT
 INTRODUCTION
 LITERATURE REVIEW
 CALCULATIONS
 COMPONENTS
 SOFTWARE
 COST ESTIMATION
 RESULTS AND CONCLUSIONS
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ABSTRACT

 The project consists of designing and fabrication of a Conveyor belt using

Programmable Logic controller (PLC) for filling bottles with liquids. The main
focus is to reduce the cost and power consumption by using less
expensive and minimum number of sensors and speed control
respectively. The system will allow user to select desire level of filling and
will be automatically controlled (i.e. the conveyor will automatically stop
when there is no bottle placed on it). The overall Objective is to achieve
sustainability by improving efficiency of the overall system.
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OBJECTIVE

The main objectives of this project is

 design and fabrication of bottle dispensing unit .

 calculates optimum parametric values for variables at its maximum

operating conditions.
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Problem Statement

 PLC controllers are part of almost every industry and so are the conveyor
systems. Filling stations are part of industries producing goods such as milk,
Soft Drinks etc. These industries have different problems related to their
filling process, such as the time it takes to fill a bottle, power consumption,
system life cycle, and maintenance required.

 A sustainable solution to these problems can be addressed using a more

efficient and less costly filling unit. This project focuses on to increase the
rate of filling (Bottles/hour), performance and efficiency. So the process
can be carried out on the most optimum way.
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INTRODUCTION

 Conveyor belt system often called conveyor system is material handling

equipment which is widely used to move materials and products from one
location to another.

 The main objective of this project is to design and fabricate the bottle
dispensing unit and calculate optimum parametric values for variable at
its maximum operating condition .For this purpose we used infrared red
sensor that sense the presence of bottle at specific point and then this
bottle is filled to specific point and the process continues for the next
upcoming bottle.
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LITERATURE REVIEW

[1] “Healthy
speed control of belt conveyors on conveying bulk materials -
Science Direct.” [Online]. Available:
https://www.sciencedirect.com/science/article/pii/S0032591018300020.
[Accessed: 29-Mar-2018].

[2] M. S. Masaki, L. Zhang, and X. Xia, “A Comparative Study on the Cost-

effective Belt Conveyors for Bulk Material Handling,” Energy Procedia, vol.
142, pp. 2754–2760, Dec. 2017.

[3] J. Luo, W. Huang, and S. Zhang, “Energy cost optimal operation of belt
conveyors using model predictive control methodology,” J. Clean. Prod., vol.
105, pp. 196–205, Oct. 2015.
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CALCULATIONS

Speed of the conveyor belt:

 Diameter of roller D = 45(mm)
 No of revolution per minute N= 30 rpm
 Then the velocity of belt can be calculated as

π × 0.045 × 30
V=
60

V= 0.07 m/s

 The diameter of roller is 45 mm and the speed of the belt is .07 meter per
second.
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CONT

Length of belt:
 Length of an endless conveyor belt can be expressed by the following
formula
H1 + H2
L= ×π+ 2×c ̵c
2
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CONT

 L= Length of conveyor belt

 H1 = H2= Diameter of roller
 C ̵ C= central distance
 As the central distance between the rollers is 560mm
45+45
L= × 3.14 + 2 × 560
2

L = 1261.3mm
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CONT

Area of the belt:

A = l×b m2
A = 1261.3× 101.6
A = 128652.6 mm2
A= 0.128 𝑚2
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CONT

WEIGHT OF BELT:
We are using the PVC belt having the Weight of 2.2 kg/m2 the mass or the
load due to belt can be calculated from the area and Weight of the material
that is

M= Weight× Area
M= 2.2×0.128
M= 0.28 Kg
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CONT

Tension in Belt:
 The total tension in the conveyor belt when the system is under static
condition and or when the belt is under steady state
T=1.37× f × l × g[2 × M1 + 2 × M2 + M3 ]
 Where
 T = Belt tension under steady state (N)
 f = friction coefficient and its value is 0.2
 l = length of the half of the total length of conveyor belt
 g = gravitational acceleration the value of gravitational is 9.81 m/s
 M1 = the load acting due to idlers on the system
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CONT

 M2 = the mass of the belt or load of the belt on the system

 M3 = the external load that is the load due to bottle

 As the weight, W=0.28kg

𝑤
 Weight per unit length W= 𝐿
.28
W=1.26

W=0.22
F=1.37× .02 × 1.26 × 9.81 + [2 × 0 + 2 × .22 + 1 cos 0 ]
F=1.78
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CONT

Belt Power:
 The power required for the system can be obtained from the force under
the static condition and the permissible speed of the belt that is 0.4 m/s

T×v
P= 1000

1.78×0.4
P= 1000

P = 0 .02 kW
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CONT

The minimum motor power required

P
Pm =
η
.02
Pm =
.5
Pm = .4 hp

Where η is the power transmission efficiency or the effective power

transmitted and Pm is Permissible power.
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COMPONENTS

Frame, Conveyor Belt Assembly and Drive

Mechanism
 A frame is designed to carry the belt and to assemble the drive
mechanism with it.

 The frame is the backbone of the prototype system and all the parts are
assembling to it.

 The belt is a PV material flat built type supported with two rollers on both
sides to rotate it.
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CONT

 One of the roller is adjustable for variating the built tension as per
requirement.

 For drive mechanism two spur gears of equal size are used to transfer the
power from motor to the conveyor assembly.

 Other components are bearings within the roller assembly and in a bearing
kit to support the roller.
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Frame

PV Belt
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Spur Gear

Bearing with Kit

Roller Assembly
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CONT

MOTOR:
 A right-angle inductance motor of model GTR HFM-15R-15-T25 is selected
to supply the required power.

 It is Speed control gearmotor which enables to select speed freely in the

wide range of speed, 50～1400rpm(50Hz) or 50～= 1700rpm(60Hz).
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CONT

Motor Assembling
Motor
supports
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CONT

PLC:
 The selected PLC is manufactured by Mitsubishi Technologies

 We have used model FX-1S for our project. For bottle detection the system
is integrated with an infrared IR sensor.

 Delta PLC and Fetek PLC are also available but we used Mitsubishi
because its software is available easily and it was compatible with our
system.
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CONT

SENSOR:
 The sensor detects the bottle and sends a signal to plc which
than stops the motor, hence drive for a specified time and in
the same time the solenoid valve opens for filling the bottle.

 The system is also incorporated with two switches that are used
to turn the system ON and OFF.
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PLC Fx;1S Switches Infra Red Sensors

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CONT

SOLENOID VALVE:
 To control the flow of liquid a solenoid valve is used that is operated
through PLC when the sensor detects a bottle.

 A solenoid valve is an electromechanical device in which the solenoid

uses an electric current to generate a magnetic field and thereby operate
a mechanism which regulates the opening of fluid flow in a valve.
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Solenoid valve
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ASSEMBLY
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SOFTWARE

GX DEVELOPER:
 The GX-DEVELOPER- FX is a simple programming software that supports the
entire PLC range.

 It is a cost effective cut down version of GX developer, specifically

designed for micro FX PLCs.

 GX developer supports all MELSEC controllers from the compact PLCs of

the MELSEC FX series.

PROTON is also available and its free but it was not compatible wit the
Mitsubishi plc.
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GX Developer Working Environment

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Ladder Logic for bottle filling development

stage
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PLC OPERATION

 PLC operation is comprised of basically four steps;

 Input Scan being the first of them, followed by Program Scan and Output
Scan, Housekeeping is the final step. The PLC continuously keeps following
all these steps.
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COST ESTIMATION:

 The complete setup is consisted of two types of components and these

are the components that have been either purchased and assembled or
are manufactured specially for this project according to the designed
values and dimensions.
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CONCLUSIONS AND RESULTS

 The designed components were assembled successfully and then the

program developed using PLC software GX developer was incorporated
with the prototype setup.

 Several test runs were conducted for the sake of optimizing the
parameters for best performance.
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CONT

 As a result we have gained knowledge of mechanical system along with

electrical system.

 It can be said that by doing this project successfully we were able to

understand how to the construct industrial systems.
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REFERENCES:

 1 “History of Conveyor Belts.” [Online]. Available:

http://www.slideboom.com/presentations/1683466/History-of-Conveyor-
Belts
 2 “file.php (1000×475).” [Online]. Available:
http://glavmex.ru/forum/download/file.php?id=17693.
 3 “3. Vijay M. Patil Niteshkumar A. Vidya Roshan L. Katkar Piyush S. Pande
‘Type of Conveyor System: A Review’ IJSRD - International Journal for
Scientific Research — Rambler/search.” [Online]. Available:
 4“1. https://www.thomasnet.com/articles/plant-facility-equipment/types-
of-conveyors/ — Rambler/search.” [Online]. Available:
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