2015AUTOMATED PRODUCTION LINE WITH BOTTLE FILLING FEEDBACK CONTROL SYSTEM

ContentsPROJECT TITLE:.......................................................................................................................................................................... 3

GROUP MEMBERS...................................................................................................................................................................... 3

ABSTRACT..................................................................................................................................................................................... 3

1.0 OBJECTIVE..............................................................................................................................................................................4

2.0 INTRODUCTION................................................................................................................................................................... 4

3.0 WORKING............................................................................................................................................................................... 4

3.1 Basic Design......................................................................................................................................................................4

3.2 Block diagram.................................................................................................................................................................. 5

3.3 Signal Flow Diagram..................................................................................................................................................... 6

3.4 Working Description…………………………………………………………………………………………………………..7

4.0 COMPONENTS DESCRIPTION........................................................................................................................................7

4.1 TIP 122................................................................................................................................................................................ 7

4.2 Sonar HC-SR04................................................................................................................................................................ 8

4.3 Solenoid valve (12V, ¼”).............................................................................................................................................8

4.4 Infrared Sensor for detection....................................................................................................................................9

4.5 LM324............................................................................................................................................................................... 10

4.6 Relay..................................................................................................................................................................................10

4.7 16x2 Character Lcd.....................................................................................................................................................10

4.8 DC motor with reduction gear box (12v, 1/100 reduction ratio)…………………………………………..9

5.0 FINANCIAL DETAILS.......................................................................................................................................................11

DATASHEETC CODE FOR ARDUINO

Project Report

PROJECT TITLE:

AUTOMATED PRODUCTION LINE WITH BOTTLE FILLING FEEDBACK CONTROL SYSTEM

GROUP MEMBERS

SAAD ABDULLAH

ABSTRACTThe project consists of a belt conveyor, for filling of bottles to a required level of liquid (height), a few sensors to take input, a controller to control actuations and some actuators to fulfill the overall task. The inputs to the system will be a preset (controllable) liquid level required. The sensors will detect the presence of a bottle under filling station and the instantaneous amount of liquid level reached while filling. The controller controls the conveyor movement and the actuator to start and stop filling. This project can be used as a simulator for automatic filling stations in beverages, pharmaceutical and dairy process industries.

1.0 OBJECTIVEThe objective of this project is to create an automated filling station for cans / bottles, using detection technique for bottles and controlled level filling.

2.0 INTRODUCTIONThe use of automatic filling stations using a belt conveyor system is most economical, fast and commonly used system used in almost all beverages and pharmaceutical (liquid) industries. This project works as a prototype for basic concept of automatic filling stations in beverages, pharmaceutical and dairy process industries.

The objective of the project is to detect the presence of a glass bottle at the filling station, fill the liquid in the bottle to a certain height and forward the bottle for further processing. The project consists of a belt conveyor, for filling of bottles to a required level of liquid, driven by a DC motor at a constant preset speed. The motor will keep driving the conveyor until an infrared (IR) sensor detects the presence of a bottle right below the filling station. The IR sensor sends the signal to the controller which in return sends a signal to the motor to stop. As soon as the conveyor stops, the actuator for filling, i.e. a solenoid valve, turns the filling on. The liquid level in the bottle is continuously monitored using an ultrasonic sensor. A preset required level of liquid is already entered in the controller. The controller compares the instantaneous level to the preset required level. As soon as the desired level is reached, the solenoid valve turns off the filling. When filling stops, the conveyor starts moving so that next bottle can be filled.

CONVEYOR

RESERVOIR

SOLE

NO

ID V

ALV

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IR SENSOR

BEAKER

LCD DISPLAY

BELT

M

DC MOTOR

ULTRASONIC SENSOR

3.0 WORKING

3.1 Basic Design

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LVE

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CON

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ETECT

IO

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LIQU

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LEVEL

DET

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3.2Block diagram

3.3Signal Flow Diagram

3. 4 WORKING DESCRIPTIONThe circuit is supplied with two different power sources (two 9 volts battery) and one 12v 2.0amp source. There are two switches which will turn on the circuit. When the beaker is placed on the conveyor belt, when it comes in between the LED and Phototransistor, then the output signal will be generated by a comparator, which has some preset value set by a potentiometer against the sensitivity of the light received by the phototransistor. This output is then read by a 8bit 32KB AVR microcontroller (ATMEGA 328) which then immediately stops the conveyor and through relay it will turn on the solenoid valve and hence the liquid will flow through it by the action of gravity into the beaker via valve from the reservoir. The ultrasonic sensor will detect the level of water, following the Doppler’s phenomena, the value of level is experimentally set in the programming. Once the level of the liquid is achieved the controller after taking decision will switch off the solenoid valve and turn on the conveyor and will weight for the other beaker to come.

3.5 SoftwareProteous ISIS is used to design and simulate the circuit before implementation.

4.0 COMPONENTS DESCRIPTION

4.1 TIP 122In electronics, the Darlington transistor (often called a Darlington pair) is a compound structure consisting of two bipolar transistors (either integrated or separated devices) connected in such a way that the current amplified by the first transistor is

amplified further by the second one.[1] This configuration gives a much higher common/emitter current gain than each transistor taken separately and, in the case of integrated devices, can take less space than two individual transistors because they can use a shared collector. Integrated Darlington pairs come packaged singly in transistor-like packages or as an array of devices (usually eight) in an integrated circuit.

Datasheet attached.

4.2 Sonar HC-SR04Ultrasonic ranging module HC - SR04 provides 2cm - 400cm non-contact measurement function, the ranging accuracy can reach to 3mm. The modules includes ultrasonic transmitters, receiver and control circuit. The basic principle of work:

(1) Using IO trigger for at least 10us high level signal,(2) The Module automatically sends eight 40 kHz and detect whether there is a pulse signal back.(3) IF the signal back, through high level , time of high output IO duration is the time from sending ultrasonic to returning.Test distance = (high level time × velocity of sound (340M/S) / 2.Datasheet attached for further details.

4.3 Solenoid valve (12V, ¼”)A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric current through a solenoid: in the case of a two-port valve the flow is switched on or off; in the case of a three-port valve, the outflow is switched between the two outlet ports. Multiple solenoid valves can be placed together on a manifold.

Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut off, release, dose, distribute or mix fluids. They are found in many application areas. Solenoids offer fast and safe switching, high reliability, long service life, good medium compatibility of the materials used, low control power and compact design.Besides the plunger-type actuator which is used most frequently, pivoted-armature actuators and rocker actuators are also used.

4.4 Infrared Sensor for detectionAn infrared sensor is a sensor that reacts to infrared (IR) ray of light projection. An infra red ray of light emerges from one terminal known as emitter and is received by another terminal known as receiver. The emitter and receiver may be on the same side or the opposite side. The sensing can be to sense an obstacle that breaks the projection to imply presence of an external object, or to sense the projection at receiver to imply moving of an object that was supposed to be breaking the light beam, or both.Installer Guide Attached.

4.5 LM324The LM324 series are lowcost, quad operational amplifiers withtrue differential inputs. They have several distinct

Pressure relief conduit;

advantages overstandard operational amplifier types in single supply applications. Thequad amplifier can operate at supply voltages as low as 3.0 V or ashigh as 32 V with quiescent currents about one−fifth of thoseassociated with the MC1741 (on a per amplifier basis). The commonmodeinput range includes the negative supply, thereby eliminating thenecessity for external biasing components in many applications. Theoutput voltage range also includes the negative power supply voltage.Datasheet is attached for detailed info.

4.6 RelayA relay is an electrically operated switch. Many relays use an electromagnet to operate a switching mechanism mechanically, but other operating principles are also used. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal. The first relays were used in long distance telegraph circuits, repeating the signal coming in from one circuit and re-transmitting it to another. Relays were used extensively in telephone exchanges and early computers to perform logical operations.

4.7 16X2 CHARACTER LCD

This 16-character, 2-line parallel liquid crystal display achieves a large viewing area in a compact

package. It features a yellow-green LED backlight and uses the common , so sample interface code is

widely available for a variety of microcontrollers. This LCD is also available without a backlight.

The DDRAM address 0x00 corresponds to the first character of the top line, address 0x0F

corresponds to the last character of the top line, address 0x40 corresponds to the first character of

the second line, and address 0x4F corresponds to the last character of the second line.

4.8 DC motor with reduction gear box (12v, 1/100 reduction ratio)Dc motor is used to operate the conveyor belt with a reduction ratio of 1/100 having output RPM of 60, this results in an speed of 0.4 m/s of conveyor. The motor is operated using a relay, no PWM is supplied or directional control circuit is connected with motor because it is not required to control the speed or direction of motor.

5.0 FINANCIAL DETAILSS. No. Component Cost (PKR)1 Conveyor Belt 3000Rs

2 DC Motor 100Rs3 Solenoid Valve 1000Rs4 Sonar Sensor 480Rs5 IR Transmitter + Receiver 120Rs6 LCD Display 250Rs7 Atmel ATmega 328 350Rs8 Relay 26 Rs9 Acrelic Box 244 Rs10 Other Misc components 630RsTotal Project Cost 6200 Rs

Program (Source Code)

#include <LiquidCrystal.h>

// initialize the library with the numbers of the interface pinsLiquidCrystal lcd(12, 11, 5, 4, 3, 2);

#define echoPin 7 // Echo Pin#define trigPin 8 // Trigger Pin#define relay 10 // Onboard LED#define Glass 9 // Bottle detection#define solenoid 13 // Solenoid detection

byte armsUp[8] = {  0b00100,  0b01010,  0b00100,  0b10101,  0b01110,  0b00100,  0b00100,  0b01010};

int maximumRange = 200; // Maximum range neededint minimumRange = 0; // Minimum range neededlong duration, distance; // Duration used to calculate distance

void setup() { lcd.createChar(4, armsUp);   lcd.begin(16, 2);  lcd.write(4);   lcd.print(" Production Line Automation by            Saad Zeeshan Waqas Saeed Adeel ");    for (int positionCounter = 15; positionCounter < 84; positionCounter++) {    // scroll one position left:    lcd.scrollDisplayLeft();     // wait a bit:    delay(400);  }  delay(1000);  lcd.clear();   delay(2000); pinMode(trigPin, OUTPUT); pinMode(solenoid, OUTPUT); pinMode(Glass, INPUT); pinMode(echoPin, INPUT); pinMode(relay, OUTPUT); // Use LED indicator (if required)}

void loop(){

 digitalWrite(trigPin, LOW); 

 delayMicroseconds(2); 

 digitalWrite(trigPin, HIGH); delayMicroseconds(10);   digitalWrite(trigPin, LOW); duration = pulseIn(echoPin, HIGH);  //Calculate the distance (in cm) based on the speed of sound. distance = duration/58.2;  int Detect_glass =digitalRead(Glass);  if(Detect_glass == HIGH)  //no glass {    digitalWrite(relay, HIGH);  //conveyor    lcd.setCursor(0, 0);    lcd.print("Conveyor Start");     digitalWrite(solenoid, LOW); if(relay==HIGH)    delay(40); //int a = a++;  }   if(Detect_glass == LOW) { lcd.setCursor(0, 0);     lcd.print("Conveyor  Stop");     digitalWrite(relay, LOW);   //conveyor off    delay(1000);    digitalWrite(solenoid, HIGH);  //solenoid on        //sonar value for level detector    if(distance<=9)    {digitalWrite(solenoid, LOW);  //water off delay(1000); digitalWrite(relay, HIGH); //conveyor on delay(3000);     } }

 delay(50);}