Download AUTOMATED PRODUCTION LINE WITH BOTTLE FILLING

2015
AUTOMATED PRODUCTION LINE WITH BOTTLE
FILLING FEEDBACK CONTROL SYSTEM
Contents
PROJECT 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 ............................................................................................................................................................................ 8
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
DATASHEET
C CODE FOR ARDUINO
Project Report
PROJECT TITLE:
AUTOMATED PRODUCTION LINE WITH BOTTLE FILLING
FEEDBACK CONTROL SYSTEM
GROUP MEMBERS
SAAD ABDULLAH
ABSTRACT
The 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 OBJECTIVE
The 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 INTRODUCTION
The 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.
3.0 WORKING
3.1 Basic Design
RESERVOIR
ULTRASONIC SENSOR
LCD DISPLAY
CONVEYOR
SOLENOID VALVE
IR SENSOR
BELT
M
BEAKER
DC MOTOR
CONVEYOR
START / STOP
BOTTLE
DETECTION
SONAR
SENSOR
CONVEYOR
BELT
(DRIVE)
LIQUID LEVEL
DETECTION
PROXIMITY
SENSOR
CONTROLLER
FLOW
START / STOP
SOLENOID
VALVE
3.2Block diagram
3.3Signal Flow Diagram
3. 4 WORKING DESCRIPTION
The 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 Software
Proteous ISIS is used to design and simulate the circuit before implementation.
4.0 COMPONENTS DESCRIPTION
4.1 TIP 122
In 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 currentgain 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-SR04
Ultrasonic 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 detection
An 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 LM324
The LM324 series are lowcost, quad operational amplifiers
withtrue differential inputs. They have several distinct
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 Relay
A 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 DETAILS
S. No. Component
1
Conveyor Belt
2
DC Motor
3
Solenoid Valve
4
Sonar Sensor
5
IR Transmitter + Receiver
6
LCD Display
7
Atmel ATmega 328
8
Relay
9
Acrelic Box
10
Other Misc components
Total Project Cost
Cost (PKR)
3000Rs
100Rs
1000Rs
480Rs
120Rs
250Rs
350Rs
26 Rs
244 Rs
630Rs
6200 Rs
Program (Source Code)
#include <LiquidCrystal.h>
// initialize the library with the numbers of the interface pins
LiquidCrystal 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 needed
int minimumRange = 0; // Minimum range needed
long 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);
}