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Automated Liquid Filling System Design

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11 views3 pages

Automated Liquid Filling System Design

Uploaded by

bernandes Suarez
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

Volume: 03 Issue: 05 | May-2016 [Link] p-ISSN: 2395-0072

Microcontroller Based Automated Solution Filling Module


Shilpa Katre1 , Jaspreet Hora2
[Link]. ,ETC Department,Rajiv Gandhi College of Engineering and Research, Nagpur, India
[Link]. ,ETC Department,Rajiv Gandhi College of Engineering and Research, Nagpur, India

---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - In this era of industrialization, technological 2. OBJECTIVE
revolution/automation is fast shrinking need of humans to
assist machinery. This system provides the provision of mixing To design a controller system which provides a particular
n number of liquids in any proportion. It’s remote control and volume of solution, user defined and reduces the labour
monitoring makes the system easily accessible and warns the effort and makes work more accurate and [Link] build a
operator in case of any fault. This paper is prototype to prototype that will be user friendly, low cost with a
massive machines used to fill the liquid in the bottle with a transparent structure and compatible for small scale
fixed quantity or fixed level, it eliminates and reduces the [Link] develop an automatic bottle filling system with a
chances of unevenness from bottle to bottle or inaccuracy deduction mechanism using sensors. Automatic filling
which is a very common mistake while filling the bottle process for all the bottles simultaneously with a user defined
manually. The research offers a hardware assembly for a selection for volume to be [Link] main objective of this
complete production line bottling incorporating the use of paper is to fill the liquid in the bottles with a fixed quantity
microcontroller which results into improved efficiency, energy or fixed level which will eliminate the chances of unevenness
saving and cost effectiveness. from bottle to bottle or inaccuracy which is a very common
mistake while filling manually
Key Words: Proximity sensors, solenoid valve.
3. METHODOLOGY
[Link] 3.1 Basic Concept

Automation is the use of control systems and information Bottles are kept in position over a circular disk, to detect
technologies which reduces the need of human work in the their presence. Proximity sensors are used for sensing the
production of goods and services. In the scope of bottles. Depending on the output of the sensor the
industrialization, automation is a step beyond corresponding pumps switch on and filling operation starts.
mechanization. Where as mechanization provides human If the particular bottle is not present then the pump in that
operation with machinery to assist them with the muscular position is switched [Link] avoids wastage of the liquid.
requirements of work, automation greatly decreases the The filling operation is accompanied with a user-defined
need for human sensory and mental requirements as well. volume selection menu which enables the user to choose
Microcontroller plays an important role in the upcoming the volume of liquid to be filled. The filling process is done
world of automation industry. It has replaced the wiring and which is based on timing. Depending on the preset value of
cabling system that was used in previous era. [1] the timer the pump is switched on for that particular period
of time and the filling process is done. [2]
Earlier the processes carried out in industries were quite
monotonous as a result there was no variation in the
production. The research offers a hardware assembly for a
complete production line bottling incorporating the use of
microcontroller which in turn results into improved
efficiency, energy saving and cost effectiveness. This paper is
prototype to massive machines used to fill the liquid in the
bottle with a fixed quantity or fixed level, it eliminates and
reduces the chances unevenness from bottle to bottle or
inaccuracy which is a very common mistake while filling
manually. It reduces the labour effort as well as make work
more accurate and reliable.

Fig -1: Block Diagram


© 2016, IRJET | Impact Factor value: 4.45 | ISO 9001:2008 Certified Journal | Page 708
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 05 | May-2016 [Link] p-ISSN: 2395-0072

3.3 Flow Chart


3.2 Input Module
The input module includes the proximity sensors and level
sensors. There are four proximity sensors whose output is
given as an input to the microcontroller. The three proximity
sensors are kept near the input side and bottles are placed
on the disk. Thus, these are the inputs given to the input
module.

Solenoid Valve:-It is an electromechanical 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 case
of three-port valve the outflow is switched two outlet ports.
Multiple solenoid valves can be placed together on a
manifold.

Microcontroller:-A microcontroller is a small computer on a


single integrated circuit containing a processor core,
memory and programmable input/output peripherals. The
P89CV51RD2 is a type of 80C51 microcontroller with
respectively 64 kB flash and 1 kB of data RAM. It has larger
RAM size and the ability to erase code memory in 128-B
page blocks. [5]

Float Sensor:-Float sensor is an electrical ON/OFF switch,


which operates automatically when liquid level goes up or
down with respect to specified level. The signal thus
available from the float sensor can be utilised for control of
motor pump or an electrical element like lamps, relays and
solenoid etc. Fig -2 Flow Chart
Bottle Detection Using Sensors:-
3.4 Software used
Bottles are kept on the circular disk on the input side. Proxy
sensors are used to detect the presence of bottles. Depending
on the output of the sensors the filling operation takes place. The software used in this paper is EAGLE, the Easy
A time delay is given in order to set the status of the bottles. Applicable Graphical Layout Editor is powerful PCB design
If bottle 1 is present the corresponding status bit in software designed to meet the needs of professionals and
microcontroller is set to 1 else it is set to 0. The outputs of engineers .EGALE is powerful and flexible PCB design
these sensors are given to the microcontroller and software which gives high level functionality of expensive
depending on this output the filling process for the bottles commercial circuit board design software at a fraction of the
takes place. Thus if all the n bottles are present in the input cost for over 20 years. EAGLE is easy to learn, easy to use as
side then the sensor gives the corresponding output to the well as easy to [Link] runs on Linux, Mac and Windows and
microcontroller which in turn switches ON the allows feature enhancement, for example simulation, data
corresponding pumps for filling operation to take place. If a import and export and self-defined commands, through User
particular bottle is not present the corresponding pumps Language Programs (ULPs) which are partly integrated in
remain OFF.[3] [4] EAGLE and available at the download area.

© 2016, IRJET | Impact Factor value: 4.45 | ISO 9001:2008 Certified Journal | Page 709
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 05 | May-2016 [Link] p-ISSN: 2395-0072

4. Future Scope
This system is very useful for future with the help of this
system more features can be added to this system. Using
appropriate pump, jet nozzle & solenoid valve in which case
precise timing is needed would increase productivity. An
extended capping & wrapping section could be introduced.
More flexibility can be introduced in nozzle positioning. The
system can be redesigned for increase bottle size and
productivity. This concept can be used in food industries,
milk industries, medicine industries mineral water, mineral
water, chemical product industries and manufacturing
industries. More features can be added to this system as
follows: depending on the size, shape and weight of the
bottles, filling and capping operations can be implemented.
Capping operation can be improvised using a piston
arrangement

REFERENCES
[1] Dr. A. S. C. S. Sastry, [Link], V S R G Krishna,
[Link] Kiran Kumar, An Automated Microcontroller
Based Liquid Mixing System, (IJCSE) International Journal
on Computer Science and Engineering, Vol. 02, No. 08,
2010, 2648-265.

Fig -3 Circuit Diagram [2] T. Kalaiselvi, R. Praveen (2012), PLC based automatic
bottle filling and capping system with user defined volume
selection, International journal of emerging technology
3. CONCLUSIONS and advanced engineering. (Vol 2, Issue 8, August2012)

The main objective of this paper is to develop a bottle filling


system based on certain specifications. We consider this [3] Rajesh G. Khatod, Chandrashekhar Sakhale ,Design &
paper as a journey where we acquired knowledge and also Fabrication of liquid dispensing machine using automatic
gained some insights into the subject. Microcontroller is control for egg. Industry, International journal of
used to control the various operations and for monitoring. innovative technology and exploring engineering
IJITEE,Vol I, Issue 5, October 2012.
Bottle filling system will provides a great deal of applications
in the field of automation, especially in mass production [4] Product Data sheet of P89CV51RB2/RC2/RD280C51
industries where there are large number of components to
be processed and handled in a short period of time and
there’s need for increased production. The programming of [5] Ashwini P. Somavanshi, Supriya B. Asutkar and Sachin A.
this system is flexible, quickly and easily done. This will More, Automatic Bottle Filling Using Microcontroller
increase the total production output, this increase in Volume Correction, International Journal of Engineering
production can yield significant financial benefits and Research and Technology IJERT, Vol. 2, Issue 3, pp. 1-
savings. 4,2013,
The performance, flexibility and reliability is based on the
investment. The entire system is more reliable, time saving
and user friendly.

The system has proved to work effectively avoiding


unnecessary spill or wastage of liquids. The system also
provides high accuracy and high precision in proportion of
liquid mixed. Although proposed system illustrates the
mixing process of two liquids any number of liquids may be
mixed in varying proportion.

© 2016, IRJET | Impact Factor value: 4.45 | ISO 9001:2008 Certified Journal | Page 710

Common questions

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Microcontrollers are crucial in modern automation systems as they simplify the control processes by integrating multiple functionalities into a single chip. In the context of bottle filling machines, like the one described in the document, microcontrollers handle inputs from sensors to detect bottle presence and manage the precise timing needed to control solenoid valves for filling operations. This facilitates improved efficiency, energy saving, and cost effectiveness by reducing human error and enhancing process reliability .

Proximity sensors enhance the accuracy and efficiency of automated bottle filling systems by detecting the presence of bottles on the rotational disk, allowing the microcontroller to activate the appropriate pumps only when bottles are present. This prevents liquid wastage and ensures that filling only occurs when a bottle is correctly placed, maintaining the consistency of filling and reducing errors associated with manual filling processes .

A timer-based control mechanism improves performance by ensuring that each bottle receives a consistent volume of liquid during filling. The system employs a pre-set timer value to manage how long the pump remains active, which eliminates inconsistencies present in manual filling methods. This approach also reduces the need for constant monitoring, thus optimizing the process for efficiency and reliability .

The system integrates user-friendly features like a user-defined volume selection menu, which allows operators to easily set the desired level of liquid to be filled. This simplifies the operation and reduces training needs for workers while minimizing the risk of human error. Such features significantly enhance system usability, ensuring adaptability in diverse working environments and increasing operator satisfaction .

Solenoid valves improve the automated filling process by providing precise control over the start and stop of liquid flow. The electric current operating these valves allows for quick response to microcontroller signals, enabling accurate timing in filling operations. The use of two-port or three-port solenoid valves in the prototype ensures that liquid flow can be seamlessly switched on or routed as required, which reduces wastage and enhances the reliability of the filling system .

Microcontroller-based systems offer several advantages over traditional manual filling, including higher precision with reduced human error, consistent filling accuracy, energy efficiency, and reduced labor costs. These systems are also scalable and can handle complex filling tasks that are impractical for manual handling, enhancing productivity and process reliability in industrial settings .

Float sensors contribute to operational reliability by automatically engaging or disengaging filling operations based on the liquid level detected in the container. This feedback mechanism ensures that pumps are only active when necessary, preventing overflow and potential spillage while also optimizing liquid use. This redundancy enhances system dependability and ensures that processes adhere to safety and operational standards .

Changing nozzle positioning could improve efficiency by optimizing the flow rate and reducing filling time per bottle. Strategic positioning could minimize splashing or spillage and accommodate different bottle types and sizes for a more seamless operation. Such adjustments would enhance the flexibility and adaptability of the filling system, allowing it to meet diverse production requirements more effectively .

Challenges include ensuring consistent fill levels amidst different bottle shapes and volumes and maintaining system timing accuracy. These can be addressed by implementing adjustable sensor arrays and programmable microcontroller settings that can be recalibrated for different configurations. Additionally, flexible nozzle positioning and adaptive control algorithms would be essential in catering to these variations efficiently .

Future developments that could enhance such systems include adding more sophisticated pump designs and precise jet nozzles for increased productivity, as well as incorporating extended sections for bottle capping and wrapping. Additionally, adapting the systems for various bottle sizes and shapes could increase versatility. These advancements could expand the system's applicability to diverse industries such as food, medicine, and chemical production .

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