IMPLEMENTATION OF PLC SYSTEM ON

BOTTLE LINE PRODUCTION SYSTEMS

Submitted to fulfill Assignment 1 of the PLC-Based Design course

di semester VIII

Prepared by:

Tijar Ahmad Yusf

2212142039

CONTROL TECHNIQUES AND INSTRUMENTATION

ELECTRICAL ENGINEERING DEPARTMENT

JENDRAL ACHMAD YANI UNIVERSITY

2016
CHAPTER I
 INTRODUCTION

1.1 Background

The growth of industry in the world is very significant, one of which is in the field of

Production certainly increases due to the growing demand in the industry. Based on
This need must certainly be accompanied by a production quantity that is in sync.
with its development. Based on that, growth in the industrial sector must be
follow the developments in automation technology, as it is clear that only
relying on a manual system (operator power) in production will not be possible
offsetting production needs.
The development of automation in the industrial sector has made the production process increasingly

easy and efficient. The implementation of automation systems is certainly very necessary besides

to expedite the production process while also saving costs for employee payments. In addition

providing solutions in production productivity certainly through implementation

The automation technology system will save the expenses of a manufacturing company.
in paying employees.
PLC systems are one of the automation solutions used in
The application of industry. This PLC can be applied to various types of needs.
automation in industry, one of which is used in controlling the filling
drink bottle is one of the industries.
In this discussion, the author will provide a simulation.
regarding the PLC system used in the operation of beverage bottle filling
packaging in the production industry. Here it is used starting from the selection of bottles

until the drink is filled in the bottle controlled by the PLC.

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1.2 Purpose of Writing

The objectives to be achieved in the writing of this task are

to understand and study the implementation of the course
The design of PLC-Based Systems studied in this eighth semester in the world
industry. In addition, this report is also submitted to fulfill Assignment 1 of the course
PLC Based Design.

1.3 Problem Scope

The limitations of the issues that will be discussed in this writing are
as follows:

a) Consists of 3 limit switches, namely bottle sensor, bottle size sensor, and sensor
determination of whether the bottle is broken or not.

b) Consists of 3 conveyors, namely the main conveyor to move empty bottles.

to be filled, large bottle output conveyor and conveyor box containing broken bottles
c) The tool functions continuously starting with pressing the START button and
stop when the STOP button is pressed.

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 CHAPTER II

LITERATURE REVIEW

2.1 Conveyor

A conveyor is a mechanical system that has a function

moving goods from one place to another. Conveyors are widely used
in the industry for transporting goods that are in very large quantities and
sustainable.

Under certain conditions, conveyors are widely used because they have value
more economical compared to heavy transportation such as trucks and freight cars. Conveyor
must mobilize goods in large quantities and continuously from one place to
other places. The relocation of that place must have a fixed location so that
The conveyor system has economic value. The weakness of this system is that it does not

having flexibility when the location of mobilized goods is not fixed and the quantity
the incoming goods are not continuous.

Conveyors have various types that are adapted to the characteristics.

goods being transported. The types of conveyors include Apron, Flight, Pivot,
Overhead, Loadpropelling, Car, Bucket, Screw, Roller, Vibrating, Pneumatic, and
Hydraulic. Here we will discuss one type of conveyor, namely Roller Conveyor.

2.1.1 Roller Conveyor

A roller conveyor is a conveyor system whose main support is
The item being transported is a roller. The roller in this system is slightly different.
with rollers on other types of conveyors. Rollers in the roller conveyor system
specifically designed to match the conditions of the goods being transported, for example

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the roller is given a rubber coating, anti-corrosion coating, and so on. Meanwhile, the roller
In other types of systems, they are designed to fit the belts they support.

Figure 2.1 Example of Roller Conveyor

2.1.2 Function and Specification of Roller Conveyor

Roller conveyors can only move items that are in unit form and not
can move bulk or grain-shaped goods. Units that can
transferred using a roller conveyor must also have certain dimensions
and a certain weight in order to be transported. To move goods within
bulk form, the bulk must be packed first into units to be able to
transported using this system.
The specifications of the roller conveyor must also be adjusted according to the dimensions and load.

the unit that will be transported. The design of the roller conveyor system must be able to

receiving the maximum load that may occur in the conveyor system. In addition,
The system dimension design must also be considered to match the unit dimensions.
that will be transported. In some cases the unit dimensions that are wider than
the width dimension of the roller is still allowed.

The advantage of a roller conveyor is that it can be used on an incline.

so that the conveyor can transport items from one level to another
others. In addition, roller conveyors can also redirect the unit's path.

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Its turn is very sharp. This is beneficial for areas that have limited space.
limited.
Selain itu, roller conveyor memmpunyai kemampuan untuk menggabungkan
2 separate paths. The merging of these 2 paths can be done in various ways.
methods such as Y-Line and accumulating roller conveyor.

2.1.3 Roller Conveyor Components

The main components of the equipment and their functions in a roller conveyor system are as follows

following:
Body Frame
The body frame has the function of supporting the roller so that the roller's location

not moving around. The installation of the roller with this body frame must
to prevent unwanted vibrations during the roller's rotation. In addition
it, the body frame also determines the appropriate distance between rollers so that
the unity that will be transported does not fall.

Figure 2.2 Body Framework

2. Support Column

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 The support pillar has the function of being the foundation for the system's structural frame.

The body frame is designed as a support for the roller conveyor.

on the land traversed by the conveyor system.

Figure 2.2 Support Column

3. Drive Motor

The drive motor has the function to move the drive roller so that
always rotates at the speed desired by the operator. Motor
This drive is generally placed at the very end of the roller track.
conveyor that can keep the transmission chain taut.

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 Figure 2.3 Drive Motor

4. Roller
The roller serves the function of moving items that will be
transported. When the roller spins, efforts are made to ensure it does not vibrate so as not to

damaging the transported goods. The dimensions of the roller must also be the same so that

the transported goods do not get stuck and the roller can support the goods
perfectly.

Rollers in the roller conveyor system require special attention because

is the most important component in this system. Thus the design
and maintenance on rollers must receive more primary attention.
Here is the design of the roller conveyor component that has been analyzed in class.

Machine Design I lecture.

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 Figure 2.4 Roller

5. Transmission System

The transmission system has the function of transmitting power.

drive to the conveyor system. The transmission on the roller conveyor system is divided

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 divided into 2 parts, namely the transmission between the drive motor and the drive roller

and transmission between the drive roller and other rollers.

The transmission system between the drive motor and the drive roller is usually

located at the very end of the conveyor path. This transmission system
usually consists of a motor, speed reducer, coupling, sprocket, and chain.

Figure 2.5 Transmission System

The transmission system between the drive roller and the roller is usually placed on
the body framework of the conveyor system. Transmission between rollers is usually used

sprocket and chain with a rotation speed ratio of 1:1 for speed
rotate between the same rollers and the transported goods can move
well.

2.2 Programmable Logic Control (PLC)

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 Programmable Logic Control (PLC) is essentially a computer.
specifically designed to control a ptosis or machine. The process that
this can be controlled as continuous variable regulation as in systems-
servo system, or it only involves controlling two states (ON/OFF), but
done repeatedly as commonly found in drilling machines, the system
conveyor, and so on. PLC has input and output devices that
used to connect with external devices such as sensors, relays, contactors
and so on. The programming language used for operating
PLC is different from regular programming languages. The language used is
Ladder, which only contains input-process-output. It is called Ladder because of its shape.

the programming language display indeed looks like a ladder display. Image 2.1
The following shows the control concept performed by a PLC.

Gambar 2.6 Diagram konseptual aplikasi PLC

Although the term PLC literally means a logic controller that can
programmed, but in reality, PLC functionally is no longer limited to
logic functions only. Nowadays, a PLC can perform calculations-
relatively complex arithmetic calculations, communication functions, documentation and
and others. Even control systems based on linear technology

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(with continuous signals) can be realized so that the PLC can now
equipped with a PID controller module.

Figure 2.7 Types of PLCs of various sizes

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2.2.1 PLC Components
In a PLC, there are several components divided into 2
part, namely hardware components and software components. Components-
this component consists of:

a) PLC hardware components:

CPU: Central Processing Unit as the data processing unit between input
module, memory and output module.
Power Supply: serves as a voltage source for
PLC components.
Memory: functions as a storage for data and programs.
functions as a receiver of signals from input devices such as
switch and sensor (using an analog module).
functions to send the results of the CPU process to the equipment
outputs such as motor, lights, fans, and others.
Programming Device: a tool used to create and
monitoring ladder diagram in PLC like computer and programming
console.

b) PLC software components:

PLC Operating System. Each PLC has an operating system that has a version and
the type depends on each vendor and is proprietary technology
(closed-system).
PLC programming language in the form of ladder diagram or mnemonics
which is written into the PLC using a programming device
or computer console (both GUI [graphical user interface] and CLI
[command line interface data utext-based].

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 2.2.2 Advantages of PLC over Conventional Systems

PLC has several advantages over conventional systems

the control panel is as follows:

Less wiring
Relatively easy maintenance
System tracking is simpler
Relatively low power consumption
Image documentation is simpler
Modification of the system is simpler and faster

2.3 Limit Switch

A limit switch is a device that functions to disconnect and

connecting electric current in a circuit, based on the mechanical structure of
the limit switch itself. The limit switch has three terminals, namely: central
normally closed (NC) terminal and normally open (NO) terminal. According to
By its name, a limit switch is used to limit the operation of a certain tool that
currently operating. The NC, NO, and central terminals can be used to disconnect
electric current in a circuit or vice versa. The same applies to a switch in
generally, the limit switch also only has 2 conditions, which are connecting or
deciding the flow of electric current. In other words, it only has an ON or
Off.

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 Figure 2.4 Limit Switch

However, the working system of a limit switch is different from that of a regular switch, if

In general, the switch system works will be controlled manually by

human (either rotated or pressed). Meanwhile, the limit switch is made with a system
different work, the limit switch is made with a work system that is controlled by
force or pressure (physical contact) from the movement of an object on the actuator, system
This work aims to limit movement or control something.
the object/machine, by interrupting or connecting the electrical flow.
that goes through its contact terminal.

Figure 2.4 Limit Switch

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 CHAPTER III

DESIGN

3.1 Block Diagram

The block diagram of the system to be created is shown in Figure 3.1.
This block diagram is an overview of the working principles of the system of the tool.
the

Figure 3.1 System Block Diagram

3.2.1 Tool Work Description

Here is a job description from Bottle Line Production Systems:
The bottle is already on the roller conveyor track.
2. When the RUN power button is on START, the bottle will move on the roller.

conveyor to input sensor. There are 3 input sensors: 1. Existing sensor

functions as a sensor for the number of bottles entering the system, 2. Limit
The switch (Large bottle sensing) functions as a detector for small bottles.

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 or large and 3. Scrap sensing works to separate bottles that
broken.
3. After each bottle has been labeled (distinguished based on
small, large, and broken bottles) by sensor input. Then the bottles will enter.
into their respective systems.
4. The scrap bottle will activate the scrapt selenoid according to the input.
given by the scrap sensor in the previous input. The solenoid will operate and
botol akan jatuh pada sistem scrapt yang telah dibuat. Botol tidak akan
walking on the roller conveyor leading to filling (flow fill) otherwise
the roller conveyor for bottle scraps.
5. Large bottle and small bottle are differentiated by sensing input (limit switch)
where when the LS context reads large bottle and vice versa reads small
context.
6. When LS reads the large context, it will automatically activate.
separator for large and small bottles. Where the large bottle will come out.
from the main roller conveyor to the special roller conveyor for large bottles.

Meanwhile, small bottles will remain on the main roller conveyor until
process completed.
7. The settings of switches A, B, and C are used to adjust the speed.
bottle filling.
The STOP button functions to stop the system.

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Figure 3.2 Illustration of Bottle Line Production Systems Design

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3.3 PLC Input and Output Addressing

Below is the list of addresses for the input and output of the PLC used
in the operation of the tool:

Table 3.1 PLC Input Addressing

No Symbol Name Type Address Description

1. Stop INPUT I:1/0

2. Start (PB,NO) INPUT I:1/1

3. Select A INPUT I:1/2 Not in use
4. Select B INPUT I:1/3 Not used
5. Select C OUTPUT I:1/4 Not used
6. Enter (PB/NO) INPUT I:1/5

7. LS 1 (EXIST) INPUT I:1/6

8 LS 2 (LARGE/SMALL) INPUT I:1/7

9. LS 3 (BROKEN) Please provideI:1/8
the text that needs to be translated.
10. LS 4 (FILL TUBE) INPUT I:1/9

11. LS 5 (LARGE FILL) INPUT I:1/10

12. LS 6 (SMALL FILL) INPUT I:1/11

13. LS 7 (CAP) INPUT I:1/12

14. LS 8 (Broken Gate) INPUT I:1/13

15. LS 9 (Large Bottle INPUT

gate) I:1/14

11. LS 10 (Box Gate) INPUT I:1/15

12. BCD INPUT I:3

Table 3.2 PLC Input Addressing

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 No Symbol Name Type Address Description
1. Main Conveyor OUTPUT O:2/0
2. Scrap Conveyor OUTPUT O:2/1
3. Divert Conveyor OUTPUT O:2/2
4. Grinder OUTPUT O:2/3
5. Scrap Gate OUTPUT O:2/4
6. Divert Gate OUTPUT O:2/5
7. Fill Tube OUTPUT O:2/6
8. Large Charge OUTPUT O:2/7
9. Small Charge OUTPUT O:2/8
10. Cap Ram OUTPUT O:2/9
11. Run Light OUTPUT O:2/10
12. Display Small OUTPUT O:2/11
13. Display Large OUTPUT O:2/12
14. Display Scrap OUTPUT O:2/13
15. Display Boxes OUTPUT O:2/14

3.4 Ladder Diagram

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20
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 CHAPTER IV

CONCLUSION

4.1 Implementation Results

From the results of the implementation of the program created for the bottle line.

production systems, the program can run all functions on the machine.
Here is the display of the process at each stage;
1. When the Start button is pressed, the Main Conveyor (O:2/0) will be ON and the bottle will

continuously moving on the Main Conveyor.

2. When the Bottle reaches LS1 (Exist) (I:1/6), the Sensor detects whether the Bottle
whether it enters the Main Conveyor or not. LS2 (I:1/7) (LARGE/SMALL)
detecting whether the incoming bottle is a Large Bottle or a Small Bottle
Bottle. LS3 (I:1/6) (BROKEN) Detecting if the incoming bottle is broken.
or not

Figure 4.1 Bottle Detection Limit Switch

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3. Limit Switch LS2 to trigger the Large Fill and Small Fill valves to start
filling the bottle. If LS2 has a bit value of 0 then the detected bottle
is a Small Bottle, while if LS2 has a value of 1 bottle that
detected is Large Bottle. The bit value read LS2 will trigger
The PLC will calculate how many bits are needed for the bottle from LS2.
to Bottle Extractor
4. LS3 (Broken) has a value of 1 when it detects a broken bottle and a value of 0
if it detects a good bottle. If LS3 is worth 0 then the bottle will
then continue to the Filling Extractor, but if LS3 has a value of 1
This will trigger the solenoid for the Broken Gate. Open and close the Broken Gate.

controlled by Limit Switch.

5. The Reject bottles will go into the Reject Box. The Reject Box conveyor will
ON if the BOX Reject counter value is at least 29. Small Bottle is worth 2 and
Large Bottle is worth 3.
6. When LS1 determines the bottle address, it will be executed to address (I:1/9) Filling

The LS2 tube detects whether it is a Large Bottle or Small Bottle.

Will it be filled with Large Charge (O:2/7) or Small Charge (O:2/8).
7. When the Filling Tube Address is fulfilled, the bottle will be continued.
use a Cap Ram to install the Lid on the desired bottle.
8. When the bottle has passed the separation bit in the Filling Tube, For LS2 that
valued at 1 (Large Bottle) then the Divert Gate valve will open and
Large Bottle will be channeled to the lower conveyor. For LS2 with a value of 0
(Small Bottle) the divert gate valve is closed and the bottle remains at
conveyor above.
The Stop button will stop all systems.

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 REFERENCES

[1] Control System Design, updated on April 13, 2014.

[Link]
[2] Anomaly System Roller Conveyor, updated on April 4, 2012,
[Link]
[3] Rakhman, Edi. 2010. BUKU AJAR SISTEM OTOMASI INDUSTRI .
Bandung: State Polytechnic of Bandung

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