PART 1: AUTOMATION AND CONTROL OF OVER-HEAD TANK FILLING AND

LEVEL CONTROL SYSTEM USING RELAYS LOGIC.

INTRODUCTION

In part 1, we are being asked to use automation and control of over-head tank filling and level control
system using relays logic. We need to design and build a logical control circuits using relays , limit switch
and push button to control the water level. First of all, relay logic is a method of implementing
combinational logic in electrical circuits by using several electrical relays wired in particular configuration.
To design relay logic, we must define the process to be controlled . Draw a sketch of the operation process.
Make sure all the components of the system are present in the drawing. Determine the sequence of
operations to be performed. List the sequence of operational steps in as much detail as possible. Write out
the sequence in sentences, or put them in table form. Write the relay logic diagram from the sequence of
operations. Next, limit switch is a switch preventing the travel of an object in a mechanism past some
predetermined point, mechanically operated by the motion of the object itself.

Figure 1: Type of relay that used during experiment

There are several steps to create relay logic:

 Step1. Input devices are placed near the left corner of the rung.
 Step 2. Only one output is placed near the right corner of the rung.
 Step 3. Input devices can be connected in series, parallel, or a combination of series and parallel.
 Step 4. Output devices cannot be connected in series.
 Step 5. Each output device can only be represented once in the diagram.
 Step 6. All the input and output devices must be placed horizontally.
 Step 7. Current in the relay logic diagram must flow from left to right.
 Step 8. Diagrams must be numbered and commented correctly.
 Step 9. The location of each contact associated with a coil can be recorded by the right-hand rail
near the coil.

Figure 2: Over-head tank filling circuit diagram

 THE STEP(PART 1)

Figure 3: The circuit for part 1.

Figure 4: The motor will turn on when sensor A which is the lower limit sensor and B which is upper
limit sensor detect the presence of water.
Figure 5: After the water fill in the tank, sensor B will turn off while sensor A will keep turning on the
motor until the water reached high level.

Figure 6: After the water reached at high level, sensor A and B will turn off the motor. It should remain
off until the level of water become less than sensor B. If the level of water is less than sensor B, both of
the sensor will turn on the motor to fill up the tank.
Figure 7: If sensor A is on while sensor B is off, the motor will not turning on because the level of water
is still at higher level.
 METHODOLOGY

The diagram of the circuit for part 1.

Figure 8: Circuit diagram for part 1

Figure above shows the circuit diagram for the automation and control of over-head tank filling and level
control system using relays logic. Based on the diagram, the switches connected in parallel in order to make
it turn into latching.
The single line diagram of the circuit.

Figure 9 : Single Line Diagram

Figure shows the single line diagram of the circuit. Sensor B connected in parallel to sensor A. When
sensor A and B detected the presence of water, it will turn on the water pump. After that, sensor B will turn
off while sensor A keep turning on. After the water at high level, both of the sensors will turn off. The
motor will remain off until the water is lower than sensor A which is the lower limit.

DISCUSSION

Limit switch and push button to control the water level of overhead tank system has been designed. This
system consists of 2 limit switches. The switches are limit switch High (LSH) and limit switch Low (LSL).
When switch 1 pressed, the pump motor will pump the water into the water tank until the water level
reached up to the level LSH. When water reached the high level, pump motor should turn off. It will remain
off until the water level becomes less than the level of LSL. It will continue cycle until the main power turn
off. This is the concept of Automation and control of over-head tank filling and level control using Relays.

Figure 10: Over-head tank filling

CONCLUSION

In conclusion, in the part 1 we implemented relays, limit switch and push button to build a over head
tank filling. We had made it using relays logic with automation and control concept. This concept is use to
apply the concept of automation in products so that less energy needed to do the work (fill the tank with
water). In part 1, we do not use real tank instead we used led as water filling. The concept is when the tank
is empty sensor 1 and sensor 2 (switch 1 and 2) is off, water will fill in. when water reached level sensor 1
(switch will be off) but water still fill in until it reach sensor 2 the switch 1 and 2 will be switch off (water
stops fill in). Next, the water level decrease pass through sensor 2(upper sensor), switch 2 will be turn on
but water still not fill in until water level reach sensor 1(lower sensor) switch 1 and 2 turn on (water fill in
).
Part 2: AUTOMATION OF PROTOTYPE CONVEYOR BELT BASED WATER
BOTTLE FILLING PLANT SYSTEM USING PLC

INTRODUCTION

In part 2, we used the automation of prototype conveyor belt based on water bottle filling plant system
using plc. First of all, the meaning of industrial automation is the control of machinery and processes used
in various industries by autonomous systems through the use of technologies like robotics and computer
software. Nowadays, the use of control systems, such as computers or robots, and information technologies
for handling different processes and machineries in an industry to replace a human being, and we need to
design and run a software to make some instructions for the robots to follow. Plc is an industrial computer
control system that continuously monitor the state of input devices and make decision based upon a custom
program to control the state output devices. This is one of the important application of plc in the bottle
filling industries where we want our bottles, which are moving on the conveyor belt, to be automatically
detected at the appropriate position and get it filled by any desired liquid and also after getting filled the
queued bottles gets chance to be filled. If this whole process is carried out manually, it will take a long time
and also the quantities will quite lesser. So plc become requisite controller for this type of industry.
SYSTEM/PLANT

The system for this part is about filling water bottle with water and to put the cap on the bottle.
There are two sensors that had been used to detect the bottle at different position. First of all, when start
button is pushed, the conveyer belt will turned on. The bottle will move on the conveyer belt. When the
bottle reaches at sensor 1 position the conveyer belt will turn off because the sensor detects the bottle. After
that, the water filling valve will turned on and fills the water until the bottle is filled. When finish fill the
water, the water filling valve will turned off and the conveyer belt will turned on again. When the bottle
reach at the sensor 2 position the conveyer belt will turn off because the sensor detects the bottle. After that,
bottle capping system valve will turn on to put the cap on the bottle. After done capping the bottle the
conveyer belt will turn on again.

Figure 11: Conveyor belt based water bottle filling plant system
 FLOWCHART

START

Press start button to

move conveyor belt

NO

Is there any bottle

under water filling?

YES

Conveyor belt = off

Water filling = on

NO

Is there any bottle under

bottle capping system?

YES

Conveyor belt = off

Bottle capping system = on

Button move forward

END
 EXPERIMENT SETUP

First step:

Through the first step, push button is switched hence the motor run and the conveyor belt is moving and
carrying the bottle towards the valve. The normally closed contact (valve) is placed to ensure that when
valve ON (in step2) the motor is OFF.

Second step:

When the bottle reaches under the solenoid valve, the normally open contact (sensor) will be ON and make
the valve ON and the motor OFF (conveyor stop).

Third step:

When valve ON, the PLC timer (ON-Delay timer) become active hence the valve is filling the bottle at time
(5 sec) by the timer. When the timer finishes, the valve will be OFF and motor is ON again and hence the
conveyor belt carrying the bottle away from the valve and the whole process will repeat again.

Fourth step:

Up counter (by PLC) is connected to the valve to count the number of bottles filled which means that every
time the valve the counter will be count.
LADDER LOGIC LANGUAGE

Figure 12: Ladder Diagram 1

Based on the figure above it shows that the conveyer belt is turn on when switch start is on.
 Figure 13: Ladder Diagram 2

Based on figure above it shows that the sensor 1 detect the bottle and the conveyer belt off. The water
filling valve fills water in the bottle within 5 second.
 Figure 14: Ladder Diagram 3

Based on the figure above it shows that water filling valve is turn off and the conveyer belt is turn on
again.
 Figure 15: Ladder Diagram 4

Based on the figure above it shows that the conveyer belt is turn off when the sensor 2 detect the bottle.
The bottle capping valve is turn on within 5seconds.
 Figure 16: Ladder Diagram 5

Based on the figure above it show that the bottle capping valve is turn off and the conveyer belt is turn on
again.
 Table 2: Input and Output

Input Device Output Device

0.00 Start push button 1.00 The conveyor
0.01 Sensor 1 (water 1.01 Water filling valve
filling valve)
0.02 Sensor 2 (bottle 1.02 Bottle capping
capping valve) valve
T0000 Counter 1
T0001 Counter 2

When the start push button (0.00) is press, the conveyer belt is on (1.00).The (0.01) and (0.02) is normally
close is for the sensor. The system is latched but when the sensor is being press the conveyor belt will turn
off. When the bottle stops at sensor 1 (0.01) it will become normally open for the water filling valve until
full water and the conveyor belt will turn off. The time from normally open turn to normally close for (0.01)
it will count for 5 seconds. The timer for water filling valve is (T0000). When the bottle stops at sensor 2
(0.02) it will become normally open for the bottle capping valve until the bottle is cap while the conveyor
belt is off. The time from normally open turn to normally close for (0.02) it will count for 5 seconds. The
timer for bottle capping valve is (T0001).

DISCUSSION
 The theory and concept of the automatic filling water system is based on the control system. In
electrical design, the features and functions of the electrical components are required to determine the
system requirement. Furthermore, the theoretical of the wiring system is required for connecting the inputs
and outputs devices to PLC. In programming design, understandings of the desired control system on how
to use and design the Ladder Diagram to translate the machine sequence of operation are the most important
parts because it has direct effect on the system performance. The main aim in this process is to apply PLC
to design automatic filling water system and all objectives in this project were successfully done as planned.

This experiment is about implement a logical control circuit diagram using PLC to automate the
conveyor belt based Water bottle filling plant system. This plant has two sensor used to detect water bottle
at different points. The conveyor belt that operates by motor, will work as to move the bottle to being filled
with water and covered with capping. This operation started when the system is turned ON by pressing start
button. The bottles then start moving on conveyor belt that operates by motor and will be sense at sensor 1
after reached it. This sensor works as to stop the conveyor from running in order to let the bottle filled with
water by using water filling valve. At this time the timer will ON for 5 second to let the bottle finish filled
up with water and the conveyor started to move again. Then the conveyor will reached at sensor 2. The
motor on conveyor belt will stop after being sense, this time the timer will ON again for 5 second delay to
let the bottle capping valve to be operated. After reached at 5 seconds delay, the bottles was finished covered
up with capping and the conveyor belt will move again to complete the operation.

CONCLUSION

An automation water filling machine system by using PLC has been developed and implemented.
After a thorough investigation, the researchers highly recommend extending the other automation processes
such as adding input, adding output devices, and also the expansion of the ladder program. The utilization
also of the other PLC brands and models may be suggested depending on the need and specifications of
different processes. Belt conveyor in bottle filling system will be controlled using Programmable Logic
Controller, sensors and Rotating mechanism, etc. In the point of view of reducing human efforts, PLCs are
important part to design with more reliable and less power. The PLC is used in this system to get more
productivity with less time high reliability for and flexible in work. The PLC also has evolved as an
important controller in the industries these days because of its simplicity and robustness. It is used for
controlling many mechanical movements of the heavy machines or to control the voltage and frequency of
the power supplies. This application includes the continuous bottle filling system, speed control of dc motor
and control of planar machine.
 UNIVERSITI KUALA LUMPUR
BRITISH MALAYSIAN INSTITUTE

AUTOMATIONS AND ROBOTICS

BPB35104
LAB 1 : AUTOMATION OF THE INDUSTRIAL PROTOTYPE PLANT
LO1-BO2

Prepared By:

Muhammad Haziq bin Hazalan (51211116111)

Wan Irsyad ‘Izzuddin bin Wan Azmi (51211116171)
Mohd Shafiq bin Noor Hisham (51211116005)
Muhammad Afiq bin Zuraimi (51211116090)