DESIGN AND SIMULATION OF A GLASS WATER DILUTION AND FILLING MACHINE

Methodology

Design planning: this project simplifies the work process of glass water dilution and filling. It helps to
solve the problem of traditional industry still using manual based system. Design planning includes;
the material needs, components, price estimates and the application of tool.

Program Design: the program used to create the program in this machine is Cx-programmer software,
with programming language using ladder systems.

Push Indicator
Button Lamp

Programma
ble logic Motor DC
control
(PLC)

Sensor Pump

Machine Design and simulation: In this process, the components of equipment needed to make this
machine is determined. The working function of each tool and tool characteristics should be noted.

 Conveyor: in designing this machine, a conveyor is used to be able to move the glass to the
place of charging. The conveyor is driven by motor 12VDC, while the direction of the
conveyor motion is horizontal. To be able to move the dc motor in supply with a voltage of
12VDC connected to the relay is set by the programming logic control to ON/OFF.
 Push button: the push button functions as a circuit breaker. In this machine, there are 3
push button functions. The first serves as a stop button, i.e. it stops the system from
working. The other two are the work command buttons for the system to run.
 Programmable Logic Control (PLC): The programmable logic control used in the simulation is
the Omron CP1L - L20DR, which has 12 inputs and 8 outputs, where the voltage source can
be 220 VAC and 24VDC. Omron type PLC is able to communicate with the program CX-
Programmer.
 Photoelectric Sensor: Photoelectric sensors operates based on the presence or absence of
objects by using their capacitance change values. Photoelectric sensors used in this machine
 is able to detect object types, either metallic, non-metallic or polymer type. The working
voltage of this photoelectric sensor ranges from 10 VDC – 30VDC.
 DC Motor: this is an electrical machine that requires electrical energy to work. It converts
electrical energy into mechanical energy. This mechanical energy is used in rotating the fan
and also the conveyor.
 DC Pump. A brushless DC pump should be installed in the exposed state of water in the
suction. This motor works at a voltage of 12 VDC, and the positive cable is indicated by
marking it red and the negative cable is marked ++blue.
 Mini Circuit Breaker (MCB): the mini circuit breaker serves as a security in scenarios where
there is a short circuit from outside that can endanger the PLC.
 Relay: The type of relay used is the Omron type MY2N - J, where the working voltage of the
coil is 24 VDC, which is capable of passing a current of 5A at 220 VAC relay working voltage,
and a current of 5A at a working voltage of 28 VDC.
 Functional Test: the functional test is an early stage test process, in which testing is done
from the design that has been created and synchronizes with controls and tools that have
been made. This is essential in reducing the occurrence of errors in the program, system
control and tools.
 Testing Tool: The testing process is a process whereby the incorporation of a program that
has been designed in the Cx- programmer software takes place, and connected to the CP1L
programmable logic control which has been connected to the circuit controls and tools that
have been made. A flow diagram showing the work process of the tool made is shown
below;

Start

Conveyor

No
Sensor Detect?

Conveyor stops,
pump fills

Conveyor running

Stop
In the flow diagram above, it is explained that the glass filling process takes place, where when
starting the filling process, the glasses already placed on the conveyor will go to the charging area.
When the photoelectric sensor detects a moving object, the conveyor stops and the DC pump fills
the glass within the period which is set. When it is done filling, the conveyor will re-run. This system
uses a continuous system loop. This tool is designed in order for it to be able to perform two types of
charging processes. In process 1, working time glass filling is set for one second and two seconds in
process 2. The steps taken in testing the machine are;

Step 1: Connect the required voltage supply to the programmable logic control and equipment.

Step 2: Connect the input and output parts to the PLC. Other hardware such as dc motor, sensors
and brushless DC pump must also be connected with the PLC.

Step 3: Select the option to adjust how much water will fill the glass. Make a selection by pressing a
push button that has been labelled.

Step 4: After pressing the button, the conveyor runs, in which there is an empty glass on top of the
conveyor.

Step 5: When the glass covers the proximity sensor, the dc motor stops. Thereafter, the DC Pump
goes to work and fill the glass with water for the duration already set in the program.

Step 6: When the working time of the DC Pump is complete, it stops. Then, the dc motor will move
back and rotate the conveyor belt.

Step 7: The stop button is used to stop the machine.