Bottle Filling Process PLC Program _ Part 1


In this section of a factory, there is a bottle
filling machine that fills the empty bottles on a conveyor belt with liquid from this tank. In this and the next lessons you’re going
to learn how this machine works and how to write a professional PLC program that fully
controls this machine. The components that I have for this machine
include input devices and output devices. The machine inputs include these momentary
switches that I have here, this three position selector switch here, and these three photo
eye sensors. For the purpose of controlling this machine
by a PLC, these components are going to be wired to the PLC input module. The machine outputs include the conveyor belt
motor, the drain valve, and these two signal lamps here which are all going to be wired
the PLC output module. As you can see, this filling machine has three
operation modes which are off, manual and automatic. These modes are determined by the three position
selector switch here. When I put the switch in the manual state,
the machine is going to operate in the manual mode and when I put the switch in the automatic
state the machine is going to operate in the automatic mode. To be able to write a proper PLC program for
this machine I need to know how exactly this machine operates. So let’s see how it works. When the machine is in the manual mode and
this switch is pressed, the motor rotates in the clockwise direction. As soon as I release the switch, the motor
stops. If I press the next switch, the motor rotates
in the counter clockwise direction and stops when I release the switch. When this switch is pressed, the drain valve
is going to be open and when I take my hand off the switch, the valve will close. So that’s how the machine operates in the
manual mode now let’s see how it’s going to operate in the automatic mode. In the automatic mode, when the start switch
is pressed, the motor rotates in the clockwise direction. When a bottle is seen in front of the sensor
number 2, the motor is going to stop and this valve will open for 7 seconds. After 7 seconds, the valve is going to close
and the motor will start rotating in the clock wise direction. This process continues until I press the stop
switch at which time, the whole system will shut down. I have two additional photo eye sensors at
the two ends of the conveyor belt. Sensor number 1 is going to be used to count
the number of the empty bottles on the conveyor belt and the sensor number 3 is going to be
used to count the number of the filled bottles. There is also a RESET switch here. This switch is going to be used to RESET the
number of the bottles counted by the sensors at the two ends of the conveyor belt. This means the empty and filled bottles counted
by the sensors will be set to zero when I press this switch once. As you can see, I have two signal lamps here
as well. These lamps are used to indicate whether the
machine is in manual or automatic mode. The “man” lamp will be lit in manual mode
and the “auto” lamp when in automatic mode. Neither lamp will be lit when in the off mode. Okay now you’re completely clear about how
the machine should operate in both manual and automatic modes but there are a few safety
points that I need to take care of while I’m writing a PLC program for this machine.

25 thoughts on “Bottle Filling Process PLC Program _ Part 1

  1. thank you, you'r really helpful, i'm new in the automation domain can u help me with some books that can help me ?
    please
    thank you .

  2. Thank you so much sir for providing videos. these all are helpful for us.
    Sir plese provide more videos.
    Thank you #realpars

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  4. hello there!..thanks for the initiative to pass on knowledge..highly appreciated, I've learnt quite a lot from your videos….I would also like to ask, which book you would recommend that better explains CFC charts, the various functions of the blocks, when and how to use them; and the use of SFC charts IN SIEMENS STEP 7…

  5. Is there any other way to pay when subscribing to your web site because it is hard to get visa card in our country ):

  6. Hey, great job 👍 I have a wish can you provide me a theory of siemen's plc in the form of pdf?

  7. Your videos are really helpful. The soft to making the video is great? Can I know the name of soft? Thank you so much.

  8. very Good demonstration.. Which software are you using to make these animated videos ?? i want to learn to make video like you RealPars…

  9. sir, can we use photo electric sensor to detect broken bottle,dirty bottle,chipped neck ?
    can we use capacitive sensor to detect torn label,without label,wrong label ?

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