We hereby solemnly declare that the work presented here in this project report has been done by us and has not previously been submitted to any university/organization for award of any degree or certificate. The operation was previously performed by humans and involved placing one bottle at a time on the conveyor belt and filling it. The process was then slow, involved spillage of liquid and uneven amounts of liquid in bottles.
The process is now what we are trying to do, carried out by PLCs in large manufacturing units now. Due to their high cost, filling is still carried out by hand in small manufacturing units. In this project we aim to study the industrial process as executed by a microcontroller, and then design a bottle filling, counting and liquid tank level monitoring system.
Automation involves remote control of processes and creation of control loops so that the operation can be performed electronically with minimal human intervention. This operation was previously performed by humans and involved placing one bottle at a time on the conveyor belt and filling it. In large-scale industries such as soft drinks and pharmaceuticals, filling is done by PLCs.
To test the operation of the bottle filling system, count and control the level of the liquid tank.
Arduino Nano
Nanos have the breadboard capability of the Boarduino and the Mini+USB with a smaller footprint than both, so users have more breadboard space. It has a pin layout that works well with the Mini or the Basic Stamp (TX, RX, ATN, GND on one top, power and ground on the other). The high-performance Microchip pico Power 8-bit AVR RISC-based microcontroller combines 32KB ISP flash memory with read-while-write capabilities, 1024B EEPROM, 2KB SRAM, 23 general-purpose I/O lines, 32 general-purpose work registers, three flexible timer/ counters with compare modes, internal and external interrupts, serial programmable USART, a byte-oriented 2-wire serial interface, SPI serial port, a 6-channel 10-bit A/D converter (8 channels in TQFP and QFN/MLF packages), programmable watchdog timer with internal oscillator, and five software selectable power saving modes.
By executing powerful instructions in a single clock cycle, the device achieves throughput approaching 1 MIPS per MHz, balancing power consumption and processing speed.
Switch Mode Power Supply (SMPS)
A linear power supply, on the other hand, regulates the output voltage by continuously dissipating power in the pass transistor. Switching power supplies can also be significantly smaller and lighter than a linear power supply due to the reduced size and weight of the transformer. 12V 5A Industrial SMPS Power Supply - 60W - DC Metal Power Supply - Good Quality - Non Waterproof with Aluminum Case.
Switched-mode power supplies are classified according to the type of input and output voltages. The input DC supply from a rectifier or battery is fed to the inverter where it is switched on and off at high frequencies of between 20 KHz and 200 KHz by the switching MOSFET or power transistors. 9 fed to the transformer's primary winding, and the secondary AC output is rectified and smoothed to produce the required DC voltages.
A feedback circuit monitors the output voltage and instructs the driver circuit to adjust the duty cycle to maintain the output at the desired level. The rectified voltage is then applied to the power factor correction (PFC) pre-regulator, followed by the downstream DC-DC converter(s). 10 As far as output connectors and pin-outs are concerned, with the exception of some sectors, such as PC and compact PCI, these are generally not standardized and are left to the discretion of the manufacturer.
There are different circuit configurations known as topologies, each with unique characteristics, advantages and modes of operation, which determine how the input power is transferred to the output. Most of the commonly used topologies such as flyback, push-pull, half-bridge and full-bridge consist of a transformer to provide isolation, voltage scaling and multiple output voltages. Switched-mode power supplies are used to power a wide variety of equipment such as computers, sensitive electronics, battery-powered devices, and other equipment that requires high efficiency.
Linear voltage IC regulators have been the basis of power supply designs for many years because they are very good at providing a continuous fixed voltage output. This allows us to create a whole range of different power rails and outputs, both single and dual power, suitable for most electronic circuits and applications. There are even variable voltage linear regulators available that provide an output voltage that is continuously variable from just above zero to a few volts below the maximum output voltage.
Typical DC Power Supply
IR Sensor
When an object intersects the sensor light, the sensor detects something. Some infrared beam is deflected from the object and the scene length of this distance. If an object comes in front of this sensor, the sensor detects it and sends a signal in the LED.
Relay
A type of relay that can handle the high power required to directly control an electric motor or other loads is called a contactor. Magnetic latch relays require one pulse of coil power to move their contacts in one direction, and another, relay pulse to move them back. Magnetic latch relays are useful in applications where intermittent power must not be able to switch the contacts.
On a single coil device, the relay operates in one direction when the current is turned on with one polarity, and resets when the polarity is reversed. In a dual coil device, the contacts will trip when polarized voltage is applied to the reset coil. The above circuit is called a low-side switch because the switch – our transistor – is on the low (ground) side of the circuit.
Alternatively, we can use a PNP transistor to create a high-side switch: similar to the NPN circuit, the base is our input and the emitter is tied to a constant voltage. Controlling a relay with Arduino is as simple as controlling an output such as an LED. NO (normally open): there is no contact between the common pin and the normally open pin.
So, when you activate the relay, it is connected to the COM pin and supply is provided to a load. NC (normally closed): there is contact between the common pin and the normally closed pin. There is always connection between the COM and NC pins, even when the relay is turned off.
When you activate the relay, the circuit opens and there is no load supply. If you want to control a light bulb for example, it is better to use a normally open circuit because we only want to turn on the light bulb every once in a while. IN2: controls the second relay (must be connected to an Arduino digital pin if you use this second relay. Otherwise, you don't need to connect it) VCC: goes to 5V.
DC Gear Motor
Specification
LCD Display
A command is an instruction given to the LCD to perform a predetermined task such as initializing it, clearing its screen, setting the cursor position, controlling the display, etc.
Mini Pump
Ultrasonic Sensor
HC-SR04 Ultrasonic Sensor - Working
- History
- Block Diagram
- Components List
- SMPS
- Methodology
- Complete Project Prototype Image
- Working Principle
- Cost Analysis
- Result
- Discussion
- Limitation
- Conclusion
- Future Scope
Since we use the ultrasonic wave, we know the universal speed of US waves at space conditions, which is 330m/s. The circuit built into the module will calculate the time it takes for the US wave to come back and turn the echo stick high at the same specific time, this way we can also know the time it takes. This pin must be held high for 10us to initialize the measurement by sending US wave.
This pin goes high for a period that will equal the time it takes for the US wave to travel back to the sensor. This system for filling, counting and monitoring the liquid tank level in bottles is such an efficient, accurate and safe process. Creating an idea for the design and construction of an automatic system for bottle filling, counting and liquid tank level control.
When it detects a bottle, it stops the conveyor belt and fills the bottle with liquid within a certain delay time. After filling this bottle, the conveyor belt will start and when the bottle is in front of another IR sensor, the conveyor belt will stop and count the number of bottles. On the other hand, the ultrasonic sensor detects the liquid level in the tank with an ultrasonic sound.
In this process, we fill a bottle, count the bottle number and measure the liquid tank level. 32 After we have placed the bottle on the conveyor belt here, it takes a maximum of 2.30 seconds before we reach the first IR sensor. And when the liquid is full, it takes up to 2.66 seconds to reach the second IR sensor.
The filling time of the bottled water and the counting of the bottles are done correctly, we have agreed with everyone that the accuracy of our system is 99%. The automatic bottle filling, counting and liquid tank level control system works accurately, efficiently and provides an easy, more accurate and reliable bottle filling process and is more advantageous than conventional methods as it reduces manual effort, errors and is highly efficient. In case of any failure, the system can be easily restored and started after diagnosis.
The main objective of this project was to develop a bottle filling, counting and liquid tank level monitoring system based on certain specifications. More functions can be added to this system as follows: depending on the size, shape and weight of the objects, bottle filling, counting and liquid tank level monitoring can be implemented.
