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WATER BOTTLING STATION

Mini Project Report submitted in partial fulfillment of the requirement for the

Mechatronics Course project of

THIRD YEAR OF ENGINEERING

IN

MECHANICAL

Under the guidance of

(B.S. CHAVAN)

Submitted by

Amogh Thatte

Amol Shetty

Dinesh Suvarna

Pranav Sawant

Pratik Soma

Vishal Jain

DEPARTMENT OF MECHANICAL ENGINEERING

DON BOSCO INSTITUTE OF TECHNOLOGY

PREMIER AUTOMOBILES ROAD, KURLA (W) – 400070

UNIVERSITY OF MUMBAI

(2013-2014)

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UNIVERSITY OF MUMBAI

2013-2014

Project Title : Water Bottling Station

Institute Name : Don Bosco Institute Of Technology

Institute Address : Premier Automoblies Road,

Kurla (West), Mumbai - 400070

Department : Mechanical Engineering

Internal Guide : Prof. B.S. Chavan

Project Group Members:

Sr. No. Roll No. Exam No. Name of candidate

1. 72 46145 Amogh Thatte

2. 66 46131 Amol Shetty

3. 71 46143 Dinesh Suvarna

4. 64 46127 Pranav Sawant

5. 70 46141 Pratik Soma

6. 81 4661 Vishal Jain

Date of Submission : 21/04/2014

Approved By : __________________

Prof. B.S. CHAVAN

Department of Mechanical Engineering

Don Bosco Institute of Technology

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CONTENTS

Sr. No. Content Page No.

1 Acknowledgement 4

2 Abstract 5

3 Problem Definition 6

4 Design 7

5 Bill of Materials 8

6 Electro Pneumatic Circuit 9

7 Allocation Table 10

8 PLC Ladder Circuit 11

9 Conclusion 12

10 Photo of setup 13

11 Group Photo 14

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ACKNOWLEDGEMENT

We are grateful to the management of Don Bosco Institute of Technology and the Principal – Dr.

N. G. Joag for providing the necessary resources for the completion of this mini project.

We would like to express our gratitude to Prof. B. S. Chavan for his constant encouragement,

interaction and support during the semester, and assisting in the completion of this electrically

connected PLC controlled mechanical setup.

We would also like to thank Sir B. S. Patil and the workshop staff for providing the technical and

practical knowledge required and access to the workshop tools and machinery.

We would like to sincerely thank all of those who have directly or indirectly helped us in the

completion of this project.

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ABSTRACT

As per the university syllabus it is mandatory for the T.E. Mechanical students to carry out a

mini project to integrate and apply the knowledge gained during the Mechatronics course. The

project had to be developed by a team of students and consists of design, setup and

implementation of a simple Mechatronics system.

Since the knowledge of the theories of Mechatronics is inadequate to understand the concepts, it

is important to put these theories into practice by making a mechanical setup and actuate it with

electro-pneumatic connections which will be controlled by a PLC.

This will help us to have a hands-on experience on the theoretical aspects with a practical

background for the subject. Also, it will create an awareness of the standard industrial practices.

Thus, with this mini project, we are exposed to the modular concepts in Mechatronics. This will

help us in the automation industry and we will be technically proficient.

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PROBLEM DEFINITION

Sample Example

A process control system illustrated in the figure is desired to fill the bottle and convey this. The

outlet valve is opened to fill the bottle as when the limit switch senses the presence of the bottle

and is closed automatically when the photosensor produces the signal as when the bottle is filled.

The level of water in the tank is maintained through a control valve. Develop a PLC ladder logic

diagram for this control application.

(Note: 1. Limit switch is replaced by IR proximity sensor.

2. Photosensor is replaced by timer.)

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DESIGN

The design for the whole setup was carefully sketched according to the specifications. A list of

materials required was prepared and it was understood that these materials would be provided by

the college workshop or would be outsourced if needed.

The following is a list of components which were provided by the workshop/outsourced :

1. Metal plates, angle plates.

2. Cast iron rods.

3. Metal cutter.

4. Hand grinder.

5. Hand drill.

6. Welding machine.

7. Drilling machine.

8. Lathe machine.

9. Teak wood.

10. Fasteners.

11. Bearings.

12. Pulleys.

13. Conveyor Belt.

14. Soldering Iron.

15. 12V DC motor.

16. 12V DC battery.

17. 220V flow control solenoid valve.

18. IR proximity sensor.

19. Ball cock.

20. Water tank & plastic bottles.

21. PVC pipe.

22. M-seal & white cement.

23. Relays and electrical wires.

24. SIEMENS PLC

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BILL OF MATERIALS

Sr.No. Description Quantity Source Cost

Rs.

Remark

1 Solenoid flow

control valve

1 In-house - 220V operating voltage

2 12V DC motor 1 Outsourced 300 High torque, low rpm

3 12V DC battery 1 In-house - Lead acid battery

4 Ball cock float 1 Outsourced 40 Small sized

5 IR Proximity

sensor

1 In-house - Range: 10 feet

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+24V

0V

3

4

K1

A1

A2

K3

1

2

PS

K2

A1

A2

T1 5

A1

A2

T2 15

A1

A2

T3 20

A1

A2

K2

3

4

T2

1

2

T4

1

2 T4 5

A1

A2

T3

3

4

M

K1

3

4

K2

1

2

T3

3

4

SV

T1

3

4

K3

A1

A2

3

4

Designation Description

Electrical connection 24V

Electrical connection 0V

Detent switch (make)

K1 Relay

K3 Break switch

PS Optical proximity switch

K2 Relay

T1 Relay with switch-on delay

T2 Relay with switch-on delay

T3 Relay with switch-on delay

K2 Make switch

T2 Break switch

T4 Break switch

T4 Relay with switch-on delay

T3 Make switch

DC Motor

K1 Make switch

K2 Break switch

T3 Make switch

SV Valv e solenoid

T1 Make switch

K3 Relay

Detent switch (make)

1 2 5 7 8 9 10 11

9 59 10 4 7

8

6 1

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ALLOCATION TABLE

Component Symbol Address Description

Photosensor PS I1 When signal = 1

motor stops

Detent switch

(start)

S1 I8 When signal = 1

entire ckt starts

functioning

Detent switch

(emergency stop)

S2 I5 When signal = 1

entire ckt stops

functioning

Relay SV Q1 When signal = 1

Solenoid valve opens

Relay M Q2 When signal = 1

DC motor starts

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CONCLUSION

The following concepts have been studied and understood from our project:

Automation in bottling industry

Operation of Programmable Logic Controller (PLC)

Use of various machines and tools

Electronic control characteristics

Range of Proximity sensor

During the initial testing phase, our primary focus was on ensuring the proper connection of

circuits and components. Proper safety measures were undertaken and the high voltage

components were earthed. Later on, our focus shifted to ensuring the proper movement of the

conveyor belt and the rotation of the pulley with respect to the motor. The timers were initially

calibrated on the basis of assumptions and were later fine-tuned as the testing progressed. The

PLC testing was primarily focused on ensuring that the program designed in the above problem

was executable.

The project has a lot of scope for additions. A setup for capping the bottles can be designed and

constructed. Separate timers can be programmed for different bottle sizes. A water filtration

system can also be integrated with this project.

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THE SETUP

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THE GROUP