Automated Bottle Filling & Capping Machine using ARDUINO

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1 Automated Bottle Filling & Capping Machine using ARDUINO Mr.Lakshmeesha, Mr.Prajwal Kotian,Mr.Shetty Ganesh, Mr.Sriganesh, Under the guidance of Prof. Ravindran K.N Alva's Institute of Engineering and Technology, Mijar, Moodbidri, Mangaluru, Karnataka Abstract - Automation has made a tremendous impact on many industries other than manufacturing. Currently automation is taking on the manual operations that are been carried out in the industries. Automation reduces human effort and completes the job in minimum time. The main intention of this paper is to implement automation in small scale bottle filling industries because the small scale industries go for manual operations to manufacture bottles, filling and capping them. These industries requires large amount of labor for operating the machines, and to increase the production rate. The expensive PLC boards that are used in large scale bottle filling industries are replaced by an ARDUINO UNO board which is much cheaper than the PLC s.the manual filling process has many shortcomings like spilling of water while filling it in bottle, equal quantity of water may not be filled, delay due to natural activities of human etc. In this paper we have tried to overcome those problems. Key words: Filling and capping, Arduino 1. INTRODUCTION The current scenario in industries is to embrace new technologies to proceed towards automation. The same vision is exercised in bottle filling plants. Filling involves use of PLC for control purpose but it is costly. Despite of all such advance technologies small industries are still involved in manual filling of bottles. They might be discouraged to adapt to new technology due to high cost involved in automation. The study emphasize on reduction in cost using Arduino Uno microcontroller. The Arduino Uno microcontroller is relatively cheap and widely available. In small industries bottle filling operation is done manually. The manual filling process has many shortcomings like spilling of water while filling it in bottle, equal quantity of water may not be filled, delay due to natural activities of human etc. This work generally emphases on small industries. It aims to eliminate problem faced by small scale bottle filling system. With this system that operates automatically, every process can be smooth and the process of refilling can reduce the man power cost and operation time. Automation promotes cost oriented reference architectures and development approaches that properly integrate human skill. This can be achieved by introducing very simple devices such as limit switches, electrical relays, solenoid valves, pneumatic actuators [6, 7]. Use of simple devices utilizing relatively cheap and readily available components, to minimize or eliminate human effort in certain operations is called Low Cost Automation. The often-told reason not to go in for automation is the high costs involved compared to the investment in manpower. However this is only one of the aspects which most of the plant engineers look into while deciding their automation requirements. The main aim of Low Cost Industrial Automation is to increase Productivity and quality of products and reduce the cost of production. 2. COMPONENTS OF BOTTLE FILLING SYSTEM 2.1 ARDUINO UNO MICROCONTROLLER An Arduino Uno is a microcontroller board in light of the ATMega 328P. It has 14 computerized input/yield pins, 6 simple data sources, 16 MHz precious stone oscillator, a USB association, a power jack, an ICSP header and a reset catch. The ArduinoUno can be fueled either from an air conditioner to DC connector or a battery by means of the USB association. The board can be worked on an outer supply of 6-20 volts. On the off chance that utilized in excess of 20 volts the board may get harmed. 92

2 "Uno" implies one in Italian and was denoted the arrival of Arduino Programming (IDE) 1.0. The Uno board and form 1.0 of Arduino Programming (IDE) were the reference renditions of Arduino, now developed to fresher discharges. The Uno board is the first in a progression of USB Arduino sheets, and the reference demonstrate for the Arduino stage. The Arduino UNO is for the most part thought about the most easy to use and well known board,with sheets being sold worldwide for under 5$ (Rs. 500 approx.) 2.2 RELAY A hand-off is an electrically worked switch. Transfers are utilized where it is important to control a circuit by a different low power flag, or a few circuits must be controlled by one flag. Numerous transfers utilize an electromagnet to mechanically work a switch. It is utilized to turn on or off electrical circuit working at high voltage utilizing a low DC controlled voltage. Transfers are utilized to give high voltage to engines. The exchanging of transfer sister performed utilizing engine controller. The core of a transfer is an electromagnet (a curl of wire that turns into a brief magnet, when power move through it). You can think about a transfer as a sort of an electric lever: switch it on with a small present and it switches on another machine utilizing a considerably greater current. As the name proposes, numerous sensors are unimaginably delicate bits of electronic gear and create just little electric current. Be that as it may, regularly we require them to drive greater bits of contraption that utilization greater streams. Transfers overcome any issues, making it feasible for little streams to enact huge ones that implies transfers can work either as a switch or as a speaker. 2.3 SOLENOID VALVE A solenoid valve is an electromechanically worked valve. The valve is controlled by an electric current through a solenoid. Their undertakings are to stop, discharge, and measurements, disperse or blend liquids. Solenoids offer quick and safe exchanging, high unwavering quality, long administration life, low control power and minimal plan. There are numerous valve plan varieties. Normal valves can have numerous ports and liquid ways. A 2-route valve, for instance, has 2 ports; if the valve is open, at that point the two ports are associated and liquid may stream between the ports; if the valve is shut, at that point ports are disconnected. In the event that the valve is open when the solenoid isn't stimulated, at that point the valve is named ordinarily open (N.O.). Thus, if the valve is shut when the solenoid isn't empowered, at that point the valve is named regularly shut. 93

3 2.4 DC MOTOR A DC engine is a class of rotating electrical machine that proselytes coordinate current electrical vitality into mechanical vitality. A DC engine is a basic part in the transport framework. An engine is a turning mover that takes into account exact control of rakish position, speed and quickening. Engines are apparently a standout amongst the most critical piece of any computerized stage. The ideal pivot speed and accessible speed scope of the engine must be mulled over. Too high of a yield that is RPM from the engine shaft will cause the transport line to move excessively quick, though too low of a yield would prompt wasteful use of time for filling. Engines come in numerous shapes and sizes. For the most part engines can be grouped into air conditioning Engines and DC Engines. Air conditioning Engines are ordinarily use for huge applications, for example, machine instruments, w3ashers, dryers, and so forth. And are fueled by an air conditioner control line. Since the run of the mill control supply utilized here is DC battery and tech utilized for changing DC to air conditioning is exceptionally costly a DC Engine is utilized. 2.5 IR SENSOR An IR sensor is an electronic gadget which is utilized to detect certain qualities of its surroundings by either transmitting or recognizing infrared radiation with no contact. IR Sensors work by utilizing a particular light sensor to distinguish a select light wavelength in the Infra-Red (IR) range. By utilizing a Drove which creates light at an indistinguishable wavelength from what the sensor is searching for, you can take a gander at the power of the got light. At the point when a protest is near the sensor, the light from the Drove ricochets off the question and into the light sensor. This outcomes in a huge hop in the power, which we definitely know can be identified utilizing a limit. Since the sensor works by searching for reflected light, it is conceivable to have a sensor that can restore the estimation of the reflected light. This kind of sensor would then be able to be utilized to gauge how "brilliant" the protest is. This is valuable for errands like line following. 94

4 2.6 CONVEYOR SYSTEM A transport framework is a typical bit of mechanical taking care of gear that moves materials starting with one area then onto the next. A level belt transport is utilized to help the containers on their area and convey them forward successively. The framework includes one engine to drive the transport line. This engine is controlled by Arduino microcontroller. Elastic transport lines are usually used to pass on things with sporadic base surfaces, little things that would fall in the middle of rollers or packs of item that would droop between rollers. Belt transports are for the most part genuinely comparative in development comprising of a metal edge with rollers at either end of a level metal bed. The belt is circled around every one of the rollers and when one of the rollers is fueled by an electrical motor the belting slides over the strong metal casing bed, moving the item. In overwhelming use applications the beds which the belting is pulled over are supplanted with rollers. The rollers enable weight to be passed on as they diminish the measure of contact produced from the heavier stacking on the belting. Belt transports are the most normally utilized fueled transports since they are the most flexible and the minimum costly. Item is passed on straightforwardly on the belt so both normal and unpredictable formed articles, extensive or little, light and substantial, can be transported effectively. These transports should utilize just the most astounding quality premium belting items, which decreases belt extend and brings about less upkeep for pressure changes. Belt transports can be utilized to transport item in a straight line or through alters in height or course. In specific applications they can likewise be utilized for static gathering or containers. 3. WORKING OF BOTTLE FILLING SYSTEM The fluid level in the hopper is checked and if the fluid level available is as per the requirement then the process begins. Firstly an empty bottle is placed on the conveyor belt. The motor is turned on and the conveyor belts starts to rotate and thus it moves the empty bottle. An IR sensor which is placed below the hopper senses the presence of bottle. The conveyor stops working and pump will remain on till the desired period. Filling process continuous until the bottle is completely filled, after which the pump is turned off and the conveyor belt starts. Now the bottle is moved forward to its final position. At final position, an optical sensor is placed which detects the presence of filled bottle and displays the number of filled bottles. Now, the bottle heads towards the capping section where it is detected by another IR sensor. A plunger with an attached spring is used for capping the bottles. Once detected by the sensor, the conveyor belt stops and the plunger rushes downwards and hits the cap of the bottle which is gently placed on the bottle. Due to the spring that is attached to the plunger, the plunger retracts after the capping is done. After the retraction process, the conveyor belt starts and the filling operation continues. 95

5 4. CONCLUSION This system can perform the task of autonomous quality control system used in industrial production and it is most suitable for small scale industries. The production of goods is being increased by automation system. Consequently, it can develop economic growth. The main goal of this paper is to implement arduino based automatic bottle filling and capping system. The cost of machine installation is cheap and it is a less time consuming work as compared to manual bottle filling technique. If properly maintained, it can run for a long period of time. In this machine, arduino has been used to control the overall system by using arduino coding. This is achieved by using sensors, relay switches, solenoid valve, dc motor and plunger. The overall process is more reliable. The operation of the machine is easy. This concept can be used in beverage and food industries, milk industries, oil mills, etc. Reference 1. Rajesh G. Khatod, Chandrashekhar Sakhale(2012), Design & Fabrication of liquid dispensing machine using automatic control for engg. Industry, International journal of innovative technology and exploring engineering (IJITEE). (Vol I, Issue 5, October 2012). [3] A.S.C.S. Sastry, K.N.H. Srinivas(2010), An automated microcontroller based liquid mixing system, International journal on computer science and engineering. (Volume II, Issue 8, August 2010). 2. Kalaiselvi T, Praveena R, Aakanksha R, Dhanya S. PLC Based Automatic Bottle Filling and Capping System With User Defined Volume Sel ection. International Journal of Emerging Technology and Advanced Engineering 2012; 2(8). 3. Arthur Pius Santiago [2010]:Insecticide Bottle Filling and Capping machines in De La Salle University.The 11 th Asia pacific Industrial Engineering and Management Systems Conference. The 14 th Asia Pacific Regional Meeting of International Foundation for production Research. 4. S.M Khalid Reza,Shah Ahsanuzzaman Md.Tariq,S.MMohsin Reza[2010]:Microcontroller Based AutomatedWater Level Sensing and Controlling: Design andimplementation Issue.Proceedings of the World Congress on Engineering and Computer Science 2010 Vol 1.WCES 2010,October 20-22, A.S.C.S. Sastry, K.N.H. Srinivas(2010), An automated microcontroller based liquid mixing system, International journal on computer science and engineering. (Volume II, Issue 8, August 2010). 6. Blog. (2014, September 09). The basic of PLCoperation [Online]. Available: 7. Siemens. (2003, June). LOGO! [Online]. Available: 96