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CHAPTER 3

METHODOLOGY

3.1 Introduction

This chapter provides the explanation of methodology used for developing automatic
filling bottles system. The purpose of the methodology is to provide the working
principle, development and methods for the whole project to works. This methodology
leads to achieving the project objective. There are a few major steps need to followed
as shown in Figure 3.1.

Design and
Literature
Planning Materials
Review Study
gathering

Testing and Result,Analysis

Build the system
troubleshooting and Conclusion

Figure 3.1: Project Development Steps

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3.2 Project methodology

As shown in Figure 3.2, this project consists of four main phases, which are planning,
design, experiment work, result and analysis. The most crucial part to start the project
is to plan the project well and ensure the process is able to progress smoothly. The
project from planning, designing, experiment work and result analysis. The detail of
the steps is explained on the following sub-chapter.

• Literature review study

Planning • List of Hardware

• Software Development
Design • Hardware Development

• Performance Testing
Experiment Work • Troubleshooting

Result and • Record result

Analysis • Analysis result

Figure 3.2: Content of methodology

3.3 Planning

Planning the whole process for the development of this project by gathering
information about the hardware and software used is needed. In this planning phase,
the major elements that need to discuss that is literature review study of the existing
water usage monitoring system to know the concept of the system.
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3.3.1 Literature Review

Study the previous work that was done is an important task to be done because of the
studies it can explain and understand the advantages and disadvantages using the
component that will be used. Therefore, before starting any new project it will be a
benefit to study project that is completed.

3.3.2 List of Hardware in Project

Below is the list of hardware in order to complete the project and make the automatic
filling bottles system function well. Some of them hardware is readily available so they
are not listed such as laptop for ladder diagram coding. Table 3.1 shows the hardware
required in order to complete this project.

Table 3.1: List of Hardware

No Item Quantity
1 PLC Module 1
2 Conveyor Belt 1
3 Reflective sensor 3
4 Power window motor 1
5 Dc pump motor 1
6 Valve 1
7 Tank 1
8 Bottles with different size (230ml,350ml,600ml) 1
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3.4 Design

The design of the system can be divided into several parts. It will divide into two main
parts which is development of hardware and software.

3.4.1 Software Development

3.4.1.1 Block Diagram

Figure 3.3: Block diagram of the system

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3.4.1.2 Control panel wiring diagram

Figure 3.4: Control panel wiring diagram

Pb = Push Button

Rb = Reset / Stop Button

S1, S2, S3 = Retro Reflective Sensor

R1= Relay for Power Window Motor

R2= Relay for Dc Motor Pump

Pw = Power Window Motor

Pm = Dc Pump Motor
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3.4.1.2 Flowchart Process

Flowchart for bottles sensing and filling system

Start
No

Conveyor runs Sensor

with empty bottle detects
bottle

Yes

Conveyor Stop

Delay

Solenoid Valve Open

Bottle Filling Start

Conveyor starts Delay

running with filled
bottle

Solenoid Valve Closed

Delay Bottle Filling Stop

Figure 3.5: Flowchart for bottles sensing and filling system

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Flowchart for bottle size detection

Sensor Measure
Size of Bottle

No

Sensor
1

Yes

Valve Open
Sensor 2
= 8 sec
No

Yes

Valve Open Sensor 3 Valve Open

= 20 sec = 14 sec
Yes No

Done

Figure 3.6: Flowchart for bottle size detection

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3.4.1.4 CX-Programmer

It is a program that uses to draw a ladder diagram. This ladder diagram uses to give
instruction to the PLC. All the PLC programming must install by this program. A
debugging environment equivalent to the actual PLC system environment can be
achieved by simulating the operation of virtual PLC on the computer. Allows program
debugging in a single PLC before the actual system has been assembled. Reduces the
total lead time required for machine/equipment development and startup.

1. Starting CX-Programmer

- CX-Programmer is activated from the Search button in Microsoft Windows

taskbar

Figure 3.7: Starting open CX program

- Once activated, a CX-Programmer window is displayed

Figure 3.8: The basic form of interface

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2. Create new the project

- Click File > New or

- Check setting for PLC:
1. Device Type: Cpm1a
2. Device Type Settings: CPU20
3. Network Type: SYSMAC WAY

Figure 3.9 : Setting for PLC

Figure 3.10: The Main Element in CX Programmer Window

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3. Work Online and Upload PLC program

This part is explaining how to work online and upload the program to the PLC. To
work online just click icon or Ctrl + W. After successful online, to upload the
program click “PLC” in menu bar “transfer” to PLC or Ctrl + T.

Figure 3.11: Transfer program to PLC

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3.4.2 Hardware Development

In the development of hardware, it consists of three major subtopic which is schematic

diagram of the process, bottle detection mechanism and development of conveyor belt.

3.4.2.1 Schematic diagram of automatic filling bottle system

Figure 3.12 shows the schematic diagram of automatic filling bottles system of this
project. The PLC will control all of the input and output operation. This machine has
3 type of power supply; it is 24VDC for PLC and relay,12VDC power window motor
and dc motor pump.

Figure 3.12: Schematic diagram of PLC controlled automatic bottle filling system

3.4.2.2 Bottle Detection Mechanism

The task of bottle detection is performed using a photoelectric sensor. Photoelectric

sensors are placed beside the conveyor belt at the filling station to detect the presence
of a bottle. The sensor has an infrared light transmitter and a receiver. When a bottle
is brought in front of the sensor by the conveyor belt, the infrared light emitted from
the emitter gets reflected from the bottle, which is then received by the receiver of the
sensor. When no object is in front of the transmitter, the receiver does not receive any
signal.
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3.4.2.3 Development of conveyor belt

In order to design the conveyor belt, Solid Word 2017 are used to design the base of
conveyor and roller. The length of conveyor is 1000mm, while the height is 230mm
and the width is 100mm. Design of conveyor are shown in Figure 3.13 to 3.16.

Figure 3.13: The length of conveyor

Figure 3.14: The width of conveyor

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Figure 3.15: The height of conveyor

Figure 3.16: Full design of base conveyor

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The length of the belt is 2000mm and the diameter of roller is 50mm.

Figure 3.17: Length of conveyor belt and diameter of roller

Below is detail information about the size of the roller:

Figure 3.18: Detail size of the roller

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Figure 3.19: Side view of the roller