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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
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.
• Software Development
Design • Hardware Development
• Performance Testing
Experiment Work • Troubleshooting
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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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.
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.
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.
Pb = Push Button
Pm = Dc Pump Motor
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Start
No
Yes
Conveyor Stop
Delay
Sensor Measure
Size of Bottle
No
Sensor
1
Yes
Valve Open
Sensor 2
= 8 sec
No
Yes
Done
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
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 3.12 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
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.
The length of the belt is 2000mm and the diameter of roller is 50mm.