SCADA Based Automated Bottle Quality & Quantity Detection and Filling System by Using PLC

Abstract

In this paper, we propose an automated bottle quality, quantity detection and filling system in a manufacturing department using a PLC (Programmable Logic Controller) and SCADA. SCADA stands for Supervisory Control and Data Acquisition system. The main objective of the project has four processing stages. Firstly, detect the fault of the bottle by using optical sensor. In the second stage, remove the faulted bottle from the conveyer belt using electronic pusher. In the next stage, detect the quantity (size) of the bottle using proximity sensor. In the final stage, bottle filling process regarding size of the bottle. The quality and quantities of the physical system in the field is sensed by the sensors and fed as inputs to the PLC which in turn sent to PC through RS-232 for necessary processing. A PLC program is developed based on the signals received from the PLC input module, process the signals and send the output signals to the PLC output modules, which is programmed to actuate the necessary electronic actuator. The SCADA screens are developed regarding four processing stages on PC using Wonderware-Intouch SCADA software. The Allen Bradley micrologix 1000 PLC to be link up with the supporting SCADA Wonderware-Intouch 9.0 by giving necessary tag names. With the help of SCADA, simulation of the physical system is also developed to monitor the quantities to be measured and status of the equipment in the plant from field point.