PLC Based Water Filling Station With Bottle Detection

Abstract

This study introduces an automated liquid flling station with advanced bottle detection capabilities, designed to enhance efciency and precision across various industries. The system employs a Programmable Logic Controller (PLC) to govern the entire process, incorporating sophisticated components such as a shaft encoder for precise bottle positioning and AI technology for bottle detection and classifcation. Additionally, an automated bottle capping mechanism is implemented to ensure seamless operation from flling to sealing. Water flling stations are prevalent in industries like beverages, pharmaceuticals, and cosmetics. Traditional systems often rely on solenoid valves for controlling liquid flow, IR sensors for bottle detection, and DC motors for conveyor belt movement. While these methods are functional, they frequently lack the precision and adaptability necessary for high-efciency production lines, leading to issues such as inaccurate flling levels, misaligned bottles, and frequent maintenance needs. To address these challenges, the proposed methodology integrates advanced technologies to refne the flling process. The PLC serves as the central controller, coordinating various components to ensure smooth operation. A shaft encoder accurately measures the distance of bottles on the conveyor belt, ensuring they stop precisely at the flling point. AI-powered camera systems continuously monitor the conveyor, detecting and classifying upright bottles to ensure only correctly positioned bottles are flled. Following the flling process, the system transitions to the capping stage, utilizing a gear motor and CNC guide for precise sealing. The AI system also detects anomalies, such as misaligned or unstable bottles, pausing the system to prevent errors. This approach demonstrates the potential of PLC-based automation in industrial processes, highlighting the benefts of integrating advanced components and AI technology. The system provides a glimpse into the future of efcient and intelligent manufacturing technologies, paving the way for enhanced productivity, reliability, and quality assurance in manufacturing environments. By leveraging these innovations, industries can achieve higher levels of operational efciency and product consistency, thereby meeting the increasing demands of modern production standards.