Bottle Filling Project with Counter Using Delta PLC 🚀

 

Introduction

In today's world of industrial automation, precision and efficiency are key to success. One of the most popular automation projects is the Bottle Filling System, where bottles are filled with a liquid in a fully automated process. In this post, we will explore how to implement a bottle-filling project using a Delta PLC with a built-in counter to track the number of bottles filled. This project is ideal for students learning PLC programming and for small-scale industrial applications. 🌟

---

Project Overview

This bottle-filling project automates the following steps:

1. Start/Stop the System: A button starts the process, and another stops it.
2. Bottle Detection: A sensor detects the presence of a bottle on the conveyor belt.
3. Filling Process: A valve controlled by a timer dispenses liquid into the bottle.
4. Bottle Movement: The conveyor motor moves the bottle forward after filling.
5. Bottle Count: A counter keeps track of how many bottles have been filled.

By the end of this project, you’ll have a clear understanding of how to integrate sensors, timers, counters, and actuators using Delta PLC ladder logic. 🏭

---

Components Required

Here’s what you’ll need to get started:

• Delta PLC (e.g., DVP14SS2 or similar model)
• Sensors (e.g., proximity or photoelectric sensors)
• Solenoid valve for liquid dispensing
• Conveyor motor
• Push buttons for start and stop
• Power supply
• Delta’s WPLSoft programming software

---

Ladder Logic Design

The logic is divided into the following networks:

1. Start/Stop Logic

   • Use a latching circuit to start and stop the system.
   • Example: X0 (Start Button) and X1 (Stop Button).

2. Bottle Detection and Timer

   • When a bottle is detected by the sensor (X2), a timer (T0) activates the valve (Y0) to fill the bottle for a preset time (e.g., 5 seconds).

3. Counter for Filled Bottles

   • After the filling is complete, a counter (C0) increments by 1.

4. Conveyor Movement

   • The conveyor motor (Y1) moves the filled bottle forward to make space for the next one.

---

Ladder Diagram Overview

Below is the ladder logic for the project:

plaintext
Network 1: Start/Stop Logic  
| X0 (Start)   X1 (Stop)     M0 (System ON Latch)       |
| --[ ]--------[/]---------------------(M0)------------ |

Network 2: Bottle Detection and Timer  
| M0 (System ON)   X2 (Bottle Sensor)   T0 (Filling Timer)   Y0 (Valve ON) |
| --[ ]------------[ ]---------------------(T0 K50)------------(Y0)------- |

Network 3: Counter for Bottles Filled  
| T0 (Timer Done)   C0 (Counter) |
| --[T0]---------------(C0)------ |

Network 4: Conveyor Motor Control  
| T0 (Timer Done)   Y1 (Conveyor Motor) |
| --[T0]---------------(Y1)---------- |

Network 5: Counter Reset  
| X3 (Reset Button)   C0 (Reset Counter) |
| --[ ]------------------(R C0)--------- |

---

How It Works

1. Press the Start Button to activate the system.
2. When a bottle is detected by the sensor, the valve opens to fill the bottle for the set duration.
3. After filling, the counter increments, and the conveyor motor moves the bottle forward.
4. The process repeats for the next bottle.
5. Use the Reset Button to clear the counter for a new batch.

---

Conclusion

This bottle-filling project is a great way to learn and apply PLC programming in real-world automation scenarios. Using Delta PLC and WPLSoft, you can create a reliable and scalable solution for small-scale production lines. Whether you’re a student or a budding automation enthusiast, this project is a perfect starting point to dive into the world of industrial automation! 💡