Liquid Level and Photoelectric Sensors Based Automatic Liquid Mixing and Filling Machine System using PLC

International Journal of Trend in Scientific Research and Development (IJTSRD)
Volume 3 Issue 5, August 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470
@ IJTSRD | Unique Paper ID – IJTSRD27835 | Volume – 3 | Issue – 5 | July - August 2019 Page 1950
Liquid Level and Photoelectric Sensors Based Automatic
Liquid Mixing and Filling Machine System using PLC
Aye Aye Mar1, Hay Man Oo2, Kyawt Kyawt Hlaing1
1Lecturer, Department of Electronic Engineering, Technological University, Monywa, Myanmar
2Lecturer, Department of Electronic Engineering, Technological University, Meiktila, Myanmar
How to cite this paper: Aye Aye Mar|Hay
Man Oo | Kyawt Kyawt Hlaing "Liquid
Level and Photoelectric Sensors Based
Automatic Liquid Mixing and Filling
Machine System using PLC" Published in
International
Journal of Trend in
Scientific Research
and Development
(ijtsrd), ISSN: 2456-
6470, Volume-3 |
Issue-5, August
2019,pp.1950-1954,
https://doi.org/10.31142/ijtsrd27835
Copyright © 2019 by author(s) and
International Journal ofTrend inScientific
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/4.0)
ABSTRACT
Today the application of PLC is more widely used in the digital world. There
are many applications of PLC especially in the industrial. Normally, the PLCs
that have been used at the industrial field are usuallytocontrol themachineor
heavy machine in order to create an efficient production process.Inthis paper,
a discussion about PLC application will be explained in more details and
specified. A machine that uses to prepare automatic liquid mixing and filling
machine system is controlled by Delta PLC which is also the heart of the entire
system. The DVP-14SS2 from the Delta PLC types is used and WPL soft is used
to write the ladder logic. The PLC can control many other electronic devices
such as pump motor, level sensors, photoelectric sensor, conveyor belt, gear
motor, solenoid valve, push buttons, relays and other devices.Themainaimof
the paper is to develop and test the real time implementation of PLC based
liquid mixing and filling machine system. Firstly, start button is pushed. The
liquids (juice and water) are mixed in the mixer tank by usingvalves.Thelevel
sensors know limited liquid levels and mixer motor starts stirring. The mixer
motor is ON by timer. When the stirring process stops,the conveyorbelt starts
moving. When the cup passes photoelectric sensor, conveyor belt stops and
then the pump motor fills the liquid mixture in the cup by timer. Whenthecup
completes filling process, the pump motor closes and conveyor belt runs
continuously. When another cup passes the photoelectric sensor, conveyor
belt stops. Filling process operates again and again.
KEYWORDS: Delta PLC, Level sensors, Photoelectric sensor, Valves, Mixer motor,
Conveyor belt, Pump motor, Relay
I. INTRODUCTION
Automation is used for all control systems and
Programmable Logic Controller (PLC) technologies areused
to reduce the human work and helps in increasing the
production. By using PLC,therearemanyadvantages suchas
safety cost and reducing space as software devices are used
instead of hardware devices, easily repairing errors byusing
computer, quicklyand exactly operatingactivities,increasing
efficient production and reducing human efforts. The PLC
plays an important role in the world of automation industry.
The mixing operation is based on the user defined volume
through which user can choose the volume of liquid to be
mixed. Two liquid level sensors which are placed beside the
mixer tank are used to sense the liquid level placed under
the mixer motor and the corresponding mixer motor is
switched on to mix the juice and water inthemixertank.The
filling operation is basedontheuserdefinedvolumethrough
which user can choose the volume of liquid to be filled. A
photoelectric sensor which is placed in the conveyor,isused
to sense the cup placed under the pump motor and the
corresponding pump motor is switched on to fill the cup.
This paper is based on that two liquids are mixed and filled
into the cup using PLC automatically. In earlier days, when
the two liquids are mixed and filled by humans, these two
liquids are not mixed and filled in equal proportion.So,there
is no precision of work. By using PLC, two liquids are mixed
and filled in equal proportion and well quantity. This avoids
wastage of liquids and reduces human efforts. Todays,
automatic liquid mixing and filling machine is used in the
industrial fields.
II. System Block Diagram
To solve the problem, this liquid level and photoelectric
sensors based automatic mixing and filling using
Programmable Logic Controller(PLC) system is very
convenient. The system for this paper is constructed with
liquid level and photoelectric sensors for the input section
and valves, mixer motor, conveyor motor and pump motor
for the liquid mixing and filling machine system. The input
section involves level sensors and photoelectric sensor. The
24V DC power supports to the PLC and 12V DC power
supports to the pump motor.
230 VAC
50HZ
Delta
PLC
( Programmable
Logic
Controller)
Relay
Relay
Relay
Relay
Relay
Mixer
motor
Valve 2
Conveyor
motor
Pump
motor
Valve 1
AC supply voltage
Photoelectric Sensor
Lower level sensor
Stop button
Start button
Upper level sensor
SMPS
24V DC
Fig1: Overall Block Diagram of the System
IJTSRD27835

International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
When the start button is pressed, the power supply is
applied to the PLC. The PLC commands the whole system by
the program. Relays are used as driversorswitchtoproduce
desired outputs. The liquids (juice and water) are mixed ina
mixer tank by using valves.Then,Level sensors knowlimited
liquid levels and mixer motor starts to stir. When mixer
motor stops, conveyor motor starts to run and the desired
cup put in a sequence on it. When the cup passes the
photoelectric sensor, the conveyor beltstops andthenpump
motor fills the mixing liquid in the cup. When the cup
completes filling process, the pump motor is closed and the
conveyor belt continuously runs and carries the cup away
from photoelectric sensor. When another cup passes the
photoelectric sensor, then the above process is repeated.
Fig.1 shows the overall block diagram of the system.
Fig2: Overall System Flowchart
The flowchart shown in Fig.2 is for the operation of the
system. In this system, the programmable logic controller
(PLC) is used as the control system consists of
Step 1: Start
Step 2: Valve 1 is ON and fill the juice into the mixer tank.
Step 3: Check lower level sensor. If the juice level is specified
lower level sensor, Valve 1 is OFF and Valve 2 is ON. Then fill
the water into mixer tank.
Step 4: Check upper level sensor. If liquid level is specified
upper level sensor, Valve 2 is OFF and mixer motor is ON for
timer 8s.Then mixer motor is OFF and conveyor motoris ON.
Step 5: Check photoelectric sensor. If the cup passes
photoelectric sensor, the conveyor motor is OFF and pump
motor is ON. The mixing liquid fills into the cup by four
seconds.
Step 7: Stop.
III. Hardware Implementation
The circuit is constructed with three main sections. The first
section is two liquid level and photoelectric sensors which
are the input section. In the second section, there is DC
motors (gear, mixer), pump motor and valves (1, 2) which
are the output section. And the last one is Delta PLC (DVP
14SS11R2). Startbutton(X0),stopbutton(X1),photoelectric
sensor (X2), lower level sensor (X3) and upper level sensor
(X4) are connected with PLC as input devices. Conveyor
motor (Y0), mixer motor (Y1), pumpmotor(Y2),valve1(Y5)
and valve 2(Y4) are connected with PLC as output devices.
Fig3: Overall Circuit Diagram of the System
For conveyor motor and mixer motor, 24 V (SMPS) is used.
For pump motor, 12 V power supply is used. The
lower/upper level sensors are connected to X3 and X4 of the
PLC respectively for the two different liquid are mixed in
equal proportion. The photoelectric sensor is connected to
X2 of PLC for cup filling. The DC motors (gear, mixer),
submersible pump motor and solenoid valves (1,2) areused
for liquid mixing and cup filling in this operation. Relays are
used as driver or switches to produce desired voltage. And
then, the whole system is based on ladder diagram language
software to operate the hardware structure. The ladder
diagram language for the liquid mixing and filling system is
based on ladder diagram language software(WPLsoft2.41).
When the start button (X0) is pressed, the relay 5 is switched

on and the other relays are switched off. The output of relay
5 is connected to valve 1. And the juice flows in the mixer
tank. When juice in the mixer tank passes the lower level
sensor, the signal is reached to Delta PLC and the relay 5 is
switched off. The output of relay 4 is connected to valve 2.
During the relay 4 is switched on, the other relays are
switched off. When the relay 4 is switched on, the water
flows in the mixer tank. When the water in the mixer tank
passes the upper level sensor (X4), the signal is reached to
Delta PLC and the relay 4 is switched off. And then the mixer
motor starts to stir. The output of relay 2 is connected to
mixer motor (Y1). During the relay 2 is switched on, the
other relays are switched off. After Stirring time (8s), the
relay 2 is switched off and conveyor motor (Y0) which is
connected to the output of relay 1 starts to run immediately.
At that time, the empty cup is placed on the running
conveyor belt. When empty cup passes the photoelectric
sensor (X2), the signal is reached to Delta PLC andtherelay 3
is switched on and other relays are switched off. The output
of relay 3 is connected to pump motor. Pump motor (Y2)
starts to fill liquid mixture into the empty cup with timer
function. For filling process, the timer is limited by four
seconds. When the liquid mixture is filled intotheemptycup
according to timer (4s), the relay 3 is switched off. Again the
conveyor belt is running continuously, until the second cup
passes photoelectric sensor. This system continuously runs
until the stop button (X1) is pressed.
IV. Results
Simulation Result for level sensors
The ladder programming language for lower level sensor is
very simple. When X0(start button) is firstly pressed, S10
set. Difference of reset and zone-reset is: normal reset (RST)
operates only one network, zone-reset (ZRST) operates the
whole network group (example; S10, S20, as useas).Assoon
as, start point operates next step, the previous step
automatically stops. When S10 set, M0 (tank-1 valve) starts.
While M0 (tank-1 valve) is operating, X3(liquidlevelsensor-
1) starts to detect. After X3 (lower level sensor-1) is
detected, S11 set and M1 (tank-2 valve) starts to operate.
Fig 4: Simulation of Lower Level Sensor
(level sensor 1)
Simulation of lower level sensor is shown in Fig.4. While M1
(tank-2 valve) is operating, X4 (upper level sensor-2) detect.
After detecting, S12 set and M2 (mixer motor) starts to stir.
Fig.5 shows the simulation of upper level sensor.
Fig 5: Simulation of Upper Level Sensor
(level sensor 2)
Simulation Result for Motors
The Ladder programminglanguageis writtenas thesimplest
form so that it is nothing to have any problemtounderstand.
Stirring time (T0) limits mixing time of two different liquids
for eight seconds. After mixing time is finished, S13 set and
M3 (conveyor motor) starts to run. Fig.6 shows the
simulation of mixer flag.
Fig 6: Simulation of Mixer Flag
While M3 (conveyor motor) is running, X2 (photoelectric
sensor) senses. Rising up is used for photoelectric sensor to
sense only one cup-one time. As X2 (photoelectric sensor)
senses the cup, M3 (conveyor motor) stops. Fig.7 shows the
simulation of conveyor motor flag.
Fig7: Simulation of Conveyor Motor Flag
And then, S14 set and M4 (fill motor) starts to fill.Fillingtimer
(T1) limits filling time of liquid mixture into the cup for four
seconds.
Fig 8: Simulation of Pump Motor Flag and Return
After filling time is finished, S15 set and S13 set back to run
M3(conveyor motor). Fig.8 shows the simulation of pump
motor and return. Always connect RET instruction
immediately after the last step point indicated as the above
diagram otherwise program error may occur.
Fig 8: Simulation of Pump Motor Flag and Return
Hardware Results
The operation is constructed with two liquid level sensors
and the photoelectric sensor. The two liquid level sensors
are placed beside the mixer tank and the photoelectric
sensor is placed in the middle of the conveyor belt. But the
lower/upper level sensors are connected to X3 and X4 of the
PLC respectively for mixing the two different liquids in equal
proportion. The photoelectric sensor is connected to X3 of
PLC for bottle filling. The DC motors (gear, mixer), pump
motor and solenoid valves (1,2) are used for liquid mixing

and filling in this operation. These are connectedtoY0,Y1,Y2,
Y5, and Y4 of the PLC respectively. When the start button is
pressed, the solenoid valve-1 is opened to fill the juice into
the mixer tank. Solenoid valves (flow control valves) are
connected to the liquid tanks. These valves are
electromagnetic plunger valves which control flow rate of
liquid. Level sensors are placed beside the mixertank. When
the juice in the mixer tank passes the lower level sensor,
liquid level sensor-1 senses it and the solenoid valve-1 is
closed.
Fig 9: Result for Solenoid valve-1
And then solenoid valve-2 is opened to fill the water into the
mixer tank. If the liquid in the mixer tank passes the upper
level sensor, the liquid level sensor-2 senses it and then, this
valve-2 is closed. DC motors were used to stir the juice and
water, to move conveyor forward and to fill the liquid
mixture into empty cup.
Fig 10: Result for Lower Level Sensor and Solenoid
valve-2
As soon as valve-2 has closed, the mixer motor starts to stir
the juice and water in the mixer tank. Mixer motor stirs the
juice and water in the mixer tank by eight seconds.
Fig 11: Result for Upper Level Sensor and Mixer Motor
After stirring process, the conveyor belt which is connected
to gear motor start to run immediately. At that time, the
empty cup is placed on the running conveyor belt. The
photoelectric sensor is placed in the middle of the conveyor.
The reflection with reflector type of the photoelectric sensor
is used. It detects an object by using light. When empty cup
passes the photoelectric sensor, it is sensed by sensor.
Fig12: Result for Photoelectric Sensor and Pump
Motor
And then, conveyor belt (motor-2) is stop. Pump motor
(motor-3) starts to fill liquid mixture into the empty cup
with timer function. For filling process, timer (T2) is limited
by four seconds. When mixed liquid is filled into the empty
cup according to timer (T2), the conveyor run continuously.
Second cup is sensed by photoelectric sensor and conveyor
motor stop. Filling process operates again and again. In this
way, this process continuouslyruntill stopbuttonis pressed.
Fig.13 shows the overall result of automatic liquid mixing
and filling machine system.
Fig13: Result for Overview of Liquid Mixing and Filling
Machine System
V. Conclusion
The PLC is used in this system to get more productivity with
less time, high reliability and flexible in work. The ladder
diagram language using totally integratedautomationportal
software (WPL soft 2.41) is used in this paper because this
language is very useful to run all types of industrial
applications and has a lot of functions so that most of the

industrial application uses this language. This system also
use very low power consumption because PLC only use
24VDC to operate their input and output device. The cost of
installation is not cheap but it can efficiently run for a long
period of time. This automation system is used to reduce
workers and help in increasing the mass production.
VI. REFERENCES
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Controllers” (Aug21, 2018), https://
Library.automationdirect.com>plc.
[2] Shaukat N., “PLC Based Automatic Liquid Filling
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[3] Multi Topic Conference, 2002.
[4] Positite. M. “Omron Beginner’s guide to PLC",
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[5] Nabil Shaukat, “A PLC Based Automatic Liquid Filling
Process”, IEEE, publication page No. 226-233, 2002.
[6] Xi Chen, YanboChe, K.W.E Cheng, “PLC and
Configuration Software BasedSupervisoryand Control
System for Oil Tanks Area”, Digital Reference:
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[7] Smith, C L “Process Control for the process Industries-
Part 2: Steady State Characteristics”. March 2017
[8] Carlos Gonzalez, “Machine Design Engineering
Essentials: What is a ProgrammableLogiccontroller?”,
June 01,2015
[9] DipaliChaudhari, Topmost 12 “Different PLC software
Brands used around the world”, August 10 , 2018
[10] Jacob Fraden, “Handbook of modern sensors” – KELM
(1993) www.kelm.ftn.uns.ac.rs>lite ratura.pdf
[11] KELLER,“OEM Pressure Measurement
Instrumentation” (Oct 1, 2000)
www.wolfautomation.com>pdf>takex.
[12] Balluff, “Photoelectric SensorHandbook”(Sep19,2016)
https:// www.machine design.com>sensors.
[13] Philip L. Skousen“ Valve Handbook” (1997)
[14] Bob. Flesher “Relays Handbook”.(1997)
[15] Billd700, “Different types of motors and their use”
(May 5, 2016). https:// www.rs-
online.com>designspark.
[16] Sbasish Ghosh, “Synchronous Motor Working
Principle” (Jul 7,2013) https:// www.electrical 4u.com
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