1. Control System Design and Implementation of Automatic down Filling Machine Based on ace PLC
NAME OF THE SUPERVISOR NAME OF THE STUDENT 
Mr.T.Senthilrajan,M.E (PhD) K.MuthuKumar ( )
Associate professor of ICE M.Muneeswaran ( )
K.Vinoth ( )
INSTRUMENTATION AND CONTROL ENGINEERING
SETHU INSTITUTE OF TECHNOLOGY
Pulloor, Kariapatti
Virudhunagar District.

2. CONTENTS INTRODUCTION SYSTEM MODEL BLOCK DIAGRAM HARDWARE DESCRIPTION
ACE PLC
NEED FOR THIS PROJECT
EXISTING METHOD
PROPOSED METHOD
SYSTEM MODEL
BLOCK DIAGRAM
BOTTLE DETECTION
FILLING OPERATION
HARDWARE DESCRIPTION
POWER SUPPLY
RELAY
SOLENOID VALVE
DC MOTOR
SOFTWARE DESCRIPTION
DEVELOPING PROGRAMS WITH VELOCIO BULIDER
TYPES OF TOOLS
RESULT ANALYSIS
PROJECT INFERENCE
ADVANTAGES
CONCLUSION
HARDWARE SNAPSHOTS
FUTURE WORKS

3. INTRODUCTION

4. ACE PLC
The Ace is the small, standalone member of the Velocio family.
It brings incredible power, in a very small package and at a very low price.
Many control system applications require 36 points of I/O or less, all located very close to the PLC .
Ace PLCs are programmable, using Velocio’svBuilder software.
The Ace connects to a PC using a standard USB communications cable.
Through this USB cable, the Ace PLC can be programmed, debugged and deployed.
NEED FOR THE PROJECT 
Fast performance compares ordinary PLC.
Obtain accuracy result using ACE PLC.
It can debug the majority of issues attaching your real system.

5. EXISTING METHOD
In this project previous method to existing using PLC with automatic water filling system.
There using PLC economically high in industrial packing system
Any change in programming is modifying difficult method in PLC.
PROPOSED METHOD
In this project we have implemented ACE PLC concept using bottle filling system
ACE PLC is like a microcontroller chip and easy reprogramming and erasable.
Space will be requires less and easily removable whole kit.

6. SYSTEM MODEL

7. ACE PLC BLOCK DIAGRAM SMPS PS O/P CONTROL VALVE IR1 IR2 SV1 IR3 SV2
PS PUSH SWITCH
SMPS - SWITCHED MODE POWER SUPPLY,
IR1, IR2, IR3 - INFRARED RADIATION SENSORS,
SV1, SV2 - SOLENOID VALVES.
SMPS PS
ACE PLC
O/P CONTROL VALVE
IR1
IR2
SV1
IR3
SV2
MONITORING UNIT

8. BOTTLE DETECTION USING SENSOR
Bottles are kept in position in their respective holders which are fixed to the conveyor at the input side.
IR sensors are used to detect the presence of bottles in the holder.
Depending on the output of the sensors the filling
. A time delay is given in order to set the status of the bottles.
If bottle 1 is present the corresponding status bit in PLC is set to 1 else it is set to 0.
FILLING OPERATION
Once the bottles are detected in the input side the conveyor motor switches ON and it starts moving in the forward direction.
The bottles then reach the desired position for filling and the conveyor stops.
The corresponding pumps in process tank switch ON and filling operation takes place.
For e.g. if only bottle 1 is present then pump 1 switches ON and pump 2 and pump 3 remain switched OFF.

9. HARDWARE
DESCRIPTION

10. POWER SUPPLY
Here Used Different Types Of Power Supply Used In This System.
ACE PLC amp And 12V transformer
Relay And IR Sensors amp And 12V transformer
Motor And Solenoid Valve amp And 24 V transformer
All they power supply used properly handled with IC regulator device.
RELAY
A relay is an electrically operated switch.
Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts.
The coil current can be on or off so relay have two switch positions and they are double throw (changeover) switches

11. The relay's switch connections are usually labeled COM, NC and NO:
The relay's switch connections are usually labeled COM, NC and NO: COM = Common, always connect to this, it is the moving part of the switch. NC = Normally Closed, COM is connected to this when the relay coil is off. NO = Normally Open, COM is connected to this when the relay coil is on. DC MOTOR: we are used to help us conveyor rotate by an dc high torque motor. They required 3amps and 24v power supply and 1200rpm

12. SOLENOID VALVE
A solenoid is an electrical device that converts electrical energy into straight line motion and force.
These are also used to operate a mechanical operation which in turn operates the valve mechanism.
Solenoid is one is which the plunger is pulled when the solenoid is energized.
SOLINOID VALVE (OR) CUT OFF VALVE
The control valve is used to control the flow direction is called cut off valve or solenoid valve.
This solenoid cutoff valve is controlled by the electronic control unit.
In our project separate solenoid valve is used for flow direction of vice cylinder.
It is used to flow the air from compressor to the single acting cylinder

13. SOFTWARE DESCRIPTION

14. DEVELOPING PROGRAMMING WITH VELOCIO BUILDER.
Velocio Builder is by far, the most advanced, most powerful, intuitive, easy to use and flexible graphical program development package in the automation market.
It is very easy to learn and use, yet provides the power to accomplish complex program op­erations easily.
With the introduction of Velocio Builder (vBuilder), PLC software technology has taken a generational leap.
Some of the major features incorporated into vBuilder are listed below.
Ladder Logic programming
Flow Chart programming
True Subroutines
Object oriented graphical programming
Reusable program objects
Embedded Objects

15. TYPES OF TOOLS:
DECISION BLOCKS
decision blocks make a decision whether something is true or not.
If it is true, the program flow will follow one branch. If it is false, it will follow another.
the decision blocks are all near the top of the toolbox, below the Wire Router and above the Turn On/off tool.
PROCESS BLOCKS
Process blocks do something.
That something can be to turn something on or off, perform a calculation, count, and filter, control a stepper motor, PID, etc.
The Process blocks begin with Turn On/Off and end with Timer.

18. RESULT ANALYSIS

19. PROJECT INFERENCE
They using of ACE PLC tools such as wiring connection is a less compared to ordinary PLC.
Then this type of ACE PLC is allocated less amount of space and size very small .
First step when we ON the switch then motor will be on.
Bottles are kept over a conveyor belt which will be attached with the motor.
When the bottles sensed by IR sensor conveyor will be stopped and solenoid valve will be open to filling the bottle is depending upon on timer and then filling conveyor moved them by motor ON.
They process will be repeatedly filling the continuous process time.
ADVANTAGES
One of the major advantages is voltage consumption very low compared to ordinary PLC. here used 5V
Greatly enhanced and efficient development process.
Can be design flow chart program

20. CONCLUSION
The main objective of this project was to develop a bottle filling specifications. This was successfully implemented. We consider this project as a journey where we acquired knowledge and also gained some insights into the subject which we have shared in this report. A lot of additional features like user defined volume specification etc. were added in the different stages in our work and the desired results were obtained. ACE PLC was used to control the various operations was done. More features can be added to this system as follows: depending on the size, shape and weight of the bottles, filling operations can be implemented.

21. HARDWARE SNAPSHOT

22. FUTURE WORK
This system is very useful for future with the help of this system: more features can be added to this system as follows: depending on the size, shape and weight of the bottles. Filling operations can be implemented. Capping operation can also be implemented. This concept can be used in food industries, paint mixing industries, chemical industries, and milk industries. Medicine industries, mineral water industries, product industries and manufacturing industries.

23. Thank you