R.D. Engineering College,: Department of Mechanical Engineering

MANUFACTURING OF BOTTLE FILLING MACHINE
With
(CONVEYOR BELT AND AUDRINO)
A PROJECT REPORT
In partial fulfillment for the award of the degree of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
Under the Guidance of

MR. SUSHIL KUMAR
Submitted by
AAKASH KUMAR SHARMA
Roll No. 1623140004
DEPARTMENT OF MECHANICAL ENGINEERING

R.D. ENGINEERING COLLEGE,
DELHI-MEERUT ROAD, DUHAI, GHAZIABAD UP-201206
AFFILIATED TO AKTU, LUCKNOW
August, 2021
i
CERTIFICATE
Certified that the dissertation Report entitled “MANUFACTURING OF BOTTLE

FILLING MACHINE is being submitted by AAKASH KUMAR SHARMA (Roll No.)
1623140004 in partial fulfillment for the award of the degree of B.Tech in Mechanical
Engineering in A.K.T.U. Lucknow, under my supervision and guidance during the academic
session 2020-21.
Mr. Sushil Kumar Dr. Sanjay Paliwal

(Project Guide) (H.O.D.)
Department of Mechanical Engineering

R.D. ENGINEERING COLLEGE GHAZIABAD
Affiliated to AKTU, Lucknow
ii
DECLARATION
I AAKASH KUMAR SHARMA (Roll No.) 1623140004 of B.Tech Mechanical Engineering

branch hereby declare that work done by me on the topic “MANUFACTURING OF
BOTTLE FILLING MACHINE” as project, under the guidance of SUSHIL KUMAR is
an indigenous piece of work.
AAKASH KUMAR SHARMA

Roll No. 1623140004
Department of Mechanical Engineering

R.D. ENGINEERING COLLEGE GHAZIABAD
Affiliated to AKTU, Lucknow
iii
ABSTRACT
This project is aimed at automating the sorting and bottle filling. This project will
automatically sort bottle according to their size by using IR sensors. Then it sorts the bottle
on the designated portion of conveyor belt and passes it to the Solenoid Operated Valves to
fill the bottles. The overall system is liberated from human intervention. The system is
comprehensive and efficient, thus can help in automating the sorting and bottle filling.
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TABLE OF CONTENTS
CERTIFICATE ii
DECLARATION iii
ABSTRACT iv
CHAPTER 1: INTRODUCTION 1-2
1.1 Introduction
1.2 Objectives
1.3 Description
CHAPTER 2: LITERATURE REVIEW 3-6

2.1 History
2.2 Conveyor belt
2.3 Sorting
2.4 Bottle filling
CHAPTER 3: MECHANICAL COMPONENTS 7-9
3.1 Bearing
3.2 Wooden shaft
3.3 Wooden rollers
3.4 Pulley
CHAPTER 4: ELECTRICAL COMPONENTS 10-15

4.1 Induction motor
4.1.1 Principle
4.1.2 Operation
4.1.3 Synchronous speed
4.1.4 Slip
4.2 Solenoid operated valve
4.3 Brushless Dc motor
4.3.1 Advantages
4.3.2 Disadvantages
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CHAPTER 5: ELECTRONIC COMPONENTS 16-22
5.4 Microcontroller 89C51
5.5 LCD (20x4)
5.6 ULN 2003MCT 2e
5.7 Relay
5.8 IR sensor
5.9 Resistor
5.10 Capacitor
CHAPTER 6: STRUCTURE OF PROJECT 23
6.1 Dimensions of conveyor belt
6.2 Dimensions of Wooden Roller
6.3 Diameter of pulley
6.4 Diameter of bearings
6.5 Dimension of shaft
6.6 Dimension of structure
6.7 Types of wood
CHAPTER 7: IMPLEMENTATION AND CONTROL 24-28
7.1 Circuit diagram
7.1.1 Simulated circuit diagram
7.1.2 Working of circuit
CHAPTER :8 APPLICATIONS AND ADVANTAGES 29-32
8.1 Application of sorting through conveyor belt
8.1.1 Advantages
8.1.2 Applications of liquid filling
CHAPTER 9: CONCLUSION AND FUTURE WORK 33
9.1 Conclusion
REFERENCE 34
GLOSSARY 35
APPENDIX 36-47
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LIST OF FIGURES
Figure 1.1 Automatic sorting and bottle filling machine 1
Figure 2.1 Conveyor belt 4
Figure 2.2 Sorting 5
Figure 2.3 Bottle filling 6
Figure 3.1 Bearing 7
Figure 3.2 Wooden roller 8
Figure 3.4 Pulley 9
Figure 4.1 Induction motor 10
Figure 4.2 Solenoid valve 13
Figure 4.3 Brushless Dc motor 14
Figure 5.1 microcontroller 16
Figure 5.2 LCD 20x4 17
Figure 5.3 ULN 2003 logic diagram 18
Figure 5.4 MCT 2e 19
Figure 5.5 Relay 19
Figure 7.1 Measurement system 25
Figure 7.2 Feedback system 25
Figure 7.3 Circuit diagram 26
Figure 7.3.1 Circuit diagram of project 27
Figure 7.3.2 Simulated circuit diagram 27
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CHAPTER 1
INTRODUCTION
1.1 Introduction
Industrial Automation plays an increasingly important part in the global economy and also in
daily experience. At present, for companies, the purpose of automation has shifted from
growing productivity and reducing costs to broader issues. This work takes the idea of
automatic sorting and bottle filling. The control system uses microcontroller. Sorting of
bottles is done on the conveyer belt via IR sensors and then these bottles are filled by
actuating the solenoid valves. The conveyors are used in many automated industries for
moving parts from one place to another. The second concern is the bottle filling. Once the
bottle is sorted, conveyer belt transfers it under the water tank for filling.
Figure 1.1 automatic sorting and bottle filling machine
1
1.2 Objectives
The main objectives of our project are:
 Sorting of bottles on the basis of their respective sizes
 Filling of bottles using SOV
1.3 Description
In automated factories production rate is very high, so sorting and filling of bottles need to
run at fast speed. To separate the bottle on the basis of their sizes, shapes or height sorting
system is applied.
After that these bottles are filled up to some specific level. For that purpose bottle filling
system is required. This type of system provide following benefits:
1. Stability and safety
2. Easy to operate and maintain
3. Factory price
4. Low running cost
In order to automate a process we need a control system .The control system is implemented
through some physical device, it is usually based on mathematical logic to get desired result.
We have used AT89C51 to implement the control in our project.
2
CHAPTER 2
LITERATURE REVIEW
2.1 History
Conveyor belts were used since the 19th century. In 1892, Thomas Robins began a series of
inventions which led to the development of a conveyor belt used for carrying coal, ores and
other products. In 1901, Sandvik invented and started the production of steel
conveyor belts. In 1905 Richard Sutcliffe invented the first conveyor belts for use in coal
mines which revolutionized the mining industry.
In 1913, Henry Ford introduced conveyor-belt assembly lines at Ford Motor Company's
Highland Park, Michigan factory. In 1972, the French society REI created in New Caledonia
the then longest straight-belt conveyor in the world , at a length of 13.8 km. Hyacynthe
Marcel Bocchetti was the concept designer. In 1957, the B. F. Goodrich Company patented a
conveyor belt that it went on to produce as the Turnover Conveyor Belt System.
Incorporating a half-twist, it had the advantage over conventional belts of a longer life
because it could expose all of its surface area to wear and tear. Mobius strip belts are no
longer manufactured because untwisted modern belts can be made more durable by
constructing them from several layers of different materials.
In 1963-64, First Indian Small Scale Industrial Unit with Japanese Plant for Rubber Belts for
Conveyor / Elevator / Transmission was installed near National Capital Territory of Delhi
and its Mr Belts Conveyor Belting has been widely used in Steel, Cement, Fertilizer,
Thermal Power, Sponge Iron Plants and Coal / Mineral establishments / Mines, Port Trusts
and similar material handling applications of Industry for the last over four decades;
3
2.2 Conveyor Belt
A conveyor belt (or belt conveyor) consists of two or more pulleys, with a continuous loop of
material - the conveyor belt - that rotates about them. One or both of the pulleys are powered,
moving the belt and the material on the belt forward. The powered pulley is called the drive
pulley while the unpowered pulley is called the idler. There are two main industrial classes of
belt conveyors; Those in general material handling such as those moving boxes along inside
a factory and bulk material handling such as those used to transport industrial and
agricultural materials, such as grain, coal, ores, etc. generally in outdoor locations. Generally
companies providing general material handling type belt conveyors do not provide the
conveyors for bulk material handling. In addition there are a number of commercial
applications of belt conveyors such as those in grocery stores.
The belt consists of one or more layers of material. They can be made out of rubber. Many
belts in general material handling have two layers. An under layer of material to provide
linear strength and shape called a carcass and an over layer called the cover. The carcass is
often a cotton or plastic web or mesh. The cover is often various rubber or plastic compounds
specified by use of the belt. Covers can be made from more exotic materials for unusual
applications such as silicone for heat or gum rubber when traction is essential.
Figure 2.1 Conveyor
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2.3 Sorting
Sorting is any process of arranging items in some sequence and/or in different sets, and
accordingly, it has two common, yet distinct meanings:
1. ordering: arranging items of the same kind, class, nature, etc. in some ordered
sequence,
2. categorizing: grouping and labeling items with similar properties together (by sorts)
Various sorting tasks are essential in industrial processes. For example, during the extraction
of gold from ore, a device called a shaker table uses gravity, vibration, and flow to separate
gold from lighter materials in the ore (sorting by size and weight). Sorting is also a
naturally occurring process that results in the concentration of ore or sediment.
Fig 2.2: Sorting
Sorting results from the application of some criterion or differential stressor to a mass to separate it
into its components based on some variable quality. Materials that are different, but only slightly so
such as the isotopes of uranium, are very difficult to separate.
5
Bottle filling:
The second part of this project is to design a microcontroller based
automatic bottle filling system. When the IR sensor detects the bottle the
conveyor belt stops at the moment. At the same time signal from the
microcontroller actuates the solenoid valve, and the filling starts. The time
required to raise the bottle few seconds,
Figure 2.3: Bottle filling
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CHAPTER 3
MECHANICAL COMPONENTS
3.1 Bearings
A bearing is any of various machine elements that constrain the relative motion between two
or more parts to only the desired type of motion. This is typically to allow and promote free
rotation around fixes axis or free linear movement; it may also be to prevent any
motion, such as by controlling the vectors of normal forces. Bearings may be classified
broadly according to the motions they allow and according to their principle of operation, as
well as by the directions of applied loads they can handle.
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. It achieves this by using at least two races to contain the balls
and transmit the loads through the balls. In most applications, one race is stationary and the
other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races
rotates it causes the balls to rotate as well. Because the balls are rolling they have a much
lower coefficient of friction than if two flat surfaces were sliding against each other.
Figure 3.1: Bearings
7
Ball bearings tend to have lower load capacity for their size than other kinds of rolling-
element bearings due to the smaller contact area between the balls and races. However, they
can tolerate some misalignment of the inner and outer races.
3.2 Wooden rollers
We used two wooden rollers in our project, clamped on the structure. They allow conveyor
belt to roll on, by providing sufficient amount of friction between the surface contacts. There
are two shafts at both end of the rollers. The diameter of the rollers is 4.5 inch each.
Figure 3.2: Wooden roller
3.3 Wooden shaft
There are two shafts at the ends of each roller. Out of four shaft one shaft is connected to the
motor via pulley. The motor rotates the shaft and hence conveyor belt starts moving. The
diameter of each shaft is 2 inch.
3.4 Pulley
A pulley is a wheel on an axle that is designed to support movement of a cable or belt along
its circumference. Pulleys are used in a variety of ways to lift loads, apply forces, and to
transmit power. A pulley is also called a sheave or a drum and may have a groove
between two flanges around its circumference. The drive element of a pulley system can be a
8
rope, cable, belt, or chain that runs over the pulley inside the groove.
Hero of Alexandria identified the pulley as one of six simple machines used to lift weights.
Pulleys are assembled to form a block and tackle in order to provide mechanical advantage to
apply large forces. Pulleys are also assembled as part of belt and chain drives in order to
transmit power from one rotating shaft to another.
Figure 3.4 Pulley
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CHAPTER 4
ELECTRICAL COMPONENTS
4.1 Induction Motor
An induction or asynchronous motor is a type of AC motor where power is supplied to the
rotor by means of electromagnetic induction, rather than a commutator or slip rings as in
other types of motor. These motors are widely used in industrial drives. The induction motor
in our project is used to drive the rollers and conveyor belt. The motor converts electrical
energy into mechanical energy.
Figure 4.1 Induction motor
4.1.1 Principle
Induction principle, in other words it depends on Faraday's law of induction (i.e. when a
conductor moves in a magnetic field, it gets some voltage (induced voltage)
4.1.2 Operation
In both induction and synchronous motors, the stator is powered with alternating current
(poly phase current in large machines) and designed to create a rotating magnetic field
10
which rotates in time with the AC oscillations. In a synchronous motor, the rotor turns at the
same rate as the stator field. By contrast, in an induction motor the rotor rotates at a slower
speed than the stator field. Therefore the magnetic field through the rotor is changing
(rotating). The rotor has windings in the form of closed loops of wire. The rotating magnetic
flux induces currents in the windings of the rotor as in a transformer. These currents in turn
create magnetic fields in the rotor, that interact with (push against) the stator field. Due to
Lenz's law, the direction of the magnetic field created will be such as to oppose the change in
current through the windings. The
cause of induced current in the rotor is the rotating stator magnetic field, so to oppose this
the rotor will start to rotate in the direction of the rotating stator magnetic field to make the
relative speed between rotor and rotating stator magnetic field zero.
For these currents to be induced, the speed of the physical rotor must be lower than that of
the stator's rotating magnetic field (ns ), or the induced. As the speed of the rotor drops below
synchronous speed, the rotation rate of the magnetic field in the rotor increases, inducing
more current in the windings and creating more torque. The ratio between the rotation rate of
the magnetic field as seen by the rotor (slip speed) and the rotation rate of the stator's rotating
field is called "slip". Under load, the speed drops and the slip increases enough to create
sufficient torque to turn the load. For this reason, induction motors are sometimes referred to
as asynchronous motors.
4.1.3 Synchronous speed
The synchronous speed of an AC motor is the rotation rate of the rotating magnetic
field created by the stator. It is always an integer fraction of the supply frequency.
The synchronous speed ns in revolutions per minute (RPM) is given by:
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Where, f is the frequency of the AC supply current in Hz and p is the number of Magnetic
pole pairs per phase. When using total number of poles, use 120 as constant instead of 60. For
example, a small 3-phase motor typically has six magnetic poles organized as three opposing
pairs 120° apart, each powered by one phase of the supply current. So there is one pair of
poles per phase, which means p = 1, and for a line frequency of 50 Hz the synchronous speed
is 3000 RPM.
4.1.4 Slip
Slip s is the rotation rate of the magnetic field, relative to the rotor, divided by the absolute
rotation rate of the stator magnetic field
Where is the rotor rotation speed in rpm. It is zero at synchronous speed and 1 (100%) when
the rotor is stationary. The slip determines the motor's torque. Since the short-circuited rotor
windings have small resistance, a small slip induces a large current in the rotor and produces
large torque. At full rated load, typical values of slip are 4-6% for small motors and 1.5-2%
for large motors, so induction motors have good speed regulation and are considered
constant-speed motors.
4.2 Solenoid operated valve
A solenoid valve is an electromechanically operated valve. The valve is controlled by an
electric current through a solenoid: A solenoid valve has two main parts: the solenoid and the
valve. The solenoid converts electrical energy into mechanical energy which, in turn, opens
or closes the valve mechanically.
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Figure 4.2: Solenoid valve
4.3 Brushless DC motor
Brushless DC motors (BLDC motors, BL motors) also known as electronically commutated
motors (ECMs, EC motors) are synchronous motors which are powered by a DC electric
source via an integrated inverter, which produces an AC electric signal to drive the motor;
additional sensors and electronics control the inverter output. A brushless DC motor is electric
engine where the stator is a classic 3 phase stator and the rotor has surface mounted
permanent magnets. It is equivalent to a reversed DC commutator motor, in which the magnet
rotates while the conductors remain stationary.
BLDC motor has no commutator and brushes, it requires electronic control for operation.
They often have external position sensors used by control unit, but sensorless control is also
possible.
BLDC motors are really AC motors, it is the controller implementation that makes them DC.
Most BLDC motors are 3 phase motors, so they have poles that are sets of three (e.g. 3 poles,
6 poles, 9 poles, 12 poles, etc...). You can connect a BLDC motor to a three phase AC
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current and it should work fine, just as you can connect them to a Controller which uses DC.
There are generally two methods of winding BLCD motors, Delta and Wye:
Figure 4.3: Brushless Dc motor
The trade-offs are as follows:
Delta windings provide (compared to "Wye" windings):
 Higher RPMs
 Lower torque at low RPMs
 Lower efficiency (but still much higher than normal motors)
Wye windings provide (compared to "Delta" windings):
 Lower RPMs
 Higher torque at low RPMs
 Higher efficiency
 More accurate positioning
14
As we can already see, it would make sense that a CD-Rom motor is a Delta configuration,
as high speed is more important than low speed torque (a plastic disk is not that heavy, so it
does not need a lot of energy to accelerate). Likewise, it is most likely that BLDC motors
used for things like fans are probably of the "Wye" configuration, as pushing air at slower
RPMs can contribute to quieter operation. A quick way of getting a rough idea of what type
of winding you have is to look at the number of connectors you motor has. Delta
configurations usually have 3 connectors, while "Wye" 4. Note that this is just a rough
estimate, you can get either configuration with 3 or 4 wires, but it is still useful as quick
initial identificataion (further observation using a multimeter can confirm).
As for controlling them, most digital controllers will happily work with both, but some
cheap controllers will only work with the "Wye" configuration (and of those, only the 4 wire
version), as they need the centre point to function.
Advantages
o Magnetic coupler like isolation
o No gearbox, speed controlled by electronic unit
o Good size/power ratio
o Water cooling
Disadvantages
o Modifying CD-ROM/floppy motors can be tricky
o Need dedicated BLDC controller
15
CHAPTER 5
ELECTRONICS COMPONENTS
5.1 Microcontroller (89C51)
AT89C51 is an 8-bit microcontroller and belongs to Atmel's 8051 family. ATMEL 89C51
has 4KB of Flash programmable and erasable read only memory (PEROM) and 128 bytes of
RAM. It can be erased and program to a maximum of 1000 times. In 40 pin AT89C51, there
are four ports designated as P1, P2, P3 and P0. All these ports are 8-bit bi-directional ports, i.e.,
they can be used as both input and output ports. Except P0 which needs external pull-ups, rest
of the ports have internal pull-ups. When 1s are written to these port pins, they are pulled high
by the internal pull-ups and can be used as inputs. These ports are also bit addressable and so
their bits can also be accessed individually.
Port P0 and P2 are also used to provide low byte and high byte addresses, respectively, when
connected to an external memory. Port 3 has multiplexed pins for special functions like serial
communication, hardware interrupts, timer inputs and read/write operation from external
memory. AT89C51 has an inbuilt UART for serial communication. It can be programmed to
operate at different baud rates. Including two timers & hardware interrupts, it has a total
of six interrupts.
Figure 5.1: Microcontroller
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5.2 LCD
A liquid crystal display (LCD) is a flat panel display, electronic visual display, or video
display that uses the light modulating properties of liquid crystals (LCs). LCs do not emit
light directly.
LCD displays are available to display arbitrary images (as in a general-purpose computer
display) or fixed images which can be displayed or hidden, such as preset words, digits,
seven segment displays, etc., as in a digital clock. They use the same basic technology, except
that arbitrary images are made up of a large number of small pixels, while other displays have
large elements
Figure 5.2: LCD
Very High Quality Yellow/Green 20x4 High-Density Character LCD with LED Backlight.
This LCD is only slightly larger than a typical 16x2 module. The compact size of this LCD
fits nicely on the development boards' LCD pin connector and greatly expands a user's ability
to display more data using the same code libraries
17
5.3 ULN 2003
The ULN2003 is a monolithic high voltage and high current Darlington transistor arrays. It
consists of seven NPN darling-ton pairs that feature high-voltage outputs with common-
cathode clamp diode for switching inductive loads. The collector-current rating of a single
darling-ton pair is 500mA. The darling-ton pairs may be parralleled for higher current
capability. Applications include relay drivers, hammer drivers, lamp drivers, display drivers
(LED gas discharge), line drivers, and logic buffers. The ULN2003 has a 2.7kilo ohm series
base resistor for each darling-ton pair for operation directly with TTL or 5V CMOS devices.
Figure 5.3: ULN 2003 logic diagram
5.4 MCT 2e
 Gallium Arsenide Diode Infrared Source Optically Coupled to a Silicon n- p-n Photo
transistor.
 High Direct-Current Transfer Ratio. Base Lead Provided for Conventional Transistor
Biasing
 High-Voltage Electrical Isolation
18
 1.5-kV, or 3.55-kV Rating
Figure 5.4: MCT 2e
5.5 Relay
A relay is an electrically operated switch. Many relays use an electromagnet to operate a
switching mechanism mechanically, but other operating principles are also used. Relays are
used where it is necessary to control a circuit by a low-power signal (with complete electrical
isolation between control and controlled circuits), or where several circuits must be
controlled by one signal.
Figure 5.5: Relay
When an electric current is passed through the coil it generates a magnetic field that
activates the armature, and the consequent movement of the movable contact (s) either makes
or breaks (depending upon construction) a connection with a fixed contact. If the set of
contacts was closed when the relay was de-energized, then the movement opens the contacts
19
and breaks the connection, and vice versa if the contacts were open. When the current to the
coil is switched off, the armature is returned by a force, approximately half as strong as the
magnetic force, to its relaxed position. Usually this force is provided by a spring, but gravity
is also used commonly in industrial motor starters. Most relays are manufactured to operate
quickly. In a low-voltage application this reduces noise; in a high voltage or current
application it reduces arcing.
5.6 IR sensor
When IR rays gets emitted from LED, it moves in the direction it is angled. When any
obstacle interferes in the path, the IR rays get cut and it produces secondary wavelets which
propagates mostly in return direction or in a direction opposite to that of the primary waves,
which produces the net result like reflection of IR rays. Infrared photo receiver is a two
terminal PN junction device, which operates in a reverse bias. It has a small transparent
window, which allows light to strike the PN junction. A photodiode is a type of photo
detector capable of converting light into either current or voltage, depending upon the mode
of operation. Most photodiodes will look similar to a light emitting diode. They will have
two leads, or wires, coming from the bottom. The shorter end of the two is the cathode, while
the longer end is the anode.
5.7 Resistor
A resistor is a passive two-terminal electrical component that implements electrical resistance
as a circuit element. The current through a resistor is in direct proportion to the voltage across
the resistor's terminals. Thus, the ratio of the voltage applied across a resistor's terminals to
the intensity of current through the circuit is called resistance. This relation is represented by
Ohm's law:
20
Where I, is the current through the conductor in units of amperes, V is the potential difference
measured across the conductor in units of volts, and R is the resistance of the conductor in
units of ohms. More specifically, Ohm's law states that the R in this relation is constant,
independent of the current. Resistors are common elements of electrical networks and
electronic circuits and are ubiquitous in electronic equipment. Practical resistors can be made
of various compounds and films, as well as resistance wire (wire made of a high-resistivity
alloy, such as nickel-chrome). Resistors are also implemented within integrated circuits,
particularly analog devices, and can also be integrated into hybrid and printed circuits.
5.8 Capacitor
A capacitor (originally known as condenser) is a passive two-terminal electrical component
used to store energy in an electric field. The forms of practical capacitors vary widely, but all
contain at least two electrical conductors separated by
a dielectric (insulator); for example, one common construction consists of metal foils
separated by a thin layer of insulating film. Capacitors are widely used as parts
of electrical circuits in many common electrical devices. When there is a potential difference
(voltage) across the conductors, a static electric field develops across the dielectric, causing
positive charge to collect on one plate and negative charge on the other plate. Energy is stored
in the electrostatic field. An ideal capacitor is characterized by a single constant value,
capacitance, measured in farads. This is the ratio of the electric charge on each conductor to
the potential difference between them. The capacitance is greatest when there is a narrow
separation between large areas of conductor, hence capacitor conductors are often called
"plates," referring to an early means of construction. In practice, the dielectric between the
plates passes a small amount of leakage current and also has an electric field strength limit,
21
resulting in a breakdown voltage, while the conductors and leads introduce an undesired
inductance and resistance.
Capacitors are widely used in electronic circuits for blocking direct current while allowing
alternating current to pass, in filter networks, for smoothing the output of power supplies in
the resonant circuits that tune radios to particular frequencies, in electric power transmission
systems for stabilizing voltage and power flow, and for many other purposes.
5.9 Led
A light-emitting diode (LED) is a semiconductor light source. LEDs are used as indicator
lamps in many devices and are increasingly used for other lighting. Introduced as a practical
electronic component in 1962, early LEDs emitted low-intensity red light, but modern
versions are available across the visible, ultraviolet, and infrared wavelengths, with very high
brightness. When a light-emitting diode is forward-biased (switched on), electrons are able
to recombine with electron holes within the device, releasing energy in the form of photons.
This effect is called electroluminescence and the color of the light (corresponding to the
energy of the photon) is determined by the energy gap of the semiconductor. LEDs are often
small in area (less than 1 mm2), and integrated optical components may be used to
shape its radiation pattern. LEDs present many advantages over incandescent light
sources including lower energy consumption, longer lifetime, improved robustness, smaller
size, and faster switching. LEDs powerful enough for room lighting are relatively expensive
and require more precise current and heat management than compact fluorescent lamp
sources of comparable output.
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CHAPTER 6
STRUCTURE (HARDWARE) OF PROJECT
6.1 Dimension of conveyor belt
Length == 12 feet Width == 21 inch
6.2 Dimension of wooden roller
Length == 28 inch Diameter of roller == 4 inch
6.3 Diameter of pulleys
Pulley 1 == 24 inch Pulley 2 == 12 inch Pulley 3 == 2 inch Pulley 4 == 2 inch
6.4 Diameter of bearings
There are four bearings used in our project, each having diameter 1.5 inch.
6.5 Diameter of shaft
There are four shafts at the end of rollers. Each shaft has diameter equal to 1.5 inch.
6.6 Dimension of structure
Length == 6 feet Width:
Upper border == 26 inch Lower border == 29 inch
Height == 18 inch
6.7 Types of wood
 Shesham
 cheerh
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CHAPTER 7
IMPLEMENTATION AND CONTROL
In order to automate a process, first of all we need some sort of control system and also a
physical device to implement that control system. Actually, control system is mathematical
logic through which we can get results whatever we desired. It provides ON/OFF,
proportional control, PID control but to implement this method, a physical device such as
microcontroller or PLC etc is required.
Following are the basic components of an automated system
1. Sensor
2. Signal conditioning
3. Control unit
4. Actuator
5. Feedback
1) SENSOR
A sensor (also called detector) is a converter that measures a physical quantity and converts
it into a signal which can be read by an observer or by an (today mostly electronic)
instrument.
For example, a mercury-in-glass thermometer converts the measured temperature into
expansion and contraction of a liquid which can be read on a calibrated glass tube.
A thermocouple converts temperature to an output voltage which can be read by a
voltmeter. For accuracy, most sensors are calibrated against known standards.
Sensors are used in everyday objects such as touch-sensitive elevator buttons (tactile sensor)
24
and lamps which dim or brighten by touching the base. There are also innumerable
applications for sensors of which most people are never aware. Applications include cars,
machines, aerospace, medicine, manufacturing and robotics.
A sensor is a device which receives and responds to a signal. A sensor's sensitivity indicates
how much the sensor's output changes when the measured quantity changes.
2) Signal conditioning
Figure 7.1: MEASUREMENT SYSTEM
Figure 7.2: Feedback system
25
Similarities between our project and the above feedback system are as follows:
Controller == Microcontroller 89C51
Sensor == IR sensor
Actuator == Dc motor Push mechanism
Signal conditioning == Transistor darling-ton pair IC ( ULN 2003)
7.1 Circuit diagram of project
Figure 7.3 Circuit diagram
26
Figure 7.3.1: Circuit diagram of project
7.1.1 Simulated circuit diagram
Figure 7.3.2: simulated circuit diagram
27
7.1.2 Working of the circuit
The IR sensors are clamped at specific height to detect the bottles according to their heights.
When the sensor detects the bottle, it gives signal to the controller. Controller drives the dc
motor for push mechanism, in this way sorting of bottle is done. In second stage, after
sorting, when the bottle reaches near to the water reservoir. IR sensor detects bottle again it
generates the logic 1. The controller receives that signal, and at the same time it performs two
functions by switching two relays. The first relay stops the motor which is driving the
conveyor belt. Secondly, solenoid valve is actuated via second relay.
28
CHAPTER 8
APPLICATIONS AND ADVANTAGES
In previous chapters we have discussed about the project. Now it’s turn to come to know
about the applications and advantages of this project. Due to these applications which we
shall discuss in this chapter, we preferred to choose this idea. The main aims of our project
were automatic sorting and liquid filling.
8.1 Applications of automatic sorting
Automated sorting systems will feature computerized controls that will allow materials to be
sorted without human control or interaction. This is suitable for high-volume jobs that would
require high levels of manpower otherwise. Automated systems tend to be more expensive
than manual systems, and operators of these machines will usually need to undergo
significant training before the system can be used effectively. Manual systems tend to be less
expensive and far easier to use; they are also more easily serviceable, whereas automated
systems may require lengthy troubleshooting and diagnostics.
Following are the application of automatic sorting:
1) Parts handling
 Conveying product from machine to packaging area or bowl feeders
 Conveying process waste and scrap products to granulator
 Separation of sprues in injection moulding process (closed loop)
 Soft Drop conveying systems for PET performs to eliminate damage
 Parts distribution for multiple box filling - The Duck is designed to convey parts from a
conveyor into boxes. Programmable to dispense precise number of parts into each box.
29
 Parts Conveyors linking with pick and place robots, including interface and guarding
 Multiple machine conveying systems for central packaging via PLC control
2) Pharmaceutical, food beverage
Pharmaceutical industries like Glaxo and Abbot Pakistan make variety of products. These
products are transported through conveyor belt. They are sorted out according to their
similarities. Automating sorting can be applied in the food and consumer goods producing
industries like Nestle and uniliver because they have variety of products.
3) Separation of defective parts
Automatic sorting is also useful in separating defective parts. In Balochistan glass
industry where production of glasses takes place, defective pieces are sorted out.
Later on, these defective pieces are reproduced.
4) Separation of boxes
In packages industry Lahore, variety of boxes are produced, which are further used
for packing for example milk pack. The boxes are separated from one another on
the basis of their size.
5) Ceramic and tiles
In Master tiles, in which heavy boxes are produced with high accuracy and speed. It
is the best application of automatic sorting.
8.1.1 Advantages of conveyor
 Reduce labor by automation
 Enables central packaging of product
30
 Eliminates manual sorting of mouldings and sprues
 Reduces possibility of surface damage to product
 Promotes good 'housekeeping
 Belt conveyors are capable of handling a wide range of bulk materials from very fine to
large lump sizes. Very fine materials such as portland cement are loaded at terminals
using belt conveyors. Large lump size materials such as coal are transported from mines
using belt conveyors.
 Belt conveyors require less horsepower to operate than other types of conveyors. Bulk
materials are carried on top of the belt and remain static, therefore requiring much less
energy to move.
 Conveyor belts are mechanical apparatuses that contain a continuous moving belt that is
used to transport materials, packages and people from one point to another. The belt
operates by forming a continuous loop on rollers or metal sliders. Power is provided by
motors operating at constant or variable speed.
8.2 Applications of liquid filling
E-PAK Machinery, Inc. offers a wide variety of liquid filling machine technologies
capable of filling viscous and non-viscous liquids as well as foamy products with a
high degree of accuracy and many options to choose from. Our filling systems are
fully capable of meeting the needs of food grade, sanitary, pharmaceutical,
hazardous, and corrosive environments. We pride ourselves on providing the
product your business needs, from big aseptic beverage or drum filling machines to
filling machines that can handle containers as small as a cup, tube, vial, or ampoule.
31
1. Automatic capsule filling machine. This machine is designed and further
improved on the base of original full auto capsule filling machine from
home and aboard.
Type: Filling Machine
2. Milk filling
32
CHAPTER 9
CONCLUSION AND FUTURE WORK
Our objectives of making this project are:
 to increase productivity and
 provide safe material handling operations,
 reduce cost and
 manpower
We did sorting on the basis of height of the bottles. However, sorting can be improved
through image processing. In image processing bottle can be sorted on the basis of colors and
shapes.
The second part of our project was bottle filling, for which we used solenoid operated valve.
We did programming in such a way that it actuated the valve for a few seconds. The
operation of filling of bottles can be improved by using level sensor.
For further improvement of material handling operations Scara Robot can be used. The robot
is very helpful in picking and placing of bottles. But in this project we manually place the
bottles on the conveyor.
33
References
 http://en.wikipedia.org/wiki/Conveyor_belt http://en.wikipedia.org/wiki/Sorting
http://en.wikipedia.org/wiki/Bearing_(mechanical) http://en.wikipedia.org/wiki/Pulley
http://en.wikipedia.org/wiki/Induction_mot r
 http://www.ziva-vatra.com/index.php?aid=26&id=RWxlY3Ryb25pY3M=
 http://www.engineersgarage.com/electronic-components/at89c51-microcontroller-
datasheet
 http://en.wikipedia.org/wiki/Liquid_crystal_display
2003http://www.datasheetcatalog.org/datasheets/120/489337_DS.pdf
http://www.datasheetcatalog.org/datasheets/90/424848_DS.pdf
http://en.wikipedia.org/wiki/Relay
\
34
GLOSSARY
Sensor
A device that measures a physical quantity and converts it into a signal which can be read by
an observer or by an instrument
Sorting
Sorting is any process of arranging items in some sequence and/or in different sets.
Transistor (BJT’s)
Three terminal electronic device constructed of doped semiconductor material and may be
used in amplifying or switching applications
Electromagnetic induction
The phenomenon in which emf is induced in a conductor, when it is moving through the
magnetic field.
Electromotive force (emf)
It tends to cause current to flow.
35
APPENDIX
PROGRAM CODE
ORG 0H CLR P2.6 CLR P2.3 CLR P2.4
MOV A,#38H ACALL COMNWRT ACALL DELAY
MOV A,#0CH ;;;DISPLAY ON CURSOR OF BUT IF WE USE 0E THEN DISPLAY WILL
BE ON BUT CURSOR WILL ALSO BE ON
ACALL COMNWRT ACALL DELAY MOV A,#01
ACALL COMNWRT
ACALL DELAY MOV A,#06H ACALL COMNWRT ACALL DELAY MOV A,#80H
ACALL COMNWRT ACALL DELAY
MOV A,#'A' ACALL DATAWRT ACALL DELAY MOV A,#'U' ACALL DATAWRT
ACALL DELAY
MOV A,#'T' ACALL DATAWRT
ACALL DELAY
MOV A,#'M' ACALL DATAWRT
ACALL DELAY ;give LCD some time
MOV A,#'A' ;cursor at line 1, pos. 5 ACALL DATAWRT ;call DATA subroutine ACALL
DELAY ;give LCD some time
MOV A,#'T' ;cursor at line 1, pos. 6
36
A CALL DATAWRT ;call DATA subroutine ACALL DELAY ;give LCD some time
MOV A,#'I' ;cursor at line 1, pos. 7
ACALL DATAWRT ;call DATA subroutine ACALL DELAY ;give LCD some time
MOV A,#'C' ;cursor at line 1, pos. 8
MOV A,#' ' ;cursor at line 1, pos. 9
MOV A,#'S' ;cursor at line 1, pos. 10 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'O' ;cursor at line 1, pos. 11 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'R' ;cursor at line 1, pos. 12 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'T' ;cursor at line 1, pos. 12 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'I' ;cursor at line 1, pos. 13 ACALL DATAWRT ;call DATA subroutine ACALL
37
MOV A,#'N' ;cursor at line 1, pos. 14 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'G' ;cursor at line 1, pos. 15
MOV A,#0C0H ACALL COMNWRT ACALL DELAY
MOV A,#'&' ;cursor at line 2, pos. 1 ACALL DATAWRT ;call DATA subroutine ACALL
DELAY ;give LCD some time MOV A,#' ' ;cursor at line 2, pos. 2
MOV A,#'B' ;cursor at line 2, pos. 3
38
MOV A,#'L' ;cursor at line 2, pos. 7
MOV A,#'E' ;cursor at line 2, pos. 8
MOV A,#'F' ;cursor at line 2, pos. 10 ACALL DATAWRT ;call DATA subroutine ACALL
t line 2, pos. 12
MOV A,#'L' ;cursor at line 2, pos. 13 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'N' ;cursor at line 2, pos. 16 ACALL DATAWRT ;call DATA subroutine
MOV A,#'G' ;cursor at line 2, pos. 17 ACALL DATAWRT ;call DATA subroutine ACALL
39
MOV A,#94H ACALL COMNWRT ACALL DELAY
MOV A,#'2' ;cursor at line 3, pos. 1
ACALL DATAWRT ;call DATA subroutine ACALL DELAY ;give LCD some time MOV
A,#' ' ;cursor at line 3, pos. 2
MOV A,#'R' ;cursor at line 3, pos. 6
40
MOV A,#'E' ;cursor at line 3, pos. 14 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#' ' ;cursor at line 3, pos. 15 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'=' ;cursor at line 3, pos. 16 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#0D4H ;cursor at line 4, pos. 1 ACALL COMNWRT ;call command subroutine
V A,#'1' ;cursor at line 4, pos. 1
ACALL DATAWRT ;call DATA subroutine ACALL DELAY ;give LCD some time MOV
A,#' ' ;cursor at line 4, pos. 2
41
ACALL DATAWRT ;call DATA subroutine
MOV A,#'R' ;cursor at line 4, pos. 6
42
MOV A,#'L' ;cursor at line 4, pos. 13 ACALL DATAWRT ;call DATA subroutine
MOV A,#'E' ;cursor at line 4, pos. 14 ACALL DATAWRT ;call DATA subroutine ACALL
MOV A,#'=' ;cursor at line 4, pos. 16 ACALL DATAWRT ;call DATA subroutine ACALL
MOV TMOD, #01100110B SETB P0.1
SETB P0.2
SETB P3.4 ;;COUNTER0 SETB P3.5 ;;COUNTER1 MOV TH0, #0FFH
MOV TH1, #0FFH
AGAIN:
B TR0 SETB TR1
:JB P0.1,TWO_LITER_BOT ; ;KEEP MONITORING VALVE TWO CLR P2.3
JB P0.2,ONE_LITER_BOT ;KEEP MONITORING VALVE ONE CLR P2.4
JB P0.3,CDROM CLR P2.6
MOV A, TL0 ACALL CONV ACALL DISPLAY JB TF0,WAHEED MOV A, TL1
ACALL CONV ACALL DISPLAY1
JNB TF1,BACK CLR TR1
43
CLR TF1
MOV TL1,#00H SJMP AGAIN
WAHEED:
CLR TR0 CLR TF0
MOV TL0,#00H SJMP AGAIN
CONV:
MOV B,#10 DIV AB MOV R2,B MOV B,#10 DIV AB ORL A,#30H MOV R4, A MOV
A,B ORL A,#30H MOV R3,A MOV A,R2 ORL A,#30H MOV R2,A RET
DISPLAY1:
MOV A,#0E5H
ACALL COMNWRT ;call command subroutine ACALL DELAY ;give LCD some time
MOV A,R4
ACALL DATAWRT ACALL DELAY MOV A,R3
ACALL DATAWRT ACALL DELAY
MOV A,R2
RET TWO_LITER_BOT:
ACALL DELAY5 CLR P2.5 ACALL DELAY
SETB P2.3 ;OPEN VALVE OF 2 LITRE BOTTLE ACALL DELAY1
SETB P2.5
CLR P2.3 SETB P2.6
ACALL DELAY2 CLR P2.6
44
LJMP BACK
ONE_LITER_BOT: ACALL DELAY3 CLR P2.5
ACALL DELAY
SETB P2.4 ;OPEN VALVE OF 1 LITRE BOTTLE ACALL DELAY4
SETB P2.5 CLR P2.4 LJMP BACK
CDROM: SETB P2.6
ACALL DELAY2 CLR P2.6
LJMP BACK
DISPLAY:
MOV A,#0A5H ACALL COMNWRT
ACALL DELAY MOV A,R4
ACALL DATAWRT ACALL DELAY MOV A,R3
MOV A,R2
RET
COMNWRT:
MOV P1,A ;copy reg A to port 1 CLR P2.0 ;RS=0 for command
CLR P2.1 ;R/W=0 for write SETB P2.2 ;E=1 for high pulse
ACALL DELAY ;give LCD some time CLR P2.2 ;E=0 for H-to-L pulse
RET
DATAWRT: ;write data to LCD MOV P1,A ;copy reg A to port 1 SETB P2.0 ;RS=1 for data
45
CLR P2.1 ;R/W=0 for write SETB P2.2 ;E=1 for high pulse
ACALL DELAY ;give LCD some time CLR P2.2 ;E=0 for H-to-L pulse
RET
DELAY: MOV R6,#20 ;250 or higher for fast CPUs HERE2: MOV R7,#200 ;R4 = 255
HERE: DJNZ R7,HERE ;stay until R4 becomes 0 DJNZ R6,HERE2
RET DELAY1:
MOV R1,#6 HERE6:MOV R2,#25 HERE5:MOV R3,#250 HERE4:MOV R4,#250
HERE3:DJNZ R4,HERE3 DJNZ R3,HERE4
DJNZ R2,HERE5 DJNZ R1,HERE6 RET
DELAY2:
MOV R5,#100
W:MOV R6,#210 ;250 or higher for fast CPUs W1: MOV R7,#100 ;R4 = 255
W2: DJNZ R7,W2 ;stay until R4 becomes 0
DJNZ R6,W1 DJNZ R5,W RET DELAY3:
MOV R5,#4
IRFAN:MOV R6,#255 ;255 or higher for fast CPUs IRFAN1: MOV R7,#255 ;R7 = 255
IRFAN2: DJNZ R7,IRFAN2 ;stay until R7 becomes 0 DJNZ R6,IRFAN1
DJNZ R5,IRFAN RET
DELAY4: MOV R1,#8
SALEEM6:MOV R2,#10 SALEEM5:MOV R3,#250 SALEEM4:MOV R4,#250
SALEEM3:DJNZ R4,SALEEM3 DJNZ R3,SALEEM4
DJNZ R2,SALEEM5 DJNZ R1,SALEEM6 RET
46
DELAY5:
MOV R5,#17
LAIQ:MOV R6,#255 ;255 or higher for fast CPUs LAIQ1: MOV R7,#255 ;R7 = 255
LAIQ2: DJNZ R7,LAIQ2 ;stay until R7 becomes 0 DJNZ R6,LAIQ1
DJNZ R5,LAIQ RET
END
47

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MANUFACTURING OF BOTTLE FILLING MACHINE

Under the Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

Certified that the dissertation Report entitled “MANUFACTURING OF BOTTLE

Mr. Sushil Kumar Dr. Sanjay Paliwal

Department of Mechanical Engineering

I AAKASH KUMAR SHARMA (Roll No.) 1623140004 of B.Tech Mechanical Engineering

AAKASH KUMAR SHARMA

Department of Mechanical Engineering

CHAPTER 2: LITERATURE REVIEW 3-6

3.2 Wooden shaft

3.3 Wooden rollers

CHAPTER 4: ELECTRICAL COMPONENTS 10-15

Figure 1.1 Automatic sorting and bottle filling machine 1

Figure 2.1 Conveyor belt 4

Figure 2.2 Sorting 5

Figure 2.3 Bottle filling 6

Figure 3.1 Bearing 7

Figure 3.2 Wooden roller 8

Figure 3.4 Pulley 9

Figure 4.1 Induction motor 10

Figure 4.2 Solenoid valve 13

Figure 4.3 Brushless Dc motor 14

Figure 5.1 microcontroller 16

Figure 5.2 LCD 20x4 17

Figure 5.3 ULN 2003 logic diagram 18

Figure 5.4 MCT 2e 19

Figure 5.5 Relay 19

Figure 7.1 Measurement system 25

Figure 7.2 Feedback system 25

Figure 7.3 Circuit diagram 26

Figure 7.3.1 Circuit diagram of project 27

Figure 7.3.2 Simulated circuit diagram 27

Figure 1.1 automatic sorting and bottle filling machine

The main objectives of our project are:

 Sorting of bottles on the basis of their respective sizes

 Filling of bottles using SOV

system is required. This type of system provide following benefits:

1. Stability and safety

2. Easy to operate and maintain

4. Low running cost

We have used AT89C51 to implement the control in our project.

mines which revolutionized the mining industry.

constructing them from several layers of different materials.

applications of belt conveyors such as those in grocery stores.

Figure 2.1 Conveyor

accordingly, it has two common, yet distinct meanings:

naturally occurring process that results in the concentration of ore or sediment.

Fig 2.2: Sorting

such as the isotopes of uranium, are very difficult to separate.

The second part of this project is to design a microcontroller based

required to raise the bottle few seconds,

Figure 2.3: Bottle filling

well as by the directions of applied loads they can handle.

Figure 3.1: Bearings

can tolerate some misalignment of the inner and outer races.

3.2 Wooden rollers

Figure 3.2: Wooden roller

3.3 Wooden shaft

diameter of each shaft is 2 inch.

transmit power from one rotating shaft to another.

Figure 3.4 Pulley