Aut

omat
icCof
feeMaki
ngMachi
neUsi
ngPLC
RashmiS,
Vai
shal
iAV,
Prof
.SandeepChapal
kar
,Day
anandaSagarCol
l
egeofEngi
neer
ing

MsKSudhaDeept
i,Day
anandaSagarUni
ver
sit
y

Abst r
act —Aut omat ioni st heuseofv ari
ouscont r ol
systems f or oper ating equi pment such as machi ner y,
processes i nf act ories,boi lers and heatt reati
ng ov ens,
switchingont elephonenet wor ks,steeringandst abili
zat ion
ofshi ps,ai rcraftandot herappl icat
ionswi t
hmi nimalor
reducedhumani nt erv ention.Somepr ocesseshav ebeen
compl etelyaut omat ed.Wi th aut omat ion through putor
product iv
ity can be i ncr eased, I mpr oved qual i
ty or
i
ncreasedpr edictabi l
ityofqual it
y,increasedconsi stencyof
outputcanbeobt ained.Aut omat ioncanbeachi evedwi th
some cont r
ollers one i s pr ogrammabl el ogic control l
er
(PLC) .ThePLCi sani ndust rialcomput er.ThePLCcont rol s
thei ndust r
ialmachi nesandpr ocesses.PLCshav emor e
advant ages compar ed t o mi cr
ocont roll
ers and per sonal
comput ers.Indi f
f erentar easoft heindust r
yPLCar ebei ng
applied,e. g.:mat erials handl i
ng,packagi ng,pal l
etizing, Fi
gur
e1Bl
ockDi
agr
am ofPLC
mill
ing,bor i
ng,gr indi ng,f i
ll
ing,sor t
ing,wei ghing.Hence
now aday ’
sal lindust ri
esar epr eferr
ingPLCsov erot her Programmabl e Logic Cont rol
l
ers continuously
controlli
ngequi pment . moni tor
st hei nputval
uesf rom var
iousi
nputsensi ng
dev i
ces( e.g.acceler
omet er,wei
ghtscale,hardwired
Key
words- Programmabl
e Logi
c Cont
rol
l
er, signals,et c.) and produces corr
espondi
ng out put
Aut
omati
on,
Cont
rolSyst
ems. dependingont henatureofpr oducti
onandi ndust r
y
I
. I
NTRODUCTI
ON [10].At ypi
calbl ockdiagram ofPLCconsistsoff our
partsnamel y
:
APLCi sacomput erspeci allydesi gnedt ooper ate
rel
iablyunderhar shi ndust rialenv ironment s–suchas •PowerSuppl
yModul
e
extreme t emper atures, wet , dr y, and/ or dust y
conditions.I tisusedt oaut omat ei ndust ri
alpr ocesses •Cent
ral
Processi
ngUni
t(CPU)andmemor
y
suchasamanuf acturingpl ant ’sassembl yl i
ne,anor e
processi ng pl ant,ora wast ewat ert reatmentpl ant. •I
nput&Out
putModul
e
PLCsshar emanyf eat uresoft heper sonalcomput er
youhav eathome.Theybot hhav eapowersuppl y,a •Communi
cat
ionI
nter
faceModul
e
CPU( Cent ral Processi ngUni t),i
nput sandout puts( I
/O),
memor y,and oper at i
ng sof t
war e( although i t
’sa
dif
ferentoper atingsof twar e).Thebi ggestdi ff
erences I
I. LI
TERATURESURVEY
aret hataPLC canper form di scr eteandcont inuous
functionswhi chaPCcannotdo,andaPLCi smuch PLC ( Programmabl eLogi cCont rol
ler)i sused t o
bettersui tedt or oughi ndust r
ialenv ir
onment s.APLC dev elopanaut omat edcof fee/teamachi neusi ngPLC
canbet houghtofasa‘ ruggedi zed’di gitalcomput er
whichmanagest heel ect r
omechani calpr ocessesofan progr ammi ng l anguages. Pr ogrammabl e Logi c
i
ndust rialenv i
ronment .PLCspl aysacr uci alroleint he Cont rollers dev eloped t o dat e, cont inues t o be
fi
eld ofaut omat ion,usi ng f ormi ng par tofa l arger percei ved as a model basi s of a moder n-day
SCADAsy stem.APLCcanbepr ogr ammedaccor ding automat ion pl atfor m,gar ner i
ng r ecogni t
ion f ori t
s
tot heoper at ionalr equi rementoft hepr ocess.I nt he robustqual it
y and hi gh- end capabi l
iti
es,i ncluding
manuf acturing i ndust ry,t her e wi l
lbe a need f or i
mpr oved per formance,compl iance wi tht he latest
reprogr ammi ng duet ot hechangei nt henat ureof networ ki ngstandar ds,andoper at i
onalcostef fi
ciency .
product ion.To ov ercome t his dif f
iculty,PLC based Desi gnedf orawi der angeofpr ocessandmachi ne
cont r
ol syst emswer ei ntroduced[ 10] . management ,itf i
ndsper fect l
yhi splacei nnumer ous
segment ssuchast heFood& Bev erageet c.[ 1]In
manyi ndustries( suchasphar maceut i
cals,bev erage
i
ndust ri
es, et
c. )
,bot t
lesar er equiredtobef ill
edupwi th
a pr e-
det ermined amount of l i
quid.I mpl ement i
ng
syst emsusi ngr elayl ogiccont rolcancauset hem t o
bei nf l
ex i
ble.Pr ogr ammabl eLogi cCont r
ollers–PLCs
–ar emor ef lexiblei naut omat ingv ari
ouspr ocesses,
since t he behav ioroft he sy st em can be changed
withoutchangi ngt heelectri
calconnecti
ons,aswel las B. PLC-
INDRALOGI
CL20DP
being ablet o moni t
ort he system under going its
operation[ .Wec
2] anoper ateandcont r
olautomat i
call
y
the bev er
age pr eparati
on by usi ng PLC.We can
moni t
ort hepar amet eroft he processi nt hepl ant
usingSCADA t echnologybecauseSCADA sy stem is
usedassuper visorormoni t
orfortheprocesst hrough
anani mation.Int hisplant,severaloperat
ionswi l
lrun
simultaneouslybyt hehelpofPLC[ 3].

I
II
. METHODOLOGY

Aut omat ioni sthet echnol ogybywhi chapr ocessor

procedur e i s per formed wi th mi nimal human
assist ance.Aut omat ionoraut omat iccont rolist heuse
ofv ar i
ouscont r
olsy stemsf oroper at i
ngequi pment
suchasmachi nery,pr ocessesi nf act ories,boi lersand
heat ing ov ens,swi tchi ng on t el ephone net wor ks,
steer ingandst abili
zat ionofshi ps,ai rcraftandot her Fi
gur
e3I
NDRALOGI
CL20DP
appl i
cat ions and v ehi cles wi th mi nimalorr educed
•Processor–STM ST40
humani nt ervent i
on.Aut omat ionhasbeenachi ev edby •Supplyvoltage–24VDC
various means i ncl udi ng mechani cal, hy dr aul i
c, •Bandwidth–166MHz
pneumat ic, el ect r
ical , el ect r
oni c dev i
ces and •Digi
tali
nput s–16
comput ers, usual ly i n combi nat ion. Compl i
cat ed •Digi
taloutputs–16
systems,such as moder nf actories,ai rpl
anes and •Communi cat i
onint
erf
ace–Ether
netTCP/I
P
shipst y picallyuseal lt hesecombi nedt echni ques.The •Permissi
blet emperat
ure–+5°C..
.+55°C
benef i
tofaut omat i
oni ncl udesl aborsav i
ngs,sav ings •Fi
rmwar eused–03V09. 1
i
n el ect ricity cost s,sav ings i n mat er i
alcost s,and
i
mpr ov ement st oqual ity,accur acy,andpr ecision.The C. TWOCONTAI
NERSFI
TTEDWI
THSOLENOI
D
coffeemachi nedi scussedher econt ains2cont ainer s VALVES
withv al ves.Onecont ainerhasdecoct ionandt heot her
hasmi lk.Ther ear et wost epsi nv olvedi nourcof fee
maki ngpr ocessnamel yaddi ngdecoct ionandaddi ng Ther ear et wocont ainers,onecont ainsdecoct ion
mi l
k.A cupi smadet omov eont heconv ey erbel t and ot her cont ai
ns mi l
k. These ar e t he f i
ll
ing
whichst opsatdecoct ioncont ai
ner .Thedecoct ioni s containersf rom whi chdecoct ionandmi l
katdi ff
erent
fi
ll
edt ot hecupf ort hedur ati
onspeci fiedbyt het imer . l
ev elsaret obef i
ll
ed
Thent hecupmov esont heconv ey orbel tandst opsat i
nt hecup.I nor dertoaut omat i
callycontrolthef l
owof
themi lkcont ai nerandmi lkisf il
ledf ort hespeci f i
ed
l
iquidf rom t he containersi ntot he cups,sol enoid
ti
mer dur ati
on. We can oper at e and cont rol
automat i
cal l
yt hecof feepr epar ati
onbyusi ngPLC. valvesar erequi red.Cupsar ef i
ll
edwi t
hdecoct ionand
milklevelssetwi ththehel poftimeri nPLCl ogic.
The cont ainers consistof sol enoidv alves whi ch
operatesat24VDCwhi chisf ixedt oit.Thesol enoid
valveist husdi r
ectlyconnect edt ot hePLC.Conv eyor
system i sar r
anged bel ow t he mai n container.The
conv eyorbel tisdesignedusi ng24VDCmot or.

Fi
gur
e2Bl
ockDi
agr
am ofanAut
omat
icCof
feeMaki
ngMachi
ne

A. PARTSOFBLOCKDI
AGRAM

Themai
npar
tsusedi
ntheblockdiagr
am of
Aut
omat
icl
evel
contr
oll
erar
egivenbelow:

•Pr
ogr
ammabl
elogi
ccont
rol
l
er(
PLC)Ver
sionL20

•Twocont
ainer
sfi
tt
edwi
thsol
enoi
dval
ves.

•Conv
eyorbel
tforcupst
opass

•Lev
eli
ndi
cat
orci
rcui
t.

Fi e4Twocont
gur ainer
swhi
chcont
ainsdecoct
ionandmi
l
k
D. CONVEYERBELT I
V. EXPERI
MENTALSETUP
A. HARDWARE
A conv ey orbel tist hecar ryi
ngmedi um ofabel t
conv eyorsy st em ( of tenshor tenedt obel tconv eyor).A
beltconv ey orsy stem i soneofmanyt ypesofconv ey or
systems.Abel tconv eyorsy stem consi stsoft woor
mor epul ley s( somet imesr eferredtoasdr ums) ,wi th
anendl essl oopofcar r
y i
ngmedi um theconv eyorbel t
thatrotat esaboutt hem.Oneorbot hoft hepul l
ey sar e
power ed,mov ingt hebel tandt hemat erialont hebel t
forward.Thepower edpul leyi scalledt hedr ivepul l
ey
whilet heunpower edpul leyi scal l
edt hei dl
erpul l
ey .
Ther e ar e t wo mai n indust rial classes of bel t
conv eyors;Thosei ngener almat eri
alhandl i
ngsuchas
thosemov i
ngbox esal ongi nsideaf actoryandbul k
mat eri
alhandl ing such as t hose used t ot ranspor t
l
argev olumesofr esour cesandagr iculturalmat eri
als,
suchasgr ain,sal t,coal ,ore,sand,ov erburdenand
mor e.Aconv ey orbel tusesawi debel tandpul leysand
i
ssuppor tedbyr oll
ersoraf l
atpanal ongi tspath.24V Fi
gur
e6Har
dwar
eSet
up
DCmot ori susedt or unt heconv eyorbel t.
B. SOFTWARE
E. LEVELI
NDI
CATORCI
RCUI
T
•I
ndr
awor
ks:
Afi
rmwar
eenv
ironment
FourLEDsar eusedf orl eveli ndication.A l i
ght-
•I
ndr
a Logi
clanguage:A pr
ogr
ammi
ng l
anguage
emitti
ngdi ode( LED)i sat wo-leadsemi conduct orl
ight
source.Iti
sap–nj unct iondi odet hatemi tslightwhen dev
elopedbyBoschRex
rot
h.
acti
vated.Whenasui tabl ev ol
tagei sappl i
edt ot he
•Ladderdi
agr
am ast
hesour
cecodet
othePLC.
l
eads,el ectrons are abl et or ecombi ne wi th holes
wit
hint he dev i
ce,r el
easi ng ener gyi nt he form of
photons.Thi s ef f
ecti s called el ectrolumi nescence.
LEDs ar et ypicall
y smal l(less t han 1 mm2)and V. LADDERDI
AGRAM
i
ntegratedopt icalcomponent smaybeusedt oshape
theradiati
onpat tern.Int hispr ototy pet heLEDsar e
Ladderdiagr
am istheindustr
ial
standar
dforwri
ti
ng
usedt oindicatethedi ffer entlevelsnamel y-decoction
contr
ollogic[
5].Ladderdiagr
am for“Aut
omati
cCoffee
addit
ion,mi l
kaddi ti
on, cy clecompl et e.
MakingMachi ne”isasshownbel ow.

Fi e5Lev
gur elI
ndi
cat
ionUsi
ngFourLEDs
 etc.Fort heuseofapl cthepr ogr ammi ngi samust .
Fort hedi ff
erentPLCsofal l thecompani est hemet hod
VI
. RESULTS ofpr ogrammi ngandt hel ogicr emai nsamebutt he
addr essingischanged, theaddr essi ngi
sal soav ai
labl
e
The whol e syst
em of “Aut
omat ic coff
ee maki ng fr
om t he sof t
war e.So,t he mosti mportantpar tis
machine”istur
nedonbyst ar
tpr ocessbutton.There progr ammi ngt heplcaccor dingt ot herequirement s.
are di
ff
erentcaseswhich i
ndicate how the cont
r ol Thepr ojectprovidesagr eatdealofappl icat i
oni nthe
fl
owsintheladderdi
agr
am.Thecasesar e: fi
eldofaut omat i
onandi nt hef iel
dofmasspr oducti
on
wher euni tsneedt obepr ocessedandmoni t
oredi na
CASE1:MOTORI
SON shor tper i
od oft i
me whi ch l eads t oi ncrease in
product ion.Fort heset upofanaut omat edmachi ne
l
iket hisusi ngPLC,t hei niti
alcostmay behi ghbuti t
offersmanyadv ant agest hatov er comest hiscost .It
l
eadst ohi ghpr oduct i
onr at e,useofl essmanpower ,
sav est heoperati
onal ti
mei npl ant setc.

REFERENCES

[
1]“ Impl ement ation of a Vendi ng machi ne usi ng
Progr ammabl e Logi c Cont roller”, by Par epal l
i
RamanammaandNay anaGH, onJune2018, IJRASET
CASE2:COFFEEDECOCTI
ONI
SADDED. Publ icat ion.
[
2]“ Aut omat edandMoni toredLi qui dFillingSy stem
using PLC Technol ogy”,by Abdul raoufI ,Abashar ,
MohammedA.Mohammedel toum,OsmanD.Abaker ,
on2017, ICCCCEEPubl i
cat ion.
[
3]“ Aut omat ionofBev er ageVendi ngMachi neusi ng
PLCandSCADA” ,byAbhi naw Kumar ,Puj aRaniand
Anjal i
, on05–May2016, AI JETPubl icati
on.
[
4]“ PLC basedaut omat ionofmul ti
plef l
ui dv ending
machi ne” ,byNi leshA.Badguj ar, Ni l
eshC.Dhobal eand
CASE3:MI
LKI
SADDED. Prof .El angoM , byAcademi a.edu.
[
5]ht tp:// www. boschr exrot h.com/ en/xc/
[
6]ht tp:// www. dsu. edu.in/ i
ndex .php/ i
nnov at i
on-l
abs/
[
7]“ PLC Tr ainingBasi cconcept s”byRex rothBosch
Group..
[
8]“ Sampl epr ogr amsf orPLC Tr aining”byRex roth
BoschGr oup.
[
9]ht tps: //realpar s.com/ pl c-progr ammi ng-languages/
[
10] ht tps://www. el
ect rical4u. com/ progr ammabl e-
CASE4:CYCLECOMPLETE l
ogi c-cont roll
er s/

VI
I. CONCLUSI
ON

PLCi samul ti
loopcont r
olsystem whi chr educesman
powerandi ncreasest hesmoot hnessoft heoper at
ion.
Ital
soi mpr ovest hequal it
yoft hepr oductandcont rols
the process par amet ers with bett eraccur acy.The
automat ionofanysy stem oranyi ndust ryisnecessar y
i
nt he pr esent compar ati
ve war df or t he better
perfor
manceoft hesy stem ori ndust r
y.Themai nand
mosti mpor tantpar tofanaut omat icsy stem i saPLC.
Byt heuseofPLC,wecanchangeanysy stem as
accordingt oourr equirementswi thoutchangi ngint he
hardwar e.Themanyot herbenef i
tsar eal sobyt hem it
i
susedl ikeit’
sr equiredl essspaceandl esspowert o
operate,ithasl ongl if
e,thechangi nginl ogiciseasy