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Automatic Empty Bottle detection using PLC Logic

Automatic Empty Bottle detection

This is PLC Program for Automatic Empty Bottle detection. This logic usually found in packing industries .

Problem Description

After completion of filling process, the bottles are moved on the conveyor for packing process. Here our objective is to Detect and remove if any empty bottle found on the conveyor. Implement PLC program for this application using ladder language.

Problem Diagram

PLC Logic to identify empty bottles in Packing

Problem Solution

  • For this application, we will use S7-300 PLC and TIA portal software.
  • In this example, we used two proximity sensors for bottle detection and empty bottle detection.
  • One proximity sensor is calibrated such that it detects only empty bottle and other one is calibrated such that it detects all bottle.
  • Conveyor used for bottle transportation. Cylinder is used to throw empty bottle out of the conveyor.

List of Inputs/Outputs

Inputs List

  • Cycle START = I0.0
  • Cycle STOP = I0.1
  • Empty bottle detector = I0.2
  • Bottle detector = I0.3

Output List

  • Cycle ON = Q0.0
  • Conveyor ON = Q0.1
  • Cylinder ON = Q0.2

PLC Ladder diagram

PLC Logic for Packing Plant

Ladder Logic Description

In this application we have used Siemens S7-300 PLC and TIA Portal Software for programming.

Network 1

In network 1 we used latching circuit for cycle ON (Q0.0) output.it can be started by pressing cycle START PB (I0.0) and STOP by pressing STOP PB (I0.1).

Network 2 

When cycle is ON, conveyor will be ON.

Network 3 

When empty bottle is detected (I0.2), relay coil will be ON for internal shift register logic.

Network 4 

Here bottle detector detects all bottles .Shift register will shift bit at every positive edge of bottle detector (I0.3).

Network 5 

Cylinder is mounted after five steps. So when empty bottle is detected, bottle detector will count steps and after 5 steps it will activate the cylinder.

Note :- Above application may be different from actual application. This example is only for explanation purpose only. We can implement this logic in other PLC also. This is simple concept of empty bottle detection using PLC, we can use this concept in other examples also.

All parameters and graphical representations considered in this example are for explanation purpose only, parameters or representation may be different in actual applications. Also all interlocks are not considered in the application.

Author : Bhavesh

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1 comment

Maher Yahya Salloom November 21, 2018 at 9:48 pm

Have a nice day

Thank you for your cooperation. Kindly, I would like to get book or file contains all your tutorials.
Hope you will help me.

Best Regards


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