1 liquid filling machine basic structure and control requirements

1.1 Production line structure and work process

The basic structure of the automatic filling machine consists of five parts: cleaning link filling link, capping link, packaging link and testing link. Cleaning link is through the recycling back to the beverage bottles for cleaning, first of all the first empty bottles into the special cleaning fluid, bottle cleaning, disinfection, and then through the bottle pouring machine will be cleaned out of the cleaning fluid and then cleaned empty bottles through the conveyor belt sent to the filling link. Filling link is PIC control solenoid valve will be air pressure conduction to control the air pressure valve to bottle filling, when the liquid level height reaches the standard air pressure valve stop filling, filling mouth will be filled bottle down, and then by the conveyor belt will be sent to the next processing link. Capping link fixed frame will put the cap into the bottle mouth so that the thread of the cap and the bottle mouth thread overlap, through the conveyor belt to measure the wall of the friction chain will be rotating the bottle to tighten the cap, to realize the sealing of the cap. Packaging link is composed of two fixed wrapping paper axis, when the bottle is sent to the packaging position, the packaging tape will be one end of the bottle side wall bonding, and then rotate the bottle, so that the wrapping paper wrapped around the bottle, wrapped around a week after the wrapping paper cut off, the other end of the wrapping paper is fixed to bond to the bonding place, the end of the packaging link. Finally, the processed products through the detection link of the sensor sensor detection of bad, including bottle external damage, cap encapsulation bad, bad packaging, filling level bad, etc., and finally the robot will be unqualified products to move to the designated area, qualified products for boxing, so that the entire processing process is over.

1.2 Control requirements

Automatic filling machine needs to be designed manually and automatically two modes of operation. Manual mode is used for equipment maintenance and debugging and counting statistics reset, automatic mode allows the start of the normal operation of the production line. And realize the following functions:

(1) emergency stop function

When equipment failure or personnel injuries wide, press the emergency stop button to stop the operation of the equipment so the requirements of each production link should be equipped with an emergency stop button, and the direct role of the power supply.

(2) Manual mode

In manual mode, the conveyor belt motor can be started and stopped by clicking the button, which is used for debugging the equipment. The qualified product count value is zeroed by the reset button. Each section can be commissioned independently through the start-stop switch of each section.

(3) Automatic mode

In automatic mode, press the start button, the system starts, the motor starts and the conveyor runs. When the empty bottle reaches the filling position, the motor stops and the filling valve opens. The filling valve closes when the filling time is up, the motor starts and the conveyor continues to run. In automatic mode, press the stop button, the system stops, the motor does not rotate, the conveyor belt stops running, and the equipment in each link is powered off and cannot be started independently.

(4) Product counting and statistics filling system can realize the statistics of product quantity, including the number of qualified products and the number of unqualified products. The number of qualified products and the number of unqualified products are displayed on the control panel, when the number of qualified products for the 12 constitute a box, the number of qualified products to clear the zero, the number of unqualified products for the 5 production line stops, the staff to carry out overhaul, the problem is dealt with manually open the start button, the system continues to work.

(5) Analog detection

The liquid level in the filling bottle is monitored by the analog level sensor, and when the liquid level is lower than the set lower limit, the feed valve should be in the open state, and when the liquid level is higher than the set upper limit, the feed valve should be in the closed state.

(6) the coordination of processing links through the coordination of each link. Realize automatic filling and a series of processing of automatic cattle production equipment, once the production line is started, the conveyor belt motor starts to drive the conveyor belt to run, after processing of empty bottles through the cleaning part of the bottle inside and outside the cleaning, sterilization, disinfection and other processing. After packing, the bottles are transferred to the inspection part by the conveyor belt, and the defective products will be moved to the designated area through the manipulator after inspection by the inspection sensors.

2 system hardware circuit design

Filling system hardware is divided into the main circuit, control circuit, auxiliary circuit three major parts, the control circuit to control the main circuit, auxiliary electric circuit to play the role of auxiliary signal display.

2.1 Main circuit design of the system

Conveyor belt with motor M1 to drive, robot up and down to drive the use of M2, robot left and right to drive the use of M3, and contactor KM1 to control the operation and stop the motor, contactor KM2 and KM3 to control the robot up and down to control the robot left and right with the contactor KM4 and KM5 to control the robot move. Overload protection is realized by thermal relays FR1, FR2 and FR3. Circuit breakers OF1, OF2, 0F3 will be introduced into the three-phase power supply, while OF1, OF2, OF3 for the circuit to provide short-circuit protection.

2.2 Control circuit design of the system

The system uses OMRON's CP1H-XA40DR-A PLC as the controller for the automatic filling machine filling system.

3 Configuration monitoring design

This system uses the configuration king 6.53 version of the development software when designing the screen flow of the filling operation station. The configuration king software has been successfully used in the chemical industry, iron and steel, electric power, sewage treatment and other winter industries, and has also been successfully used in national defense, aerospace and other major fields.

The whole process of automatic filling, first from the beginning of the cleaning process, and then in turn is the filling process, capping process, packaging process, inspection process, the control panel in the upper right corner of the figure, through the control panel can be manually controlled by the system, the control panel also provides the number of qualified products and the number of unqualified products.

First of all, according to the order of processing to create the required processing link, which has five parts: cleaning link, filling link, capping link, packaging link, testing link, and then design the manual control interface, due to the first bottle into the cleaning link. Filling session, capping session, packaging session and testing session all need to stop working, so the control interface should have control switches for each session to ensure no waste of raw materials and smooth transfer of products. The cleaning process utilizes flashing water droplets to represent the cleaning process however, the actual cleaning process is much more complex than it appears. The filling process ensures that the last movement of the bottle is placed just at the filling port, and the filling process of the liquid inside the bottle is shown by the filling in the animation link. The capping process requires the capper to be lowered when the bottle stops at the capping port, thus simulating a process of capping. Packaging is relatively simple, and only requires an animated link to make the implied logo appear in time at the final stopping point of the bottle. Detection link with a robot, randomly grabbing bottles, used to show the process of testing products.

4 system operation and debugging

Installed on the computer CX-ONE software, the program is programmed, the program will be entered into the CXProgram software, the initial simulation debugging on the computer, test the program without writing errors to the laboratory in kind according to the external wiring diagrams connected to the real thing, the first PLC program written in the program controller. And PLC and configuration king communication connection. In accordance with the working order of the system to control the system, the system will be turned on the system indicator will light up, the system enters the automatic operation state, press the manual control buttons of each link can be manually controlled on the system, randomly press the test sensing button to simulate the test sensing the working state to control the test link of the working state, in turn, press the up and down left and right travel switch buttons to control the robot's up and down left and right Move. Observe the PLC control of the various output ports in accordance with the programmed order of work, the system for a reasonable and appropriate adjustment.