1 Introduction

An automatic filling machine is a mechanical automation device that automatically packages liquids". The liquid is stored in a finished container and is generally filled by gravity into the target container to be packaged. As an example of an automatically packaged liquid as a cream, the edible is to be filled into empty bottles. First of all, the empty bottle through the conveyor belt is transported to the end, and then into the automatic filling machine, the first process for the empty bottle wall cleaning bit, through the solenoid valve to open the flushing mechanism, to the bottle of high-pressure water, after a certain time delay; liquid filling machine rotary body motor rotation, into the next station a drying / disinfection bit, the drying motor running to dry the empty bottle, and the use of high-temperature heaters for disinfection; and then into the next station for automatic weighing, sterilization, and then into the next station. Then enter into the next station for automatic weighing, filling, by gravity, filling the paste into the empty bottle; and then enter the capping / labeling position, after the completion of the action of the rejection of the next line, into the full bottle conveyor line, transported to the end, by the packing robot to grab the full bottle of paste for boxing, so that a bottle of paste to complete the processing process.

The filling production line is an automation technology control system integrating automatic cleaning, automatic drying/sanitizing automatic weighing and filling, automatic capping/labeling rejecting, cartoning and other processes. With stable system operation, high reliability, low failure rate and so on.

2 system overall program design

2.1 Filling machine control process analysis

Based on the filling system control function and process analysis, the system is used by the conveyor motor to drive the operation of the conveyor belt; rotary mechanism motor for the unidirectional rotation, the rotation process will be triggered by the position of each position signal, so that you can judge the position of the rotary mechanism; drying motor for the fixed An rotating, play a role in the drying of empty bottles.4 the whole set of system technology action process is as follows: empty bottles by the conveyor belt is delivered to the Rotary dispenser, installed at the end of the conveyor belt has a detection switch to detect whether the empty bottle in place; such as empty bottles, the dispenser to complete a cycle back to the initial position, that is, the automatic cleaning position, then the conveyor belt running to the empty bottle filling machine, while blocking the photoelectric switch in place; if there is no empty bottles, the conveyor belt has been running until the empty bottles to the end of the conveyor.

When the empty bottle into the filling machine, the filling machine is equipped with a detection switch to detect the empty bottle in place, when the detection signal is ON, that the empty bottle has been in place to carry out the next sequence of operations. Subsequently, open the cleaning valve to release high-pressure water to clean the empty bottle, delayed for a period of time, the cleaning action is complete, the filling machine began to rotate to the drying/sanitizing station;

When the quantitative filling machine is transferred from the cleaning station to the drying/disinfecting station, the drying/disinfecting station detects that the sensor signal is ON, opens the drying motor to blow-dry the empty bottles, and at the same time opens the high-temperature heater, and after a time delay, the blow-drying/disinfecting action is completed, and the dispenser begins to rotate to the filling station for filling of the paste;

When the weighing and filling machine rotates to the filling station, when the weighing is finished, open the unloading valve and start to fill the empty bottles, due to gravity control of the paste flowing into the empty bottles, the empty bottles have a certain volume, so use the delay time to control whether the empty bottles are full or not, and after a certain delay time, the empty bottles are full, the filling machine starts to rotate and turn to the capping/labeling station;

When the metering filling machine to reach the capping / labeling station, first open the capping valve using a pneumatic way to drive the capping mechanism of the full bottle of paste for capping, while labeling, after the completion of the action, the side of the filling machine is installed with a rejection cylinder, rejection valve is electrically powered to drive the cylinder to the filling of a good full bottle of paste rejection out, rejection and then rotate to the initial position to wait for the next empty bottle into the next cycle to complete the action of the question;; the action of the question. The action of the next cycle is completed;

When the full bottle of paste is rejected to the full bottle conveyor belt, along the conveyor belt forward, transported to the tail end, the carton robot action, the full bottle of paste to grab the code to the empty box, thus completing the production process of a bottle of paste.

2.2 Automatic weighing part

Automatic weighing is the core of the whole filling system, the whole weighing part is mainly composed of 2 parts:

The first part is the weighing hopper in the lower center, which adopts the hanging installation structure. And above the connection of 2 weighing modules, used to detect the weight of the hopper, if the weight reaches the packaging requirements, the system automatically opens the drop valve mechanism, after a certain delay, the valve closes, above the hopper to continue to put the material;

The second part is the feeding mechanism located at the top, which is processed inside the upper conical part, and the bottom is the automatic feeding device, which is driven by servo motor. If the lower hopper is empty or not, the controller controls the servo motor to open the automatic feeding mechanism, when the hopper is about to reach the packaging weight, the servo motor to the feeding mechanism to close the small, not completely closed, after a certain delay time, the servo motor at high speed to the feeding mechanism is completely closed, to complete the automatic weighing of a time.

The control process described above is a very typical closed-loop filling system. The Unipulse F701 automatic weighing controller is used to control the servo system by collecting the weight value fed back from the weighing module and adjusting the opening degree of the feeding mechanism automatically. When the weighing is finished, the weighing completion interlock signal is transmitted to the PLC system of the filling machine, the PLC detects whether there are empty bottles running to the filling position, if running in place, the empty bottles in place of the interlock signal is fed back to the weighing filling system, and the weighing control system will control the opening of the drop valve mechanism, and the weighing is completed for filling.

2.3 Selection and requirements of the system control program

Select PLC control of automatic filling machine, filling processed liquid is food-grade, so the filling machine automation equipment system should meet the needs of clean grade; the production capacity of the whole set of filling equipment should meet the needs of the factory; the set of automation equipment should be easy to repair and maintenance, and low failure rate; the whole set of equipment, the electrical system program is friendly, easy for users to operate the use of the equipment; equipment, the action process is coherent, to be able to Maximize the time saving.

2.4 System hardware circuit design

According to the automatic filling machine process flow for effective selection of electrical components to determine the main control principle of the automatic dispenser, SB1 and SB2 were used as the system's start button and stop button to control the start and stop the entire system; H1-H4 for the dispenser body rotary body of the detection of each position of the switch, the system according to the location of the body for the implementation of each process; SG1 for the detection of empty bottles ultrasonic SG1 is the ultrasonic proximity switch for detecting empty bottles, and the PLC receives the signal from the load cell to control the running status of the conveyor belt motor; KM1-KM3 are the control contactors of the conveyor belt motor, the rotary motor of the filling machine body, and the drying motor, which receives the commands from the PLC to control the suction and breakage of the contact points, and the AC contactor adopts a 24V power supply coil, which can be directly connected to the PLC's output; YV1-YV4 are the solenoid valves of the control system, which also receive the command from the PLC. YV1-YV4 are the solenoid valves of the control system, also receiving control commands from the PLC, and the coil is powered by 24V.

2.5 System Programming

PLC program design (part) is analyzed as follows: network 4 and network 5 is when the empty bottle into the initial position, open the cleaning valve on the empty bottle cleaning part of the program. After the system runs M0.0 turn on, when the filling machine body back to the initial position, I0.2 signal is ON, after a delay of 2S, the conveyor belt to empty bottles into the filling machine body, empty bottles in place signal I0.7 is ON, to meet the above conditions, there will be a rising edge, set Q0.3, the cleaning valve opens to clean the empty bottles. When the cleaning valve is opened for 5S, timer T41 is turned on, resetting the cleaning valve QO.3.

When the automatic operation, the cleaning valve action program, when the system is in the stop state, can be debugged by the manual cleaning solenoid valve button on the touch screen, press the button, cleaning valve action, release the button, cleaning valve reset. Network 10 and Network 11 for the action program of the unloading valve. When the filling machine body rotates to the filling position, that is, 0.4 signal state is ON at this time the empty bottle in place signal I0.7 has been ON, to meet these conditions, it will trigger the unloading valve to start unloading, the empty bottle for the beverage filling, when the unloading valve opens 2S, the time relay T43 on, reset the unloading valve Q0.4.

When the system stops, you can debug the unloading valve through the manual unloading solenoid valve button on the touch screen, when the button is pressed, the unloading valve is actuated, and when it is released, the unloading valve is reset.

According to the system's process flow, the use of touch-screen program written by the human-computer interaction, as shown in Figure 9, the system's start-up program interface, the interface can see the PLC's input signals and output signals of the state of change, debugging the system, you can observe the interface for the PLC wiring calibration. In the lower part of the interface, you can press the start button, and the start button on the operating panel plays the same role, when the process requires stopping the system, you can also press the stop system button on the interface, and the stop on the operating panel Anne plays the same role, when clicking on the button to run the monitoring interface, it will jump to another interface.

The system's monitoring interface in the interface can also start or stop the system, but also when the system is stopped, through the left side of the manual test button area of the system's winter components of the debugging test, press the appropriate button, the system will perform the corresponding action.

At the top right of the screen, you can observe the number of finished products that have been produced by the system, and when each shift is handed over, you can press the Count Zero button to clear the displayed count.

In the lower right corner of the screen, to be able to monitor the system's current faults, if a fault occurs, in the text box will have the appropriate prompts, when dealing with the faults and lifting the alarm, the contents of the text area will be cleared.

3 Conclusion

This study is still in the theoretical method of exploring the stage put into consideration as a slightly better fluidity viscous liquid, that its flow rate and flow rate in a certain period of time is fixed. The weighing of good into the empty bottle is the use of delay, that is, after a certain delay time after the drop valve is fully open, it is considered to fall completely in the empty bottle.

This study combines PLC, photoelectric switch, AC contactor and solenoid valve to initially realize the system control of rotary filling machine, while using simulation software to verify the correctness of the PLC program. But all the research results are in the exploratory stage, for the physical characteristics of the change is not well thought out, for the filling machine for each position detection should increase the limit switch to protect the system to avoid flying. The next step of the research work should be centered on the above mentioned problems for research and exploration, and the filling of the physical object to expand.