plc bottle label

8/12/2019 Plc Bottle Label

1/12

IJRRAS 6 (4) March 2011 www.arpapress.com/Volumes/Vol6Issue4/IJRRAS_6_4_10.pdf

434

AUTOMATION OF A PROTOMATIC LABELLER OF A BREWERYUSING SIEMENS SIMATIC STEP 7 CONTROL SOFTWARE: A CASE

STUDY OF ACCRA BREWERY LIMITED (ABL), GHANA

Erwin Normanyo1

, Afua Pokua2

& Isaac A. Adetunde3

1,2Department of EEE, Faculty of Engineering, University of Mines & Technology, Tarkwa, Ghana3Department of Mathematics, Faculty of Engineering, University of Mines and Technology, Tarkwa, Ghana

ABSTRACTIn this study, Siemens Simatic Step 7 control software was considered and used to make the labelling of bottled beerfaster; make the operations effective and efficient to meet the current line demand of 30,000 bottles per hour. ASiemens Step 7 Control Software based automated Protomatic labeller ensures the targeted 30,000 bph. For theautomation, inputs and outputs were established leading to choice of I/O modules. A PLC ladder logic program wasdeveloped and simulation was conducted using Simatic PLC SIM. Simulation results validated the applicability ofthe ladder logic program. Protomatic labeller automation guaranteed reduction in downtime, realization of targeted

production, easier troubleshooting and maintenance.

Keywords: Automation, Brewery, Protomatic labeller, PLC programming, Simulation, Software, Accra Brewery Limited (ABL).

1. INTRODUCTIONIn 1999, Webb and Reis in their book titled Programmable Logic Controllers: Principles and Applications emphasized extensively on PLCs as replacements for traditional relay-contactor logic, which were still in use atmost Plants or Industries. PLCs have become favourite tools in the control industry because of their simplicity,robustness, I/O interface and reliable performance. The traditional relay-contactor logic systems have proven to beinformation barriers to enterprise-wide data access. Evidence shown by Bryan and Bryan (1997) in their bookProgra mmable Controllers, Theory and Implementation that even though PLCs had no communicationscapability, they can be used in situations where communications was a desirable feature. At the time being,manufacturers of PLCs have devised many Communications techniques and pseudo-standard protocols, which areutilized in industry (Johnson, 1994, Clements-Jewery and Jeffcoat, 1996, Baily and Nipenz, 2003). The belief is thatthe inherent proprietary design of PLCs has limited data access for a number of reasons, such as limited amount ofmemory, the nature of programming language and the data access. In the light of the above talked about so far weshall now look into the Protomatic labeller of ABL, as one of the main machines at the packaging section of aBrewery. It is used to label bottled beer after filling and pasteurization by the filler and pasteurizer plantsrespectively. The former electrical design of the Protomatic labeller at its electrical panel at the packaging hall is a

big issue as it does not enable the labeller to meet the current line design of 30,000 bottles per hour; evidence hasshown that the current production output of 12,000 bottles per hour is starving the packer plant of labelled bottles.Some of the design problems are leveled below:

The electrical panel is purely based on relay logic controls, making troubleshooting more difficult and timeconsuming due to its inherent complexity.

The control of speed is through a mechanical gearing system and it is not time and event driven. Thismakes dynamic speed control more difficult.

The shift registers for determining bottle position are complex and hard wired and does not synchronize properly with the speed of the labeller.

Difficulty in synchronizing the hard wired controls of labeller with the programmable logic controllerswhich run the bottle conveyor lines for speed and interface controls.

The protomatic labeller currently does some void labelling due to lack of speed synchronisation between itand the conveyor system. This negatively affects the packaging process, thereby drastically reducing theentire packaging efficiency.

The aforementioned problems are a canker eating deep into the production and performance targets of the entire packaging system. A fully automated labeller using SIEMENS SIMATIC STEP 7 control software (SimaticManager) mitigates these problems.This paper is meant to:

Automate the protomatic labeller to meet the current line design of 30,000 bottles per hour. Enable easy troubleshooting of fault so as to reduce troubleshooting time.


2/12

IJRRAS 6 (4) March 2011 Normanyo & al. Automation of a Protomatic Labeller of a Brewery

435

Electrically control the speed and cause it to change dynamically. Give proper determination of the bottle position using soft shift registers. Increasing the production rate and output per hour. Increasing the operational flexibility of the labeller system.

Automation of the labeller plant is therefore imperative as it will improve its operational efficiency to meet thecurrent line demand of 30,000 bottles per hour.

Major developments have occurred in the area of automation in recent years. Industrial automation therefore, offersthe advantages of Quality factor, improved productivity, optimization of manufacturing operations, reduction ofwaste and labor costs (Bryan and Bryan, 1997, Webb and Reis, 1999, Erickson, 2005). Notwithstanding the meritsautomation provides, its demerits cannot be overlooked: technology limits, unpredictable development costs,relatively high initial costs (Parr, 2001).Beer brewing begins with raw material supply to the milling plant, milling, brewing, fermentation, filtration, storage

before it is sent to the packaging hall for bottling and finally ends with a palletised beer to the warehouse. Labelling plays a key role in the beer packaging process. The process cannot be complete without the filled bottled beerunlabelled thus identifying a particular beer residing in a filled bottle. Labelling can be done manually orelectrically. At Accra Brewery Limited (ABL), it is by electrical means which is accomplished by the KRONESPROTOMATIC labeller. Figure 1 shows a picture of a part of the protomatic labeller.

Figure 1. Part of the Krones protomatic labeller

The functional block diagram of the Krones Protomatic Labeller is presented in Figure 2.

Figure 2. Functional block diagram of the Krones Protomatic Labeller

Magazime

BottleBrush

BottleHolder


3/12


436

1.1. Mode of Operation of the Existing Protomatic Labeller SystemThe filled bottles from the pasteuriser through the conveyors come to the labeller to be labelled. The operator

presses the start push button at the console to start the labeller. The labeller runs on idle speed (lowest speed) untilthe bottles coming are sensed by the in-feed monitoring inductive proximity sensor. The bottles are allowed toaccumulate to the next proximity sensor after which the bottle stopper opens automatically (i.e. if bottle stopper ison automatic mode) to allow bottles into the labeller. The bottle present inductive proximity sensor senses the presence of the bottles which actuates the shift register tostart processing the positions of the bottles. The shift register signals the magazime at labelling station 1 to shootforward if the bottle is almost at the labelling station. The label pallet picks up glue at the glue station and takes alabel at the label rail which rides on the magazime. The gripper cylinders pick up the labels from the pallet and whenat labelling position release the label on the bottle. This labelling station labels the front and the neck of the bottles.The bottles leave and travel through brushes for smooth labelling to the labelling station 2 where the bottle seat isrotated by mechanisms to position the bottle for back labelling. After bottle rotation and fine tuning, the shiftregister prompts the magazime at station 2 to shoot for the same process that occurred at station 1 to take place.After the labelling station 2 labels the first bottle, the labeller then builds up speed from the idle run speed to rampup speed and finally to full speed set by the operator at the console. The speed is measured in number of bottles perhour (bph). The labelled bottles then find their way to the fulls packer through the labeller discharge conveyors.There are label monitoring sensors that check whether the body, neck and back labels are present on the bottles andalso broken bottle detection sensors to check for broken bottles. Currently, control and operation of the ProtomaticLabeller at ABL is relay-contactor based. Mere looking at the mode of operation of the existing protomatic labellersystem, coupled with some of the problems and the disadvantages mentioned earlier gave birth to the relevance ofits automation.

2. MATERIALS AND METHODS2.1. Steps, Components and AnalysisThis study was conducted at the Department of Electrical and Electronic Engineering, Faculty of Engineering,University of Mines and Technology, Tarkwa in connection with evidence of what we saw and information gatheredat Accra Brewery Limited (ABL) in Accra, Ghana.

2.2. Siemens Simatic Step 7 SoftwareThe Step 7 software is a proprietary software produced by Siemens Automation and Drive. The software is userfriendly, which supports the user throughout all phases of automation solutions - from the design andimplementation stage through to plant monitoring and failure diagnostics. Step 7 contains numerous tools andfunctions for the most varied tasks in an automation project. Figure 3 below shows how the hardware and software

are combined.

Figure 3. Components of the hardware and software in using Step 7 control software


4/12


437

Applications of the Siemens Step 7 PLC Automation Control Software have been reported in the Literature. In theIndustrial Installations, the following works were done using the Siemens Step 7 Control Software: Duangsoithongand Kongnam, (2008), developed a PLC-based turbine control system for small hydroelectric power generation withKaplan turbine type. Miciu, (2008) developed an automation system for the optimisation of electrical and thermalenergy production in cogenerative gas power plants. Li, et al , (2009), designed a remote control laboratory-basednetwork. A gas storage facility was programmed by Strickler, (2000). Ioannides (2004) designed and implemented amonitoring control system for an Induction Motor using PLCs. Goff (1990) reported on the experience gained inautomating three skid-mounted reciprocating gas engine compressor packages on Gulf of Mexico remote unmanned

platforms. To add to these, the following works have also been done with regard to Brewery Installations: The PLCwas used in a yeast cropping system to monitor yeast concentration with the aid of a yeast probe thereby directing a

portion of yeast crop to an assigned storage vessel (Carvell and Turner, 2003). Ogawa and Henmi, (2006) employedthe PLC in conjunction with the personal computer to automate a major Japanese beer brewery company with theaid of an advanced brewing integrated control systems (ADBIC). Buttrick, (2006) reassured of significant benefits to

be gained from installing efficient PLC based automated beer l ine cleaning equipment.In this paper, use is made of the Siemens Step 7 Control Software to automate the Protomatic Labeller of AccraBrewery Limited. The Step 7 Standard package provides a series of applications within the software. These are:simatic manager, symbol editor, hardware diagnostics, hardware configuration and communication configuration.

2.3. A Siemens Step 7 Software Based Automated Protomatic LabellerIn automating the Krones Protomatic Labeller, the flow chart below gives the operation of Siemens Step 7 controlsoftware.

Figure 4. Flowchart of considerations in automating the protomatic labellerProgramming of the Protomatic labeller starts by first (not always the case but it is the best method) configuring thehardware. The total process input signals number 43 whilst total output signals number 33. With 43 input signalsneeded to the PLC, a total of two (2), 32 channel digital input modules with module number, DI 32 * DC 24 V,312-1BL00- 0AA0 are selected. With 33 output signals needed from the PLC, a total of two (2), 32-channel digitaloutput modules with module number, DO 32 * DC 24 V, 322-1BL00- 0AA0 is required.

2.4. Programme SimulationThe SIMATIC PLC SIM is the software for simulation of step 7 program without physical hardware. This programcan be used to simulate any step 7 program but becomes inconvenient for simulating very large programs as therewill be more inputs and outputs. The software is part of the Simatic Step 7 Professional software package.


5/12


438

3. GENERAL REMARKS ON THE STEP 7 PLC PROGRAMS OF THE PROTOMATIC LABELLER

3.1 STEP-7 PLC ProgramSamples of Networks of the PLC program using Siemens Step-7 Software are presented in Figures 6 to 15.

Figure 5. Safety doors healthy and E-stops programming

Figure 6. System healthy programming


6/12


439

Figure 7. Machine run command programming

Figure 8. Bottle stopper open programming


7/12


440

Figure 9. Accumulation delay programming

Figure 10. Machine height adjustment up command programming


8/12


441

Figure 11. Machine height adjustment down command programming

Figure 12. Shift register programming

Figure 13. Front label carriage solenoid valve programming


9/12


442

Figure 14. Front label carriage glue scrapper solenoid valve programming

Figure 15. Back label carriage solenoid valve programming


10/12


443

3.2 Simulation ResultsSamples of simulation results are presented in Figures 16 to 19

Figure 16. Simulation of machine height adjustment up program

Figure 17. Simulation of machine height adjustment down program


11/12


12/12


445

4. DISCUSSION OF RESULTSIn the program simulation, the green light depicts the presence of power and the dotted line an absence of power. Thenetwork with all green lights means that there is power through the inputs and output on the rung, hence they are activated.The network with green lights and dotted lines show that there is power although the input/output are not activated. Thismay happen if the input/output signal that is to energise the device has not been received for action.

5. CONCLUSIONThe Protomatic labeller forms a vital part of the packaging section. Its existing system causes a lot of down time which

reduces production. Automation of the Protomatic labeller has been successfully undertaken in this paper. The PLC ladderlogic program engulfed all listed inputs and outputs. Simulation of the program using Simatic PLC SIM was conductedtaking one rung at a time since all codes cannot be simulated at a go. Simulation results validated the correctness andapplicability of the generated PLC program. The program for the first run took less than 45 minutes to run. From theresults of the automated protomatic labeller, the expected production output of 30,000 bph has been met, assured isreduced downtime and ease of troubleshooting. Speed control was effected electrically in order to be able to synchronisewith the speed of the bottle conveyors. From the simulation results, the automation of the Protomatic Labeller is possibleand when automated will help Accra Brewery Limited to meet and improve their current line design of 30,000 bottles perhour to increase real time production capacity. Aside, easier troubleshooting in less time is assured, speed control becomestime driven, better interface controls, good synchronization of shift registers with labeller speed and conveyor systemfacilitating void labeling,. The automation of the Protomatic Labeller need be considered and accepted by AccraBrewery Limited for full scale implementation.

6. REFERENCES[1]. Anon, (1999), Siemens Simatic S7, Programming with Step 7 V5.0, Siemens Automation Industry Manual , Chapter

one, pp. 2-5.[2]. Anon, (2002), Startup PLC -Programming with Step 7 , Siemens Automation and Drive Technology, pp. 14.[3]. Anon, (2007), SIPARK SSD Car Park Guiding System, A Professional Solution Designed to Industrial World,

available at http:// www.siemens.com/traffic, accessed on 29/04/2010, 12 pp.[4]. Anon, (2008), End -to- end Automation for Breweries, A vailable at http://www.logicsmagazine.com accessed on

22/02/2010.[5]. Anon, (2010a), Industrial Automation, available at http://prograplc.blogspot.com accessed on 11/01/2010.[6]. Baily, D. and Nipenz, E. W (2003), Practical SCADA for Industry (IDC Technology) (Paperback), Newness Publishers,

Oxford, UK. ISBN: 0750658053.[7]. Bryan, L.A. and Bryan, E. A. (1997), Programmable Logic Controllers : Theory and Implementation , Industrial Text

Company Publication, Second Edition, Atlanta, Georgia USA, ISBN 0-944107-32-X, pp. 4.[8]. Buttrick, P. (2006), Automated Beer line cleaning, The Brewer and Distiller, Vol. 2, Issue 8. Available at

www.ibd.org.uk.[9]. Carvell, J. P. and Turner, K. (2003), New Applications and Methods Utilizing Radio-Frequency ImpedanceMeasurements for Improving Yeast Management, Master Brewers Association of the Americas(MBAA TQ), Vol. 40,

No. 1. Pp. 30-38. Publication no. T-2003-0305-01.[10]. Clements-Jewery, K. and Jeffcoat, W . (1996), The PLC Workbook. Prentice Hall Europe, UK. ISBN: 013 -489840-0.[11]. Duangsoithong, T. and Kongnam, C. (2008), Project Report, 2008. Available at www.hadooji.com.[12]. Erickson, K. T. (2005), Programmable Logic Controllers: An Emphasis on Design and Application, Dogwood Valley

Press, LLC, Rolla, USA. 1450 pp. ISBN: 0-9766259-0-3 .[13]. Goff, W. H. (1990), Automation of Reciprocating Gas Engine Compressor Packages using Programmable Logic

Controllers. IEEE Transactions on Industry Applications, Vol. 26, No. 5 . September/October 1990.[14]. Ioannides, M. G. Design and Implementation of PLC - based Monitoring Control System for Induction Motor, IEEE

Transactions on Energy Con version, Vol. 19, No. 3, September 2004, pp 469-476. DOI: 10.1109/TEC. 2003.822303.[15]. Johnson, G. W. (1994 ), Lab View Graphical Programming, McGraw-Hill, Inc., New York, USA. ISBN: 0-07-032692-4.[16]. Li, P., Nie, L. and Jing, J., (2009), A Remote Control Laboratory Based on Network, in Proceedings of the

International Symposium on Intelligent Informa tion Systems and Applications (IISA09). Qingdao, P. R., China, Oct. 28-

30, pp.608-612.[17]. Miciu, I., (2008 ), Automation System for Optimization of Electrical and Thermal Energy Production in Cogenerative

Gas Power Plants, World Academy of Science, Engineering and Technology, 47, 2008. pp. 114-118.[18]. Ogawa, M. and Henmi, Y. (2006), Recent developments on PC+PLC based control systems for Beer Brewery Process

Automation Applications. SICE -ICASE International Joint Conference, 2006, Oct. 18-21, 2006 in Bexco, Busan, Korea.[19]. Parr, E. A. (2001), Programmable Controllers: An Engineers Guide, 2 nd Edition, Newness, Oxford, UK. ISBN: 0-7506-

39350.[20]. Strickler, J., ((2000), Gas Storage Facilities Saves Time, Money while Maximising Safety, Pipeline and Gas Journal ,

Oct. 2000, pp. 1-2.[21]. Webb, J. W. and Reis, R. A. (1999), Programmable Logic Controllers: Principles and Applications, 4 th Edition, Prentice

Hall, New Jersey, USA. ISBN: 0-13-679408-4.
http://www.siemens.com/traffichttp://www.logicsmagazine.com/http://prograplc.blogspot.com/http://prograplc.blogspot.com/http://prograplc.blogspot.com/http://www.logicsmagazine.com/http://www.siemens.com/traffic

plc bottle label

Documents