1. EcoFill Bottling Report
Prepared for: Neal Mohammed, Program Coordinator of Automation and Robotics
Prepared by: Chris Uccello, Lucas D’Erman, Ahmad Khabbas, Mattay Chabursky
Course: ATMN 310 - Electromechanical Engineering Technology, Automation and Robotics
Submitted Date: Thursday, April 21st 2016
ECOFILLL
BOTTLING

2. 2
Eco Fill
Automated Bottling Service
The Eco Fill bottling station is an automated recycling process of previously used bottles. It
cleans, fills, and caps used bottles through an eco-friendly process. The idea behind the station is
to encourage users to recycle used bottles at the EcoFill station. The process is simple, the user
deposits a number of bottles, as to which, an ABB robot transfers the bottles to a neighbouring
conveyor belt, which takes them through a cleaning process. After this, the bottles are sent to a
station where they are filled and capped. The last step in the process is using a state of the art
quality control system, to ensure the bottles are ready for packaging. The bottles are then
packaged and ready for pick up by the new customers.
Chris Uccello: Project Leader, Electrical and Pneumatic lead, PLC support
Mattay Chabursky: PLC & HMI programming lead, Electrical support
Ahmad Khabbas: Mechanical and Robotics lead, Design support
Lucas D’Erman: Design and Mechanical Lead, Electrical Support

3. 3
Table of Contents
ABSTRACT.................................................................................................................................................. ………………………….1
TABLE OF CONTENTS.................................................................................................................................. ..............................…...2
LIST OF ILLUSTRATIONS .............................................................................................................................. ………………………….5
1.0.0 PROJECT OBJECTIVE – OLD REVISION................................................................................................ ………………………….7
1.1.0 GROUP MEMBER RESPONSIBILITIES....................................................................................... ………………………….9
1.2.0 METHODOLOGY..................................................................................................................... ……………………..….10
1.3.0 ECOFILL SYSTEM................................................................................................................... ……………………… ..11
1.4.0 PROCESS FLOW CHART......................................................................................................... ………………………...12
1.5.0 STATION BREAK DOWN .......................................................................................................... ………………………...14
1.6.0 FUNCTION OF DEVICES........................................................................................................... ………………………...16
1.7.0 CONCLUSIONS ...................................................................................................................... ………………………...17
1.8.0 COMPONENTS NEEDED .......................................................................................................... ………………………...18
1.9.0 COST ESTIMATE .................................................................................................................... ………………………...19
1.10.0 TIMELINE ............................................................................................................................ ………………………...20
1.11.0 HMI INTERFACES................................................................................................................. ………………………...21
2.0.0 PROJECT OBJECTIVE – NEW REVISION ............................................................................................... ………………………...23
2.1.0 METHODOLOGY..................................................................................................................... ………………………...23
2.2.0 OBJECTIVE............................................................................................................................ ………………………...25
2.3.0 PROBLEMS ENCOUNTERED.................................................................................................... ………………………...25
2.4.0 PROCESS.............................................................................................................................. ………………………...26
2.5.0 FLOW CHART PROCESS......................................................................................................... ………………………...26
2.5.1 FLOW CHART PROCESS ..................................................................................................... ………………………...26
2.6.0 DETAILED PROCESS .............................................................................................................. ………………………...28
2.7.0 STATION BREAKDOWN........................................................................................................... ………………………...30
2.7.1 STATION 0:BOTTLE DROPOFF ............................................................................................ ………………………...30
2.7.2 STATION 1:RECYCLING CLEANING ..................................................................................... ………………………...30
2.7.3 STATION 2 BOTTLE FILL...................................................................................................... ………………………...30
2.7.4 STATION 3 CAP PLACEMENT ............................................................................................... ………………………...30
2.7.5 STATION 4 CAP TIGHTENING............................................................................................... ………………………...31
2.7.6 STATION 5 PACKAGING....................................................................................................... ………………………...31
2.8.0 FUNCTION OF DEVICES.......................................................................................................... ………………………...32
2.8.1 ABB IRB 1200................................................................................................................... ………………………...32
2.8.2 CONVEYOR ........................................................................................................................ ………………………...32
2.8.3 HMI ................................................................................................................................... ………………………...32
2.8.4 ACTUATORS....................................................................................................................... ………………………...32
2.8.5 ABB IRB 1200................................................................................................................... ………………………...33
2.8.6 FEEDER ............................................................................................................................. ………………………...33
2.8.7 LIGHT CURTAINS................................................................................................................ ………………………...33
2.8.8 SMC SLIDERS ................................................................................................................... ………………………...33
2.8.9 COGNEX VISION................................................................................................................. ………………………...33

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2.9.0 MECHANICAL ADDITIONS....................................................................................................... ………………………...34
2.9.1 HMI ................................................................................................................................... ………………………...34
2.9.2 FEEDING / CLEANING STATION ............................................................................................ ………………………...34
2.9.3 CAP PLACEMENT................................................................................................................ ………………………...34
2.9.4 FILLING NOZZLES............................................................................................................... ………………………...35
2.9.5 CAP TIGHTENING ............................................................................................................... ………………………...35
2.9.6 ROBOT REJECTION ............................................................................................................ ………………………...35
2.9.7 PNEUMATICS...................................................................................................................... ………………………...35
2.10.0 COGNEX VISION (SETUP)..................................................................................................... ………………………...36
2.11.0 HMI DESCRIBED ................................................................................................................. ………………………...38
2.12.0 PROFESSIONAL PRACTICE................................................................................................... ………………………...52
2.12.1 WIRING............................................................................................................................ ………………………...52
2.12.2 LABELLING...................................................................................................................... ………………………...52
2.12.3 SAFETY............................................................................................................................. ………………………...52
2.12.4 NEATNESS........................................................................................................................ ………………………...52
2.13.0 PNEUMATIC DIAGRAMS......................................................................................................... ………………………...53
2.14.0 INPUTS AND OUTPUTS TABLE............................................................................................... ………………………...55
2.15.0 PROGRESS REPORTS .......................................................................................................... ………………………...60
2.16.0 ABB IRB 1200 ROBOT (INSTALL)........................................................................................ ………………………...63
2.16.1 BACKGROUND ................................................................................................................. ………………………...63
2.16.2 PROBLEMS ENCOUNTERED............................................................................................... ………………………...63
2.17.0 ABB IRB 1200 ROBOT (MANUAL) ....................................................................................... ………………………...65
2.17.1 INITIAL SETUP .................................................................................................................. ………………………...65
2.17.2 UNPACKING ..................................................................................................................... ………………………...65
2.17.3 CALIBRATION ................................................................................................................... ………………………...66
2.17.4 FLEXPENDANT ................................................................................................................. ………………………...67
2.17.5 & 2.17.6 ROBOT STUDIO .................................................................................................. ………………………...69
2.17.7 COLLABORATION AND INTEGRATION ................................................................................. ………………………...71
2.17.8 SAFETY............................................................................................................................. ………………………...80
2.18.0 WORK CELL LOAD CALCULATIONS...................................................................................... ………………………...85
2.19.0 PLC PROGRAMMING............................................................................................................ ………………………...88
2.20.0 ACHIEVEMENTS................................................................................................................... ………………………...92
2.21.0 FULL USER MANUAL............................................................................................................ ………………………...93
2.22.0 TROUBLESHOOTINGGUIDE.................................................................................................. ………………………...95
2.23.0 GROUP COLLABORATION..................................................................................................... ………………………...114
2.24.0 APPENDIX........................................................................................................................... ………………………...115
2.25.0 ABB ROBOT PROGRAM CODE ............................................................................................. ………………………...124
2.26.0 PLC PROGRAMMING CODE.................................................................................................. ………………………...124
2.27.0 EXTRAS AND IDEAS .............................................................................................................. ………………………...124

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List of Illustrations
ECOFILL WORK CELL................................................................................................................................. ………………………….2
OLD CELL LAYOUT...................................................................................................................................... ..............................……8
CLEANING STATION..................................................................................................................................... ………………………...10
U-SHAPE GRIPPER ..................................................................................................................................... ……………………….. 11
OLD FLOW CHART ...................................................................................................................................... ………………………...12
COMPONENTS NEEDED ............................................................................................................................... ……………………...…18
COST BREAKDOWN..................................................................................................................................... ………………………...19
TIMELINE.................................................................................................................................................... ………………………...20
OLD HMI .................................................................................................................................................... ………………………...21
USER DROP OFF STATION ........................................................................................................................... ………………………...24
NEW PROCESS FLOW CHART ...................................................................................................................... ………………………...26
NEW CELL ................................................................................................................................................. …………………….…..29
DRAWING OF NEW CELL ............................................................................................................................. ………………………...31
COGNEX VISION SYSTEM............................................................................................................................. ………………………...36
HMI SCREEN SHOTS................................................................................................................................... ………………………...38
PNEUMATIC DIAGRAMS ................................................................................................................................ ………………………...53
INPUTS & OUTPUT TABLES.......................................................................................................................... ………………………...55
MOUNTED ABBIRB 1200 ........................................................................................................................... ………………………...64
ABB IRB ROBOT (CONTROLLER) ............................................................................................................... ………………………...65
ABB IRB ROBOT (BASEPLATE) .................................................................................................................. ………………………...66
ABB IRB ROBOT (TEACH PENDANT CALIBRATION) ..................................................................................... ………………………...66
ABB IRB ROBOT (FLEX PENDANT) ............................................................................................................. ………………………...67
ABB IRB ROBOT (FLEX PENDANT BUTTONS) .............................................................................................. ………………………...67
ABB IRB ROBOT (FLEX PENDANT HOME) ................................................................................................... ………………………...68
ABB IRB ROBOT (ROBOTSTUDIO) ............................................................................................................. ………………………...69
ABB IRB ROBOT (FLEX PENDANT JOGGING) .............................................................................................. ………………………...71
ABB IRB ROBOT (FLEX PENDANT NEW ROUTINE) ...................................................................................... ………………………...72
ABB IRB ROBOT FLEX PENDANT PP) ......................................................................................................... ………………………...73
ABB IRB ROBOT (FLEX PENDANT IFSTATEMENTS) ..................................................................................... ………………………...73
ABB IRB ROBOT (FLEX PENDANT PROGRAMMING IFSTATEMENTS) ............................................................. ………………………...74
ABB IRB ROBOT (FINAL AND REJECTION BASKETS) ................................................................................... ………………………...75
ABB IRB ROBOT (ROBOTSTUDIO STARTUP) ............................................................................................... ………………………...75
ABB IRB ROBOT (ROBOTSTUDIO GOING ONLINE) ...................................................................................... ………………………...76
ABB IRB ROBOT (ROBOTSTUDIO AUTHORIZATION) .................................................................................... ………………………...76
ABB IRB ROBOT (ROBOTSTUDIO MASTER/SLAVE SETUP) .......................................................................... ………………………...76
ABB IRB ROBOT (ROBOTSTUDIO ETHERNET/IP) ........................................................................................ ………………………...77
ABB IRB ROBOT (ROBOTSTUDIO INPUTS/OUTPUTS) .................................................................................. ………………………...77
ABB IRB ROBOT (FLEX PENDANT DIGITAL INPUTS) .................................................................................... ………………………...77
ABB IRB ROBOT (ETHERNET FIELD BUS ADAPTER) ................................................................................... ………………………...78
RSLOGIX 5000 (ABB CONTROLLER TAGS) ................................................................................................. ………………………...78

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ABB IRB ROBOT (DUAL CHANNEL GUARD STOP CONTACTS) ..................................................................... ………………………...81
ABB IRB ROBOT (GUARD STOP WIRING DIAGRAM) ..................................................................................... ………………………...82
CLEANING STATION BOTTLE DROP BASKET.................................................................................................. ………………………...93
HMI FINAL PAGE ........................................................................................................................................ ………………………...94
CELL INDICATOR LIGHTS ............................................................................................................................ ………………………...95
RSLOGIX 5000 (ERROR CODE) .................................................................................................................. ………………………...97
RSLOGIX 5000 (PLC END CAP) .................................................................................................................. ………………………...98
RSLOGIX 5000 (SAFETY POINT IOERROR) ................................................................................................. ………………………...98
SAFETY POINT IO ....................................................................................................................................... ………………………...99
POINT IOINPUTS ........................................................................................................................................ ………………………...100
POINT IOOUTPUTS ..................................................................................................................................... ………………………...100
POINT IOERROR ........................................................................................................................................ ………………………...101
SAFETY PROGRAMMING .............................................................................................................................. ………………………...102
IO EXTENDER ............................................................................................................................................. ………………………...103
RSLOGIXI 5000 NETWORK CONFIG ............................................................................................................ ………………………...104
RSLINX EDS FILE ...................................................................................................................................... ………………………...105
RSLINX SETUP ........................................................................................................................................... ………………………...105
RSLINX RSWHO ........................................................................................................................................ ………………………...106
RSLINX DEVICE FAILURE ........................................................................................................................... ………………………...106
SMC OVER FLOW ERROR .......................................................................................................................... ………………………...107
SMC DRIVE ERROR ................................................................................................................................... ………………………...108
EVENT LOG ROBOTSTUDIO ........................................................................................................................ ………………………...109
ROBOT STUDIO ERROR 50028 .................................................................................................................... ………………………...110
ROBOT STUDIO ERROR 20206 .................................................................................................................... ………………………...110
ROBOT STUDIO ERROR 20072 .................................................................................................................... ………………………...111
ABB IRC 5 CONTROLLER BUTTONS............................................................................................................ ………………………...112
LIGHT CURTAIN RESET................................................................................................................................ ………………………...107
GROUP COLLABORATION ............................................................................................................................ ………………………...114
APPENDIX PHOTOS (CELL PARTS)............................................................................................................... ………………………...115
APPENDIX PHOTOS (ILLUSTRATIONS AND PROTOTYPES) .............................................................................. ………………………...115
APPENDIX PHOTOS (FINAL CELL)................................................................................................................ ………………………...124

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1.0.0 Project Objectives – OLD REVISION
The Eco Fill Bottling station is intended to provide users with an environmentally conscious
recycling system. This systemwill take recycled bottles, fully sterilize and clean them, and then
fill them up with a specific drink. In our case, water will be our specific liquid, but the options
are endless. Our project will accomplish the following: provide users with a clean, new product
and reward them with GreenCoins, for helping reduce their carbon footprint in the world. In
this project, we aim to have the user do as little work as possible, and have the automation of
the work cell do the rest of the work. The user will be provided a specific amount of GreenCoins
for how many bottles they are dropping off. The GreenCoin systemwill encourage users to use
the EcoFill recycling station.
Listed throughout the sections beginning with 1.0,1.1 and so on.
Possible Problems & Fixes
While brainstorming all possible ideas to improve the work cell, we came across several
important issues. Problems that we need to take into account are as follows: GreenCoin
system, capping station and the cleaning station.
Green Coin System
The plausible issue we may encounter with the GreenCoin systemis how many GreenCoins the
user will receive after using the EcoFill system. Determining if the user will receive coins for
using the system once, or will receive coins per bottle being recycled is the main issue. To fix
this concern, we will be making it mandatory for the user to bring back 6 bottles to be filled
which fit perfectly into the case. This will avoid any confusion for the user and as well in the
work cell.
Capping Station
The problem with the capping station presented from the previous version of this cell, is that
sometimes, the system flaws, and the bottle is not properly capped. We plan to fix this
complication by gripping the bottle in a more effective manner just before it is going to be
capped. Ensuring the sturdiness of the bottle will allow for a proper alignment of the cap just
before the capping mechanism will be placed on top of the bottle. The solution to this dilemma,
from what all the group members have come to agree on, is having two actuators properly grip
and stop the bottle from moving.

8. 8
Cleaning Station
The third obstacle we found, will be our new implementation of a cleaning system. What this
system will do, is stop the bottles on a conveyor belt, clean them with pressurized air
(simulated cleaning solution) and then send them on their way to be filled up at the fill station.
The issue we found was that the bottles may not always align properly with the three cleaning
nozzle heads. To guarantee proper alignment we will be adding an actuator which will have
three, “U” shaped sections which will stop the bottles from moving. Cleaning the bottles with
high pressured air will certainly move the bottles around as air will be flowing into the bottles.
Properly securing the three bottles on the conveyor before they are going to be cleaned, will
stop them from moving and avoid any damage.
Illustration2
Thisabove SolidWorksimage isof the oldEcoFill Bottlingrevision.Thissystemshowsthe twoconveyor
beltsalongwiththe cleaningstationattachedtothe firststationof the workcell. Thisisthe firstrevision
planof the EcoFill Bottlingstation

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1.1.0 Group Member Responsibilities and
Workload
Chris Uccello: Project Lead, Electrical and & Pneumatic lead, PLC support
Mattay Chabursky: PLC programming and Mechanical lead, Electrical support and Safety
Ahmad Khabbas: Robotics lead, Design and Mechanical support
Lucas D’Erman: Design and HMI lead, Electrical support
Each group member is assigned anarea of major responsibility. The role of each member will be focused
on throughout thewhole length of the project. The areas of responsibly for each group member are as
follows:
Chris Uccelloisassigned theproject lead, and will guide the group to perform specific designated tasks.
He will be in charge of managingthe tasks andduties of all the team members. Aside from being group
leader, he will be focusing onthe electrical andpneumatics of the cell. The electrical wiring diagram will
be created after research oneach component ofthe cell is found. The same concept will be done for the
pneumatics of the system;research and then a wiring construction will be made. Chriswill alsobe
providingsupportinthe PLC of the automated cell. Aside from the three focuses a general mechanical
supportwill be provided.
Mattay Chaburskyisassigned the PLCand HMI role for the project. He will be doing extensive research on
both, the Allen Bradley CompactLogix PLC, and the PanelView Plus 700 HMI. Research onall of the
inputs and outputs capable of both components will be doneand ladder logic for the mainprocess will be
constructed in the PLC appropriatesoftware. The programmingandvisual interface layoutwill be created
as well for the HMI systemincorporatingall appropriate EcoFill steps (i.e. username, password,
GreenCoins and numberof bottlechoice). Mattay will be providingsupportinthe electrical and research
of components within the cell andwill physically wire the cell. Research andwiring of safety components
will be done as well as safety aspects are mandatory inall automated cells.
Ahmad Khabbas willbe takingthe mechanical and robotics responsibility. He will be focusinghis role
towards all of the mechanical aspects of the cell. The physicallayoutof the whole cell, each component,
sensorand station will be laid outand physically assembled in place when all of the designand research is
completed. Extensive research onthe robotarm (ABB) will be needed in order to be able to programit.
Research on the ABB’scapabilities will be needed first, in order to achieve our EcoFill station process. He
will fully program the robotandresearch ways to communicatebetween the PLCprogramand the robot.
Ahmad will be providingsupportinthe overall cell design. He will provideways which may be more
effective toincorporate in each station of the cell.

10. 10
Lucas D’Ermanwill be takingthe design andmechanical lead within the project. Takingthe role of design,
he will be responsiblefor the layoutof each station, wiring and pneumaticdesign, and positioningof each
component. By finding the bestlocation for each componentinthe cell, we will be able to optimizeand
utilize all of the space provided onthe cell. He will be responsiblefor the designof the HMI user
interface. This designof the HMI will include all aspects of the EcoFill process. Lucas will also be providing
electrical supportonthe work cell and will help with the physicalwiring of each electrical componentas
well as a proper electrical diagram.
1.2.0 Methodology
The group has decided to focus on building a fully automated bottle recycling / filling station and
integrate all the automated aspects of a self-relying work cell.
We decided to add a new station to the cell in order to enhance the performance and increase
productivity. In the first weeks, the plan was to add one nozzle to clean one bottle at a time, with
the upcoming weeks we decided on a 3 way nozzle that will be able to clean 3 bottles at a time,
which will speed the process and increase productivity.
Cleaning Station Prototype
Illustration3
The abovedrawing is a prototypewhichwas designedto be the systemscleaning station. Thisstation
would be the startingpoint which the bottleswould be placed on by the robot.

11. 11
Another problem we are facing will be placing the cap on top of the bottle without crossing the
threads, we have done research on how to solve the problem, and it could be solved with rotating
the tightening mount half a rotation backwards before doing the full tightening process. If other
methods or ideas arise while building the project, the team will consider new applications. (See
Illustration 2 Below)
Illustration4
Stability of the bottles within the capping station also seems to be a problem that we inherited
from previous groups that worked on the cell. We believe that the bottles are not being held in
place properly, so the tightening mount can do its job efficiently. Adding rubber cushions to both
the side bar and the bottle gripper, could solve the stability problem. Bottle grippers will be
incorporated within the cleaning station, the filling station and the capping station to ensure
stability, safety, and quality throughout the process.
1.3.0 Eco Fill System
Process
The main idea behind this project is to integrate the automation industry in a way that can benefit the
environment by introducing the recycling station within our project. The recycling station will encourage
both commercial and industrial clients to implement this system due to its green approach. This project
currently has a number of stations including the filling, capping and finally the packaging station.

12. 12
Incorporating the recycling station will give this project an edge by allowing it to be used by the public in
shoppingmalls, residences, and even airports. The project can be described as one unit that has multiple
stations working together to deliver a final high quality product to the consumer in a very short time.
Incorporatinga “Green Coin”credit system will entice the customers to use the unitmore often to collect
more coins thatcan be used toward a discounted EcoFill Service or to at the any participatingsuper store.
1.4.0 Process Flow Chart – VERSION 1.1
Illustration 5
Above is a process flow chart which describes all of the steps involved in the EcoFill station
process. It explains in depth what each sensor will be doing during each station.

13. 13
Illustration6
The aboveflow chart illustrates the old EcoFill Bottling process from the revision1.0. Thisprocess involves
the two conveyorsystemwith the cleaning stationattached to the first 3 foot longconveyorbelt.

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1.5.0 Station Break Down
Station0: Unpacking Station
This is where it all begins, in this station the customerdeposits the empty bottle in the designated area
andinserts their personal information on tothe screen (HMI Screen) to access their profile in the green
coin system. After the customeris finished with entering the data needed, the process then starts.
Photoelectric Sensors will confirm that the bottles are in the right position and give the robota signalto
start the process. The robotwill pick up the bottles and drop them ontop of the conveyorbelt1.
Station1: Recycling/ CleaningStation
In this station the process moves onto the next stage, the robotwill drop off the bottles onto a still
conveyorbelt 1, a photoelectric sensorwill detect that the bottles are present and will delay the start
signal of the conveyorbelt to ensure the bottles remain in the upright position. Theconveyorbelt will
then trigger and moveonforward towards the cleaning nozzles. A photoelectric sensorwill ensure the
drop zone is clear. The three bottles are then stopped by an extended pneumaticcylinder andline up side
by side underthe cleaning nozzles. A sensorwill then send a signal tothe conveyorbelt to come to a
complete stop. The nozzles will then extend into the bottle andstart the cleaning process, a pneumatic
systemwill simulate the cleaning solution being sprayed in the bottles for 3 seconds. The cleaning nozzles
will then retract upwards away from the bottle, once fully retracted a reed/limit switch will activate and
send a signal tostart the conveyorbelt. The stopperwill retract allowing the bottles to continue the
process and moveto the next station.
Station2: BottleFeeder
Once the bottles have reached the end of conveyor1 andthe cleaning process is complete they will stop
via a wall. A sensor will check to makesure a bottle is present. Next, a horizontally positionedpneumatic
actuatorwill pull one bottleoff conveyor1 and load it in front of conveyor2 where a second pneumatic
actuatorpushesthe bottle onto a movingconveyor2. This process is repeated until three bottle are
loaded onconveyor2. Reed switches are in place ensuringpneumaticactuators are functioningproperly.
Station3: FillingStation
Once three bottles havebeen loaded onto conveyor2 they will move untilthey are stopped by an
extended actuator. The actuatorstops the bottles, so they are positioned for filling. Photoelectric sensors
will check to make sure three bottles are in place, if true, it will send a signal to start the filling process.
The filler is pneumatically driven, and works on the principle of gravity. First, two pneumaticcylinders
positionedvertically, will extend so thatthe filling nozzles are inserted into the bottles. As soonas the

15. 15
nozzles are inserted into the tops of the bottles, a horizontally placed cylinder will unblock the flow in
order to fill the bottles full of product. After specified time, the horizontally placed cylinder will extend to
its original position, blockingthe flow of the product. A reed switch will ensure this doubleacting cylinder
is at its extended position and a send a signal to the PLC. Thissignal will then retract the vertically placed
cylinder, when its retracted reed switch activates, this will then active conveyor2 to start moving.
Station4: CapPlacing Station
The next step of the process is placing the caps onto the bottles. After the bottles are filled, they move
down the conveyoruntil they are sensed by a photoelectric sensor. This triggers a pneumatic cylinder to
extend and secure the one bottle againstthe wall of the conveyor. Duringthis motion, a vertically facing
pneumaticcylinder fixed to slider, will retrieve one bottle cap. The slider is located aboveconveyor2 and
is fixed perpendicular to the conveyor. Thisallows the slider tobe able to reach and retrieve the caps
from the cap hopper, as well as place themon the bottles. The cap hopperis runningparallel with
conveyor2. The slider will moveto the position abovethe cap hopper. Next, the pneumaticactuatorwill
extend and at this time, a suction circuit will activate. A suction cap located at the bottom of the cylinder
will then grab onto one cap. After a onesecond delay, the cylinder will then retract. Next, the slider will
moveto its aboveconveyorposition andthe cylinder will extend. The suction circuit will disable at this
point, and the cylinder will retract. The process repeatsitself for the next bottle and reed switches will
ensure full strokes of cylinders are reached.
Station5: CappingStation
At this point, the bottles have received their caps and now they must be screwed on tight. First, the bottle
will move down conveyor2 untilthey reach the capping station. A photoelectric sensorwill detect thata
bottle is present andactivate a pneumaticcylinder toextend securing the bottle to the wall. Next a
pneumaticcylinder positioned vertically will extend, once fully extended, an electric motorwill turn on.
First, it will spin counterclockwise to avoid cross threading when screwing on. Next, the motorwill turn 2
full revolutions andnow the cap will now be secured, andthe cylinder will retract. A vision system will
ensure bottles are capped correctly, if acceptable the bottles will move on.
Station6: Packaging
After the bottle are filled and capped, they mustmoveon to be packed. At the end of conveyor2, three
bottles will line up. A photoelectric sensorthis will ensure bottles are in the correct position. Oncethe
bottles are in place, the robotwill pick themoff conveyor2 and load themin to the packing crate. The
process is repeated twice, tofill one crate (6 bottles per crate).

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1.6.0 Functions of Devices
ABB Robot IRB 1200Compact
The ABB Robotarmbeing incorporated with ourcell will serve as a great advantage. Itis a compactand
very versatile robotarm. Aside from the previously used Denso robotarm, the ABB robothas a much
greater range of motion andwill benefits ourwork cell. The purposeof this robotarm will be used for
picking upthe bottles (3 at a time) and placing them onconveyorbelt 1 and once ready for pick up, pick
them upat the end of conveyorbelt and place them in the bottle case.
Conveyorbelts
Both of the conveyorbelts that will be in our cell are goingto serve as the main flow of bottles in each
station. From the momentthe ABB robotpicks upthe three bottles and places them onthe first conveyor
belt the flow of bottles begins. Conveyorbelt 1 (Consists of cleaning station)will be connected tothe
second conveyorbelt 2 (Consists of filling andcappingstations). Actuators will push a bottle oneat a time
to go onto conveyorbelt 2. Once bottles are on conveyorbelt 2, the flow of bottles continues untilready
for packaging.
HMI PanelViewPlus700
The HMI (Human Machine Interface) will be the main communications between the user and the
machine. The HMI will promptthe user to typein a user nameand password they will make for their
account. The user account will be stored within the databasein the programandhold their information
andGreenCoin amount. Thepurposeof the HMI will be to showthe user the status of the system,
GreenCoin amount, and final receipt after use. Another feature we plan to incorporatewill be a
maintenanceinterface. This interface will be for the maintenanceworker toview the status, read error
messages, diagnoseand toggle any stations manually.
Actuators
ThroughouttheEcoFill work cell there are several different kinds of actuators. Each actuatorserves its
uniquepurposewithin the cell. The actuating cylinders work in a forward back linear motion. This motion
will be beneficial in the various stations of our work cell. The actuatorcylinders are used in the cleaning
station to stop the bottles in the rightpositions, bringdown the cleaning head for the bottles and transfer
the bottles from conveyor1 to conveyor2. There are more actuators in the filling station which movethe
feeder head upand down, actuators to stop the bottles in the right position in the filling station. Lastly
there are actuators in the cap placement and cappingstation. The actuators will firmly stop the bottles in
place which will then press and twist the caps onto the bottles.

17. 17
Reed Switches
There are reed switches onmostof ourdouble and single acting cylinders. They are used tomake sure
the actuatorhas reached the extended, or the retracted position. Thisis fairly helpful for a process
systemas it will give usinformation of each step of the process. The reed switches will also help prevent
damageto the physical systembe stoppingtheactuatorfrom going beyond its designed point.
Cognex Vision Control
The Cognex Vision systemis an incredible quality assurancepiece of equipment. It can makeall the
difference in ourautomated process. For oursystem, this helps us makesure each bottleis aligned
properly before the cappingaction takes place. If one of the bottles is notcapped properly, then the
Cognex will see the false alignment and it will be sent off asa reject. Havingthis vision system can almost
guarantee a steady stream of quality productfor the customer.
FeederHead
The previously built feeder head was constructed using2 actuators to pushdown the feeder head for the
filling process. The feeder headis madeup of 3 nozzles so the liquid can be fed easily into the bottles, and
keep the bottles aligned properly. The feeder head is a key component in our process as it fills the bottles
up with the liquid for repackaging.
Omron LightCurtain
This control reliable safety device is used in many automation systems. Inoursystem itwill be used to
ensure safety in the work cell, this device is used to avoid any possibleharmto the user or the work cell.
This safety device will be situated right in front of the robot’s rotatingarm.
1.7.0 Conclusion
Based onour project idea, cost estimate and feasibility, this project will be challenging, but most
importantly, practical. As third year Humber students, we haveimplemented concepts from our previous
year courses, such aspanel wiring, troubleshooting, mechanicaland electrical drawing to help us create
this idea. With the excellent teaching regime that our programhas to offer, we will succeed in our efforts
to build this proposed project. Ouroverall costneeded is substantially low. The initial, low level
investmentneeded will be returned easily, as this concept is the future, andthe future, is a step in the
right direction. The group hopes to have this system up andrunningwell before April of 2016 inorder to
focus our energy towards the troubleshooting ofthe system. Alongthe way, we doexpect to encounter
several if not many problems with the full integration between all of the electrical components.

18. 18
1.8.0 Components Required
Illustration 7
The abovetable highlights all thatwe will be needed, notethat this requirements cost breakdown is in
terms of the old EcoFill Revision 1.0. The image below is a SolidWorks designlayoutof the old revision 1.0
Illustration 8
Product Name Model Number
Manufactur
er Price Quote Quantity Total Price
PneumaticAir4 way air hose splitter a11120200ux0438 Uxcell
$ 18.85 1 $18.85
Actuator SR03 Parker
$ 13.66 3 $40.98
PhotoElectric Sensor EBF-R2B4 Omron $ 121.01
3
$363.03
Conveyer Belt System
1M042-
0400711D010119
$
1,200
.00 1 $1,200.00
+________
Sum
$1,622.86

19. 19
1.9.0 Cost Estimate
Illustration 9

20. 20
1.10.0 Timeline
Illustration10

21. 21
1.11.0 HMI Interfaces
Illustration 11
Thiswindow above will be the userstartpage on the HMI interface. Thispage will promptthe userto
entertheirusername andpassword whichwill be storedintothe HMI database.
Illustration 12
Thisinterface above will be the maintenance window. Thispage will only be usedbythe operatorwho
can only access itthougha keypadspecificcode. Thispage allows accesstoeachof the stationswithin
the cell and whatstate the stationis at.

22. 22
Illustration 13
Thisabove HMI interface iswithinthe maintenance section of the programwhichisagainonly
accessible throughthe operatorwindow. Thispage will displayall of the components andtheirstatus
whetherthe inputoroutputison or off. The I/O’scan manually be toggledthroughthiswindow.
Illustration 14
Thisabove userinterface page isthe final page thatthe userwill be able tointeractwith. The methodof
paymentandas well the GreenCoin amountwithinthe usersaccountwill be displayed. The total
accumulatedbottles returned, filledandGreenCoins will be displayed aswell.

23. 23
2.0.0 EcoFill Bottling - Final Revision
Following ourold work cell idea which consistedof a new conveyorbelt and cleaning stationattachedto
it, the grouphas decided to makea significant change. The sections which begin with 2.0, 2.1 andso on,
will consist of the structure, format, and designof the new and final constructionof the EcoFill work cell.
Regarding the EcoFill Bottling revision2.0, it will explain andtalk aboutwhat we havekept andtaken out
fom our original cell layout. Throughourefforts to try and complete ouroriginal idea, we needed to take
a step back and look at the bigger picture. As we had many groupmeetings, we wanted to be completely
practical andhonestwith ourselves, so we lookedback at our feasabilty aspect of this project. Couldwe
finish in time with what we wanted to add?Shouldwe focus ongetting the main functionworking first
before addingin different elemens? How confident are we in ourskills? These sort of questionscame up
andwe discussedthe issues.
2.1.0 Methodology
Our grouphasdecided to build andrepair a fully functioning automatedfilling/recycling stationand
integrate all automation aspectstomake this idea truly, self-relying, butwith some minorchanges.
We decided totake out the first conveyorbelt to eliminate any extra issues andcost, along with moving
the cleaning stationto anotherspot which is a much more logical approach. The groupagreed thatnew
conveyorbelt systemfor the cleaning stationwouldbring us problemsandset us back in termsof
perfecting the existing stationsin the work cell. We will revert back to a single nozzle thatextends
downwardfrom an overheadactuator. The single nozzlewill be placed just before the filling station, as
we will movethe filling station further downthe conveyorbelt so we can squeeze bothstationsonthe
one conveyorbelt. Having bothstationsonthe one conveyorbelt will make the whole process much
more linear andflow nicely.
The removal of the old conveyorbelt will add a lot of focus on the main linearity of the work cell. Keeping
the focus on the existing linear flow of the work cell will make the perfecting of the cell mucheasier. We
plan to focusall of our energy on the existing stationspresentas we havebeen told that the existing
cappingstation is notperfect. The groupplans toperfect each of these stations by dedicating time to
each stationand makethem wok flawlessly. With havingtwo conveyorbelts todeal with would holdus
back in achieving thisgoal. We would hate to havetried overachieving and notbe able to achieve what
we really want which is a flawless runningsystem.

24. 24
User Drop-Off Section
Somethingelse we changed is the manorof which the bottlesget fed into the system. We will
now let the customer dropoff the bottlesdirectly ontothe startof the conveyorbelt. The way we will do
this is adda mini slidingdoor madeof Lexan and a reed switch, so the whole process will begin, once the
sliding dooris closed. If the door is openedat any time duringthe process is running, themachines will
stop, sothat incorporatessomesafety into our new cell layout. We cannot stressthat safety is very
importantin what we believe in. The new ABB robotwill be surroundedbeLexan or guarding toeliminate
any potential threatsand hazards. The ABB is a fairly big robotthat can easily hurtsomeone, sowe are
takingthe proper protective actions. We will also just use the robotto transfer the bottlesfrom the
conveyorbelt to the packagingsystem.
Illustration15
This SolidWorksimage is goingto be EcoFill’s userdrop off section. This stationwill be the primary start
to the usersexperience with the work cell station. Attached to this stationwill be the HMI which will also
be the interaction of the user with the beginningandending of their experience.

25. 25
2.2.0 Objective
Regarding ourpreviousproposal, ourobjectives have changedin slight ways, but we are still keeping
track of our old objectives for goodreference from ouroriginal concept. Our maingoal is still to work
strongly as a team, and builda fully automatedrecycling/filling/capping andpackagingstation. We are
keeping a strict emphasison thismain goal, asit encompassesourskills andideas. For the
implementationof the reward system, we are keeping true to benefiting our customers throughanHMI
for easy use andto help promoteour product. We want to give somethingback to thosethat useour
system.
Integrationis a big part of this project, as it brings all the different pieces together, to be able towork as
one. This integration reflects our group, aswe are comingtogether to buildand complete it. Integrationis
importantonmany different platforms, including the safety one. We want to produce a quality product,
butwithin a safe environmentthatcustomerscan enjoy without being harmed.
2.3.0 Problems Encountered
We have faced many issuesand dilemmasaboutour project, butwe are striving tocollectively overcome
these issues. We have foundsolutionsto mostof our problems, andwe are on the right direction now.
We had a great idea at first with addingthe secondconveyorbelt, butquickly did we realize thatit would
be too muchwork andwe would notfinish on time. The hardestpart aboutgreat ideas like this, is
admittingthere is a problemin your idea thatyoumustaddress. Another major issuethat we
encountered, was our whole cell was notcompletely level. One of the wheels was flattened to due sitting
in the same spotfor many months. We usedthe pumptruck in class to lift ourcell, and repositionthe
wheel. Nowour cell is completely balanced with no leveling issues.
Another problemwe encounteredwas the proper plate size and screw sizes for the mountingplateof the
ABB robot. Comparedto the otherrobotsin the classroom, the ABB is the Godzilla of robots, so we
needed a hefty 12”x 12”x 1” aluminumplate and large boltsto hold the robotin place. The hole sizes
hadto be exact and properly measured. We referenced the ABB installationguide which had the proper
distance measurements, whichwe then were able to drill the holesto spec. The only issueswith the plate
anddrilling the holes, were the limited shoptime thatwas available.
Someproblems thatwe may encounter in the future, will be time, keepingon track, troubleshooting, and
communication. Timeis the mostvaluablecommodity in today’ssociety. Havingbeen givenample
warnings abouttime constraints, we are keeping two eyes on the clock at all times. Communicationis
very importantaswell, we mustalways speak our ideas andconcerns sowe can addresspossible issues
right away. We havebeen using online utilities and applicationsto help uscommunicatequickly, and
effectively.

26. 26
2.4.0 Process
The main idea behind this project is to integrate the automation industry in a way that can benefit the
environment by introducing the recycling station within our project. The recycling station will encourage
both commercial and industrial clients to implement this system due to its green approach. This project
currently has a number of stations including the filling, capping and finally the packaging station.
Incorporating the recycling station will give this project an edge by allowing it to be used by the public in
shoppingmalls, residences, and even airports. The project can be described as one unit that has multiple
stations working together to deliver a final high quality product to the consumer in a very short time.
Incorporatinga “Green Coin”credit system will entice the customers to use the unitmore often to collect
more coins that can be used toward a discounted Eco Fill Service or toat the any participating superstore.
2.5.0 Process Flow Chart
Illustration16

27. 27
Above is a process flow chart which describes all of the stepsinvolvedin the present Eco Fill station
process. It explains in depthwhat each sensor, actuatorandmotorwill be doingduringeach station.
2.5.1 Process Flow Chart Continued
Illustration12
Above is a process flow chart which describes all of the stepsinvolvedin the present Eco Fill station
process. It explains in depthwhat each sensor, actuatorandmotorwill be doingduringeach station.

28. 28
2.6.0 Process Explained
The main ideaology behindthisprojectistoputautomationintowork,to integrate all thatwe have
learnedinthe 3 yearsat HumberCollege intoone solidcell thatcoversthe aspectsof of engineeringand
automation.The processof our cell revolves around buildingastationthatcan take a productwhichis
consideredwaste andrecyclingittomake ita product that can be providedbackto the consmer.In
orderto achieve thisgoal the cell hasto go througha verysophisticatedandplannedprocssthatinclude
multiple partsfromsensorstoactuators,convyorbelts,robotsandHMI programming.Italsorequiresa
lotof software pogrammingsuchaselectrical diagramsusingAutoCadElectrical,Mechanical drawings
usingsolidworksandmultible PLCprogrammingsoftwarestoachieve acompletecell thatprovides
qualityandsafetyaspectstoboth the manufacturerandconsumer.
Claritywasone of the mainpilarswe basedthisprojecton,we wantedto make sure that the usercan
be involvedinthisprocessfromthe startall the way to the end.The Customerwill startthe processby
simplytouchingthe HMIscreenand selectingthe service thattheyneedwhichwill include the amount
of bottlesthatwill be filled,the customerwill thenslide the doorforthe depositbox anddepositethe
emptyusedbottlesthattheybroughtalongwiththem.Aftertheydepositethe bottl andslide the door
closedthe circuitclosestoallowthe processto start,it will alsoactas a safetyfeature tomake sure the
consumerissafe and the processwontstart untill the doorisclosed.The processthenstartsby the
sensingof the sensorstothe bottleswhere asignal will be senttoanactuator to push the bottle
towardsthe firststationontothe convyorbeltwhichisthe cleaningstation.
As soonas the sensordetectsthe bottle acleaningnozzle attachedtoanactuator will lowerdowninto
the bottle andshootair intothe bootle simulatingthe cleaningprocess,afterthatthe actuator will
retract back up clearingthe wayforthe bottle tomove forwardtothe nextstation.Signalsfromthe
actuator retractingwill sendsignalstothe convyorbelgttoconinue the pcessandmove the bottle
towardsthe nextstationwhichisthe fillingstation.
Whenthe cleanbottlesarrive atthe fillingsationthe sensorswill sendacommandtothe convyorbel to
stopin oorderforthe pocesstotake place.The fillingnozzelswhichare attachedtoa 4” actuatos will
lowerintothe bottlesandthe nozzelswillstartfillingthe bottles,the nozzleswill remainuntillthe
botlesare filledwiththe ightamountof liquid.The actuatorswill thenretractthe nozzelsfullyanda
reedswitchwill activate the convyorbeltwhichwill take the bottlesontothe nextstepof the process,
whichwill be the cap placmentstation.
Whenthe sensorssense the presence of the bottle atthe cap placmentstationthe convyorbeltwill
thenstopto allowthe processto take place a pnematicsuctioncupwill pickupa cap froma cap holde
nextto the bottle andthenslide overusingasliderovertothe bottle andan actuator will extendto
allowthe suctioncupto place the cap ontop. The actuators will thenretractto take the suctioncup
away fromthe bottle toits original place ontopof the cap holder.Whenthe processiscomplete and
the cap placmentassemblyisbackto itsoriginal place,areedswitchwill activate the convyorbelt
allowingthe processtocontinue ontothe nect stationwhichwill be the cappingstation.

29. 29
At the stationthe processwill be close toan end.The sensorwill sendasignal tothe conveyorbeltto
stopand the cappingchuck to start loweringusingthe actuatorsontothe cap. The cappingchuck will
rotate to make sure thatthe cap has beenplacedandtightenedproperlyontothe bottle,the actuators
will retractupwardsto go back totheirnormal place.Whenthisprocessiscomplete the COGNEXvision
will take aquickimage of the completedproducttomake sure the rightamount of liquidisfilledandthe
cap was placedandtightenedproperly.If the final bottlepassesthe COGNEXqualitycheckthenthe ABB
robot arm will pickitupand place it inthe packagingare where the customerwill be able topickitup.If
the bottle failsthe COGNEXqualitycheckthenitwill be rejectedandthe robotwill pickit upand place it
inside anareaspecifiedforrejectedbottles.
Whenthat isdone the customerwill be promptedbythe HMI to selecttheirmethodof payment,after
the paymentgoesthroughthe customerwill be able toaccessthe bottle forpick upand a greencoin
receiptwill be printedforthemwiththe amountof greencoinsthattheyhave collectedtouse towards
theirpurchases.
Illustration17
ThisSolidWorkscell layoutthe newandfinal cell layoutdesign.Thisshowsall of the stations
accordingly,the userdropoff,cleaningstation,fillingstation,capplacement,captighteningandfinal
pickup stage. Alsoincludedisthe rejectionbasket. Thisdrawingwasdesignedbythe EcoFill Bottling
members.

30. 30
2.7.0 Station Break Down
2.7.1 Station 0: Bottle Drop off Station
Thisis where the whole processshall begin.Inthisstation,the customershall openthe slidingdoorand
place the emptybottle inthe dropoff box.Afterthe customerclosesthe slidingdoor, he/she will goto
the HMI screento pressthe HMI Start button.Afterthe sliding doorisclosed,the processthencan
beginandthe SMC sliderwill beginthe processsendingthe bottlestothe cleaningstation.
2.7.2 Station 1: Recycling / Cleaning Station
In thisstation,the processmovesontothe nextsage.Fromthe dropoff box,the SMC sliderwill move
slightlyforward,anddirectlybelow ourcleaningnozzle.A photoelectricsensorwilldetectthatthere are
bottlesthere inbothrows,andthiswill signal the conveyorbelttostopmoving.Whenthe conveyorbelt
isstopped,andthe bottle isreadyto be cleaned,apneumaticnozzle willextendinthe downward
position,rightintothe bottle head,where itwill simulate acleaningfluidbysprayingairinside for3
seconds.The cleaningnozzle willthenretractupwardsawayfromthe bottle,once fullyretracted,a
reed/limitswitchwill activate andsendasignal tostart the conveyorbeltagaintobe sentto the next
station.
2.7.3 Station 2: Bottle Filling Station
Once one, two, or three bottles have beencleanedthey will move until they are stopped byanextended
actuator. The actuator stopsthe bottlessothey are positioned forfilling. Photoelectricsensorswill
checkto make sure the bottlesare inplace, if true it will sendasignal tostart the fillingprocess. The
filleriscompletely pneumatically drivenandworks onthe principle of gravity. Firsttwopneumatic
cylinders position vertically extendsothatthe fillingnozzles are inserted intothe bottles. Assoonasthe
nozzles are inserted intothe topsof the bottles, ahorizontally placedcylinderwill unblock the flow in
orderto fill the bottles full of product. How many battlesthere are, only those willgetfilled. After
specified time the horizontally placedcylinderwillextendtoitsoriginal position blockingthe flow of the
product. A reedswitchwill ensure thisdoubleactingcylinderisatits extended position andasenda
signal tothe PLC. This signal will thenretractthe vertically placedcylinder, whenitsretractedreed
switchactivates, thiswill thenactive aconveyor2to start moving.
2.7.4 Station 3: Cap Placing Station
The nextstepof the process isplacingthe caps ontothe bottles. Afterthe bottlesare filledthey move
downthe conveyoruntil they are sensed byaphotoelectricsensor, thistriggersapneumaticcylinderto
extendandsecure the one bottle againstthe wall of the conveyor. Duringthisavertically facing
pneumaticcylinderfixedtosliderwill retrieveone bottle cap. The sliderislocatedabove conveyor2and
isfixedperpendiculartothe conveyor. Thisallows the slidertobe able toreach and retrieve the caps

31. 31
fromthe cap hopper, aswell asplace themon the bottles. The caphopperis runningparallel with
conveyor2. The sliderwill move tothe position abovethe caphopper. Nextthe pneumaticactuatorwill
extendandat thistime a suction circuitwill active. A suction caplocatedat the bottomof the cylinder
will thengrabontoone cap. Aftera one second delay the cylinderwillthenretract. Nextthe sliderwill
move to itsabove conveyorposition andthe cylinderwillextend. The suctioncircuitwill disable atthis
pointand the cylinderwillretract. The process repeatsitself forthe nextbottle. Reedswitches will
ensure full strokes of cylinders are reached.
2.7.5 Station 4: Capping Station
At thispointthe bottles have received theircapsandnow they mustbe screwed ontight. Firstthe
bottle will move down the conveyoruntil theyreachthe cappingstation. A photoelectricsensorwill
detectthat a bottle ispresentandactivate a pneumaticcylindertoextend andsecure the bottle tothe
wall. Nextapneumaticcylinderpositioned vertically abovethe bottle positionwillextend, once fully
extended, anelectricmotorwill turnon. Firstitwill spincounterclockwise toavoidcrossthreading
whenscrewingon. Nextthe motorwill turn2 full revolutions. The capwill now be securedandthe
cylinderwill retractup.A vision systemwill ensure bottlesare cappedcorrectly. If acceptable the
bottleswill move on.
2.7.6 Station 5: Packaging
Afterthe bottle are filledandcappedthey mustmove ontobe packed. Atthe endof the conveyor, one
to three bottles will line up.A photoelectricsensorwillensure bottlesare inthe correct position. Once
the bottles are inplace, the robot will pickthemoff the conveyorbeltandloadthemintothe packing
crate. The process isrepeated once ortwice, to fill the package withone tosix bottlesworthof bottles.
If any of the bottles were rejectedduringthisprocess, theywillbe individually pickedupanddropped
intothe rejection basketwhere the operatorwill pickthemupwhen itisfull.
Illustration18

32. 32
2.8.0 Function of Devices
2.8.1 ABB Robot IRB 1200 Compact
The ABB Robotarmbeing incorporated with ourcell will serve as a great advantage. Itis a compactand
very versatile robotarm. Aside from the previously used Denso robotarm, the ABB robothas a much
greater range of motion andwill benefits ourwork cell. The purposeof this robotarm will be usedfor
picking upthe bottles (3 at a time) and placing them in the packagingbasketand once ready for pick up. If
there are any rejected bottles sentdown the conveyorbelt, the ABB Robotwill individually pick upthese
bottles and place them into the rejection basketlocated at the back of the work cell.
2.8.2 Conveyor belt
The conveyorbelt that will be in our cell is goingto serve as the main flow of bottles in each station.
When the user drop off station’s actuatorsends the bottles to the conveyorbelt the flow of bottles
begins. The cleaning station will be connected to the side of the filling and cappingstations. Actuators will
pushthe bottle oneat a time to go onto the conveyorbelt from the user drop station. Once bottles are
on the conveyorbelt, the flow of bottles continues until filling, cap place and cap press is completed.
2.8.3 HMI Panel View Plus 700
The HMI (Human Machine Interface) will be the main communications between the user and the
machine. The HMI will promptthe user to typein a user nameand password they will make for their
account. The user account will be stored within the databasein the programandhold their information
andGreenCoin amount. Thepurposeof the HMI will be to showthe user the status of the system,
GreenCoin amount, andfinal receipt after use. Another feature we plan to incorporatewill be a
maintenanceinterface. This interface will be for the maintenanceworker toview the status, read error
messages, diagnoseand toggle any stations manually.
2.8.4 Actuators
ThroughouttheEcoFill work cell there are several different kinds of actuators. Each actuatorserves its
uniquepurposewithin the cell. The actuating cylinders work in a forward back linear motion. This motion
will be beneficial in the various stations of our work cell. The actuatorcylinders are used in the cleaning
station to stop the bottles in the rightpositions, bringdown the cleaning head for the bottle andtransfer
the bottle from the user drop off station to the next station which is the cleaning station. There are more
actuators in the filling station which movethe feeder head upand down, actuators to stop the bottles in
the right position in the filling station. Lastly there are actuators in the cap placementand capping
station. The actuatorswill firmly stop the bottles in place which will then press andtwist the caps onto
the bottles.

33. 33
2.8.5 Reed Switches
There are reed switches onmostof ourdouble and single acting cylinders. They are used tomake sure
the actuatorhas reached the extended, or the retracted position. Thisis fairly helpful for a process
systemas it will give usinformation of each step of the process. The reed switches will also help prevent
damageto the physical systembe stoppingtheactuatorfrom going beyond its designed point.
2.8.6 Feeder Head
The previously built feeder head was constructed using2 actuators to pushdown the feeder head for the
filling process. The feeder headis madeup of 3 nozzles so the liquid can be fed easily into the bottles, and
keep the bottles aligned properly. The feeder head is a key component in our process as it fills the bottles
up with the liquid for repackaging.
2.8.7 OmronLight Curtain
This control reliable safety device is used in many automation systems. Inoursystem itwill be used to
ensure safety in the work cell, this device is used to avoid any possibleharmto the user or the work cell.
This safety device will be situated right in front of the robot’s rotatingarm.
2.8.8 SMC Slider
The SMC Sliderwill serverone mainfunction andthisfunction isinthe capplacementstation. Attached
to thislinearmotiondevice isthe cappickupand cap place actuator. Thisdevice will work withthe
attachedactuator to aidin pickingupthe caps to cap the bottles. The sliderwill slidethe actuatorto the
cap feederrail, the actuatorwill extendtoallow the suctioncupto pickup eachcap individually. One
the cap ispickedupthe actuator will retractup andthe sliderwill engage toslide tothe correctposition
above the bottle tobe capped. The sliderwill stopandthe actuatorwill extendandthe suctioncupwill
release the capand itwill be place correctly forit to stayon the bottle forthe nextcappingstation.
2.8.9 Cognex Vision Control
The Cognex Vision systemisanincredible quality assurancepiece of equipment. Itcanmake all the
difference inourautomatedprocess. Foroursystem, thishelpsusmake sure eachbottle isaligned
properly before the cappingactiontakesplace. If one of the bottlesisnotcappedproperly, thenthe
Cognex will see the falsealignmentanditwill be sentoff asa reject. Havingthisvisionsystemcan
almostguarantee a steady streamof quality productforthe customer.

34. 34
2.9.0 Mechanical Additions
2.9.1 HMI
The HMI was raised toeye level makingitmore comfortableforthe operatororuser to view the screen.
Thiswas alsodone to allowthe userto place bottlesintothe UserBasket,whichislocatedunderneath
the HMI screen.
2.9.2 Feeding/Cleaning Station
A slidingdoorwasaddedtothe space underneaththe HMIto provide protectiontothe userfrom
movingcomponents.Thisslidingdoorismade fromLexanwhichwaslasercut and engravedwithin
HumberCollege.A limitswitchismountedonaluminumextrusionatthe closedpositionof the sliding
door,thisis to signal the PLCwhenthe door isfullyclosed.The oldfeedingapparatuswasremovedand
was replacedwithaSMC sliderwhichrunperpendiculartothe HMI screen.There isa ‘User Basket’that
ismountedonto the SMC slider.The basketiscomprisedof lasercutLexan.The basketisbuiltwithtwo
rowsthat run parallel tothe conveyorbelt.Withintheserowsare where thatbottlesare tobe placed.A
total of 6 bottlescanbe placedwithinthisbasketata time (3 foreach row).Two photoelectricsensor
are fixedtothe cell sothat whenthatbasketisat itloadingpositiontheyare pointdownthe rowsof the
basket.These photoelectricsensorsdetectif bottlesare presentwithinthe rowsof the Userbasket.
The cleaningstationiscomprisedof apneumaticcylindermountedabove the userplacementbasket
and directlyinline withthe conveyorbelt.Itismountedona lengthof aluminumextrusion.Attachedto
the endof the cylinderisa concave rectangularplate withthree nozzle insertedintothe inside.The
nozzlesare space out sothat one will insertintoeachof the three bottles.These nozzlesare attachedto
pneumaticairlineswhichspraycleaningsolutionintothe bottles.
To off loadthe bottlesontothe conveyor apneumaticcylinderwasaddedparallel tothe conveyor.The
pneumaticcylinderisattachedthe mainbodyof the fillingstationbymountingbrackets.Atthe endof
the cylinder’srodisa customcut piece of Lexanwhichfitsinbetweenthe rowsof the userbasket.This
iswhat actuallypullsthe bottlesontothe conveyoris.The stroke of the cylinderextendspassthe SMC
slideranduserbasket,thisisdone sothat the user basketisable topass the bottle pullerwithout
collidingwithit.A guildrodwasaddedunderthe cylinder’srodtoprovide stabilityandeliminatesany
rotatingmotion.
2.9.3 Cap Placement
A newcap hopperwasdesigned,cutandassembledoutof Lexan.The caphopperwasdesignedto
house 24 caps.The hopperisa fullyenclosedwithopeningsoneachendtoallow forcaps to be loaded
intothe hopperas well aspickedupby the system.The cap hopperispositionedonanextrusionpiece
whichismountedtothe outside of the mainbodyof the fillingstation.The hopperismountedwitha
slightdownwardsangle,thisistohelpthe capsreachthe endof the hopper.There isan Airknife

35. 35
mountedtothe loadingendof the hopper,thisisdone to pushthe caps to the other endof the hopper
and allowsthemtobe pickedup.Alsothiscausesthe effectthataftera cap is pickedup,anothercap
will slide intopositionreadytobe pickedup.Minorchangeswere done tothe pickupsystemwitha
replacementof the bracketwhichthe suctioncupislocatedon.The purpose of the change was to make
a bracket strongersothat the positionof where the capis pickedupisrepeatable.
2.9.4 Filling Nozzles
The filling nozzles in the EcoFIll Bottling Servicearethe method in which the bottles get filled.The actuator
extends down and the nozzle tips go insidethe bottle heads. EcoFill decided to add new nozzle tips as the old ones
were slightly awkward in their nature. The new nozzle tips were 3d printed with ease and precision.With the new
nozzle tips,they sliderightinto the bottles with no resistanceand control the flow of material very nicely,without
blockage.
2.9.5 Cap Tightening
The cap tightening was an area of focus that EcoFill really needed to get properly done. EcoFill removed lastyear’s
cap tightening mechanism and it didn’t do a good job, nor did itlook nice. With the use of the 3d printer, there was
a new design of the cap tightening piece which works very efficiently and well.A new bracket was also installed to
increasestrength, precision and accuracy of the process.Itcan be confirmed to work 100% of the time if the cap is
placed properly on the bottle from the cap placement station.
2.9.6 Rejection Basket
The rejection basketwas added to the cell as a way of disposing of improperly capped bottles. The addition of this
was a good choicesincethere was no placeto put the failed bottles. With the brand new ABB, it was easy to utilize
the robot to add in a rejection system, as itis similarto a real world application.The rejection basket was a fairly
lastminute addition.
2.9.7 Pneumatics
Pneumatics is a very important aspectwithin our cell as itallows thesystem to breathe and live.Every single
actuator that the cell has,is powered by air pressure.May it be the holding cylinders in the filling station,or the
cleaning solution in thecleaning station,pneumatics drives our cell.In order to feed the caps for the cap
placement station,there is an air knifeatthe top of a long plastic slidewhich blows down the caps in order for the
cap vacuum to pick up the caps.The cap vacuum is partof the pneumatic system as well,but with negative
pressure,to give the suction feel.

36. 36
2.10.0 Cognex Vision System (Setup)
The Cognex Visionsystemisthe maineyeswithinthe workcell.Thisvisionsystemwill be inspectingthe
bottlesrightafterthe cap isplacedon top of them.Once the bottle isunderthe cap tighteningmotor,
the Cognex will take animage of the currentbottle andits state of cap on topof it.The Cognex system
was programmedandconfiguredfirstviaInSightExplorer4.7.3software.
The parametersforthe passingcapon top of the bottle wasconfiguredthroughthissoftwareanddone
as follows.Firstthe bottle wouldbe infrontof the visioncamera,thenacap wouldbe placedontopof
the bottle as if itwouldhave beenplacedbythe SMC slidervacuum.Thenthe Cognex image will be
triggeredandan image will be displayedonthe screen.Thisimage will onlyshow uponscreenwhenthe
Cognex visionsystemisconnectedtothe computersnetworkviaEthernet.The image belowillustrates
the set upfor the cap pass or fail.
Illustration19
The first‘Pattern_1’ is the mainimage whichthe visionsystemwill lookforinitswindow.Thiswindow
will be illustratedwithinthe nextimage,itissetupinthe mainpart locatorwithinthe software.
The Greenwindowlocatedinthe viewof the camerais the window whichthe camerawill initiallylook
for.If there isno bottle presentorthere isnocap placedon topof the bottle ,the camerawill trigger
yetfail the currentstate.This passand fail systemwasconfiguredusingthe measure tool.The two
distances,‘Distance_1’and‘Distance_2’were pointssetonthe insightexplorerprogram.
The two greendotslocatedonthe image onthe nextpage locatedat the top of the cap are the two
pointswhichthe cognex visionsystemwilllookfor.If the capis placedcorrectly andthe cap iswithin
the parameters,the jobwill pass.If thiscap isplacedona steepangle,and/orthe capis notplacedat
all,the currentjob will fail.

37. 37
Job Cap Pass: Illustration20
Job Cap Fail: Illustration21
Illustratedabove are boththe Cognex systemsabilitytodetermine whichbottlesare apassor fail.
Whena bottle hasfailed,itisindicatedwithredandredboxesinthe topright cornerwhere itis
inspected.

38. 38
2.11.0 HMI Pages Described
Welcome toEcoFill!Thatis the firstpage on the cell’sHMI screen. Thiswill coverthe HMI layoutandthe
basicnavigation of the humanmachine interface. Let’sstartwiththe firstpage. Whenthe cell is
powered up,the HMI opens upwiththe mainscreenfrom promptingyoutopickyour nextdestination.
May itbe onesfirsttime usingthe cell, ortheir100th. Illustration 22
From here, the customerwould choose eitherthe greenbutton, “Firsttime?Clickhere!”indicatingitis
theirfirsttime usingEcoFill BottlingService. If the customerhasusedourcell before, they would simply
pickthe blue button, “Returningcustomer?Clickhere!”Forthisexample, we willgoinorderof one
beinga firsttime customer.

39. 39
Once the firsttime customerbuttongetspressed, they willbe broughttothismenuwhere some
instructions are setinplace. They are easily legible andinpointformforease of the user. First, the user
wantsto pressthe, “Start” buttonfirstto get started. Afterthisaction, the sliderwill doitsstarting
motionandmove towardsthe slidingdoor. Fromthere, the customerwill openthe doorthe userwill
notice a flashingindicator, “Waitforslidertobe inplace.”Once thishappens, the doorcan be slidopen
and the empty bottles canbe placedinside the dropoff basket. Afterthe bottlesare inplace, the user
mustclose the door inorder forthe process tobegin. Illustration 23
If the userattemptstoopenthe door before the sliderisinplace, orattemptto press, “Start” while the
door isopen, the process will pause until the requirements are met. There are some indicators inplace
to assistthe userin whicharticle mustsatisfied inordertocontinue. The, “returningcustomer”page is
similartothisone, so let’stake alook at thatpage to see the differences.

40. 40
Takinga look at the screenshotbelow, one canalready begintosee the similarities. Some minor
differences are the factthat the instructions are more brief intheirdescription, assumingthe returning
customerremembers the process frombefore. Illustration24
Looking at the “monitoring”button, the usermightwantto monitorthe variouscomponents energize
and de-energizewhile the automatedprocess runs. Forexample, if the userwantstosee that certain
sensors are, “on” or, “off”they will see thathappen inreal time. Letme show the setuponce,
“monitoring”ispressed. Illustration26

41. 41
From the screenshotabove, thisisthe screen that the userwill be promoted toowhen, “monitoring”is
pressed. There is a listof each stationwithinourcell:CleaningStation, FillingStation, CapPlacement
Station, CapTighteningStation, and, PackagingStation. Asacustomer, they have the option of
monitoringthe cell inputsandoutputsasthe process ensues. Since the cell movesinalinearfashion,
the customerwouldpressonthe firstmonitoringstation, “MonitoringCleaningStation.”If the customer
attemptedtopressthe blue button, “Station1” they will be deniedaccess. The blue stationbuttonscan
only be accessed bymaintenance personal withvalidloginusernameandpassword. Let’stake alook
whathappens when, “MonitoringCleaningStation”getspressed.
Illustration27
Thisscreenshotgets broughtup, as the customerwould see, there are differentcircle indicators that
simply show whichsensor, motororcylinderhasbeen energized ornot. Beside eachindicatoristhe
label asto whichit isreferringtoo. Forexample, sincethe slidingdoorlimitswitchwasclosedatthe
time of takingthisscreenshot, the slidingindicatorwason, signifyingthe energized state. The listof this
page, inorder is:BasketSensor1, BasketSensor2, SlidingDoorLS, Bottle PusherLS, Slider, Cylinder
PushBottles, CylinderCleaning, andCleaningSolution. Movingonto, “MonitoringFillingStation.”The
layoutisfairly similar.
As the customerwould notice, itisthe exactsame formatat the previous monitoringstation, the only
difference isdifferentinputandoutputstotake a look at. In thisstation, we have a few more
components working. Inthissection, the liststates:CylinderHopperCutOff 1, CylinderHopperCutOff
2, CylinderHopperCutOff 3, Cylinder:CutOff, CylinderFillingNozzles, FillingSensor1, FillingSensor2,
and, FillingSensor3.

42. 42
Illustration28
Movingonto, “MonitoringCap Placement”, whichisroughly half waythrough the process, the
monitoringindicators look comparable tothe previous station. Illustration29
Thispage hasfewerindicators initsdimensions asthere islessgoingon. One would be able tonotice
the cappingcylinderlightcome upwhen the cappingtakesplace.

43. 43
Transitioningtothe fourthmonitoringstation, “MonitoringCapTighteningStation”, the simplicity and
layoutstaysthe same. Again, withmuchlessgoingonin thispart of the station, withonly 4components
beingindicated:ConveyorBelt, Cylinder:Bottle Hold, CapMotor, Cylinder:CapTightening.
Illustration30
Lookingat the final stationtomonitor, “MonitoringFinal Station”, there are some interestingnew
features. The customerwouldsee whichprogramthe ABBrobot will be running. Mayitbe the firstor
secondrow, or the first, second, third, orfourthrejection routine, the userwill have achance to see
whatthe robotis thinking. Illustration31

44. 44
Now that the monitoringstations have beensortedthrough, the maintenance andloginpagescannow
be looked at.From a maintenance pointof view,thattechnician canloginusingconfidential EcoFill
credentials. Below, the technicianwould pressthe, “login”button. Illustration31
Once the, “loginbuttonhas beenpressed, they willbe broughttothispage here. The technician will
inputhisinformation andlookingatthe top right, the, “default”indication willchange to, “TECH” to
signify thatthe technicianiscurrently loggedin. The defaultloginindication shows thatthe customeris
currently usingthe cell. Illustration32

45. 45
An example of the loginstatusisshownhere inthe picture below. Inthe toprightof the photo, youcan
see the currentloggedintechnician. There isanarrow attachedforreference
Illustration33
Let’sgo back to the maintenance screentotake a look at the some of the options fromwhenthe
technician isloggedin. Here isa reference of whatthe maintenance page lookslike again
Illustration34

46. 46
Takinga look at the screenshotbelow, the technician will haveaccesstoall of the blue coloured
buttonslabeled, “Station1, Station2, Station3, Station4, and Station5.” From here, the technician can
readand write the inputsandoutputsineach station.
Illustration35
When“Station1” getspressed, the technician will be broughttothe followingpage shownbelow. Inside
‘Station1’ the Technician isable tomonitorand override any of the systems actuators, valves, or
motors. Illustration36

47. 47
Since the technician ispartof the maintenance team, the techhasfull readandwrite capabilities of the
inputsandoutputs. The technician cando certaindiagnostics througheachstation. If there isa
componentthatisnot working, the technician canpressthe buttonto energize thatindividual
componenttosee if itis workingornot, a manual override, if youwill. Instation1 page 1, there are
three buttons available topress, andone indication. The sliderindicatorjustshows if the slideris
movingor not. The, “Cylinder:PushBottles”isthe actuatorthat transfers the bottles ontothe conveyor
belt, the “Cylinder:Cleaning”isthe actuatorthat drops downon top of the bottles tosimulate the
cleaningaspect, andthe, “CleaningSolution”isthe airthat simulates some sortof cleaningchemicals.
On page two, there are 4 indicators. Twosimple sensors toshow if the bottles are inthe dropoff basket,
and twolimitswitches. One forthe slidingdoor, andthe otherforthe bottle pusheractuator.
Illustration37
Movingonto the nextstation, the technicianwill have anew setof options available. Here below is,
“Station2.”
Illustration38

48. 48
In Station2, there are five buttons thathave write capabilities. “Cylinder:FillingNozzles 1,2, and3”, are
all the cut off actuators for the hopperupabove the cell. Afterthat, there is, “Cylinder:CutOff”whichis
the linearactuatorwhichextends andretractsa metal rod to stopthe bottles onthe conveyorbelt, from
advancingfurther. Nextis, “Cylinder:FillingNozzles”, whichisthe full fillingapparatuswhichdropsthe
nozzles down intothe bottles toinitiatethe fillingprocess.
Illustration39
In “Station2: FillingPage 2”, there are only three indicators. There is, “FillingSensor1, 2 and 3” which
are the three sensors rightbelow the fillingnozzles toindicate there are bottlespresentthere. Onto,
“Station3: CapPlacement”, there are multiple buttons tobe pressed whichwill be explained
Illustration40

49. 49
Station3 starts off with, “ConveyorBelt.”Thisisself explanatory asif the technician wishes, he can
energize the conveyorbelttomove the bottles downthe line. Next, is, “CapVacuum”, thisisthe cap
vacuumwhich picksup the bottle capsin orderto transferthemfromthe cap binto the bottle heads.
After, isthe, “Slider”indicator. Justlikebefore, itwasmentioned thatthisindicates wetherthe slideris
runningor not. The, “Cylinder:Bottle Hold”isahalf circle shaped piece of rubberandplasticto holdthe
bottlesinplace while the capsgetplaced. “Cylinder:CapPlacement”isthe actuatorthat lowersthe
actual cap ontothe bottles.
Transitioningto,“Station4:Cap Tightening”the same process will be covered. Illustratedbelow there
are some new buttons tolook at.
Illustration41
As mentioned before, the, “ConveyorBelt”caneasily be energized tomove the bottles furtherdown the
line. Similartostation3, “Cylinder:Bottle Hold”willholdthe bottle inplace whilethe, “Cylinder:Cap
Tightening”actuatordrops downhuggingthe cap, and, “Cap Motor” will thenenergize, tighteningthe
cap onto the bottle. Now finally movingontothe laststation, “Station5: Final”, there are some buttons
that utilize the ABBrobot.
Station5 has many buttons, asthe technician will come across. Tostart off, “ABB RobotBusy” issimilar
to the, “Slider”buttoninthe otherstations where itjustindicates the statusif it’srunningornot. “ABB
RunningFirstandSecond Row” indicate whichprogramroutine the ABBisrunning. There are nomanual
overrides forthese buttons. “ABBRunFirstandSecond Row” are manual override buttons. Both
program routines canbe manually runby the technician fortroubleshootingpurposes.

50. 50
Illustration42
Movingonto, “Station5: Final Page 2” there are all of the rejection routines thatcanbe manually run
and are indicated.
Referencingthe screen shotbelow, itissimilartopage one of Station 5. “ABB RunningFirst, Second,
Thirdand FourthReject”, are just indicators toshow whichprogramis running. The buttons onthe right,
“ABB Run First, Second, ThirdandFourthReject”are manual overrides thatcancall up one of the
programs, if the technician desires todoso.
Illustration43
Going back to the eitherthe firsttime orthe returningcustomerpage, there isabutton on there that
showswhatto do whenthe full process hasbeencompleted. Lookingdownatbothimages, there are
arrows beside the buttonsthatleadtothe final page of the humanmachine interface.

51. 51
Illustration44
Lookingdown below, the final HMIscreen hassome new features andlabelsthatneed some explaining.
The, “ResetCycle”buttonisself-explanatory.Once the customerpresses it, itcompletely resetsthe cycle
and the systemisready to fill anew batch of bottles. The, “Total Pass”and, “Total Fail”numbers
indicate the total numberof passesandfailsforthe life cycle of the cell. Thisisa cool feature to see the
successrate. The, “Current Pass”and, “CurrentFail”showsthe currentpasses andfailsof the batch of
bottlesthatiscurrently beingfilledbythe station. The greencoinsystemisourincentivetocustomers.
If a bottle hasfailedandnotproperly capped, EcoFill rewards the currentcustomerwithavalidgreen
cointo use as a methodof paymentfortheirnexttime usingthe cell.
Illustration45

52. 52
2.12.0 Professional Practice
Throughoutthe whole spanof the projectup until full completion,the groupwill be incorporatingall
aspectsof professional practice.Theseaspectswill make ourworkcell standoutamongstthe other
workcell stations.Professionalpractice isimportanttoincorporate withinanyelectrical systembecause
it ensuresqualityandperfection.Whatwe plantoincorporate intoour workcell iswiring,labelling,
safetyandneatnesspractices.
2.12.1 Wiring - Whenphysicallywiringthe inside panelof the workcell,the wire lengthsmustbe
veryspecific.Properwire gaugeswill be usedaccordingtothe specsof the device needingwiring.For
instance the 120 VACpowersupplyintothe workcell’swireswill be differentthanthatof those going
intothe PLC’s inputcard.Properwire lengthswill be takenintoaccountaswell.Since there islimited
space inside of the panel of the workcell,we will needtocutwiresdownaccordinglytofitintothe wire
tracks. Since there are a lotof wiresinside of the panel,therewillnotbe enoughspace withinthe wire
tracks to fitoverlengthenedwires.
2.12.2 Labelling –To avoidconfusionandmix upwhendealingwiththe componentsinside and
outside of the workcell,we will be addingappropriatelabelswhereneeded. Addingthese labelswill
allowthe groupas well asa third partyuserto easilyfindthe componentwithinthe workcell.Labelling
of componentswillmake troubleshootingthe workcell mucheasier,ratherthanhavingtoscramble
lookingforthe dysfunctionalcomponentorworkpiece.
2.12.3 Safety –Knowingthatsafetyplaysa bigrole inthe industryof automation,the groupwill be
incorporatingmany,if notall aspectsof safetyintothe EcoFill Bottlingworkcell.Appropriate E-Stop
safetybuttonsare inthe workcell whichwill be usedtohaltall actiongoingon inthe work cell.Thisisto
ensure the useror a group memberdoesnotgethurt byany faultedcomponentorstationmalfunction.
Since we have an ABB IRB 1200 robotarm whose workarea isabout 35 inchescircular,we must
incorporate all roboticsafetyfeatures.AnOMRON lightcurtainsystemisalreadyexistinginthe work
cell fromthe prior Densorobotarm. Thislightcurtainisusedto avoidany groupmemberor userfrom
gettinginjuredby the robotor gettingtheirhandstuckinside the workframe of the workcell.Limit
switchesandreedswitcheswill be usedonall of the existingpneumaticactuatorsinthe workcell.
2.12.4 Neatness –Neatnessandesthetics,whenvisuallyappealing, are quite pleasingtothe eye.In
the EcoFill Bottlingstationthe groupwill be applyingall professional neatnesspractices.Properpanel
wiringinside of the cell’spanelswill be done correctlyandclean.Wireswill notcrossone anothernorbe
bentand twistedoutof place.All pneumatichoseswillbe measuredandcutaccordinglytogive room
for the movingactuatorsinthe workcell.The hoseswill nothave anykinksinthemtorestrictair flow.
Whendealingwithwiresandhosesoutside of the inside panel,we willbe applyingproperwiring
practices.Ziptieswill be usedalongthe appropriate wireandhose bundlesever5-6inchesdownthe
line of wires.

53. 53
2.13.0 Pneumatic Diagrams
Illustration46

54. 54
2.13.1 Pneumatics Diagrams - Continued
Illustration47

55. 55
2.14.0 Inputs & Outputs
EcoFill Bottling - Inputs 1 Table 1
Device Function of Device PLC Input – Slot 0
MASTER START INITIAL START PUSH BUTTON TO
START THE SYSTEM
I:0/00
START PB 1 START BUTTON TO RETURN
SYSTEM TO RUN FROME-STOP
I:0/01
STOP PB 1 STOPS THE SYSTEM IN THE
INITIAL STATE
I:0/02
STOP PB 2 STOPS THE SYSTEM IN THE
INITIAL STATE
I:0/03
MASTER E- STOP HALTS ALL DEVICES IN THE
SYSTEM RESET NEEDED
TO PIO…
MASTER E- STOP HALTS ALL DEVICES IN THE
SYSTEM RESET NEEDED
TO PIO…
LIGHT CURTAIN RESET RESETS THE LIGHT CURTAIN I:0/05
PHOTO ELECTRIC SENSOR 2 AT
CLEANING STAION
SENSOR AT THE CLEANING
STATION
I:0/06
PHOTO ELECTRIC SENSOR 2 AT
CLEANING STAION
SENSOR AT THE CLEANINIG
STATION
I:0/07
PHOTO ELECTRIC SENSOR 3 AT
PLEXY DOOR BOTTLE PLACE
SENSOR TO CHECK FOR USER
BOTTLE PLACE
I:0/08
PHOTO ELECTRIC SENSOR 4
TRANSFER TO CLEANING SATION
SENSOR TO ENSURE BOTTLE
TRANSFER OCCURS
I:0/09
PHOTO ELECTRIC SENSOR 5
BOTTLE FILLING - BOTTLE 1
BOTTLE 1 POSITOIN UNDER
FILLING SATION
I:0/10
PHOTO ELECTRIC SENSOR 6
BOTTLE FILLING - BOTTLE 2
BOTTLE 2 POSITION UNDER
FILLING STATION
I:0/11
PHOTO ELECTRIC SENSOR 7
BOTTLE FILLING - BOTTLE 3
BOTTLE 3 POSITOIN UNDER
FILLING STATION
I:0/12
PHOTO ELECTRIC SENSOR 8 CAP
PLACE – BOTTLE AT STATION
ENSURES BOTTLE IS AT CAP
PLACE STATION
I:0/13
PHOTO ELECTRIC SENSOR 9 CAP
PRESS – BOTTLE AT SATION
ENSURES BOTTLE ISAT CAP PRESS
STATION
I:0/14
PHOTO ELECTRIC SENSOR 10
FINAL STAGE – BOTTLE AT STAGE
ENSURES BOTTLE HAS REACH THE
END OF THE CONVEYOR
I:0/15

56. 56
2.14.1 Inputs & Outputs
EcoFill Bottling - Inputs 2 Table 2
Device Function of Device PLC Input – Slot 1
LIMIT SWICH CLEANING SATION –
BOTTLE STOPPER RET
ACTUATOR RETRACTED LIMIT I:1/00
LIMIT SWICH CLEANING SATION –
BOTTLE STOPPER EXT
ACTUATOR EXTENDED LIMIT I:1/01
LIMIT SWICH CLEANER RET CLEANER ACTUATOR RETRACTED
LIMIT
I:1/02
LIMIT SWICH CLEANER EXT CLEANER ACTUATOR EXTENDED
LIMIT
I:1/03
FILLING STATION 3 TUBE SYSTEM
ACT 1 RET
ACTUATOR TO ENSURE 3 TUBE
SYSTEM RETRACTS
I:1/04
FILLING STATION 3 TUBE SYSTEM
ACT 2 RET
ACTUATOR TO ENSURE 3 TUBE
SYSTEM RETRACTS
I:1/05
FILLING STATION 3 TUBE SYSTEM
ACT 1 EXT
ACTUATOR TO ENSURE 3 TUBE
SYSTEM EXTENDS
I:2/06
FILLING STATION 3 TUBE SYSTEM
ACT 2 EXT
ACTUATOR TO ENSURE 3 TUBE
SYSTEM EXTENDS
I:2/07
FILLING STATION PRODUCT
RELEASE 1 EXT
ACTUATOR LIMIT TO RELEASE
PRODUCT
I:2/08
FILLING STATION PRODUCT
RELEASE 2 EXT
ACTUATOR LIMIT TO RELEASE
PRODUCT
I:2/09
FILLING STATION PRODUCT
RELEASE 3 EXT
ACTUATOR LIMIT TO RELEASE
PRODUCT
I:2/10
CAP PICK UP ACT 1 RET ACTUATOR RETRACTED LIMIT I:2/11
CAP PRESS ACT 1 RET ACTUATOR RETRACTED LIMIT I:2/12
INPUT SIGNAL FROMCOGNEX
VISION SYSTEM
INPUT SIGNAL FROMCOGNEX I:2/13
PHOTOELECTRIC SENSOR BOTTLE
STOP AT CAP PRESS
ENSURES BOTTLE ISAT CAP PRESS I:2/14
PHOTOELECTRIC SENSOR BOTTLE
STOP AT CAP PLACE
ENSURES BOTTLE IS AT CAP
PLACE
I:2/15

57. 57
2.14.2 Inputs & Outputs
EcoFill Bottling - Inputs 3 Table 3
Device Function of Device PLC Input – Slot 2
SMC POSITION SIGNAL SENDS SIGNAL TO THE PLC I:2/00
SMC POSITION SIGNAL SENDS SIGNAL TO THE PLC I:2/01
2.14.3 Inputs & Outputs
EcoFill Bottling - Outputs 3 Table 4
Device Function of Device PLC Outputs – Slot 5
SMC SLIDER POSITION CONTROL SENDS SIGNAL TO THE SMC
CONTROLLER
O:5/00
SMC SLIDER POSITION CONTROL SENDS SIGNAL TO THE SMC
CONTROLLER
O:5/01
SMC SLIDER POSITION CONTROL SENDS SIGNAL TO THE SMC
CONTROLLER
O:5/02
STACKLIGHT YELLOW LIGHT STACKLIGHT TO INDICATE
SYSTEM IDLE
O:5/03

58. 58
2.14.4 Inputs & Outputs
EcoFill Bottling - Outputs 1 Table 5
Device Function of Device PLC Outputs – Slot 3
SOLENOID – CLEANING SATION
BOTTLE STOP
ACTUATOR TO STOP BOTTLE AT
CLEANINIG STAION
O:3/00
SOLENOID – CLEANING SATION
AIR BOTTLE CLEANER
ACTUATOR TO EXTEND BOTTLE
CLEANER
O:3/01
SOLENOID – BOTTLE TRANSFER
TO CLEANING STATION
ACTUATOR TO SEND BOTTLE TO
CLEANING STATION
O:3/02
SOLENOID – PRODUCT FILL ACT 1 ACTUATOR TO RELEASE PRODUCT O:3/03
SOLENOID – PRODUCT FILL ACT 2 ACTUATOR TO RELEASE PRODUCT O:3/04
SOLENOID – PRODUCT FILL ACT 3 ACTUATOR TO RELEASE PRODUCT O:3/05
SOLENOID – FEEDER DROP ACT 1 ACTUATOR TO DROP FILLING
HEAD
O:3/06
SOLENOID – FEEDER DROP ACT 2 ACTUATOR TO DROP FILLING
HEAD
O:3/07
SOLENOID – CAP PICK UP ACT 1 ACTUATOR TO PICK AND PLACE
THE CAPS
O:3/08
MOTOR OUTPUT SIGNAL TO SMC
SLIDER SYSTEM
OUTPUT SIGNAL TO THE SMC
SLIDER DEVICE
O:3/09
SOLENOID – CAP PRESS ACT 1 ACTUATOR TO EXTEND CAP
PRESS MOTOR
O:3/10
MOTOR OUTPUT TO CAP
TIGHTENING MOTOR
MOTOR SIGNAL TO TURN MOTOR
ON
O:3/11
SOLENOID – BOTTLE STOP AT
FILLING STATION ACT 1
ACTUATOR TO STOP BOTTLE AT
FILLING STATION
O:3/12
SOLENOID – BOTTLE STOP AT CAP
PRESS
ACTUATOR TO STOP BOTTLE AT
CAP PRESS
O:3/13
SOLENOID – CAP PRESS ACT 1 ACTUATOR AT CAP PRESS O:3/14
SOLENOID – BOTTLE STOP AT CAP
PLACE
ACTUATOR TO STOP BOTTLE AT
CAP PLACE
O:3/15

59. 59
2.14.5 Inputs & Outputs
EcoFill Bottling - Outputs 2 Table 6
Device Function of Device PLC Outputs – Slot 4
SYSTEM RUNNING LIGHT LIGHT INDICATING SYSTEMIS ON
AND RUNNING
O:4/00
SYSTEN RUNNING LIGHT LIGHT INDICATING SYSTEM IS ON
AND RUNNING
O:4/01
STANDBY LIGHT SYSTEM IDLE LIGHT O:4/02
STANDBY LIGHT SYSTEM IDLE LIGHT O:4/03
STOPPED LIGHT SYSTEM STOPPED LIGHT AFTER E-
STOP
O:4/04
STOPPED LIGHT SYSTEM STOPPED LIGHT AFTER E-
STOP
O:4/05
ENABLE AUTO LIGHT AUTO MODE LIGHT O:4/06
OUTPUT TO DORNER MOTOR
CONTROL
SIGNAL TO DORNER CONTROLLER O:4/07
OUTPUT TO DORNER MOTOR
CONTROL
SIGNAL TO DORNER CONTROLLER O:4/08
STACKLIGHT GREEN LIGHT GREEN LIGHT INDICATING
SYSTEM ON
O:4/09
STACKLIGHT RED LIGHT RED LIGHT INDICATING SYSTEM
STOPPED
O:4/10
COGNEX VISION TRIGGER + TRIGGER SIGNAL TO COGNEX O:4/11
COGNEX VISION INPUT 7 TRIGGER SIGNAL TO COGNEX O:4/12
SMC SLIDER CONTROL SIGNAL TO SMC CONTROLLER O:4/13
SMC SLIDER CONTROL SIGNAL TO SMC CONTROLLER O:4/14
SMC SLIDER CONTROL SIGNAL TO SMC CONTROLLER O:4/15