Design and Development of Prototype for Bottle Washer Machine

Abstract

Beverage filling and packaging process involves different types of machines based on the type of container used to carry the beverage. The Bottle Washer Machine is used to clean Returnable Glass Bottle (RGB) and Polyethylene terephthalate (PET) Bottles before the filling and packaging of the beverage is carried out. Primarily, the understanding of the process and the working of the Bottle Washer Machine has been acquired and discussed. The main controlled variables of the different treatment zones of the prototype of the Bottle Washer Machine are temperature and level. The literature survey of the different methods of controlling level and temperature for the similar process has been carried out. The prototype of the bottle washer machine has been designed considering the design and cost constraints on Creo platform. Controlled variables and manipulated variables for the different treatment zones of the prototype of the Bottle Washer Machine have been decided based on the requirement of the process. Different control schemes of temperature control namely On-Off control, Differential Gap control, Proportional Integral and Derivative (PID) control and Model Predictive Control (MPC) have been discussed. It has been shown that PID temperature control scheme provides finer control compared to On-Off control and Differential Gap control schemes. There are various methods of PID tuning are available, out of which Ziegler Nichols and Auto-tuning methods have been discussed and implemented. An advanced control technique which is becoming popular nowadays, to tackle the complex control problems is the MPC strategy. The real time implementation of MPC using MATLAB Simulink and KEPServerEX 5 with Siemens 300 series PLC has been discussed and accomplished. The comparison between Ziegler Nichols tuned PID, Auto-tuned PID and MPC has been carried out. It has been shown that MPC provides better performance compared to Ziegler Nichols tuned PID and Auto-tuned PID, based on the comparison of the various performance indices. The complete sequential process logic has been developed for the Bottle Washer Machine. The prototype of the bottle washer machine will be developed based on the design and cost constraints and the automation of the same will be accomplished by means of PLC and HMI.