Automation Design For A Syrup Production Line Using Siemens PLC S7-1200 and TIA Portal Software

2017 International Conference on Communication, Control, Computing and Electronics Engineering (ICCCCEE), Khartoum,
Sudan
Automation Design for a Syrup Production Line

Using Siemens PLC S7-1200 and TIA Portal
Software
Husam Salih, Hammam Abdelwahab, Areej Abdallah
Department of Electrical and Electronic Engineering
University of Khartoum
Khartoum, Sudan
Husam.salih94@gmail.com, Hammam9497@gmail.com, Areej.widaa@hotmail.com
Abstract—In the world of Automation Industrial, then bottles on a conveyor must be filled with the mixed
Programmable Logic Controllers (PLCs) are the dominant syrup. This is process is controlled used Siemens PLC S7-
types of automatic controllers, and so engineers are racing to 1200 [3].
develop the best software to give it the ultimate abilities to A control system to automate this process is designed
maximize the outcome. Basically, for understanding the
concepts of controlling any process. Mathematical modeling is a
supported with a human machine interface (HMI).
mandatory procedure and hence this paper describes a method Mathematical modeling for the tank system is derived [4] and
to model tank systems in order to control the input flow and the the response for open loop system is tested. The hardware
output flow. This paper also discusses the use of the Siemens components and the software structure including the
PLC S7-1200 as the system controller with provision of the flowchart are described. Also the ladder diagram for the PLC
algorithm and the equipment needed. This paper describes the is shown and explained. The designed monitoring interface
general concepts of controlling liquid flows and capacity in for the system is also described.
tanks as this process is useful in the automation industrial field.
The proposed system is implemented with simple equipment in
order to demonstrate the concept of the process and how it is
controlled. II. MODELLING OF THE TANK SYSTEM
Keywords—TIA Portal, PLC, Tanks, Mixer, HMI.
I. INTRODUCTION
Process control is an engineering discipline that deals with
architectures, mechanisms and algorithms for maintaining
the output of a specific process within desired operational
conditions.
One of the simplest processes is the mixing process which
can generally be used in the production of colors [1],
chemicals, solvents and syrups.
Soft drinks manufacturing is a common process and the
syrup room is a main part of all soft drinks factories. Some
syrup types need simple process.
Since the mixing process is a multivariable system. The
mathematical modelling is very important to select the best
control design in order to automate the plant. Programmable
Logic Controllers are the most widely used type of controllers
in the industry. This is due to their robustness, flexibility and
efficiency. There is an increasing demand on SCADA
Figure 1: Syrup Production Line System.
(Supervisory Control and Data Acquisition) in order to
monitor the plant and help in reducing errors caused by The need of modeling is mandatory in order to find a
humans [2]. suitable methodology of control. Here the operating
In this paper, a syrup room that consists of two tanks parameters to be used are [5]:
containing two different liquids is considered. These liquids
– Flow rate of sub tank 1
must be mixed in the third tank with specific quantities, and
– Flow rate of sub tank 2
978-1-5090-1809-3/17/$31.00 ©2017 IEEE

– Total inflow of the sub tanks
– Tank volume
– Tank’s base area
ℎ – Height of the Tank
– The restriction to the discharge flow
 – Density
– Gravity
K – Gain
Ʈ – Time Constant
Since the two sub tanks opens simultaneously:
+ = (1)
From mass balance equation [2]:
Δ Figure 2: Open Loop Response for the Tank System.

+ = (2)
Δ
From the analysis of the model it appears that this model is
dℎ applicable to the proposed system since the two sub tanks
+ = (3)
d opens simultaneously.
 ℎ
= (4)
III. HARDWARE STRUCTURE
 ℎ ℎ This part describes all the hardware components used in

− = A (5) the system. It should be noted that some components were
implemented in the testing procedure for the purpose of
assurance of the functionality of the designed system.
+ ℎ = ∗ (6)
Ʈ + = ∗ (7)
Using Laplace transformation:
= (8)
Ʈ
Where:
K= (9) Figure 3: Hardware Structure (1) Tanks and Mixer.

The components are:
• SIEMENS SIMATIC S7-1200
Ʈ= (10) • Omron mk3p-I Relays
• Photo-electric sensor
• Conveyor
• Mixer
• Electrical Valves
The open loop response for the tank system has been • Water Tank
analyzed using MATLAB and Simulink as shown in figure 2. • Level Sensor (A float with a potentiometer is used).
The response seems as a first order response which shows that
PID control may not be necessary in order to maintain stable
flows.
However, implementing PID controller may enhance the
flow modeling depending on the process applied with the
tanks.
Figure 4: Hardware Structure (2) Conveyor.
Figure 5: Hardware Structure (3) Siemens S7-1200 PLC, Power Supply.
IV. SOFTWARE STRUCTURE
A. The Algorithm
The flowchart shown in figure 6 demonstrates the behavior
of the controller measure the tank capacity and fills the bottles.
The algorithm consists of the following:
• Checking the tank’s capacity.
• Activating the mixer for a prefixed quantum of time.
• Activating the conveyor which holds the bottles on it Figure 6: Syrup Production Line Flowchart.
for the operation of filling. B. The Code
• Filling the bottles with the mixed syrup.
The used PLC (S7-1200) was programmed using ladder
• Maintaining the process till the finish of the content Diagram via TIA Portal as shown in figures (7, 8).
of the tank.
Figure 7: Ladder Diagram part 1.
Figure 8: Ladder Diagram part 2.
A push button (I0.0) is pressed to start the process by
opening the outlet valves of the sub tanks (V1, V2) containing After the end of the mixing phase the conveyor start to
the liquids to be mixed in the main tank. These valves are open operate carrying the bottles to be filled with the mixed syrup.
simultaneously which ensure equal amount from each one. It will be moving until the first cup cuts the photocell sensor
The level inside the main tank is determined by the reading of (I 0.3). The bottle continues to move for fixed time to be
the level sensor (IW64). When the level inside the main tank aligned with the outlet pipe of the main tank. Then the syrup
reaches the predetermined value, the PLC automatically starts to fill the cup for specific time. At the end of this time
closes V1 and V2 and start the operation of the mixer of a the bottles come back to moving until the next bottle cuts the
fixed time assigned in the mixer timer (DB1). The mixer stops photocell.
immediately at the end of this time. This operation will continue to repeat until the main tank
becomes empty and so it needs to be filled again. And the
process starts to repeat again by the authorization of the
operator.
C. HMI Implementation
The graphical implementation was made using the HMI
tool integrated at the TIA Portal. It provides a real-time
monitoring for the system as shown in figure below. It works
by connecting the tag of each measurement value with its
corresponding visual component in the interface.
The HMI was designed only for monitoring purposes and
so no input method was displayed.
Figure 9: Syrup Production Line HMI.
CONCLUSION AND FUTURE WORK

This paper introduced a simple design of an automated
syrup production line which includes processes as mixing and
filling. The implementation of the automatic syrup production
line is presented. The experimented results were as expected
and the system moved from start to end smoothly. At end of
each cycle the operator needs to push the button to start new
cycle.
The availability of the analog to digital converter eased the
monitoring of the liquid in the tank. It has been found that the
most reliable level sensors and indicators to use are the
proximity sensors such as the ultra-sonic types, but the
automation using PLC and these simple and easy to get
equipment provided a high efficiency compared to the low
cost which will work very well for small firms as local
production and also for research labs for further
developments. This algorithm can also be applied for large
and complex systems.
ACKNOWLEDGMENT
This work was supported by the Control Lab of
Electrical and Electronic Engineering Department at
University of Khartoum.
REFERENCES
[1] S.T.Sanamdikar, Vartak C, "Color making and mixing process using

PLC" in International Journal of Emerging Trends & Technology in
Computer Science, 2013.
[2] Laurentiu Schiop, Marian Gaiceanu, "Mathematical Modelling of
Color Mixing Process and PLC Control Implementation by Using
Human Machine Interface" in 3rd International Symposium on
Electrical and Electronics Engineering, 2010.
[3] Siemens PLC S7-1200 , more information in the website:
http://w3.siemens.com/mcms/programmable-logic-
controller/en/basic-controller/s7-1200/pages/default.aspx
[4] Modeling a Process - Filling a Tank
http://eleceng.dit.ie/gavin/Control/Modeling/Filling%20a%20Tank.ht
m [Accessed 5 August 2016].
[5] Bela G.Laptik, Instrument Engineers' Handbook, Fourth Edition,
Volume One: Process measurement and analysis, 2003.

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2017 International Conference on Communication, Control, Computing and Electronics Engineering (ICCCCEE), Khartoum,

Automation Design for a Syrup Production Line

Keywords—TIA Portal, PLC, Tanks, Mixer, HMI.

978-1-5090-1809-3/17/$31.00 ©2017 IEEE

Since the two sub tanks opens simultaneously:

From mass balance equation [2]:

Δ Figure 2: Open Loop Response for the Tank System.

 ℎ ℎ This part describes all the hardware components used in

Using Laplace transformation:

K= (9) Figure 3: Hardware Structure (1) Tanks and Mixer.

Figure 5: Hardware Structure (3) Siemens S7-1200 PLC, Power Supply.

IV. SOFTWARE STRUCTURE

CONCLUSION AND FUTURE WORK

[1] S.T.Sanamdikar, Vartak C, "Color making and mixing process using

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