Automatic Ball Counting, Box Filling, and Packaging System using Schnieder PLC and HMI

Problem Statement

In industries where small objects like balls (plastic, rubber, or metal) need to be counted and packed, manual counting leads to:

Human errors in counting

Time-consuming process

Inconsistent packaging

Increased labor costSo, an automated system is required to accurately count balls, fill bxes, and package them efficiently with minimal human intervention.

 Objective

To design an automated system using PLC

To count balls accurately using sensors

To fill boxes with a predefined number of balls

To automate box movement and packaging

To monitor and control system using HMI

System Components

Software-Based System (Simulation Model)

This project is developed using a PLC simulation environment and HMI interface, without physical hardware implementation. The system behavior is designed and tested virtually.

 

Software Used

PLC Programming Software (e.g., Control Expert classic)

HMI Design Software (e.g., Vijeo Designer)

Virtual Components Used

Since this is a simulation, all components are represented digitally:

Virtual PLC – Executes ladder logic program

HMI Screen – Used to control and monitor system

Virtual Sensors (IR/Proximity) – Simulated input signals for ball detection

Virtual Conveyor Motor – Represented through output indicators

Virtual Limit Switch – Detects box position in simulation

Internal Counters G Timers – Used for counting and sequencing

 

System Nature

No physical wiring or hardware used

All inputs/outputs are simulated using software

HMI acts as the main interface for control and monitoring

Working Principle

Balls are placed on a conveyor belt.

Conveyor motor starts moving balls forward and second Conveyor motos start with same time to move a box forward.

A sensor detects each ball passing through a point.

PLC counts each ball using sensor signals.

When the count reaches a preset value (e.g., 10 balls):

Conveyor stops

Balls are dropped into the box

A limit switch ensures the box is in position.

After filling:

Conveyor restarts

Filled box moves forward for packaging

The next empty box is positioned automatically

Cycle repeats

 

Ladder Diagram for the application

 

Explanation

The system is controlled using a PLC and monitored using an HMI screen. When the START button is pressed from the HMI, the PLC activates the conveyor motor and begins the process.

 

As balls move on the conveyor, a sensor sends signals to the PLC, which counts each ball using a counter. The count is displayed on the HMI as Product Count. When the preset number of balls is reached, the PLC stops the conveyor and activates the dropper to fill the box.

 

After filling, the system resets the counter and starts the next cycle. A second conveyor moves the filled boxes forward, and a sensor updates the Box Count on the HMI.

The HMI also provides START/STOP control and shows system status, making it easy to monitor and control the process.

 

HMI Design

On HMI screen, include:

Start Button

Stop Button

Reset Button

Ball Count Display

Target Count Input (User can change value)

System Status (Running/Stopped)

Advantages Of PLC

High accuracy in counting and control

Fast and reliable operation

Easy to modify program (flexible)

Reduces human errors

Suitable for industrial automation

 

Advantages of HMI

Easy monitoring of system (counts, status)

User-friendly control (Start/Stop buttons)

Real-time data display

Reduces need of manual supervision

Improves overall system control and safety

 

Applications

Toy manufacturing industry

Bearing ball packing

Food industry (small items like candies)

Pharmaceutical industry

 

Conclusion

The automatic ball counting and packaging system using PLC and HMI provides an efficient and reliable solution for industrial automation. It reduces errors, increases productivity, and ensures accurate packaging. The system can be further enhanced with advanced sensors and IoT integration.