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.
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.
