Bottle filling systems

Description

This function block controls a fully automatic bottle filling system with a conveyor belt infeed, valve control, and integrated safety logic. The implementation in Structured Control Language (SCL) can be used directly in the Siemens TIA Portal – ideal for simulating industrial applications in beverage, pharmaceutical, or chemical production.

Note: All modules are designed exclusively as a learning and optimization basis and are not approved for live operation. System modules, in particular, must be finally tested and commissioned by qualified personnel before productive use.

How it works

At startup, the system checks all safety-relevant signals: emergency stop, stop button, and the fill level of the storage tank. If one of these conditions is activated or the tank is empty, the process stops immediately, all actuators are shut down, and the sequence is reset to step 0.

If the automatic function is activated and the tank is sufficiently filled, a start button is sufficient to start the cycle:

1. Infeed conveyor starts running until a bottle is detected by the sensor
2. Filling valve opens for the specified filling time – controlled by an IEC timer
3. Valve closes , belt runs shortly after
4. The process starts again – for the next bottle

Technical details

• Safety check has the highest priority: Emergency stop, stop button and empty signal stop everything immediately
• An FSM pedometer controls the entire process reliably and clearly
• Edge detection detects bottle inlet and end of filling time
• The filling time is precisely controlled by an IEC timer (TON)
• The outputs BandEinlauf , VentilAuf and FuellungAktiv provide clear TRUE/FALSE signals for HMI, relay or PLC logic

Possible applications

Perfectly suited for automated filling lines – whether in the beverage industry, pharmaceutical dosing systems, or chemical filling. The module also demonstrates in a practical way how safety and process logic go hand in hand in training and test systems. Thanks to its modular structure, it can be easily adapted to different filling volumes or bottle types.

compatibility

• Runs on Siemens S7-1200 and S7-1500 controllers
• Developed for the TIA Portal from version V13
• Recommended: TIA Portal V16 or higher for simulation with PLCSIM and HMI integration

Scope of delivery

• .scl file with complete input and output declaration
• Including trigger, timer and step logic
• Commented header with instructions for adjusting fill time, safety parameters and sensor behavior
• The download link is available immediately after purchase

Support

I am happy to support you with:

• adjusting filling times or sensor values
• the extension of further safety functions (e.g. pressure sensors)
• integration into existing lines or visualizations

Simply contact me via email or shop support – I’m available for any custom extension.