Mechanical · Machine and manufacturing · Final year project
Automatic Water Level Control System Using PLC
A PLC-based tank level controller that prevents overflow. Two level sensors mark the minimum and maximum levels, and the PLC starts the pump when water falls below the minimum and stops it at the maximum.
What is the Automatic Water Level Control System Using PLC project?
A PLC-based tank level controller that prevents overflow. Two level sensors mark the minimum and maximum levels, and the PLC starts the pump when water falls below the minimum and stops it at the maximum.
Key facts
- Branch
- Mechanical & Automobile Engineering; also suits Mechatronics, Instrumentation
- Type
- Final year project · Advanced
- Suitable for
- Diploma capstone and B.E / B.Tech final year
- Build time
- 6 to 8 weeks
- Estimated component cost
- ₹14,500 – ₹21,300
- Guidance from
- ₹9,999 (Hardware / IoT Final Year)
How the Automatic Water Level Control System Using PLC works
- The mild steel frame and fabrication forms the base that carries every other part, so it is designed first from the load and size of the machine.
- The Compact PLC runs the ladder logic that sequences the machine's inputs and outputs, the way industry automates processes.
- The Water / rain level sensor detects the presence or level of water.
- The Solenoid lock locks or unlocks the door when energised.
Block diagram
Power
Solenoid lockMini submersible water pumpStructure
Frame and mountsComponents list and cost
Typical prices from Indian online stores and electronics markets (Lamington Road, Budhwar Peth, SP Road). Buy from one store where you can to save on shipping.
| Component | Qty | What it does | Approx. cost |
|---|---|---|---|
| Compact PLC (e.g. Delta DVP / Siemens LOGO!) | 1 | Runs the ladder logic that sequences the machine's inputs and outputs, the way industry automates processes. | ₹9,500 |
| Water / rain level sensor | 1 | Detects the presence or level of water. | ₹70 |
| Solenoid lock (12 V) | 1 | Locks or unlocks the door when energised. | ₹450 |
| Mini submersible water pump (12 V) | 1 | Moves water for irrigation, dispensing or cooling. | ₹180 |
| LEDs (assorted) | 1 | Indicate status. | ₹20 |
| Mild steel frame and fabrication | 1 | Forms the main structure that holds all parts. | ₹2,500 |
| Welding, cutting and machining labour | 1 | Needed for this type of build. | ₹2,200 |
| Buttons | 1 | Part from the design specification | ₹400* |
| Lamps | 1 | Part from the design specification | ₹400* |
| Mounts, screws, nuts and small hardware | 1 | Enclosure, mounts and fasteners. | ₹300 |
| Paint, finishing and workshop consumables | 1 | Project overhead | ₹600 |
| Transport of material | 1 | Project overhead | ₹400 |
| Estimated total | Varies with brand, quality and city | ₹14,500 – ₹21,300 |
Prices are estimates for budgeting; items marked * depend on the exact size or model chosen. We confirm the bill of materials when your design is frozen, and components are charged at actual cost with bills.
How much does this project cost?
| Option | What you get | Cost |
|---|---|---|
| Components only | You buy the parts and build it yourself | ₹14,500 – ₹21,300 |
| Hardware / IoT Final Year | Working model or guided build, Circuit diagram and bill of materials, Firmware / code with explanation | from ₹9,999 + components |
| Capstone Project (CPE) | Working project or model, Black book in MSBTE format, Step-by-step explanation | ₹9,999 + components |
| Diploma ITR | 100% working source code, Project report PDF, PPT | ₹1,999 + components |
No GST and no hidden charges. Use the cost calculator for a quote with your deadline and add-ons, or see all plans.
Download the project brief (PDF)
Summary, working, components and cost and viva questions on one branded PDF to show your guide or team. To get it developed, contact us on WhatsApp.
What you submit with this project
- Working model with circuit diagram and program code
- Project report or black book in your university's chapter order (block diagram, circuit, calculations, results)
- Presentation for the review and final viva
- Synopsis for topic approval, if your college asks for one
Mechanical viva questions on this project
What is the aim of the Automatic Water Level Control System Using PLC project?
A PLC-based tank level controller that prevents overflow. Two level sensors mark the minimum and maximum levels, and the PLC starts the pump when water falls below the minimum and stops it at the maximum.
Explain the working of your project in short.
The mild steel frame and fabrication forms the base that carries every other part, so it is designed first from the load and size of the machine. The Compact PLC runs the ladder logic that sequences the machine's inputs and outputs, the way industry automates processes. The Water / rain level sensor detects the presence or level of water. The Solenoid lock locks or unlocks the door when energised.
Why is a PLC preferred over a microcontroller in industry?
A PLC is rugged, works on 24 V industrial signals, tolerates noise and heat, and is programmed in ladder logic that maintenance staff understand. It is also easy to modify on site.
How is water detected by this sensor?
The exposed conductive tracks are open circuit when dry. Water bridges them and lowers the resistance, and the controller reads the change as a level or as rain.
How does a solenoid lock work?
When current flows, the coil becomes an electromagnet and pulls the plunger in, releasing the latch. When current stops, the spring pushes the plunger back to lock.
How is the pump switched by the controller?
Through a relay or MOSFET, because the pump runs at 12 V and draws more current than the controller pin can provide.
Why is a resistor connected in series with an LED?
It limits the current to a safe value (about 10–20 mA). Without it, the LED would draw too much current and burn out. R = (supply voltage − LED voltage) ÷ current.
Which material did you select for the main parts and why?
Mild steel (MS) is used for the frame because it is strong, cheap, easy to cut and weld and available everywhere. Shafts are made of EN8 or bright mild steel for strength, and parts that do not carry load can be aluminium or acrylic to reduce weight.
What factor of safety did you take in your design?
A factor of safety of 2 to 3 is taken for static parts and 3 to 5 for parts under shock or fatigue loading. Allowable stress = yield strength ÷ factor of safety, and each part is checked against it.
How did you estimate the cost of the project?
The cost is the sum of raw material, bought-out parts, machining or fabrication and overheads. Our estimate for this model is about ₹14,500 to ₹21,300, depending on size, material and the workshop rates in your city.
Which manufacturing processes were used?
Cutting and grinding of sections, arc or MIG welding of the frame, drilling for mounting holes, followed by assembly, alignment and painting.
Is your system open-loop or closed-loop?
Closed-loop: sensors measure the actual position, distance or condition and the controller corrects the actuators until the target is reached.
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