Development of a PLC-Integrated Stepper Motor Dosing System for Precision and Efficiency in Chemical Industry Automation

This research paper presents the design and development of a PLC-controlled stepper motor-based dosing system aimed at enhancing precision, reliability, and efficiency in industrial liquid dosing applications. With the increasing demand for accurate dosing in pharmaceutical manufacturing, chemical processing, and packaging industries, this system employs a hybrid NEMA 17 stepper motor with a 0.9-degree step angle, ensuring precise volumetric control. The dosing mechanism integrates advanced PLC logic, real-time monitoring via HMI, and a robust auger system equipped with non-return valves to maintain consistent fluid flow and prevent back-flow. Unlike traditional microcontroller-based systems, PLC-based automation offers superior flexibility, real-time error handling, and minimal system downtime. Extensive testing at predefined volume settings (50, 100, 150, and 200 mL) demonstrated the system’s accuracy and repeatability, with an error margin as low as 0.03%. The automated operation minimizes manual intervention, optimizing efficiency and ensuring product consistency. This study highlights the importance of PLC-driven control systems in industrial automation, offering an expandable and adaptable solution for precise liquid dosing across multiple industries.