🏭 ICS Automated Bottle Filling & Capping Simulator

Filling Valve

Type: Analog Output

Function: Controls liquid flow rate and volume

Control: PWM signal or 4-20mA for valve position

Conveyor Motor + VFD

Type: Analog Output (Variable Frequency Drive)

Function: Variable speed control with direction

Control: 0-10V or 4-20mA for speed, Digital for direction

Features: Ramp up/down, emergency stop, feedback

Capping Arm Actuator

Type: Digital Output

Function: Pneumatic/servo motor for cap placement

Control: Extend/Retract commands

VFD Parameters

Speed Range: 0-100% (0-60Hz typical)

Direction: Forward/Reverse via logic signals

Safety: Must stop before direction change

Feedback: Speed confirmation, fault monitoring

Sequential Control

Process follows strict sequence: Wait → Fill → Cap → Move → Repeat

Each step has entry conditions and completion criteria

Feedback Loops

Sensors provide real-time feedback to PLC

System adjusts based on actual vs. expected conditions

Timing Control

Critical for synchronization between stations

Prevents overflow, ensures quality, optimizes throughput

Emergency Stop

Immediately halts all operations

Safety-rated circuits with redundant contacts

Must be manually reset after cleared

Fail-Safe Modes

System defaults to safe state on power loss

Valves close, motors stop, alarms activate

Interlocks & Guards

Prevents unsafe operations (e.g., filling without bottle)

Light curtains, safety mats, guard switches

Network Segmentation

Separate OT networks from IT infrastructure

DMZ for HMI/SCADA systems

Firewalls with industrial protocols

Access Control

Role-based permissions for operators

Multi-factor authentication

Audit trails for all changes

Monitoring & Detection

ICS-specific intrusion detection

Anomaly detection for process parameters

Regular security assessments