Designing and assembling of a programmable logiccontrols (PLC) laboratory trainer and advanced research setup

Abstract

A Programmable Logic Controller (PLC) is an industrialized computer control system that constantly monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices. Almost any production line, machine function, or process can be greatly enhanced using this type of control system. However, the biggest benefit in using a PLC is the ability to change and replicate the operation or process while collecting and communicating vital information. It is also a modular system. It can be mixed and matched the types of Input and Output devices to best suit of any laboratory application and industrial control application. Training setup consists of an industrial grade PLC, Variable Frequency Drives, Servomotors coupled with drives, induction motors, Human Machine Interface (HMI), industrial networking capabilities, and many other ancillaries. The setup can be used for demonstrating the principles of programmable controllers and sequence control systems, advanced cam profile and advanced computation for controlling industrial processes. It is suitable for training both basic and advanced principles of PLC. Industrial grade PLC components are permanently mounted on the panel; it is also coupled, activated and controlled with numerous configurations such as with Variable Frequency Drive (VFD), servo drive, servo Motor, and induction motor, along with Human Machine Interface (HMI). This Laboratory Trainer and research setup system is fully integrated with PLC Motion Animation software that will help students observe and understand the control logic behind the operation of industrial PLCs. The software tool can be used as an offline and online animation tool with its collection of sample HMI applications. The trainer can be used alternately for operation and control of industrial manufacturing processes. The example ladder logic program in the trainer describes the methods of running servomotor and servo drive that are widely used in almost every industry where automation is required. Smart vision checking system which is used for sorting and many other purposes can also be interfaced with the setup. This setup has at least two VFD to control various functions of induction motor. Such as conveyor speed, acceleration, and many other motion related aspects of an induction motor. The combination of software and hardware offers practical and effective trainer and research engine for industrial control and manufacturing. Also help students to know about smart vision checking system, servo drive, servomotor, induction motor, Variable Frequency Drive (VFD), HMI, industrial networking, and interfacing with real world packaging machines. In addition, one of the main advantages of this trainer setup panel is its modular capability. This trainer setup can be modified, coupled with any industry related control system that might need in the future for training purpose. Above all, this laboratory training and control panel setup is performed in two stages. First, the machine design and electrical control for the entire operational process is conducted and then the study of effectiveness of re-configurable and portable Programmable logic controller system with proper statistical analysis.