A Hardware-in-the-Loop and 3D Simulation Framework for Active Learning in Engineering Education

Abstract

This paper describes the implementation of an industrial control system using the Hardware-in-the-Loop (HIL) technique, integrating a Siemens S7-1200 PLC with a virtual plant developed in Unity 3D, using the Modbus TCP communication protocol. This integration allows real-time simulation of industrial processes in a safe, immersive and interactive environment, facilitating the design, testing and validation of control strategies without the need for a physical plant. As part of the study, usability tests were carried out to verify whether the proposed solution is suitable for use as a teaching resource by engineering students. The evaluation was applied to two groups of 20 students each, who interacted with the virtual environment and executed control and monitoring tasks of the simulated process. The results obtained show a satisfactory acceptance of the platform, highlighting its usefulness as a support tool for the understanding and manipulation of automated processes in a controlled environment. This approach proves to be an efficient, safe and scalable alternative for training in industrial automation, aligned with the principles of Industry 4.0.