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Design and Implementation of a PLC Trainer Workstation Advances in Science, Technology and Engineering Systems Journal Vol. 5, No. 4, 755-761 (2020) ASTESJ www.astesj.com ISSN: 2415-6698 Design and Implementation of a PLC Trainer Workstation Matthew Oluwole Arowolo*, Adefemi Adeyemi Adekunle, Martins Oluwaseun Opeyemi Department of Mechatronics Engineering, Federal University Oye – Ekiti, 371104, Nigeria A R T I C L E I N F O A B S T R A C T Article history: The Programmable Logic Controller (PLC) is an important component for industrial Received:28 May, 2020 automatic engineering operation. Hence, the need to comprehend its basis of operation Accepted:05 August, 2020 becomes an inevitable task. Some of the problems is industrial PLC is an expensive, pre- Online: 28 August, 2020 built hardware kit, acquisition of programming software and its requisite programming competence is a challenge. Thus, this paper present’s the design steps for a desktop PLC Keywords: trainer workstation for industrial automatic engineering operation. Although researchers PLC have proposed and reported several PLC trainers but they fail to discuss the hardware Ladder logic connection of the input/output components neither is the basic PLC automatic - operation PLC Workstation nor PLC component symbols with description discussed. These are the areas discussed in Programming this paper to train participant on PLC programming knowledge. The develop PLC Software workstation consist of push buttons and switches for input signals and for output signal buzzer, indicator lights and blower. The control aspect comprises the PLC, timer and relay. The PLC module is the MITSUBISHI FX 1S-30MR-001, the simulation software is the MITSUBISHI FXTRN-BEG-EL and the programming software is the MITSUBISHI GX Developer version 8. Authors presented two automatic control application scenarios to train participants and evaluate how the trainer is applicable to real-world situation. We conducted a survey after training to measure the impact of our approach for PLC programming knowledge for participants and result show enhanced knowledge in design step module and LL programming module significantly with our approach. 1. Introduction application become imperative for student and person with interest in the field of industrial automation. Nevertheless, some The PLC replaced the antique relay control logic in the late of the problems is that industrial PLC is an expensive, prebuilt 1970s in the control of machines and processes [1]-[3]. Some of hardware kit also, to acquire programming software and its the benefits of the PLC over the relay control logic are flexibility, requisite programming competence is a challenge [2]. higher reliability, communication possibilities, faster response The programming languages defined by IEC 6-1131 for PLC time, and easier troubleshooting [1]. Hence, it has become a vital is the Ladder Logic (LL), Structure Text (ST), Function Block component in the industry for engineering operation control. The (FB) and Instruction List (IL) [3]. The PLC programming device PLC is a microprocessor-based controller; it receiver’s analogue can be a handheld device or the personal computer (PC). However, and digital signal input from input component such as switches the PC is commonly used for PLC programming because it is and sensors and apply instructions stored in it programmable readily available and portable. The LL is the most used memory to control outputs to output components such as motors, programming language because it is simple to comprehend and pneumatic devices and status indicator. It implement’s functions implement [5]. Although researchers have proposed and reported such as logic and sequence [1,4]. The rapid pace of technological several PLC trainers but they fail to discuss the hardware development with new model and innovation of PLC technology connection of the input/output components neither is the basic and its flexibility has encouraged its application beyond industrial PLC - automatic operation nor PLC component symbols with control spectrum. Therefore, the development of competence description discussed. These are the areas discussed in this paper through training in the cabling, programming of PLC and its to train participant on PLC programming knowledge. *Corresponding Author: Matthew. O. Arowolo , Department of Mechatronics Authors in [2] described the development of an embedded Engineering, Federal University Oye – Ekiti, 371104, Nigeria, +2348038066827 PLC for teaching students. Authors combined LabVIEW software & [email protected] www.astesj.com 755 https://dx.doi.org/10.25046/aj050489 M. O. Arowolo et al. / Advances in Science, Technology and Engineering Systems Journal Vol. 5, No. 4, 755-761 (2020) and the AVR Microcontroller with the VB modules to achieve the software. A PLC training kit compact and portable for learning embedded PLC built bottle filling plant for it application. The on industrial automation practice is presented in [11]. The programming language used for the embedded PLC is the FB. hardware includes: PLC Omron CP1E-N20R, plug and play I/O Although the embedded PLC setup is flexible, relatively easy and interface, DC motor module, electro-pneumatic module affordable to teach the basic principle for PLCs, they did not integrated in a portable box with dimension 41 × 23 × 11.8 cm. present or discuss FB program for the bottle filling application. The objective of this paper is to present design steps for a Also, survey report of their application shows moderate desktop PLC trainer workstation for industrial automatic performance in stability and reliability. In [6] the development of engineering operation with emphasis on hardware connection of a PLC Trainer Kit Simulator Automation Lab at the Polytechnic the input/output components. We present basic PLC automatic of Sultan Abdul Halim Mu’adzam Shah (POLIMAS) was operation such as latching and PLC component symbols with described. The training kit comprises the Omron PLC CPU unit description. In order to train students and person’s with interest in with 12 inputs and 8 outputs control. Input and output devices are the field of automatic control for industrial automation. The design bank of switches and light indicators respectively. They used CX- and implementation comprise the cabling, programming of PLC Programmer for CP1E version 1.0 to program the PLC using using ladder logic with the PC, downloading and uploading the ladder diagram and instruction list PLC programming languages. program to the PLC through USB cable and testing on the The fabrication of a multiple input/output (I/O) PLC module for workstation. educational purpose to enhance the learner’s theoretical 2. Design Step comprehension and hands-on skill especially for programming, cabling, circuit design and problem solving is presented in [7]. The materials for the development of the proposed PLC Their module consists of I/O devices such as push buttons training workstation are: MITSUBISHI FX 1S-30MR-001 PLC, (normally open), DC motor (24V), DC relay (24V), DC solenoid simulation software; MITSUBISHI FXTRN-BEG-EL and piston cylinder (24V) and DC light (24V) capable of interfacing programming software; MITSUBISHI GX Developer version 8, with PLC controller produced by Matsushita, Omron, Siemens. Power Supply Unit, USB programming cable, switches, push Survey report from the trainees show that 95.70 % attest to the enhancement in their theoretical comprehension and hands-on buttons, blower, relay and buzzer. skill competence in their learning process. However, the 2.1. MITSUBISHI FX 1S-30MR-001 PLC programming aspect of the PLC is not discussed. Authors in[8] presented a PLC Based Electrical Machine Trainer Kit developed Mitsubishi PLC is applied in this work to achieve the desired for Electrical Engineering Practices in the Department of control specification written in LL. We used the MITSUBISHI Electrical Engineering Education at Faculty of Engineering, GX Developer version 8 programming software to write the LL Universitas Negeri Yogyakarta. Their approach is research and program. The PLC has 28 number of I/O (discrete, I = 14, O =14), development with reference to the ADDIE model from 24 V DC input signal and power supply, with relay and transistor RobertMaribe Branch. The installed PLC is Zelio SR2.201FU and the console dimension is 44.1 cm ×100 cm and 92.7 cm ×100 cm output type. Figure 1 shows the PLC diagram. with a front tilt angle of 80 °. Authors examined the performance of trainer kit on 8 practical experiment; rotation control of DC motors; rotation control of three phase induction motor; rotation control of one phase induction motor; starting DC motor; starting 3 phase induction motor using auto-transformer; dynamic DC motor braking; DC motor braking by plugging; and braking 3- phase induction motor by DC injection. Result show the trainer kit has a good performance, indicated by the electrical components and the practical work description can function Figure 1: Mitsubishi FX 1S-30MR-001 PLC appropriately as planned. The development of an affordable and portable PLC trainer for industrial control process application is 2.2. Power supply unit described in [9]. They used the Delta DVP14SS2 PLC, WPLSoft software and switches as inputs and pilot lamps as outputs. The PLC operate on 24 V DV converted from a 220 V AC Instructors trained student on cabling and programming of PLC source voltage. The 24 V DC is distributed through the I/O with hands-on training on Traffic light automation application. peripherals as shown in Figure
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