An Indigenous and Conducive PLC Lab Trainer Having Variety of Industrial Applications for Substantial Hand on Exposure
Role of Programmable Logic Controller (PLC) in our indutries is indispensable due to its deployment for wide variety of applications. On the other hand, Engineers and Technical Staff are not fully familiar with PLC features due to lack of hands on opportunity and restrictions of
2025-06-28 16:30:13 - Adil Khan
An Indigenous and Conducive PLC Lab Trainer Having Variety of Industrial Applications for Substantial Hand on Exposure
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryRole of Programmable Logic Controller (PLC) in our indutries is indispensable due to its deployment for wide variety of applications. On the other hand, Engineers and Technical Staff are not fully familiar with PLC features due to lack of hands on opportunity and restrictions of working on live system.
To cope up with above cited challenge, a feasible solution is being proposed in this project, which deals with the designing of an Indigenous and Conducive Programmable Logic Controller (PLC) trainer that will provide substantial Practical Exposure on popular PLC based Industrial application such as Level Control, Motor Speed Control and Conveyor Belt Control. Moreover, Human Machine Interface (HMI) is used to dispaly all related parameters pramaters.
This trainer will be an effective source of learning for industry staff, trainees and studnets to understant working and implementation of PLC in indsutrial application by directly dealing with the process control loops. Morover the user friendly mechanism of the trainer will offer the student to carry out research and development in the field of control and automation by carrying out experiements on logiv and applying it on avaiable spre input and out put channels of the PLC.
Project ObjectivesTo overcome the gap of Practical Exposure and PLC related Knowledge ammong Industry staff and students in the field of industrial control and automation.
To offer the platform to do the research and development for industrial control loops.
Project Implementation MethodA trainer Kit will be preapred on which a PLC its Input out put cards, Human Machine Interface (HMI) and Power supply will be installed.
As a first application, a tank made of transparent plastic sheets will be designed t fill up with water, on which a level transmitter will be installed to measure the level of the tank. a valve on the tank discharge end will be installed to control the level according to given setpoitn from PLC
Second Application, a DC Motor operated by PLC command signal, and its speed will be monitored by a speed sensor. the speed of the motor will be controlled by PLC as per set point given from HMI.
Third application will Conveyor Belt control. In this application a DC motor driven Conveoyr belt will be controlled by PLC signal, on conveyor belt an object sensor will be installed which will count the objects passing infront of the snesor, the PLC will count the objects and display them on HMI, if there is no object moving on conveyor belt for an specific time the PLC will stop the Conveyor belt.
Just like an industry these all applications will have safety limits for their paramters, where associated alarms will be recorded and displayed on HMI.
Benefits of the ProjectPractical interaction with PLC
Implemntation of theoritical Knowledge of control automation on industrial proto type designs
Carreer Development of the Engineering graduates, by having skills of PLC
Research and Development in the field of control automation, e.g. Inventions of effective control logic/loops
Technical Details of Final DeliverableA trainer Board equipped with a PLC and its Input out put cards, a Power supply and a Human Machine Interface (HMI) to display all process parameters. a Tank with level transmitter, a DC motor with speed sensor and a conveyor belt with object sensor.
- PLC Fatek 24vDC, 8 DI &6 DO, 4 AI & 2 AO
- Weintek 10'' Human Machin Interface color touchscreen
- DC Motor 24 V 1000 RPM ( 4 to 20mA )
- Speed Sensor 20 RPM to 3000RPM
- Optical Object sensor (Range 300mm)
- Ultrasonic Level tranmsitter (4 to 20mA )
- Solenoid Valve 24vDC
- Tank made of transparent sheets 2x1x1 Feet
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 79950 | |||
| PLC Main unit | Equipment | 1 | 15000 | 15000 |
| Analog Input Card | Equipment | 1 | 12500 | 12500 |
| Analog Out Put Card | Equipment | 1 | 17300 | 17300 |
| HMI | Equipment | 1 | 19750 | 19750 |
| DC Motor | Equipment | 2 | 2700 | 5400 |
| Panel Board | Miscellaneous | 1 | 7000 | 7000 |
| Belt | Miscellaneous | 1 | 3000 | 3000 |