Programmable Logic Controller Based Lab Trainer for PLC learning

Project Title

Programmable Logic Controller Based Lab Trainer for PLC learning

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

The project is based on the design of Programmable Logic Control Based Lab Trainer and also in this project, the implementation of seven experiments will be performed.  As the PLC will be programmed for different experiments then the project is divided into two main parts: the software part where we will program (Ladder Logic) our PLC for every required experiment and the hardware part where we will implement the experiments by using the wired connection between PLC and required experiment module. In this PLC lab trainer, the 7 experiments can be performed these are: Speed control of DC motor using pulse width modulation, traffic light control, Boolean operation, relays and switches, Temperature based speed control, Serial communication between human-machine interface (HMI) and PLC, 7-Segment display, measure and control of analog inputs and many connecters and pinions. PLC trainer will be a designed prototype which will allow beginners and students to wire, program and simulate real-time control process. It is more flexible because of less noise, easy programming and having high operating voltage. The trainer hardware consists of PLC, I/O module, power supply, input and output process components. I/O modules will be digital and analog. Input will be switches, push-button, etc. The output will be controlled elements like DC motors and indictors.

    As with the passage of time, the demand for automation systems is increasing in industries, the importance of learning PLC is increasing. But the problem is the cost of PLC is high individuals can't buy it easy to learn it independently. This PLC-based lab trainer will help the students to learn PLC at the industrial level.

Project Objectives

Following are the objectives of our FYP project:

1. Design and implementation of a modern control system laboratory-based trainer using PLC.
2. The trainer facilitates digital as well as analog handling.
3. To design different experiment modules like digital, analog, PWM and serial.
4. The designed trainer will be portable.

Project Implementation Method We can perform different experiments on PLC trainer module by following these steps:

The Project is divided into two parts:

1) Software Part

2) Hardware Part

Software Part:

In the software part, we design the Ladder Logic of each experiment.

For example, the Ladder Logic of Module 1 is given below with simulation:

The alarm conditions are:

1. Low level with high pressure

2. High level with high temperature

3. High level with low temperature and    high pressure

We now define a Boolean expression with AND, OR operations that will give a for each condition:

????= A ?.???? ????= A.C ????= A.B.???? ?

Now implementing OR gate logic the final equation will be:

????=???? ?.????+????.????+A.B.???? ?

Hardware Part:

In the hardware part, we interface the different components with the main controller programmable logic controller. The connection of buttons, indicators, sensors, and motor, etc. The hardware is given below ( the work is still going):

The PLC we are using is Fatek FBs-32MAR-AC and analog Module is FBs-4A2D is shown in picture below:

Benefits of the Project

Following are the benefits of our project:

• PLC is the most used controller in the industry this project give a hand-on experience about the use and handling of PLC.
• The PLC Trainer will help the students to learn Ladder Logic and interfacing different components with PLC.
• This trainer will help the students to learn HMI as this trainer will include the HMI section.
•  The trainer will be portable means we can easily carry from it from one place to another.

Technical Details of Final Deliverable

• Following are the seven experiments modules which we designed to learn PLC:
• Main Trainer Module ( Main module where PLC, analog Module, Power Supply will be placed).
• Gate Module (To perform Basic AND, OR,  and Boolean operation).
• Relay Module (To perform basic relay logic hardwired and latching operation).
• 7-Segment Module (To display the number from 0-9).
• Traffic Light Module (To control the traffic signals from one way up to 4 ways).
• DC Motor Module (To control the speed of DC motor using PWM).
• Temperature Module (To control any operation dependent on the temperature variation). Interface PLC with HMI using serial communication.     

Current Work:

Till now we have designed 5 experiments and two left these are analog handling and temperature control.

The current work is given below:

1) Module 1 is Gate Module:

The size of module is 11.7 x 6.7 inches

2) Module 2 is Relay Module:

The size of module is 6 x 5.7 inches

3) Module 3 is Trffic Light Module:

The size of module is 14.8 x 14

 inches

4) The main Trainer Module:

The size of the module is 19.6 x 9,7 inches

5) The PLC trainer is:

Note: The project is not completed as several things are remaining to be design and some components on these modules also left so the work is on going and will be completed soon InshAllah. Thanks for your time and support!

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Energy Core Technology RoboticsOther Technologies Artificial Intelligence(AI), Internet of Things (IoT)Sustainable Development Goals Quality Education, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	73290
PLC (FBs-32MAR-AC)	Equipment	1	19000	19000
Analog Module (FBs-4A2D)	Equipment	1	16500	16500
RS-232 Programming Cable	Equipment	1	2500	2500
24V DC Motor	Equipment	1	1600	1600
Printed Board of Each Module	Equipment	1	15000	15000
Female connectors (4mm)	Equipment	250	20	5000
24V DC Indicators	Equipment	25	50	1250
Push Buttons Self Lock	Equipment	5	30	150
Push Button Momentary Lock (NO)	Equipment	22	30	660
Push Button Momentary Lock (NC)	Equipment	5	30	150
Relays	Equipment	2	120	240
Male Connectors	Equipment	30	25	750
Wire (meters)	Equipment	12	40	480
Card Board	Equipment	1	1200	1200
7-Segment Display	Equipment	1	100	100
Temperature Sensor PT100	Equipment	1	350	350
LM 7805 Regolators	Equipment	8	20	160
24V Power Supply	Equipment	1	1200	1200
Other Compoents	Miscellaneous	1	7000	7000