Development of an IoT-Based PLC Trainer: Bridging the Practical Divide in Industrial Automation Education

In the dynamic landscape of digitalization, the fusion of Internet of Things (IoT) tech-nology with Programmable Logic Controllers (PLCs) has emerged as a pivotal avenue, promising enriched practical experiences and heightened comprehension. This paper navi-gates through recent studies elucidating the applications of IoT-based PLCs in diverse con-texts, from smart home automation to traffic control and resource management. Notable contributions include remote monitoring systems, smart traffic control, water level moni-toring, and automated greenhouses. Acknowledging persistent challenges in understanding and implementing PLCs, this research introduces an innovative IoT-based PLC Trainer Kit. The kit aims to elevate prac-tical learning by providing hands-on experiences, refining skills, and optimizing applica-tions across various domains. Emphasizing the pivotal role of practical training in PLC education, the study conducts a needs analysis, followed by the design, development, and testing phases of the IoT-based PLC Trainer. The prototype, employing an Omron CPM1A PLC, pneumatic components, sensors, and an intuitive interface, undergoes meticulous testing, affirming its readiness for deployment. The development of the IoT-based PLC Trainer marks a significant achievement, ad-dressing the gap between theoretical knowledge and practical application. Through metic-ulous design, material selection, and testing, the trainer demonstrates optimal functionali-ty and user-friendliness. Anticipating its deployment in educational institutions and in-dustrial setups, the trainer is poised to contribute to the realm of industrial automation, offering a practical understanding of PLC applications within the Internet of Things con-text. This project not only signifies technical expertise but also bridges the gap between theory and practice in the dynamic domain of IoT-driven programmable logic control-ler

An Asynchronous Course/Laboratory Development for Automation Controls

The development of asynchronous courses is to help students who are restricted by work requirements, family responsibilities, geographical distance, disabilities, and combination of these factors. It also provides flexibilities to on-campus students. In this paper, the framework structure of an asynchronous course and laboratory development for an automation control is presented. The challenge in this development is to implement the hands-on laboratory experience to those distance learning students who may not be able to access the real equipment. Results of the implementation including opinion feedbacks and grade distributions show that students welcome the format of this development

An Industrial Automation Course: Common Infrastructure for Physical, Virtual and Remote Laboratories for PLC Programming

This work describes the development of a teaching strategy to leverage current simulation tools and promote learning of industrial automation systems. Specifically, Programmable Logic Controller (PLC) programming in an industrial automation course. We propose an infrastructure where it is possible to work with physical, virtual and mixed laboratories

Design and Development of a Low-Cost Multi-Channel Re-Programmable Electro-Pneumatic Actuator Kit

The objective of the research was to develop a low-cost, multi-channel electro-pneumatic actuator kit that would be conveniently accessible for students' learning experiences, trainings, and research at the individual and academic level. The essential feature of this kit was the inclusion of multi-channel outputs, which implies that the student may not only examine the behavior of basic pneumatic actuators but also train their minds to operate complicated actuation systems. With this electro-pneumatic actuation kit, a student can build and utilize it in a variety of research areas, as well as regulate a system synchronously or asynchronously with greater efficiency. The device is portable, inexpensive, and simple to use. It has a power source of 12 VDC for the electrical circuit and can provide a maximum pressure of 90 kPa as well as vacuum of -40 kPa. Relays were being integrated to satisfy the smooth automation of the kit. It features the MPX700 differential pressure sensor, which allows the user to measure and manage the needed pressure. All of the components were controlled by the Arduino Board, which is affordable and can be programmed to do the required function. With this research, academic institutions will be able to create their own kits for their students, allowing them to discover numerous new inventive concepts

Design and Development of a Low-Cost Multi-Channel Re-Programmable Electro-Pneumatic Actuator Kit

The objective of the research was to develop a low-cost, multi-channel electro-pneumatic actuator kit that would be conveniently accessible for students' learning experiences, trainings, and research at the individual and academic level. The essential feature of this kit was the inclusion of multi-channel outputs, which implies that the student may not only examine the behavior of basic pneumatic actuators but also train their minds to operate complicated actuation systems. With this electro-pneumatic actuation kit, a student can build and utilize it in a variety of research areas, as well as regulate a system synchronously or asynchronously with greater efficiency. The device is portable, inexpensive, and simple to use. It has a power source of 12 VDC for the electrical circuit and can provide a maximum pressure of 90 kPa as well as vacuum of -40 kPa. Relays were being integrated to satisfy the smooth automation of the kit. It features the MPX700 differential pressure sensor, which allows the user to measure and manage the needed pressure. All of the components were controlled by the Arduino Board, which is affordable and can be programmed to do the required function. With this research, academic institutions will be able to create their own kits for their students, allowing them to discover numerous new inventive concepts

2022 (Fall) ENSI Informer Magazine

The ENSI Informer Magazine published in the fall of 2022

Design of A Virtual Laboratory for Automation Control

In the past, only students who studied on campus were able to access laboratory equipment in traditional lab courses; distance learning students, enrolled in online courses, were at a disadvantage for they could learn basic lab experiment principles but could never experience hands-on learning. Modeling and simulation can be a powerful tool for generating virtual laboratories for distance learning students. This thesis describes the design and development of a virtual laboratory for automation control using mechanical, electrical, and pneumatic components for an automation and control course at Old Dominion University. This virtual laboratory application was implemented for two platforms — Windows personal computers and Android smartphones. The virtual lab serves as pre-lab session for on-campus students and a virtual lab tool for distance-learning students to gain some “hands-on” lab experience. Utilizing the virtual learning environment as a supplement to engineering-based laboratories is also beneficial for students to prepare for the physical experiment and obtain a “hands-on,” practical lab experience without the hazards present in the physical lab. Such a methodology can also be applied to experiments in different fields such chemistry, etc

A Review of Pneumatic Actuators Used for the Design of Medical Simulators and Medical Tools

International audienc

Model-based training of manual procedures in automated production systems

Maintenance engineers deal with increasingly complex automated production systems (aPSs). Such systems are characterized by an increasing computerization or the addition of robots that collaborate with human workers. The effects of changing or replacing components of such systems are difficult to assess since there are complex interdependencies between process parameters and the state of the components. This paper proposes a model-based training system that visualizes these interdependencies using domain-independent SysML models. The training system consists of a virtual training system for initial training and an online support system for assistance during maintenance or changeover procedures. Both systems use structural SysML models to visualize the state of the machine at a certain step of a procedure. An evaluation of the system in a changeover procedure against a paper-based manual showed promising results regarding effectiveness, usability and attractiveness.Comment: 25 pages, https://www.sciencedirect.com/science/article/pii/S095741581830080

Integration of sensor and actuator networks and the SCADA System to promote the migration of the legacy flexible manufacturing system towards the industry 4.0 concept

Se implementan redes de sensores y actuadores en los procesos de fabricación automatizados utilizando buses de campo industriales, donde las unidades de automatización y los sistemas de supervisión también están conectados a intercambiar información operacional. En el contexto de la cuarta revolución industrial entrante, llamada Industria 4.0, la gestión de las instalaciones de legado es una cuestión primordial a tratar. Este documento presenta una solución para mejorar la conectividad de un sistema de fabricación flexible heredado, que constituye el primer paso en la adopción del concepto de Industria 4.0. Tal sistema incluye el PROCESO de bus de campo FIELD BUS (PROFIBUS) alrededor del cual se interconectan los sensores, actuadores y controladores. En orden para establecer una comunicación efectiva entre la red de sensores y actuadores y una red de supervision se implementa un enfoque de hardware y software que incluye la conectividad Ethernet. Este se prevé que la labor contribuya a la migración de los sistemas heredados hacia la desafiante industria 4.0 marco. Los resultados experimentales prueban el correcto funcionamiento del FMS y la viabilidad de la propuesta.Networks of sensors and actuators in automated manufacturing processes are implemented using industrial fieldbuses, where automation units and supervisory systems are also connected to exchange operational information. In the context of the incoming fourth industrial revolution, called Industry 4.0, the management of legacy facilities is a paramount issue to deal with. This paper presents a solution to enhance the connectivity of a legacy Flexible Manufacturing System, which constitutes the first step in the adoption of the Industry 4.0 concept. Such a system includes the fieldbus PROcess FIeld BUS (PROFIBUS) around which sensors, actuators, and controllers are interconnected. In order to establish effective communication between the sensors and actuators network and a supervisory system, a hardware and software approach including Ethernet connectivity is implemented. This work is envisioned to contribute to the migration of legacy systems towards the challenging Industry 4.0 framework. The experimental results prove the proper operation of the FMS and the feasibility of the proposal.peerReviewe