Virtual Simulation System with Various Examples and Analysis Tools for Programmable Logic Controller Training

Abstract

The purpose of this research is to design a virtual educational simulation device as a training aid for the Programmable Logic Controller. This software is equipped with an extensive library of process models to mimic the functional behavior of real factory processes, thus helping students to practice controlling various industrial processes by using various tools from PLC. The advantage of this simulator is that it provides analytical tools to get concise information about the output performance of the controlled system. The method used in this research is the Descriptive Analysis Method which consists of five stages, namely problem identification, literature study, instrument design, implementation, and testing and evaluation. The implementation of this software is based on LabVIEW (Laboratory Laboratory Workbench) on the PC. Exchange of control signals between the actual PLC (any PLC can be used) and the PC via the signal conditioning circuit and the Arduino. The results of this study are that three factory models have been made. The first factory model is a traffic light control system of two adjacent intersections. The second factory model is water level control in the tank. The third factory model is a multi elevator control system. The analysis tools for the first plant is information about the total waiting time of all vehicles passing through the intersection. The analysis tools for the second plant is a system performance graph that is equipped with maximum overshoot, settling time, and steady state error information. The analysis tools for the third plant is the total average floor displacement time of all elevator users. Therefore, this research has succeeded in making a virtual education simulation which, consists of three plant simulations and their analysis tools. The impact of this research is expected to increase students’ understanding of PLC and control techniques.