IIOT Enabled PLC-based Sorting Process Control Application Training System
FEATURES
The PLC (Allen-Bradley/Siemens) system is equipped with 8 digital inputs, 6 digital outputs, 2 analog inputs, and 1 analog output, providing the necessary I/O capabilities for various industrial automation tasks. It also features Ethernet communication support, enabling seamless integration into industrial networks for remote monitoring, control, and diagnostics. The system comes with licensed PLC programming software, allowing users to program the PLC using standard languages such as ladder logic or structured text. Real-world components like pneumatic solenoid valves and pneumatic cylinders with reed switches, a small air compressor, conveyor belt with DC brushless motor and its driver, inductive and capacitive proximity sensors, toggle switches, selector switches, visual and audio indicators, DC motors, relays, contactors, and voltage displays offer students hands-on, practical experience with equipment they might encounter in the field. The system also allows sorting process monitoring and control from anywhere using mobile devices and applications.
TECHNICAL SPECIFICATIONS
The PLC has 8 digital inputs, 6 digital outputs, 2 analog inputs with 10-bit resolution, and 1 analog output with Ethernet communication facility. The system includes 8 toggle switches, 5 push-to-ON switches, 1 proximity sensor, 1 selector switch, 4 visual indicators, 1 audio indicator, 1 DC motor, 1 relay card containing 2 relays, 1 contactor, 2 pneumatic solenoid valves, 2 pneumatic double-acting cylinders with magnetic reed switches, a Nema17 planetary geared BLDC motor (14 Kg cm, 290 RPM) with industrial brushless DC motor driver (BLDC, 250W) with RS485 Modbus, a small air compressor, and 1 IIOT device.
EXPERIMENTS
Program operation of NO (normally open) and NC (normally closed) instructions, types of logic gates, set and reset bit, types of timers (TON, TOFF, TONR), types of counters (CTU, CTD, CTUD), types of compare instruction, types of math functions, MOV instruction, analog input and outputs, SCALE_X (scale) and NORM_X (normalize) instructions. Interfacing of inductive and capacitive proximity sensors with PLC. Interfacing of pneumatic solenoid valves and pneumatic cylinders with PLC. Writing a ladder program for sorting metallic and nonmetallic objects using inductive and capacitive proximity sensors, pneumatic solenoid valves, pneumatic cylinders, and PLC. Real-time interface of web SCADA with PLC. Learning how to develop and utilize cloud-based SCADA systems for global access to process data and remote control. With cloud SCADA, users can access live process data, control operations, and monitor systems from anywhere using mobile devices and applications. Gain experience in data logging, downloading data, and analyzing alarm histories through the cloud SCADA system. Users can export data directly into Excel to track process performance, monitor trends, and optimize operations.
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