2015 Innovation & Commercialization of Medical Electronic Technology Conference (ICMET), 30 November 2015, Blue Wave Hotel, Shah Alam, Malaysia
Multiple Input/Outputs Programmable Logic Controller (PLC) Module for Educational Applications Ibrahim Burhanl, Ahmad Aftas Azman2, Saharuddin Talib3
Electrical Engineering Department Politeknik Sultan Salahuddin Abdul Aziz Shah 40460, Shah Alam, Selangor, Malaysia lbibrahim 197
[email protected] [email protected] [email protected]
Abstract-
Multiple
input/output
Programmable
Logic
Controller (PLC) module for educational purposes is fabricated because of current PLC Kit that was unable to enhance learners theoretical
understanding
programming,
wiring,
and
hands-on
skill
especially
for
design of circuit and problem solving.
The available PLC Kit comes with a casing which learners struggling in comprehend the theoretical knowledge, cabling connection between input components, PLC modules and output components
respectively.
developed and
Newly
fabricated
designed
PLC
modules
are
with additional input and output
devices, cost effective and user friendly. Moreover, this module come with multiple
Input/Output (I/O) devices such as push
buttons (normally open) , DC motor solenoid piston cylinder
(24V)
(24V),
DC relay
and DC light
(24V)
(24V)
, DC
and able to
interfacing with different kinds of PLC controller produced by Matsushita,
Omron,
Siemens
and
surveyed, it is found that on average of
etc.
Through
93.20%
conducted
agreed that newly
developed Multiple I/O PLC module is user friendly, safe and attractive to be used while
95.70%
participants agreed that there
are enhancements in theoretical understanding and hands-on skill aspect in their learning process.
Index Terms-Programming Logic Controller (PLC) modules, multiples
input/outputs,
theoretical
understanding,
hands-on
skill.
I.
INTRODUCTION
In the advancement of research and technology, programmable logic controller (PLCs) is one of the controller that still popular in the manufacturing industries and still remain as a leading controller types in the future. PLC can be classified as a digital computer used in various manufacturing industries. This is due to some beneficial advantages offered by PLC such as cost effective, flexible, reliable, and etc. PLC programs are typically written through ladder diagram or other conventional programming method that can be copied from a workstation (i.e.: computer or laptops) or even through PLC hand-held console via cable. A compact PLC has a perpetual number of connecting terminals constructed for input/output (I/O) connection and could be extended if the controller having insufficient I/O (in the case of future expansion). Furthermore, it can be programmable and reprogrammable for various task, thus make the construction it flexible and adaptable to the future changes demand by relevant industries [I].
978-1-4673-8799-6/15/$31.00 ©2015 1EEE
Studying PLC-programming in engineering education especially in polytechnic system is relatively significant. Electrical Engineering Department of Sultan Salahuddin Abdul Aziz Shah Polytechnic (PSA) offered four major programme which are Bachelor in Electronic Engineering (Medical), Diploma in Electronic Engineering (Control), Diploma in Electronic Engineering (Communication) and Diploma in Electronic Engineering (Medical). Learners should experience hands-on skills in PLC as it is a major component in engineering courses especially for learner taking instrumentation and control subject. Theoretical knowledge and hands-on skills experience in PLC control principles provide more career opportunities besides meeting the emerging of workforce and education need for global industries [2], [3]. Unfortunately, unavailability of suitable devices to perform hands-on skills aspect during the practical session in executing the syllabus for several courses such as Automation & Programmable Logic Controller, Industrial Control, Process Measurement, Instrumentation and Final Year Project (FYP). This is due to the existing equipment equipped
with toggle switches as the input devices, which it is unsuitable for practical implementation and lights are used as to display the output module (one source of output devices only). The design and fabrication of multiple 110 PLC module also emphasis more on candidates studying PLC courses offered in Malaysian polytechnics curriculum and specifically stressing on practical implementation [4]. 11.
EXECUTION OF EXISTING PLCs COURSE
PLC-programming is best learned through hands-on training dealing with machines, or actual components, or in an automated system [5], [6]. Back in 1997, when the operation of Sultan Salahuddin Abdul Aziz Shah Polytechnic, the available devices for educational application is as shown in Figure I. The 110 module is not available to show the function of this controller. Due to this constraint, it is hard to measure educational objective as outlined in the syllabus. Furthermore, the design and fabrication of this module is typically due to the problem facing by the instructor and learners at Electrical Engineering Department, PSA. Strong theoretical understanding of PLC-programming is best couple
39
2015 Innovation & Commercialization of Medical Electronic Technology Conference (lCMET), 30 November 2015, Blue Wave Hotel, Shah Alam, Malaysia
by hands-on training, Unfortunately, the eXlstmg facility at Electrical Engineering Department does not meet the hand-on requirement base on the curriculum outlined by Department of Polytechnic, Ministry of Higher Education (MoHE) and as a higher educational institution is to produce semi skill workers to the industrial also demand the leaners to acquired wiring experience between I/O devices and PLC.
Existing PLC Trainer Kit (purchase from trainer supplier) also unsuitable for educational purposes, for example, as in the Figure 2 it come with toggle switch which provide normally close contact (permanently close latch) at all time. The toggle switches is best replaced by push button where it will have close contact when push (or press) and open contact when release. Separate individual equipment is needed such as the Program Module, PLC Module and I/O Module must be together for hands-on purposes. During practical implementation, the lab workbench is full of apparatus and it looks messy and full of wires. For safety reason, more comprehensive and flexible multiple I/O PLC modules was designed. There are two main objectives in the design, development and fabrication of multiple I/O PLC modules which are to enhance the learner's theoretical knowledge and hands-on skills for PLC related courses and at the same time to fabricate multiples types of I/O mechanisms embedded in one compact PLC hardware.
Figure 1: PLC- NAlS FPI-C24
Before the development of this newly multiple input/output PLC module, several series of PLC kit had been developed and implemented as show in Table 1, unfortunately the previous kits still have some room for improvement.
Series 01
III.
A. Design stage The PLCs provide analogue and digital series input/ output that can be used to control the output module. Figure 3 shows the block diagram of multiple I/O PLC modules. It consists of PLC itself, Input Module, Output Module, 24VDC Power Supply unit and common connection for Input/Output.
Table 1: Previous PLC Trainer Board Problem Finding
Previous PLC Trainer Board =.c'
"
Using male and female
.
t
),..'
. .�
'
.
.
� ..... """ -. -...
-
..
jack). Lamp
'l! 1\ �
Structure
from
..
.
Year: 2011
.
POWER SUPPLY 24VDC
the
·�·i
plastic
casing. Various output components
--"
as
output indicator.
02
�.
connector wire (banana
Only
Year : 2007 Unit: II No of students : 301
such
motor.
as
solenoid
cylinder,
relay
and
to
controller
to
connect this
MODULE (INPUT)
MODULE (OUTPUT)
5 PUSH BUTTON (l\OR"L\L'rOPli�)
2DC MOTOR J DC LIGHT
PLC NAIS FPI·C24 (Matsushita)
lamps. Need
DESIGNING STAGE
I/O
module.
1 MAGNETIC RELAY 1 SOLENOID CYLINDER
Figure 3: Block Diagram for Multiple I/O PLCs module
Although, every department have a specific budget allocation for equipment acquisition, but the instructor facing problems in obtaining appropriate devices which most of the equipment available in the market are hardly available to meet the curriculum requirement [7], [8].
B. Software and Hardware Hardware devices associated for this research are: Controller: Matsushita (NAIS FPI-C24) manufacture by i) Panasonic as in Figure 4. The advantage of selecting this type of controller because it is inexpensive, easy programming and configuration of 110 channels. This PLC has 16 inputs and 8 outputs with build-in 110 channel. 240VAC as the input power supply to the PLCs generating 24VDC for the output. ii) FP Programmer II also known as Programming Console or hand-held purposely for download the program to the PLC via the FPJ peripheral cable. iii) 24 VDC External Power Supply connected to the output channel of PLCs. iv) 24 VDC Motor. v) 24 VDC Solenoid Piston Cylinders.
Row of Toggle Switches
Figure 2: Available PLC Trainer Kit come with toggle switch
40
2015 Innovation & Commercialization of Medical Electronic Technology Conference (ICMET), 30 November 2015, Blue Wave Hotel, Shah Alam, Malaysia
programming, PLC, and I/O segment respectively as show in Figure 7.
vi)
Normally Open Push Button is suitable to be used in this Multiple 110 PLC module due to it will disconnect once the button been release. Push Button is suitable for trainer compared to others type switches in PLCs application. vii) 24 VDC Green Light as indicator for the output modules FP1 Control Unit
�-'I
-� �I �I------�--�I �I---'IProgramming I/O
PLC
Segment
Segment
Segment
Peripheral Cable
Figure 7: Top view of multiple I/O PLC modules
The PLC segment ( NAIS FP1-C24) is basically come with eight inputs and eight outputs connection from the PLC module being relocated to the front aluminium panel. It also consists of RUN/PROG switches. PROG (PROGRAM) is for write or download the program from hand-held programmer to PLC via peripheral cable and when switched to RUN is used to execute the program. In this section also consist of Input and Output Common and +24VDC supply to power up the I/O Section. The I/O Segment consist of 5 Normally Open pushbutton, 3 green light, 2 unit of 24VDC motor, I unit 24VDC relay and I unit of 24VDC solenoid piston cylinder. All the I/O components was attached with female connector for easy of connection during the practical session. Banana plug (male connector) was used for the purpose of connecting the 110. Via peripheral cable, the hand-held programming console will be connected at programming segment for the purpose of downloading the program to PLC module.
FP Programmer 11 Figure 4: PLCs control unit and hand-held Programmer (Programming Console)
IV. FABRICATION OF THE MULTIPLE I/O PLCs MODULE Wiring connection starts from the external 100 - 240VAC power cord to the PLCs as shows in Figure 5. 100 V to 240 V AC
Figure 5: Connection of lOO-240VAC Power Supply
0000
0000
OUTPUT
INPUT
The designed and fabrications of this PLC module are separated into three main segments which are the PLC module, 35° slope panel made from aluminium alloy structure, and 24VDC power supply respectively. Figure 6 show the dimensions of the multiple I/O PLC modules. 1 .7" 3
COM OUTP T
7 . 5"
COM INPUT
.5 3 " .
--
5 � 1111== 1 ==== •• "
(a) Top view
1 LAMP24V
PIB N/C
PIB N/O
(b) Side view
Figure 8: Schematic diagram for multiple I/O PLC modules
Figure 6: Dimension of casing for multiple I/O PLC modules
Schematic diagram as show at Figure 8 represents the complete multiple I/O PLC modules wiring connection. The
Furthermore, the aluminium alloy structure at the front panel is divided into three main segments which are the
41
2015 Innovation & Commercialization of Medical Electronic Technology Conference (lCMET), 30 November 2015, Blue Wave Hotel, Shah Alam, Malaysia
(FYP)
PLC module port, input and output devices was connected to the common connection point of +24VDC supply and for a complete circuit the PLC module port also was connected with -24VDC supply, V,
EXECUTION STAGE OF PLC MODULE
The complete structure of multiple I/O PLC modules as depicted in Figure 9 was used as training platform in executing hands-on practical associates with PLC courses which are Automation & Programmable Logic Controller,
Industrial Control, Process Measurement, Instrumentation, Control System and Final Year Project (FYP) to the Electrical Engineering learners, In order to measure the enhancement of theoretical knowledge and hands-on skills and the layout of the newly developed PLC module, five different classes selected from Electrical Engineering Department was asked to fill in a survey form, The participants are selected from Electrical Engineering Department learners attending theoretical classes either Automation and Programmable Logic Controller (EJ50l) in semester 5 or Project 112 (EE50 1/EE60 1) in semester 5/6 during their Diploma in Electronic Engineering (Control) study, Furthermore, these participants also need to have electrical engineering background and direct hands-on lab experiences with the newly developed Multiple I/O PIC module, A total of 64 participants was selected to fill in the questionnaire from five different classes which are DlK5A, DJK5B, DJK6, DEP6 and DEU6 respectively, The survey was distributed and collected by the in-charge instructor,
with PLC) TOTAL
64
This survey is distributed to the participant at each of the classes towards the end of the semester, This is because to provide enough time frames for the participant to absorb the teaching and learning process and they can complete all hands-on practical that was impose for that particular subjects. Each participant needed to complete 5 laboratory (minimum) works as determined in the curriculum syllabus guideline or applying PLC devices for their final year project (FYP) as a basic evaluation for learners understanding and hands-on skill. VI.
DISSCUSSION OF RESULTS
Table 3 shows the summary of the conducted surveys. It was separated into two different sections which are to gauge the hardware section of the Multiple I/O PLC trainer (Section A) and knowledge (understanding) and hands-on skill of the participants (Section B). Table 3: Summary of finding for implementation of multiple I/O PLC modules Not
Frequency Item
No.
Agree
Not
Agree
Agree
(Y)
Agree
(%)
(%)
(N) Section A: Hardware development of multiple 110 PLC module
1
It is easy to use the PLC
hands-on
60
4
93.75
6.25
59
5
92.19
7.81
60
4
93.75
6.25
93.20
6.77
during
module
of
because
its user friendly. 2
Are the safety feature are emphasize in this newly developed PLC module.
3
The
of
the
on
this
layout
components PLC
attracts
module
me to study. Average Section B:
1
My
Knowledge lJnderstanding and Hands-on skill
understanding
61
3
95.31
4.69
62
2
96.87
3.13
62
2
96.87
3.13
61
3
95.31
4.69
60
4
93.75
6.25
about PLC input and output
Figure 9: Complete multiple I/O PLC modules
This survey was conducted during lun 20 14 session, Table 2 shows the numbers of participant, classes and subjects involved in this survey, Classes
Table 2' Total Number of participants
Subjects
devices
are
enhanced.
No. of participants
D.lK SA
E.l501: Automation and Programmable Logic Controller
18
DJK5B
EJ501: Automation and Programmable Logic Controller
20
DJK5 (FYP)
EE50 I: Project 1
5
D.lK6, DEP6 & DEU6
EE601: Project 2
21 (project related
2
It is easy to understand the
from
connection
input to output. 3
Using
PLC
this
module
can
the
understanding
enhance
about logic control. 4
My hands-on skill for PLC programming
IS
improved. 5
Hand-on module some
ideas
final
year
(FYP)
42
using can
PLC
provide for
my
project
2015 Innovation & Commercialization of Medical Electronic Technology Conference (ICMET), 30 November 2015, Blue Wave Hotel, Shah Alam, Malaysia
6
Using
PLC
this
module
can
61
3
95.31
4.69
61
3
95.31
4.69
62
2
96.S7
3.13
95.70
4.30
my hands-on skills 7
My interest in learning about PLC is enhanced when using this PLC module.
S
It is easy to understand the
ACKNOWLEDGMENT
enhance
theoretical
Authors would like to express our thanks to Management Team of Electrical Engineering Department, Sultan Salahuddin Abdul Aziz Shah Polytechnic in allowing us to used material and tools for fabrication and implementation of this project. REFERENCES
part
when using this PLC module. Average
[1]
X. L. X. Li, S. Munigala, and Q.-A. Z. Q.-A. Zeng, "Design and Implementation of a Wireless Programmable Logic
From the conducted survey, it show that majority of the participants are satisfied with the hardware build-up or structure of the newly developed multiple I/O PLC module with 93.20% agreed it was user friendly, attractive and safe. During the hands-on session, the laboratory workbench only need to accommodate one single module without others unnecessary apparatus. Furthermore, majority of the participants (95.70%) agreed that the multiple 110 PLC modules help them in enhancing their knowledge understanding and hands-on skill which is good for preparing them to enter the job industries once they are graduated from this institution. VII.
CONCLUSION
Through this newly designed, developed and fabrication of multiple I/O PLC modules, assist the participants to accomplish the educational objective especially in enhancing the theoretical knowledge and hands-on skill aspect through ladder diagram design, programming execution, and problem solving. The fabrication of multiple 110 PLC modules has been designed and improved by adding additional output components, cost effective, compact, and it was user friendly whereby all the I/O devices are embedded in one compact module. Moreover, it was supported by the survey distributed to the relevant participants which show that on average of 93.20% agreed that the multiple I/O PLC modules is user friendly, safe and attractive to be used and 95.70% participants agreed that there are enhancement in theoretical understanding and hands-on skill aspect in their learning process.
Controller System," Electr. Control Eng. (ICECE), 2010 Int. Con/. , 201O .
[2]
A. F. Kheiralla, O. Siddig, A. A. E. Mokhtar, M. Esameldeen, and O. Addalla, "Design and Development of a Low Cost Programmable Logic Controller Workbench for Education Purposes," in International Conference on Engineering Education - ICEE 2007, 2007, pp. 1-6.
[3]
R. Zhen, H. Meng, X. L. Wu, 1. Li, and S. M. Liu, "Exploration on a New System of PLC Three-Dimensional Teaching," Adv. Mater. Res., vol. 271-273, pp. 1231-1234, luI. 2011.
[4]
"Curriculum Development and Evaluation Division Curriculum Document, Department of Polytechnic Education, Ministry of Higher Education, Malaysia." 2011.
[5]
1. Burhan, S. Talib, and A. A. Azman, "Design and fabrication of Programmable Logic Controller Kit with multiple output module for teaching and learning purposes,"
2012 IEEE 8th Int. Colloq. Signal Process. its Appl., pp. 14IS, Mar. 2012. [6]
1. Burhan, A. A. Azman, and A. A. Ab. Aziz, "Development of Programmable Integrated Circuit (PIC) Module with Multiple Outputs for Students Psychomotor Skill Enhancement," Appl. Mech. Mater., vol. 773-774, pp. 751755, 2015.
[7]
"Omron Industrial Automation." [Online]. Available: http://www.omron-ap.com.my/products/.
[S]
"Unitech Scales And Measurements Pvt. Ltd." [Online]. Available: http: //www.unitechscales.org/plc-trainers.html.
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