PLC/HMI Based Portable Workbench for PLC and Digital Logic Learning and Application Development

A Programmable logic controller (PLC) uses the digital logic circuits and their operating concepts in its hardware structure and its programming instructions and algorithms. Therefore, the deep understanding of these two items is staple for the development of control applications using the PLC. This target is only possible through the practical sensing of the various components or instructions of these two items and their applications. In this work, a user-friendly and re-configurable ladder, digital logic learning and application development design and testing platform has been designed and implemented using a Programmable Logic Controller (PLC), Human Machine Interface panel (HMI), four magnetic contactors, one Single-phase power line controller and one Variable Frequency Drive (VFD) unit. The PLC role is to implement the ladder and digital logic functions. The HMI role is to establish the virtual circuit wiring and also to drive and monitor the developed application in real time mode of application. The magnetic contactors are to play the role of industrial field actuators or to link the developed application control circuit to another field actuator like three phase induction motor. The Single -phase power line controller is to support an application like that of the soft starter. The VFD is to support induction motor driven applications like that of cut-to-length process in which steel coils are uncoiled and passed through cutting blade to be cut into required lengths. The proposed platform has been tested through the development of 14 application examples. The test results proved the validity of the proposed platform.