Development of a Programmable Logic Controller Experiential Learning Platform

An experiential learning platform was recently developed to expose graduate engineering students, as well as undergraduate junior and senior mechanical engineering students, to the concept, components, operation, and application of programmable logic controllers (PLCs).The platform consists of a programmable logic controller, which can be programmed with a desktop PC, in order to control several simple output devices.The system allows students to write their own ladder logic programs, and to experiment with the program structure needed to control particular output devices.Student feedback to date suggests the availability of this platform, which encourages self-exploration, has had a very positive impact on student learning in a recently run graduate course.Plans for implementing an experiential learning approach using an updated version of the same platform in the undergraduate engineering curriculum are also discussed. Basic Components of the PLC PlatformIn order to give students an opportunity to experience how computer automation and control is accomplished in a manufacturing environment, a demonstration apparatus was built containing actuation and sensing devices, a computer interface, feedback control, and an Allen Bradley MicroLogix 1500 programmable logic controller.This platform can be utilized by the instructor in a classroom environment for demonstration purposes, as well as by students as part of an active learning environment within or outside of the classroom.The apparatus is flexible so as to allow students to investigate how a basic control system works to perform an automated task, including the basics of how the various components of the system function and communicate with each other, and to investigate the theory associated with proportional, integral, derivative control and associated techniques.