Hardware and software system for simulation, control, and communication between industrial automation programs and PLC control used in educational institutions

This work presents the design and implementation of a system for studying industrial automation in the classroom, enabling students to conduct automation practices using Siemens, Festo, and RealGames software. It complements their learning with physical digital devices connected to a computer to activate and deactivate both analog and digital inputs and outputs, as well as sensors and actuators connected through communication networks and bus-type protocols. This system allows for save cost in the classroom. With minimal investment, each student can have their own “PLC”; using an ESP32 microprocessor-based device. They can couple power components onto baseboards for the device and run the developed server, enabling the device to communicate and activate the specified outputs in the control system, with minimal programming required. The clientserver communication libraries were developed using Python, and the ESP32 programming was done using microPython. The maximum number of applications that can be interconnected is up to 127 devices. The maximum response speed or latency is 500ms, and the approximate cost per complete simulation unit is one thousand Mexican pesos. Compared to the cost of a traditional laboratory of this type, it is less than 10% of the cost of a laboratory equipped with PLCs from recognized brands.