Scalable hybrid laboratories: Application in industrial automation

• A hybrid lab integrates real control devices with digital replicas of industrial processes, enabling scalable, realistic hands-on training for automation engineers. • The proposed architecture is designed for easy expansion or downsizing, accommodating diverse indus- trial scenarios while maintaining cost-effectiveness and flexibility. • A practical implementation demonstrates the lab’s scalability, transitioning from a single-tank system to a multi-sector water distribution network. • The lab utilizes OPC servers, SCADA systems, and industrial-grade software to mirror real-world automation environments, bridging the gap between academia and industry. Some of the most critical competencies that automation and control students must acquire to become capable engineers require hands-on laboratory experiences under conditions that closely resemble real-world work environments. However, current practical laboratories often face challenges in recreating realistic and scalable industrial contexts, making it difficult to develop these competencies. This article presents the development and implementation of a hybrid laboratory proposal to address these challenges. The prototype, designed for training automation engineers, integrates real control devices with simulated digital replicas of processes, allowing the scalability of the system to address a wide variety of industry-like scenarios. The general design, its physical and virtual implementation, the communication of its components, and the installation and operation context are detailed. The article concludes with the potential advantages and benefits of the hybrid laboratory from an academic teaching perspective, the training of industry professionals, and the technical optimization of the engineering problem addressed.