Efficient Cost Hardware-in-the-Loop System for Liquid Process Control Teaching Aligned with ABET Standard

This study presents a cost-efficient Hardware-in-the-Loop platform for liquid-level process control education, designed to bridge the gap between theoretical learning and real-world industrial practice. The proposed system integrates NI myRIO and NI myDAQ hardware with LabVIEW-based real-time simulation and controller implementation, enabling flexible experimentation across a range of linear and nonlinear tank models. Through real-time controllers, students can design, tune, and validate classical digital controllers while gaining hands-on experience with real-time process dynamics. Experimental results from Model-in-the-Loop and Hardware-in-the-Loop configurations confirm the high accuracy between simulated and hardware responses, with low normalized root mean square error (NRMSE < 0.07) and high normalized cross-correlation (NCC > 0.99) between MIL and HIL responses. Additionally, learning outcomes were assessed using rubrics and student perception surveys aligned with ABET criteria. The platform successfully satisfies ABET student outcomes (SO1, SO2, SO7) by promoting modeling, system identification, and real-time implementation skills. Student surveys reveal high satisfaction mean = 5.44 and a Cronbach’s α of 0.91367, highlighting enhanced engagement, flexibility, and confidence in control system design. This work demonstrates an adaptable, scalable educational solution that strengthens engineering competencies while keeping implementation costs low.