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Designing and Assembling of a Programmable LogicControls (PLC) Laboratory Trainer and Advanced Research Setup

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2016 ASEE Annual Conference & Exposition


New Orleans, Louisiana

Publication Date

June 26, 2016

Start Date

June 26, 2016

End Date

August 28, 2016





Conference Session

Instrumentation Division Technical Session 1

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Paper Authors


Priom Chakraborty Purdue University - Calumet

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Priom Chakraborty, B.S, currently working as a Teaching assistant of Purdue University calumet .He is now doing his Masters focusing in Mechatronics Engineering Technology. He also worked as lab assistant in AWAKE (Assisting Workforce by Advancing Knowledge for Employment) program in Purdue University Calumet. His was a co author of designing of Bottle Washing Machine in Virtual Environment Using the New Mechatronics System Design Technology.his recent work is to build a control Panel of Designing and Assembling of a Programmable Logic Controls (PLC) Laboratory Trainer and
Advanced Research Setup.He has done his B.S. In American international University of Bangladesh(AIUB) his interests are in the area of programmable logic controlled devices, FPGA system design by Verilog programming, Application of process control in industrial works, Robot programming.

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Akram Hossain Purdue University - Calumet

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Akram Hossain, Purdue University Calumet
Akram Hossain is a professor in the department of Engineering Technology and Director of the Center for Packaging Machinery Industry at Purdue University Calumet, Hammond, IN. He worked eight years in industry at various capacities. He is working with Purdue University Calumet for the past 27 years. He consults for industry on process control, packaging machinery system design, control and related disciplines. He is a senior member of IEEE and he served in IEEE/Industry Application Society for 15 years at various capacities. He served as chair of Manufacturing Systems Development Applications Department (MSDAD) of IEEE/IAS. Currently, he is serving a two-year term as the chair of the Instrumentation of ASEE (American Society of Engineering Education). He authored over 29 refereed journal and conference publications. In 2009 he as PI received NSF-CCLI grant entitled A Mechatronics Curriculum and Packaging Automation Laboratory Facility. In 2010 he as Co-PI received NSF-ATE grant entitled Meeting Workforce Needs for Mechatronics Technicians. From 2003 through 2006, he was involved with Argonne National Laboratory, Argonne, IL in developing direct computer control for hydrogen powered automotives. He is also involved in several direct computer control and wireless process control related research projects. His current interests are in the area of packaging machinery system design & control, industrial transducers, industrial process control systems, modeling and simulation of Mechatronics devices and systems in virtual environment, programmable logic controllers, programmable logic devices, renewable energy related projects, wireless controls, statistical process control, computer aided design and fabrication of printed circuit board.

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Vivek Pillarisetty P.E. Purdue University - Calumet

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Vivek Pillarisetty is an Indian Graduate Student studying Mechatronics in Purdue University, Calumet in the state Indiana. He has done his under graduation in KLUniversity, Vijayawada, India. He is an outstanding student and favorite for all of his professors.
He is an active participant in both co curricular and extra curricular activities. He is an avid reader and an interpreter. He learns the subject in depth and tries to work hands on whatever he learns. He is currently doing his research in packaging technology under Professor Akram Hossain in Purdue University, Calumet. After seeing his insight, the Professor offered him a Teaching Assistant position in the laboratory for guiding the students in the subject of Mechatronics.

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A Programmable Logic Controller (PLC) is an industrialized computer control system that constantly monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices. Almost any production line, machine function, or process can be greatly enhanced using this type of control system. However, the biggest benefit in using a PLC is the ability to change and replicate the operation or process while collecting and communicating vital information. It is also a modular system. It can be mixed and matched the types of Input and Output devices to best suit of any laboratory application and industrial control application. Training setup consists of an industrial grade PLC, Variable Frequency Drives, Servomotors coupled with drives, induction motors, Human Machine Interface (HMI), industrial networking capabilities, and many other ancillaries. The setup can be used for demonstrating the principles of programmable controllers and sequence control systems, advanced cam profile and advanced computation for controlling industrial processes. It is suitable for training both basic and advanced principles of PLC. Industrial grade PLC components are permanently mounted on the panel; it is also coupled, activated and controlled with numerous configurations such as with Variable Frequency Drive (VFD), servo drive, servo Motor, and induction motor, along with Human Machine Interface (HMI). This Laboratory trainer and research setup system is fully integrated with PLC Motion simulation software that will help students observe and understand the control logic behind the operation of industrial PLCs. The software can be used as an offline, simulation tool with its collection of sample HMI applications. The trainer alternately, can be used for online operation and control of industrial PLCs such as the Allen Bradley MicroLogix series. This system also describes the methods of running servomotor by servo drive which is widely used in almost every industry where automation is required. Smart vision checking system which is used for sorting and many other purposes can also be interfaced with the setup. This setup has at least two VFD to control various functions of induction motor. Such as conveyor speed, acceleration, and many other motion related aspects of a motor. The combination of software and hardware offers practical and effective trainer and research engine for industrial control and manufacturing. Also help students to know about smart vision checking system, servo drive, servomotor, induction motor, Variable Frequency Drive (VFD), HMI, industrial networking, and interfacing with real world packaging machines. In addition, one of the main advantages of this trainer setup panel is its modular capability. This trainer setup can be modified, coupled with any industry related control system that might need in the future for training purpose.

Above all, this laboratory training and control panel setup is performed in two stages. First, the machine design and electrical control for the entire operational process is conducted and then the study of effectiveness of Re configurable and portable Programmable logic controller system with proper statistical analysis.

Chakraborty, P., & Hossain, A., & Pillarisetty, V. (2016, June), Designing and Assembling of a Programmable LogicControls (PLC) Laboratory Trainer and Advanced Research Setup Paper presented at 2016 ASEE Annual Conference & Exposition, New Orleans, Louisiana. 10.18260/p.26701

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