Virtualized industrial process logic control using hardware-in-the-loop simulation for teaching programmable logic controllers

Abstract

This article demonstrates the feasibility of the hardware-in-the-loop technique as a facilitator tool for teaching programmable logic controllers in industrial automation. To achieve this goal, a technological study was conducted using the Factory I/O simulator and a real programmable logic controller. The study resulted in the development of a logic controller for a virtualized industrial process consisting of conveyor belts and transfer stations for pallet movement. The logic controller was developed using the classic method of condition analysis through truth tables, and later, the output logical equations were simplified using Karnaugh Maps. The results indicate that the hardware-in-the-loop technique is an important tool for teaching and learning industrial control and automation. It allows students to perform practical experimentation in a simulated environment, providing them with access to complex industrial processes and the development of their respective controllers, visualizing their functioning in a realistic controlled system, benefiting the understanding and retention of theoretical concepts.