This repository was developed to satisfy the requirements of the Mechanical Engineering Senior Design course at the FAMU-FSU College of Engineering by Team 519. Team 519 was tasked with developing curriculum for the Introduction to Mechatronics course to enable students to learn how to use PLCs. In this repository, there are a number of learning tools, including MATLAB simulation tools, instructions on using OpenPLC, wiring diagrams, and lab designs and solutions.
A Programmable Logic Controller (PLC) is an industrial computer that is designed for automation processes, minimizing manual labor and increasing efficiency. These digital devices are used to monitor inputs, make programmed decisions through software applications, then control outputs. PLCs are rugged, making them widely used in large facilities, because they can withstand extremely harsh conditions. Additionally, they speed up processes by constantly scanning inputs, processing logic, and generating outputs within milliseconds.
PLCs play a vital role in industrial automation, yet the FAMU-FSU College of Engineering does not cover their applications. With the rise of automation and smart manufacturing, there is a growing demand for engineers with exposure to PLCs. They are widely used in transportation, robotics, and manufacturing. Integrating PLCs into the curriculum will equip students with Ladder Logic programming skills, thus enhancing their technical abilities and broadening their interest in industrial automation. This curriculum design ensures students will obtain hands-on experiences while simulating real world applications and preparing them for technological advancements, overall making them more competitive in the job market.
PLC's were developed to replace physical relays. Previously, rewiring relays was a time consuming process that led to waste as boards would frequently be thrown away instead of repurposed. Now, PLCs are used widely in industrial settings as they provide flexibile and robust programming of industrial equipment.
The Introduction to Mechatronics course at FAMU-FSU College of Engineering plans to incorporate PLCs by adding three labs for students to complete by the end of the semester. The labs will cover I/O control, sensor-actuator integration, and Ladder Logic programming – the most common language. This tutorial will allow students to incorporate this new concept of Ladder Logic into MATLAB, simulating manufacturing processes digitally and fully grasping the logic behind making PLCs operate successfully.
This project uses OpenPLC and MATLAB
See OpenPLC Download Page to download this software.
It is not recommended to use the Arduino PLC IDE as it has demonstrated worse compatability and insufficient error-correcting documentation.
See MATLAB Download Page to download MATLAB if you have not already.
You will need to download Simulink
You will need to download the Simulink PLC Coder package to run the MATLAB simulations of Ladder Diagrams.
You will need to download the Arduino IDE in order to partition the memory. Follow the steps at the provided link to partition the memory on the PLC, a step that is necessary to allow Arduino sketches and Ladder Logic sketches to exist simultaneously. This is useful as it allows us to use Arduino packages such as LiquidCrystalI2c.
To get started with Matlab Simulations of PLCs in Simulink, see the MatlabExamples folder. Also in this folder is the Matlab Functions Readme if you want more details of the functions.
The MATLAB simulations are used to provide students an oppurtunity to learn ladder logic without being concerned about using or damaging hardware. A number of objects and functions have been included to make the simulation as straight-forward as possible.
For Lab 1, only the simulation tools will be used. For Labs 2 and 3, students may choose to use the simulation to debug their logic, but it is not required. There are a number of useful functions and objects provided to make the process of learning ladder logic smoother.
Review the Open PLC Readme to get started with OpenPLC.
OpenPLC is the IDE that will be used to program the PLCs. Examples are provided for Ladder Logic diagrams that can be used as Solutions to Labs 2 and 3.
Help with Expansion Modules
Lab 1: Simulation lab using only the simulation tools that we have developed in MATLAB manual
Lab 2: Conveyor actuation lab using two buttons and the OPTA. manual
Lab 3: Competition between user and PLC for pushing boxes off of the conveyor belt. manual
Opta Digital Expansion Documentation
Error:
Failed uploading: uploading error: exit status 74
Solution:
Press the 'reset' button on the top of the OPTA. You will need to use a pen or something thin to access the button.
Error:
Unrecognized function or variable 'BOOL'
Solution:
The PLC types required have not been loaded. Run:
>> plcloadtypes
MIT © Jack Vranicar