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In modern industries, automatic control system ismostly utilised as process control system. One of themost widely used control system is ProgrammableLogic Controller (PLC). Survey indicated that 15% ofthe failure in industrial process control system basedon PLC is caused by damages in PLC centralprocessing unit and input/output module. Mistake inwiring connecting PLC with external devices andpower supply leads to the damage.Most educational institution does not have sufficientresources to educate the students to become skilledPLC user. High student to lecturer ratio, limittedlaboratory session and insufficient equipment tosupport laboratory assignment are among thereasons. Thus a PLC training system is required toovercome the problem.

The software invented for the PLC training systemhas the following features.

1. Editor for programming ladder diagram.2. Simulator for displaying electrical circuit

wiring connecting PLC with external devicesand monitoring PLC input/output status.

3. Communication between server computerand PLC.

4. Communication between sever computerand client computer through internet.

Basically the PLC trainning system has threecomponents; PLC, server computer and clientcomputer. PLC is connected to server computerthrough RS232C cable whereas client computercommunicate to server computer via internet TCP/IPprotocol. Omron Sysmac CPM1A PLC, which iswired to external devices, is used. Pentium IIIpersonal computer using Windows 98 operatingsystem with National Instrument LabVIEW 6.1graphical programming language is utilized asserver computer. The developed software is runningin the server computer communicating to the PLCand waiting for the client computer request. Any webbrowser can be utilised to access the developedsoftware from client computer which can be anycomputer. Through the web browser the student canprogram the ladder diagram, download it, view theelectrical circuit wiring and monitor the PLCinput/output status.

INVENTIVENESS/VALUEADDED

SOLUTION

IMPACT

COMPETITORS

The PLC training system is user friendly forprogramming ladder diagram since the student doesnot required to type the syntext in comparison withother PLC softwares. The electrical circuit wiringdisplay automatically changes based on the ladderdiagram program, which helps the student inlearning wiring PLC to external devices and powersupply.Moreover, the PLC training system allows thestudent to experiment the PLC from any clientcomputer connected to internet. Without coming tothe laboratory, the student still can run experimentany time. It also elliminates troubles in installing PLCsoftware since the student only need web browser.

International well-known company: Omron,Siemens,Allen Bradley, Fanuc, and MitsubishiCOSTSSoftware cost: RM 300.00

Programmable Logic ControllerSimulation Software

Dr. Zahurin SamadRusmay Abdullah

Contact :

zahurin@eng.usm.my

Dr. Zahurin SamadSchool of Mechanical Engineering, Engineering CampusUniversiti Sains MalaysiaSeri Ampangan,14300, Nibong Tebal,Seberang Perai Selatan, Penang, MalaysiaTel: 04-5937788 Ext: 6312 Fax: 04-5941025 Mobile: 013-4463965E-mail: