Programmable Logic Controller

Simulation Software
Dr. Zahurin Samad
Rusmay Abdullah

In modern industries, automatic control system is IMPACT

mostly utilised as process control system. One of the
most widely used control system is Programmable
Logic Controller (PLC). Survey indicated that 15% of
the failure in industrial process control system based
on PLC is caused by damages in PLC central
processing unit and input/output module. Mistake in
wiring connecting PLC with external devices and
power supply leads to the damage.
Most educational institution does not have sufficient
resources to educate the students to become skilled
PLC user. High student to lecturer ratio, limitted
laboratory session and insufficient equipment to
support laboratory assignment are among the
reasons. Thus a PLC training system is required to
overcome the problem.
The PLC training system is user friendly for
programming ladder diagram since the student does
not required to type the syntext in comparison with
other PLC softwares. The electrical circuit wiring
display automatically changes based on the ladder
diagram program, which helps the student in
learning wiring PLC to external devices and power
supply.
Moreover, the PLC training system allows the
student to experiment the PLC from any client
computer connected to internet. Without coming to
the laboratory, the student still can run experiment
any time. It also elliminates troubles in installing PLC
software since the student only need web browser.

INVENTIVENESS/VALUE ADDED COMPETITORS

The software invented for the PLC training system International well-known company: Omron,
has the following features. Siemens, Allen Bradley, Fanuc, and Mitsubishi
1. Editor for programming ladder diagram. COSTS
2. Simulator for displaying electrical circuit Software cost: RM 300.00
wiring connecting PLC with external devices
and monitoring PLC input/output status.
3. Communication between server computer
and PLC.
4. Communication between sever computer
and client computer through internet.

SOLUTION

Basically the PLC trainning system has three

components; PLC, server computer and client
computer. PLC is connected to server computer
through RS232C cable whereas client computer
communicate to server computer via internet TCP/IP
protocol. Omron Sysmac CPM1A PLC, which is
wired to external devices, is used. Pentium III
personal computer using Windows 98 operating
system with National Instrument LabVIEW 6.1
graphical programming language is utilized as
server computer. The developed software is running
in the server computer communicating to the PLC
and waiting for the client computer request. Any web
browser can be utilised to access the developed
software from client computer which can be any
computer. Through the web browser the student can
Contact :
program the ladder diagram, download it, view the Dr. Zahurin Samad
electrical circuit wiring and monitor the PLC School of Mechanical Engineering, Engineering Campus
input/output status. Universiti Sains Malaysia
Seri Ampangan,14300, Nibong Tebal,
Seberang Perai Selatan, Penang, Malaysia
Tel: 04-5937788 Ext: 6312 Fax: 04-5941025 Mobile: 013-4463965
E-mail:zahurin@eng.usm.my
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