A modular PLC simulation method for virtual replication of a cost-effective industrial automation laboratory

Area of Science:

• Engineering
• Computer Science
• Education

Background:

• Hands-on programmable logic controller (PLC) training is hindered by the expense and complexity of physical automation laboratories.
• Existing simulation tools often fail to align with real hardware, limiting their educational value.

Purpose of the Study:

• To present a modular PLC simulation method for accurate virtual replication of a cost-effective industrial automation laboratory.
• To provide an effective alternative for PLC training that overcomes the limitations of physical labs and current simulation software.

Main Methods:

• Developed a modular simulation framework in Unity, integrating a custom ladder logic execution engine with interactive 3D models.
• The virtual environment precisely mirrors the input/output structure and behavior of a physical automation laboratory.
• Enabled users to program, test, and debug PLC logic within a realistic virtual setting with immediate visual feedback.

Main Results:

• Validated the simulation method by comparing its outputs against a physical system for traffic light control, elevator operation, and automated filling systems.
• Achieved functional equivalence, with virtual and physical setups producing matching I/O sequences within ±10ms for all tested automation tasks.
• Confirmed the simulation's ability to accurately reflect real-world PLC operational behavior.

Conclusions:

• The proposed modular simulation method offers a cost-effective and scalable solution for PLC training.
• The virtual laboratory accurately replicates physical systems, enhancing the effectiveness of automation education.
• This approach provides a viable alternative for practical PLC programming and debugging without the need for physical hardware.