Today, manufacturing processes have become a lot more efficient due to the Internet of Things (IoT), intelligent automation, advanced robotics, and other smart factory initiatives. Despite rapid changes in technology, programmable logic controller (PLC) and the human-machine interface (HMI) continue to play a vital role in the manufacturing and act as central processors for all real-time decisions.
PLC and HMI have adapted well in modern Industry 4.0 programming will continue to play an integral role in the manufacturing processes. Further, the integrated HMI PLC is enabling lean automation-boosting efficiencies and reducing waste, both in terms of equipment and time. Looking at career opportunities offered by Industry 4.0, Tesca  has designed a Universal PLC platform with HMI and Siemens PLC. 52014AH, 52015AH, 52016AH is an ideal setup to study the working of PLC and HMI used for industrial applications. It has been designed to learn and practice:
• Wiring of PLC with different inputs and outputs.
• Push to ON switch, toggle switch, proximity sensor, selector switch as an input to PLC.
• Realistic simulation that can drive visual indicators, audio indicators, and DC motor, relay and contactor.
• Communication of PLC with HMI for monitoring and controlling.

Features
7” Human Machine Interface (HMI) display.
Select Siemens PLC according to required Input- Output e.g. 52014AH, 52015AH and 52016.
Open platform to explore wide PLC and HMI applications.
Industrial look & feel.
Toggle switches, push to ON switch, proximity sensor, selector switch, visual indicator, audio indicator, DC motor, relay card, contactor and voltage display.
Din rail mounting for PLC.
Powerful instruction sets.
Several sample ladder and HMI programs.
High execution speed.
PC based ladder and HMI programming.
Extremely easy and student friendly software to develop different programs.
Easy downloading of programs.
Practice troubleshooting skills.
Compact tabletop ergonomic design.
Robust construction.

Experiments 
Scope of Learning
Exposure to technology of Programmable Logic Controller (PLC) and understanding the importance of automation in industries.
Student will be familiarized with a variety of ladder logic instruction to create complete PLC program from scratch.
Study the difference between digital and analog signals and how to bring them into a PLC, process them and send them back out. 

PLC hardware
PLC configuration.
Source and sink concept.
PLC history.
Input/output configuration.
Installation.
Switches and sensor interfacing.
Actuator interfacing.

PLC operation
Sequence of operation.
Program scans cycle.
Addressing example.
Upload/download/monitoring.

Program operation
NO (normally open) and NC (normally closed) instructions.
Types of logic gates.
Set and reset bits.
Types of timers (TON, TOFF and TONR).
Types of counters (CTU, CTD and UDCTR).
Types of compare instructions (greater than, equal to and less than).
Types of math instructions (addition, subtraction, multiplication and division).
Analog input and analog output instructions using MOV instruction.

Installation
Wiring and connection.
Communication setup.
Programming devices connection.

Program operation
NO (normally open) and NC (normally closed) instruction.
Types of logic gates.
Set and reset bit.
Types of counter.
Compare, MOV and PWM instructions.
Types of math instructions: (addition, multiplication, subtraction and division).
Human Machine Interface (HMI)
Human Machine Interface (HMI).
Creating applications/screens in HMI.
Downloading and uploading programs.

Design screen for:
Switch and indicator in HMI for communication with PLC.
Timer in HMI for communication with PLC.
Counter in HMI for communication with PLC.
Trend in HMI for communication with PLC.
Alarm in HMI for communication with PLC.

Application Modules (Optional)
Water level control by PLC - 52021/PLC-01
Scope of Learning
Study of water level.
Study and use of timers and memory bit.
Water level control by PLC through ladder program.

Elevator control by PLC- 52022/PLC-02
Scope of Learning
Study of elevator.
Study and use of latch switches and timers.
Elevator control by PLC through ladder program.

Traffic light control by PLC- 52023/PLC-03A
Scope of Learning
Study of traffic light.
Study and use of memory bit and timers.
Traffic light control by PLC through ladder program.
Study of signal indications for two direction.

Traffic light control by PLC- 52023/PLC-03B
Scope of Learning
Study of traffic light.
Study and use of timers.
Traffic light control by PLC through ladder program.
Study of all three signals red, green and orange i.e. ready, go and stop. Signal indications for all direction at any square.

Temperature control by PLC- PLC-04
Scope of Learning
Study of temperature control.
Study and use of compare instruction.
Study and use of temperature sensors and voltage to current convertor.
Study and use of controlling a heater and fan.
Temperature control by PLC through ladder program.

Conveyor control by PLC - PLC-05 
Scope of Learning
Study of conveyor.
Study and use of memory bit, timers, counters, compare instruction.
Study and use of IR sensor, proximity sensor, push to on switch.
Study and use of DC motor.
Conveyor control by PLC through ladder program.
Learn to count metallic container using a proximity switch.
Learn to run and control conveyor in manual and auto mode using a PLC.
Learn to control direction a of DC motor.

Sorting system control by PLC- PLC-05B

Scope of Learning

Study of conveyor.

Study and use of memory bit, timers, counters, compare instruction.

Study and use of input device like proximity sensor, push to on switches and output device like DC motor, 5/2 solenoid valve and double acting cylinder.

Conveyor control by PLC through ladder program.

Ladder program for count metallic container using a proximity switch.

Ladder program for run and control conveyor in manual and auto mode using a PLC.

Ladder program for control direction a of DC motor.

Ladder program for sorting of metallic object using double acting cylinder and PLC.

 

Scope of Learning

Study of DC motor.

DC motor control by PLC through ladder program.

Study and use of PWM (pulse width modulation) and voltage to frequency convertor.

Learn to run DC motor in clockwise and anticlockwise direction.

Learn to change the speed of DC motor.

 

Scope of Learning

Study of stepper motor, thumbwheel switch and limit switch.

Stepper motor, thumbwheel switch and limit switch control by PLC through ladder program.

Study of speed control of stepper motor using a thumbwheel switch.

Learn to step (position) control of stepper motor using a limit switch.

Learn to run stepper motor in clockwise and anticlockwise direction.

Study and use of PWM (pulse width modulation).

 

Scope of Learning

Study of start delta motor starter. 

Study of direct online starter.

Study and use of latching.

Study and use of timer.

control by PLC.

Ladder program for star delta motor starter by PLC.

Ladder program for direct online starter control by PLC.