Work in Progress: Hardware-in-the-Loop Process Control Simulation Labs

Abstract An automation course typically covers the topic of process control. If available, this involves the use of a physical process trainer for each individual student. Our university is limited to just four trainers for an entire class. This leads to students being teamed up on a process trainer which can limit the hands-on experience for some students. To achieve a positive experience for all students, while covering the same objectives as having a physical trainer for each student, a hardware-in-the-loop (HIL) process control simulation has been implemented. This allows for 1. Individualized learning, 2. An ability to cover the objectives without having physical trainers, and 3. Instructs students about hardware-in-the-loop simulation. This paper presents the work to date on hardware-in-the-loop (HIL) process control simulation labs for SCADA (Supervisory Control and Data Acquisition) Systems Design. The implementation uses a programmable logic controller (PLC) for the controller and a simulation of the process (plant) written in Python by the author running on a desktop computer. The desktop computer and the PLC communicate via Modbus. The subject of the simulation is control of water level in a tank. The course is open to all juniors and seniors in all programs in the Engineering Department. It covers programming of PLCs, process control, and industrial networks. Direct assessment in the form of labs graded with a rubric and indirect assessment in the form of an end of semester survey of learning outcomes is presented to illustrate student performance.