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A Cost-Effective Modular Laboratory Solution for Industrial Automation and Applied Engineering Education

MethodsX 2025年

作者： Musa Al-Yaman Dana Alswaiti Adham Alsharkawi Majid Al-Taee Mechatronics Engineering Department University of Jordan Amman Jordan Independent Consultant of Computing and Systems Engineering Liverpool UK

In today’s digital landscape, affordable programmable logic controllers (PLCs) for industrial automation and applied engineering education are essential, as traditional setups are often too costly for many institutions and individuals. In this paper, a cost-effective, modular PLC lab was designed and developed to enable hands-on learning in industrial automation. The lab accommodates ten pairs of trainees, allowing for simultaneous experimentation using modular simulation kits tailored for various applications, such as traffic light systems, elevators, and automated filling systems. Trainees can prepare, test, and verify their code on these kits in real-time, enhancing their hands-on experience with programmable logic controllers. Each kit offers a set of features, including an integrated input/output interface that supports a variety of input types (e.g., switches, sensors, and push buttons) and output options (e.g., lights, motors, and actuators). This well-rounded setup is specifically designed to meet the educational and training objectives of the lab, promoting an interactive learning environment that develops essential automation skills and builds trainee confidence in applying PLC technology across real-world scenarios . • Offers a cost-effective PLC solution for industrial automation and engineering education, addressing the high cost of traditional systems. • Provides a scalable PLC lab setup developed to facilitate hands-on learning and practical experience in industrial automation, enabling simultaneous experimentation and collaborative learning. • Aligns with educational objectives, fostering an interactive, hands-on environment that builds essential automation skills, by enabling real-code preparation, testing and verification.

关键词： Applied Engineering Education interactive training experience hands-on learning modular lab design programmable logic controller simulation kits

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Enhanced TARA model for heavy-duty vehicles using ISO/SAE 21434 and Fuzzy Analytic Hierarchy Process (FAHP)

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Expert Systems with Applications 2025年

作者： Narges Rahimi Beth-Anne Schuelke-Leech Mitra Mirhassani Department of Mechanical Automotive and Materials Engineering University of Windsor Windsor ON N9B 3P4 Canada Department of Electrical and Computer Engineering University of Windsor Windsor ON N9B 3P4 Canada

In recent years, the automotive industry has increasingly recognized the importance of Threat Analysis and Risk Assessment (TARA) as a critical first step in cybersecurity planning. While standards such as ISO/SAE 21,434 provide a structured framework, they are primarily designed for light-duty vehicles and do not fully address the unique characteristics, operational environments, and vulnerabilities of heavy-duty (HD) commercial vehicles—despite their crucial role in public transportation, freight systems, and the supply chain. This study addresses that gap by customizing the ISO/SAE 21,434 risk assessment model specifically for HD vehicles. It employs a Multi-Criteria Decision-Making (MCDM) methodology to assign weights to the severity and feasibility criteria using expert input through the Fuzzy Analytic Hierarchy Process (FAHP). Expert-driven pairwise comparisons were conducted to evaluate the relative importance of each criterion separately for severity and feasibility assessment. The resulting model provides a tailored and robust approach for analyzing and assessing cybersecurity threats in HD vehicles, reflecting their distinct needs and risk profiles.

关键词： Heavy-duty vehicles Risk assessment Safety Security FAHP AHP Analytic Hierarchy Process DFD Data Flow Diagram ECU Electronic Control Unit EVITA E-safety Vehicle Intrusion proTected Applications FAHP Fuzzy Analytic Hierarchy Process FMEA Failure Mode and Effects Analysis GVWR Gross Vehicle Weight Rating HD Vehicle Heavy-Duty Vehicle HEAVENS HEAling Vulnerabilities to Enhance Software, Security, and Safety LD Vehicle Light-Duty Vehicle MCDM Multi-Criteria Decision Making MD Vehicle Medium-Duty Vehicle OBD On-Board Diagnostic PLC programmable logic controller TARA Threat Analysis and Risk Assessment TMT Microsoft Threat Modeling Tool

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Advancing food systems with industry 5.0: A systematic review of smart technologies, sustainability, and resource optimization

Sustainable Futures

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Sustainable Futures 2025年 9卷

作者： Kumari Amita Singh Falguni Patra Tabli Ghosh Nikhil Kumar Mahnot Himjyoti Dutta Raj Kumar Duary Department of Dairy Science & Food Technology Institute of Agricultural Sciences Banaras Hindu University (BHU) Varanasi Uttar Pradesh 221005 India Mansinhbhai Institute of Dairy & Food Technology Dudhsagar Dairy Campus Mehsana Gujarat 384002 India Department of Food Engineering and Technology Tezpur University Tezpur Assam 784028 India Department of Food Technology Rajiv Gandhi University Rono Hills Doimukh Arunachal Pradesh 791112 India Department of Food Technology Mizoram University Mizoram India

The advent of Industry 5.0 represents a transformative shift towards integrating advanced computational technologies—such as AI, IoT, robotics, and big data—with human-centric collaboration to achieve sustainable food production systems. This systematic review examines the link between Industry 5.0 and sustainability, focusing on computational innovations, resource management, and eco-friendly practices within food industries. The study addresses the pressing challenge of balancing industrial growth with environmental stewardship and identifies the untapped potential of Industry 5.0 to enhance food safety, reduce waste, and enable personalized food solutions. Using a qualitative methodology, the review synthesizes findings from scholarly articles, industry reports, and case studies to analyze applications of smart sensors, blockchain, and robotics in optimizing supply chains, precision farming, and vertical agriculture. Results indicate that Industry 5.0 facilitates real-time monitoring, predictive analytics, and adaptive production, improving resource efficiency and minimizing environmental impacts. Smart packaging, digital twins, and AR are highlighted as emerging tools for enhancing traceability, quality control, and consumer engagement. However, high implementation costs, data management challenges, and the need for policy frameworks emerge as critical barriers. The discussion emphasizes how these challenges can be mitigated through multidisciplinary research, cross-sector collaboration, and government incentives. Overall, Industry 5.0 offers a pathway to sustainable, efficient, and personalized food systems by leveraging cutting-edge technologies while fostering human-machine collaboration. Future research should focus on scalable applications, cost-effective solutions, and regulatory alignment to accelerate Industry 5.0 adoption in food sectors. This study underscores the urgency of advancing computational technologies to shape resilient and sustainable food p

关键词： Industry 5.0 Internet of Things Blockchain Digital twin Cobots Food industries IoT Internet of Things 1IR first industrial revolution 2IR second industrial revolution IT information technology 3IR third industrial revolution 4IR fourth industrial revolution AI artificial intelligence 3D three dimensional ML machine learning IoE internet of everything EC edge computing COBOTS collaborative robots 4G fourth generation 5G fifth generation 6G sixth generation XR extended reality AR augmented reality RAS robotics and autonomous system THz terahertz UAVs unmanned aerial vehicles HACCP hazard analysis and critical control point CNNs convolutional neural networks ANN artificial neural networks CPSs cyber physical, systems CPPS cyber physical production system GMP good manufacturing practices GHP good hygienic practices MAP modified atmospheric packaging NFC near field communication NLP Natural language processing ANN artificial neural network TDS total dissolved solids EC electrical conductivity PLC programmable logic controller SCADA supervisory control and data acquisition

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Process Control Using programmable logic controllers: Application Considerations

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IFAC Proceedings Volumes 1992年第8期25卷 103-110页

作者： Ahmed F. Sakr Mohamed M.F. Sakr Electrical Engineering Dept. Faculty of Engineering Cairo University Cairo EGYPT

The use of programmable logic controllers (PLC's) in food industries provides various benfits concern-ing the improvement of quality and productivity. In this paper, special considerations in the application of PLC's in industrial processes are discussed. PLC-based distributed control system for a food packing plant is introduced as case study. The experience gained during different stages of the development cycle of this automation system is also presented

关键词： programmable logic controller food industry logic control process control computer control

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Didactic approach to multivariable control using IEC 61131 model-based design and programmable logic controllers

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IFAC Proceedings Volumes 2013年第17期46卷 220-225页

作者： Berno J.E. Misgeld Anake Pomprapa Steffen Leonhardt Philips Chair for Medical Information Technology (MedIT) Helmholtz-Institute for Biomedical Engineering RWTH Aachen University Germany

Recent advances in the programming standardisation and hardware development in the automation industry offer new possibilities for control engineering education. The IEC 61131 is nowadays widely used and there exist automatic code generators for high level simulation languages. The relatively cheap, but powerful hardware and the applicability of the programmable logic controller (PLC) to automation and complex control tasks make this combination a valuable tool for undergraduate and postgraduate control engineering classes. In this paper, the application of the model-based tool chain using Matlab/Simulink, IEC 61131 and a PLC is presented and applied to the well-known four-tank model as an experimental platform. Several educational examples used in linear and nonlinear control engineering classes are explained in detail and implemented in the hardware setup. Experimental results are shown and compared to simulation data.

关键词： programmable logic controller linear control IEC 61131 decoupling control

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A new approach to supervisor design with sequential control Petri-net using minimization technique for discrete event system

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2006年第11-12期29卷 1267-1277页

作者： Cansever, G. Kucukdemiral, I. B. Yildiz Tech Univ Fac Elec Elect Dept Elect Engn TR-34349 Istanbul Turkey

This paper proposes a systematic approach for the design of a supervisory controller for discrete event systems (DES) and their ladder logic diagrams (LLD). The method is based on Petri nets, which is used for modeling the systems. It involves, defining the control policy and simplifying it by using Espresso software to form the compiled controller by adding inhibiting and enabling arcs to the original model and then the method is used to drive structured ladder logic code. A design example is presented to clarify the full procedure.

关键词： discrete event system minimization technique multi level logic conversion programmable logic controller sequential control Petri-net supervisor design

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PLC and SCADA based Real Time Monitoring and Train Control System for the Metro Railways Infrastructure

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WIRELESS PERSONAL COMMUNICATIONS 2023年第1期129卷 521-548页

作者： Tomar, Ishu Sreedevi, Indu Pandey, Neeta Delhi Technol Univ Dept Elect & Commun Engn Delhi 110042 India

Industrial Control Systems (ICS) and SCADA systems play a critical role in the management and regulation of critical infrastructure. SCADA systems brings us closer to the real-time application world. All process and equipment control capability is typically provided by a Distributed Control System (DCS) in industries such as power stations, railways, agricultural systems, chemical and water treatment plants. This article proposes to adopt SCADA and PLC technology in the improvement of the performance of real time signaling & train control systems in metro railways infrastructure. The main concern of this work is to minimize the failure in automated metro railways system operator and integrate the information coming from Operational Control Centre (OCC), traction SCADA system, traction power control, and power supply system. This work presents a simulated prototype of an automated metro train system operator that uses PLC and SCADA for real time signaling, monitoring and control of metro railway systems. Here, SCADA is used for the visualization of an automated process operation and then the whole operation is regulated using OMRON (NX1P2-9024DT1) PLC and OMRON's Sysmac studio programming software is used for developing the ladder logic of PLC. The metro railways system has deployed infrastructure based on SCADA from the power supply system, and each station's traction power control is connected to the OCC remotely which commands all the stations and has the highest command priority. An alarm is triggered in the event of an emergency or system congestion. This proposed system overcomes the drawbacks of the current centralized automatic train control (CATC) system. This system provides prominent benefits like augmenting services which may enhance a network's full load capacity and network flexibility, which help in easy modification in the existing program at any time.

关键词： Automation Train control system programmable logic controller Operations control Supervisory control and data acquisition

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Black box modeling of PIDs implemented in PLCs without structural information: a support vector regression approach

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NEURAL COMPUTING & APPLICATIONS 2015年第3期26卷 723-734页

作者： Salat, Robert Awtoniuk, Michal Warsaw Univ Life Sci Dept Prod Engn PL-02787 Warsaw Poland

In this report, the parameters identification of a proportional-integral-derivative (PID) algorithm implemented in a programmable logic controller (PLC) using support vector regression (SVR) is presented. This report focuses on a black box model of the PID with additional functions and modifications provided by the manufacturers and without information on the exact structure. The process of feature selection and its impact on the training and testing abilities are emphasized. The method was tested on a real PLC (Siemens and General Electric) with the implemented PID. The results show that the SVR maps the function of the PID algorithms and the modifications introduced by the manufacturer of the PLC with high accuracy. With this approach, the simulation results can be directly used to tune the PID algorithms in the PLC. The method is sufficiently universal in that it can be applied to any PI or PID algorithm implemented in the PLC with additional functions and modifications that were previously considered to be trade secrets. This method can also be an alternative for engineers who need to tune the PID and do not have any such information on the structure and cannot use the default settings for the known structures.

关键词： Support vector regression programmable logic controller PID

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A smart PLC-SCADA framework for monitoring petroleum products terminals in industry 4.0 via machine learning

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MEASUREMENT & CONTROL 2022年第7-8期55卷 830-848页

作者： Rashad, Ossama Attallah, Omneya Morsi, Iman Arab Acad Sci Technol & Maritime Transport Coll Engn & Technol Dept Elect & Commun Engn Alexandria 1029 Egypt

The paper introduces a programmable logic controller (PLC) / Human Machine Interface (HMI) system incorporated along with machine learning (ML) classifiers. Although some other studies have incorporated ML techniques to predict and control petroleum product terminals in terms of concentration, the proposed framework incorporates Add On Instruction (AOI) programming, PLC, and ML methods to automatically monitor petroleum products terminals. The framework adds an AOI in programming to achieve maximum usage of processor capabilities. Moreover, it uses AOI for programming in cooperation with the ladder diagram (LD). This leads to simplifying the LD graphical programming language, reducing the time of scanning, and making facilitate troubleshooting. The AOI is merged with ML to automate tank level detection and maintain good operational conditions and consequently protect these expensive essential assets. The introduced framework consists of three stages. The first stage is the PLC programming phase where the PLC is created using Add-On instructions. Next, HMI graphic displays are drawn and linked to the PLC tags in the following stage. During the third stage, the actual process readings are applied to the system based on ML algorithms to test its functionality. The proposed system results indicates a reduction in the LD number, highest program size, and maximum time of scanning. The results indicate that the AOI can help to trace the program more easily in fault situations. Besides, additional program instructions could reduce processor memory, system construction costs, and upgrade projects.

关键词： industry 4 0 SCADA HMI programmable logic controller real-time systems oil refinery process petroleum products machine learning level detection

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Auto-Generation of IEC Standard PLC Code Using t-MPSG

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INTERNATIONAL JOURNAL OF CONTROL AUTOMATION AND SYSTEMS 2009年第2期7卷 165-174页

作者： Thapa, Devinder Park, Chang Mok Park, Sang C. Wang, Gi-Nam Induk Inst Technol Dept Technol & Syst Management Seoul 139749 South Korea Ajou Univ Dept Ind & Informat Syst Engn Suwon 443749 South Korea

The objective of this paper is to reduce the development time of a PLC (programmable logic controller) by automating the task of code generation. For this Purpose, we applied t-MPSG (Timed-Message Based Part State Graph). The t-MPSG is an extended finite state automata used to model and generate an execution module for a real-time shop floor controller system. In Our proposed method, t-MPSG is used to model the formal specification of the controller system that can be translated into textual structure. After the verification of the t-MPSG model, it can be used as an input to the plc-builder tool. The plc-builder tool is an extended version of a conventional MPSG Simulator. It can be used to translate the textual structure of the t-MPSG into an IEC standard PLC code. Finally, the generated code can be downloaded to a PLC emulator or a PLC device for the purpose of simulation and execution. The similarity in the hierarchical structure of the t-MPSG and the IEC standard PLC program has made it convenient to transform from one form to another. Furthermore, an illustration of the methodology to auto-generate IEC standard PLC code using t-MPSG is explained with a suitable example.

关键词： IEC 61131-3 programmable logic controller symbolic model verifier t-MPSG

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