The Development of Training Programmable Logic Controller Control Ac Servo Motor and Vision System

Abstract

This paper presents the design and development of a Programmable Logic Controller (PLC) training kit for AC-servo motion control integrated with a machine-vision subsystem. The kit is designed to enhance
learners' ability to integrate high-precision motion control with visual perception for Industry 4.0 applications. The primary objective is to provide a hands-on instructional instrument that allows users to develop PLC programs for commanding servo axes and executing vision-based decisions for real-time automated sorting.
The methodology followed a three-phase approach: (1) Architectural design and sequence specification, including comprehensive wiring diagrams and I/O mapping; (2) System implementation, utilizing ladder logic within GX Works2 interfaced with a Python-based Raspberry Pi application for image processing (shape classification of circles and squares) to drive servo and pneumatic actuators; and (3) System verification, encompassing camera triggering, signal handshaking, and safety circuit validation. A usability evaluation was conducted using a five-point Likert scale across four dimensions: hardware installation, control-system design, laboratory suitability, and practical applicability. Results yielded an overall mean score of 4.14 (Very Good). While hardware installation and structural robustness were identified as primary strengths, ease of use received a moderate score (mean 3.35), highlighting an area for iterative improvement. Ultimately, the training kit serves as an effective instructional aid for PLC, AC-servo, and machine-vision integration, successfully bridging the gap between theoretical concepts and industrial practice. Future work will focus on enhancing user interface (UI) accessibility, SCADA connectivity, and expanded quantitative performance metrics.