Design and Implementation of a Cost-Effective PLC Learning Module for Industrial Automation

Abstract

Programmable Logic Controllers (PLCs) are the backbone of modern industrial automation; however, the high procurement and maintenance costs of industrial-grade training kits often limit hands-on access for students in resource-constrained engineering and polytechnic institutions. This paper presents the design, implementation, and pedagogical evaluation of a cost-effective PLC learning module based on the Siemens LOGO! 12/24RCE logic module. The developed system integrates essential industrial components—including digital inputs, relay outputs, and Ethernet-based communication—into a portable, user-friendly interface suitable for introductory and intermediate automation courses. To validate the module's effectiveness, a series of structured laboratory exercises was developed, ranging from basic logic gates to complex sequential control using Ladder Diagram (LD) and Function Block Diagram (FBD) programming. Preliminary results from student pilot groups indicate a significant improvement in technical competency and troubleshooting confidence compared to simulation-only environments. Furthermore, a comparative cost analysis demonstrates that the proposed module achieves a 60%–80% cost reduction relative to standard industrial trainers without compromising essential learning outcomes.