A Low-Cost and Scaled Automation System for
Education in Industrial Automation
1st Alejandro Mejia Rojas
Department of Mechanical Engineering
Universidad de Los Andes
Cra. 1 Este No. 19A-40, Bogotá (CO)
a.mejia13@uniandes.edu.co
Abstract—Modern automation systems consist of assemblies
of mechanical and electrical components commanded through
digital controllers. The physical implementation of automation
systems in education is difficult due to the current costs of indus-
trial automation hardware. This constrains automation courses
to only theoretical and/or virtual activities. This paper proposes
the implementation of a scaled automation system through
the mixing of industrial and prototype hardware. The defined
low-cost architecture allows students to practically experience
fundamental concepts of industrial automation as PLC code
design and verification, SCADA development, and system remote
control.
Index Terms—Industrial automation, scaled automation sys-
tem, education, design pattern, prototype hardware.
I. I NTRODUCTION
Automation is the use of various control systems for oper-
ating equipment with minimal or reduced human intervention
[1]. Industrial automation deals with the automation of man-
ufacturing, quality control and material handling processes.
Current industrial automation systems (IASs) are characterized
by the following elements [2]:
• Supervisory Control and Data Acquisition (SCADA): al-
lows machine operators to interact with machinery in
order to activate devices or processes and get status
feedback. Human machine interface (HMI) with mem-
brane push buttons are mainly utilized, along with touch
screen panels. Remote control may also be implemented
as shown in [3];
• Computer control: performs both sequential and feedback
control and is in charge of the I/O management part of the
automation system. Real-time operating systems (RTOSs)
as Programmable Logic Controllers (PLCs) are mainly
utilized;
• Interface: interface between the computer control, and
the sensors and actuators. Converters are used for trans-
forming the electrical signals of sensors into digital ones,
while drivers for controlling the actuators;
• Automation plant: consists of:
– Sensors and actuators: respectively convert physical
quantities into electrical signals and displace ele-
ments of the physical plant;
978-1-7281-0303-7/19/$31.00 ©2019 IEEE
2nd Giacomo Barbieri
Department of Mechanical Engineering
Universidad de Los Andes
Cra. 1 Este No. 19A-40, Bogotá (CO)
g.barbieri@uniandes.edu.co
– Physical plant: the plant to be controlled and gener-
ally consists of mechanisms that transfer or transform
forces from one form or direction into others;
– Power supply: provides to the system the energy nec-
essary to operate. Distribution blocks, transformers,
circuit breakers, fuses and relays are examples of
utilized elements.
IASs have shifted from mainly mechanical-based systems
to aggregations of Mechatronic Systems (MSs) [4]. MSs are
defined as systems of collaborating computational elements
controlling physical entities [5]. Mechanics, electrics and com-
puter science must be integrated within courses of industrial
automation.
A fundamental part of industrial automation courses is
focused on the computer control since is the main responsible
for the system operation. In particular, concepts of sequential
control [6] as the managing of system nominal and exceptional
behaviour must be dealt, along with software: (i) design
and verification [7]; (ii) syntax and architecture [8]; (iii)
computation in RTOSs [9].
In literature, many references introduce the theoretical con-
cepts of computer control [10] and many tools can be found for
simulating the behaviour of IASs; e.g. virtual commissioning
tools [11]. However, approaches based on physical case studies
are necessary in education for illustrating all the available
possibilities for software design and verification. The high cost
of industrial automation hardware makes the implementation
of IASs difficult for universities and professional institutes.
On the other hand, the price of prototype motors, sensors and
controllers has decreased in the last years bringing to new
educational opportunities [12].
Within this paper, an architecture for the low-cost imple-
mentation of a scaled IAS is illustrated. A mix of industrial
and prototype hardware is proposed, along with design patterns
for the communication of the different elements. The paper
is structured in this way: state of the art is illustrated in
Section II, while the proposed architecture and design patterns
are introduced in Section III. Section IV applies the approach
to a selected case study. Obtained results are summarized in
Section V, while conclusion and future work are discussed in
Section VI.
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 II. S TATE OF THE A RT
Different methods can be utilized for the design and veri-
fication of the software of IASs. These methods vary on the
basis of the strategy used for reproducing the behavior of the
automation plant. These can be:
1) PLC Modeling: the differential equations that model the
behavior of the automation plant are discretized and
computed in a PLC program [13];
2) Virtual Commissioning: a virtual prototype is built
through the utilization of a simulation software. Two
possibilities can be implemented according to [14]: (i)
full simulation of machinery: both the automation plant
and the control hardware are simulated; (ii) hardware in
the loop: automation plant is simulated in real-time and
connected to the real controller [15];
3) Physical Implementation: the automation plant is built
and the software is verified through the connection of
the controller to the plant.
The three approaches have pro and cons and should be
taught within courses of industrial automation. In fact, modern
design methodologies may implement them at different phases
of the design process [16]. PLC modeling can be easily applied
since free tools for PLC programming can be downloaded
as the programming tool for Codesys PLCs [17]. Whereas,
the application of Virtual Commissioning and Physical Im-
plementation approaches in education is complex since: (i) a
licensed simulator is required for virtual commissioning; (ii)
industrial hardware should be utilized for the implementation
of the automation plant in order to reproduce the elements of
modern IASs. Within this paper, a low-cost solution for the
physical implementation approach in education is proposed.
The presented approach is based on the communication of
industrial and prototype hardware. In literature, few works can
be found on the topic. For example, [18] illustrates how to
set up a serial communication between a PLC and Arduino
through the Modbus Protocol. Whereas, a different approach
based on the TCP communication is shown in [19]. The use
of Arduino as an input expander for a PLC, transmitting
information from a serial sensor through LAN network to
a MySQL server, a PHP web page and a PLC is illustrated
in [20]. Eventually, the communication between a PLC and
Arduino is shown in [21], along with the use of a Xbee to
control and transfer data from sensors. However, a complete
architecture that reproduces all the elements of IASs has not
been proposed yet.
III. P ROPOSED A RCHITECTURE
An architecture for the low-cost implementation of a scaled
IAS is described within this section and shown in Fig. 1.
A mix of industrial and prototype hardware is proposed,
along with design patterns for the communication of the
different elements. An important characteristic of the proposed
architecture is that can be applied to scaled and simplified
version of industrial problems. A soft-real time system is
implemented in which failures are not going to generate any
kind of risk.
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Fig. 1. Proposed hardware architecture for a scaled industrial automation
system
Next, the actors selected for implementing the elements
that reproduce an IAS in a scaled and low-cost version are
illustrated:
• SCADA: mySCADA [22] is proposed for the SCADA
system and run in a personal computer (PC). mySCADA
contains all the features of modern SCADA systems
and can be utilized for free. Moreover, the software
offers a multiplatform support (i.e. Windows, Mac, iOS,
Android, Linux) and multiple PLC protocols. Addition-
ally, mySCADA has a web-based service that allows the
remote access through a browser;
• Computer control: since IASs are controlled through
PLCs, a PLC is used as computer control actor. This is
the only industrial hardware utilized within the proposed
architecture and is necessary in order to provide an
education aligned with the practices of the automation
industry. Since mySCADA can communicate through
multiple PLC protocols, an arbitrary PLC manufacture
can be selected;
• Interface: PLCs can read the outputs of sensors and
command actuators. However, this functionality requires
the acquisition of high cost interface modules, and the
utilization of industrial sensors and actuators within the
automation plant. Therefore, prototype hardware is pro-
posed. A microcontroller such as Arduino or Raspberry Pi
is used for the communication with the automation plant
by means of interface elements as electrical drivers. The
interface elements must be able to communicate with the
selected microcontroller and must be compatible with the
utilized sensors and actuators;
• Automation plant: the design of a prototype automation
plant is proposed in order to generate a low-cost case
study that can be controlled through a PLC. Nowadays,
different tools can be used for the implementation of a
 prototype such as 3D printing and laser cutter. Moreover,
low-cost sensors and actuators are widely diffuse.
Once identified the actors constituting the scaled IAS,
communication must be set in order to operate the proposed
architecture; i.e. the arrows in Fig. 1. Next, design patterns are
proposed for interfacing the selected actors:
• SCADA ↔ Computer control: the simplest way to in-
terface mySCADA with the selected PLC is through a
client-server architecture [23]. Then, the communication
can be performed in a web-based form in which server
and client lie on the same network. In the same way,
other devices can communicate with the SCADA system
in order to allow the remote control and monitoring of
the system; e.g. mobiles, tablets, etc.
• Computer control ↔ Interface: the selected PLC and
microcontroller communicate by means of electrical sig-
nals. Two types of signals can be exchanged: (i) digital
signals: can assume only one value over a range of
possible discrete values. Only two values are generally
utilized: 0V and high voltage; (ii) analogue signals:
assume values within a range. The distance in between
the possible values is a function of different factors such
as the resolution of the measuring device and the bits
of the controller. Next, a design pattern is proposed for
communicating the two types of signal:
– Digital signals: PLC digital signals are characterized
with 0V as low value and 24V as high value, whereas
microcontrollers as 0V and 5V respectively. There-
fore, a voltage conversion must be performed for
implementing the communication. In order to send
a digital signal from the PLC to the microcontroller,
voltage must be decreased from 24V to 5V. Either
a potentiometer or a resistance must be placed in
between the communicating pins. The proposed elec-
trical scheme is shown in Fig. 2 in which Arduino
Uno is used as microcontroller. The potentiometer
is indicated as R1, while the resistance as R2. The
value of R1 and R2 can be calculated through the
Ohms Law by knowing the current flowing out the
PLC:
R = (VP LC −VM icrocontroller
I
)
The value of the current can either be measured or
read in the PLC specifications. For the connection
from the microcontroller to the PLC, a relay is
introduced as shown in Fig. 2. The Arduino 5V
signal activates the relay letting a 24V signal flow.
– Analogue signals: different possibilities can be im-
plemented in order to send analogue signals from
the PLC to the microcontroller and vice-versa. These
are: (i) direct connection: the signal should be am-
plified/reduced in order to allow the communication;
(ii) serial communication: PLC and microcontroller
communicate over a serial line through the Modbus
Protocol [18]; (iii) server-client architecture through
TCP protocol [19]. The direct connection would
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require the additional acquisition of PLC analogue
modules and therefore is discharged. The client-
server architecture is selected since simpler that the
serial one.
• Interface ↔ Automation plant: converters and drivers
must be selected able to communicate with the utilized
microcontroller, and respectively with the sensors and
actuators of the prototype automation plant.
IV. C ASE S TUDY
The approach proposed in Section III is applied for the
development of a scaled IAS for grinding coffee beans. The
utilized actors and the design patterns implemented for their
communication are next described:
• Automation plant: the designed prototype plant is the au-
tomated grinding module with blade grinders represented
in Fig. 3. Its main characteristics are:
– Four degrees of freedom (DoFs) machine: the im-
plemented DoFs are: (i) grinder horizontal displace-
ment: transport the coffee grinder onto stations for:
receiving toasted coffee, grinding coffee and deliv-
ering the ground coffee to the next module; (ii) lid
vertical displacement: selected grinder operates only
once a lid is on top of it. Therefore, a lid placed
on the grinder station must be moved vertically; (iii)
grinder rotation: grinder must be able to rotate in or-
der to deliver the ground coffee onto the subsequent
module; (iv) blade rotation: rotates the blade in order
to chop the coffee beans for grinding;
– Manufacturing: two prototype manufacturing tech-
niques were utilized: (i) laser cutter for the gen-
eration of the wood structure; (ii) 3D printing for
the implementation of mechanical parts as gears and
bearing supports;
– Actuators: three NEMA 17 steppers motors are re-
spectively utilized for the horizontal displacement,
the lid displacement and the grinder rotation. Ad-
ditionally, a DC motor is responsible for the blade
rotation;
– Sensors: since stepper motors are based on an open-
loop control, limit switch sensors must be utilized
in order to set the zero position once the machine
is started. Moreover, a thermostat NTC 100K 3950
is used to monitor the temperature of the grinding
station and an infrared sensor to detect once coffee
has been received in the input station.
• Interface: Arduino MEGA is selected for interfacing
digital signals, while Arduino Ethernet for analogue
signals. Arduino MEGA commands the utilized stepper
motors through the Pololu A4988 driver. Moreover, the
drivers, the Arduino MEGA, and the limit switch and
infrared sensors are interfaced through a Ramps 1.4
shield. Whereas, the thermistor sensor is connected to
an Arduino Ethernet since analogue signals are sent to
the PLC through the TCP protocol. In this first iteration,
 Fig. 2. Digital signal from the PLC to the microcontroller (left-hand side) and vice-versa (right-hand side)

the Arduino MEGA software contains the target positions

of the stepper motors for each movement. Therefore,
the PLC just sends start/stop digital signals in order to
implement the movements. In a future work, the PLC
may send the target positions to the Arduino Ethernet.
Then, the Arduino Ethernet may pass this information
to the Arduino MEGA through serial communication.
This would allow a complete hardware abstraction, even
if complexity would increase since a protocol must be
established in order to associate each target position to
the corresponding motor.
• Computer control: a SIEMENS Simatic S7 300 PLC is
selected since already available in the university. The PLC
was programmed to control the grinding machine dur-
ing nominal functioning. However, exceptional behaviour Fig. 3. Prototype automation plant of a grinding machine
management can be added in future. Digital signals are
sent to the Arduino MEGA through a 100K potentiometer
Fig. 4. Then, the state-machine was converted into ladder PLC
for each channel, while are read from the Arduino MEGA
code and verified through the physical verification technique.
through 5V Adafruit relays. Whereas, analogue signals
SCADA system was implemented for monitoring and con-
are exchanged with a client-server architecture through
trolling the automation plant. The SCADA system contains
TCP protocol. PLC and Arduino Ethernet are connected
an HMI that can be accessed from PCs and mobile devices
through an Ethernet cable and PLC is set as server, while
making remote control possible.
the microcontroller as client. The Settimino library is
utilized for implementing the Ethernet communication. Eventually, a cost analysis is presented since the main
• SCADA: the implemented HMI consists in: (i) start but- objective of this work was the implementation of a low-cost
ton; (ii) indication of the current state; (iii) temperature architecture. Table I illustrates the total cost for each category.
of the grinder. The communication between the HMI and The cost of the PC in which the SCADA system runs is not
the PLC is performed with a client-server architecture. considered in the analysis since university laboratories are
The PC in which mySCADA runs is set as server host, already equipped with PCs.
while the PLC as client. Moreover, a mobile phone was The following considerations can be performed after the
set as client and was able to remotely control and monitor cost analysis:
the automation plant. • PLC cost was included in the analysis even if universities
and professional institutes are generally equipped with
V. R ESULTS PLCs. Therefore, total implementation cost can be further
The objective of this work was to define a low-cost architec- reduced since the PLC represents the most expensive cost;
ture that allows students to practically experience fundamental • The cost for interfacing the PLC and the automation
concepts of industrial automation as PLC code design and plant is 100USD, while a commercial PLC module costs
verification, SCADA development, and system remote control. about 300USD. Moreover, different modules should be
Within this section, how the proposed architecture can be used acquired as analogue I/Os, digital I/Os and PWM control.
for reaching these purposes is shown. Therefore, the proposed approach is more economic than
A state-machine was implemented for conceptualizing the the acquisition of industrial hardware;
nominal behaviour of the automation plant as shown in • The cost of the automation plant varies on the basis of the

442
 Fig. 4. State-machine of the machine nominal behavior
selected application. However, the selected application
provides an idea of the order of magnitude.
TABLE I
C OST A NALYSIS FOR THE P ROPOSED S CALED I NDUSTRIAL AUTOMATION
S YSTEM
Category Cost (USD)
Automation Plant 350
Interface 100
Computer Control 1400
TOTAL 1850
VI. C ONCLUSIONS AND F UTURE W ORK
An architecture for the low-cost implementation of a scaled
IAS has been presented within this paper. The proposed system
allows the design and verification of the PLC code through
the physical implementation approach. Moreover, it can be
utilized for practical applications within courses of industrial
automation as the development of SCADA systems and the
remote control of an automation plant.
Future work will implement a serial communication be-
tween the Arduino MEGA and Arduino Ethernet in order
to allow the PLC to send the target positions for the motor
movements. Moreover, a distributed system will be designed
in which two scaled automation plants are commanded through
two different PLCs and are coordinated through a hierarchical
control. Eventually, a Raspberry Pi and a camera will be inte-
grated within the proposed architecture in order to investigate
the use of machine vision for quality control.
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