Development of a PLC and its extensions using OPEN PLC on an Arduino Mega 2560 to control a small robotic arm.

Abstract

This research presents the development and construction of a Programmable Logic Controller (PLC) using an Arduino Mega 2560 board as the main processor. This serves as a low-cost PLC prototype for learning and application in small-scale industrial systems. The control program is designed and written using OpenPLC Editor software, with the ladder logic programmed into the board. The program is then uploaded to the board to control the system's inputs and outputs. The system is designed to control a small robotic arm using an Arduino Uno, allowing users to control the robot's operation. Variables in the PLC are redefined on OpenPLC according to the IEC 61131-3 standard to receive and send data from the Arduino Uno. Testing showed the system functioned correctly within the designed limits. The PLC has 54 digital input/output pins and 16 analog input/output pins. Ladder logic programming is possible, with a stability level suitable for educational and experimental applications. The basic program has an input read/process/output time of approximately 59.6 µs, increasing when processing the developed ladder extensions for robotic arm control. This research represents a promising approach for developing low-cost automated control systems. And it can be further developed for use in small-scale industries or in education in the future.