I, Device overview

1.1 General Introduction

“Electrical control and PLC application technology virtual and practical integrated
training device” includes real electrical training, PLC control circuit construction, frequency
conversion and touch screen control, and other real hardware training. It also has 3D
resource learning ， virtual simulation training for each course, process evaluation and
assessment function. This device is suitable for theoretical and practical teaching of core
courses：

“Electrical Control Technology”,
“PLC Application Technology”,
“Frequency Control Technology”,
“Servo Control Technology”…

Of the majors of Electrical Automation, Electrical and mechanical Technology,
Intelligent Control Technology, Industrial Robot Technology, etc, which can train students
in equipment cognition, system combination design, equipment installation and wiring,
parameter setting and debugging, combined circuit control, programming and
configuration monitoring, operation and maintenance, and failure Eliminate professional
skills in such areas.

1.2 Training mode

“Electrical control and PLC application technology virtual reality integration training
device” adopts the combination of virtual reality and real hardware, which can meet three
training modes:

(1) Hardware process training: meet equipment recognition, system design, cable
laying, equipment installation, process wiring, frequency conversion control, servo control,
touch screen debugging, PLC programming, Wincc configuration monitoring, etc .;
(2) Software simulation training: It integrates 3D resource learning, virtual simulation
training for each course, and process evaluation and assessment.
(3) Software-hardware combination of virtual reality training: 25 PLC application
scenarios interact with real PLC, touch screen and other equipment, and support I / O
point allocation, PLC programming and Wincc configuration monitoring;

1.3. Advantage

The device can be used for theoretical teaching and practical teaching of core courses,
such as operating scenarios and experimental support; through the training of simulation
equipment recognition and simulation scenarios, students can systematically train their
professional skills, practical hands-on, design planning, communication, teamwork,
efficiency awareness and Innovative thinking and other abilities, while training its rigorous
work style and good professional quality.
Solved multiple teaching problems:

(1) Combining teaching items such as “hardware practical training, process training”,
“software virtual simulation learning and training”, “software and hardware virtual reality
combined simulation training” and other teaching items, which satisfies theoretical
teaching, simulation functional verification, and hardware practice Needs for the whole
cycle of teaching such as practical training.
(2) Solve the problem of difficult teaching evaluation, the system automatically monitors
the learning status of the students, collects key skills information completed during the
simulation training process, automatically uploads it to the platform, and generates
performance information;
(3) Contextualized teaching, which solves the problem of less scene resources and poor
teaching experience in the teaching process;
(4) Solve the problem that only a few people operate by hand during the teaching process,
and meet more people to conduct training at the same time;
(5) Solved the current teaching situation in the training room where only the hardware is
difficult to use, or it is difficult to restore the restoration after the use;
(6) Solved the problems of higher equipment consumables cost, equipment damage, and
low repeated utilization during teaching;
(7) Solve the problem of personnel safety, repeated training in the virtual simulation
environment, and synchronized safety precautions;
(8) The software virtual simulation remote update and hardware modular expansion
structure solve the problem of equipment update iteration.

II Hardware Description

The hardware includes: training device platform, power supply access and display,
working power, electrical components, various control units, fault nodes and gateways,
SuperIO communication conversion module and consumable tools, etc., to support
hardware training and virtual reality Combined signal communication.

2.1 list of hardware:

2.1.1 PLC

(1) Size: W x H x D (mm) 130 x 100 x 75
(2) Power consumption: 12W
(3) Available current (24VDC): max. 400 mA (sensor power)
(4) Digital input current consumption (24VDC): 4 mA for each input used
(5) On-board digital: I / O: 14 points input, 10 points output (solid-state MOSFET)
(6) On-board analog I / O: 2 points input, 2 points output
(7) High-speed counters: 6 in total, single-phase: three clock frequencies of 100 kHz and
three 30 kHz; quadrature phase: three clock frequencies of 80 kHz and three 20 kHz
(8) Pulse output: up to 4 pulse generators can be configured
(9) Pulse capture input: 14
(10) Number of ports: 2
(11) Type: Ethernet
(12) Number of connections: 3 for HMI, 8 for client GET / PUT (S7 communication
between CPUs), 1 for programming device, 8 for Ethernet instructions in user program, 3
for / PUT on the server (S7 communication between CPUs)
(13) Data transmission rate: 10/100 Mb / s
(14) Isolation (external signal and PLC logic side): transformer isolation, 1500VDC
(15) Cable type: CAT5e shielded cable
(16) Voltage range: 20.4-28.8VDC / 22.0-28.8 V DC (ambient temperature -20ºC-0ºC)

2.1.2 Analog input and output module

(1) Power consumption: 2.0 W
(2) Current consumption (SM bus): 80 mA
(3) Current consumption (24 V DC): 60 mA (no load)
(4) Number of inputs: 4
(5) Number of output channels: 2

2.1.3 communication module

(1) By using the PROFIBUS DP master communication module, the S7-1200 device can
communicate with other CPUs, programming devices, and human-machine interfaces.
(2) Interface: 9-pin D-type female connector
(3) Protection level: IP20
(4) Power supply type: DC
(5) External power supply: 24V
(6) Overall dimensions: 30mm × 100mm × 75mm
2.1.4 touch screen
(1) Display: TFT true color LCD screen, 64K colors
(2) Size: 7 inches
(3) Resolution: 800 × 400
(4) User memory: 10MB
(5) Interface: PROFINET (Ethernet)
(6) Available configuration software: Wincc Basic V13 SP1 or higher

2.1.5 Inverter

(1) With operation panel
(2) Rated power: 1.5KW
(3) Input voltage: three-phase 380V-480V
(4) No built-in filter
2.1.6 Server
(1) Maximum motor power: 0.75KW
(2) Rated output current: 4.7A
(3) Maximum output current: 14.1A
(4) Voltage: 200-240V AC
(5) Frequency: 50HZ / 60HZ
(6) Cooling: self-cooling
(7) Overall dimensions: FSC 80mm × 170mm × 195mm

2.1.7 Servo motor

(1) Shaft height: 40
(2) Rated power: 0.75KW
(3) Horsepower: 1.02HP
(4) Rated torque: 2.39Nm
(5) Maximum torque: 7.2Nm
(6) Maximum speed: 5000r / min
(7) Rated current: 4.7A
(8) Protection level: IP65
(9) Recommended load inertia to motor inertia ratio: up to 20 times
(10) Encoder type: incremental encoder TTL2500ppr, 21-bit single-turn absolute encoder

2.1.8 SuperIO signal processing module

(1) 19-inch rack-mounted module, installation space: 1U;
(2) Support multiple signals coexistence, configure at least 20 UI ports, at least 20 UO
ports, 2 DO ports, 2 DO ports, 2 COM ports, communication using TCP / IP protocol, and
configure a LAN network port ;
(3) Collect the point signal of each device (sensor, actuator, electromechanical equipment)
in the scene through SuperIO signal processing module, including 4 modes of digital input,
digital output, analog input, and analog output; the signals are all It is a communication
signal for actual engineering equipment, which fully meets the signal control and
transmission requirements of the system;
(4) Combining the software scene with the controller host, you can perform external point
design, installation wiring, linkage debugging, configuration programming, screen
synchronization, system assessment, and other operations;
(5) After opening a virtual scene, the IO corresponding to each device in the scene and
the definition of each IO in the lower part of the virtual simulation training terminal shall be
determined by referring to the point table in the scene, and the students shall organize the
wiring according to the point table.

2.1.9 Virtual simulation training terminal system software

The virtual simulation training terminal system software runs in the background of the
virtual simulation training terminal, and connects the SuperIO signal processing module
with the application software, so that signals can be transmitted and feedback normally. .

2.1.10. Fault node

(1) Support PowerBus bus communication method
(2) Support remote node communication control
(3) The failure nodes are independently set, with a total number of not less than 20

2.1.11. Fault communication gateway

(1) Support summary communication of faulty nodes
(2) Support TCP / IP communication
(3) Support computer simulation software setting failure

2.1.12, management computer

(1) CPU: Intel I5-8500 processor (main frequency ≥ 3.0GHz, 6C)
(2) Motherboard: Intel 300 series chipset
(3) Memory: 8G DDR4 2666MHz memory, maximum support 32G memory capacity;
(4) Graphics card: integrated graphics
(5) Sound card: integrated HD Audio, support 5.1 channels
(6) Hard disk: 1T hard disk;
(7) Network card: integrated 10/100 / 1000M Ethernet card;
(8) Optical drive: DVD burning
(9) Expansion slot: 1 PCI-E * 16, 2 PCI-E * 1, 1 1 PCI slot;
(10) Display: 2 sets of 21.5-inch LED backlit displays with a resolution of 1920×1080 (16:
9), brightness of not less than 200, contrast of not less than 600: 1, response time of 5ms,
VGA interface with cable, DVI interface without Cable, display has mercury-free backlight
and arsenic-free glass, the display has low blue light eye protection, and can switch
between normal mode and low blue light mode.
(11) Keyboard and mouse: waterproof keyboard and antibacterial mouse;
(12) Interfaces and functions: 8 USB interfaces (4 front USB 3.1 Gen 1, 4 rear USB 2.0),
VGA + HDMI interface (VGA non-relay), no serial port, cable keyhole, network connection
Transmit, wireless network card with Bluetooth
(13) Power supply: 110 / 220V 180W energy-saving power supply
(14) Operating system: pre-installed genuine Win 10 operating system
(15) Security features: USB shielding technology, which only recognizes USB keyboards
and mice, cannot identify USB reading devices, effectively preventing data leakage;

2.2 Hardware training project

(1) Debugging and maintenance of motor jog control circuit
(2) Self-locking control circuit of three-phase asynchronous motor
(3) Forward and reverse control circuit of three-phase asynchronous motor with button
interlock
(4) Contactor interlocking three-phase asynchronous motor forward and reverse control
circuit
(5) Double interlocking three-phase asynchronous motor forward and reverse control
circuit
(6) Contactor switching star / delta start control circuit
(7) Button switch star / delta start control circuit
(8) Time relay switching star / delta start control circuit
(9) Sequence control circuit of three-phase asynchronous motor
(10) PLC control motor jog and self-locking control
(11) PLC control motor manual forward and reverse control
(12) PLC control motor with delayed forward and reverse control
(13) PLC-controlled motor with limit automatic reciprocating motion control
(14) PLC control motor start and stop control
(15) PLC control motor sequence control
(16) PLC controlled motor reverse braking
(17) PLC control motor star / delta start automatic control
(18) PLC control motor star / delta start manual control
(19) Basic operation and parameter setting of the inverter
(20) Inverter stepless speed regulation
(21) External terminal jog control
(22) The inverter controls the motor to rotate forward and backward
(23) Multi-step speed selection with variable frequency speed regulation
(24) Open-loop speed control of external voltage of inverter based on PLC control
(25) Multi-stage speed control of inverter based on PLC control
(26) PLC-based inverter controls motor forward and reverse
(27) Touch screen picture editing and function debugging
(28) Parameter setting of AC servo motor driver
(29) Siemens servo software controls servo operation
(30) PLC control of steering and speed of servo motor
(31) PLC control servo system comprehensive operation
(32) PLC, stepper motor driver and servo motor driver electrical circuit connection
(33) Programming of single-axis positioning control program for PLC and stepper motor
driver
(34) Programming of single-axis positioning control program for PLC and servo motor
driver
(35) Programming of spindle alignment control program based on servo absolute position
system
(36) Programming of single-axis high-speed synchronous operation based on touch
screen control
(37) Setting and troubleshooting of system electrical faults

III Software Description

The software part includes: electric control technology virtual reality training software, PLC
application technology virtual simulation training device software, variable frequency
control technology virtual simulation training software, servo control technology virtual
simulation training software, and C / S ( Client / server) architecture. Also possible for the
software with each computer by U card for installation.

3.1 Introduction:

3.1.1 Electrical control technology virtual simulation training software

(1) Number of low-voltage electrical equipment cognitive training scenarios: ≥ 10; basic
electrical control training scenarios: ≥ 11; machine tool electrical training scenarios: ≥ 5;
PLC electrical control: ≥ 15;
(2) The PLC electrical control sub-module adopts a virtual-real combination mode.
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3.1.2, PLC application technology virtual simulation training device software

(1) Basic training scenarios for PLC application technology: ≥20; five-station modular
production line simulation scenarios ≥5;
(2) Can complete point allocation, virtual wiring, program editing, configuration monitoring
and other operations;
(3) Adopt the virtual-real combination mode.

3.1.3 Virtual simulation training software for frequency conversion control technology

(1) Basic training scenarios of variable frequency control technology: ≥8;
(2) It can complete the setting of frequency conversion parameters, installation wiring and
setting of various speed regulation modes;

3.1.4 Virtual simulation training software for servo control technology

(1) Basic training scenes of servo control technology: ≥8;
(2) It can complete the parameter setting of AC servo system and step drive system, and
the setting and programming of PLC and touch screen;

3.2 Basic functional requirements

3.2.1. Using the virtual-real combination mode

The device consists of three layers: the management layer, the control layer, and the field
layer. It simulates the operation of a real engineering system and meets the actual signal
interaction between the PLC control unit and the simulation system.

3.2.2 Support real PLC communication of multiple brands
The SuperIO signal processing module uses a physical jumper connection method to
connect the simulation software to a real PLC, and students can make jumper
connections according to the designed points.

3.2.3 Support online virtual simulation experiment training
Combined with the virtual simulation comprehensive training teaching platform, the virtual
simulation training software has an online virtual simulation function, which can make
students free from the space limitations of the classroom, and can perform online
simulation learning and training at any place and at any time.

3.2.4. Support multiple teaching modes
It has three modes of learning, training and examination, covering all aspects of user
training and teaching. It can learn the training process in combination with digital
resources in multiple dimensions, and iterative training can be achieved through virtual
simulation. At the same time, it has the function of process evaluation and evaluation to
achieve the effect of learning purpose.
（1）Learning mode
After the trainee enters the teaching mode operation interface of the training task, the
system provides the task source, task description, ability goals, related knowledge and
skills, knowledge preparation, equipment cognition, and theoretical learning. After
completing the knowledge preparation and theoretical knowledge learning for each
training task, the system will automatically complete the theoretical level test.
1) Training purpose: To understand the basic skills, key skills, knowledge goals and
professional literacy goals that should be mastered after the training task is completed;
2) Detailed list of electrical components required for training: a detailed list of electrical
components required for the task, including graphical symbols, names, models, quantities
and parameter remarks;
3) Electrical control drawings: circuit schematic diagram, electrical wiring diagram,
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equipment layout diagram, control flowchart;
4) Relevant knowledge and skills module: provide professional theoretical knowledge
related to training tasks.
5) Device recognition module: Contains the equipment used for each training task, and
displays equipment details.

① Including but not limited to 9 categories including low-voltage electrical components,
control unit equipment, electromechanical execution equipment, sensor equipment,
instrumentation, power equipment, tools, cable auxiliary materials, etc .;
② 3D equipment model, physical structure, equipment description, functional parameters,
installation instructions, wiring instructions, communication terminals, etc.
③ At the same time, the 3D model exhibition can be rotated 360 ° arbitrarily, and it can be
enlarged and reduced;
④ For complex equipment, the internal structure of components can be decomposed by
exploded diagrams to help students learn the principle of internal structure of
components;
⑤ The device can be transparentized from the appearance and display the internal
structure.

（2）Practice Mode
After the trainee enters the practice mode interface of the training task, the system
provides 3D simulation training scenes. The trainee can roam the scene arbitrarily through
the mouse or keyboard, and can perform wiring, point assignment, setting and other
exercises. At the same time, the system provides teaching videos, operation manuals,
system wiring diagrams, demonstration operation tasks and other related materials. By
showing the equipment structure, wiring effects, operation guidelines and function
demonstrations, the students can understand the task content and scenarios, and master
the practical methods and results demonstration.
[Note: The simulation operation of the virtual scene is mainly concentrated in the practice
mode and the assessment mode, and all software training projects have this mode]

（3）Assessment mode
After the trainee enters the assessment mode interface of the training task, the system
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provides 3D simulation training scenes. The trainee is required to complete the equipment
selection, wiring, operation and function demonstration according to the assessment
content of the task. Each training task has a specific assessment scoring standard
assessment item, and each completion of the assessment item shows that the
assessment passed; when all assessment items have passed, the task assessment
passes. The system will automatically complete the result evaluation and automatic
scoring, and complete the process evaluation and assessment.

3.2.5 Support installation of equipment in virtual space

The operation interface is equipped with a device library. Students can independently
select the equipment required for the experiment, and install and operate according to the
independently designed layout;

3.2.6 Support connection operation between devices in virtual space

(1) Cable connection: Students can select different types of wires for system wiring. The
wires can be added, deleted, modified, moved, or grasped at both ends of the wires.

3.2.7. Support the selection and use of virtual tools

The operation interface is provided with a tool auxiliary material library, and students can
choose the corresponding tools and materials on their own.

3.2.8 Support setting and debugging of virtual equipment

Students can set up and debug virtual equipment, including but not limited to virtual
inverters, virtual servers, virtual motor units, etc .;

3.2.9 Support physical signal measurement

Supports physical multimeters to measure virtual simulation input and output signals,
including but not limited to digital signals and 0-10V analog signals.

3.2.10 Support the use of virtual instruments

Students can choose the various instruments to measure the quantity or status of system
lines or equipment;

3.2.11 Support automatic result evaluation function

The system can determine the type of the device’s wiring port. If the type of the device’s
port does not match the wire, it cannot be connected. Students can freely connect wires
by selecting cables, such as power lines, signal lines, and communication lines. After the
line is connected, the system is powered on, and the system can automatically determine
the fault. If a conventional wiring error occurs, the fault status is displayed or a fault
message is displayed.

3.2.12 Support point allocation inside simulation software

Students can freely assign PLC I / O points according to design;

Type 1

Type 2

3.2.13. Support Siemens Botu software for direct interaction

Simulation software scenarios can interact with Botu software through simulation
middleware plug-ins.
Students perform strategy programming according to the designed points in Siemens
Broadway software (or STEP Basic), and control the equipment actions in the simulation
scenario and monitor the equipment operation status in real time

3.2.14. Support Wincc configuration monitoring
Simultaneously monitor the status and execution of devices in simulation scenarios.

3.2.15. Support multiple control modes
Support both local and remote control modes. The software needs to be configured with a
debug button to set parameters in the software scene and trigger events; remote control is
monitored by the PLC.

3.2.16 Support fault setting and troubleshooting
Various types of electrical faults can be set inside the simulation scenario. Students will
submit the fault information after the fault is eliminated and manually remove it.

3.2.17. Have 3D resource library
Matching with each system module, the number of devices is ≥120, including 3D device
models (rotatable), device descriptions, functional parameters, installation instructions,
wiring instructions, communication terminals, etc.

3.2.18. Have a tool library
Number of tools: ≥6 types, including but not limited to wiring tools and measuring tools;

3.2.19 Support recording function
This product supports recording the training operation process into a universal Mp4 format
video file and saves it to a specified location locally. It can be used to submit the recorded
video file as an attachment when submitting an experiment report; it also supports
lectures and micro-lectures. Recording to support the construction of the resource library
project.

3.2..20. Support export training operation data
During the training process, students’ parameter settings, I / O point allocation and other
data can be exported as data files, which can be used to write training reports.

3.2.21, support for saving experimental snapshots
Under the same account, save the current experimental task node as an experimental
snapshot for quick access next time. Saving the experiment snapshot again will overwrite
the last saved result.

3.2.22, support timing function
In the assessment mode, the timing function takes effect, and records when the user
completes the assessment operation.

3.3 Simulation software Training Project

3.3.1. Simulation training project of electrical control technology

A. low-voltage electrical awareness

(1) Basic knowledge of electrical appliances
(2) Signal appliance recognition
(3) Performance of electrical appliances
(4) Fuse recognition
(5) Leading appliance recognition
(6) Switching appliance recognition
(7) Relay recognition
(8) Contactor recognition
(9) Commonly used measuring instruments
(10) Common electrical installation accessories

B. Basic electrical control

(11) Jog control of three-phase asynchronous motor
(12) Three-phase asynchronous motor self-locking control
(13) Three-phase asynchronous motor overload protection self-locking control
(14) Single-point starting control of three-phase asynchronous motor
(15) Two-phase and multi-phase control of three-phase asynchronous motor
(16) Three-phase asynchronous motor interlocking forward and reverse control
(17) Sequential start control of three-phase asynchronous motor
(18) Natural braking of three-phase asynchronous motor
(19) Energy consumption braking of three-phase asynchronous motor
(20) Reverse braking of three-phase asynchronous motor
(21) Three-phase asynchronous motor feedback braking

C. Machine control
(22) Analysis of electrical control circuit
(23) Electric control of C650 horizontal lathe
(24) Electrical control of universal milling machine
(25) Electric control of Z3040 radial drilling machine
(26) T68 horizontal boring machine electrical control
(27) Electrical control of combined machine tools

D. PLC electrical control (combining virtual and physical)
(28) Start-stop training of three-phase asynchronous motor with touch screen control
(29) Touch screen control three-phase asynchronous motor forward and reverse training
(30) Training time control of three-phase asynchronous motor with touch screen control
(31) Touch screen and PLC control motor jog and self-locking project
(32) Touch screen and PLC control motor forward and reverse project
(33) Star-delta startup project with touch screen and PLC control motor
(34) Reverse braking project of touch screen and PLC control motor
(35) Touch screen and PLC control inverter speed training

3.3.2, PLC application technology simulation training project

A. PLC basic training module (combination of virtual and actual)
(1) Simulation control experiment of the responder control system
(2) Simulation control experiment of traffic light control system at intersection
(3) Simulation control experiment of water tower water level control system
(4) Simulation control experiment of sky tower light control system
(5) Simulation control experiment of stage lighting control system
(6) Simulation control experiment of mail sorting control system
(7) Simulation control experiment of conveyor control system
(8) Simulation control experiment of multiple liquid mixing device control system
(9) Simulation control experiment of manipulator control system
(10) Simulation control experimental system of music fountain control system
(11) Simulation control experiment of reversible operation energy consumption braking
system
(12) Simulation control experiment of star delta control system
(13) Simulation control experiment of three-speed motor control system
(14) Simulation control experiment of seven-segment digital tube display control system
(15) Simulation control experiment of production line control system for electroplating tank
(16) Simulation control experiment of automatic feeding trolley control system
(17) Simulation control experiment of three-story elevator control system
(18) Simulation control experiment of constant pressure water supply system
(19) Simulation control experiment of automatic packing production line
(20) Simulation control experiment of surface grinder control system;

B. Five-stop automatic production line training module (combination of virtual and actual)
(21) Simulation control experiment of bottle feeding unit
(22) Simulation control experiment of capping and screwing unit
(23) Simulation control experiment of detection unit
(24) Simulation control experiment of cross arm handling unit
(25) Simulation control experiment of stereo storage unit
(26) Simulation control experiment of five-station free combination linkage design

3.3.3 Frequency conversion control technology simulation training project

(1) Basic operation and parameter setting of the inverter
(2) Stepless speed regulation of inverter
(3) External terminal jog control
(4) The inverter controls the motor to rotate forward and backward
(5) Multi-stage speed selection with variable frequency speed regulation
(6) Open-loop speed control of external voltage of inverter based on PLC control
(7) Multi-stage speed control of inverter based on PLC control
(8) PLC-based inverter controls motor forward and reverse

3.3.4 Servo control technology simulation training project

(1) Parameter setting of AC servo motor driver
(2) PLC controls the steering and speed of the servo motor
(3) PLC control servo system comprehensive operation
(4) PLC, stepper motor driver and servo motor driver electrical circuit connection
(5) Writing of single-axis positioning control program for PLC and stepper motor driver
(6) Writing of single-axis positioning control program for PLC and servo motor driver
(7) Programming of spindle alignment control program based on servo absolute position
system
(8) Programming of single-axis high-speed synchronous operation based on touch screen
control