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Abstract
Industrial automation has significantly enhanced productivity, efficiency, and product quality by integrating advanced technologies such as robotics, artificial intelligence, and IoT. This study focuses on rehabilitating and developing the DL-MS6000 automatic industrial production line training system at the Ministry of Higher Education and Scientific Research in Baghdad, Iraq. The system, comprising six stations controlled by six PLCs, had issues, including hardware failures, the need for periodic updates, and a lack of SCADA control. The development process replaced the six PLCs with a single CYMON PLC and eliminated the need for CC-Link network devices, reducing system complexity and cost. The system was optimized using a new control algorithm. The system achieved high precision, zero steady-state error, and a settling time of 40 ms by using the Root Locus method in the MATLAB program. Additionally, a SCADA/HMI system was implemented to enhance control and monitoring. The newly developed system offers increased reliability, cost-efficiency, and ease of use, making it a suitable tool for educational purposes in university training rooms.
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