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DIY PLC Trainer - Arduino Uno - Phase 3 (Motor Integration)

This project simulates a basic industrial Programmable Logic Controller (PLC) system using an Arduino Uno.
It models machine states (Stopped, Running, Fault) and now controls a real 12V DC motor through a relay.

PLC Trainer Setup

📽️ Demo Video

Watch the demo

▶️ Watch on YouTube

Features

✅ Start Button (Hold 3 seconds to start motor)
✅ Stop Button (Hold 3 seconds to stop motor)
✅ Fault Simulation Button (Instantly trigger fault)
✅ Motor Relay Control
✅ Visual LED Feedback
✅ Audible Buzzer Feedback
✅ Fault Recovery via EEPROM
✅ Non-blocking millis() timing for LED and buttons
✅ Clean C++ classes for LED and buzzer handling

System Behavior

State LED Feedback Buzzer Feedback Motor Relay
Stopped (OFF) Solid Red 2 beeps (stop success) OFF
Running Solid Green 1 beep (start success) ON
Holding Start/Stop Flashing Yellow None during hold (Depends)
Fault Active Fast Flashing Red 3 quick beeps OFF
Fault Clearing Slow Flashing Red 2 beeps when cleared OFF

Hardware Requirements

Component Notes
Arduino Uno Standard AVR
Terminal Breakout Shield For easier wiring
NeoPixel LED 3 pins: 5V, ground and data
Piezo Buzzer 2 pins: ground and data
4-Channel Relay Module 5V type, triggered LOW
12V DC Motor Driven by Relay Channel 4
12V 10A Power Supply Powers entire system
3x Momentary Buttons Start, Stop, Fault Sim
3D-Printed DIN Rail mounting parts Optional for neatness

Wiring Overview

Arduino Pin Connected To
D2 Fault Simulation Button
D3 Stop Button
D4 Start Button
D7 NeoPixel LED (Signal)
D8 Piezo Buzzer
D12 Relay Channel 4 (Motor Control)
VIN/GND Buck converter + relay + Arduino

Setup Instructions

  1. Clone the repository:

    git clone https://github.com/Beedlebub/plcTrainer_Uno.git

  2. Open project in VSCode + PlatformIO.

  3. Verify platformio.ini settings:

    [env:uno]
platform = atmelavr
board = uno
framework = arduino
lib_deps = 
  adafruit/Adafruit NeoPixel@^1.12.5
monitor_speed = 115200

  4. Connect hardware as per wiring diagram.

  5. Upload firmware:

    • Press PlatformIO "Upload" button or use pio run --target upload.

  6. Open Serial Monitor (115200 baud) to watch debug output.

Versioning

  • Phase 3.0.5
    • Updated HARDWARE_OVERVIEW.md:
      • Added 12V DC Motor entry to hardware requirements
      • Documented Relay Channel 4 (D12) controlling the motor
      • Specified Buck Converter supplying power via VIN/GND
      • Clarified NeoPixel and Piezo functions
    • General documentation cleanup for better clarity and maintainability
    • Confirmed Arduino Uno pin mappings are complete and accurate
    • Minor wording improvements in existing documentation files

Future Roadmap

  • Add some analog sensors to the circuit: light and temp
  • Work on an Arduino Nano RP2040 Connect hardware variant
  • Port this functionality to OpenPLC
  • Expand system to higher voltages (12V and eventually 24V).

License

MIT License

Build smart. Build safe. Build awesome. And above all — build fun things! 🚀