2023 ASEE Annual Conference & Exposition

Integrating the components of an automated system is a complex and multi-faceted cognitive skill. Instructional technologies are being used successfully to teach some aspects of system integration, such as PLC programming and system design. However, there has been relatively little emphasis on developing technologies to help students learn about the devices and machines that make up systems, interfacing, and system troubleshooting. Students typically get their first exposure to PLC interfacing during labs. Making the correct connections between a PLC and the various types of input/output devices, bridging devices, machine controllers, machine vision systems, human machine interface (HMI) panels, and power supplies can be confusing and intimidating. Students often spend precious lab time waiting for an instructor to check a circuit or answer a question. An integrated problem-solving environment (I-PSE) is being developed to address this gap.
This paper presents the design, development, and evaluation of several interactive web-based instructional modules to help students learn PLC interfacing concepts such as ladder logic and I/O devices, basic wiring, and interfacing with bridge devices. Groups of learners ranging from 34 to 65 individuals reviewed the modules. They completed pre- and post-tests to assess instructional effectiveness, a survey to provide feedback about the design and usefulness of the modules, and a self-assessment of their knowledge of I/O interfacing concepts. Results suggest that the modules have a positive impact on student learning. In addition, the self-efficacy survey results suggest that the experience of using the modules—together with lectures and labs—has a strong positive impact on learners’ self-efficacy related to writing ladder logic and interfacing I/O devices.