Mechanical Electrical Automation Control System Based on PLC Technology

In response to the increasingly complex mechanical and electrical automation control needs in modern industry, this paper studies a mechanical and electrical automation control system design scheme based on PLC (Programmable Logic Controller) technology. This study first starts with the system architecture and builds an industrial automation control system, including power supply, input/output modules, control logic, human-computer interaction, communication and safety modules. The system core uses Siemens S7-1500 PLC; the input/output module uses photoelectric isolation technology to improve signal stability; the control logic module integrates the adaptive PID (Proportion Integral Differential) algorithm; the human-computer interface realizes real-time data and alarm display based on the WinCC platform. The communication module uses the PROFINET network enhanced by TSN (Time-Sensitive Networking); the safety module is designed with emergency stop and light curtain sensor mechanisms. During the test, the performance of the system is verified through hardware-in-the-loop (HIL) simulation technology, and the stability and parameter sensitivity of the control algorithm are analyzed using the gray box test method. Experimental results show that in the position control experiment, the maximum absolute error of the system is 0.1 mm, the velocity fluctuation rate is controlled within $\pm 0.3 \%$, and the force control error is maintained within $\pm 0.2 ~\mathrm{N}$. Under a variety of load and environmental conditions, the system exhibits excellent dynamic response and robustness. The research results show that the PLC control system designed in this paper has strong adaptability and efficiency in industrial automation control applications, and can effectively meet the needs of modern industry for high-precision control and multi-device collaboration.