Design of A Remote PLC Laboratory Using WECON V-Box and Modicon M221

Abstract

The evolution of Industry 4.0 has emphasized the need for practical, remote learning tools in technical and vocational education training (TVET). The limitation of the availability of physical lab infrastructure, high equipment costs, geographical or scheduling constraints often affected the delivery of hands-on Programmable Logic Controller (PLC) training. This paper presents the system design and development of a SmartLab infrastructure enabling remote access to a PLC laboratory. The focus is on establishing seamless communication between the Schneider Electric Modicon M221 PLC and a cloud-based remote access system using the Wecon V-Box. The methodology involved a structured four-phase process: system specification, cloud configuration, PLC and V-Box setup, and client-server integration with remote testing. The system architecture allows a user from a remote location to securely connect to the PLC, monitor input and output (I/O) states, and perform ladder logic programming using EcoStruxure Machine Expert. Functional validation included successful registration of the V-Box, consistent Internet Protocol (IP) communication, secure Virtual Private Network (VPN) tunnelling, and physical output control through remote ladder execution. The results demonstrated stable remote access with low latency, confirming the feasibility and scalability of the SmartLab setup. This approach supports flexible TVET delivery and can be replicated across institutions aiming to modernize industrial automation training. Future enhancements will focus on expanding multi-user capabilities, improving cybersecurity, and integrating additional industrial communication standards and mobile platforms.