🤖 PLC Programming: Industrial Process Control Using PLCs

🤖 PLC Programming: Industrial Process Control Using PLCs

Course Code: 2039-MECH/NC
Category: Industrial Control & Automation
Duration: 5 Weeks (15 sessions, 2 hours each)

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📝 1. Introduction

PLC (Programmable Logic Controller) systems form the backbone of modern industrial automation. This course teaches you how to program, simulate, and troubleshoot PLC-based control systems, covering both digital and analog operations, and integration with HMIs.

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👥 2. Target Audience

• Control & Automation Engineers

• Electrical & Electronics Engineers

• Industrial Maintenance Technicians

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🎯 3. Objectives

By the end of this course, you will:

• Understand the core components and types of PLCs

• Write and test basic to advanced control programs

• Connect PLCs to industrial equipment and sensors

• Implement hands-on projects for process control

• Integrate PLC systems with HMI for real-time monitoring

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✅ 4. What You Will Learn

• Basics of PLCs and their architecture

• Ladder Logic (LD) programming language

• Digital and analog I/O configuration

• Using timers, counters, and PID controllers

• Communication protocols (Modbus, Profibus)

• Fault diagnosis and system simulation

• Connecting PLCs to HMI systems

• Designing real-time monitoring dashboards

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📚 5. Materials Provided

• PLC programming manuals (Siemens & Allen Bradley)

• Sample ladder logic programs and exercises

• Simulation files and lab setups

• Troubleshooting guides

• Case studies and real-world scenarios

• Session recordings and Q&A summaries

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🧰 6. Requirements

• Basic understanding of automation or electrical systems

• Laptop with TIA Portal or Studio 5000 (trial versions acceptable)

• Enthusiasm for industrial control systems and programming

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🕒 7. Time Frame

• Total Duration: 5 Weeks

• Sessions: 15 sessions (2 hours each)

• Schedule: 3 sessions/week (e.g., Sunday, Tuesday, Thursday)

• Support: Weekly feedback and troubleshooting assistance

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💻 8. Course Format

• Instructor-led live sessions (Zoom/MS Teams)

• Interactive labs and simulation-based tasks

• Weekly assignments and code reviews

• Final project with evaluation

• Completion certificate provided

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🗂️ 9. Detailed Weekly Breakdown

📅 Week 1: Introduction to PLCs and System Components

• What is a PLC and types (Siemens, Allen Bradley)

• Core components: CPU, I/O modules, power supplies

• Introduction to Ladder Logic programming (LD)

• Setting up programming environment (TIA Portal or Studio 5000)
  Practice: Basic PLC configuration and I/O testing

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📅 Week 2: Basic Programming & Digital Control

• Writing programs using Ladder Logic

• Configuring digital inputs and outputs

• Working with timers and counters
  Practice: Motor control and traffic light simulation

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📅 Week 3: Analog Control and Communication

• Analog I/O configuration

• Implementing PID controllers in PLC

• Industrial protocols: Modbus, Profibus
  Practice: PID-based temperature control project

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📅 Week 4: Advanced Projects & Troubleshooting

• Multi-device control: Conveyor belts, batch mixers

• Debugging and error handling

• System testing and simulation

• Best practices for code structure and maintenance
  Practice: Full production line control scenario

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📅 Week 5: HMI Integration & Real-Time Monitoring

• Connecting PLCs to Human-Machine Interfaces (HMIs)

• Designing user-friendly HMI screens

• Real-time data display and alarms
  Final Project: Full PLC-HMI integration with process monitoring

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