Applied PLC Programming: Timers, Counters, and Analog I/O
This senior-level course builds upon foundational PLC knowledge, immersing students in advanced programming techniques essential for modern industrial automation systems. It delves into the sophisticated application of various timer and counter types, including retentive, non-retentive, high-speed, and specialty timers/counters, demonstrating their utility in sequencing, timing critical processes, and production monitoring. Students will learn to select, configure, and troubleshoot these instructions within diverse ladder logic, structured text, and function block diagram environments. A significant portion of the course is dedicated to understanding and implementing analog I/O, covering scaling, normalization, control loop fundamentals (PID), and data acquisition. Students will gain practical experience with transducers, signal conditioning, A/D and D/A conversion principles, and the integration of analog signals for process control, temperature regulation, and motor speed control. The curriculum emphasizes industry best practices, safety considerations, and effective debugging strategies through extensive laboratory exercises and a culminating hands-on project.
Prerequisites
Course outline
Lectures, virtual labs, and graded assignments — completed in your browser.
Syllabus
Course Objectives: Upon successful completion of this course, students will be able to: 1) Design and implement complex control sequences using advanced timer and counter instructions. 2) Select appropriate analog input/output modules and sensors for process control applications. 3) Scale and interpret analog signals for precise data acquisition and control. 4) Apply PID control principles to regulate industrial processes using PLCs. 5) Troubleshoot advanced PLC programs involving timers, counters, and analog I/O, adhering to industry standards. 6) Develop and present a functional PLC-based automation project. Topics by Week: Week 1: Review of PLC Fundamentals, Introduction to Advanced Instruction Sets Week 2: Timer Instructions: TON, TOFF, RTO, Time-based Sequencing Week 3: Counter Instructions: CTU, CTD, High-Speed Counters, Production Monitoring Week 4: Advanced Timer/Counter Applications: State Machines, Shift Registers Week 5: Introduction to Analog I/O: Sensors, Transducers, Signal Conditioning Week 6: Analog Input Modules: Wiring, Configuration, Data Acquisition Week 7: Analog Scaling and Normalization Techniques, Data Manipulation Week 8: Midterm exam Week 9: Analog Output Modules: Wiring, Control Actuators, DAC Principles Week 10: Process Control Fundamentals: Open/Closed Loop, On/Off Control Week 11: Introduction to PID Control: Proportional, Integral, Derivative Action Week 12: PID Tuning Methods and Practical Application Week 13: Data Logging, Alarming, and HMI Integration for Analog Processes Week 14: Final project Grading Policy: Homework & Lab Reports (30%), Quizzes (10%), Midterm Exam (25%), Final Project (35%). All lab work and programming assignments are mandatory. Attendance and active participation are expected.