Industrial Networks, Drives, and System Troubleshooting
This senior-level course delves into the critical components and methodologies required for designing, implementing, and maintaining robust industrial automation systems. Students will gain a deep understanding of various industrial communication protocols, including Ethernet/IP, Profinet, and Modbus TCP, alongside practical experience in configuring and diagnosing network issues. The curriculum emphasizes data integrity, network security considerations, and the integration of diverse devices within a complex industrial ecosystem. A significant portion of the course is dedicated to industrial motor control, exploring variable frequency drives (VFDs), servo drives, and stepper motor control. Students will learn the principles of motor operation, drive selection, parameterization, and advanced control strategies like PID loops. Hands-on labs will focus on integrating these drives with PLCs, optimizing performance, and troubleshooting common drive-related faults. The course culminates in a comprehensive system troubleshooting approach, preparing students to diagnose and resolve complex issues involving networked PLCs, drives, sensors, and actuators in a real-world industrial environment.
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. Analyze and select appropriate industrial networking protocols for various applications. 2. Configure, commission, and troubleshoot industrial communication networks (e.g., Ethernet/IP, Profinet, Modbus TCP). 3. Understand the theory and operation of AC/DC motors, VFDs, servo drives, and stepper motors. 4. Design, implement, and tune motor control systems using PLCs and industrial drives. 5. Apply systematic troubleshooting methodologies to diagnose and resolve complex faults in integrated PLC, network, and drive systems. 6. Develop and execute practical projects demonstrating proficiency in industrial automation system integration and troubleshooting. **Topics by Week:** * **Week 1:** Introduction to Industrial Automation & Advanced PLC Concepts Review * **Week 2:** Ethernet/IP Architecture, Configuration, and Device Integration * **Week 3:** Profinet Network Design, IO-Device Setup, and Diagnostics * **Week 4:** Modbus TCP/RTU Communication, Messaging, and Gateway Applications * **Week 5:** Industrial Network Security and Cybersecurity Best Practices * **Week 6:** Introduction to Industrial Drives: AC/DC Motors and VFD Fundamentals * **Week 7:** VFD Parameterization, Control Modes, and Advanced Functions (PID Control) * **Week 8:** Midterm exam * **Week 9:** Servo Drives: Principles, Tuning, and Motion Control Integration with PLCs * **Week 10:** Stepper Motors and Advanced Motion Control Techniques * **Week 11:** Sensor and Actuator Integration: Advanced I/O Modules and Fieldbus Devices * **Week 12:** Systematic Troubleshooting Methodologies for PLC, Network, and Drive Faults * **Week 13:** System Diagnostics, Alarm Management, and Data Logging for Predictive Maintenance * **Week 14:** Final project **Grading Policy:** * Homework Assignments & Lab Reports: 30% * Quizzes: 10% * Midterm Exam: 20% * Final Project (Design, Implementation, & Presentation): 40%