Programmable Controller Systems (PLC) (FSI-VPL-K)

The aim of the subject is to introduce capabilities offered by programmable logical controlles (PLC) and modern control systems, as well as understanding of typical develeloper activities, from elementary definition of the hardware, work with process variables, principles and advantages of cyclic multitasking, through graphical user interfaces, up to the principles of State Machine programming in process control and drive management, all in simple laboratory applications.

The subject brings capability of practical orientation in engineering applications which require use of programmable control systems, selection of proper automation hardware, as well as development of  control software for the related technological tasks. 

Students are expected to have at least basic knowledge of the Automation theory, Electrotechnics, Control equipment, and work with textual or graphical programming languages.

The course extends the Automation and Control Equipment subjects with topics related to structure, parameters, programming and capabilities of modern industrial contol systems. The emphasis is placed mainly on the operation of programmable logical controllers  (PLC) and complex multitask systems, in conjunction with the controlled I/O technology, drives, user interfaces, and and its direct integration into the "Industry 4.0" framework.

The course is taught through lectures explaining the basic principles and theory of the discipline. Teaching is suplemented by practical laboratory work.

Course-unit credit requirements: Active participation in laboratory seminars, including successful elaboration of project software for the assigned tasks.

Attendance at lectures is recommended, attendance at laboratory seminars is required. It is at the teacher's discretion to decide how to make up for missed seminars.

Introduction: history, development of technology and hardware in industrial automation.
Scalable architecture of modern modular and distributed control systems, including integration of Safety and drive technologies.
Specific programming languages for cyclic PLC code development.
Principles of real-time operation, state machines and structured data operation in multitask control systems.
Key features and tools in typical development environment, intended for the reference control system (on-line auto-diagnostics, monitoring IO and variables, specifics of debugging and seamless cyclic code updates during the machine operation).
HW and SW solutions for actuators and electric drives, operation of various electrical engines, servo drive technology and its tuning.
Advantages and limitations of work in simple simulated environment, comparison of "Digital twin" technique.
Characteristic approaches to hardware (I/O) design, graphical (HMI) and remote (VNC, SCADA, OPC-UA, WWW) user interfaces.
Integration of PLC and distributed control systems (DCS) into higher management layers within Industry 4.0 framework.

Introduction: history, development of technology and hardware in industrial automation.
Scalable architecture of modern modular and distributed control systems, including integration of Safety and drive technologies.
Specific programming languages for cyclic PLC code development.
Principles of real-time operation, state machines and structured data operation in multitask control systems.
Key features and tools in typical development environment, intended for the reference control system (on-line auto-diagnostics, monitoring IO and variables, specifics of debugging and seamless cyclic code updates during the machine operation).
HW and SW solutions for actuators and electric drives, operation of various electrical engines, servo drive technology and its tuning.
Advantages and limitations of work in simple simulated environment, comparison of "Digital twin" technique.
Characteristic approaches to hardware (I/O) design, graphical (HMI) and remote (VNC, SCADA, OPC-UA, WWW) user interfaces.
Integration of PLC and distributed control systems (DCS) into higher management layers within Industry 4.0 framework.

Introduction of typical development environment for the reference control system at the laboratory, based on simple simulated project.
Basic ST code programming, integrated on-line monitoring of the cyclic program and variables, concepts of "variable based" operation of typical graphical user interface (vnc simulation of PLC HMI).
Introducing the benefits of data structures and "State machine" approach in programming of multi-speed multitask cyclic processes.
Practical examples of real PLC Ethernet connection, methods of definition, detection and diagnosis of the connected automation hardware, mapping I/O datapoints into process variables and structures.
Introduction of typical procedures used in comissioning, tuning and state control of multi-channel actuators, as part of simple models of multi-axis numerically controlled devices.