Course Overview

Industrial Automation (EEE / Mechanical)

Module 1: Programmable Logic Controllers (PLC) & SCADA Basics

This foundational module introduces the concept of Industrial Automation and the role of key control technologies. Learners will gain a deep understanding of Programmable Logic Controllers (PLCs): their architecture (CPU, I/O modules, power supply), their operation cycle (Scan Time), and basic programming using standardized languages, primarily Ladder Logic . We will also introduce SCADA (Supervisory Control and Data Acquisition) systems, covering their architecture (RTUs, MTU), function in data collection and monitoring, and their role as the Human-Machine Interface (HMI) for operators to control complex, geographically distributed processes.

Module 2: Power Systems and Industrial Electrical Basics

This module provides the necessary electrical engineering context for industrial environments. Topics cover Three-Phase AC Power Systems, including star and delta connections, power factor correction, and basic load balancing. Emphasis is placed on the components that protect and distribute power within a plant, such as Circuit Breakers, Fuses, Contactors, and Relays. Understanding industrial wiring standards, grounding principles, and electrical safety protocols is paramount, ensuring that control systems are implemented safely and reliably within the larger electrical infrastructure.

Module 3: Automation Sensors and Data Acquisition

This module focuses on the Input devices that feed real-time data into the PLC. Learners will study the principles, selection, and interfacing of critical industrial sensors, including:

1. Proximity Sensors (Inductive, Capacitive) for object detection.
2. Photoelectric Sensors for distance and presence sensing.
3. Temperature Sensors (Thermocouples, RTDs).
4. Encoders for position and speed feedback. The focus will be on the electrical interfacing: distinguishing between NPN and PNP outputs, and ensuring proper signal conditioning (analog-to-digital conversion) for robust data acquisition by the PLC’s input modules.

Module 4: Advanced Motor Control Systems

This core module delves into the most critical actuators in industry: electric motors. We cover the operational principles and control techniques for AC Induction Motors and DC Motors. Key topics include:

1. Direct-On-Line (DOL) Starting and reduced-voltage starting methods.
2. Variable Frequency Drives (VFDs): Understanding their role in controlling motor speed, torque, and energy consumption.
3. Servo Control Systems: Analyzing the use of servo motors and feedback loops for high-precision, closed-loop position control in robotic and CNC applications. The module will involve programming sequential logic to achieve various motor control modes.

Module 5: Mini PLC Simulation Project

The final module is a hands-on, project-based capstone where learners integrate all acquired knowledge. The Mini PLC Simulation Project requires designing and implementing the control logic for a simple industrial process (e.g., an automated bottling plant, a traffic light system, or a conveyor sorting system). Using industry-standard PLC Simulation Software, learners will:

1. Develop the Ladder Logic program.
2. Interface simulated Sensors and Actuators.
3. Implement sequential control and basic HMI visualization. This project emphasizes robust system design, troubleshooting control logic errors, and applying safety interlocks.