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Last Updated S012019

ME507

Unit Name PROGRAMMABLE LOGIC CONTROLLERS
Unit Code ME502
Unit Duration 12 weeks
Award

Graduate Diploma of Engineering (Industrial Automation)
Duration: 1 year


Master of Engineering (Industrial Automation)
Duration: 2 years  
Year Level 1st
Unit Creator / Reviewer Dr. Steve Mackay
Core/Sub-Discipline: Core
Pre/Co-requisites None
Credit Points


3


Grad Dip total course credit points = 24
(3 credits x 8 (units))


Masters total course credit points = 48
(3 credits x 12 (units) + 12 credits (Thesis))
Mode of Delivery On-Campus or Online
Unit Workload 10 hours per week:
     Lecture - 1 hour
     Tutorial Lecture - 1 hour
     Practical / Lab - 1 hour (where applicable)
     Personal Study recommended - 7 hours (guided and unguided)

Unit Description and General Aims

This subject provides the fundamentals of programmable controllers used in industrial automation. The subject covers in-depth principles of operation of programmable controllers, networking, distributed controllers, and programming control strategies. Students will undertake project work to design an industrial process automation solution.

Student assessment

Assessment Type
(e.g. Assignment - 2000 word essay (specify topic)
Examination (specify length and format))

When assessed

(e.g. Week 5)

 Weighting (% of total unit marks) Learning Outcomes Assessed

Assignment 1


Type: Report / Group work / Short answer questions / Case study


Example topics: Short answer questions demonstrating deep understanding of body of knowledge on programmable controllers and programming control applications.

 Week 5 15% 1, 2

Assignment 2


Type: Multi-choice test / Group work / Short answer questions / Role Play / Self-Assessment / Presentation


Example topics: Short answer questions demonstrating use of PLC program packages and languages via application to typical control applications. 2 hours

 Week 7 20% 3, 4

Assignment 3 - Project

Type: Project


Example: In the form of question answers, case studies and reports

 Continuous (due Week 10) 30% 1, 2, 3, 4, 5, 6

Assignment 4 - Practical


Type: Practical

Example topics: Design software programmable controller algorithm for a given process application.


(Student will simulate in codesys and troubleshoot the program, demonstrate the results along with a report)

 Final Week 30% 1, 2, 3, 4, 5, 6

Attendance/ Tutorial Perticipation

Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.

 Continuous 5% 1, 2, 3, 4, 5, 6

Prescribed and Recommended Readings

Required textbook

  • Patil, (2013) Programmable Logic Controllers (PLCs) for Automation and Process Control, Rev. 4.1, IDC Technologies
  • Bolton, W., (2006) Programmable Logic Controllers, 5th. Edition, Elsevier Publication, Sydney ISBN: 13:978-856177511

Recommended textbooks

  • Bryan, L. A., Bryan, E.A., (1997) Programmable Controllers – Theory and Implementation, 2nd edition, Industrial Text Company Publication, USA ISBN 0-944107-32-X
  • Kelvin T. Erickson (2011) Programmable Logic Controllers: An Emphasis on Design and Application ISBN: 978-0976625926
  • MacDonald, D., 2004, Practical Machinery Safety: Elsevier – ISBN: 9780750662703


Reference Materials

Number of peer-reviewed journals and websites (advised during lectures). Some examples are listed below.

  • International journal of information and computer science
  • Examples include but not limited to IEEE publications, International Journal of Automation and Control. These are peer-reviewed journals. Other relevant peer-reviewed journals will be advised.
  • IDC notes and Reference texts as advised.
  • Other material advised during the lectures

Learning Outcomes

On successful completion of this subject/unit, students are expected to be able to:

  1. Evaluate and select programmable controllers and associated hardware equipment for a process control application.
    Bloom’s Level 5
  2. Develop control programs for a process application and troubleshoot.
    Bloom’s Level 6
  3. Evaluate and select programmable controller hardware, software and control program techniques for complex control applications such as high speed control, machine vision, safe and reliable (redundancy) control.
    Bloom’s Level 5
  4. Examine program optimisation techniques to address hardware and software limitations, use of high level programming languages, and programming specialised intelligent expansion modules.
    Bloom’s Level 5
  5. Evaluate and select communication architecture for process control applications.
    Bloom’s Level 5
  6. Design and specify safety control systems for an industrial process control application.
    Bloom’s Level 6

Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topics 1

PLC reviews

  1. PLC basics
  2. Codesys

Topics 2 and 3

Introduction to programmable controllers

  1. Programmable controllers and their applications
  2. Principles of operation of a controller
  3. Components of a programmable controller system
  4. Discrete input/output systems
  5. Analogue input/output systems
  6. Special function input/output systems

Topics 4, 5 and 6

Controller programming

  1. Programming languages and standards
  2. Controller functions and advanced programming functions
  3. Control strategy, planning and designing control programs
  4. System programming, implementation and documentation
  5. Programming and troubleshooting
  6. Programming for special function input/output modules

Topics 7

Programmable controller Implementation in the real world

  1. Primary loop control and interlocking
  2. Field devices, communication networks, interfacing to enterprise systems
  3. Distributed control systems and configurations
  4. Reliability issues, cost issues, program and data backup
  5. Power supply requirements

Topics 8

Special function I/O and intelligent peripheral devices

  1. Fast response input/output and timer/counter/encoder modules
  2. Stepper motor control and machine vision control
  3. Future trends on smart instruments
  4. Highway Addressable Remote Transducer (HART)
  5. ASCII and intelligent communications devices

Topics 9

Advanced programming

  1. Program optimisation needs and techniques of implementing optimisation
  2. Programmable automations controllers, soft programmable controllers
  3. High level language programming, simulation and modelling
  4. Programming special function modules

Topics 10

Communication networks

  1. Common industrial protocols
  2. Future trends in industrial data communications
  3. Field bus
  4. Communication network design and implementation

Topics 11

Programmable controller installation – good practices

  1. Controller system layout
  2. Power requirements and safety circuits
  3. Noise, heat and voltage considerations (Input/output wiring, power supplies and industrial control panel layouts)
  4. Control room requirements
  5. Start-up procedures and commissioning a control system
  6. System maintenance and troubleshooting

Topics 12

Safety programmable controller systems

  1. Introduction to safety PLCs
  2. Architectures of Safety PLCs
  3. Characteristics of Safety PLCs
  4. Hardware and software characteristics of safety PLCs
  5. Redundant architectures for high reliability
  6. Application Software for Safety PLC
  7. Project and Course Review

In the final week students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work, to clarify any outstanding issues, and to work on finalising the major assessment report.

 

Engineers Australia


The Australian Engineering Stage 1 Competency Standards for the Professional Engineer, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

 

Stage 1 Competencies and Elements of Competency

1.

Knowledge and Skill Base

1.1

Comprehensive, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline.

1.2

Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences which underpin the engineering discipline.

1.3

In-depth understanding of specialist bodies of knowledge within the engineering discipline.

1.4

 Discernment of knowledge development and research directions within the engineering discipline.

1.5

 Knowledge of engineering design practice and contextual factors impacting the engineering discipline.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the specific discipline.

2.

Engineering Application Ability

2.1

Application of established engineering methods to complex engineering problem solving.

2.2

Fluent application of engineering techniques, tools and resources.

2.3

Application of systematic engineering synthesis and design processes.

2.4

Application of systematic approaches to the conduct and management of engineering projects.

3.

Professional and Personal Attributes

3.1

Ethical conduct and professional accountability.

3.2

Effective oral and written communication in professional and lay domains.

3.3

Creative, innovative and pro-active demeanour.

3.4

Professional use and management of information.

3.5

Orderly management of self, and professional conduct.

3.6

Effective team membership and team leadership.

Software/Hardware Used

Software

  • Codesys Version 3.5.17.0
    Installation Instructions
    • Visit Codesys Store at https://store.codesys.com/ and create an account
    • Page to https://store.codesys.com/codesys.html?___store=en#All%20versions and choose correct version to download
    • Install on your PC, do a vanilla installation
    • In Options:
      • Enable IL
      • Enable title and comments on LD rungs

Hardware

  • Siemens S7-1200 PLC CPU 1212C AC DC Relay 6ES7212-1BE40-0XB0, Model No.: S7-1200 PLC CPU 1212C S7-1212C Relay output

Unit Changes Based on Student Feedback

 

1. Additional Practical sessions added to help students understading PLC programming and to guide with practical-based assessments.

2. Videos for practical PLC based projects and programming added to teaching content to help students with additional learning materials

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