BEIA511 

Module Name	Introduction to Programmable Logic Controllers
Module Code	BEIA511
Level	Five
Credits	15

  

Module Description and General Aims 

The objective of this module is to impart to the students: the ability to interpret electrical control schemes and their digital equivalent schemes; and, to design such schemes to achieve a given set of control objectives. Students will also be given sufficient instruction for them to have a thorough knowledge of the internals of a PLC, and the ability to create simple programs to achieve a given set of requirements. Students will complete a project covering the design of a control scheme, program the same on a PLC (simulation), and test the operation of this program. 

  

Learning Outcomes 

On successful completion of this Module, students are expected to be able to: 

1. Discuss the evolutions in industrial control system and manufacturing processes. 
   Bloom’s Level 2 

2. Create logic diagrams to achieve specific control functionalities. 
   Bloom’s Level 6 

3. Translate the logic diagram to create hardwired control schemes (ladder type). 
   Bloom’s Level 4 

4. Design control systems of feedback/feed-forward type of control and evaluate their stability. 
   Bloom’s Level 6 

5. Explain the fundamental principles behind programmable logic controllers (PLC). 
   Bloom’s Level 4 

6. Distinguish between different methods of programming PLCs based on IEC 61131-3. 
   Bloom’s Level 4 

7. Create and test a PLC program to achieve specific control functionalities. 
   Bloom’s Level 6 

  

Student Assessment 

Assessment Type	When assessed	Weighting (% of total module marks)	Learning Outcomes Assessed
Assessment 1 Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation Example Topic: Logic diagrams and control circuit development. Students will complete a written assignment with approximately 10 questions to demonstrate a detailed knowledge of Boolean algebra and logic diagrams.	Due after Topic 5	15%	1, 2, 3
Assessment 2 Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation Example Topic: PLCs Vs Hardwired control schemes. Students will complete a quiz with MCQ type answers to 30 questions to demonstrate a detailed knowledge of hardwired logics and PLC equipment.	Due after Topic 9	20%	4, 5
Assessment 3 Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation / Project / Report Example Topic: Students will complete a project covering the design of a control scheme, program the same on a PLC (simulation), and test the operation of this program. The project should include PLC program using C language and other languages having IEC 61131-3 compliance.	Due after Topic 11	20%	5, 6, 7
Assessment 4 Type: Examination  An examination with a mix of detailed essay type questions and numerical problems to be completed within 2 hours.	Final Week	40%	All
Attendance / Tutorial Participation Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.	Continuous	5%

  

Overall Requirements: Students must achieve a result of 40% or above in the exam itself to pass the exam and must pass the exam to be able to pass the module. An overall final module score of 50% or above must be achieved to pass the module once all assessment, including the exam, has been completed. 

Prescribed and Recommended Readings 

Textbooks 

• IDC Technologies Course manual on PLC programming 

• IDC Technologies course manual on Control loop tuning 

Notes and Reference Texts 

• Raghunath Ram, 2020, An Industrial Automation: Industrial PLC Programming & Network System Basics (Series Book 1), available: https://www.goodreads.com/book/show/40679937-an-industrial-automation 

• Phipps, CA, 1999, Fundamentals of Electrical Control, 2nd Edition, Fairmont Press, ISBN 978-0130126993 

• Majid Pakdel, 2020, Advanced PLC Programming, 1^st edition, ISBN: 9781925823790, available: https://www.booktopia.com.au/advanced-plc-programming-majid-pakdel/book/9781925823790.html 

• IDC Technologies, Practical Programmable Logic Controllers (PLCs) for Automation and Process Control, IDC Technologies, Perth. 

• Hackworth JR, Hackworth FD, Programmable Logic Controllers: Programming Methods and Applications. Online version available at: http://www.nfiautomation.org/FREE_Download/Technical%20Documents/PLC/%28eBook%29%20%20PLC%20Programming%20Methods.pdf 

• References from authentic websites on the Internet: For example: 
  http://www.plcdev.com/a_quick_tutorial_on_rslogix_emulator_5000 : A Quick Tutorial on RSLogix Emulator 5000 

  

Module Content 

  

Topic 1: Overview of Industrial Control System (ICS) & Applications 

1. Evolution of ICS 

2. ICS operation and Components  

3. ICS in Manufacturing Industries 

4. ICS and Interdependencies in Critical Infrastructure  

Topics 2, 3 and 4: Control scheme interpretation and design 

1. Need for control schemes 

2. Symbols used in control circuits 

3. Motor controls – unidirectional 

4. Motor control – reversing 

5. Interlocks for control/safety 

6. Interpreting the operation of a control circuit 

7. Design a control circuit in the form of a logic diagram for a given set of requirements and evaluation using Boolean algebra principles 

8. Translating a logic diagram into a control circuit 

9. Control systems (Open and closed loop), transfer function and block diagrams 

10. Feedback controls and feed forward controls 

11. Implementation of Proportional, integral and derivative (PID) controller 

12. Analog and digital control 

13. System stability criteria and loop tuning 

Topics 5 and 6: Digital logic circuits and integrated circuits for logic applications 

1. Fundamentals of digital electronics 

2. Introduction to Logic gates 

3. Diode-resistor logic (DRL) 

4. Emitter coupled logic (ECL) 

5. Resistor-transistor logic (RTL) 

6. Diode transistor logic (DTL) 

7. Transistor to transistor logic (TTL) 

8. Positive and negative logic 

9. Typical circuits for logic functions 

10. Logic gates using integrated circuits 

11. Other useful functions such as timers, counters, flip-flop (two-state) devices and etc. using ICs 

12. Introduction to clocked (dynamic) digital logic circuits 

Topics 7 and 8: Programmable logic controller basics 

1. Historical overview 

2. Clocked logic as the basis of programmable logic controllers 

3. Fundamentals of PLC hardware 

4. Block diagram of a PLC 

5. PLC processor module 

6. Internal memory and its organisation 

7. Input-output section 

8. Power supplies 

9. Noise control from I/O connections 

10. Recommended precautions in wiring 

11. Operation of dynamic logic by step-by-step execution 

12. Comparison of hard-wired logics with PLCs 

13. Possible concerns in using PLC (focus on safety systems) 

Topics 9 and 10: Programming methods based on IEC standard 61131-3 

1. PLC programming basics 

2. The need for a programming standard 

3. Ladder logic programming 

4. Structured text method 

5. Function block method 

6. Instruction list 

7. Sequential function chart 

8. Comparison between IEC61131-3 and C programming 

9. Good programming habits 

10. Code organisation and documentation 

11. Maintenance of program code and change documentation 

12. Simple examples of programming 

13. Communication between PLCs 

Topic 11: Program creation and testing 

1. Demonstration of program writing using RSLogix 5000 emulator (or any other simulator) 

2. Use of chassis monitor 

3. Step-by-step development 

4. Demonstration of the program using the simulator 

5. Testing/troubleshooting 

  

Topic 12: Future/ Emerging Trends 

1. Introduction to distributed programming and IEC 61499  

2. Function Blocks (FB) & Programming Organizational Units (POU)  

3. Functional Interfaces and FB Networks  

4. IEC61499-Engineering Methodologies and Design Patterns 

5. Modelling Intelligent Distributed Automation Systems 

Software/Hardware Used  

Software 

• Codesys & RSLogix 5000 

• Version: 3.5.18.20 & 20.05 

• Instructions: N/A 

• Additional resources or files: N/A 

Hardware 

• N/A