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Programmable Logic Controller (PLC) Principle, Practice and Trouble Shooting
Background & About the Course
Programmable Logic Controllers (PLCs) are essential components of modern industrial automation systems, controlling machinery and processes across various sectors, including manufacturing, oil and gas, automotive, and food production. A PLC comprises hardware and software designed to automate processes that demand high reliability, ease of programming, and resilience to environmental factors. As industries increasingly depend on PLCs to enhance operational efficiency, it is vital for engineers and technicians to understand their functionality, troubleshoot effectively, and optimize performance. This three-day training program offers a comprehensive overview of PLC principles, practical applications, and troubleshooting techniques to help professionals maintain and improve automation systems.
Course Objectives
- Understand the basic principles of PLCs, including components, functions, and operations.
- Program a PLC using ladder logic and other common programming languages.
- Develop practical skills for configuring and implementing PLC systems in various automation environments.
- Troubleshoot and diagnose common PLC problems and faults.
- Utilize diagnostic tools and techniques to enhance system reliability and performance.
- Optimize PLC-controlled systems for increased operational efficiency.
- Learn about the latest advancements in PLC technology and their real-world applications.
Who Should Attend
- Maintenance Engineers and Technicians
- Automation Engineers
- Control System Engineers
- Electrical Engineers
- Technicians and Operators
- Project Managers
Course Outline
Introduction to PLCs and Basic Programming
- Introduction to PLCs
- Overview of PLC components (CPU, I/O, etc.)
- Types of PLCs and their applications
- Installation, wiring, and setup basics
- PLC Programming Languages
- Introduction to Ladder Logic programming
- Basic syntax and functions in Ladder Logic
- Hands-on: Creating simple ON/OFF programs
- PLC Communication and I/O
- Digital vs. analog I/O systems
- Working with I/O modules
- Hands-on: Configuring and wiring basic I/O
Advanced Programming, Applications, and Integration
- Advanced Ladder Logic Programming
- Using timers, counters, and memory management
- Advanced programming techniques (sequencers, shift registers)
- Hands-on: Developing a complex program
- PLC Integration with Other Systems
- PLC and SCADA/HMI systems integration
- Communication protocols (Modbus, Profibus, etc.)
- Hands-on: Integration of PLC with SCADA or HMI
- Practical PLC Applications
- Real-world applications in manufacturing and process control
- PLC in motion control and robotics
- Hands-on: Implementing a basic control system
PLC Troubleshooting and Optimization
- Common PLC Faults and Troubleshooting
- Identifying common PLC faults (I/O, power, communication issues)
- Troubleshooting tools and diagnostic methods
- Hands-on: Troubleshooting a PLC fault simulation
- Preventive Maintenance and Optimization
- Best practices for PLC preventive maintenance
- Optimizing PLC programs for reliability
- Hands-on: Optimizing a PLC control system
- Advanced Troubleshooting and Case Study
- Analyzing a complex PLC failure scenario
- Review of troubleshooting steps and methods
- Hands-on: Solving real-world PLC problems
About the Course Leader
Prof. Ir. Endra Joelianto, Ph.D., SMIEEE is an expert in control engineering with extensive research in hybrid control systems, discrete event control systems, Petri nets analysis and application on PLCs, robust PID controllers, advanced process control, and industrial automation using PLC/DCS. He earned his first degree (Ir.) in Engineering Physics in 1990 from the Department of Engineering Physics at ITB and his Doctor of Philosophy (PhD) in Control Engineering in 2001 from the Department of Engineering at The Australian National University, Australia.