Engineering Institute of Technology

 

Unit Name

ELECTRICAL CONTROL CIRCUITS AND PLC PROGRAMMING

Unit Code

BEE304S

 

Unit Duration

Term

Award

Bachelor of Science (Engineering)

 

Duration 3 years

Year Level

Three

Unit Creator/Reviewer

 

Core/Sub-discipline

Sub-discipline

Pre/Co-requisites

BSC101C, BEE106S

Credit Points

3

 

Total Program Credit Points 81 (27 x 3)

Mode of Delivery

Online or on-campus.

Unit Workload

(Total student workload including “contact hours” = 10 hours per week)

Pre-recordings / Lecture – 1.5 hours Tutorial – 1.5 hours

Guided labs / Group work / Assessments – 2 hours Personal Study recommended - 5 hours

The objective of this unit 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 Unit, students are expected to be able to:

 

  1. Create logic diagrams to achieve specific control functionalities.

  2. Translate the logic diagram to create hardwired control schemes (ladder type).

  3. Design control systems of feedback/feed-forward type of control and evaluate their stability .

  4. Explain the fundamental principles behind programmable logic controllers (PLC).

  5. Distinguish between different methods of programming PLCs based on IEC 61131-3.

  6. Create and test a PLC program to achieve specific control functionalities.

    Completing this unit may add to students professional development/competencies by:

    1. Fostering personal and professional skills and attributes in order to:

      1. Conduct work in a professionally diligent, accountable and ethical manner.

      2. Effectively use oral and written communication in personal and professional domains.

      3. Foster applicable creative thinking, critical thinking and problem solving skills.

      4. Develop initiative and engagement in lifelong learning and professional development.

      5. Enhance collaboration outcomes and performance in dynamic team roles.

      6. Effectively plan, organise, self-manage and manage others.

      7. Professionally utilise and manage information.

      8. Enhance technologist literacy and apply contextualised technologist skills.

    2. Enhance investigatory and research capabilities in order to:

      1. Develop an understanding of systematic, fundamental scientific, mathematic principles, numerical analysis techniques and statistics applicable to technologists.

      2. Access, evaluate and analyse information on technologist processes, procedures, investigations and the discernment of technologist knowledge development.

      3. Foster an in-depth understanding of specialist bodies of knowledge, computer science, engineering design practice and contextual factors applicable to technologists.

      4. Solve basic and open-ended engineering technologist problems.

      5. Understand the scope, principles, norms, accountabilities and bounds associated with sustainable engineering practice.

    3. Develop engineering application abilities in order to:

      1. Apply established engineering methods to broadly-defined technologist problem solving.

      2. Apply engineering technologist techniques, tool and resources.

      3. Apply systematic technologist synthesis and design processes.

      4. Systematically conduct and manage technologist projects, work assignments, testing and experimentation.

The Australian Engineering Stage 1 Competency Standards for Engineering Technologists, 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

Systematic, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the technology domain.

1.2

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

1.3

In-depth understanding of specialist bodies of knowledge within the technology domain.

1.4

Discernment of knowledge development within the technology domain.

1.5

Knowledge of engineering design practice and contextual factors impacting the technology domain.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the technology domain.

2.

Engineering Application Ability

2.1

Application of established engineering methods to broadly-defined problem solving within the technology domain.

2.2

Application of engineering techniques, tools and resources within the technology domain.

2.3

Application of systematic synthesis and design processes within the technology domain.

2.4

Application of systematic approaches to the conduct and management of projects within the technology domain.

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.

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 7 criteria, Engineers Australia Stage 1 Competency Standards for Engineering Technologists and the Sydney Accord:

 

Graduate Attributes

(Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Learning Outcomes

A. Knowledge of Science and Engineering Fundamentals

A1. Breadth of knowledge of engineering and systematic, theory-based understanding of underlying principles, and depth of knowledge across one or more engineering sub- disciplines

 

1.1, 1.3

 

1, 2, 3, 4, 5

A2. Knowledge of mathematical, statistical and computer sciences appropriate for engineering technology

 

1.2

 

2, 6

A3. Discernment of knowledge development within the technology domain

1.4

1, 2, 3, 4, 5, 6

A4. Knowledge of engineering design practice and contextual factors impacting the technology domain

 

1.5

 

5, 6

B. Problem Solving, Critical Analysis and Judgement

B1. Ability to research, synthesise, evaluate and innovatively apply theoretical concepts, knowledge and approaches across diverse engineering technology contexts to effectively solve engineering problems

 

1.4, 2.1, 2.3

 

2, 6

B2. Technical and project management skills to design complex systems and solutions in line with developments in engineering technology professional practice

 

2.1, 2.2, 2.3, 3.2

 

1, 2, 6

C. Effective Communication

C1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience

 

3.2

 

3, 4

C2. Ability to engage effectively and appropriately across a diverse range of cultures

3.2

 

D. Design and Project Management

D1. Apply systematic synthesis and design processes within the technology domain

2.1, 2.2, 2.3

2, 6

D2. Apply systematic approaches to the conduct and management of projects within the technology domain

 

2.4

 

E. Accountability, Professional and Ethical Conduct

E1. Innovation in applying engineering technology, having regard to ethics and impacts including economic; social; environmental and sustainability

 

1.6, 3.1, 3.4

 

E2. Professional conduct, understanding and accountability in professional practice across diverse circumstances including team work, leadership and independent work

 

3.3, 3.4, 3.5, 3.6

 

This table details the mapping of the unit graduate attributes to the unit learning outcomes and the Australian Engineering Stage 1 Competency Standards for the Engineering Technologist.

 

 

 

Graduate Attributes

A1

A2

A3

A4

B1

B2

C1

C2

D1

D2

E1

E2

 

Engineers Australia Stage 1 Competency Standards for Engineering Technologist

1.1

 

 

 

 

 

 

 

 

 

 

 

1.2

 

 

 

 

 

 

 

 

 

 

 

1.3

 

 

 

 

 

 

 

 

 

 

 

1.4

 

 

 

 

 

 

 

 

 

 

1.5

 

 

 

 

 

 

 

 

 

 

 

1.6

 

 

 

 

 

 

 

 

 

 

 

2.1

 

 

 

 

 

 

 

 

 

2.2

 

 

 

 

 

 

 

 

 

 

2.3

 

 

 

 

 

 

 

 

 

2.4

 

 

 

 

 

 

 

 

 

 

 

3.1

 

 

 

 

 

 

 

 

 

 

 

3.2

 

 

 

 

 

 

 

 

 

3.3

 

 

 

 

 

 

 

 

 

 

 

3.4

 

 

 

 

 

 

 

 

 

 

3.5

 

 

 

 

 

 

 

 

 

 

 

3.6

 

 

 

 

 

 

 

 

 

 

 

 

Unit Learning Outcomes

LO1

 

 

 

 

 

 

 

 

 

LO2

 

 

 

 

 

 

LO3

 

 

 

 

 

 

 

 

 

LO4

 

 

 

 

 

 

 

 

 

LO5

 

 

 

 

 

 

 

 

 

LO6

 

 

 

 

 

 

Student Assessment

 

 

Assessment Type

When Assessed

Weighting

 

(% of total unit 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.

 

Week 5

 

15%

 

1, 2

 

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.

 

Week 9

 

20%

 

3, 4

 

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.

 

Week 11

 

20%

 

4, 5, 6

 

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%

-

Prescribed and Recommended Readings

 

Required textbook(s)

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

IDC Technologies Course manual on PLC programming IDC Technologies course manual on Control loop tuning

Reference Materials

References from authentic websites on the Internet: For example:

https://www.plcdev.com/a_quick_tutorial_on_rslogix_emulator_5000 : A Quick Tutorial on RSLogix Emulator 5000.

 

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.

 

Topic 1

Boolean algebra and logic diagrams (Revision of earlier material)

  1. Boolean laws

  2. Solving simple Boolean equations

  3. Logic gates and their Boolean equivalent

  4. Truth tables

  5. Interpretation of complex logic circuits

  6. Synthesis of logic circuits

  7. Applying Boolean laws to simplify logic diagrams

 

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 evalution using Boolean algebra prinicples

  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. Proportional, integral and derivative (PID) control

  12. Alanog 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

Unit 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 and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

The Engineering Institute of Technology (EIT) is dedicated to ensuring our students receive a world-class education and gain skills they can immediately implement in the workplace upon graduation. Our staff members uphold our ethos of honesty and integrity, and we stand by our word because it is our bond. Our students are also expected to carry this attitude throughout their time at our institute, and into their careers.