HMI (Human-Machine Interface) and PLC (Programmable Logic Controller) Programming: Build and Interface Industrial Systems Course

Lesson 1 • Core System Components

Identifies sensors, actuators, controllers, and networks as the four pillars of any automated system. Connects each component to its functional role in a control loop.

Lesson 2 • Electrical Fundamentals for Automation

Reviews DC and AC circuit theory, signal types, and wiring conventions essential for PLC I/O work. Provides the electrical literacy needed before touching hardware.

Lesson 3 • Industrial Automation Overview

Covers the evolution from manual to automated production and the economic drivers behind it. Establishes context for every hardware and software decision made later.

Lesson 1 • PLC System Architecture

Examines CPU, power supply, backplane, and I/O module roles within a PLC chassis. Grounds students in hardware before software concepts are introduced.

Lesson 2 • Specialty and Communication Modules

Introduces high-speed counter, motion, and communication modules that extend base PLC capability. Prepares students for advanced I/O scenarios encountered in later chapters.

Lesson 3 • Discrete I/O Modules

Covers sourcing and sinking wiring, input filtering, and output relay vs. transistor types. Students wire digital sensors and actuators to I/O modules correctly.

Lesson 4 • Analog I/O Modules

Explains 4–20 mA and 0–10 V signal standards, resolution, and scaling for process variables. Connects analog I/O knowledge to real sensor integration tasks.

Lesson 1 • Program Organization and Structure

Covers tasks, programs, function blocks, and subroutines for modular code design. Structured programs are easier to debug and maintain in industrial environments.

Lesson 2 • IEC 61131-3 Language Overview

Surveys all five standard PLC languages and their appropriate use cases. Establishes a common vocabulary for the programming chapters that follow.

Lesson 3 • Data Types and Memory Organization

Defines BOOL, INT, REAL, and STRING data types and maps them to PLC memory areas. Correct data typing prevents runtime errors in all subsequent programs.

Lesson 4 • Ladder Diagram Logic Instructions

Teaches contacts, coils, timers, counters, and comparison instructions through worked examples. Students build combinational and sequential logic rungs from scratch.

Lesson 1 • PID and Analog Control

Configures PID function blocks for closed-loop control of temperature, pressure, and flow. Students tune a simulated loop using manual and auto-tuning methods.

Lesson 2 • Reusable Library Development

Creates parameterized function blocks and libraries that can be imported across projects. Reduces development time and enforces consistency across plant-wide deployments.

Lesson 3 • Function Block Diagram Programming

Builds graphical FBD networks using standard and custom function blocks for signal processing. Reinforces modular design principles introduced in the previous chapter.

Lesson 4 • Structured Text Programming

Applies ST syntax for arithmetic, loops, conditionals, and string handling beyond Ladder capability. Enables compact, readable code for complex calculations and algorithms.

Lesson 1 • HMI Software Environment

Navigates the HMI development environment, project structure, and tag database setup. Familiarity with the tool accelerates all subsequent screen-building tasks.

Lesson 2 • Human Factors in HMI Design

Applies cognitive load theory, situation awareness, and ISA-101 display philosophy to screen design. Good human factors reduce operator error and improve response time.

Lesson 3 • Alarm Management Systems

Builds alarm tags, priorities, shelving, and acknowledgment workflows per industry best practices. Effective alarm management is a regulatory and safety requirement.

Lesson 4 • Dynamic Objects and Animations

Configures fill levels, color changes, rotation, and visibility animations tied to PLC tags. Dynamic feedback gives operators real-time process status at a glance.

Lesson 1 • Trending and Data Logging

Configures historical and real-time trend displays and data logs for process analysis. Logged data supports quality audits, troubleshooting, and continuous improvement.

Lesson 2 • Network Configuration and Security

Configures IP addressing, VLANs, and firewall rules for isolated industrial networks. Network segmentation protects control systems from unauthorized access.

Lesson 3 • Tag Linking and Data Mapping

Maps HMI tags to PLC addresses using direct and indirect addressing methods. Correct mapping ensures every screen object reflects accurate real-time data.

Lesson 4 • Industrial Communication Protocols

Compares Modbus, EtherNet/IP, PROFINET, and OPC UA for HMI–PLC data exchange. Protocol selection directly affects system performance and interoperability.

Lesson 1 • Project Documentation Deliverables

Produces as-built drawings, program backups, spare parts lists, and operation manuals. Complete documentation is required for handover, maintenance, and future modifications.

Lesson 2 • Control System Design Process

Applies a structured design process from functional specification through detailed design. A disciplined process prevents scope creep and rework during integration.

Lesson 3 • Site Acceptance Testing and Startup

Performs SAT on-site, including field wiring verification, live process testing, and operator sign-off. SAT confirms the system performs correctly in its final operating environment.

Lesson 4 • Factory Acceptance Testing

Develops and executes FAT scripts that verify every I/O point, control sequence, and alarm. FAT catches defects before equipment ships to the customer site.

Lesson 1 • HMI Fault Diagnosis

Diagnoses HMI communication errors, screen freezes, and tag quality faults using built-in diagnostics. HMI faults often mask underlying PLC or network issues.

Lesson 2 • Preventive Maintenance Programs

Designs scheduled maintenance tasks for batteries, firmware, fan filters, and connection integrity. Preventive maintenance extends equipment life and prevents unplanned shutdowns.

Lesson 3 • PLC Diagnostic Tools

Uses online monitoring, cross-reference tools, and data trace functions to observe live program behavior. Diagnostic tools expose hidden logic errors invisible during offline review.

Lesson 4 • Systematic Fault Diagnosis

Applies a structured five-step diagnostic process to isolate hardware, software, and network faults. A repeatable process reduces guesswork and shortens repair time.