Basic automation course

Lesson 1 • Business Value and ROI of Automation

Examines productivity gains, quality improvements, and cost reduction driven by automation. Introduces basic return-on-investment reasoning for automation projects.

Lesson 2 • Safety and Regulatory Foundations

Outlines workplace safety obligations and industry safety standards relevant to automated environments. Frames compliance as a prerequisite for all automation work.

Lesson 3 • Key Components of Automated Systems

Identifies sensors, actuators, controllers, and communication links as core building blocks. Provides a system-level view that underpins all later technical chapters.

Lesson 4 • What Automation Means Today

Defines automation and distinguishes it from mechanisation and manual processes. Establishes shared vocabulary used throughout the course.

Lesson 1 • Core Electrical Concepts

Covers voltage, current, resistance, and power as the basis for all circuit analysis. Directly supports reading and building automation control circuits.

Lesson 2 • Control Circuit Components

Examines relays, contactors, fuses, circuit breakers, and switches used in control panels. Connects component function to protective and switching roles in automation.

Lesson 3 • Electrical Safety Practices

Covers arc flash awareness, grounding, and safe work procedures for energised equipment. Establishes non-negotiable safety habits before students handle live systems.

Lesson 4 • Electrical Measurement and Testing

Introduces multimeter use, continuity testing, and voltage verification procedures. Builds hands-on diagnostic skills applied in every subsequent hardware chapter.

Lesson 1 • Analog and Digital Signal Types

Distinguishes discrete on/off signals from analog voltage and current signals. Establishes signal type knowledge needed for controller input configuration.

Lesson 2 • Sensor Wiring and Power Supply

Covers two-wire, three-wire, and four-wire sensor connections and power supply requirements. Prevents common wiring errors that cause signal faults.

Lesson 3 • Sensor Types and Operating Principles

Compares proximity, photoelectric, temperature, pressure, and flow sensors by operating principle. Guides appropriate sensor selection for common automation tasks.

Lesson 4 • Sensor Calibration and Verification

Teaches zero/span calibration, range adjustment, and output verification procedures. Ensures measurement accuracy before integrating sensors into control loops.

Lesson 1 • PLC Scan Cycle and Memory

Describes the read-execute-write scan cycle and data memory organisation. Explains how scan time affects control responsiveness and program design.

Lesson 2 • Downloading and Testing PLC Programs

Walks through project creation, I/O configuration, program download, and online monitoring. Builds confidence in the full development-to-commissioning workflow.

Lesson 3 • Basic Ladder Logic Instructions

Introduces normally open/closed contacts, output coils, and branching rungs as core programming elements. Students write simple start/stop and interlock circuits.

Lesson 4 • PLC Architecture and Hardware

Explains CPU, power supply, I/O modules, and backplane as the physical PLC platform. Provides hardware context required before any programming activity.

Lesson 1 • Actuator Maintenance and Troubleshooting

Covers preventive maintenance schedules, wear indicators, and fault diagnosis for actuators. Reduces unplanned downtime through systematic inspection routines.

Lesson 2 • Controlling Actuators with a PLC

Demonstrates wiring solenoid valves and motor starters to PLC outputs and programming control logic. Integrates sensor feedback for position and speed confirmation.

Lesson 3 • Pneumatic Actuator Systems

Covers cylinders, directional control valves, and air preparation units in pneumatic circuits. Connects pneumatic components to PLC digital outputs for control.

Lesson 4 • Electric Motors and Drives

Examines AC induction, servo, and stepper motors alongside variable frequency drives. Prepares students to select and configure motor-drive combinations.

Lesson 1 • Ethernet-Based Industrial Protocols

Covers industrial Ethernet variants, IP addressing, and switch configuration for deterministic control. Connects Ethernet skills to modern PLC and HMI integration.

Lesson 2 • Network Troubleshooting and Security

Applies ping, packet capture, and cable testing to isolate communication faults. Introduces basic network segmentation and access control for OT security.

Lesson 3 • Industrial Network Fundamentals

Introduces OSI model layers relevant to industrial networks and compares IT vs. OT networking needs. Frames network design decisions made throughout the chapter.

Lesson 4 • Common Fieldbus Protocols

Surveys widely used serial and fieldbus protocols including their physical layer and addressing schemes. Enables informed protocol selection for device integration projects.

Lesson 1 • HMI Testing and Operator Handover

Covers simulation testing, usability review, and structured operator training for HMI acceptance. Completes the design-to-deployment cycle for the HMI application.

Lesson 2 • Alarm Management on the HMI

Configures alarm triggers, priorities, and acknowledgment workflows following industry alarm management guidelines. Reduces nuisance alarms and improves operator response.

Lesson 3 • Configuring Tags and Data Bindings

Maps HMI tags to PLC memory addresses and configures data types and update rates. Ensures accurate real-time data display on all operator screens.

Lesson 4 • HMI Hardware and Software Overview

Compares panel-mount, PC-based, and mobile HMI platforms and their development environments. Establishes platform selection criteria before screen design begins.

Lesson 1 • Loop Checks and Functional Testing

Executes point-to-point loop checks, I/O verification, and sequence functional tests. Confirms every signal path and control function performs to specification.

Lesson 2 • Commissioning Sign-Off and Handover

Completes punch-list resolution, as-built documentation, and formal operator handover procedures. Transfers system ownership to operations with full supporting documentation.

Lesson 3 • Software Configuration and Download

Integrates PLC program, HMI application, and network configuration into a unified project. Validates software consistency before energising the system.

Lesson 4 • Hardware Installation and Wiring

Covers panel mounting, cable routing, termination standards, and labelling conventions for control systems. Produces a neat, verifiable installation ready for testing.