Automation and Industrial Computing Course

Lesson 1 • Automation Safety and Standards

Covers functional safety concepts, risk assessment methods, and compliance with international safety standards. Prepares students to design systems that protect personnel and equipment.

Lesson 2 • Introduction to Automation Concepts

Defines automation, its historical evolution, and industrial relevance. Establishes vocabulary and mental models needed for all subsequent technical content.

Lesson 3 • Industrial System Architectures

Examines how automation components are organised into hierarchical control structures. Connects system-level thinking to component-level study in later chapters.

Lesson 4 • Electrical Fundamentals for Automation

Reviews DC and AC circuit principles essential for understanding control hardware. Ensures students can read schematics and interpret electrical specifications.

Lesson 1 • Ladder Logic Programming Basics

Introduces contacts, coils, timers, and counters as the core elements of ladder logic. Students write programmes that implement simple sequential and combinational control.

Lesson 2 • Programme Debugging and Testing

Introduces online monitoring, force functions, and simulation tools for verifying PLC programmes. Builds systematic troubleshooting habits used throughout the course.

Lesson 3 • PLC Hardware Architecture

Examines CPU, memory, power supply, and I/O modules that form a PLC system. Provides the hardware context needed before programming is introduced.

Lesson 4 • Data Types and Memory Organisation

Covers integer, floating-point, Boolean, and string data types within PLC memory. Enables students to manipulate process data accurately in control programmes.

Lesson 1 • Modular and Reusable Code Design

Applies software engineering principles to PLC programming through functions and function blocks. Reduces development time and improves maintainability of large programmes.

Lesson 2 • Structured Text Programming

Teaches variables, expressions, control flow, and loops in structured text. Enables students to implement algorithms that are impractical in ladder logic alone.

Lesson 3 • IEC 61131-3 Programming Languages

Surveys all five IEC-standard PLC languages and their appropriate use cases. Positions ladder logic within a broader programming ecosystem students will apply.

Lesson 4 • Sequential Function Chart Design

Covers steps, transitions, actions, and divergence structures for process sequencing. Students model multi-step batch and assembly processes using SFC methodology.

Lesson 1 • Network Troubleshooting and Diagnostics

Applies packet capture, diagnostic LEDs, and protocol analysers to locate communication faults. Reinforces all protocol knowledge through systematic fault-finding exercises.

Lesson 2 • Industrial Ethernet Protocols

Examines EtherNet/IP, PROFINET, and Modbus TCP for high-speed device integration. Connects network theory to practical switch configuration and IP addressing tasks.

Lesson 3 • Fieldbus Protocols

Covers PROFIBUS, DeviceNet, and Modbus as widely deployed serial fieldbus standards. Students configure devices and interpret diagnostic data on each protocol.

Lesson 4 • OPC UA for Device Integration

Introduces OPC UA information modelling, security, and client-server communication. Enables students to expose PLC data to higher-level systems and cloud platforms.

Lesson 1 • HMI Hardware and Software Platforms

Surveys panel-mounted, PC-based, and mobile HMI platforms and their selection criteria. Establishes the hardware context before screen design and communication are addressed.

Lesson 2 • HMI Security and Access Control

Implements user authentication, role-based access, and audit logging on HMI systems. Protects process control from unauthorised changes while maintaining operator efficiency.

Lesson 3 • Alarm Management Systems

Covers alarm philosophy, priority classification, and ISA-18.2-aligned alarm management practices. Students configure alarm lists, shelving, and suppression to reduce nuisance alarms.

Lesson 4 • Screen Layout and Navigation Design

Applies industrial usability principles to screen hierarchy, navigation flow, and layout grids. Students create consistent, intuitive interfaces that minimise operator cognitive load.

Lesson 1 • Motion System Commissioning and Tuning

Applies auto-tuning tools and manual PID adjustment to achieve target dynamic performance. Students validate motion profiles against position error and settling time specifications.

Lesson 2 • Motion Controller Programming

Programmes single-axis moves, cam profiles, and electronic gearing using motion-specific instructions. Connects PLC programming skills to dedicated motion control environments.

Lesson 3 • Servo Drive and Encoder Systems

Introduces servo amplifiers, feedback devices, and closed-loop position control principles. Enables students to wire and configure a servo axis for precise positioning tasks.

Lesson 4 • Variable Frequency Drive Configuration

Covers VFD parameter setup, V/Hz and vector control modes, and protective functions. Students commission a drive from power-up through full-speed operation.

Lesson 1 • Data Acquisition and Tag Configuration

Configures I/O servers, OPC connections, and tag databases to bring field data into SCADA. Builds on networking and OPC UA knowledge from Chapter 4.

Lesson 2 • Process Graphics and Trend Displays

Creates dynamic process mimics, trend pens, and group displays for operator situational awareness. Applies HMI design principles from Chapter 5 at the SCADA scale.

Lesson 3 • SCADA Architecture and Components

Maps the data flow from field devices through RTUs and communication servers to SCADA clients. Establishes system-level understanding before individual component configuration begins.

Lesson 4 • SCADA Security and Cyber Hardening

Applies defence-in-depth principles, network segmentation, and patch management to SCADA systems. Addresses the unique cybersecurity challenges of operational technology environments.

Lesson 1 • Factory and Site Acceptance Testing

Designs and executes FAT and SAT test protocols against functional specifications. Ensures the system meets all performance and safety requirements before handover.

Lesson 2 • System Integration and Loop Checkout

Executes I/O loop checks, network verification, and inter-system communication testing. Validates that all hardware and software components interact correctly before process startup.

Lesson 3 • Automation Project Planning

Covers scope definition, functional specifications, and work breakdown structures for automation projects. Provides the project management foundation needed before integration work begins.

Lesson 4 • Startup, Commissioning, and Handover

Guides the controlled energisation sequence, process startup, and operator training handover. Completes the project lifecycle from installation through sustained production operation.