Industrial Automation Technology Course

Lesson 1 • History and Evolution of Automation

Traces automation from mechanical relay logic to modern cyber-physical systems. Establishes context for understanding why current technologies exist and how they interconnect.

Lesson 2 • Core Automation System Architecture

Defines the layered structure of field devices, controllers, and supervisory systems. Connects hardware roles to overall system performance and reliability.

Lesson 3 • Types of Industrial Control Systems

Differentiates discrete, process, batch, and hybrid control paradigms. Enables correct system selection based on production requirements.

Lesson 4 • Safety and Regulatory Frameworks

Introduces functional safety standards, hazard identification, and compliance obligations. Grounds all subsequent technical work in safe engineering practice.

Lesson 1 • Electrical Safety Practices

Covers lockout/tagout procedures, arc flash awareness, and personal protective equipment selection. Establishes non-negotiable safety habits before hands-on lab work begins.

Lesson 2 • Grounding, Shielding, and Noise Reduction

Explains proper grounding strategies and cable shielding to prevent signal interference. Directly supports reliable sensor and communication system performance.

Lesson 3 • DC and AC Circuit Principles

Covers Ohm's law, power calculations, and AC waveform characteristics essential for automation wiring. Provides the mathematical basis for all subsequent electrical work.

Lesson 4 • Industrial Electrical Components

Identifies contactors, relays, fuses, circuit breakers, and terminal blocks used in control panels. Links component selection to protection and control requirements.

Lesson 1 • Actuator Types and Selection

Examines electric, pneumatic, and hydraulic actuators including solenoids, cylinders, and motors. Guides selection based on force, velocity, precision, and environmental requirements.

Lesson 2 • Troubleshooting Field Device Faults

Applies systematic fault-finding methods to common sensor and actuator failures. Reinforces electrical fundamentals while introducing process-specific diagnostic strategies.

Lesson 3 • Calibration and Verification Procedures

Teaches zero/span calibration, loop checks, and documentation practices for field instruments. Connects calibration accuracy to process quality and safety outcomes.

Lesson 4 • Sensor Technologies and Signal Types

Surveys proximity, photoelectric, temperature, pressure, and flow sensors with their output signal types. Establishes the vocabulary for specifying and troubleshooting field instrumentation.

Lesson 1 • Advanced PLC Instructions

Introduces function block, structured text, and data manipulation instructions beyond basic ladder. Expands programming capability for complex sequencing and data handling tasks.

Lesson 2 • I/O Addressing and Tag Databases

Explains fixed and slot-based addressing schemes and tag-based programming conventions. Establishes consistent naming practices that improve program readability and maintenance.

Lesson 3 • PLC Hardware Architecture

Describes CPU, power supply, I/O modules, and backplane communication in a PLC chassis. Provides the hardware knowledge needed to configure and expand PLC systems.

Lesson 4 • Program Structure and Organisation

Introduces tasks, programs, routines, and subroutines for modular PLC code design. Promotes maintainable, scalable programs aligned with industrial coding standards.

Lesson 5 • PLC Configuration and Commissioning

Walks through hardware configuration, I/O forcing, online monitoring, and program download. Prepares students to bring a PLC system from bench setup to live operation.

Lesson 1 • Alarm Management and Notification

Configures alarm limits, priorities, acknowledgement workflows, and alarm history logging. Aligns with alarm management best practices to reduce nuisance alarms and operator fatigue.

Lesson 2 • Screen Layout and Navigation Design

Applies human factors principles to screen hierarchy, colour coding, and navigation flow. Reduces operator error by aligning display design with cognitive ergonomics.

Lesson 3 • HMI Hardware and Software Platforms

Surveys panel-mounted, PC-based, and mobile HMI platforms and their communication requirements. Establishes platform selection criteria based on environment and operator needs.

Lesson 4 • Tag Linking and Dynamic Objects

Connects HMI graphic objects to PLC tags for real-time data display and control. Demonstrates how tag binding drives animated indicators, numeric displays, and control buttons.

Lesson 1 • Network Design and Segmentation

Applies VLAN segmentation, DMZ architecture, and redundancy strategies to OT networks. Balances performance, availability, and security in industrial network design.

Lesson 2 • Network Diagnostics and Troubleshooting

Uses packet capture, ping, and protocol diagnostic tools to isolate communication faults. Builds systematic troubleshooting skills applicable across all industrial protocols.

Lesson 3 • Fieldbus and Serial Protocols

Examines legacy serial and fieldbus protocols used in process and discrete automation. Enables integration with existing installed base equipment during modernisation projects.

Lesson 4 • Industrial Network Fundamentals

Covers OSI model layers, network topologies, and the distinction between IT and OT networks. Provides the conceptual base for all industrial protocol and topology decisions.

Lesson 1 • Drive Tuning and Fault Diagnosis

Applies auto-tune procedures and manual PID gain adjustment to optimise drive response. Diagnoses overcurrent, overvoltage, and encoder fault codes to restore operation.

Lesson 2 • Servo Drive and Motor Systems

Explains servo amplifier architecture, encoder feedback, and closed-loop position control. Prepares students to configure servo axes for precise positioning applications.

Lesson 3 • Motion Programming and Profiles

Programmes trapezoidal and S-curve motion profiles, cam tables, and coordinated multi-axis moves. Connects motion programming to PLC-based motion control instructions.

Lesson 4 • Variable Frequency Drive Configuration

Covers VFD power section, control modes, and parameter setup for velocity and torque control. Enables students to commission drives for pump, fan, and conveyor applications.

Lesson 1 • Safety Instrumented Systems

Covers SIS architecture, safety function design, and proof-test procedures for high-hazard processes. Integrates safety system design with the functional safety concepts introduced in Chapter 1.

Lesson 2 • Advanced Control Strategies

Introduces cascade, ratio, feedforward, and model-predictive control for difficult processes. Expands control toolkit beyond single-loop PID for multi-variable process challenges.

Lesson 3 • Process Control Fundamentals

Defines process variables, setpoints, manipulated variables, and control loop terminology. Establishes the language and concepts underlying all subsequent control strategy work.

Lesson 4 • Control System Performance Analysis

Uses trend data, loop performance indices, and process capability metrics to evaluate control quality. Connects performance analysis to continuous improvement and energy efficiency goals.

Lesson 5 • Sequential Function Chart Programming

Programmes SFC steps, transitions, and actions for batch and sequential process automation. Builds structured sequencing skills that complement ladder and structured text programs.