Control and Automation Engineer Course

Lesson 1 • Industrial Standards and Safety Basics

Introduces functional safety concepts and industry standards for automation. Prepares students to design compliant and safe systems.

Lesson 2 • Automation System Architecture

Describes field, control, and supervisory layers of automation. Provides context for where PLCs, sensors, and SCADA fit.

Lesson 3 • Signals and Signal Types

Covers analog, digital, and discrete signals used in automation. Connects signal classification to sensor and actuator selection.

Lesson 1 • Transfer Functions and System Models

Derives transfer functions from differential equations and block diagrams. Forms the analytical core for controller design chapters.

Lesson 2 • Frequency Domain Analysis

Applies Bode and Nyquist methods to characterize system behavior. Connects frequency response to stability and performance metrics.

Lesson 3 • State-Space Representation

Introduces state-space modeling as an alternative to transfer functions. Prepares students for modern control design methods.

Lesson 1 • Industrial Sensor Technologies

Surveys temperature, pressure, flow, and level sensors used in industry. Connects sensor characteristics to measurement accuracy and range.

Lesson 2 • Sensor Calibration and Maintenance

Teaches calibration procedures, error sources, and preventive maintenance. Directly supports measurement reliability in automated systems.

Lesson 3 • Actuator Types and Selection

Covers electric, pneumatic, and hydraulic actuators and their control interfaces. Links actuator choice to process dynamics and energy requirements.

Lesson 1 • PLC Networking and Communication

Covers EtherNet/IP, Modbus, and PROFIBUS protocols for PLC connectivity. Enables integration with SCADA and other controllers.

Lesson 2 • Ladder Logic Programming

Teaches contacts, coils, timers, counters, and data instructions in ladder logic. Builds the primary programming skill used in most industrial PLCs.

Lesson 3 • IEC 61131-3 Programming Languages

Introduces structured text, function block diagram, and sequential function chart. Expands programming capability beyond ladder logic.

Lesson 4 • PLC Hardware and Architecture

Describes CPU, I/O modules, power supply, and backplane components. Provides the hardware context needed before programming begins.

Lesson 1 • Advanced PID Enhancements

Covers anti-windup, bumpless transfer, and cascade control structures. Addresses practical limitations of basic PID in industrial loops.

Lesson 2 • Process Identification Methods

Teaches step-test and frequency-response methods to identify process models. Accurate models are prerequisite to systematic PID tuning.

Lesson 3 • PID Implementation on PLCs and DCS

Configures PID function blocks in PLC and DCS environments. Bridges theoretical tuning to real control system deployment.

Lesson 4 • PID Tuning Methods

Applies Ziegler-Nichols, Cohen-Coon, and IMC-based tuning rules. Compares methods by robustness, speed, and ease of implementation.

Lesson 1 • Wireless Industrial Communication

Introduces WirelessHART, ISA100, and Wi-Fi for industrial applications. Addresses reliability and security considerations unique to wireless OT networks.

Lesson 2 • Industrial Ethernet Protocols

Examines EtherNet/IP, PROFINET, and Modbus TCP for real-time control. Connects Ethernet protocols to PLC and SCADA integration tasks.

Lesson 3 • Fieldbus Technologies

Covers PROFIBUS, Foundation Fieldbus, and DeviceNet architectures and wiring. Establishes fieldbus knowledge before Ethernet-based protocols are introduced.

Lesson 1 • Alarm Management Systems

Designs alarm systems following rationalization and management best practices. Directly reduces nuisance alarms and improves operator response.

Lesson 2 • Tag Configuration and Data Acquisition

Configures I/O tags, scaling, and historian data collection in SCADA. Enables accurate real-time and historical process data management.

Lesson 3 • HMI Screen Design Principles

Applies human factors and ISA-101 guidelines to operator display design. Reduces operator error through effective visual hierarchy and navigation.

Lesson 4 • SCADA System Architecture

Describes SCADA components: RTUs, communication networks, servers, and clients. Provides the structural foundation for all SCADA configuration work.

Lesson 1 • Control Strategy Selection and Justification

Provides a decision framework for choosing among PID, MPC, fuzzy, and adaptive strategies. Develops engineering judgment for real-world control design.

Lesson 2 • Multivariable Control Systems

Addresses interaction, decoupling, and relative gain array analysis for MIMO systems. Prepares students to control processes with multiple interacting loops.

Lesson 3 • Fuzzy Logic Control

Designs fuzzy inference systems for processes with uncertain or nonlinear dynamics. Provides a rule-based alternative when mathematical models are unavailable.

Lesson 4 • Model Predictive Control Principles

Explains MPC prediction horizon, cost function, and constraint handling. Builds on transfer function and state-space knowledge from earlier chapters.