Automation Design Project with PLC Programming

This Expert-level program (Level 3) focuses on real-world automation project design using Rockwell/Allen-Bradley PLCs, VFDs, HMIs, and industrial networks. Unlike earlier levels, this course is project-driven: participants apply their advanced programming and integration knowledge to design, configure, and troubleshoot complete automation systems.

​Through hands-on case studies, learners will replicate industrial practices such as MCC integration, process control, and automated material handling. By the end, participants will have the skills to deliver end-to-end industrial automation solutions aligned with industry standards.

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Learning Outcomes

By the end of this course, participants will be able to:

• Design, configure, and deploy complex industrial automation projects.

• Integrate Rockwell PLCs, VFDs, and HMIs for complete automation solutions.

• Apply advanced process control techniques (PID, cascade loops, device calibration).

• Implement PLC-to-PLC communication for distributed control architectures.

• Troubleshoot, document, and validate systems using FAT/SAT procedures.

• Optimize automation systems for safety, reliability, and efficiency.
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Course Content

Module 1: Expert PLC Project Development

• Project planning, I/O allocation, and architecture design.

• Advanced PLC programming standards: UDFBs, structured text, ladder logic.

• Interlocks, safety logic, and redundancy strategies.

• PLC-to-PLC communication and distributed control.
   

Module 2: Motor Control Centers (MCC) & Drives

• Design and integration of MCCs with Rockwell PLCs.

• Commissioning and tuning Variable Frequency Drives (VFDs).

• MCC interlocking schemes and protection systems.

• HMI integration with PanelView for monitoring and control.
   

Module 3: Process Automation & Control

• Advanced process control loops (PID, cascade, ratio control).

• Analog sensor/actuator integration: scaling, calibration, diagnostics.

• HMI–PLC communication for real-time data monitoring.

• Simulation, Factory Acceptance Testing (FAT), and Site Acceptance Testing (SAT).

• Documentation: I/O lists, system architectures, compliance standards.
   

Module 4: Automated Conveyor & Material Handling Systems

• Conveyor sequencing with PLC logic (start/stop, load balancing, safety).

• Integration of barcode/RFID systems for product tracking.

• Load management, throughput monitoring, and alarm handling.

• Designing operator-friendly HMI dashboards for conveyor monitoring.

• Performance analysis and system optimization.
   

Module 5: System Validation, Troubleshooting & Optimization

• Real-world debugging of industrial automation systems.

• Network troubleshooting (Ethernet/IP, ControlNet).

• Alarm and diagnostic system optimization.

• Project validation workflows and compliance reporting.

• Continuous improvement for system reliability and efficiency.
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Case Studies (Hands-On Projects)

🔹 Case Study 1: Motor Control Center (MCC) Integration

• Design and configure a Rockwell-based MCC with PLC–VFD integration.

• Deploy PanelView HMI for motor control, alarms, and diagnostics.

• Implement PLC-to-PLC communication for distributed motor operations.
   

🔹 Case Study 2: Process Control System

• Program advanced PID and cascade loops for temperature, pressure, or flow regulation.

• Integrate analog sensors/actuators with scaling and calibration.

• Validate system performance using FAT/SAT with proper documentation.
   

🔹 Case Study 3: Automated Conveyor System

• Develop a warehouse conveyor system with sequencing, interlocks, and safety logic.

• Integrate RFID/barcode devices for item tracking.

• Configure HMI dashboards with real-time trends and alarms.

• Analyze throughput data to optimize conveyor efficiency.
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General Skills Developed

• Expert-level Rockwell PLC programming (Studio 5000, ControlLogix, CompactLogix).

• Advanced HMI development with PanelView for industrial applications.

• Communication network setup and troubleshooting (Ethernet/IP, ControlNet).

• Integration of VFDs, analog/digital I/O modules, and field devices.

• System validation through FAT/SAT methodologies.

• Industrial project documentation, compliance, and reporting.

• Real-world troubleshooting, optimization, and performance improvement.