Government of Pakistan National Vocational and Technical Training Commission Prime Minister Hunarmand Pakistan Program "Skills for All" gi NAVTTG Course Contents / Lesson Plan Course Title: INDUSTRIAL AUTOMATION (PLC) Duration: 6 MonthsTrainer Name Course Title INDUSTRIAL AUTOMATION (PLC) Objective of Course This is a comprehensive course designed to train students in the field of INDUSTRIAL AUTOMATION AND PROGRAMMABLE LOGIC CONTROL. This course will increase prospects of a better carrier opportunity for a student who has just completed his basic education. Aim of the course is segregated in to two major parts, basic concepts of industrial automation, and programmable logic controllers. The course will start by building the basic concepts of the students about industrial automation and its related components like transducers and controllers. Then the focus of the course moves to relatively complex concepts like complete control systems, their types and design. After 2 comprehensive study of basic concepts the student will focus totally on automation of industrial processes through PLCs. Learning Outcome of the Course Knowledge proficiency details © Basic Electrical Wiring © Basic Engineering Drawing * Occupational Health & Safety + Metrology/Measurements ‘+ Knowledge of basic concepts of switches, sensors. + Knowledge of different types of Temperature transducers. ‘+ Knowledge of different types of Pressure transducers. ‘+ Knowledge of different types of Flow transducers. + Knowledge of different types of Level transducers. © Knowledge of basic concepts of control systems. ‘+ Knowledge of different types of control systems like on/off Control © Knowledge of ADC, DAC and data acquisition systems. * Knowledge of basic and components of PLCs.Trainer Name Course Title INDUSTRIAL AUTOMATION (PLC) Objective of Course This is a comprehensive course designed to train students in the field of INDUSTRIAL AUTOMATION AND PROGRAMMABLE LOGIC CONTROL. This course will increase prospects of a better carrier opportunity for a student who has just completed his basic education. Aim of the course is segregated in to two major parts, basic concepts of industrial automation, and programmable logic controllers. The course will start by building the basic concepts of the students about industrial automation and its related components like transducers and controllers. Then the focus of the course moves to relatively complex concepts like complete control systems, their types and design. After 2 comprehensive study of basic concepts the student will focus totally on automation of industrial processes through PLCs. Learning Outcome of the Course Knowledge proficiency details © Basic Electrical Wiring © Basic Engineering Drawing * Occupational Health & Safety + Metrology/Measurements ‘+ Knowledge of basic concepts of switches, sensors. + Knowledge of different types of Temperature transducers. ‘+ Knowledge of different types of Pressure transducers. ‘+ Knowledge of different types of Flow transducers. + Knowledge of different types of Level transducers. © Knowledge of basic concepts of control systems. ‘+ Knowledge of different types of control systems like on/off Control © Knowledge of ADC, DAC and data acquisition systems. * Knowledge of basic and components of PLCs.© Automation trainer for workers and lower management of industries. No of Students | 25 Learning Place Classroom / Lab Instructional Resources https://euroec.by/assets/files/siemens/s71200 easy book en-US en- US.pdf https//bin95.com/siemens-plc-programming-example1.pdf httpsi//cache.industry.siemens.com/dil/files/056/18652056/att_70829/v 1S7prv54_e.pdt http://www.pledev.com/book/export/html/373 httpsy d2dc-4e74-ad41-759e47e4e444/Programovani-S7-1200-1500-2018.pdf httpsi//cache.industry.siemens.com/di/files/822/45523822/att_82001/v LsTkop _b.pdt http://www.deltronics.ru/images/manual/DOPSoft_ UM EN 20181101. pdf http://dl.weintek.com/public/EBPro/UserManual/eng/EasyBuilderPro. UserManual_en.pdf https://www.kepware.com/en-us/products/kepserverex; https://www.kepware.com/getattachment/5759d980-7641-42e8-b4fb- 7293c835a2f9/kepserverex-manual.pdf https://www.automation.siemens.com/salesmaterial- as/brochure/en/df fa {10077-00- 7600 ipdf wince systemoverview en.pdf https://cache.indust: iemens.com/dl/files/596/73505596/att_77660/v1/GettingStarted_en-US.odf 8/v1/WinCC Working with WinCC en-US en-US.odf ifs?fup _b.pdf httpsi//docs.factoryio.com/tute https://cache.industry.siemens.com/dl/files/220/109736220/att 87978 https://cache.industry.siemens.com/di/files/487/45522487/att_61497/v Scheduled Module Title Learning Units Remarks Week Week 1 Introduction * Motivational Lecture © Course Introduction © Success stories © Job market * Course Applications * Institute/Work ethics Week 2 Basic Concepts © ACand DC Supply © Pure DC and Pulsating DC * Diodes Theory + Carry out Diode Application + DC Power supplies + BIT, FET & Thyristor Theory ‘* Electronic Components Identification © Characteristics of Single Phase and Three Phase Supply.Week 3 ‘Basic Engineering Drawing Understand & Draw Basic Manual Drawing Understand Electrical Symbols & Drawings Understand Pneumatic Symbols & drawing Understand Hydraulic Symbols & drawing Basic Testing and Wiring, Tools Multimeter / Oscilloscope / Logic Tester Measurements with Multimeter/ Oscilloscope Troubleshoot the faults via Multimeter Tools handling Identification of Field Input and Output Devices Week 4 Basic Electrical Wiring Carryout Basic Electrical Installation Install Simple Electrical Wiring Perform Testing of Electrical Wiring Series and Parallel Board Repair/ Maintenance of Electrical Installations Carryout Estimation and Planning Week 5 Circuit Breakers Single and three phase Circuit Breakers Installation of Circuit Breakers Relays Relay and its Types SPST, SPDT, DPST, DPDT SSR Relays based switching circuits Week 6 Contactors Contactors (AC/DC) and their applications Forward Reverse Operation of three phase motor via Contactors Star Delta Operation of three phase motor via Contactors Week 7 Introduction to PLC 360 degree Overview of PLC Role of PLC in Industry Types of PLCsBrands of PLCs. PLC Hardware Components of PLC V/O Section Digital /O Modules Analog I/O Modules Special Modules S232 and 485 Communication Protocols Week 8 PLC Software Install PLC software Integrate the Simulator in PLC Software Configure Software for desired tasks Industrial Simulation (Online and Offline) Week 9 PLC Languages Introduction of PLC languages in software Function block diagram Ladder diagram Statement List Week 10 Ladder Logic Programming | Master control reset Latching Interlocking Logic Gates Ladder Logic Programming On-Delay Timer Ladder Logic Programming Off-Delay Timer Ladder Logic Programming Retentive On-Delay Timer Ladder Logic Programming Retentive Off-Delay Timer Ladder Logic Programming, Pulse Timer Ladder Logic Programming Online and Offline Simulation of Above tasks Real Time Clock Practical industrial scenarios for Digital /OsWeek 11 Ladder Logic Programming Il Counters Ladder Logic Programming Up Counter Down Counter Up down Counter Special Instructions Online and Offline Simulation of Above tasks Practical industrial applications Week 12 Comparators Programming Greater than and equal to Comparator Programming, Less than and equal to Comparator Programming Equal to Comparator Programming Online and Offline Simulation of Above tasks Timers Comparison Programming Counters Comparison Programming Data Registers Comparison Programming Online and Offline Simulation of Above tasks Demonstrate the basic function of Proximity sensors Demonstrate the basic function of limit switch Practical industrial scenarios for Digital Os Week 13 ‘Analog data ADC and DAC Analog Values Scaling Related Problems Week 14 Analog Programming Analog IOs Programming Applications of Analog Programming in Industry Online and Offline Simulation of Analog Programming Practical industrial scenarios for Analog I/OsWeek 15 Mid-Term Assignment/Exam Week 16 Analog Sensors | Interfacing RTDs with PLC ‘* Automation of RTDs via PLCs ‘+ Programming for Automation of RTDs Interfacing Thermocouples with PLC ‘* Automation of Thermocouples via PLCs ‘+ Programming for Automation of Thermocouples Week 17 Analog Sensors u Interfacing Load cell with PLC ‘Automation of Load cell via PLCs + Programming for Automation of Load cell Interfacing Level Sensor with PLC * Automation of Level Sensor via PLCs ‘+ Programming for Automation Level Sensor Week 18 HMI Programming ‘+ Overview of HMls + Types of HMIs, + Planning and Designing of HMIs Recipes of HMI Week 19 Project Design PLC based mini Projects Week 20 Project Design ‘© PLC based mini ProjectsWeek 21 Employable Project/Assignm ent (6 weeks ie. 21-26) in addition of regular classes. oR On job training ( 2 weeks) © Guidelines to the Trainees for selection of students ‘employable project like final year project (FYP) * Assign Independent project to each Trainee + Aproject based on trainee’s aptitude and acquired skills. * Designed by keeping in view the emerging trends in the local market as well as across the globe. * The project idea may be based on Entrepreneur. © Leading to the successful employment. * The duration of the project will be 6 weeks + Ideas may be generated via different sites such as: hhttps://1000projects.org/. https://nevonprojects.com, ty /technofizi.net/best-computer-science-and- engineering-cse-project-topics-ideas-for-students/ + Final viva/assessment will be conducted on project assignments. ‘© At the end of session the project will be presented in skills, competition * The skill competition will be conducted on zonal, regionaland National level. « The project will be presented in front of Industrialists for ‘commercialization ‘* The best business idea will be placed in NAVTTC business incubation center for commercialization. OR ‘On job training for 2 weeks: « Aims to provide 2 weeks industrial training to the Trainees as part of overall training program * Ideal for the manufacturing trades ‘* Asan alternate to the projects that involve expensive equipment © Focuses on increasing Trainee’s motivation, productivity, efficiency and quick learning approach. Week 22 Case Study 01: Automation in Textile sector Demonstration of Site Visit/ Laboratory Trainer Survey Feasibility Report Model Simulation (Prototype) Week 23 Case Study 02: Automation in Batching sector Demonstration of Site Visit/ Laboratory Trainer Survey Feasibility Report Model Simulation (Prototype) Week 24 Case Study 03: Automation in in Manufacturing sector* Demonstration of Site Visit/ Laboratory Trainer © Survey © Feasibility Report + Model simulation (Prototype) Week 25 Case Study 04: | Automation in in Pharma sector * Demonstration of Site Visit/ Laboratory Trainer Survey + Feasibility Report ‘* Model simulation (Prototype) Week 26 Entrepreneur | Job Market Searching ‘Self-employment ship and Final ‘Freelancing sites Assessment in i * Introduction project ‘+ Fundamentals of Business Development * Entrepreneurship ‘Startup Funding ‘+ Business Incubation and Acceleration * Business Value Statement * Business Model Canvas *# Sales and Marketing Strategies + How to Reach Customers and Engage CxOs * Stakeholders Power Grid ‘RAC! Model, SWOT Analysis, PEST Analysis SMART Objectives * OKRs * Cost Management (OPEX, CAPEX, ROCE etc.) © Final AssessmentList of Machinery / Equipment ‘ : oe a ae —. dae rey eee Jame of item as er curieulum 7 ee 1. | Siemens/ Delta / Fatek PLC Trainer or equivalent oS 2. | Contactors Single Phase /3 Phase 06 3. | Electrical Relay 24V DC 15 4, | Switch Module 06 5. | Indicator Module 12 6. | Proximity Sensors 15 7. | Limit Switch 15 8. | Variable Power Supply 06 9. | Digital Multimeters 15 10. | Screw Drivers Set 10 11. | Pliers 10 4-20 mA Source 06 12. 0-10 Volt Source 06 13. | veo 02 14, | Three Phase Motor 02 15. | Pneumatic Linear actuator 06 16. | Solenoid Operated Directional Control Valve 06 17. | Analog Sensors ( RTD, Thermocouple, Load Cell, Level 06 each‘Sensors ) 18, | Fixed Power Supply 24 /SA 06 1. Software List a WPL/ISP Soft Delta 2 GX Developer Mitsubishi 3 Fx GP Wink E5/UL 4. Easy Builder 8000 (HMI) 5 DOP Soft 6 Factory 10 ie 7 Mitsubishi PLC 8 Fatek PLC 9. HMI. ( Easy View) 10. | Other PLC supported software 2. Minimum Qualification of Teachers / Instructor ‘The minimum qualifications in teacher / instructor should be + Ph.D. / M.Sc. Electrical Engineering /B.Sc. Electrical Engineering with Minimum 3 Years Experience Required/ DAE 10 Years experience3. Supportive Notes S.No ‘Nameof Books | Author ‘A beginner's guide to Programmable Logic Controllers Elvin Pérez Adrover Programmable Logic Controllers (English) 3rd Edition Frank Petruzella 3 Programmable Logic Controllers (English) Sth Edition Goerge Bolton 4. Programmable Logic Controllers : Programming Methods and HACKWORTH Applications 5. Programmable Logic Controller (PLC) ‘Stephen P. Tubbs PLC Programming Using RSLogix 500: Basic Concepts of Ladder Logic Gary D. Anderson Programming PLCs Using Rockwell Automation Controllers Jon Stenerson 8 Programmable Logic Controllers and Industrial Automation: An MadhuchhandaMitra and Introduction SamarjtSemgupta 3. PLC Programming for Industrial Automation 2016” Kevin Collins