PLC in Industrial Controls Course

Abstract Electrical and computer engineering programs typically help students learn fundamental concepts and skills, but often strive to help the students become exposed to and learn more industrial applications. For example, many programs have courses in analog and digital circuits, microcontrollers, signals and systems and feedback control. This knowledge is the basis for industrial control applications, such as those that utilize programmable logic controllers (PLC) as a primary acquisition device for sensors and controller for actuators in the industrial processes. Many electrical and computer engineering students may not have used PLC prior to working in industry. In an effort to bridge the gap, we recently developed an industrial controls course that covers the concepts, devices and common practices associated with control systems, with a primary focus on industrial applications. The course explores the hierarchical implementation of industrial control theory. Students will acquire knowledge and develop skills related to PLC, which serve in many industrial applications as the primary edge note for sensors, actuators and communication. Electrical industrial engineering and safety standards are presented throughout the course. This industrial control course is offered as an elective for upper level undergraduate and graduate students for electrical and computer engineering major. The course structure is 2-hour lecture, 2-hour lab, for a 3-credit course. The following topics are introduced to students: feedback control, digital controllers, state diagrams, ladder logic diagrams, PLC implementation, manufacturing flow line analysis, hierarchical control, and network communications. Problem sets related to these topics were assigned. In order to improve motivation and learning, application-oriented and hands-on PLC design labs and projects were developed. Click Koyo Model C0-12DRE-2-D PLC were used in the course. Evaluations were based on student surveys (course evaluations) and student work (assigned homework, exams and in class lab exercises). The course was first offered in Summer 2022. 19 students took the course in Summer 2022 and 2023. All students finished the PLC labs and projects and took the survey. 95% of students "agree" or "strongly agree" that PLC labs and projects helped them to apply course material to improve thinking and problem solving. 89% of students "agree" or "strongly agree" that PLC labs and projects related course material to real life applications.