Expert Industrial Automation

Expert Industrial Automation: Multi-Domain Integration (Level 5)

This expert-level course is the culmination of all previous training. It focuses on specialized, high-demand skills in industrial automation, including functional safety, advanced instrumentation, and the integration of control systems with business-level platforms. This level prepares students for the demands of complex, multi-domain industrial projects.

Our PLC (Programmable Logic Controller) courses cover everything from the fundamentals to advanced programming, ensuring learners gain practical, job-ready expertise. With hands-on training, real-world projects, and expert instructors, we prepare our students to excel in automation, manufacturing, and industrial control systems.

At EITS Academy, we believe education should have no boundaries. That’s why, in addition to our on-campus classes in Lahore, we offer comprehensive online training programs accessible to learners across the globe. Whether you are in Pakistan or anywhere in the world, you can benefit from our industry-relevant curriculum and personalized learning approach.

Our commitment to quality training, affordable fees, and career-focused learning has made us a trusted choice for engineers, technicians, and aspiring automation professionals. Join EITS Academy today and take the next step towards mastering PLC programming and advancing your career in engineering and IT.

Course Outline:

Module 1: Complete Functional Safety

Fundamentals of Functional Safety

  • In-depth understanding of safety concepts, risk assessment, and safety lifecycle.
  • Detailed study of international safety standards: IEC 61508 (Functional Safety of E/E/PE Safety-Related Systems) and ISO 13849 (Safety of Machinery – Safety-related parts of control systems).

Safety PLCs & System Design

  • Detailed comparison between standard PLCs and Safety PLCs.
  • Hands-on introduction to a specific safety PLC platform (e.g., Siemens S7-1200F/1500F or Rockwell GuardLogix).
  • Designing and implementing a complete safety system, including an Emergency Stop circuit, light curtains, and safety mats.
  • Understanding the principles of redundant systems and fail-safe designs.

Module 2: Advanced Industrial Instrumentation & Communication Protocols

Types of Specialized Sensors

  • In-depth study of various sensors: encoders (incremental & absolute), LVDT (Linear Variable Differential Transformer), load cells, and advanced proximity sensors.
  • Configuring and wiring these sensors for use with a PLC.

Advanced Fieldbus Communication

  • Mastering serial communication protocols like Modbus RTU and Modbus TCP/IP.
  • Hands-on practice configuring a PLC to communicate with smart instruments using Modbus.
  • Configuring digital protocols like HART or Profibus PA.

PID Control & Tuning

  • Advanced concepts of PID control loops.
  • Practical sessions on tuning a PID loop for stable and efficient process control, including anti-windup and auto-tuning features.

Module 3: Motion Control with Servos & Steppers

Introduction to Motion Control

  • Understanding the difference between VFDs, stepper motors, and servo motors.
  • The role of encoders in closed-loop motion control systems.

Stepper Motor Control

  • Basic wiring and configuration of a stepper motor with a PLC.
  • Programming the PLC to control the stepper motor’s speed and position.

Servo Motor Control

  • In-depth study of servo motors and servo drives.
  • Wiring and configuring a servo drive with a PLC.
  • Using dedicated motion control instructions in the PLC to perform precise tasks like point-to-point positioning and electronic gearing.

Module 4: MES & ERP Integration

Introduction to Manufacturing Execution Systems (MES)

  • The role of MES in bridging the gap between the plant floor and business operations.
  • Key functions of MES (e.g., production scheduling, quality management).

SCADA to MES/ERP Connectivity

  • Understanding how data is transferred from the SCADA system to a higher-level MES or ERP system.
  • Introduction to data exchange methods (e.g., OPC UA).

Data-driven Decision Making

  • How real-time data from the plant floor is used to improve efficiency, quality, and overall production.

Module 5: Capstone Project: Complete Big Project

Project Scope:

  • Students will design, program, and implement a comprehensive project simulating a complete industrial process (e.g., a batch mixing plant or a robotic arm with a conveyor system).
  • The project will integrate a multi-brand PLC, an HMI, a SCADA system, advanced instruments (including encoders), a safety system, and motion control.

Documentation & Presentation

  • Students will create full project documentation, including hardware configuration, P&ID (Piping and Instrumentation Diagram) interpretation, program logic, and HMI/SCADA design.
  • A final presentation to demonstrate mastery of all course levels and their seamless integration.

Module 6: Final Review & Integration of All Levels

Review of Foundational Concepts (Level 1)

  • Quick revision of PLC basics, wiring, and simple programming.

Advanced Programming & Communication (Level 2)

  • Recap of advanced instructions, data handling, and network protocols.

SCADA & Instruments (Level 3)

  • Summarizing SCADA principles, instrumentation, and PID control.

Multi-Brand & Modern Systems (Level 4)

  • Revisiting the concepts of multi-brand PLCs, VFDs, and IIoT.

Expert Integration (Level 5)

  • Final discussion on the seamless integration of functional safety, advanced motion control, and high-level system connectivity.