Course Title: Develop, enter and verify programs for industrial control systems using high level instructions

Part B: Course Detail

Teaching Period: Term2 2009

Course Code: EEET6791C

Course Title: Develop, enter and verify programs for industrial control systems using high level instructions

School: 130T Vocational Engineering

Campus: City Campus

Program: C6085 - Advanced Diploma of Electrical - Technology

Course Contact: Program Manager

Course Contact Phone: +61 3 9925 4703

Course Contact Email: william.lau@rmit.edu.au


Name and Contact Details of All Other Relevant Staff

Luigi La Forgia
99254864
luigi.laforgia@rmit.edu
Zoran Savic
9925 4996
zoran.savic@rmit.edu.au

Nominal Hours: 60

Regardless of the mode of delivery, represent a guide to the relative teaching time and student effort required to successfully achieve a particular competency/module. This may include not only scheduled classes or workplace visits but also the amount of effort required to undertake, evaluate and complete all assessment requirements, including any non-classroom activities.

Pre-requisites and Co-requisites

UEENEED007B 

Course Description

This unit covers development, installation and testing of programs for an industrial system requiring advance control functions. It encompasses working safely, using structure logic, acceptable design techniques, applying knowledge of high level instructions, and documenting development and programming activities.


National Codes, Titles, Elements and Performance Criteria

National Element Code & Title:

UEENEED009B Develop, enter and verify programs for industrial control systems using high level instructions

Element:

Develop and enter and programs for industrial control systems

Performance Criteria:

2.1 Established OHS risk control measures and procedures for carrying out the work are followed.
2.2 Control solutions are developed and documented based on the operational mode and using acceptable methods for designing control system that contain numeric variables and values.
2.3 Developed control system is converted to an appropriate form, such as flow, state and ladder diagrams, using a personal computer and software applicable to the programmable controller into which the program is to be entered.
2.4 Programming elements are written and used to manipulate word data. (See Note 1)
1. Example of programming elements are loading data from discrete input switches to an internal register; manipulating internal registers using arithmetic, logical and other functions; driving outputs from internal registers; utilizing thumbwheel switches and displays; manipulating double registers with
mathematical operations; loading constants, variables and presets in and out of memory; using masking of registers to obtain desired data; using tables for the storage of data.
2.5 Program control values are assigned using an applicable numbering system and code. (See Note 2)
2. Examples are binary and signed binary, numbering systems and codes such as BCD or ASCII codes
2.6 Programs are written to read and write analog signals offset using applicable software tools.
2.7 Arithmetic functions are used to scale analog inputs to a specified span.
2.8 Program is entered into the programmable control using a personal computer and appropriate software.
2.9 Methods for dealing with unexpected situations are selected on the basis of safety and specified work outcomes.

Element:

Monitor, verify and document programming activities

Performance Criteria:

3.1 Device operation is tested in strict accordance OHS requirements and procedures.
3.2 Entered instructions and settings are tested as meeting those specified for the control mode requirements.
3.3 Appropriate methods and tools are used to test and monitor control programs and operating faults, anomalies are identified and rectified. (See Note 3)
3. Examples of control program testing and monitoring methods and tools are locating status bits (flags); examining and modifying watchdog timer; investigating the implications of rung positioning in relation to scan.
3.4 OHS work completion risk control measures and procedures are followed.
3.5 Control system specification and program are documented in accordance with established procedures.

Element:

Prepare to develop industrial control systems programs

Performance Criteria:

1.1 OHS procedures for a given work area are identified, obtained and understood through established routines and procedures.
1.2 Established OHS risk control measures and procedures are followed in preparation for the work.
1.3 Mode of operation of the control system is determined from job specifications of the process/plant/machine to be controlled, and through consultation with appropriate person(s).
1.4 Equipment, software and testing devices needed to carry out the work are obtained and checked for correct operation and safety.
1.5 Installation of programmable controller is checked for compliance with regulations and job specification.


Learning Outcomes



Details of Learning Activities

Simulated work activities with classroom tutorial and practical exercises to demonstrate an understanding of the knowledge and performance of the skills in developing, entering and verifying programs for industrial control systems using high level instructions in terms of the topics detailed in the Teaching schedule below.


Teaching Schedule

WeekLectureLab/Tutorial
1Safety of machinery – Legal requirements and technical guidance. Electrical safety, protective devices and safe isolation of electrical and other power sources. Emergency procedures for the rescue of an electric shock victim equipmentRevision from EEET6790. Creating sequencer structure from the process specification
2Safety of machinery – Risk assessment, risk control and failsafe systemsSequencers 1. Adding machine reset on start-up, control stop, emergency stop, GUI, automatic and manual mode control
3PLC hardware components and field devices. PLC modes of operation. PLC addressing and memory organisation. Scan time. Risk assessment and risk control on training machines. Sequencers 2 Adding timers to the process
4Sequencers in IEC61131 LD and SFC Sequencers 3 Adding counters to the process
5Edge and bistable instructionsSequencers 4 Adding bypass of physical feedback to the process
6Sequencers 4 Adding bypass of physical feedback to the process Sequencers 5. Traffic control application
7Data Manipulation- arithmetic instructions, add, subtract, multiply, divide & square rootSequencers 6 Cascaded sequencers
8Data Manipulation – compare and move MID-SEMESTER TEST
9Data Manipulation – direct, indirect and indexed addressingControl system diagnostics and fault location. PLC memory interrogation and bit manipulation (bit set, bit clear, bit test)
10Analogue modules, ADC, DAC, field devices and common signal typesControl system diagnostics and fault location. PLC memory interrogation and bit manipulation (bit set, bit clear, bit test)
11Analogue control. Resolution , scaling, signal offsetMPS feeding control application
12Analogue control. Closed-loop control systemsMPS testing control application with BCD conversion, move and compare instruction added to the process
13Analogue control. Steady-state response and transient responseMPS testing control application with BCD conversion, move and compare instruction added to the process
14Analogue control. Steady-state error correction and stabilityMPS testing control application with BCD conversion, move and compare instruction added to the process
15Data Manipulation – Bit-shift and word-shift registers, word devices Open loop & closed loop control of motor speed
16Error processing and error loggingOpen loop & closed loop control of motor speed
17No lectureFINAL EXAM
18No lectureSupplementary assessment


Learning Resources

Prescribed Texts


References


Other Resources

Omron Manuals


Overview of Assessment

This course may be assessed through a range of practical exercises, assignments and progressive tests.


Assessment Tasks

Assessment for this course consists of Laboratory Exercise, 2 Projects and 2 Practical Tests as outlined in the table below.

For the Practical Test you will be given a brief which specifies the requirements of a Industrial control system for which you are to create a project in class within a given time limit.

When the time is up, your Assessor will come around to assess you.

Allocation of Marks:

Topic Covered        Major Assessment task           Proportion of final assessment           Date
Wks 1 - 7                 Practical Test 1                          30 %                                                         Wk 8
Wks 8 - 16               Practical Test 2                          40 %                                                         Wk 17
All wks                      Practical Test 1                         10 %                                                         Wks 2 - 10
All wks                      Projects                                     20 %                                                         Wk 14 & 16


Assessment Matrix

Competency National CodeCompetency TitleCluster TitleAssessment TypesAssessment TypesAssessment TypesAssessment TypesAssessment Types
   labAssignmentProject/
Presentation
TestWIL
UEENEED09BIndustrial Control X XX 

Course Overview: Access Course Overview