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

Part B: Course Detail

Teaching Period: Term2 2011

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

Zoran Savic
Phone: +61 3 9925 4996
Email: zoran.savic@rmit.edu.au

Jan Jia

Phone +61 3 9925 4390
Email: jan.jia@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

 

WeekLecture 
1

State charts and process modelling. State sequencers programming in LD.

UEENEED009B: 1.1, 1.2, 1.3, 1.4, 1.5, 2.1, 2.2, 2.3, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

 
2

Discrete control and process control systems. Introduction to IEC 61131 Sequential Function Chart (SFC).

UEENEED009B: 1.1, 1.2, 1.3, 1.4, 1.5, 2.1, 2.2, 2.3, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Parking gate application in Ladder
3

Discrete field devices and I/O interfacing.

UEENEED009B: 1.3, 2.2, 2.3, 2.8, 2.9, 3.2, 3.3, 3.4, 3.5

 
4

Floating point arithmetic instructions (add, subtract, multiply, divide, square root) and logical instructions (<, >, =,≠) in LD. Data format conversion in LD.Floating point arithmetic instructions (add, subtract, multiply, divide, square root) and logical instructions (<, >, =,≠) in LD. Data format conversion in LD.

UEENEED009B: 1.3, 2.2, 2.3, 2.8, 2.9, 3.2, 3.3, 3.4, 3.5

Parking gate application in SFC
5

Arithmetic instructions ( add, subtract, multiply, divide & square root) in LD and introduction to Structured Text language

UEENEED009B: 1.3, 2.2, 2.3, 2.4, 2.5, 2.7, 2.8, 3.2, 3.3, 3.4, 3.5

 
6

Bit-shift and word-shift registers. Omron bit-shift instruction in LD. Typical applications.

UEENEED009B: 1.3, 2.2, 2.3, 2.4, 2.5, 2.7, 2.8, 3.2, 3.3, 3.4, 3.5

Temperature conversion. Comparing LD and ST
7

Project planning. MS Project. Machine safety. Hazard identification and risk estimation. Risk control hierarchy and safety measures.

UEENEED009B: 1.1, 1.2, 1.3, 1.4, 1.5, 2.1, 2.2, 2.3, 2.4, 2.5, 2.8, 2.9 , 3.2, 3.3, 3.4, 3.5

Part tracking application with bit-shift registers
8

Analogue field devices and I/O interfacing (current and voltage signals). Omron analogue input and output modules (resolution, scaling, and signal offset). Scaling analogue input data by programming.

UEENEED009B: 1.1, 1.2, 1.3, 1.4, 1.5, 2.1, 2.2, 2.3

Project MPS distribution machine and MPS testing machine.


9

Number systems and codes. PLC memory organisation. Omron CJ1M memory organisation.

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

TEST
10

Indirect and indexed addressing.

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project

11

Common control system faults (short circuit and open circuit faults). Control system diagnostics, alarm processing and logging. Integration with CX Designer.

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project
12

Open-loop and closed-loop control systems

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project 
13

Steady-state response and transient response. Steady-state error correction and stability

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project 
14

PID control and the PID instruction

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project 
15

System intergration and introduction to data communications

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project – System integration and final testing. Project demonstration and report.
16

Introduction to industrial communication networks

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project  – System integration and final testing. Project demonstration and report.
17&18

Centralised Exam Period

 

Projects


Learning Resources

Prescribed Texts


References

Programmable logic controllers, James A. Rehg & Glenn J. Sartori.


Other Resources

CX-Programmer Introduction Guide
CX-Simulator Introduction Guide
SFC Introduction Guide
FB ST Introduction Guide


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 1 team-based Project, 1 Practical Test , 1 Exam and 1 Assignment comprising written and practical components as outlined in the table below.

 

Assessment                          Due                                  Marks
Assignment                           Week 5                              10%

Test                                         Week 9                             40 %
Project  1                                Week 11                           20 % 
Project  2                                Week 16                           30 %

This course is graded using the following course grades-

CHD- Competent with High Distinction
CDI- Competent with Distinction
CC- Competent with Credit
CAG- Competency Achieved - Graded
NYC- Not Yet Competent
DNS- Did Not Submit for Assessment

Make sure you understand the special consideration policy available at -

http://www.rmit.edu.au/browse;ID=qkssnx1c5r0y


Assessment Matrix

 

Competency National CodeCompetency TitleCluster TitleLABASSIGNMENTPROJECTTESTWIL
 UEENEED09B Develop, enter and verify programs for industrial control systems using high level instructionsIndustrial ControlXXXX 
        

Other Information

* In this course, minimum student directed hours are 12 in addition to 48 scheduled teaching hours.
* Student directed hours involve completing activities such as reading online resources, assignments, project work, individual student-teacher course-related consultation, and writing lab reports.

Course Overview: Access Course Overview