The word automation was not used until the 1940s and it originated in the automotive manufacturing sector as a method designed to reduce labour costs and improve the quality, accuracy and precision of the finished products. We are all now very familiar with the sight of dancing robots, not only in the production of cars but in everything from washing machines to pharmaceuticals. As a result of this technology the products we purchase may have never been touched by human hands and we all benefit from a reduction in costs and improvement in quality.

The aim of this unit is for students to investigate how Programmable Logic Controllers (PLCs) and industrial robots can be programmed to successfully implement automated engineering solutions.

Among the topics included in this unit are: PLC system operational characteristics, different types of programming languages, types of robots and cell safety features. On successful completion of this unit students will be able to program PLCs and robotic manipulators to achieve a set task, describe the types and uses of PLCs and robots available, write simple PLC programs, and program industrial robots with straightforward commands and safety factors.

System operational characteristics:
Modular, unitary and rack mounted systems
Characteristics, including speed, memory, scan time, voltage and current limits
Input and output devices (digital, analogue)
Interface requirements
Communication standards (RS-232, RS-422, RS-485, Ethernet)
Internal architecture
Different types of programming languages (IEC 61131-3)
Programming language
Signal types
Number systems (binary, octal, hexadecimal)
Allocation lists of inputs and outputs
Communication techniques
Network methods
Logic functions (AND, OR, XOR)
Associated elements (timers, counters, latches)

Test and debug methods:
Systematic testing and debugging methods
Proper application of appropriate testing and debugging methods

Element considerations:
Types of robots
Mobile robotics
Tools and end effectors
Programming methods
Robot manipulators (kinematics, design, dynamics and control, vision systems, user interfaces)

Safety:
Cell safety features
Operating envelope
Operational modes
User interfaces

A PLC based assignment of 1500 words assessing learning outcomes 1 and 2, weighted 50%.

A robotics based assignment of 1500 words assessing learning outcomes 3 and 4, weighted 50%

Whole group lectures will be used to deliver new material and to consolidate previous material. Small-group tutorials, with activities designed to enhance the understanding of the material delivered in the lectures, will be used to apply the skills and knowledge learned. A mixture of classroom based and practical activities will take place supported by staff.

Describe the design and operational characteristics of a PLC system.

Design a simple PLC program by considering PLC information, programming and communication techniques.

Describe the key elements of industrial robots and be able to program them with straightforward commands to perform a given task.

Investigate the design and safe operation of a robot within an industrial application.

PC with standard software such as Microsoft Excel and industry standard software for programming

PLC and Robotics lab

Fanuc off-line programming units

BOLTON, W. (2015) Programmable Logic Controllers. 5th Ed. Elsevier.
DAWKINS, N. (ed.) (2014) Automation and Controls: A guide to Automation, Controls, PLCs and PLC Programming.
PEREZ ANDROVER, E. (2012) Introduction to PLCs: A beginner's guide to Programmable Logic Controllers.

http://www.plcmanual.com/ PLC Manual (General Reference)
http://www.plcs.net/ PLC Programming Info (General Reference)
http://www.learnaboutrobots.com/ Learn About Robots Industrial Robots (General Reference)

Must be registered on HNC/D Electrical and Electronic Engineering provision at South Staffordshire College

The word automation was not used until the 1940s and it originated in the automotive manufacturing sector as a method designed to reduce labour costs and improve the quality, accuracy and precision of the finished products. We are all now very familiar with the sight of dancing robots, not only in the production of cars but in everything from washing machines to pharmaceuticals. As a result of this technology the products we purchase may have never been touched by human hands and we all benefit from a reduction in costs and improvement in quality.

The aim of this unit is for you to investigate how Programmable Logic Controllers (PLCs) and industrial robots can be programmed to successfully implement automated engineering solutions.

Among the topics included in this unit are: PLC system operational characteristics, different types of programming languages, types of robots and cell safety features. On successful completion of this unit you will be able to program PLCs and robotic manipulators to achieve a set task, describe the types and uses of PLCs and robots available, write simple PLC programs, and program industrial robots with straightforward commands and safety factors