EMCT Programming

Course Description

ETM2606C – EMCT Programming is a combined lecture and laboratory course (denoted by the "C" suffix) within the Engineering Technologies taxonomy, under the Mechanics, Fluids, and Heat discipline area. The course introduces students to the programming principles and practices fundamental to Electro-Mechanical Control Technology (EMCT) systems used in modern industrial and manufacturing environments. Students develop skills in writing, testing, and troubleshooting programs for automated electromechanical systems, including Programmable Logic Controllers (PLCs), CNC (Computer Numerical Control) machinery, and related automated control devices. Laboratory activities reinforce lecture concepts through hands-on programming exercises using industry-standard hardware and software platforms.

Learning Outcomes

Required Learning Outcomes

Upon successful completion of this course, students will be able to:

• Write, edit, and execute PLC ladder logic programs to control electromechanical systems and processes.
• Identify and apply fundamental PLC programming instructions, including contacts, coils, timers, counters, and comparison instructions.
• Interpret and apply input/output (I/O) module configurations and wiring for discrete and analog signals.
• Develop and test programs that implement sequencing and logic control functions for industrial machinery.
• Read and interpret electrical and control system diagrams to support programming and troubleshooting tasks.
• Apply systematic troubleshooting techniques to identify and correct faults in PLC programs and associated electromechanical systems.
• Demonstrate safe laboratory practices and adherence to industrial safety standards when working with electromechanical control equipment.

Optional Learning Outcomes

Depending on institutional focus and available equipment, students may also:

• Write and simulate basic CNC G-code and M-code programs for machining operations, including tool path planning and offset management.
• Configure and program Variable Frequency Drives (VFDs) and electronic motor drives for speed and torque control applications.
• Implement Human-Machine Interface (HMI) screens and integrate them with PLC programs.
• Apply IEC 61131-3 programming standards, including Structured Text (ST), Function Block Diagram (FBD), and Sequential Function Chart (SFC) languages.
• Program and integrate servo motors and stepper motors using motion control instructions.
• Utilize CAM (Computer-Aided Manufacturing) software to generate and transfer NC programs to CNC machines.
• Develop programs incorporating industrial sensor feedback, including temperature, pressure, flow, and position transducers.

Major Topics

Required Topics

• Introduction to EMCT and Industrial Automation: Overview of electromechanical control systems, their role in manufacturing, and industry safety standards.
• PLC Hardware Architecture: Physical components of a PLC system — CPU, power supply, I/O modules (discrete and analog), and communication interfaces.
• Ladder Logic Programming Fundamentals: Normally open/closed contacts, output coils, branching, latching, and program scan cycle concepts.
• Timers and Counters: Programming and application of on-delay (TON), off-delay (TOF), retentive timers, and up/down counters in control sequences.
• Data Comparison and Math Instructions: Equal, greater than, less than, add, subtract, multiply, and divide instructions for process control logic.
• Sequencing and Control Logic: Designing programs for multi-step machine sequences, including motor start/stop interlocks and safety permissives.
• I/O Wiring and Configuration: Wiring AC/DC discrete inputs and outputs; configuring analog I/O modules for sensors and actuators.
• Program Download, Upload, and Monitoring: Connecting to PLCs via programming software, online monitoring, forcing I/O, and data table manipulation.
• Troubleshooting and Fault Diagnosis: Using program status indicators, fault codes, and I/O diagnostics to identify and resolve system faults.
• Electrical and Control Diagram Interpretation: Reading ladder diagrams, wiring diagrams, and P&ID (Piping and Instrumentation Diagrams) relevant to programmed systems.

Optional Topics

• CNC Programming (G-Code/M-Code): Manual data input, coordinate systems, tool offsets, canned cycles, and basic part program creation for milling and turning operations.
• Advanced PLC Instructions: File/data manipulation, indirect addressing, PID (Proportional-Integral-Derivative) loop programming for process control.
• Motion Control Programming: Servo and stepper motor configuration, axis homing, positioning moves, and velocity profiles.
• HMI Development: Creating operator interface screens, linking tags to PLC data, and configuring alarms.
• Industrial Networking and Communications: Overview of industrial protocols (EtherNet/IP, DeviceNet, Modbus) and connecting PLCs to network devices.
• Pneumatic and Hydraulic Control Programming: Programming solenoid valve sequences for fluid power actuator control within PLC systems.
• CAM Software and NC Code Generation: Creating 2D/3D tool paths in CAM software and post-processing to machine-specific NC code.

Resources & Tools

• PLC Hardware: Allen-Bradley / Rockwell Automation MicroLogix or CompactLogix series PLCs (industry standard in Florida manufacturing); Siemens S7 series (supplemental)
• Programming Software: Rockwell Studio 5000 Logix Designer or RSLogix 500; Siemens TIA Portal (where applicable)
• CNC Equipment: Lab CNC mills and/or lathes with standard G/M-code controllers; CAM software such as Mastercam or Fusion 360
• HMI Software: Rockwell FactoryTalk View or equivalent HMI development environment
• Simulation Tools: PLC simulator software (RSLogix Emulate, Factory I/O) for program development without physical hardware
• Textbooks / References: Programmable Logic Controllers by Frank D. Petruzella; manufacturer programming manuals (Rockwell, Siemens)
• Safety Equipment: Personal protective equipment (PPE) per OSHA standards required in all laboratory sessions

Career Pathways

Completion of ETM2606C prepares students for roles in Florida's growing advanced manufacturing, defense, aerospace, and industrial automation sectors. Applicable occupations include:

• PLC Programmer / Controls Technician – Programs and maintains automated control systems in manufacturing facilities
• CNC Programmer / Machinist – Develops and executes CNC part programs for precision machining operations
• Electro-Mechanical Technician – Installs, programs, maintains, and troubleshoots electromechanical systems (O*NET SOC 17-3024.00)
• Automation Technician – Supports automated production lines across aerospace, food processing, and industrial manufacturing
• Industrial Maintenance Technician – Applies PLC and control programming skills to preventive and corrective maintenance
• Field Service Engineer (Entry Level) – Commissions and services automated equipment at customer sites

This course is commonly part of the Associate in Science (A.S.) in Engineering Technology or related Technical Certificate programs at Florida state colleges.

Special Information

Laboratory Component: The "C" suffix in ETM2606C designates this as a combined lecture and laboratory course meeting in the same location. Students should expect significant hands-on lab time each week working with PLC hardware, wiring panels, and programming workstations.

Industry Certification Alignment: Course content is aligned with competencies assessed by the NIMS (National Institute for Metalworking Skills) CNC Programming credentials and supports preparation for Rockwell Automation's ControlLogix Specialist credential pathways. Students pursuing industrial automation careers are encouraged to seek these certifications after course completion.

OSHA Safety Compliance: Per Florida college standards, all laboratory work must comply with OSHA 29 CFR 1910 General Industry safety regulations. Students may complete OSHA 10-Hour General Industry training as a co-curricular activity.