Industrial Applications using PLCs and Robotics

Course Description

ETS1540C is a combined lecture and laboratory course in the Engineering Technologies: Specialty Engineering Technology taxonomy. The course introduces students to the industrial use of Programmable Logic Controllers (PLCs) and robotics in automated manufacturing and process control environments. Students study PLC hardware architecture, numbering systems, memory organization, programming software, and program analysis, while also exploring the fundamentals of industrial robotic systems. Laboratory activities reinforce theoretical concepts through hands-on configuration, programming, and troubleshooting of industrial control equipment. The course is a component of the Florida statewide Engineering Technology (A.S.) degree framework, developed in partnership with the Florida Advanced Technological Education (FLATE) Center and the Florida Department of Education.

Learning Outcomes

Required Outcomes

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

• Identify and describe the hardware components of a Programmable Logic Controller (PLC) system, including CPU, I/O modules, and power supply.
• Convert between numbering systems (binary, octal, hexadecimal, and decimal) used in PLC environments.
• Explain PLC memory organization and data file structures.
• Use PLC programming software to create, edit, upload, and download ladder logic programs.
• Analyze and interpret PLC ladder logic programs for proper function and control sequence.
• Describe the principles of basic process control and automated manufacturing processes.
• Demonstrate safe operating practices consistent with industrial safety, health, and environmental requirements.
• Identify and classify types of industrial robots including their basic operation, structure, and applications.
• Troubleshoot basic PLC and robotic system faults using appropriate instruments and diagnostic techniques.

Optional Outcomes

The following outcomes may be covered depending on institutional specialization and available laboratory equipment:

• Program and operate motor control circuits using motor starters and Variable Frequency Drives (VFDs) controlled by PLCs.
• Interface electro-mechanical devices such as relays, timers, counters, proximity sensors, and photo sensors with PLC systems.
• Configure and test PID (Proportional-Integral-Derivative) control loops for process variables such as temperature, pressure, level, and flow.
• Demonstrate Fanuc robotic system operation in preparation for Fanuc Certified Robotic Training certification.
• Explain mechatronics system concepts integrating mechanical, electrical, and software subsystems.
• Apply quality assurance and quality control methods in an automated production context.

Major Topics

Required Topics

• PLC Hardware Overview: CPU architecture, I/O modules, power supplies, chassis, and communication interfaces.
• Numbering Systems: Binary, octal, hexadecimal, and decimal conversions for PLC data representation.
• PLC Memory Organization: Data files, program files, status files, and bit/word addressing.
• PLC Programming Fundamentals: Ladder logic concepts, contact and coil instructions, rung construction, and scan cycle.
• PLC Programming Software: Installation, project setup, online/offline editing, forced I/O, and program documentation.
• Timer and Counter Instructions: TON, TOF, RTO, CTU, CTD instructions and their industrial applications.
• Process Control and Automation Basics: Open-loop vs. closed-loop control, sensors, actuators, and control sequence design.
• Industrial Robotics Introduction: Robot classification, coordinate systems, axes of motion, end-effectors, and teach pendants.
• Industrial Safety: Lockout/tagout (LOTO), electrical safety, guarding, and OSHA standards applicable to PLC and robotic environments.
• Troubleshooting Techniques: Fault diagnosis using PLC status indicators, I/O force functions, and multimeters.

Optional Topics

• Advanced Ladder Logic: Data manipulation, math instructions, comparison instructions, and jump/subroutine programming.
• Motor Control with PLCs: Variable Frequency Drives (VFDs), motor starters, and motion control using Allen-Bradley or equivalent platforms.
• Electro-Mechanical Control Devices: Solid-state relays, photoelectric sensors, inductive/capacitive proximity sensors, and encoder feedback.
• PID Process Control: Analog I/O modules, scaling, proportional, integral, and derivative tuning for industrial process variables.
• Fanuc Robotics Programming: Robot teach pendant programming, point-to-point motion, and program management aligned with Fanuc Certified Robotic Training.
• Servo and Stepper Drive Systems: Servo point-to-point, stepper control, Cartesian, and pneumatic PLC-controlled robot types.
• Mechatronics System Integration: Sensors, pneumatics, electrical, and robotic subsystems operating as a unified automated cell.
• Human-Machine Interface (HMI): Introduction to HMI panels for monitoring and controlling PLC-based systems.

Resources & Tools

• PLC Hardware: Allen-Bradley MicroLogix, CompactLogix, or ControlLogix series PLCs (most common in Florida college labs); Siemens S7 series also used at some institutions.
• Programming Software: Rockwell Automation RSLogix 500 / Studio 5000 Logix Designer; Siemens TIA Portal (optional).
• Robotic Training Equipment: Fanuc LR Mate or equivalent educational robotic arms; simulation software such as Fanuc ROBOGUIDE.
• Lab Equipment: Industrial trainers with I/O panels, VFDs, motor starter kits, sensor arrays, and process control trainers.
• Textbooks: Programmable Logic Controllers by Frank Petruzella (McGraw-Hill) — widely adopted at Florida colleges; manufacturer training manuals.
• FLATE Resources: Florida Advanced Technological Education Center curriculum support materials aligned to MSSC standards.
• Safety References: OSHA 29 CFR 1910 General Industry standards; NFPA 70E Electrical Safety in the Workplace.

Career Pathways

Successful completion of ETS1540C prepares students for entry-level and advancement opportunities in Florida's manufacturing and industrial automation sectors, including:

• PLC Technician / Controls Technician — Programming, maintaining, and troubleshooting PLC-based control systems in manufacturing plants.
• Automation Technician — Operating and maintaining automated production lines integrating PLCs, robotics, and vision systems.
• Industrial Maintenance Technician — Diagnosing and repairing electrical and electro-mechanical equipment in industrial facilities.
• Robotics Technician — Setting up, programming, and servicing industrial robotic systems in automotive, aerospace, and electronics manufacturing.
• Process Control Technician — Monitoring and adjusting automated process control systems in chemical, food processing, and utility industries.
• Manufacturing Engineer Technologist (with completion of A.S. degree) — Supporting production engineering teams in process improvement and automation projects.

Special Information

Certification Preparation

• Fanuc Certified Robotic Training: Students who successfully complete ETS1540C at institutions such as College of Central Florida are eligible to sit for Fanuc Certified Robotic Training credentials, a nationally recognized industry certification.
• MSSC Certified Production Technician (CPT): This course contributes to the Engineering Technology core aligned with the Manufacturing Skills Standards Council (MSSC) CPT certification pathway, a nationally portable credential valued across all manufacturing sectors.
• SACA Automation Credentials: Some Florida colleges (e.g., College of Central Florida) align ETS coursework to SACA (Society of Automation, Control and Architecture) credentials including C-201 through C-310 series for industrial automation.

Lab Fee

A lab fee is typically required for this course due to consumable materials, software licensing, and specialized equipment usage. Students should verify the current fee with their institution's bursar at time of registration.

Program Context

ETS1540C is a course in the Florida Engineering Technology (A.S.) statewide degree framework, developed collaboratively by FLATE, the Florida Department of Education, and more than 20 Florida state colleges. The course carries a "C" lab indicator in the SCNS, signifying a combined lecture and laboratory format that meets at the same time and place.